Z45 PDF

Introduction August 2011
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the Genie Z-45/25 DC & these models:
Genie Z-45/25J DC Operator's Manual before
attempting any maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled Z-45/25 DC and Z-45/25J DC Service Manual
maintenance information for the machine owner and (after serial number 23235) ................................ 107939
user. It also provides troubleshooting fault codes
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 an
authorized Genie dealer service center.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 2011 Terex Corporation
http://www.genielift.com 106726 Rev C August 2011

e-mail: awp.techpub@terex.com Second Edition, Third Printing
"Genie" and "Z" are registered trademarks of

Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
ii Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
INTRODUCTION
Serial Number Legend
Model: Z-45/25
Serial number: Z452505-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0273
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg
Z4525 05 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 45 ft 6 in/ 13.8 m
Maximum platform reach : 25 ft 3 in/ 7.7 m Model Sequence
Gradeability: N/A number
Country of manufacture: USA Year of
This machine complies with: manufacture
ANSI A92.5
CAN B.354.4
Terex South Dakota, Inc.

500 Oak Wood Road
Watertown, SD 57201
USA
PN - 77055
Part No. 106726 Z-45/25 DC • Z-45/25J DC iii

August 2011
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iv Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-45/25 DC and
Genie Z-45/25J DC 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:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 106726 Z-45/25 DC • Z-45/25J DC v

August 2011
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for use.
Keep work surfaces clean and free of
Safety alert symbol—used to alert debris that could get into machine components and
personnel to potential personal cause damage.
injury hazards. Obey all safety
messages that follow this symbol Be sure any forklift, overhead crane or
to avoid possible injury or death. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates an imminently hazardous
weight to be lifted. Use only chains or straps that
situation which, if not avoided, will
are in good condition and of ample capacity.
result in death or serious injury.
Be sure that fasteners intended for one
Indicates the potentially hazardous
situation which, if not avoided, time use (i.e., cotter pins and self-locking
could result in death or serious nuts) are not reused. These components
injury. may fail if they are used a second time.
Indicates a potentially hazardous Be sure to properly dispose of old oil or

situation which, if not avoided, other fluids. Use an approved container.
may cause minor or moderate Please be environmentally safe.
injury. Be sure that your workshop or work area is
Indicates a potentially hazardous properly ventilated and well lit.
situation which, if not avoided,
may result in property damage.
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.
vi Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

C Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
Machine Torque Specifications .............................................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 5
SAE and Metric Fasteners Torque Charts .............................................................. 2 - 6
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
C Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 6
A-2 Perform Function Tests ................................................................................ 3 - 6
A-3 Perform 30 Day Service ............................................................................... 3 - 7
A-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 3 - 7
Part No. 106726 Z-45/25 DC • Z-45/25J DC vii

August 2011
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

C Checklist B Procedures
B-1 Check the Batteries ...................................................................................... 3 - 8
B-2 Inspect the Electrical Wiring ......................................................................... 3 - 9
B-3 Check the Lug Nut Torque (including the tires and wheels) ......................... 3 - 10
B-4 Confirm the Proper Brake Configuration ...................................................... 3 - 10
B-5 Check the Oil Level in the Drive Hubs ........................................................ 3 - 11
B-6 Test the Ground Control Override ............................................................... 3 - 12
B-7 Test the Platform Self-leveling ................................................................... 3 - 12
B-8 Test the Drive Brakes ................................................................................ 3 - 13
B-9 Test the Drive Speed - Stowed Position ..................................................... 3 - 13
B-10 Test the Drive Speed - Raised or Extended Position .................................. 3 - 14
B-11 Test the Alarm Package (if equipped) ........................................................ 3 - 14
B-12 Test the Turntable Rotation Stop ................................................................ 3 - 15
B-13 Check the Electrical Contactors ................................................................. 3 - 16
B-14 Perform Hydraulic Oil Analysis ................................................................... 3 - 16
C Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 17
C-2 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 17
C Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 20
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 20
D-3 Check the Free-wheel Configuration ........................................................... 3 - 22
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 23
D-5 Replace the Hydraulic Tank Return Filter ................................................... 3 - 24
D-6 Calibrate the Platform Overload System (if equipped) ................................ 3 - 24
C Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 26
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 27
viii Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
C Platform Controls
1-1 Controllers .................................................................................................... 4 - 2
C Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2 Platform Rotator ........................................................................................... 4 - 5
C Jib Boom Components, Z-45/25J
3-1 Jib Boom ...................................................................................................... 4 - 7
3-2 Jib Boom Lift Cylinder .................................................................................. 4 - 8
C Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 10
4-2 Primary Boom ............................................................................................ 4 - 14
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 17
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 18
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 19
C Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 21
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 26
C Hydraulic Pumps
6-1 Auxiliary Pump ........................................................................................... 4 - 27
6-2 Function Pump ........................................................................................... 4 - 27
Part No. 106726 Z-45/25 DC • Z-45/25J DC ix

August 2011
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

C Manifolds
7-1 Function Manifold Components (before serial number 17841) ..................... 4 - 28
7-2 Function Manifold Components (from serial number 17841 to 20379) ......... 4 - 32
7-5 Valve Adjustments - Function Manifold ...................................................... 4 - 38
7-6 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 40
7-7 Turntable Rotation Manifold Components ................................................... 4 - 41
B Turntable Rotation Components
8-1 Rotation Hydraulic Motor (before serial number 18367) ............................... 4 - 42
8-2 Turntable Rotation Assembly (from serial number 18367 to 23235) ............ 4 - 44
B Motor Controller
9-1 Motor Controller .......................................................................................... 4 - 45
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
B Fault Code Chart .................................................................................................... 5 - 3
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
Power Cable Diagrams
A Power Cable Diagram (before serial number 16839) ............................................... 6 - 5
A Power Cable Diagram (from serial number 16840 to 21179) ................................... 6 - 6
x Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Electrical Schematics, Z-45/25
A Electrical Schematic, Z-45/25 (before serial number 13361) ................................... 6 - 9
A Electrical Schematic, Z-45/25 (from serial number 13361 to 14078) ..................... 6 - 11
A Electrical Schematic, Z-45/25, ANSI and CSA Models
(from serial number 22051 to 23235) .................................................................... 6 - 23
A Electrical Schematic, Z-45/25, CE Models
Electrical Schematics, Z-45/25J
A Electrical Schematic, Z-45/25J (before serial number 13361) ............................... 6 - 27
A Electrical Schematic, Z-45/25J (from serial number 13361 to 14078) ................... 6 - 29
A Electrical Schematic, Z-45/25J, ANSI and CSA Models
A Electrical Schematic, Z-45/25J, CE Models
Part No. 106726 Z-45/25 DC • Z-45/25J DC xi

August 2011
TABLE OF CONTENTS

Ground Control Box Wiring Diagrams, Z-45/25
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(before serial number 13361) ................................................................................ 6 - 45
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
xii Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
TABLE OF CONTENTS

ANSI and CSA Models (from serial number 22051 to 23235) ............................... 6 - 59
CE Models (from serial number 22051 to 23235) .................................................. 6 - 61
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
Part No. 106726 Z-45/25 DC • Z-45/25J DC xiii

August 2011
TABLE OF CONTENTS

Platform Control Box Wiring Diagrams
A Platform Control Box Wiring Diagram, Z-45/25
(with platform load sense and LVI/BCI option)
xiv Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011
TABLE OF CONTENTS

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
A Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078) ................................................................... 6 - 100
Part No. 106726 Z-45/25 DC • Z-45/25J DC xv

August 2011
TABLE OF CONTENTS

A Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
Hydraulic Schematics
B Hydraulic Schematic (before serial number 16962) .............................................. 6 - 113
B Hydraulic Schematic (from serial number 16962 to 20379) .................................. 6 - 114
xvi Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011 Section 2 • Specifications
REV C
Specifications
Machine Specifications Fluid capacities
Tires and wheels Hydraulic tank 8 gallons

30.3 liters
Wheel diameter 14.5 inches
Hydraulic system 11 gallons
Wheel width 7 inches (including tank) 41.6 liters
Drive hubs (refer to tag on drive hub to determine type)
Wheel lugs (before serial number 16128)
EW1 type 17 fl oz
Front 8 @ 5/8 -18
0.51 liter
Rear 9 @ 5/8 -18
W1 type 23 fl oz
Wheel lugs (after serial number 16127) 0.68 liter
Front 9 @ 5/8 -18 Drive hub oil type: SAE 90 multipurpose hypoid gear oil
Rear 9 @ 5/8 -18 API service classification GL5
Lug nut torque 125 ft-lbs Batteries
169.5 Nm
Type 6V DC
Tire size 9-14.5 LT
Quantity 8
Tire ply rating Tread 8
Capacity 350 AH
Sidewall 6
Tire contact area 43.5 sq in Reserve capacity @ 25A rate 750 minutes
280 sq cm
Overall tire diameter 28 in

71 cm Continuous improvement of our products is a
Genie policy. Product specifications are
Tire pressure 100 psi
subject to change without notice.
6.89 bar
For operational specifications, refer to the

Operator's Manual.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 2-1

Section 2 • Specifications August 2011
SPECIFICATIONS REV C
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds, maximum
Jib boom up, Z-45/25J 30 to 40 seconds
Drive speed, stowed 3 mph
All models 4.8 km/h Jib boom down, Z-45/25J 18 to 23 seconds
40 ft/9 sec Primary boom up 30 to 36 seconds
12.2 m/9 sec
Primary boom down 26 to 32 seconds
Drive speed, boom 0.6 mph
raised or extended, 1 km/h Secondary boom up 38 to 42 seconds
all models 40 ft/45 sec
12.2 m/45 sec Secondary boom down 32 to 36 seconds
Braking distance, maximum Primary boom extend, Z-45/25 25 to 30 seconds
High range on paved surface 5 to 7 ft Primary boom extend, Z-45/25J 16 to 24 seconds
1.5 to 2 m
Primary boom retract, Z-45/25 21 to 30 seconds
Gradeability (boom stowed) 30%
Primary boom retract, Z-45/25J 13 to 23 seconds
Turntable rotate, 359° 76 to 82 seconds

primary boom retracted
Platform rotate, 180°, Z-45/25 6 to 10 seconds
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
2-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C SPECIFICATIONS
Hydraulic Specifications Function pump
Before serial number 20926 Type: Fixed displacement gear pump

Hydraulic oil type Shell Donax TG (Dexron III) Displacement 0.183 cu in
After serial number 20925 3 cc
Hydraulic oil type Chevron Rykon MV equivalent Flow rate 2.1 gpm
Approximate SAE grade 5W-20 7.9 L/min
Viscosity index rating 200
Hydraulic tank 10 micron with
Cleanliness level, minimum 15/13 return filter 25 psi / 1.7 bar bypass
Water content, maximum 200 ppm Function manifold
Chevron Rykon MV oil is fully compatible and Function relief valve pressure 3200 psi
mixable with Shell Donax TG (Dexron III) oils. 220.6 bar
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic Primary boom down 2300 psi
systems, have the ability to perform over a wide relief valve pressure 158.6 bar
temperature range, and have a minimum viscosity index (before serial number 11819)
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and Secondary boom down 1800 psi
foam and aeration suppression properties. relief valve pressure 124 bar
(before serial number 22566)
Optional fluids
Secondary boom down 2000 psi
Biodegradable Petro Canada Premium ECO 46 relief valve pressure 138 bar
Statoil Hydra Way Bio Pa 32 (from serial number 22566 to 23235)
BP Biohyd SE-S
Platform level flow regulator 0.1 gpm
Fire resistant UCON Hydrolube HP-5046 (before serial number 20380) 0.38 L/min
Quintolubric 822
Platform level flow regulator 0.6 gpm
Mineral based Shell Tellus T32 (from serial number 20380 to 23235) 2.27 L/min
Shell Tellus T46
Chevron Aviation A Jib boom/platform rotate flow regulator 0.6 gpm
(before serial number 22566) 2.27 L/min
Jib boom/platform rotate flow regulator 0.4 gpm

(from serial number 22566 to 23235) 1.5 L/min
Note: Use Chevron Aviation A hydraulic oil when in
ambient temperatures consistently below 0°F / - Auxiliary pump
18°C.
Type: fixed displacement gear pump
Note: Use Shell Tellus T46 hydraulic oil when oil
Displacement 0.5 gpm
temperatures consistently exceed 205°F / 96°C.
1.9 L/min
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 2-3

Manifold Component Machine Torque Specifications

Specifications
Platform rotator
before serial numbers Z45/25-16962 / Z45/25J-16935
Plug torque
1 -8 center bolt (grade 2) 200 ft-lbs
SAE No. 2 36 in-lbs / 4 Nm
271 Nm
SAE No. 4 10 ft-lbs / 13 Nm 1 -8 center bolt (grade 8) 480 ft-lbs
651 Nm
SAE No. 6 14 ft-lbs / 19 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
SAE No. 8 38 ft-lbs / 51 Nm 60 Nm
SAE No. 10 41 ft-lbs / 55 Nm Platform rotator

after serial numbers Z45/25-16961 / Z45/25J-16934
SAE No. 12 56 ft-lbs / 76 Nm
3 /4 -10 center bolt (grade 8) 380 ft-lbs
Valve Coil Resistance Specification 515 Nm
Description Specification 3 /8 -16 bolts, GR 8 44 ft-lbs
60 Nm
Solenoid valve, 3 position 4 way, 20V DC 25 to 29Ω
(schematic items E, H, J, K, L, M, CC, DD, Turntable rotate assembly
EE, FF, HH, II, BB, BC, BD, BE, BF, BG, CB,
CD, CE, CF and CH) Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm
Solenoid valve, 2 position 3 way, 20V DC 25 to 29Ω
(schematic items N, P, AA, BB, BA, BJ, Drive motor/brake mounting bolts, dry 110 ft-lbs
CA, CK and CR) 149 Nm
Solenoid valve, 2 position 3 way, 20V DC 17 to 21Ω Drive motor/brake mounting bolts, lubricated 80 ft-lbs
(schematic item CR) 108 Nm
Solenoid valve, 2 position 3 way, 20V DC 25 to 28Ω Drive motor and hubs
(schematic item DC)
Drive hub mounting bolts, lubricated 180 ft-lbs
Solenoid valve, 2 position 2 way, 20V DC 22 to 26Ω 244 Nm
(schematic items DA and DB)
Drive motor mounting bolts, lubricated 55 ft-lbs
Proportional solenoid valve, 24V DC 17 to 21Ω 75 Nm
(schematic items G, JJ, BH and CI)
Solenoid valve, N.C. poppet, 20V DC 25 to 28Ω

(schematic items F, LL and BI)
Solenoid valve, N.O. poppet, 20V DC 25 to 28Ω

(schematic items B, VV and BT)
2-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
SAE O-ring Boss Port number 49612).
(tube fitting - installed into Aluminum)
2 Lubricate the O-ring before installation.
SAE Dash size Torque
3 Be sure that the face seal O-ring is seated and
-4 11 ft-lbs / 14.9 Nm retained properly.
-6 23 ft-lbs / 31.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-8 40 ft-lbs / 54.2 Nm tight.
-10 69 ft-lbs / 93.6 Nm 5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm

6 Operate all machine functions and inspect the
hoses and fittings and related components to
-20 172 ft-lbs / 233.2 Nm confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 24.4 Nm
-6 35 ft-lbs / 47.5 Nm -6 27 ft-lbs / 36.6 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm
-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm
-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm
-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm
Part No. 106726 Z-45/25 DC • Z-45/25J DC 2-5

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2-6 Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Observe and Obey: Each procedure includes a description, safety
warnings and step-by-step instructions.
Maintenance inspections shall be completed by
a person trained and qualified on the Symbols Legend
maintenance of this machine.
Safety alert symbol—used to alert
Scheduled maintenance inspections shall be personnel to potential personal
completed daily, quarterly, six months, annually injury hazards. Obey all safety
and every 2 years as specified on the messages that follow this symbol
Maintenance Inspection Report. to avoid possible injury or death.
Failure to properly complete each Indicates an imminently hazardous
inspection when required may situation which, if not avoided, will
cause death, serious injury or result in death or serious injury.
substantial machine damage.
Indicates a potentially hazardous
Immediately tag and remove from service a situation which, if not avoided,
damaged or malfunctioning machine. could result in death or serious
injury.
Repair any machine damage or malfunction
before operating machine. Indicates a potentially hazardous
Use only Genie approved replacement parts. may cause minor or moderate
injury.
Machines that have been out of service for a
period longer than 3 months must complete the Indicates a potentially hazardous
quarterly inspection. situation which, if not avoided,
Unless otherwise specified, perform each
procedure with the machine in the following Indicates that a specific result is expected after
configuration: performing a series of steps.
• Machine parked on a firm, level surface Indicates that an incorrect result has occurred
after performing a series of steps.
• Boom in the stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3-1

Section 3 • Scheduled Maintenance Procedures August 2011
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

There are five types of maintenance inspections
Note: The following symbols have been used in this that must be performed according to a schedule—
manual to help communicate the intent of the daily, quarterly, six months, annual, and two year.
instructions. When one or more of the symbols The Scheduled Maintenance Procedures Section
appear at the beginning of a maintenance and the Maintenance Inspection Report have been
procedure, it conveys the meaning below. divided into five subsections—A, B, C, D and E.
Use the following chart to determine which group(s)
of procedures are required to perform a scheduled
Indicates that tools will be required to inspection.
perform this procedure.
Inspection Checklist
Indicates that new parts will be required Daily or every 8 hours A

to perform this procedure.
Quarterly or every 250 hours A+B
Six months or every 500 hours A+B+C

Indicates that a cold motor, pump or
engine will be required to perform this Annual or every 1000 hours A+B+C+D
procedure.
Two year or every 2000 hours A+B+C+D+E
Indicates that a warm motor or pump will Maintenance Inspection Report

be required to perform this procedure.
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Indicates that dealer service will be Make copies of the Maintenance Inspection Report
required to perform this procedure. to use for each inspection. Maintain completed
forms in compliance with employer, job site and
governmental regulations.
3-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Make copies of this form to use for each Pre-Delivery
Pre-delivery Preparation. Preparation.
The Pre-delivery Preparation is performed prior to each Use the operator’s manual on your machine.
delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it is The Pre-delivery Preparation consists of completing
put into service. the Pre-operation Inspection, the Maintenance items
and the Function Tests.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered Use this form to record the results. Place a check in
condition is discovered, the machine must be tagged the appropriate box after each part is completed.
and removed from service. Follow the instructions in the operator’s manual.
Repairs to the machine may only be made by a If any inspection receives an N, remove the machine
qualified service technician, according to the from service, repair and re-inspect it. After repair, place
manufacturer's specifications. a check in the R box.
Scheduled maintenance inspections shall be performed Legend

by qualified service technicians, according to the Y = yes, completed
manufacturer's specifications and the requirements N = no, unable to complete
listed in the responsibilities manual. R = repaired
Comments
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
3-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

Maintenance Inspection Report

Model Checklist A - Rev B Y N R Checklist C - Rev B Y N R
A-1 Pre-operation C-1 Grease platform
Serial number inspection overload (if equipped)
Date A-2 Function tests C-2 Test platform

Perform after 50 hours: overload (if equipped)
Hour meter A-3 30 Day Service
Perform every 100 hours: Checklist D - Rev B Y N R
Machine owner D-1 Boom wear pads
A-4 Grease rotation
Inspected by (print) bearing D-2 Turntable bearing bolts
D-3 Free-wheel
Inspector signature Checklist B - Rev B Y N R configuration
B-1 Batteries D-4 Drive hub oil
Inspector title D-5 Hydraulic return filter
B-2 Electrical wiring
Inspector company B-3 Lug nut torque D-6 Calibrate platform
overload system
B-4 Brake configuration
Instructions (if equipped)
B-5 Drive hub oil level
• Make copies of this page to use for
each inspection. B-6 Ground control
Checklist E - Rev B Y N R
override
• Select the appropriate checklist(s) for E-1 Hydraulic oil
B-7 Platform leveling
the type of inspection to be E-2 Wheel bearings
performed. B-8 Drive brakes
B-9 Drive speed - stowed
Daily or 8 hour
B-10 Drive speed - raised
Inspection: A
B-11 Alarm package
Quarterly or 250 hour
(if equipped)
Inspection: A+B
B-12 Turntable rotation stop
Six Month or 500 hour
Inspection: A+B+C B-13 Electrical contactors
B-14 Hydraulic oil analysis
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
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3-5

Checklist A Procedures REV C
A-1 A-2
Perform Pre-operation Inspection Perform Function Tests
Completing a pre-operation inspection is essential Completing the function tests is essential to safe
to safe machine operation. The pre-operation machine operation. Function tests are designed to
inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The pre-operation inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the Genie Z-45/25 DC and
Complete information to perform this procedure is Genie Z-45/25J DC Operator's Manual on your
available in the Genie Z-45/25 DC and machine.
Genie Z-45/25J DC Operator's Manual on your
machine.
3-6 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C CHECKLIST A PROCEDURES
A-3 A-4
Perform 30 Day Service Grease the Turntable Rotation
Bearing and Rotate Gear
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 Genie specifications require that this procedure be
interval, refer to the maintenance tables for performed every 100 hours of operation. Perform
continued scheduled maintenance. this procedure more often if dusty conditions exist.
1 Perform the following maintenance procedures: Frequent application of lubrication to the turntable
• B-3 Check the Lug Nut Torque bearing and rotate gear is essential to good
(including tires and wheels) machine performance and service life. Continued
• D-2 Check the Turnable Rotation Bearing use of an improperly greased bearing and gear will
Bolts result in component damage.
• D-5 Replace the Hydraulic Tank Return 1 Locate the grease fitting on the front turntable
Filter cover.
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
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3-7

Checklist B Procedures REV C
B-1 4 Remove the battery vent caps and check the

specific gravity of each battery cell with a
Check the Batteries hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.026, the battery must be
replaced.
Proper battery condition is essential to good
machine performance and operational safety. 5 Check the battery acid level of the battery. If
Improper fluid levels or damaged cables and needed, replenish with distilled water to the
connections can result in engine component bottom of the battery fill tube. Do not overfill.
damage and hazardous conditions.
6 Install the battery vent caps.
Electrocution/burn hazard. Contact
7 Be sure the battery packs are wired correctly.
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.
Note: Perform this procedure after fully charging the

batteries.
Note: For a more accurate determination of battery
condition, fully charge the batteries and allow the
batteries to rest 24 hours before performing this
procedure to allow the battery cells to equalize.
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 cable connections are tight.
3-8 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C CHECKLIST B PROCEDURES
B-2 8 Inspect the following areas for burnt, chafed,

corroded, pinched and loose wires:
Inspect the Electrical Wiring
• Cable track on the primary, jib and
Maintaining electrical wiring in good condition is secondary booms
essential to safe operation and good machine
• Jib boom to platform cable harness
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in • Inside of the platform control box
unsafe operating conditions and may cause 9 Inspect for a liberal coating of dielectric grease
component damage. at the following location:
Electrocution/burn hazard. Contact • All wire harness connectors to the platform
with hot or live circuits could result control box
all rings, watches and other
jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
• Power units
• Inside of the ground control box
• Turntable manifold wiring
2 Inspect for a liberal coating of dielectric grease
at the following location:
• All wire harness connectors to the ground
control box
3 Raise the secondary boom until the mid-pivot is
approximately 10 feet / 3 m off the ground.
4 Remove the center turntable cover.
5 Inspect the turntable center area for burnt,
chafed and pinched cables.
6 Install the center turntable cover.
7 Lower the boom to the stowed position and turn
the machine off.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3-9

CHECKLIST B PROCEDURES REV C
B-3 B-4
Check the Lug Nut Torque Confirm the Proper
(including the tires and wheels) Brake Configuration
Maintaining the tires and wheels in good Proper brake configuration is essential to safe
condition is essential to safe operation and good operation and good machine performance.
performance. Tire and/or wheel failure could result Hydraulically-released, spring-applied individual
in a machine tip-over. Component damage may wheel brakes can appear to operate normally when
also result if problems are not discovered and they are actually not fully operational.
repaired in a timely fashion.
1 Check each drive hub disconnect cap to be
Bodily injury hazard. An over- sure it is in the engaged position.
inflated tire can explode and could
result in death or serious injury. brake disengaged position
Tip-over hazard. Do not use

temporary flat tire repair products.
Note: The tires on some machines are foam-filled
brake engaged position
and do not need air added to them.
1 Check the tire surface 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. Refer to
Section 2, Specifications.
4 Check the pressure in each air-filled tire.
Refer to Section 2, Specifications.
3 - 10 Z-45/25 DC • Z-45/25J DC Part No. 106726

B-5 2 Remove the plug located at 90 degrees and

check the oil level.
Check the Oil Level
Result: The oil level should be even with the
in the Drive Hubs
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
Failure to maintain proper drive hub oil levels may side plug hole.
cause the machine to perform poorly and 4 Models with pipe plugs: Apply pipe thread
continued use may cause component damage. sealant to the plugs and install the plugs.
1 Drive the machine to rotate the hub until one of Models with O-ring plugs: Install the plugs
the plugs is located on top and the other one is into the drive hub.
at 90 degrees.
5 Repeat steps 1 through 4 for the other drive
hub.
6 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
models with pipe plugs
a models with o-ring plugs
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 11

B-6 B-7
Test the Ground Control Override Test the Platform Self-leveling
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 Automatic platform self-leveling throughout
ground controls whether or not the Emergency the full cycle of boom raising and lowering is
Stop button on the platform controls is in the ON or essential for safe machine operation. The
OFF position. This function is particularly useful if platform is maintained at level by the platform
the operator at the platform controls cannot return leveling slave cylinder which is controlled by the
the boom to the stowed position. master cylinder located at the base of the primary
1 Push in the platform red Emergency Stop boom. A platform self-leveling failure creates an
button to the off position. unsafe working condition.
2 Turn the key switch to ground control and pull 1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on out the red Emergency Stop button to the on
position. position.
2 Lower the boom to the stowed position.
3 Operate each boom function through a
partial cycle at the ground controls. 3 Hold the function enable toggle switch to either
side and adjust the platform to a level position
Result: All boom functions should operate. using the platform level toggle switch.
4 Raise and lower the primary boom through
a full cycle.
Result: The platform should remain level at
all times to within ±5 degrees.
3 - 12 Z-45/25 DC • Z-45/25J DC Part No. 106726

B-8 B-9
Test the Drive Brakes Test the Drive Speed -
Stowed Position
Proper brake action is essential to safe machine

operation. The machine uses drive motor Proper drive function movement is essential to
regenerative braking to stop the machine. safe machine operation. The drive function should
Hydraulically-released individual wheel brakes hold respond quickly and smoothly to operator control.
the machine once it has stopped. The drive motor Drive performance should also be free of
regenerative braking should operate smoothly, free hesitation, jerking and unusual noise over the
of hesitation and jerking. Hydraulically-released entire proportionally controlled speed range.
individual wheel brakes can appear to operate
normally when not fully operational. Note: Select a test area that is firm, level and free
of obstructions.
Collision hazard. Be sure that the
machine is not in free-wheel or 1 Create start and finish lines by marking two lines
partial free-wheel configuration. on the ground 40 feet / 12.2 m apart.
Refer to B-4, Confirm the Proper
Brake Configuration. 2 Lower the boom into the stowed position.
Note: Select a test area that is firm, level and free 3 Choose a point on the machine; i.e., contact
of obstructions. patch of a tire, as a visual reference for use
when crossing the start and finish lines.
1 Mark a test line on the ground for reference.
4 Bring the machine to maximum drive speed
2 Lower the boom into the stowed position. before reaching the start line. Begin timing
when your reference point on the machine
3 Choose a point on the machine; i.e., contact crosses the start line.
patch of a tire, as a visual reference for use
when crossing the test line. 5 Continue at full speed and note the time when
the machine reference point passes over the
4 Bring the machine to maximum drive speed finish line. Refer to Section 2, Specifications.
before reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
5 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 13

B-10 B-11
Test the Drive Speed - Raised or Test the Alarm Package
Extended Position (if equipped)
The alarm package includes:
• Travel alarm
Proper drive function movement is essential to • Descent alarm
safe machine operation. The drive function should
respond quickly and smoothly to operator control. • Flashing beacon
Drive performance should also be free of Alarms and a beacon are installed to alert
hesitation, jerking and unusual noise over the operators and ground personnel of machine
entire proportionally controlled speed range. proximity and motion. The alarm package is
installed on the turntable covers.
Note: Select a test area that is firm, level and free
of obstructions. Note: The alarms and beacon will operate with the
engine
1 Create start and finish lines by marking two lines running or not running.
on the ground 40 feet / 12.2 m apart.
1 Turn the key switch to ground control and pull
2 Raise the platform more than 5 feet / 1.5 m.
out the red Emergency Stop button to the on
3 Choose a point on the machine; i.e., contact position at both the ground and platform
patch of a tire, as a visual reference for use controls.
when crossing the start and finish lines.
Result: The flashing beacon should be on and
4 Bring the machine to maximum drive speed flashing.
before reaching the start line. Begin timing
2 Move the function enable switch to either side
when your reference point on the machine
and activate the primary boom toggle switch in
crosses the start line.
the down position, hold for a moment and then
5 Continue at full speed and note the time when release it.
the machine reference point passes over the
Result: The descent alarm should sound when
finish line. Refer to Section 2, Specifications.
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.
3 - 14 Z-45/25 DC • Z-45/25J DC Part No. 106726

4 Z-45/25J: Move the function enable toggle B-12

switch to either side and activate the jib boom
toggle switch in the down position, hold for a Test the Turntable Rotation Stop
moment and then release it. The turntable is capable of rotating the boom 355
Result: The descent alarm should sound when degrees and is stopped midpoint between the steer
the switch is held down. wheels by the rotation stop. Detecting a rotation
stop malfunction is essential to safe operation and
5 Turn the key switch to platform control. good machine performance. If the turntable rotates
Result: The flashing beacon should be on past the rotation stop, component damage may
and flashing. result.
6 Press down the foot switch. Activate the 1 Turn the key switch to platform control and pull
primary boom toggle switch in the down out the red Emergency Stop button to the on
position, hold for a moment and then release it. position at both the ground and platform
controls.
the control handle is held down. 2 Rotate the turntable to the left as far as it
will go.
7 Press down the foot switch. Activate the
secondary boom toggle switch in the down Result: Movement should stop when the
position, hold for a moment and then release it. primary boom reaches mid-point between the
steer tires.
the control handle is held down. 3 Rotate the turntable to the right full circle as far
as it will go.
8 Z-45/25J: Press down the foot switch. Activate
the jib boom toggle switch in the down position, Result: Movement should stop when the
hold for a moment and then release it. primary boom reaches mid-point between the
Result: The descent alarm should sound when steer tires.
9 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.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 15

B-13 B-14
Check the Electrical Contactors Perform Hydraulic Oil Analysis
Maintaining the electrical contactors in good Replacement or testing of the hydraulic oil is
condition is essential to safe machine operation. essential for good machine performance and
Failure to locate a worn or damaged contactor service life. Dirty oil and suction strainers may
could result in an unsafe working condition and cause the machine to perform poorly and
component damage. continued use may cause component damage.
Extremely dirty conditions may require oil changes
1 Remove the drive chassis cover from the to be performed more often.
non-steer end of the machine and locate the
electrical contactors mounted on the Note: Before replacing the hydraulic oil, the oil may
component mounting panel. be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
2 Visually inspect the contact points of each
necessary. If the hydraulic oil is not replaced at
contactor for the following items:
the two year inspection, test the oil quarterly.
• Excessive burns Replace the oil when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
• Excessive arcs
• Excessive pitting
with hot or live circuits could result
all rings, watches and other
jewelry.
Note: Replace the contactors if any damage is
found.
3 - 16 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C
Checklist C Procedures
C-1 C-2
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever performed every 500 hours or six months,
comes first. Perform this procedure more often if whichever comes first.
dusty conditions exist.
Testing the platform overload system regularly is
Application of lubrication to the platform overload essential to safe machine operation. Continued
mechanism is essential to safe machine operation. use of an improperly operating platform overload
Continued use of an improperly greased platform system could result in the system not sensing an
overload mechanism could result in the system not overloaded platform condition. Machine stability
sensing an overloaded platform condition and will could be compromised resulting in the machine
result in component damage. tipping over.
1 Locate the grease fittings on each pivot pin of Note: Perform this procedure with the machine on a
the platform overload assembly. firm, level surface.
2 Thoroughly pump grease into each grease 1 Turn the key switch to platform control.
fitting using a multi-purpose grease.
2 Level the platform from the platform controls.
3 Determine the maximum platform capacity.
Refer to the machine serial plate.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 17

CHECKLIST C PROCEDURES REV C
4 Using a suitable lifting device, place an 7 Carefully move the test weights to each
appropriate test weight equal to that of the remaining location in the platform.
maximum platform capacity in one of the
Result: The alarm should be sounding.
locations shown.
The platform overload indicator light should be
flashing at both the ground and platform
controls.
Result: If the alarm does not sound and the
platform overload indicator light does not come
on with the test weights in any of the platform
locations, the platform overload system needs
to be calibrated. See D-6, Calibrate the
Platform Overload System.
Note: There may be an approximate 2 second delay
before the overload indicator light turns on and the
Result: The platform overload indicator light alarm sounds.
should be off at both the ground and platform
controls. 8 Test all machine functions from the platform
controls.
5 Carefully move the test weight to each
remaining location. Result: All platform control functions should not
operate.
Result: The platform overload indicator light
should be off at both the ground and platform 9 Turn the key switch to ground control.
controls.
10 Test all machine functions from the ground
6 Add an additional 10 lbs / 4.5 kg of weight to controls.
overload the platform.
Result: All ground control functions should not
Result: The alarm should be sounding. operate.
The platform overload indicator light should be
Note: Machine functions should still operate with
flashing at both the ground and platform
auxiliary power at the ground controls.
controls.
Result: If the alarm does not sound and the 11 Lift the test weights off the platform floor using a
platform overload indicator light does not come suitable lifting device.
on with the test weights in any of the platform Result: The platform overload indicator light and
locations, the platform overload system needs alarm should turn off at both the ground and
to be calibrated. See D-6, Calibrate the platform controls.
Platform Overload System.
Note: There may be an approximate 2 second delay before the overload indicator light and alarm turn
before the overload indicator light turns on and the off.
alarm sounds.
3 - 18 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C CHECKLIST C PROCEDURES

controls.
Result: All ground control functions should
operate normally.
13 Turn the key switch to platform control.
14 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, see D-6, Calibrate the Platform
Overload System.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 19

Checklist D Procedures REV C
D-1 D-2
Check the Primary Boom Check the Turntable Rotation
Wear Pads Bearing Bolts
Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing
is essential to safe machine operation. Wear pads bolts is essential to safe machine operation.
are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe
friction, replaceable wear pad between moving operating condition and component damage.
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in 1 Raise the primary boom and place a safety
component damage and unsafe operating chock on the lift cylinder rod. Carefully lower
conditions. the boom onto the lift cylinder safety chock.
Crushing hazard. Keep hands
1 Measure each wear pad. Replace the wear pad
away from cylinder and all moving
once it reaches the minimum allowable
parts when lowering the boom.
thickness. If the wear pad is still within
specification, shim as necessary to obtain Note: A lift cylinder safety chock is available
minimum clearance with zero binding. through Genie (part number 33484).
2 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.
Note: Always maintain squareness between the
outer and inner
boom tubes.
Primary boom wear

pad specifications New Minimum
Top, bottom and side wear pads 3 /4

inch 5/8 inch
(platform end of boom) 19 mm 15.9 mm
Side and bottom wear pads 5 /8

inch 1/2
inch
(pivot end of boom) 15.9 mm 12.7 mm
Top wear pads 3 /4

inch 5/8 inch
(pivot end of boom) 19 mm 15.9 mm
3 - 20 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C CHECKLIST D PROCEDURES
2 Check to be sure that each turntable mounting 3 Lower the boom to the stowed position.
bolt is torqued in sequence to specification.
4 Remove drive chassis covers from both the
Refer to Section 2, Specifications.
steer end and the non-steer end of the
9 machine.
5 1
5 Check to be sure that each bearing mounting
bolt under the drive chassis is torqued in
3 11 sequence to specification. Refer to Section 2,
Specifications.
1
8 7
9
7
12 4
2 6 5 4
10
Bolt torque sequence
3 6
18 1
9 11
8 2
6 7
16 13 (before serial number 23332)
3 20 1
9 11
19 4 6 7
14 15 16 13
8 5
3 4
12 10
2 17
14 15
(after serial number 23331)
8 5
12 10
2
(after serial number 23331)
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 21

CHECKLIST D PROCEDURES REV C
D-3 5 Manually rotate each non-steer wheel.

Check the Free-wheel Result: Each non-steer wheel should rotate with
minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
Proper use of the free-wheel configuration is the hub disconnect caps. Rotate each wheel to
essential to safe machine operation. The check for engagement. Lift the machine and
free-wheel configuration is used primarily for remove the jack stands.
towing. A machine configured to free-wheel without
operator knowledge could result in death or serious Collision hazard. Failure to
injury and property damage. engage the drive hubs could result
in death or serious injury and
Collision hazard. Select a work property damage.
site that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
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.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each non-steer
wheel hub.
brake disengaged position
brake engaged position
3 - 22 Z-45/25 DC • Z-45/25J DC Part No. 106726

D-4 4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
Replace the Drive Hub Oil hole.
Replacing the drive hub oil is essential for good 5 Models with pipe plugs: Apply pipe thread
machine performance and service life. Failure to sealant to the plugs and install the plugs.
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and Models with O-ring plugs: Install the plugs
continued use may cause component damage. into the drive hub.
1 Select the drive hub to be serviced. Then drive 6 Repeat steps 1 through 5 for the other drive
the machine until one of the two plugs is at the hub.
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
models with pipe plugs
a models with o-ring plugs
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 23

CHECKLIST D PROCEDURES REV C
D-5 D-6
Replace the Hydraulic Tank Calibrate the Platform Overload
Return Filter System (if equipped)
Replacement of the hydraulic tank return filter is Genie specifications require that this procedure be
essential for good machine performance and performed every 1000 hours or annually, whichever
service life. A dirty or clogged filter may cause the comes first.
machine to perform poorly and continued use may
cause component damage. Extremely dirty Yearly calibration of the platform overload system
conditions may require that the filter be replaced is essential to safe machine operation. Continued
more often. use of an improperly calibrated platform overload
system could result in the system failing to sense
Bodily injury hazard. Beware of an overloaded platform. The stability of the
hot oil. Contact with hot oil may machine is compromised and it could tip over.
cause severe burns.
Note: Perform this procedure with the machine on a
1 Locate the hydraulic return filter next to the firm, level surface.
hydraulic tank.
1 Level the platform.
2 Place a suitable container under the hydraulic
filter. 2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove the filter with an oil filter wrench.
3 Using a suitable lifting device, place an
4 Apply a thin layer of oil to the new oil filter appropriate test weight equal to that of the
gasket. maximum platform capacity at the center of the
5 Install the new filter and tighten it securely by platform floor.
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls.
7 Activate any boom function and inspect the filter
and related components to be sure that there
are no leaks.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
3 - 24 Z-45/25 DC • Z-45/25J DC Part No. 106726

Determine the limit switch trigger point: Confirm the setting:

4 Gently move the platform up and down by hand, 5 Turn the key switch to platform control.
so it bounces approximately 1 to 2 inches /
6 Lift the test weight off the platform floor using a
2.5 to 5 cm. Allow the platform to settle.
suitable lifting device.
Result: The overload indicator light and the
7 Place the test weight back onto the center of
alarm is on. Slowly tighten the load spring
the platform floor using a suitable lifting device.
adjustment nut by turning it clockwise just until
the overload indicator light and alarm turns off. Result: The alarm should be off. The platform
overload indicator light should be off at both the
Note: The platform will need to be moved up and
ground and platform controls.
down and allowed to settle in between adjustments.
before the overload indicator light and alarm turn
before the overload indicator light turns on and the
off.
alarm sounds.
8 Add an additional 10 lb / 4.5 kg test weight to
Result: The overload indicator light and
the original test weight to overload the platform.
alarm is off. Slowly loosen the load spring
adjustment nut by turning it counterclockwise Result: The alarm should be sounding.
just until the overload indicator light and alarm The platform overload indicator light should be
turn on. flashing at both the ground and platform
controls.
before the overload indicator light turns on and the Note: There may be an approximate 2 second delay
alarm sounds. before the overload indicator light turns on and the
alarm sounds.
Note: The platform will need to be moved up and
down and allowed to settle in between adjustments. 9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
10 Turn the key switch to ground control.
controls.
Result: All ground control functions should not
operate.
Note: If the platform overload system is not
operating properly, repeat steps 1 through 4.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 25

Checklist E Procedures REV C
E-1 3 Completely drain the tank into a container of

suitable capacity. Refer to Section 2,
Test or Replace the Hydraulic Oil Specifications.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
Replacement or testing of the hydraulic oil is
essential for good machine performance and 4 Tag, disconnect and plug the hydraulic hose
service life. Dirty oil and suction strainers may from the hydraulic tank filter at the tank.
cause the machine to perform poorly and
Bodily injury hazard. Spraying
continued use may cause component damage.
hydraulic oil can penetrate and
Extremely dirty conditions may require oil changes
burn skin. Loosen hydraulic
to be performed more often.
connections very slowly to allow
Note: Before replacing the hydraulic oil, the oil may the oil pressure to dissipate
be tested by an oil distributor for specific levels of gradually. Do not allow oil to squirt
contamination to verify that changing the oil is or spray.
necessary. If the hydraulic oil is not replaced at Bodily injury hazard. Beware of
the two year inspection, test the oil quarterly. hot oil. Contact with hot oil may
Replace the oil when it fails the test. cause severe burns.
Note: Perform this procedure with the boom in the 5 Remove the hydraulic tank mounting fasteners.
stowed position.
6 Pull the hydraulic tank out slightly to access the
Note: When removing a hose assembly or fitting, two suction hoses.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during 7 Tag, disconnect and plug the two suction hoses
installation. Refer to Section 2, Hydraulic Hose and on the back of the hydraulic tank.
Fitting Torque Specifications. Bodily injury hazard. Spraying
1 Place a suitable container under the hydraulic
tank. See capacity specifications.
2 Remove the drain plug from the hydraulic tank. the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 - 26 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C CHECKLIST E PROCEDURES
8 Remove the hydraulic tank from the machine. E-2

Component damage hazard. The Grease the Steer Axle
hydraulic tank is plastic and may
become damaged if allowed to fall.
Wheel Bearings
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Rinse out the inside of the tank using a mild Maintaining the steer axle wheel bearings is
solvent. essential for safe machine operation and service
life. Operating the machine with loose or worn
11 Install the suction strainer and drain plug using
wheel bearings may cause an unsafe operating
a thread sealer on the threads.
condition and continued use may result in
12 Place the hydraulic tank onto the machine. component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
13 Install the hydraulic hoses. washing of the machine may require that this
14 Install the hydraulic tank retaining strap. procedure be performed more often.
Component damage hazard. The 1 Loosen the wheel lug nuts. Do not remove
hydraulic tank may become them.
damaged if the tank strap
2 Block the non-steer wheels, then center a lifting
fasteners are over tightened.
jack under the steer axle.
15 Fill the tank with hydraulic oil until the fluid is
3 Raise the machine 6 inches / 15 cm and place
within the FULL and ADD marks on the hydraulic
blocks under the drive chassis for support.
tank. Do not overfill.
4 Remove the lug nuts. Remove the tire and
16 Clean up any oil that may have spilled. Properly
wheel assembly.
discard of oil.
5 Check for wheel bearing wear by attempting to
17 Operate all machine functions through a full
move the wheel hub side to side, then up and
cycle and check for leaks.
down.
Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 3 - 27

CHECKLIST E PROCEDURES REV C
6 Remove the dust cap from the hub. Remove the 15 Install a new bearing grease seal into the hub by
cotter pin from the castle nut. pressing it evenly into the hub until it is flush.
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to Note: Always replace the bearing grease seal when
seat the bearings. removing the hub.
8 Loosen the castle nut and re-tighten to 16 Slide the hub onto the yoke spindle.
8 ft-lbs / 11 Nm.
Component damage hazard. Do
9 Check for wheel bearing wear by attempting to not apply excessive force or
move the wheel hub side to side, then up and damage to the lip of the seal may
down. occur.
Result: If there is no side to side or up and 17 Place the outer bearing into the hub.
down movement, continue with step 10 and
grease the wheel bearings. 18 Install the washer and castle nut.
Result: If there is side to side or up and down 19 Tighten the castle nut to 35 ft-lbs / 47 Nm to
movement, continue to step 10 and replace the seat the bearings.
wheel bearings with new ones. 20 Loosen the castle nut and re-tighten to
Note: When replacing a wheel bearing, both the 8 ft-lbs / 11 Nm.
inner and outer bearings, including the pressed-in 21 Install a new cotter pin. Bend the cotter pin
races, must be replaced. to lock it in.
10 Remove the castle nut. Note: Always use a new cotter pin when installing a
castle nut.
11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub. 22 Install the dust cap, then the tire and wheel
12 Place the hub on a flat surface and gently pry assembly. Torque the wheel lug nuts to
the bearing seal out of the hub. Remove the specification. Refer to Section 2, Specifications.
rear bearing.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of the
hub.
3 - 28 Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011 Section 4 • 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
Observe and Obey: appropriate repair procedure after troubleshooting
the problem.
Repair procedures shall be completed by a
person trained and qualified on the repair of this Perform disassembly procedures to the point
machine. where repairs can be completed. Then to
reassemble, perform the disassembly steps in
Immediately tag and remove from service a reverse order.
damaged or malfunctioning machine.
Symbols Legend
Repair any machine damage or malfunction
before operating the machine. Safety alert symbol—used to alert
personnel to potential personal
Before Repairs Start: injury hazards. Obey all safety
messages that follow this symbol
Read, understand and obey the safety rules
to avoid possible injury or death.
and operating instructions in the
Genie Z-45/25 DC and Genie Z-45/25J DC Indicates an imminently hazardous
Operator’s Manual on your machine. situation which, if not avoided, will
result in death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use. Indicates a potentially hazardous
Use only Genie approved replacement parts. could result in death or serious
Read each procedure completely and adhere injury.
to the instructions. Attempting shortcuts may Indicates a potentially hazardous
produce hazardous conditions. situation which, if not avoided,
may cause minor or moderate
Unless otherwise specified, perform each
injury.
repair procedure with the machine in the
following configuration: Indicates a potentially hazardous
• Machine parked on a firm, level surface situation which, if not avoided,
• Boom in stowed position
• Turntable rotated with the boom between Indicates that a specific result is expected after
the non-steer wheels performing a series of steps.
• Turntable secured with the turntable Indicates that an incorrect result has occurred
rotation lock after performing a series of steps.
• Key switch in the off position with the
key removed
• Wheels chocked
from the machine
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4-1

Section 4 • Repair Procedures August 2011
Platform Controls REV C
1-1 Boom Function Speed

Controllers Controller Adjustments
Note: Do not adjust the controllers unless the static
Platform Controls battery supply voltage is above 24V DC at the
The drive joystick is connected to the drive motor platform red Emergency Stop button.
controller located under the non-steer end drive Electrocution/burn hazard. Contact
chassis cover. The drive motor controller can also with electrically charged circuits
recognize machine drive malfunctions and display could result in death or serious
controller fault codes by flashing an LED at the injury. Remove all rings, watches
ground controls. See the Troubleshooting section and other jewelry.
of this manual for a list of fault codes and
additional information. There are no adjustments 1 Turn the key switch to platform control and pull
needed on the drive joystick controller. For further out the red Emergency Stop button to the on
information or assistance, consult the Genie position at both the ground and platform
Industries Service Department. controls.
2 Open the platform control box lid and locate the
boom function speed controller.
a threshold adjustable trimpot

b max-out adjustable trimpot
c white/red wire to TP6
d boom function speed controller
b a
a boom function speed controller

b drive joystick
4-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C PLATFORM CONTROLS
Before serial number 21180: 8 Set the max-out: Press down the foot switch,
then move the primary boom toggle switch in
3 Remove the wht/red wire from TP6. Temporarily the down position. Adjust the amperage to 0.54
insert a short piece of stripped wire into TP6. to 0.55A. Turn the max-out trimpot adjustment
4 Connect the red (+) lead from an amp meter to screw clockwise to increase the amperage or
the wht/red wire. Connect the black (-) lead to counterclockwise to decrease the amperage.
the piece of wire at TP6. 9 Before serial number 21180: Remove the
From serial number 21180 to 23235: temporary wire from TP6 and install the wht/red
wire into TP6.
3 Disconnect the blk/red wire of the boom
function speed controller from the wht/red wire. Boom function speed
4 Connect the red (+) lead from an amp meter to controller specifications
the blk/red wire. Connect the black (-) lead to
Threshold 0.17 to 0.18A
the wht/red wire.
All models: Max-out 0.54 to 0.55A
5 Turn the boom function speed controller to the

CREEP position.
6 Set the threshold: With the boom in the stowed

position, press down the foot switch and move
the primary boom toggle switch in the down
position until the amperage reading appears.
Adjust the amperage to 0.17 to 0.18A. Turn the
threshold trimpot adjustment screw clockwise to
increase the amperage or counterclockwise to
decrease the amperage.
7 Turn the boom function speed controller to
the 9 position.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4-3

Platform Components REV C
2-1 4 Tag, disconnect and plug the hydraulic hoses

from the slave cylinder at the unions and
Platform Leveling Slave Cylinder connect them together using a connector.
Connect the hoses from the cylinder together
The slave cylinder and the rotator pivot are the using a connector.
two primary supports for the platform. The slave
cylinder keeps the platform level through the Bodily injury hazard. Spraying
entire range of boom motion. It operates in a hydraulic oil can penetrate and
closed-circuit hydraulic loop with the master burn skin. Loosen hydraulic
cylinder. The slave cylinder is equipped with connections very slowly to allow
counterbalance valves to prevent movement in the oil pressure to dissipate
the event of a hydraulic line failure. gradually. Do not allow oil to
squirt or spray.
How to Remove the Platform 5 Remove the pin retaining fastener from the
Leveling Slave Cylinder slave cylinder rod-end pivot pin. Do not remove
the pin.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no 6 Z-45/25J: Remove the external snap rings from
air in the closed loop. the slave cylinder barrel-end pivot pin. Do not
remove the pin.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be Z-45/25: Remove the pin retaining fastener
replaced and then torqued to specification during from the slave cylinder barrel-end pivot pin. Do
installation. Refer to Section 2, Hydraulic Hose and not remove the pin.
Fitting Torque Specifications. 7 Place a block under the slave cylinder for
1 Z-45/25J: Extend the primary boom until the support. Protect the cylinder rod from damage.
slave cylinder barrel-end pivot pin is accessible.
2 Raise the primary boom slightly and place
blocks under the platform for support.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
4-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C PLATFORM COMPONENTS
8 Use a soft metal drift to drive the rod-end pivot 2-2

pin out.
Platform Rotator
Crushing hazard. The platform
could fall when the slave cylinder
rod-end pivot pin is removed if not
How to Bleed the Platform
properly supported. Rotator
Component damage hazard. The Note: This procedure will require two people.
slave cylinder rod may become
damaged if it is allowed to fall if 1 Move the function enable toggle switch to either
not properly supported by the side and activate the platform rotate toggle
lifting device. switch to the right then the left through two
platform rotation cycles, then hold the switch to
9 Use a soft metal drift and drive the barrel-end the right position until the platform is fully
pin out. rotated to the right.
10 Carefully pull the cylinder out of the primary 2 Connect a clear hose to the top bleed valve.
boom. Place the other end of the hose in a container
to collect any drainage. Secure the container to
How to Bleed the Slave Cylinder the boom.
1 Raise the primary boom to a horizontal position. 3 Open the top bleed valve on the rotator, but do
2 Move the platform level switch up and down not remove it.
a
through two platform leveling cycles to remove
any air that might be in the system.
d c b
a top bleed valve

b bottom bleed valve
c container
d clear hose
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4-5

PLATFORM COMPONENTS REV C
4 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
valve. 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 toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
valve. 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 fully in both directions and
inspect the bleed valves for leaks.
4-6 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C
Jib Boom Components, Z-45/25J
3-1 6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
Jib Boom remove the pin.
7 Remove the pin retaining fasteners from both
How to Remove the Jib Boom platform rotator pivot pins. Do not remove the
Note: Perform this procedure with the boom in the pins.
stowed position. 8 Use a soft metal drift to remove the leveling arm
Note: When removing a hose assembly or fitting, pivot pin and let the leveling arms hang down.
the O-ring on the fitting and/or hose end must be 9 Use a soft metal drift to remove the platform
replaced and then torqued to specification during rotator pivot pin and remove the platform rotator
installation. Refer to Section 2, Hydraulic Hose and from the machine.
Fitting Torque Specifications.
10 Slide both of the jib boom leveling arms off of
1 Remove the platform. the jib boom cylinder rod-end pivot pin.
2 Tag and disconnect the electrical connectors 11 Remove the hose and cable cover from the side
from the jib boom/platform rotate select of the jib boom. Remove the hose and cable
manifold mounted to the platform support. separators.
3 Tag, disconnect and plug all of the hydraulic 12 Attach a lifting strap from an overhead crane to
hoses from the jib boom/platform rotate select the jib boom.
valve manifold. Cap the fittings on the manifold
and pull the hoses out through the platform 13 Support the barrel end of the jib boom lift
rotator. cylinder with a suitable lifting device.
Bodily injury hazard. Spraying 14 Tag, disconnect and plug the jib boom lift
hydraulic oil can penetrate and cylinder hydraulic hoses. Cap the fittings on the
burn skin. Loosen hydraulic cylinder.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to burn skin. Loosen hydraulic
squirt or spray. connections very slowly to allow
4 Remove the platform mounting weldment. the oil pressure to dissipate
gradually. Do not allow oil to
5 Attach a lifting strap from an overhead crane to squirt or spray.
the platform rotator for support.
15 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4-7

JIB BOOM COMPONENTS, Z-45/25J REV C
16 Use a soft metal drift to remove the pin and let 3-2
the cylinder hang down.
Jib Boom Lift Cylinder
Crushing hazard. The jib boom
could fall when the barrel-end pivot
pin is removed if not properly
How to Remove the Jib Boom
supported by the overhead crane. Lift Cylinder
17 Remove the pin retaining fastener from the jib Note: Perform this procedure with the boom in the
boom pivot pin. Use a soft metal drift to remove stowed position.
the pin, then remove the jib boom from the
bellcrank. Note: When removing a hose assembly or fitting,
Crushing hazard. The jib boom replaced and then torqued to specification during
could become unbalanced and fall installation. Refer to Section 2, Hydraulic Hose and
when removed from the machine if Fitting Torque Specifications.
not properly attached to the
overhead crane. 1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
18 Attach a lifting strap from an overhead crane to lower the jib boom until the platform is resting
the lug on the rod end of the jib boom lift on the blocks just enough to support the
cylinder. platform.
19 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib Note: Do not rest the entire weight of the boom on
boom lift cylinder from the bellcrank. the blocks.
Crushing hazard. The jib boom lift 2 Tag, disconnect and plug the jib boom lift
cylinder could become unbalanced cylinder hydraulic hoses. Cap the fittings on the
and fall when removed from the cylinder.
machine if not properly attached to
the overhead crane. Bodily injury hazard. Spraying
the oil pressure to dissipate
squirt or spray.
4-8 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C JIB BOOM COMPONENTS, Z-45/25J
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 suitable
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.
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not properly
supported by the overhead crane.
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 jib boom lift
cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall when removed from the
the overhead crane.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4-9

Primary Boom Components REV C
4-1 5 Tag, disconnect and plug the platform rotator

hydraulic hoses at the union located above the
Cable Track primary boom lift cylinder. Cap the fittings on
the unions.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
Z-45/25 from the "V1" and "V2" ports on the
counterbalance valve manifold located on the
Note: When removing a hose assembly or fitting, platform rotator. Cap the fittings on the
the O-ring on the fitting and/or hose end must be manifold.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and Bodily injury hazard. Spraying
Fitting Torque Specifications. hydraulic oil can penetrate and
1 Locate the cables from the primary boom cable connections very slowly to allow
track to the platform control box. Number each the oil pressure to dissipate
cable and its entry location at the platform gradually. Do not allow oil to
control box. squirt or spray.
2 Disconnect the cables from the platform control 7 Tag, disconnect and plug the hydraulic hoses
box. from the platform leveling master cylinder. Cap
3 Pull all of the electrical cables out of the plastic the fittings on the cylinder.
cable track. Do not pull out the hydraulic hoses. Bodily injury hazard. Spraying
4 Raise the primary boom to a horizontal position. hydraulic oil can penetrate and
squirt or spray.
4 - 10 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C PRIMARY BOOM COMPONENTS
8 Tag and disconnect the hydraulic hoses from 14 Remove the cable track mounting fasteners that
the platform leveling slave cylinder and connect attach the lower cable track to the primary
them together using a connector. Cap the boom.
fittings on the cylinder.
15 Remove the cable track from the machine and
Bodily injury hazard. Spraying place it on a structure capable of supporting it.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
overhead crane.
squirt or spray. Component damage hazard.
Cables and hoses can be
9 Pull the four hydraulic hoses toward the
damaged if they are kinked or
platform to clear the rod end of the primary
pinched.
boom lift cylinder.
10 Place blocks in between the upper and lower How to Remove the Cable Track,
cable tracks and secure the upper and lower Z-45/25J
tracks together.
Crushing hazard. If the upper and the O-ring on the fitting and/or hose end must be
lower cable tracks are not properly replaced and then torqued to specification during
secured together, the cable track installation. Refer to Section 2, Hydraulic Hose and
could become unbalanced and fall Fitting Torque Specifications.
when removed from the machine.
1 Locate the cables from the primary boom cable
11 Remove all hose and cable clamps from the
track to the platform control box. Number each
underside of the primary boom.
cable and its entry location at the platform
12 Attach a strap from an overhead crane to the control box.
cable track.
2 Disconnect the cables from the platform control
13 Remove the mounting fasteners from the upper box.
cable track at the platform end of the extension
3 Remove the hose and cable cover from the side
boom.
of the jib boom. Remove the hose and cable
separators.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 11

PRIMARY BOOM COMPONENTS REV C
4 Remove the hose clamp on the primary boom 8 Tag, disconnect and plug the hydraulic hoses
bellcrank. from the jib boom/platform rotate manifold. Cap
the fittings on the manifold.
5 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses. Bodily injury hazard. Spraying
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.
squirt or spray.
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.
gradually. Do not allow oil to Bodily injury hazard. Spraying
squirt or spray. hydraulic oil can penetrate and
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
squirt or spray.
using a connector.
10 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master cylinder. Cap
the fittings on the cylinder.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to burn skin. Loosen hydraulic
squirt or spray. connections very slowly to allow
squirt or spray.
4 - 12 Z-45/25 DC • Z-45/25J DC Part No. 106726

11 Raise the boom to a horizontal position. 20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
12 Place blocks between the upper and lower cable
primary boom lift cylinder.
tracks and secure the upper and lower tracks
together. 21 Raise the rod end of the primary boom lift
cylinder back into position and install the rod-
Crushing hazard. If the upper and
end pivot pin. Install the pin retaining fasteners.
lower cable tracks are not properly
secured together, the cable track 22 Attach a strap from an overhead crane to the
could become unbalanced and fall cable track.
when removed from the machine.
23 Remove the mounting fasteners from the upper
13 Attach a lifting strap from an overhead 5 ton / cable track at the platform end of the extension
5,000 kg capacity crane to the platform end of boom.
the primary boom for support. Do not lift it.
24 Remove the cable track mounting fasteners that
14 Remove all hose and cable clamps from the attach the lower cable track to the primary
underside of the primary boom. boom.
15 Support the rod end of the primary boom lift 25 Remove the cable track from the machine and
cylinder with a suitable lifting device. place it on a structure capable of supporting it.
16 Remove the pin retaining fasteners from the Crushing hazard. The cable track
primary boom lift cylinder rod-end pivot pin. Do could become unbalanced and fall
not remove the pin. if not properly attached to the
overhead crane.
17 Raise the primary boom slightly with the
overhead crane to relieve the pressure on the Component damage hazard.
primary boom lift cylinder rod-end pivot pin. Cables and hoses can be
damaged if they are kinked or
18 Use a soft metal drift to remove the primary
pinched.
boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the lifting device.
19 Lower the rod end of the primary boom lift
cylinder approximately 12 inches / 30 cm.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 13

How to Repair the Primary Boom 4-2

Cable Track Primary Boom
Component damage hazard. The
primary boom cable track can be How to Remove the Primary
damaged if it is twisted. Boom
Note: A 7 link repair section of cable track is Bodily injury hazard. This
available through the Genie Service Parts procedure requires specific repair
Department. skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
a component damage. Dealer
service is strongly recommended.
b Note: Perform this procedure with the boom in the
stowed position.
a link separation point the O-ring on the fitting and/or hose end must be
b lower clip
1 Use a slotted screwdriver to pry down on the installation. Refer to Section 2, Hydraulic Hose and
lower clip. Fitting Torque Specifications.
2 To remove a single link, open the lower clip 1 Remove the platform.
and then use a screw driver to pry the link to
2 Z-45/25: Remove the platform rotator and
the side.
platform mounting weldment.
3 Repeat steps 1 and 2 for each link.
Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
3 Remove the cable track. See 4-1, How to
Remove the Cable Track.
4 Raise the primary boom to a horizontal position.
4 - 14 Z-45/25 DC • Z-45/25J DC Part No. 106726

5 Remove the hose and cable cover from the 13 Remove the hose clamp at the pivot end of the
upper pivot. boom.
6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead crane to the
master cylinder barrel-end pivot pin. Use a soft center point of the primary boom.
metal drift to remove the pin. Then lower the
15 Attach a similar lifting device to the primary
cylinder and let it hang down.
boom lift cylinder.
Component damage hazard.
16 Place support blocks under the primary boom
When lowering the master cylinder
lift cylinder.
down, be sure not to damage the
master cylinder hoses or fittings. 17 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
7 Locate the primary boom drive speed limit
a soft metal drift to remove the pin.
switch inside of the upper pivot.
Crushing hazard. The boom lift
8 Remove the primary boom drive speed limit
cylinder and primary boom will fall
switch mounting fasteners. Do not disconnect
if not properly supported.
the wiring.
18 Lower the rod end of the primary boom lift
9 Locate the primary extension boom drive speed
cylinder onto support blocks. Protect the
limit switch inside of the extension boom.
cylinder rod from damage.
10 Remove the primary extension boom drive
19 Remove the pin retaining fasteners from the
speed limit switch mounting fasteners. Do not
primary boom pivot pin.
disconnect the wiring.
20 Remove the primary boom pivot pin with a soft
11 Pull the limit switch and the wiring out of the
metal drift, then carefully remove the primary
extension tube and move it out of the way.
boom from the machine and place it on a
12 Tag, disconnect and plug the primary boom structure capable of supporting it.
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
boom could become unbalanced
Bodily injury hazard. Spraying and fall when removed from the
hydraulic oil can penetrate and machine if not properly attached to
burn skin. Loosen hydraulic the overhead crane.
squirt or spray.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 15

How to Disassemble the Primary 6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
Boom platform end of the extension tube. Use a soft
Note: Complete disassembly of the boom is only metal drift to remove the pin.
necessary 7 Support and slide the extension cylinder out of
if the outer or inner boom tube must be replaced. the base end of the extension tube. Place the
The extension cylinder can be removed without extension cylinder on blocks for support.
completely disassembling the boom. See 4-4, How
to Remove the Primary Boom Extension Cylinder. Crushing hazard. The extension
cylinder could become unbalanced
1 Remove the primary boom. See How to Remove and fall when removed from
the Primary Boom. primary boom extension tube if not
properly supported.
2 Place blocks under the barrel end of the primary
boom extension cylinder for support. Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
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.
4 Remove and label the location of the wear pads
from the platform end of the primary boom.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
5 Support and slide the extension tube and

extension cylinder assembly out of the boom
tube.
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
4 - 16 Z-45/25 DC • Z-45/25J DC Part No. 106726

4-3 6 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on the
Primary Boom Lift Cylinder cylinder.
The primary boom lift cylinder raises and lowers the Bodily injury hazard. Spraying
primary boom. The primary boom lift cylinder is hydraulic oil can penetrate and
equipped with a counterbalance valve to prevent burn skin. Loosen hydraulic
movement in the event of a hydraulic line failure. connections very slowly to allow
How to Remove the Primary gradually. Do not allow oil to
squirt or spray.
Boom Lift Cylinder
Bodily injury hazard. This primary boom lift cylinder rod-end pivot pin. Use
procedure requires specific repair a soft metal drift to remove the pin.
skills, lifting equipment and a
suitable workshop. Attempting this Crushing hazard. The primary
procedure without these skills and boom will fall if not properly
tools could result in death or supported when the primary boom
serious injury and significant rod-end pivot pin is removed.
component damage. Dealer 8 Place a support block across both turntable
service is strongly recommended. covers under the primary boom lift cylinder.
Note: When removing a hose assembly or fitting, 9 Lower the rod end of the lift cylinder onto the
the O-ring on the fitting and/or hose end must be block. Protect the cylinder rod from damage.
installation. Refer to Section 2, Hydraulic Hose and Crushing hazard. The primary
Fitting Torque Specifications. boom lift cylinder could fall if not
properly supported.
1 Raise the primary boom to a horizontal position.
10 Support the barrel end of the primary boom lift
2 Raise the secondary boom until the primary cylinder with an overhead crane or similar lifting
boom lift cylinder barrel-end pivot pin is above device.
the turntable covers.
11 Remove the primary boom lift cylinder barrel-
3 Attach a 5 ton / 5000 kg overhead crane to the end pivot pin retaining fasteners. Use a slide
primary boom for support. hammer to remove the barrel-end pivot pin.
4 Raise the primary boom with the overhead Carefully remove the primary boom lift cylinder
crane slightly to take the pressure off the from the machine.
primary boom lift cylinder pivot pins. Crushing hazard. The lift cylinder
5 Support the rod end and the barrel end of the could become unbalanced and fall
primary boom lift cylinder with a second if not properly supported and
overhead crane or similar lifting device. secured to the lifting device.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 17

4-4 4 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the
Primary Boom Extension fittings on the cylinder.
Cylinder Bodily injury hazard. Spraying
The primary boom extension cylinder extends and burn skin. Loosen hydraulic
retracts the primary boom extension tube. The connections very slowly to allow
primary boom extension cylinder is equipped with the oil pressure to dissipate
counterbalance valves to prevent movement in the gradually. Do not allow oil to
event of a hydraulic line failure. squirt or spray.
How to Remove the Primary 5 At the platform end of the boom, remove the
external snap rings from the extension cylinder
Boom Extension Cylinder rod-end pivot pin. Use a soft metal drift to
Bodily injury hazard. This remove the pin.
procedure requires specific repair
6 Remove the barrel-end pivot pin retaining
skills, lifting equipment and a
fasteners.
suitable workshop. Attempting this
procedure without these skills and 7 Place a rod through the barrel-end pivot pin and
tools could result in death or twist to remove the pin.
serious injury and significant
8 Support and slide the extension cylinder out of
component damage. Dealer
the upper pivot.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. Component damage hazard. Be
careful not to damage the
1 Raise the primary boom to a horizontal position. counterbalance valves on the
2 Extend the primary boom until the primary primary boom extension cylinder
boom extension cylinder rod-end pivot pin is when removing the cylinder from
accessible in the primary boom extension tube. the primary boom.
3 Remove the hose and cable guard from the Component damage hazard. Hoses
upper pivot. and cables can be damaged if the
primary boom extension cylinder is
dragged across them.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.
4 - 18 Z-45/25 DC • Z-45/25J DC Part No. 106726

4-5 3 Attach overhead crane or similar lifting device to

the master cylinder.
Platform Leveling
Master Cylinder master cylinder barrel-end pivot pin.
The master cylinder acts as a pump for the slave 5 Place a rod through the barrel-end pivot pin and
cylinder. It’s part of the closed circuit hydraulic loop twist to remove the pin.
that keeps the platform level through the entire
6 Remove the pin retaining fastener from the rod-
range of boom motion. The master cylinder is
end pivot pin.
located at the base of the primary boom.
7 Place a rod through the rod-end pivot pin and
How to Remove the Platform twist to remove the pin.
Leveling Master Cylinder 8 Remove the master cylinder from the machine.
Note: When removing a hose assembly or fitting, Crushing hazard. The master
the O-ring on the fitting and/or hose end must be cylinder could become unbalanced
replaced and then torqued to specification during and fall if not properly attached to
installation. Refer to Section 2, Hydraulic Hose and the overhead crane.
1 Raise the secondary boom until both the rod-end
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.
squirt or spray.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 19

Secondary Boom Components REV C
a b c
h d
Secondary Boom components

a upper secondary boom
(number 1 arm)
b upper tension link
(number 2 arm)
c lower tension link
(number 3 arm)
d mid-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 pivot
4 - 20 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C SECONDARY BOOM COMPONENTS
5-1 5 Attach a lifting strap from an overhead crane to

the lug on the rod end of the primary boom lift
Secondary Boom cylinder. Then raise the primary boom lift
cylinder with the crane, to a vertical position.
How to Disassemble the 6 Tag, disconnect and plug the hydraulic hoses at
Secondary Boom the primary boom lift cylinder. Cap the fittings
on the cylinder.
Bodily injury hazard. The
procedures in this section require Bodily injury hazard. Spraying
specific repair skills, lifting hydraulic oil can penetrate and
equipment and a suitable burn skin. Loosen hydraulic
workshop. Attempting this connections very slowly to allow
procedure without these skills and the oil pressure to dissipate
tools could result in death or gradually. Do not allow oil to squirt
serious injury and significant or spray.
component damage. Dealer
service is required.
primary boom lift cylinder barrel-end pivot pin.
Follow the disassembly steps to the point required
8 Use a slide hammer to remove the pin. Remove
to complete the repair. Then reassemble the
the primary boom lift cylinder from the machine.
secondary boom by following the disassembly
steps in reverse order. Crushing hazard. The primary
boom lift cylinder could become
Note: When removing a hose assembly or fitting, unbalanced and fall if not properly
the O-ring on the fitting and/or hose end must be supported by the overhead crane.
installation. Refer to Section 2, Hydraulic Hose and 9 Tag, disconnect and plug the hydraulic hoses
Fitting Torque Specifications. on both of the secondary boom lift cylinders.
Cap the fittings on the cylinders.
1 Remove the platform.
2 Z-45/25J: Remove the jib boom. hydraulic oil can penetrate and
See 3-1, How to Remove the Jib Boom. burn skin. Loosen hydraulic
3 Remove the primary boom. See 3-2, How to connections very slowly to allow
Remove the Primary Boom. the oil pressure to dissipate
4 Remove the master cylinder. See 4-5, How to or spray.
Remove the Master Cylinder.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 21

SECONDARY BOOM COMPONENTS REV C
10 Remove the pin retaining fasteners from both 17 Attach a lifting strap from a second overhead
sides of the secondary boom lift cylinder rod- crane to the number 1 arm at the mid-point
end pivot pin and barrel-end pivot pin. Do not between the upper pivot and mid-pivot.
remove the pins.
11 Attach a strap from an overhead crane to the number 1 arm pivot pins at the mid-pivot and
lug on the rod end of one of the secondary the upper pivot. Do not remove the pins.
boom lift cylinders for support. Do not apply any
19 Use a soft metal drift to drive both pins out.
lifting pressure.
20 Remove the number 1 arm from the machine.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of Crushing hazard. The number 1
the secondary boom lift cylinder and let it hang arm could become unbalanced
down. and fall when removed from the
13 Use a soft metal drift to drive the rod-end pivot
the overhead crane.
pin half way out.
Crushing hazard. The upper pivot
14 Remove the secondary boom lift cylinder from
could fall when the number 1 arm
the machine.
is removed from the machine if not
15 Repeat steps 11 through 14 for the other properly supported by the
secondary boom lift cylinder. overhead crane.
Crushing hazard. The secondary 21 Using the overhead crane attached to the upper
boom lift cylinder could become pivot, raise the secondary boom assembly
unbalanced and fall when approximately 30 inches / 76 cm.
removed from the machine if not
22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
properly attached to the overhead
between the number 2 arm and the boom rest.
crane.
Then lower the secondary boom assembly onto
Component damage hazard. When the block.
removing a secondary boom lift
Crushing hazard. The secondary
cylinder from the machine, be
boom assembly could fall if not
properly supported by the
counterbalance valve at the barrel
4 x 4 x 11 inch / 10 x 10 x
end of the cylinder.
28 cm block.
16 Attach a lifting strap from an overhead crane to
the upper pivot for support. Do not lift it.
4 - 22 Z-45/25 DC • Z-45/25J DC Part No. 106726

23 Pull all of the cables and hoses out through the 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
upper pivot. block between the number 3 arm and the
number 4 arm at the mid-pivot end.
Component damage hazard.
Cables and hoses can be 32 Attach a lifting strap from the overhead crane to
damaged if they are kinked or the mid-pivot for support. Do not lift it.
pinched.
24 Remove the hose and cable covers from the top number 2, 3 and 4 arm pivot pins at the
of the number 2 arm. mid-pivot. Do not remove the pins.
25 Pull all of the hoses and cables out of the upper 34 Use a soft metal drift to drive each pin out. Then
pivot and out through the mid-pivot. Lay the remove the mid-pivot from the secondary boom
hoses and cables on the ground. assembly.
Component damage hazard. Crushing hazard. The mid-pivot
Cables and hoses can be could become unbalanced and fall
damaged if they are kinked or when removed from the
pinched. secondary boom assembly if not
overhead crane.
number 2 arm pivot pin at the upper pivot. Use
a soft metal drift to remove the pin. 35 Attach the lifting strap from an overhead crane
to the center point of the number 2 arm for
27 Remove the upper pivot from the machine.
support. Do not lift it.
Crushing hazard. The upper pivot
36 Remove the pin retaining fasteners from both
could become unbalanced and fall
compression link pivot pins. Do not remove the
when removed from the machine if
pins.
not properly attached to the
overhead crane. 37 Use a soft metal drift to remove the lower
compression link pivot pin at the number 3 arm.
28 Attach the lifting strap from an overhead crane
to the number 2 arm at the upper pivot end. 38 Support the compression link with an
appropriate lifting device.
29 Raise the number 2 arm slightly and remove the
4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest
pad.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 23

39 Use a soft metal drift to remove the upper 43 Open the ground controls side turntable cover.
compression link pivot pin from the number 2
44 Remove the retaining fastener from the ground
arm. Remove the compression link from the
control box and function manifold pivot plate.
machine.
45 Lower the ground control box and function
Crushing hazard. The number 2
manifold pivot plate to access the number 3
arm could fall when the
arm pivot pin.
compression link is disconnected
from the number 2 arm if not 46 Attach the lifting strap from the overhead crane
properly supported by the to the centerpoint of the number 3 arm for
overhead crane. support. Do not lift it.
Crushing hazard. The 47 Remove the mounting fasteners from the cover
compression link may fall if not located in the boom storage area to access the
properly supported when removed number 3 and number 4 arm pivot pin retaining
from the secondary boom fasteners at the turntable riser.
assembly.
40 Remove the number 2 arm from the machine. number 3 arm at the turntable riser. Do not
remove the pin.
arm could become unbalanced 49 Use a slide hammer to remove the number 3
and fall when removed from the arm pivot pin from the turntable pivot through
secondary boom assembly if not the access hole behind the ground control box.
overhead crane. 50 Remove the number 3 arm from the machine.
41 Remove the upper and lower hose and cable Crushing hazard. The number 3
covers from the number 3 arm. arm could become unbalanced
42 Pull all of the cables and hoses from the machine if not properly supported
number 3 arm and lay them over the turntable by the overhead crane.
counterweight.
51 Remove the upper and lower hose and cable
Component damage hazard. covers from the number 3 arm.
Cables and hoses can be
damaged if they are kinked or 52 Remove the secondary boom drive speed limit
pinched. switch mounting fasteners from the number 4
arm at the mid-pivot end. Do not disconnect the
wiring.
4 - 24 Z-45/25 DC • Z-45/25J DC Part No. 106726


number 4 arm at the turntable riser. Do not
remove the pin.
54 Attach a lifting strap from the overhead crane to
the center point of the number 4 arm. Do not
lift it.
55 Use a slide hammer to remove the number 4
arm from the turntable riser through the ground
controls side bulkhead.
56 Remove the number 4 arm from the machine.
arm could become unbalanced
machine if not properly supported
by the overhead crane.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 25

5-2 3 Tag, disconnect and plug the hydraulic hoses

on the secondary boom lift cylinder.
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders hydraulic oil can penetrate and
incorporated in the structure of the secondary burn skin. Loosen hydraulic
boom assembly. These cylinders operate in connections very slowly to allow
parallel and require hydraulic pressure to extend the oil pressure to dissipate
and retract. Each secondary boom lift cylinder is gradually. Do not allow oil to squirt
equipped with a counterbalance valve to prevent or spray.
movement in the event of a hydraulic line failure. 4 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin
How to Remove a Secondary and barrel-end pivot pin. Do not remove the
Boom Lift Cylinder pins.
Bodily injury hazard. This 5 Attach a strap from an overhead crane to the
procedure requires specific repair lug on the rod end of the secondary boom lift
skills, lifting equipment and a cylinder for support. Do not apply any lifting
suitable workshop. Attempting this pressure.
procedure without these skills and 6 Use a soft metal drift to drive the barrel-end
tools could result in death or pivot pin half way out. Lower the barrel end of
serious injury and significant the secondary boom lift cylinder and let it hang
component damage. Dealer down.
7 Use a soft metal drift to drive the rod-end pivot
Note: When removing a hose assembly or fitting, pin half way out.
replaced and then torqued to specification during 8 Remove the secondary boom lift cylinder from
installation. Refer to Section 2, Hydraulic Hose and the machine.
Crushing hazard. The secondary
1 Lower the secondary boom to the stowed boom lift cylinder could become
position. unbalanced and fall when
2 Raise the primary boom so that it is above the properly attached to the overhead
secondary boom lift cylinder rod-end pivot pin. crane.
Component damage hazard. When
removing a secondary boom lift
cylinder from the machine, be
counterbalance valve at the barrel
end of the cylinder.
4 - 26 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C
Hydraulic Pumps
6-1 6-2
Auxiliary Pump Function Pump
How to Remove the Auxiliary How to Remove the Function

Pump Pump
Note: When removing a hose assembly or fitting, Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. Fitting Torque Specifications.
1 Place a suitable container under the hydraulic 1 Place a suitable container under the hydraulic
tank. See capacity specifications. tank. See capacity specifications.
2 Remove the drain plug from the hydraulic tank. 2 Remove the drain plug from the hydraulic tank.
3 Completely drain the hydraulic tank into a 3 Completely drain the hydraulic tank into a
container of suitable capacity. Refer to container of suitable capacity. Refer to
Section 2, Specifications. Section 2, Specifications.
Bodily injury hazard. Beware of Bodily injury hazard. Beware of
hot oil. Contact with hot oil may hot oil. Contact with hot oil may
cause severe burns. cause severe burns.
4 Tag, disconnect and plug the hydraulic hoses 4 Tag, disconnect and plug the hydraulic hoses
from the auxiliary pump. from the pump.
Bodily injury hazard. Spraying Bodily injury hazard. Spraying
hydraulic oil can penetrate and hydraulic oil can penetrate and
burn skin. Loosen hydraulic burn skin. Loosen hydraulic
connections very slowly to allow connections very slowly to allow
the oil pressure to dissipate the oil pressure to dissipate
gradually. Do not allow oil to squirt gradually. Do not allow oil to squirt
or spray. or spray.
5 Remove the auxiliary pump mounting bolts. 5 Remove the pump mounting bolts. Carefully
Carefully remove the pump. remove the pump.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 27

Manifolds REV C
7-1
Function Manifold Components (before serial number 17841)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque
1 Differential sensing valve .................. A ........... All functions ....................................... 20-25 ft-lbs / 27-34 Nm
2 Solenoid valve, N.O. poppet .............. B ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
3 Orifice, 0.050 inch / 1.27 mm ............. C ........... Brake circuit
4 Orifice, 0.060 inch / 1.5 mm ............... D ........... Steer circuit
5 Solenoid valve, 3 position 4 way ....... E ........... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
6 Solenoid valve, N.C. poppet .............. F ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
7 Proportional solenoid valve ............... G ........... All functions ....................................... 25-30 ft-lbs / 34-41 Nm
8 Solenoid valve, 3 position 4 way ....... H ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
9 Counterbalance valve ........................ I ............ Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
10 Solenoid valve, 3 position 4 way ....... J ............ Jib boom up/down and
Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm
11 Solenoid valve, 3 position 4 way ....... K ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
12 Solenoid valve, 3 position 4 way ....... L ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
13 Solenoid valve, 3 position 4 way ....... M .......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
14 Solenoid valve, 2 position 3 way ....... N ........... Primary boom extend ........................ 20-25 ft-lbs / 27-34 Nm
15 Orifice, 0.037 inch / 0.94 mm ............. O ........... Secondary boom up
16 Solenoid valve, 2 position 3 way ....... P ........... Primary boom retract ........................ 20-25 ft-lbs / 27-34 Nm
17 Relief valve, 2300 psi / 158.7 bar
(before serial number 11819) ............ Q ........... Primary boom down ........................... 25-30 ft-lbs / 34-41 Nm
18 Relief valve, 1800 psi / 124.1 bar ...... R ........... Secondary boom down ...................... 25-30 ft-lbs / 34-41 Nm
19 Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... S ........... Turntable rotate left/right
(prevents overflowing
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
This list continues. Please turn the page
4 - 28 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
25
24
15
23
16
22 21 20 19 18 17
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 29

MANIFOLDS REV C
Function Manifold Components (before serial number 17841), continued

Index Schematic

0.6 gpm / 2.27 L/min .......................... T ........... Jib boom up/down,
platform rotate left/right and
platform level up/down
(prevents overflowing
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
21 Counterbalance valve ........................ U ........... Platform level down ........................... 35-40 ft-lbs / 47-54 Nm
22 Relief valve, 3200 psi / 220.6 bar ...... V ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
23 Diagnostic nipple ............................... W .......... Testing
24 Check valve ....................................... X ........... Pressure switch circuit ........................ 10-12 ft-lbs / 14-6 Nm
25 Pressure switch ................................. Y ........... Brake circuit
4 - 30 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
25
24
15
23
16
22 21 20 19 18 17
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 31

MANIFOLDS REV C
7-2
Function Manifold Components (from serial number 17841 to 20379)
Index Schematic
1 Solenoid valve, 2 position 3 way ....... AA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 2 position 3 way ....... AB ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ....... AC ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... AD ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... AE ......... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ....... AF ......... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
7 Counterbalance valve ........................ AG ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
8 Solenoid valve, 3 position 4 way ....... AH ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm
9 Solenoid valve, 3 position 4 way ....... AI .......... Steer left/right ............................................... 25 ft-lbs / 34 Nm
10 Proportional solenoid valve ............... AJ ......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
11 Differential sensing valve .................. AK ......... All functions .................................................. 25 ft-lbs / 34 Nm
12 Solenoid valve, 2 position 2 way,
N.C. poppet ....................................... AL ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
13 Relief valve, 1800 psi / 124 bar ......... AM ........ Secondary boom down ................................ 20 ft-lbs / 27 Nm
0.6 gpm / 2.27 L/min .......................... AN ........ Platform rotate, turntable rotate
and jib boom circuits (Z-45/25J) .................. 20 ft-lbs / 27 Nm
15 Flow control valve,
0.1 gpm / 0.38 L/min .......................... AO ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
16 Counterbalance valve ........................ AP ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
17 Relief valve, 3200 psi / 220.6 bar ...... AQ ........ System relief ................................................ 20 ft-lbs / 27 Nm
18 Diagnostic nipple ............................... AR ........ Testing
19 Check valve ....................................... AS ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
20 Orifice, 0.060 inch / 1.5 mm ............... AT ......... Steer circuit
21 Pressure switch ................................. AU ........ Brake circuit
N.O. poppet ....................................... AV ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm
(located under item VV) ..................... AW ........ Brake circuit
23 Orifice, 0.046 inch / 1.17 mm ............. AX ......... Secondary boom up
4 - 32 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9
10
11
12
23
22
21
20
19
18
17 16 15 14 13
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 33

MANIFOLDS REV C
7-3
Index Schematic
1 Solenoid valve, 2 position 3 way ....... BA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... BB ......... Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... BC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... BD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... BE ......... Platform rotate left/right and
6 Solenoid valve, 3 position 4 way ....... BF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Solenoid valve, 3 position 4 way ....... BG ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
8 Proportional solenoid valve ............... BH ........ Controls flow to functions ............................. 27 ft-lbs / 37 Nm
N.C. poppet ....................................... BI .......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
10 Solenoid valve, 2 position 3 way ....... BJ ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
0.6 gpm / 2.27 L/min .......................... BK ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
12 Counterbalance valve ........................ BL ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
13 Flow control valve .............................. BM ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
14 Relief valve, 3200 psi / 220.6 bar ...... BN ........ System relief ................................................ 20 ft-lbs / 27 Nm
15 Diagnostic nipple ............................... BO ........ Testing
16 Check valve ....................................... BP ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... BQ ........ Steer circuit
18 Differential sensing valve .................. BR ........ All functions .................................................. 25 ft-lbs / 34 Nm
19 Pressure switch ................................. BS ......... Brake circuit
N.O. poppet ....................................... BT ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
(located under item BT) ..................... BU ........ Brake circuit
21 Orifice, 0.046 inch / 1.17 mm ............. BV ......... Secondary boom up
22 Counterbalance valve ........................ BW ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
23 Relief valve, 1800 psi / 124 bar ......... BX ......... Secondary boom down ................................ 20 ft-lbs / 27 Nm
4 - 34 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
1 2 3 4 5 6 7
8
23 9
22
21
20
19
18
10
17
16
15
14 13 12 11
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 35

MANIFOLDS REV C
7-4
Index Schematic
1 Solenoid valve, 2 position 3 way ....... CA ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... CB ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... CC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... CD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... CE ........ Platform rotate left/right and
6 Solenoid valve, 3 position 4 way ....... CF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Shuttle valve ...................................... CG ........ Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm
8 Solenoid valve, 3 position 4 way ....... CH ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
9 Proportional solenoid valve ............... CI .......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
10 Pressure switch ................................. CJ ......... Brake circuit
11 Solenoid valve, 2 position 3 way ....... CK ........ Primary boom extend ................................... 20 ft-lbs / 27 Nm
0.4 gpm / 1.5 L/min ............................ CL ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
13 Needle valve ...................................... CM ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar ......... CN ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar ...... CO ........ System relief ................................................ 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar ............... CP ........ Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... CQ ........ Steer circuit
18 Orifice, 0.030 inch / 0.76 mm ............. CR ........ Proportional valve circuit
19 Solenoid valve, 2 position 3 way ....... CS ........ Brake circuit ................................................. 20 ft-lbs / 27 Nm
(from serial number 22566 to 22628
and after serial number 23235)
(located under item CS) ..................... CT ......... Brake circuit
20 Orifice, 0.037 inch / 0.94 mm ............. CU
21 Check valve, pilot operated ............... CV ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar ......... CW ....... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm
4 - 36 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
1 2 3 4 5 6 7 8
22
10
21
20
19
18
17
16
11
15 14 13 12
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 37

MANIFOLDS REV C
7-5 How to Adjust the Primary Boom

Valve Adjustments - Down Relief Valve
Function Manifold (before serial number 11819)
Note: Perform this procedure with the boom in the
How to Adjust the System stowed position.
Relief Valve 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
Note: Perform this procedure with the boom in the gauge to the test port on the function manifold.
stowed position.
2 Move and hold the function enable toggle switch
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure to either side and hold the primary boom
gauge to the test port on the function manifold. up/down toggle switch in the down direction
with the primary boom fully lowered. Observe
2 Move and hold the function enable toggle switch the pressure reading on the pressure gauge.
to either side and hold the primary boom Refer to Section 2, Specifications.
extend/retract toggle switch in the retract
direction with the primary boom fully retracted. 3 Turn the machine off. Hold the primary boom
Observe the pressure reading on the pressure down relief valve with a wrench and remove
gauge. Refer to Section 2, Specifications. the cap (item Q).
3 Turn the machine off. Hold the system relief 4 Adjust the internal hex socket. Turn it clockwise
valve with a wrench and remove the cap to increase the pressure or counterclockwise to
(item V, AQ, BN or CO). decrease the pressure. Install the relief valve
cap.
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to Tip-over hazard. Do not adjust
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 5 Repeat steps 2 through 4 and recheck relief
the relief valve higher than valve pressure.
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
4 - 38 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
How to Adjust the Secondary

Boom Down Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port on the function manifold.
2 Move and hold the function enable toggle switch
to either side and hold the secondary boom
up/down toggle switch in the down direction
with the secondary boom fully lowered.
Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
3 Turn the machine off. Hold the secondary boom
down relief valve with a wrench and remove
the cap (item R, AM, BX or CW).
4 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.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 39

MANIFOLDS REV C
7-6
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to platform support.

Index Schematic
1 Solenoid valve, 2 position 2 way ...... DA ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
2 Solenoid valve, 2 position 2 way ...... DB ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
3 Solenoid valve, 2 position 3 way ...... DC ........ Jib boom / platform rotate select .................. 20 ft-lbs / 27 Nm
1 2 3 1 2
From serial number

Before serial number 16963
16963 to 22565
From serial number 22566 to 23235
4 - 40 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV C MANIFOLDS
7-7
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
1 Shuttle valve 2 position 3 way ........... CX ........ Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ CY ........ Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve ........................ CZ ........ Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm
1 2 3
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 41

Turntable Rotation Components REV B
8-1 3 Remove the retaining fasteners from the center

turntable cover. Remove the cover from the
Rotation Hydraulic Motor machine.
(before serial number 18367) 4 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor manifold. Cap
How to Remove the Rotation the fittings on the manifold.
Hydraulic Motor Bodily injury hazard. Spraying
installation. Refer to Section 2, Hydraulic Hose and
or spray.
1 Raise the secondary boom until the upper pivot
5 Remove the turntable rotation motor mounting
is above the turntable covers. Turn the machine
fasteners. Remove the motor from the brake.
off.
6 Remove the turntable rotation motor from the
2 Secure the turntable from rotating with the
machine.
turntable rotation lock pin.
Crushing hazard. The machine
could tip over when the turntable
rotation assembly is removed if
the turntable rotation lock is not in
the locked position.
Unlocked position
Locked position
4 - 42 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV B TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable 3 Remove the retaining fasteners from the center
Rotation Brake machine.
(before serial number 18367) 4 Tag, disconnect and plug the hydraulic hoses
Note: When removing a hose assembly or fitting, from the turntable rotation motor manifold and
the O-ring on the fitting and/or hose end must be the brake. Cap the fittings on the manifold and
replaced and then torqued to specification during the brake.
installation. Refer to Section 2, Hydraulic Hose and Bodily injury hazard. Spraying
Fitting Torque Specifications. hydraulic oil can penetrate and
1 Raise the secondary boom until the upper pivot burn skin. Loosen hydraulic
is above the turntable covers. Turn the machine connections very slowly to allow
off. the oil pressure to dissipate
2 Secure the turntable from rotating with the or spray.
5 Remove the turntable rotation motor mounting
Crushing hazard. The machine fasteners. Remove the motor from the brake.
rotation assembly is removed if 6 Remove the brake mounting bolts. Remove the
the turntable rotation lock is not in turntable rotation brake from the machine.
the locked position. Crushing hazard. The machine
rotation assembly is removed if
Unlocked position
Locked position
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 43

TURNTABLE ROTATION COMPONENTS REV B
8-2 3 Remove the retaining fasteners from the center

Turntable Rotation Assembly machine.
(from serial number 18367 4 Tag, disconnect and plug the hydraulic hoses
to 23235) from the turntable rotation motor manifold. Cap
the fittings on the manifold.
How to Remove the Turntable Bodily injury hazard. Spraying
Rotation Assembly hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring on the fitting and/or hose end must be the oil pressure to dissipate
replaced and then torqued to specification during gradually. Do not allow oil to squirt
installation. Refer to Section 2, Hydraulic Hose and or spray.
5 Attach a lifting strap from an overhead crane or
1 Raise the secondary boom until the upper pivot other suitable lifting device to the turntable
is above the turntable covers. Turn the machine rotation assembly.
off.
6 Remove the turntable rotation assembly
2 Secure the turntable from rotating with the mounting fasteners.
7 Carefully remove the turntable rotation
Crushing hazard. The machine assembly from the machine.
rotation assembly is removed if Crushing hazard. The machine
the turntable rotation lock is not in could tip over when the turntable
the locked position. rotation assembly is removed if
Crushing hazard. The turntable
rotation assembly could become
unbalanced and fall when
Unlocked position
overhead crane.
Locked position
4 - 44 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV B
Motor Controller
9-1 4 Press the release tab on the motor controller
harness connector and remove the motor
Motor Controller controller harness connector from the motor
controller.
The drive motor controller is located under the non-
steer end drive chassis cover. The drive motor 5 Connect the leads from an ohmmeter to test
controller can recognize machine drive each motor controller terminal combination
malfunctions and display controller fault codes by listed below and check for resistance.
flashing a LED at the ground controls and on the Result: All desired results must be 500 kilohms
motor controller. See the Troubleshooting section
or more. If any test has a result less than
of this manual for a list of fault codes and
500 kilohms, replace the motor controller.
additional information. There are no adjustments
needed on the drive joystick controller. For further
information or assistance, consult the Genie Test Desired result
(in kilohms)
Industries Service Department.
F1 to F2 500kΩ or more
How to Test the Motor Controller
Note: Use the following procedure to test the motor F1 to B- 500kΩ or more
controller. If the motor controller is found to be
faulty, note which test failed and which fault code F1 to M- 500kΩ or more
(if any) was present at the time of failure.
F1 to B+ 500kΩ or more
1 Turn the key switch to the off position and
disconnect the battery packs from the machine. F2 to B- 500kΩ or more
2 Remove the chassis cover from the non-steer F2 to M- 500kΩ or more

end of the machine.
F2 to B+ 500kΩ or more
3 Tag and disconnect all power cables from the
motor controller.
B- to M- 500kΩ or more
with electrically charged circuits M- to B+ 500kΩ or more
could result in death or serious
injury. Remove all rings, watches Pin 17 to B- 500kΩ or more
and other jewelry.
Pin 20 to B- 500kΩ or more
Part No. 106726 Z-45/25 DC • Z-45/25J DC 4 - 45

4 - 46 Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie Z-45/25 DC and Genie Z-45/25J DC
Operator’s Manual on your machine.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropriate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing

before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
• Machine parked on a firm, level surface
with electrically charged circuits
• Boom in stowed position may result in death or serious
• Turntable rotated with the boom between injury. Remove all rings, watches
the non-steer wheels and other jewelry.
• Key switch in the off position with the Bodily injury hazard. Spraying
key removed hydraulic oil can penetrate and
• Wheels chocked burn skin. Loosen hydraulic
from the machine
squirt or spray.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 5-1

Section 5 • Fault Codes August 2011
FAULT CODES
Tip-over hazard. When adjusting The controller status indicator light will flash a fault
the raised drive speed settings, code to aid in troubleshooting. This indicator light
the maximum raised drive speed is mounted on the left side of the ground control
must not exceed 0.6 mph / 1Km/h box.
or 40 feet/45 seconds /
12.2 meters / 45 seconds. If the Fault codes are two digits. The controller status
machine is allowed to drive faster indicator light will blink the first digit of a two digit
than specification, the machine code, pause for 1 second, and then blink the
could become unstable and will tip second digit. There will be a 2 second pause
over. between codes.
Note: Additional troubleshooting of the fault codes

may by accomplished by using the hand-held For example: the indicator light blinks 4
pendant motor controller programmer (Genie part consecutive times, pauses for 1 second, and then
number 128551). blinks 1 time. That would indicate Fault Code 41.
Note: When using the hand-held pendant motor

controller programmer, the M1 MAX SPEED needs
to be set to 33. If needed, adjust the M1 MAX
SPEED higher or lower to achieve the maximum
raised drive speed of 0.6 mph / 1Km/h or 40 feet /
45 seconds /
12.2 meters / 45 seconds.
5-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV B
Fault Code Chart
Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display
Push in the ground

control red Emergency
The key switch or red Stop button to the OFF
Controller Emergency Stop position and wait for 5
status indicator button(s) was cycled on seconds. Pull out the
COMMUNICATION
light is OFF or ERROR
Machine will not drive. and off faster than 5 ground control red
is ON but not seconds OR controller Emergency Stop button
sensed an internal error out to the ON position. If
blinking
during start up. problem persists,
replace the motor
controller.
01 Normal operation.
The motor controller Replace the motor
12 HW FAILSAFE 1-2-3 Machine will not drive.
failed self test. controller.
The motor controller
Test the motor
has a internal short
13 M- SHORTED Machine will not drive.
between M- and B-
controller, see the
Repair Section.
terminals.
Check for loose or open

connections at the drive
Motor wiring is loose motors and motor
OR motor is defective controller OR replace
FIELD OPEN Machine will not drive.
OR motor controller has the defective drive
an internal short. motor OR test the motor
controller. See the
Repair Section.
Defective motor Replace the motor

ARM SENSOR Machine will not drive.
controller. controller.
Defective motor Replace the motor
FLD SENSOR Machine will not drive.
controller. controller.
Continued on next page
Part No. 106726 Z-45/25 DC • Z-45/25J DC 5-3

FAULT CODE CHART REV B
Code Scanner
Display
Open in wht/red wire

#32 at pin 14 or red/wht
wire #29 at pin 16 on
the motor controller
going from drive joystick
Consult Genie
to pins 14 and 16 at the
21 THROTTLE FAULT 1 Machine will not drive.
motor controller OR pin
Industries Service
Department.
14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick
defective.
Pin 14 (wht/red #32) is

shorted to power or
Consult Genie
ground OR the
THROTTLE FAULT 2 Machine will not drive. Industries Service
potentiometer on the
Department.
drive joystick is
defective.
Main contactor (PR1) Replace main contactor

coil defective OR brake PR1 or brake release
31 CONT DRVR OC Machine will not drive.
release relay CR5 relay CR5 OR replace
defective. the motor controller.
Main contactor (PR1)

contacts stuck closed
OR grn wire at pin 17 on
motor controller shorted Consult Genie
32 MAIN CONT WELDED Machine will not drive. to ground OR open in Industries Service
motor armature wiring Department.
OR motor controller has
a internal short to
ground.
Repair short between

B+ terminal on motor
controller and ground
External short between
OR replace motor
B+ terminal on motor
controller.
33 PRECHARGE FAULT Machine will not drive. controller and ground
Note: Short can be on
OR motor controller is
any part of circuit
defective.
connected to the B+
terminal on the motor
controller.
5-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV B FAULT CODE CHART
Code Scanner
Display
Motor controller does
Consult Genie
not detect the main
34 MISSING CONTACTOR Machine will not drive.
contactor PR1 or brake
Industries Service
Department.
release relay CR5.
Main contactor PR1 or

brake release relay CR5
did not close OR open
Consult Genie
in org/red wire to PR1
MAIN CONT DNC Machine will not drive. Industries Service
and/or CR5 OR main
Department.
contactor and/or brake
release relay is
defective.
Completely charge
batteries OR check
Battery supply voltage battery cable condition
LOW BATTERY
41 VOLTAGE
Machine will not drive. to motor controller less OR check for corrosion
than 32V DC. or loose connections at
battery terminals and
motor controller.
Battery supply voltage

to motor controller more Be sure the battery
than 55V DC OR charger is disconnected
42 OVERVOLTAGE Machine will not drive. machine is being OR check for loose
operated with the battery cables or poor
battery charger plugged connections
in.
Operate machine within

Machine being operated
specified temperature
outside of temperature
limits OR check for
range of -13°F to
debris around motor
185°F / -25°C to 85°C
controller preventing
43 THERMAL CUTBACK Machine will not drive. OR machine being
proper cooling of the
driven under excessive
controller OR check for
load OR motor
mechanical restrictions
controller is not being
causing excessive load
cooled sufficently.
on the machine.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 5-5

5-6 Z-45/25 DC • Z-45/25J DC Part No. 106726

August 2011 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
with electrically charged circuits
Observe and Obey: could result in death or serious
injury. Remove all rings, watches
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions printed in the
Genie Z-45/25 DC and Genie Z-45/25J DC
Operator's Manual on your machine. Malfunction Identify Troubleshoot
discovered symptoms
Be sure that all necessary tools and test
equipment are available and ready for use.
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6-1

Section 6 • Schematics May 2005
Electrical Symbols Legend

REV A
TB17
15AMP.
TS6
Circuit breaker
GRN/BLK
ORG/BLK-1
LEFT
RIGHT
Toggle switch DPDT
Wire color
with cable
number
RED
Solenoid or Ground GRN
relay coil supression
BLK/RED
WHT
TB20 circuit
BP1
Terminal Boom function

speed controller
Horn NC NO
TP29 LS3
Limit switch
Quick disconnect L1 FB
terminal
Light LS1
NO
BLK #21
TB21
T-circuits connect Limit switch

at terminal normally open
held closed
PLAT
KS1
T-circuits Tilt sensor GRND

connect
Key switch
LS2
NC
Connection
no terminal HORN P4
Limit switch
normally closed
held open
Horn button
normally open
Circuits crossing
no connection
P1 PR4
Red Emergency
Stop button Relay panel
Diode normally closed contactor
TS3
CR4
-
PLAT. DWN
PLAT. UP
Battery Relay contact

normally open Toggle switch SPDT
6-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

May 2005 Section 6 • Schematics
Hydraulic Symbols Legend

REV A
0.035”
Orifice with size
Pressure gauge
3 position 4 way directional
Differential sensing valve solenoid valve
Variable orifice
or shut-off valve
Filter Solenoid operated Shuttle valve

proportional valve
Check valve
Check valve, pilot operated

Fixed displacement pump
Relief valve
Solenoid operated
Spring applied, proportional valve
hydraulically released (after serial number 22565)
brake
N.O.
Priority flow regulator
COM
N.C.
Bi-directional motor Pressure switch
2 position 2 way
M solenoid valve
Pump prime mover (motor)
Solenoid operated 2 pos.,

3 way, directional valve
Cylinder
Counterbalance valve
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6-3

6-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

Power Cable Diagram

Power Cable Diagram REV A

A B C D E F G H I J K L M N
1
TO BASE CONTROL BOX
AND ENGINE PANEL
AC POWER CABLE
LEFT SIDE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RED-2GA
BATTERY PACK
+
+
-
2 AC D1
CHASSIS HARNESS
-
BATTERY A2
_
CHARGER
-
+ A1
PRIMARY
LIFT PUMP +
RED-2GA
AUXILIARY LIFT
+ PUMP
D1
3 -
BLACK-2GA +
RED-2GA
-
RED#20-12GA
-
-
+ WHITE-FROM CHARGER
ORG/RED-R2 +
4 FUSE-F3, 500A BLACK-2GA

FUSE-F5, 10A
BLACK-2GA
BLACK-2GA BLACK-2GA
FUSE-F4, 500A
RED-2GA
+ -
+ + DIODE
3
4 5 6
7
DIODE
2
AP-1
8
1
9
- - - -
AMMETER
AC
GRN/WHT-19
AP-2 LIFT CONTACTOR DRIVE CONTACTOR

AUXILIARY POWER + + CHARGER
5 PR-2 PR-1 UNIT CONTACTOR PR-3 PLUG
BLACK-FROM CHARGER
ORG/RED-42
BLACK-2GA
ORG/RED-42 ORG/RED-42
RED-2GA
BLACK-2GA
BLACK-2GA
BRN-J9 BRN-J9
RED-2GA
RED-2GA
RED-2GA
RED-27 RED-27
RED-2GA
BRN-J8 RED#20-12GA
RED-2GA
RED-2GA RED-2GA
RED-10GA RED-10GA 24V DC
48V
F2-200A
F1-200A
WHT/RED-32
RED/WHT-29
RED-10GA RED-10GA
RED/BLK-R5
RED-2GA
GREEN
7 E2 E1
A2
J1
A1
ORG/RED-42
ORG/RED-42
24 23 22 21 20 19 18 17 16 15 14 13
RED-10GA
12 11 10 9 8 7 6 5 4 3 2 1
RED-2GA
RED-2GA
E1 E2
ORG/RED-42
ORG/RED-42
BLU/WHT-12
WHT/BLK-31
BLU/RED-39
ORANGE-40
BLACK-LED
RED-10GA
WHT-30
A1 A2
BRN-J8
BLK-2GA
8 LEFT SIDE DRIVE MOTOR BLACK-FROM CHARGER RED-10GA RIGHT SIDE DRIVE MOTOR
BLK-2GA F1 F2
BRN-J8
BLK-2GA BLK-2GA
BLACK-2GA
RED-2GA
NOTES:
CHASSIS GROUND B- M- B+ MOTOR CONTROLLER 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED
6-5 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV A Power Cable Diagram

(from serial number 16840 to 21179)
N M L K J I H G F E D C B A
1
TO BASE CONTROL BOX
AND ENGINE PANEL
AC POWER CABLE
LEFT SIDE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RED-2GA
BATTERY PACK
+
+ 2
-
AC D1
CHASSIS HARNESS
-
BATTERY A2
_
CHARGER
-
+ A1
PRIMARY
LIFT PUMP +
RED-2GA
AUXILIARY LIFT
+ PUMP
3
D1
BLACK-2GA +
-
RED-2GA
-
RED#20-12GA
-
-
+ WHITE-FROM CHARGER
+
ORG/RED-R2 4
FUSE-F5, 10A
FUSE-F3, 500A BLACK-2GA BLACK-2GA
BLACK-2GA BLACK-2GA
FUSE-F4, 500A
RED-2GA
+ -
+ + DIODE
3
4 5 6
7
DIODE
2
AP-1
8
1
9
- - - -
AMMETER
AC 5
GRN/WHT-19
AP-2 LIFT CONTACTOR DRIVE CONTACTOR
AUXILIARY POWER + + CHARGER
PR-2 PR-1 UNIT CONTACTOR PR-3 PLUG
BLACK-FROM CHARGER
ORG/RED-42
BLACK-2GA
RED-2GA
BLACK-2GA
BLACK-2GA
BRN-J9 BRN-J9
RED-2GA
RED-2GA
RED-2GA
RED-27 RED-27
RED-2GA
BRN-J8 RED#20-12GA
6
RED-2GA
RED-2GA RED-2GA
RED-10GA RED-10GA 24V DC
48V
F2-200A
F1-200A
WHT/RED-32
RED/WHT-29
RED-10GA RED-10GA
RED/BLK-R5
RED-2GA
GREEN
E2 E1
A2
J1
A1
ORG/RED-42
ORG/RED-42
24 23 22 21 20 19 18 17 16 15 14 13
RED-10GA
12 11 10 9 8 7 6 5 4 3 2 1
RED-2GA
RED-2GA
E1 E2
ORG/RED-42
ORG/RED-42
BLU/WHT-12
WHT/BLK-31
ORANGE-40
BLACK-LED
RED-10GA
WHT-30
A1 A2
8
BRN-J8
BLK-2GA
LEFT SIDE DRIVE MOTOR BLACK-FROM CHARGER RED-10GA RIGHT SIDE DRIVE MOTOR
BLK-2GA F1 F2
BRN-J8
BLK-2GA BLK-2GA
BLACK-2GA
RED-2GA
NOTES:
CHASSIS GROUND B- M- B+ MOTOR CONTROLLER 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6-6

Power Cable Diagram

Power Cable Diagram

Power Cable Diagram REV A

TO GROUND CONTROL BOX
CONNECTOR C6B
1 LEFT SIDE
AC POWER CABLE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RD-2GA
BATTERY PACK
+
+
-
FUNCTION HARNESS
D1
A2 -
AC
2 _
BATTERY PRIMARY
CHARGER LIFT PUMP
-
+ A1
AUXILIARY LIFT +
RD-2GA
PUMP
+
D1
BK-2GA +
-
3 RD-2GA
-
RD-20-12GA
-
-
+ WH-FROM CHARGER
P42BAT OR/RD +
F3 500A BK-2GA F5 10A BK-2GA

BK-2GA BK-2GA
4
WH
F4 500A
BK
RD-2GA
+ -
TOP VIEW OF
+ + DRIVE CONTACTOR DRIVE CONTACTOR AUXILIARY POWER UNIT 3
4 5 6
7
2
AP-1
8
CONTACTOR
9
BATTERY - -
- -
AMMETER
AP-2 DIODE DIODE AC
33
GR/WH-19
PR-1 DIODE
+ + CHARGER
33 PLUG
5 PR-2 PR-1 CONTROLLER PR-3

BK-FROM CHARGER
LIFT R42BAT OR/RD

CONTACTOR R42BAT OR/RD R42BAT OR/RD
RD-2GA
BK-2GA
BRN-J8 BRN-J8
R27AUX RD RD
RD-2GA
RD-2GA
RD-2GA
BK-2GA
BK-2GA
BRN-J8
BK BK BK BK RD-2GA
RD-20-12GA
RD-2GA RD-2GA
6
RD-2GA
RD-10GA RD-10GA 24V DC
48V DC
F2
F1-200A 200A
C29JSH RD/WH
C32JSL WH/RD
RD-10GA RD-10GA
CR5 RD/BK
RD-2GA
F2 F1
7
GR
A2 A1
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
RD-10GA
RD-2GA
C31REV WH/BK
C12DRE BL/WH
R42BAT OR/RD
R42BAT OR/RD
OR/RD
OR/RD
RD-2GA
F1 F2
C30FWD WH
RD-10GA J1
C40LS OR
CFIL BK
A1 A2
BRN-J8
BK-2GA RIGHT SIDE

LEFT SIDE DRIVE MOTOR
8 DRIVE MOTOR
BK-FROM CHARGER
BK-2GA
RD-10GA
F1 F2
BRN-J8
BK-2GA BK-2GA
BK-2GA
RD-2GA
B- M- B+
NOTES:
CHASSIS
GROUND 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
MOTOR CONTROLLER
6-7 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV A Power Cable Diagram

TO GROUND CONTROL BOX

CONNECTOR C6B
1
AC POWER CABLE
LEFT SIDE DC AMMETER CABLE
BATTERY PACK
RD-2GA RIGHT SIDE
- BATTERY PACK
-
+
FUNCTION HARNESS
D1 +
AC A2
_ BATTERY
CHARGER PRIMARY
LIFT PUMP
-
+ A1
AUXILIARY LIFT +
RD-2GA
- PUMP
D1 -
+ BK-2GA
3
RD-2GA +
RD-20-12GA
-
-
+ WH-FROM CHARGER
P42BAT OR/RD +
F5 10A BK-2GA
BK-2GA
BK-2GA
BK-2GA
4
WH
BK
+ -
TOP VIEW OF AUXILIARY POWER UNIT
+ + DRIVE CONTACTOR DRIVE CONTACTOR CONTACTOR 3
4 5 6
7
2
AP-1
8
1
9
BATTERY - -
- -
AMMETER
AP-2 DIODE DIODE AC
+ + CHARGER
GR/WH-19
33 PR-1 DIODE
33 PLUG 5
P42BAT OR/RD
PR-2 PR-1 CONTROLLER PR-3

BK-FROM CHARGER
LIFT R42BAT OR/RD

CONTACTOR R42BAT OR/RD R42BAT OR/RD
RD-2GA
BK-2GA
BRN-J8 BRN-J8
F4
R27AUX RD RD
RD-2GA
BK-2GA
BK-2GA
BRN-J8
500A
BK BK BK BK RD-2GA
RD-20-12GA
RD-2GA RD-2GA
6
RD-2GA
RD-10GA RD-10GA 24V DC
48V DC
F2
F1 200A
200A
C29JSH RD/WH
C32JSL WH/RD
RD-10GA
CR5 RD/BK
RD-2GA
F2 F1 7
GR
A2 A1
24 23 22 21 20 19 18 17 16 15 14 13
A1 12 11 10 9 8 7 6 5 4 3 2 1
RD-2GA
C31REV WH/BK
C12DRE BL/WH
R42BAT OR/RD
R42BAT OR/RD
OR/RD
OR/RD
RD-2GA
F1 F2
C30FWD WH
RD-10GA
C40LS OR
CFIL BK
A2
BRN-J8
LEFT SIDE
BK-2GA
BK-FROM CHARGER
RIGHT SIDE
DRIVE MOTOR
8
DRIVE MOTOR RD-10GA
BK-2GA F1 F2 RD-10GA
BRN-J8
BK-2GA BK-2GA
BK-2GA
RD-2GA NOTES:
CHASSIS B- M- B+ 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
GROUND
MOTOR CONTROLLER
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6-8

Power Cable Diagram

Electrical Schematic, Z-45/25 REV A

LOAD SENSE OPTION RED/WHT #29

1
ORG/RED
WHT/RED #32
L4
1 2 3 4 WHT #30
LOAD SENSE PCB P2 FS1 WHT/BLK #31

87a RED-FS
BLK LSTOP BLK-26 BLK-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7
BRN
86 CR17 LOAD SENSE OPTION (SEE DETAIL ABOVE)

3A CR17 FS1
85 P2
BLK-2 BLK#26 BLK-FS
RED L1 WHT-FS TP24 WHT-24
TP22 TP26
2 RED
ORG/RED-42
RED
ORG/RED-42
RED/WHT-3
P3 RED
HORN
PLATFORM CONTROLLER
10 A P1 KS1
BLK/RED-9
RED 20 FAULT LED
TB22 + L3
CB1 GROUND TILT
ALARM
A1 TP3
TP32
TP30
TP29
TP31
TP39
3 TP9 TP23 TP28 TP42
BLK/RED-3
BLU/RED-1
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
TB39
RED
TB29
TB31
TB32
TB30
TB20 ORG #40 TB40 RED-8

TB3
4
TB42
CR2
WHT-
RED/
BLU/WHT #12
ORG/RED R2
RED
WHT#30
WHT/BLK#31
WHT/RED#32
RED/WHT#29
BLU/WHT #12
ORG/RED #42
ORG/RED #42
BLU/RED #39
ORG/RED #42
ORG/RED
21
F5 LS4
ORG/RED
10 A 22 (SEC.)
F4 AP2 48V 86 30
BLK-8
CR2
500 A PR1 86
+48 V TB23
INDICATOR LED L2
CONTROLLER FAULT
85 87
+
COIL-PR1
CR5
F2
5 200 A
85 TB50 TB28
OFF-LIMIT SPEED INPUT
86 30
CR1
BLK #22
RED-6
RED 20
RED/BLK #28
-
LEFT 85 87
DIODE RETURN
BOX 21
RED/BLK-R5
+
TB9
INTERLOCK
-
+48V INPUT
LS2
FAULT LED
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
C1 1
BLK-6
GRN
0.1 ENABLE WHT #21

BLK
HM TB21
mF 3
BLK/RED #CR4
RED/WHT #23
RED/WHT #23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
AP2
6 CURTIS 1244
RED-7
F3 24 V SEPEX CONTROLLER
13
500 A F1
+24 V
AP1
200 A
F2 M- B+ F1 B- LS1 *
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
*SWITCH
WHT
LEFT A2 A2 E2 E1
MOTOR These items SHOWN 30 86
-
RIGHT
RIGHT removed after WITH BOOM
BOX E2 E1 A1 A1 MOTOR EXTENDED. CR4
7 serial number
+
+
10667. 87 85
PUMP PUMP CHARGER
BLK
+
-
+
BLK
-
BRN
GROUND AC POWER (GND)

10 A HORN
(GND)
AP1 CB2 BRN
8
48V POWER RELAY CR2
48V POWER RELAY CR1
HOUR METER
HORN RELAY
PUMP
PRIMARY LIFT
BOX GROUND
GROUND CONTROL
(OPTION)
FLASHING BEACON
TILT SENSOR
PUMP
AUXILIARY LIFT
48V CHARGER
BLACK
2 GA.
CHASSIS
GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT AS NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.
6-9 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV A Electrical Schematic, Z-45/25

RED/WHT #29 NOTES: 1

WHT/RED #32 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
WHT #30
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
WHT/BLK #31
WHT-24 WHT-24
ORG/RED-42
WHT-24 RED
2
TURNTABLE PLATFORM
BLU/WHT#12
SECONDARY PRIMARY PRIMARY PLATFORM
ORG/RED-42 ROTATE BOOM BOOM BOOM JP1 (REMOVE FOR CE VERSION)
LEVEL ROTATE
DP1
RED
TS12 TS10 TS11 TS13 TS9 TS7
1 20K A
LEFT
RIGHT
DOWN
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
2 B
RED/BLK-R6
3 FWD C
ORG/RED-16
TS1 DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
5 L TS15 ENABLE
BP1 STEER
ROTARY RED
ORG/BLK-R6
87
85
3
TP4 TP5 TP11 TP10 TP2 TP1 TP8 TP7 TP15 TP14 TP17 TP18 OEM BRN DRIVE
FLOW + TP27 TP37 TP36 TP41 ENABLE
GRN/BLK-3
GRN-3
BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT3
BLK-3
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
BCI
E
TP19
TP13
TP6
BLU/RED - 3
BLU/WHT - 3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
4
BLU/WHT #12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM
ROTATE BOOM BOOM BOOM LEVEL ROTATE
RED
TB41
TS62 TS60 TS61 TS63 TS59 TS57
BRAKE
RELEASE 30 5
RED
JACK CR5
DOWN
DOWN
DOWN
EXTEND
UP
LEFT
RIGHT
UP
UP
RETRACT
LEFT
RIGHT
J1 87
PS1
TB27
GRN/WHT #19 GRN/WHT#19 TB48 TB13
TB19
BLK-7
BRN-2
ORG/RED - 3
TB18 TB37
WHT-7
TB4 TB5 TB11 TB10 TB2 TB1 TB8 TB7
TB17 TB6
TB36
WHT/RED #6
6
BLU/BLK #37
BLU #36
GRN/WHT
GRN/BLK #18
WHT/RED #6
RED #27
GRN #17
RED/WHT #48
BLU/BLK #11
BLU #10
BLK/WHT # 8
BLK #7
ORG
WHT/BLK #5
RED/BLK #2
RED #1
WHT #4
13
TB14 22
TB15 LS3*
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
30
14 21
86
*
RED-7
86 86 CR3 SWITCH SHOWN WITH
30 30 87a 87 85 BOOM ROTATED PAST
EITHER NON-STEER WHEEL
CR10B 87 87 CR10A 85
RED
GRN/WHT
85
7
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3 13
LS2
FUNCTION 14
MANIFOLD
(GND) GROUND BRAKE/STEER
MANIFOLD
(GND) GROUND
PRESSURE SWITCH (PS1)

BRAKE RELEASE
BRAKE RELEASE N.O.

STEER LEFT
BRAKE RELEASE N.C.
TRAVEL ALARM
BRAKE RELEASE
LIMIT SWITCH
DRIVE ENABLE
RELAY COIL (CR3)
AUXILIARY CONTROL
STEER RIGHT
PUMP RELAY COIL (PR3)
AUXILIARY LIFT
BRN
ROTATE LEFT
8
PLATFORM
ROTATE RIGHT
PLATFORM
UP
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RELAY COIL (PR2)

LIFT PUMP
BOOM UP
SECONDARY
RETRACT
PRIMARY BOOM
VALVE
PROPORTIONAL
DOWN
PLATFORM LEVEL
DOWN
PRIMARY BOOM
UP
PLATFORM LEVEL
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
TURNTABLE
BOOM DOWN
SECONDARY
(OPTION)
DESCENT ALARM
RELAY (CR10B)
DOWN CUTOUT
PLATFORM LEVEL
(CR10A)
UP CUTOUT RELAY
PLATFORM LEVEL
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 10

Electrical Schematic, Z-45/25


1 LOAD SENSE OPTION RED/WHT-29
ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
LOAD SENSE PCB P2 87a FS1
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN
86 LOAD SENSE OPTION (SEE DETAIL)

3A CR17 P2 FS1
85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
KS1 PLATFORM CONTROLLER
BLK/RED-9
10 A P1
RED-20 FAULT LED
TB22 +
CB1 A1
GROUND TILT
ALARM
3
TP32
TP30
TP29
TP31
TP9 TP23 TP28 TP3 TP42
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30
TB20 ORG-40 TB40 RED-8

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4
F4
WHT
10A
ORG/RED
22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
-
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX
RED/BLK-R5
21
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
GRN
BLK-6
BLK
HM
ENABLE WHT-21
TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
6 AP2
RED-7
24V DC MOTOR CONTROLLER

F3
13
500A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
7 BOX E2 E1 A1 A1
RIGHT
MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
6 - 11 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
Section 6 • Schematics
6 - 12
ENABLE
SWITCH
3
DRIVE
ENABLE
LIMIT
A
LED L1
DRIVE
BRN-2
TB13
21
22
TP13 BLU/RED-3 BLK-7 BRN-7

LS3
TB16
BLU/WHT-12 TP12 BLU/WHT-3 WHT-7 RED-7

TB12
14
13
ORG/RED-16 TP16 ORG/RED-3

A2
JP1 (REMOVE FOR CE VERSION)
CR6 86
85
BRN PLATFORM BRAKE RELEASE

B
TB48
CONTROL BOX TRAVEL ALARM (A2)

TB41
+
CR5
GROUND
ORG/BLK-1 RED/WHT-48
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
ENABLE
N.C. COIL
RED
BRAKE/STEER
BRAKE RELEASE
Z-45/25 DC • Z-45/25J DC
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

TS15
JACK
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
C
TB37
BLU/BLK-1 BLU/BLK-37
STEER RIGHT COIL
TP37
C
R
A
L
DRIVE
LIFT
STEER
ORG/BLK-R6
L R
GRN/WHT-19
20K
D
FWD
REV
1
2
3
4
5
DP1
AUXILIARY
PUMP
RED - 1
TS1
CR3
85
86
RED RED RED-27

TP27
AUXILIARY CONTROL
E
BCI
RELAY COIL CR3

AUXILIARY
POWER
TB27
TS51
F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
Part No. 106726
TB19
TP19
87
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
May 2005
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW CONTROL
GRN/WHT-19
COIL
RED
BRN
F
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18 ROTATE RIGHT

ROTARY
PLATFORM
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
RIGHT GRN/BLK-3
GRN-3
PLATFORM
G
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
14
13
WHT-24
(CE MODELS ONLY)
WHT-40
RED
H
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
UP ORG #14 PLATFORM LEVEL
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
I
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
DOWN TB7
TP15
EXTEND BLK-7 PRIMARY BOOM

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
RETRACT RETRACT COIL
TB8
TP7
EXTEND BLK-3
J
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
RETRACT UP RED-1 PRIMARY BOOM
TP8
UP COIL
PRIMARY
RED/BLK-2 PRIMARY BOOM
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
K
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
BLU/BLK-11 SECONDARY BOOM
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
RIGHT WHT/BLK-5 ROTATE RIGHT
TURNTABLE
COIL
L
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
TS12 WHT-3
LEFT
TP4
FUNCTION
3 SWITCH SHOWN WITH BOOM ROTATED

ENABLE
M
PAST EITHER NON-STEER WHEEL.

WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
NOTES:
REV A
N


ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

3A CR17 P2 FS1
85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
BLK/RED-9
10 A P1
RED-20 FAULT LED
TB22 +
CB1 A1
GROUND TILT
ALARM
3
TP32
TP30
TP29
TP31
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4
F4 10A
ORG/RED
22 (SEC.)
WHT
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
-
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX
RED/BLK-R5
21
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
GRN
BLK-6
BLK
ENABLE WHT-21
HM TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
6 AP2
RED-7

F3
13
500A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
7 BOX E2 E1 A1 A1
RIGHT
MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 13 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 14
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2
86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
Z-45/25 DC • Z-45/25J DC
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
TP36
C
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106726

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
GRN/
May 2005
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
(CE VERSION ONLY)
H
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
BOOM
TS10
L
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
LEFT
TP4
M
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
WHT-LOAD WHT-24 WHT-30
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-2 BLK BLK-(FS)
2 LOAD SENSOR OPTION TP22 TP26
RED
WHT-(FS) TP24 WHT-24
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
BLK/RED-9
P1
RED-20 FAULT LED
TB22 +
CB1 GROUND TILT
10A ALARM
A1
3
TP32
TP30
TP29
TP31
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
21
WHT
F5 LS4
F4
ORG/RED
10A 22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
BLK-6
GRN
BLK
ENABLE WHT-21
HM TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
1
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
RIGHT
7 BOX E2 E1 A1 A1 MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 15 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 16
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2
86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
Z-45/25 DC • Z-45/25J DC
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
C
PS1 BRAKE RELEASE

JACK
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

Part No. 106726
TS51
TB27
F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
May 2005
87
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

F
TB6
87a
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42

H
LS2
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
I
TS59
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
L
BLU/BLK-3
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
M
LEFT
TP4
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN
KS1 PLATFORM
BLK/RED-9
P1
RED-20
TB22 +
CB1 GROUND TILT
10A ALARM
A1
3
TP32
TP30
TP29
TP31
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F5 LS4
WHT
F4
ORG/RED
10A 22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
BLK-6
GRN
BLK
ENABLE WHT-21
HM TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
1
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
RIGHT
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 17 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 18
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2
86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
Z-45/25 DC • Z-45/25J DC
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
TP36
C
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106726

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
GRN/
May 2005
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
(CE VERSION ONLY)
H
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
BOOM
TS10
L
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
LEFT
TP4
M
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN
KS1 PLATFORM
BLK/RED-9
P1
RED-20
TB22 +
CB1 GROUND TILT
10A ALARM
A1
3
TP32
TP30
TP29
TP31
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F5 LS4
F4
ORG/RED
(SEC.)
WHT
10A 22
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
BLK-6
GRN
BLK
ENABLE WHT-21
HM TB21
+
BLK/RED-9
RED/WHT-23
RED/WHT-23
-
+
-
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 F2 F1
MOTOR 30 86
+
-
RIGHT
RIGHT
7 BOX F2 F1 A1 A1 MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 19 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 20
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13

A2
B
86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
Z-45/25 DC • Z-45/25J DC
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
TP36
PRESSURE SWITCH PS1

TB36
C
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
PUMP
RED - 1
E
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
F
Part No. 106726

+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
GRN/
30
WHT-3 GRN/WHT
May 2005
GRN/WHT LIFT PUMP

TP6
RELAY COIL PR2

TB6
87a
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
F
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
RIGHT GRN/BLK-3
G
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
H
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
30
87a
TB15
I
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
UP RED-3
K
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
BOOM
TS10
L
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE WHT-3
TS12
LEFT
TP4
M
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 P2 FS1
RD-(FS) C9P-3 LOAD
C7P-1 P22BAT BK C9P-1 BK BK-(FS) BK SENSOR
P25BAT C29JSH RD/WH
P26BAT MODULE
WH-(FS) C9P-2 C
P24BAT WH C32JSL WH/RD
WH-LOAD
BK-26 LOAD B+ GND 8 C30FWD WH
OR-LOAD
BRN
C31REV WH/BK
LOAD SENSOR OPTION LOAD
C40LS OR
CELL
NOTES:
2 2 SWITCH SHOWN WITH BOOM EXTENDED. LOAD SENSOR OPTION (SEE DETAIL)
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. FS1
P2 RD-(FS) C9P-3
P22BAT C7P-1 C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH P24BAT WH
BK P26BAT
RD
R42BAT OR/RD
C7B-1
RD
PLATFORM RD
P1 KS1
P20BAT RD P3
TB22 HORN +
TILT
CB1 ALARM
10 A GROUND
C1P-4
C1P-5
C1P-6
C1P-3
A1
C2P-2
3
C3P-9
C7P-2
C1P-2
C3P-3
C2P-4
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
C9HRN BK/RD
P23SWBAT WH
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
P20BAT RD
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
4
C3B-9
C7B-2
C1B-2
C3B-3
C2B-4
C7B-4
C6B-30
C6B-31
C6B-32
C6B-29
OR TB40 OR P20BAT RD
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
F5
OR/RD
F4
OR/RD
10A
C6B-12
C6B-24
500 A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
CR2 86
5 PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK
WH
RD/BK
BK
BK/RD
+
COIL-PR1
CR5
BL/WH
F2 85
200 A 30
86
CR1
RD 20
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-28
C6B-34
+
DIODE RETURN
85
-
C6B-25 CFIL BK
LEFT 87
BRN
BRN
BOX
INTERLOCK
+48V INPUT
+
BK-4
WH-4
BK-5
WH-5
FORWARD
POT. LOW
REVERSE
POT. HI
21 + C12DRE BL/WH
GR
6 LS4
(SEC) _
HM
+
-
22
1
10
11
14
16
17
20
AP2 30
RD/WH
RD/BK
86
RD
CURTIS 1244 CR4
F3 24 V DC
BK-5
RD-5
SEPEX CONTROLLER 87 85
500 A F1 BK
AP1
C8-A
C8-C
F2 M- B+ F1 B-
+24 V 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
+
RD
WH
FB
7
WH-6
BK-7
WH-7
BK-6
WH
LEFT A2 A2 F2 F1
MOTOR
+
-
RIGHT
RIGHT
BOX F2 F1 A1 A1 MOTOR LS2 21 13
+
+ (PRI) LS1 2
PUMP PUMP CHARGER (EXT)
22
BK
14
BK 2 GA
BRN
-
AC POWER +
C8-B
BK
+
-
BRN
GROUND
(GND)
8 AP1 BK
PR2
BK
PR2
PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
6 - 21 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 22
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22
C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3
C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8

TB12
14
13
B
C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86
85
BRN
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM
CR6
+
CR5
CR8
(A2)
Z-45/25 DC • Z-45/25J DC
C27-1 C27-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH
BRAKE RELEASE
C2P-3 RD/WH
DRIVE 30
87
87
30
N.C. COIL
30
87
RD/BK-R6
CE VERSION:
ENABLE
BRAKE RELEASE
TS15
RD C26-1 C26-2
AND ADD
RD/WH N.O. COIL

REMOVE
JUMPER
C
RELAY
RELEASE
J1
BRAKE
PS1 BRAKE RELEASE

JACK
CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C1P-10
TB37
C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
D
C6B-23 P20BAT RD
C31REV WH/BK
10
C29JSH RD/WH
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH
C1P-1 C27AUX RD C1B-1

TS1
E
PR2
RD-AUX
87
30
OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION
GR/WH RELAY COIL PR2

BCI
Part No. 106726

BK
F
CR3
+
BCI OPTION
OR/RD
AUX
85
ON
86
DISCHARGE
OR/RD RD RD AUXILIARY CONTROL

SET TO "N"
May 2005
RELAY COIL CR3

TS51
TB27
CR20
33
2
PR3
OR
3
3
F
OR/RD AUXILIARY LIFT

5
L.V.I.
4
C6B-27 PUMP RELAY COIL PR3

OR/BK
4
RD
TB19
87
BCI
SET TO "B"
6
RESET
30
C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86
GR/WH CONTACTOR RELAY

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD FLOW CONTROL

COIL
BK
85 BRN
BK/RD
CR19A
BRN
GR/WH
RD
86
TB18
C23-1 C23-2 PLATFORM

CONTROL
RIGHT
CR19B
C6B-18 GR/BK ROTATE RIGHT

ROTARY
PLATFORM
G
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
PLATFORM
ROTATE
RIGHT C4P-6 C18PRR GR/BK C4B-6 GR/BK

C4P-5 C17PRL GR C4B-5 GR
TS7
LEFT
H
I
TB14
UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
C4P-3 C15PLD OR/BK C4B-3
TS9
TB7
DOWN
J
EXTEND C16-1 C16-2

C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY C6B-8 BK/WH PRIMARY BOOM
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM
EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13
TB1
RETRACT C12-1 C12-2
UP C6B-1 RD PRIMARY BOOM
UP COIL
PRIMARY
K
C6B-2 RD/BK PRIMARY BOOM
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM
UP C3P-1 C1PBU RD C3B-1

30
87
C3P-2 C2PBD RD/BK C3B-2

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
L
DESCENT
BOOM
ALARM
UP C3P-10 C10SBU BL C3B-10
A3
OPTION (A3)
+
87
30
C3P-11 C11SBD BL/BK C3B-11
TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
M
RIGHT C3P-5 C4TRR WH/BK C3B-5

C3P-4 C4TRL WH C3B-4
TS12
R42BAT OR/RD
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
P20BAT RD
C40LS OR
TS55
(GND)
REV A
PR2
PR3
CR5
BK
RD
N

Electrical Schematic, Z-45/25, ANSI and CSA Models REV A

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132 PLI BL/WH C1P-12 RD

7
C1B-12
+ A1
RD
LS18 TILT
P3 ALARM L48
CB1 HORN
KS1 PLATFORM
10 A P1
C7P-2
C3P-3
C2P-4
P20BAT RD D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C3BAT RD/WH
R42BAT OR/RD
4 5
C32
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C3B-3
C2B-4
P20BAT RD
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5
BK/RD
F4
OR/RD
10A
C6B-12
C6B-24
500A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
CR2 86
PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
5 200A 86
CR1
30
RD 20
BL/WH
OFF-LMT SPD INP
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
C6B-28
+
C6B-34
85
-
LEFT 87
+48V INPUT
BRN
BRN
BOX
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
POT. HI
21 +
GR
C12DRE BL/WH
LS4 HM
_
+
(SEC)
-
2
9
14
10
11
16
17
20
5
1
22
AP2
30
RD/WH
RD/BK
86
RD
U6A
MOTOR CONTROLLER CR4
24V DC
6
BK-5
RD-5
87 85
F1 BK
AP1
C8-A
C8-C
F1 M- B+ F2 B-
+24V DC 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
RD
WH
FB
WH-6
BK-7
WH-7
BK-6
WH
LEFT A2 A2 F2 F1
MOTOR
+
RIGHT
RIGHT
+
+ (PRI) LS1
PUMP PUMP 2
CHARGER (EXT)
22
BK
7 14
BK 2 GA
-
BRN
+
C8-B
BK
+
BRN
GROUND A2
AC POWER
(GND)
AP1 BK BK
PR2 PR2
PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC

NOTES: 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 7 ANSI/CSA
6 - 23 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
Electrical Schematic, Z-45/25, ANSI and CSA Models
6 - 24
ENABLE
SWITCH
3
DRIVE
A
ENABLE
LIMIT
LED L1
DRIVE

21
22
LS3

TB12
14
13

86
85
BRN
B
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30
87
87
30
30
87
RD/BK-R6
Z-45/25 DC • Z-45/25J DC
CE VERSION:
ENABLE
TS15
AND ADD
REMOVE
JUMPER
RELAY
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C
C24-1 C24-2
RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
D
C31REV WH/BK
10
C29JSH RD/WH
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH

TS1
PR2
RD-AUX
BCI OPTION
E
87
30

LVI/BCI OPTION

BCI
BK
AUXILIARY
F
POWER
CR3
Part No. 106726

+
OR/RD
85
86
DISCHARGE

SET TO "N"
1
RELAY COIL CR3

TS51
TB27
CR20
33
2
PR3
OR
3
3
May 2005

5
L.V.I.
4
C6B-27 PUMP RELAY COIL

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
F
RESET
30

WH
85
86

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK
85 BRN
BK/RD
CR19A
COIL
BRN
GR/WH
RD
86
TB18

CONTROL
RIGHT
CR19B

ROTARY
PLATFORM
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
G
PLATFORM
ROTATE

TS7
LEFT
H
TB14
UP C20-1 C20-2
PLATFORM
I
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL

TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
TS9
TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY
C6B-8 BK/WH PRIMARY BOOM

BOOM
TS63
J
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
RETRACT C12-1 C12-2
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
K
BOOM

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
L
87
30

TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
TS12
R42BAT OR/RD
M
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
REV A
N
Electrical Schematic, Z-45/25, ANSI and CSA Models

Electrical Schematic, Z-45/25, CE Models REV A

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132PLI BL/WH C1P-12 RD
C1B-12
+
RD
A1
LS18 TILT
P3 L4 ALARM
CB1 HORN 5
10A KS1 PLATFORM
P1
C7P-2
C3P-3
C2P-4
P20BAT RD D39 D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C7P-2
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C3BAT RD/WH
R42BAT OR/RD
4 5
U33
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C3B-3
C2B-4
P20BAT RD
A6 L45
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5
BK/RD
F4
OR/RD
10 A
C6B-12
C6B-24
500 A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
CR2 86
PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
5 200 A
86
CR1
30
RD 20
BL/WH
OFF-LMT SPD INP
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
C6B-28
+
C6B-34
85
-
LEFT 87
+48V DC INPUT
BRN
BRN
BOX
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
POT. HI
21 +
GR
C12DRE BL/WH
LS4 HM
_
+
(SEC)
-
14
10
16
17
20
11
22
3
9
5
2
1
AP2
30
RD/WH
RD/BK
86
RD
U6A
CR4
6 24V DC MOTOR CONTROLLER
BK-5
RD-5
87 85
F1 BK
AP1
C8-A
C8-C
F1 M- B+ F2 B-
+24V DC 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
RD
WH
FB
WH-6
BK-7
WH-7
BK-6
WH
LEFT A2 A2 F2 F1
MOTOR
+
RIGHT
RIGHT
+
+ (PRI) LS1
PUMP PUMP 2
CHARGER (EXT)
22
BK
7 14
BK 2 GA
-
BRN
+
C8-B
BK
+
BRN
GROUND A2
AC POWER
(GND)
AP1 BK BK
PR2 PR2
PR3 PR3
48V DC POWER RELAY CR2

HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
FLASHING BEACON OPTION

TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC

NOTES: 5 CE & PLATFORM LOAD SENSE OPT.
6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
6 - 25 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
Electrical Schematic, Z-45/25, CE Models
6 - 26
ENABLE
SWITCH
3
DRIVE
ENABLE
LIMIT
LED L1
A
DRIVE

21
22
LS3

TB12
14
13

86
85
BRN
A2
B
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30
87
87
30
30
87
RD/BK-R6
CE VERSION:
ENABLE
Z-45/25 DC • Z-45/25J DC
TS15
AND ADD
REMOVE
JUMPER
RELAY
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
C

RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
C31REV WH/BK
10
C29JSH RD/WH
D
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH

TS1
PR2
RD-AUX
BCI OPTION
87
30

LVI/BCI OPTION
E

BCI
BK
AUXILIARY
F
POWER
CR3
+
OR/RD
Part No. 106726

85
86
DISCHARGE

SET TO "N"
1
RELAY COIL CR3

TS51
TB27
CR20
33
2
PR3
OR
3

May 2005
L.V.I.
4

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30
LIFT PUMP
F
C4P-7 C19LPMP GR/WH C4B-7 GR/WH

WH
85
86

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK
85 BRN
BK/RD
CR19A
COIL
BRN
GR/WH
RD
86
TB18

CONTROL
RIGHT
CR19B

ROTARY
PLATFORM
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
G
PLATFORM
ROTATE

TS7
LEFT
H
TB14
UP C20-1 C20-2
PLATFORM
UP COIL
I
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL

TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
TS9
TB7
DOWN C16-1 C16-2
EXTEND COIL
PRIMARY

BOOM
TS63 RETRACT RETRACT COIL
TB8
J
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
RETRACT C12-1 C12-2
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM
K

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
87
30
L

TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
TS12 C3P-4 C4TRL WH C3B-4
R42BAT OR/RD
LEFT
M
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
REV A
N
Electrical Schematic, Z-45/25, CE Models

Electrical Schematic, Z-45/25J REV A

1 LOAD SENSE OPTION

RED/WHT #29
ORG/RED
WHT/RED #32
L4
1 2 3 4 WHT #30
P2 FS1 WHT/BLK #31

LOAD SENSE PCB 87a RED-FS
1 2 3 4 5 6 7 8 9 10 1112 WHT-FS
30 87 TP26
RED L7 CR17
BRN
86 LOAD SENSE OPTION (SEE DETAIL BELOW)

3A CR17
85 P2 FS1 RED-FS
BLK-2 BLK#26 BLK-FS
RED L1 WHT-FS TP24 WHT-24
2 TP22 TP26
RED
ORG/RED-42
RED
RED/WHT-3
P3 RED
ORG/RED-42
HORN
PLATFORM CONTROLLER
10 A P1 KS1
BLK/RED-9
RED 20 FAULT LED
TB22 + L3
CB1 GROUND TILT
ALARM
A1 RED
3 TP3
TP32
TP30
TP29
TP31 TP39 TP9 TP23 TP28 TP42
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLU/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
TB39 RED
TB29
TB31
TB32
TB30
TB20 ORG #40 TB40 RED-8

TB3
4
TB42
CR2
WHT-
RED/
BLU/WHT #12
ORG/RED #CR2
RED
WHT#30
WHT/BLK#31
WHT/RED#32
RED/WHT#29
BLU/WHT #12
ORG/RED #42
ORG/RED #42
BLU/RED #39
ORG/RED #42
ORG/RED
21
F5 LS4
WHT
ORG/RED
10 A 22 (SEC.)
F4 AP2 48V 86 30
BLK-8
CR2
500 A PR1 86
+48 V TB23
INDICATOR LED L2
CONTROLLER FAULT
85 87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200 A
86 30
CR1
BLK #22
RED-6
RED 20
RED/BLK #28
+
-
LEFT 85 87
DIODE RETURN
BOX 21
RED/BLK-R5
-
+
INTERLOCK
TB9
+48V INPUT
LS2
FAULT LED
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
C1 1
BLK-6
GRN
0.1 ENABLE
BLK
WHT #21
mF
HM TB21
3
BLK/RED #CR4
RED/WHT #23
RED/WHT #23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
6 AP2
CURTIS 1244
RED-7
F3 24 V SEPEX CONTROLLER
13
500 A AP1 F1
F2 M- B+ F1 B- LS1
+24 V 200 A (EXT.)*
PR3 PR2 +
14
BLK-7
-
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1 *SWITCH
These items 30 86
+
MOTOR SHOWN
-
RIGHT removed after

RIGHT
7 BOX E2 E1 A1 A1 MOTOR serial number
WITH BOOM CR4
-
+
+ EXTENDED
10667. 87 85
PUMP PUMP CHARGER
BLK
+
-
+
-
BLK
BRN
GROUND AC POWER (GND)

10 A HORN
(GND)
AP1 CB2 BRN
8
48V POWER RELAY CR2
48V POWER RELAY CR1
HOUR METER
BLACK
HORN RELAY
LIFT PUMP
PRIMARY
BOX GROUND
GROUND CONTROL
(OPTION)
FLASHING BEACON
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V
2GA.
CHASSIS
GROUND
NOTES:
1. ALL LIMIT SWITCHES ARE SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT WHERE NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.
6 - 27 Z-45/25 DC • Z-45/25J DC Part No. 106726

REV A Electrical Schematic, Z-45/25J

1
RED/WHT #29
NOTES:
WHT/RED #32
WHT #30 2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
WHT/BLK #31
WHT-24 WHT-24
ORG/RED-42 2
WHT-24 RED
TURNTABLE PLATFORM JIB BOOM
BLU/WHT#12
ORG/RED-42 ROTATE BOOM BOOM BOOM ROTATE CR7A JP1 (REMOVE FOR CE VERSION)
LEVEL
30
87 DP1
RED
TS12 TS10 TS11 TS13 TS9 TS7 TS8
20K
DOWN
1 A
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
2 B
RED/BLK-R6
3 FWD C
TS1
ORG/RED-16
DRIVE
4 REV R
CR6 86
L R DRIVE 30
3
PUMP
AUXILIARY
RED
5 L TS15 ENABLE
BP1 STEER
TP45 85
30 ROTARY RED 87
CR7B ORG/BLK-R6
T1 FLOW + TP27 TP37 TP36 TP41 ENABLE
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED - 3
BLU/WHT - 3
RED
GROUND
CONTROL BOX
PLATFORM
4
WHT-3
GRN/
WHT-1
GRN/
BLU/WHT #12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
5
RED
TB41
BRAKE
TS62 TS60 TS61 TS63 TS59 TS57 TS58 RELEASE 30
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
GRN/WHT#19 TB48 TB13

GRN/WHT #19 TB19
BLK-7
BRN-2
ORG/RED - 3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED #6
TB36 6
BLU/BLK #37
BLU #36
GRN/WHT
GRN/BLK #18
WHT/RED #6
RED #27
GRN #17
RED/WHT #48
BLU/BLK #11
BLU #10
BLK/WHT # 8
BLK #7
ORG
WHT/BLK #5
RED/BLK #2
RED #1
WHT #4
13
TB14 22 *SWITCH SHOWN
TB15 LS3*
PLATFORM LEVEL CUTOUT WITH BOOM ROTATED
(CE VERSION ONLY) PAST EITHER
14 21 NON-STEER WHEEL.
30 86
RED-7
86 86 CR3
30 30
87 87
87a 87 85
7
CR10B CR10A 85
RED
GRN/WHT
85
WHT #40
BRN-7
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3 13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
BRAKE RELEASE N.O.

STEER LEFT
BRAKE RELEASE N.C.
TRAVEL ALARM
BRAKE RELEASE
LIMIT SWITCH
DRIVE ENABLE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT
PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB BOOM UP
ROTATE LEFT/
PLATFORM
JIB BOOM DOWN
ROTATE RIGHT/
PLATFORM
UP
PRIMARY BOOM
EXTEND
PRIMARY BOOM
COIL PR2
LIFT PUMP RELAY
UP
SECONDARY BOOM
RETRACT
PRIMARY BOOM
VALVE
PROPORTIONAL
RELAY CR10B
DOWN CUTOUT
PLATFORM LEVEL
DOWN
PLATFORM LEVEL
DOWN
PRIMARY BOOM
UP RELAY CR10A
PLATFORM LEVEL
UP
PLATFORM LEVEL
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
TURNTABLE
DOWN
SECONDARY BOOM
(OPTION)
DESCENT ALARM
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 28

Electrical Schematic, Z-45/25J


ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

3A CR17 P2 FS1 RED-FS
85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
BLK/RED-9
10 A P1
RED-20 FAULT LED
TB22 +
CB1 A1
GROUND TILT
ALARM RED
3
TP32
TP30
TP29
TP31
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4
WHT
F4 10A
ORG/RED
22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
-
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX
RED/BLK-R5
21
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
GRN
BLK-6
BLK
HM
ENABLE WHT-21
TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
6 AP2
RED-7

F3
13
500A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
7 BOX E2 E1 A1 A1
RIGHT
MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 29 Z-45/25 DC • Z-45/25J DC Part No. 106726


RED/WHT-29
1
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 WHT-24
ORG/RED-42
WHT-24 RED
2
BLU/WHT-12
ORG/RED-42 ROTATE CR7A JP1 (REMOVE FOR CE VERSION)
ROTATE BOOM BOOM BOOM LEVEL
30
87a DP1
RED
20K
DOWN
1 A
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
2 B
RED/BLK-R6
ORG/RED-16
3 FWD C
TS1 DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1
5
STEER
L TS15
ENABLE
85
3
30 ROTARY RED 87
CR7B ORG/BLK-R6
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
GRN/WHT-19 GRN/WHT-19 TB48 TB13
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
PLATFORM LEVEL CUTOUT ENABLE
(CE VERSION ONLY) LIMIT
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
UP COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 30



ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

3A CR17 P2 FS1
85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
BLK/RED-9
10 A P1
RED-20 FAULT LED
TB22 +
CB1 A1
GROUND TILT
ALARM RED
3
TP32
TP30
TP29
TP31
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4
F4 10A
ORG/RED
22 (SEC.)
500 A AP2 48V DC 30
WHT
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
-
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX
RED/BLK-R5
21
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
GRN
BLK-6
BLK
ENABLE WHT-21
HM TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
2
9
6
14
10
11
16
17
20
5
1
TB49
6 AP2
RED-7

F3
13
500A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
7 BOX E2 E1 A1 A1
RIGHT
MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 31 Z-45/25 DC • Z-45/25J DC Part No. 106726


RED/WHT-29 RED/WHT-29
WHT/RED-32 WHT/RED-32
1
WHT-30 WHT-30
WHT/BLK-31 WHT/BLK-31
WHT-24 WHT-24 WHT-24
ORG/RED-42
RED
DP1
WHT-24 20K

1
2
BLU/WHT-12
SECONDARY PRIMARY PRIMARY PLATFORM 2
ORG/RED-42 BOOM ROTATE CR7A
ROTATE BOOM BOOM LEVEL FWD 3
30 JP1 (REMOVE FOR CE VERSION)
87a REV 4
RED
TS12 TS10 TS11 TS13 TS9 TS7 TS8 ORG/BLK-R6
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
10 ENABLE
RED BP1 STEER
TP45 85
TP4 TP5 TP11 TP10 TP2 TP1 TP8 TP7 TP15 TP14
30 CR7B ROTARY
OEM
RED
BRN
87
DRIVE
3
TP17 TP18
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
RED
TB41
BRAKE
TS62 TS60 TS61 TS63 TS59 TS57 TS58 RELEASE 30 5
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
TB36
WHT/RED-6
6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
87a 87a
CR10B CR10A 85
RED
GRN/WHT
85
7
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
8
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
UP COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 32



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3
BLK/RED-9
P1
RED-20 FAULT LED
TB22 +
CB1 GROUND TILT
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
21
F5 LS4
F4
ORG/RED
(SEC.)
WHT
10A 22
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
BLK-6
GRN
BLK
ENABLE WHT-21
HM TB21
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
1
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
RIGHT
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 33 Z-45/25 DC • Z-45/25J DC Part No. 106726


1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
UP COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 34



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN
KS1 PLATFORM
BLK/RED-9
P1
RED-20
TB22 +
CB1 GROUND TILT
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
LS4
WHT
F5
F4
ORG/RED
10A 22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
1
BLK-6
GRN
BLK
ENABLE WHT-21
HM
3
BLK/RED-9
RED/WHT-23
RED/WHT-23
+
-
2
1
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 E2 E1
MOTOR 30 86
+
-
RIGHT
RIGHT
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 35 Z-45/25 DC • Z-45/25J DC Part No. 106726


1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
UP COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 36



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
P3 RED
ORG/RED-42
RED/WHT-3
HORN
KS1 PLATFORM
BLK/RED-9
P1
RED-20
TB22 +
CB1 GROUND TILT
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F5 LS4
WHT
F4
ORG/RED
10A 22 (SEC.)
500 A AP2 48V DC 30
86
BLK-8
CR2
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
CR1
BLK-22
RED-6
RED 20
RED/BLK-28
+
85
-
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21
RED/BLK-R5
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
22 (PRI.)
POT. HI
BLK-6
GRN
BLK
ENABLE WHT-21
HM
+
BLK/RED-9
RED/WHT-23
RED/WHT-23
-
+
-
10
11
14
16
17
20
TB49
6 AP2
RED-7
CURTIS 1244
F3 24V DC
SEPEX CONTROLLER 13
500 A AP1 F1
F2 M- B+ F1 B- LS1 2
+24V DC 200A
PR3 PR2 (EXT.) +
14
BLK-7
+
FB
RED
WHT
WHT
LEFT A2 A2 F2 F1
MOTOR 30 86
+
-
RIGHT
RIGHT
7 BOX F2 F1 A1 A1 MOTOR CR4
+
+
PUMP PUMP 87 85
CHARGER
BLK
+
-
BRN
AC POWER
BLK
+
-
BRN
GROUND
(GND)
HORN
(GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
6 - 37 Z-45/25 DC • Z-45/25J DC Part No. 106726


RED/WHT-29 RED/WHT-29 1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
1 2
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
10 ENABLE
RED BP1 STEER
TP45
30 CR7B ROTARY RED 87
85
3
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
RED
TB41
BRAKE
RELEASE 30
5
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
TB36
WHT/RED-6
6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
87a 87a
CR10B CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
8
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
UP COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 38



1 C7P-1 P22BAT BK
P2
C9P-1 BK BK-(FS)
FS1
RD-(FS) C9P-3 LOAD
SENSOR
P25BAT BK C29JSH RD/WH
P26BAT MODULE
WH-(FS) C9P-2 C
P24BAT WH C32JSL WH/RD
WH-LOAD
BK-26 LOAD B+ GND 8 C30FWD WH
OR-LOAD
BRN
C31REV WH/BK
LOAD SENSOR OPTION LOAD
C40LS OR
CELL
NOTES:
2 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
FS1
P2 RD-(FS) C9P-3
P22BAT C7P-1 C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH P24BAT WH
BK P26BAT
RD
R42BAT OR/RD
C7B-1
RD
PLATFORM RD
P1 KS1
P20BAT RD P3
TB22 HORN +
TILT
CB1 ALARM
10 A GROUND
C1P-4
C1P-5
C1P-6
C1P-3
A1
C2P-2
C3P-9
C7P-2
C1P-2
C3P-3
C2P-4
3
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
C9HRN BK/RD
P23SWBAT WH
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
P20BAT RD
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
C3B-9
C7B-2
C1B-2
C3B-3
C2B-4
4
C7B-4
C6B-30
C6B-31
C6B-32
C6B-29
OR TB40 OR P20BAT RD
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
F5
OR/RD
F4
OR/RD
10A
C6B-12
C6B-24
500 A
C6B-20 RD
AP2 48V DC C6B-40 OR 30
CR2 86
5 PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK
WH
RD/BK
BK
BK/RD
+
COIL-PR1
CR5
BL/WH
F2 85
200 A 30
86
CR1
RD 20
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-28
C6B-34
+
DIODE RETURN
85
-
C6B-25 CFIL BK
LEFT 87
BRN
BRN
BOX
INTERLOCK
+48V INPUT
+
BK-4
WH-4
BK-5
WH-5
FORWARD
POT. LOW
REVERSE
POT. HI
21 + C12DRE BL/WH
GR
LS4 HM
_
6 (SEC)
+
-
22
1
10
11
14
16
17
20
AP2 30
RD/WH
RD/BK
86
RD
CURTIS 1244 CR4
F3 24 V DC
BK-5
RD-5
SEPEX CONTROLLER 87 85
500 A F1 BK
AP1
C8-A
C8-C
F2 M- B+ F1 B-
+24 V 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
+
RD
WH
FB
WH-6
BK-7
WH-7
BK-6
WH
7 LEFT
MOTOR
A2 A2 F2 F1
+
-
RIGHT
RIGHT
+
+ (PRI) LS1 2
PUMP PUMP CHARGER (EXT)
22
BK
14
BK 2 GA
BRN
-
AC POWER +
C8-B
BK
+
-
BRN
GROUND
(GND)
AP1 BK BK
8 PR2 PR2
PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC
6 - 39 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
6 - 40
A
3
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

21
22
LS3

B
TB12
14
13

86
85
BRN
A2
86
85
Z-45/25 DC • Z-45/25J DC
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C27-1 C27-2
BRAKE RELEASE
C2P-3 RD/WH
DRIVE 30
87
87
30
N.C. COIL
30
87
RD/BK-R6
CE VERSION:
ENABLE
C
BRAKE RELEASE
TS15
RD C26-1 C26-2
AND ADD
RD/WH N.O. COIL

REMOVE
JUMPER
RELAY
RELEASE
J1
BRAKE
PS1 BRAKE RELEASE

JACK
CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D
OR/BK-R6
C6B-23 P20BAT RD
C31REV WH/BK
10
C29JSH RD/WH
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
E
PUMP
33
GR/WH

TS1
PR2
RD-AUX
Part No. 106726
87
30

LVI/BCI OPTION

BCI
BK
F
E
May 2005
CR3
+
OR/RD
AUX
85
ON
86
DISCHARGE

BCI OPTION
SET TO "N"
1
RELAY COIL CR3

F
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30

WH
85
86

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD FLOW

CONTROL
BK
85 BRN
BK/RD
CR19A
BRN
GR/WH
COIL
RD
86
TB18
PLATFORM
G
C23-1 C23-2
CONTROL
DOWN
CR19B
C6B-18 GR/BK ROTATE RIGHT /

ROTARY
JIB DOWN
FLOW
OEM
C6B-17 GR PLATFORM
BOOM
BP1
TS58
UP ROTATE LEFT /
TB17
C22-1 C22-2
86
85
JIB
JIB UP
TB44
C2P-6 C44JDA GR/BK C2B-6

BOOM
JIB
DOWN C4P-6 C18PRR GR/BK C4B-6 GR/BK

TS8
UP
H
RIGHT
BK C44DA C6B-33
PLATFORM
87a
ROTATE
TS57
LEFT
CR7
30
85
86
PLATFORM
ROTATE
RIGHT
GR/WH
JIB MANIFOLD
TS7
LEFT
I
C2P-7 C45JSV GR/WH C2B-7

UP TB14 C6B-14 OR
C20-1 C20-2
PLATFORM LEVEL
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
J

TS9
TB7
DOWN C16-1 C16-2
PRIMARY EXTEND COIL
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
C12-1 C12-2
K
RETRACT UP C6B-1 RD PRIMARY BOOM

UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
L
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
87
30 C3P-11 C11SBD BL/BK C3B-11
TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
M
ROTATE
RD
TS12
R42BAT OR/RD
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
P20BAT RD
C40LS OR
REV A
TS55
(GND)
PR2
PR3
CR5
BK
RD

Electrical Schematic, Z-45/25J, ANSI and CSA Models REV A

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132 PLI BL/WH C1P-12 RD

7
C1B-12
+ A1
RD
LS18 TILT
P3 ALARM L48
CB1 HORN
KS1 PLATFORM
10 A P1
C7P-2
C3P-3
C2P-4
P20BAT RD D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C3BAT RD/WH
R42BAT OR/RD
4 5
C32
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C3B-3
C2B-4
P20BAT RD
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5
BK/RD
F4
OR/RD
10A
C6B-12
C6B-24
500A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
CR2 86
PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
5 200A 86
CR1
30
RD 20
BL/WH
OFF-LMT SPD INP
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
C6B-28
+
C6B-34
85
-
LEFT 87
+48V INPUT
BRN
BRN
BOX
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
POT. HI
21 +
GR
C12DRE BL/WH
LS4 HM
_
+
(SEC)
-
2
9
14
10
11
16
17
20
5
1
22
AP2
30
RD/WH
RD/BK
86
RD
U6A
MOTOR CONTROLLER CR4
24V DC
6
BK-5
RD-5
87 85
F1 BK
AP1
C8-A
C8-C
F1 M- B+ F2 B-
+24V DC 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
RD
WH
FB
WH-6
BK-7
WH-7
BK-6
WH
LEFT A2 A2 F2 F1
MOTOR
+
RIGHT
RIGHT
+
+ (PRI) LS1
PUMP PUMP 2
CHARGER (EXT)
22
BK
7 14
BK 2 GA
-
BRN
+
C8-B
BK
+
BRN
GROUND A2
AC POWER
(GND)
AP1 BK BK
PR2 PR2
PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
OPTION
BEACON
FLASHING
TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC

NOTES: 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 7 ANSI/CSA
6 - 41 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
Electrical Schematic, Z-45/25J, ANSI and CSA Models
6 - 42
A
3
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

21
22
LS3
BL/WH WH-8 RD-8

B
C3P-12 C12DRE BL/WH C3B-12 C6B-26 C12DRE

TB12
14
13

86
85
BRN
A2
86
85
Z-45/25 DC • Z-45/25J DC
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
C2P-3 RD/WH N.C. COIL
DRIVE 30
87
87
30
30
87
RD/BK-R6
CE VERSION:
ENABLE
C
TS15
AND ADD
REMOVE
JUMPER
RELAY
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D
OR/BK-R6
C31REV WH/BK
10
C29JSH RD/WH
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
E
PUMP
33
GR/WH

TS1
PR2
RD-AUX
Part No. 106726
87
30

LVI/BCI OPTION

BCI
BK
F
E
May 2005
CR3
+
OR/RD
AUX
85
ON
86
DISCHARGE

BCI OPTION
SET TO "N"
1
RELAY COIL CR3

F
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30

WH
85
86

7
CR20
TB6
87a
8

CONTROL
BK
85 BRN
BK/RD
CR19A
BRN
GR/WH
COIL
RD
86
TB18
G

CONTROL
DOWN
CR19B

ROTARY
JIB DOWN
FLOW
OEM
C6B-17 GR PLATFORM
BOOM
BP1
TS58
UP ROTATE LEFT /
TB17
C22-1 C22-2
86
85
JIB
JIB UP
TB44

BOOM
JIB

TS8
UP
H
RIGHT
BK C44DA C6B-33
PLATFORM
87a
ROTATE
TS57
LEFT
CR7
30
85
86
PLATFORM
ROTATE
WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
LEFT
I
C2P-7 C45JSV GR/WH C2B-7

TB14
UP C20-1 C20-2
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
J

TS9
TB7
DOWN C16-1 C16-2
EXTEND COIL
PRIMARY
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
C12-1 C12-2
K
RETRACT UP C6B-1 RD PRIMARY BOOM

UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
L
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
87
30
TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
M
ROTATE
RD
TS12
R42BAT OR/RD
P24BAT WH LEFT
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
REV A
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
Electrical Schematic, Z-45/25J, ANSI and CSA Models

Electrical Schematic, Z-45/25J, CE Models REV A

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132PLI BL/WH C1P-12 RD
C1B-12
+
RD
A1
LS18 TILT
P3 L4 ALARM
CB1 HORN 5
10A KS1 PLATFORM
P1
C7P-2
C3P-3
C2P-4
P20BAT RD D39 D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C7P-2
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C3BAT RD/WH
R42BAT OR/RD
4 5
U33
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C3B-3
C2B-4
P20BAT RD
A6 L45
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5
BK/RD
F4
OR/RD
10 A
C6B-12
C6B-24
500 A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
CR2 86
PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
5 200 A
86
CR1
30
RD 20
BL/WH
OFF-LMT SPD INP
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
C6B-28
+
C6B-34
85
-
LEFT 87
+48V DC INPUT
BRN
BRN
BOX
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
POT. HI
21 +
GR
C12DRE BL/WH
LS4 HM
_
+
(SEC)
-
14
10
16
17
20
11
22
3
9
5
2
1
AP2
30
RD/WH
RD/BK
86
RD
U6A
CR4
6 24V DC MOTOR CONTROLLER
BK-5
RD-5
87 85
F1 BK
AP1
C8-A
C8-C
F1 M- B+ F2 B-
+24V DC 200A
PR3 PR2
C6B-9 BK/RD
+
C11-3
C11-4
C11-1
C11-2
RD
WH
FB
WH-6
BK-7
WH-7
BK-6
WH
LEFT A2 A2 F2 F1
MOTOR
+
RIGHT
RIGHT
+
+ (PRI) LS1
PUMP PUMP 2
CHARGER (EXT)
22
BK
7 14
BK 2 GA
-
BRN
+
C8-B
BK
+
BRN
GROUND A2
AC POWER
(GND)
AP1 BK BK
PR2 PR2
PR3 PR3

HOUR METER
HORN
HORN RELAY
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
FLASHING BEACON OPTION

TILT SENSOR
LIFT PUMP
AUXILIARY
CHARGER
48V DC

NOTES: 5 CE & PLATFORM LOAD SENSE OPT.
6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
6 - 43 Z-45/25 DC • Z-45/25J DC Part No. 106726

8
Electrical Schematic, Z-45/25J, CE Models
6 - 44
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

21
22
LS3

TB12
14
13

B
86
85
BRN
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
Z-45/25 DC • Z-45/25J DC
C2P-3 RD/WH N.C. COIL

DRIVE 30
87
87
30
30
87
RD/BK-R6
CE VERSION:
ENABLE
TS15
AND ADD
REMOVE
JUMPER
RELAY
C
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
D
C31REV WH/BK
10
C29JSH RD/WH
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH

TS1
PR2
RD-AUX
E
87
30

LVI/BCI OPTION

BCI
Part No. 106726

BK
F
CR3
+
OR/RD
AUX
85
ON
86
DISCHARGE

BCI OPTION
SET TO "N"
1
RELAY COIL CR3

May 2005
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4
F

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30

WH
85
86

7
CR20
TB6
87a
8

CONTROL
BK
85 BRN
BK/RD
CR19A
BRN
GR/WH
COIL
RD
86
TB18

CONTROL
DOWN
CR19B

ROTARY
JIB DOWN
FLOW
OEM
C6B-17 GR PLATFORM
G
BOOM
BP1
TS58
UP ROTATE LEFT /
TB17
C22-1 C22-2
86
85
JIB
JIB UP
TB44

BOOM
JIB

TS8
UP
RIGHT
BK C44DA C6B-33
PLATFORM
87a
ROTATE
TS57
H
LEFT
CR7
30
85
86
PLATFORM
ROTATE
WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
LEFT C2P-7 C45JSV GR/WH C2B-7

TB14
I
UP C20-1 C20-2
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL

TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
TS9
TB7
DOWN C16-1 C16-2
J
EXTEND COIL
PRIMARY

BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
RETRACT C12-1 C12-2
UP COIL
PRIMARY
BOOM
K
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
L
ALARM
A3
OPTION (A3)
+
87
30

TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
M
TS12
R42BAT OR/RD
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
REV A
N
Electrical Schematic, Z-45/25J, CE Models

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25

8
7
6
5
4
3
2
1
6 - 45
TERMINAL BASE (TB)
D C B A
RED
RED RED-1
1 PRIMARY BOOM UP 1
RED/BLK BLK
RED/BLK RED/BLK-2
2 PRIMARY BOOM DOWN 2
A
SPARE
RED/WHT
PLUGGED
RED/WHT-3
#3
3 48 V RELAY COIL POWER 3
M.H.
WHT
WHT WHT-4
4 TURNTABLE ROTATE RIGHT 4
WHT/BLK
WHT/BLK WHT/BLK-5
5 TURNTABLE ROTATE LEFT 5
WHT/RED
WHT/RED GRN/WHT
6 LIFT FLOW CONTROL 6
BLK
B
BLK BLK-7
7 PRIMARY BOOM EXTEND 7
BLK/WHT
BLK/WHT BLK/WHT-8
8 PRIMARY BOOM RETRACT 8
BLK/RED
CABLE #4
BLK/RED-R4
9 HORN 9
BLU
BLU BLU-10
10 SECONDARY BOOM UP 10
SECONDARY
LIMIT SWITCH (LS4)

BLU/BLK BLK
SECONDARY BOOM
BLU/BLLK BLU/BLK-11
11 SECONDARY BOOM DOWN 11
BLU/WHT WHT-12
M.H.
EXT.
C
WHT BLU/WHT-12
12 FOOTSWITCH POWER #2 12
BLU/RED
CABLE #6
BLK
13 DRIVE ENABLE LIGHT 13
ORG
BOOM EXTEND
ORG-14
LIMIT SWITCH (LS1)

14 PLATFORM LEVEL UP 14
ORG/BLK
ENABLE
ORG/BL-15
15 PLATFORM LEVEL DOWN 15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
16 DRIVE ENABLE RELAY COIL 16
GRN
CABLE #5
GRN GRN-17
D
17 PLATFORM ROTATE RIGHT 17

GRN/BLK
PRIMARY BOOM
GRN/BLK GRN/BLK-18
18 PLATFORM ROTATE LEFT 18
LIMIT SWITCH (LS2)

GRN/WHT GRN/WHT
PRIMARY
GRN/WHT GRN/WHT-19
19 LIFT PUMP 19
GRN/WHT-19 GRN/WHT-J19
19 LIFT PUMP 19
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
RED-20 RED-20
20 +24 VOLT POWER 20
WHT-12
#3
WHT-21 WHT-21
E
21 HOUR METER ENABLE 21
CABLE #7
BLK
BLK BLK-22
SWITCH (LS3)
22 +24 VOLT TO PATFORM 22
WHT RED-ALARM
RED/WHT-23 WHT-23
DRIVE ENABLE LIMIT

23 KEYSWITCH POWER 23
BOOM
WHT-23
CABLE #3
24 (UNUSED) 24
#2
25 (UNUSED) 25
ENABLE
PRIMARY
F
May 2005
EXTENTION
26 (UNUSED) 26
Part No. 106726

GRN/WHT-19
SECONDARY
RED RED-27
#1 RED-27
27 AUXILIARY PUMP SELECT 27
RED/BLK
CHASSIS HARNESS
MANIFOLD HARNESS
RED/BLK-28 WIRE GOES TO
28 TILT ALARM 28 RELAY #3 ON THE
RED/WHT
SWITCH PANEL
RED/WHT-29
29 JOYSTICK POT. HIGH 29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
G
WHT/BLK-31
31 REVERSE 31
BASE BOX HARNESS
WHT/RED
BOOM
CABLE #2
WHT/RED-32
32 JOYSTICK POTENTIOMETER LOW 32
BLK
BLK-33
33 START ENGINE 33
BLK/WHT
RED-ALARM (USED ONLY FOR FLASHING BEACON OPTION)
BLK/WHT-34
34 GLOW PLUG 34
BLK/RED
LED
BLK/RED-35
FAULT
35 HIGH/LOW RPM 35
STATUS
BLU
H
+ BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLU/BLK-37 GRN/WHT-J19
BLK-LED 37 STEER RIGHT 37
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
39 CONTROLLER FAULT LED 39
ORG
BOOM
CABLE #1
ORG-40 RED
40 OFF LIMIT SPEED 40
ORG/BLK
I
ORG/BLK-41
41 DRIVE ENABLE OUTPUT 41
ORG/RED ORG/RED-42 LED
42 SWITCH 48 VOLTS 42
GRN
#2
#1
43 (SPARE) 43
GRN/BLK
ENABLE
PRIMARY
44 (SPARE) 44
EXTENTION
GRN/WHT
GRN/WHT-19
SECONDARY
GRN/WHT-45
HARNESS
MANIFOLD
FUNCTION
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
J
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
RED/WHT-48 RED/WHT-48 GROUND
48 BRAKE RELEASE 48 CONTROL
BLK
BOX
RED HARNESS
49 LS1-LS2 JUNCTION 49
BLK
RED
50 LS2-LS4 JUNCTION 50 (TO
K
SWITCH
PANEL)
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
ORG/RED-42 LED
ORG/BLK ORG/BLK
ORG ORG
WHT WHT-40
BLU/WHT-12 BLU/WHT-12
RED-27 RED-27P
ORG/RED-R2 ORG/RED-R2
CHASSIS
HARNESS
RED/BLK-R5 RED/BLK-R5
L
RED-PBRK RED-POWER
RED-PISM6
GRN/WHT-19 GRN/WHT-R3
BLK/RED-9 BLK/RED-R4
RED-ALARM
BLK-ALARM
GRN/WHT-19
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
M
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
GROUND CONTROL BOX HARNESS
REV A
N
N
REV A
M
L
EMERGENCY
STOP KEY SWITCH AUXILIARY
K
P1 KS1 PUMP TS51

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
WHT-23 WHT-23 WHT-23 RED
BLK-22
RED RED
J
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
BLK/WHT-8
I
BLK/RED-7
3 BRN RED-1
RED/BLK-2
WHT-21 WHT-21
PRIMARY PRIMARY
BOOM BOOM
TS61 EXTEND/
HOUR METER
RETRACT
H.M.
TS63
BLK
H
GROUND CONTROL BOX HARNESS RED

BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
BLK-22
BLK
RED
G
BLU/BLK-11
RED TURNTABLE
ROTATE
BLU-10 TS62
SECONDARY RED
BOOM TS60 RED
BLK
BLK
GRN-17
RED
RED
RED
F
RED
ORG-14
GRN
BLK BLK
GRN-17
RED RED
May 2005
GRN/BLK
RED-20
BLK
RED
ORG/BLK
RED
Part No. 106726
ORG
FUNCTION CIRCUIT
RED
ENABLE TS55 BREAKER 10A ORG/BLK-15 RED

BLK
CB1
RED RED PLATFORM PLATFORM
E
LEVEL TS59 ROTATE TS57

GRN/BLK-18
RED RED
GRN/WHT-45 GRN/WHT-45
GRN/BLK-18 GRN/BLK-18
BLK BLK
ORG
ORG/BLK
D
ORG/RED-R2
RED/WHT-3
RED/WHT-3 48 V BRN
48 V POWER POWER AUXILIARY CONTROL
RELAY CR1 RELAY CR2 RELAY CR3
30 30 30
BRN
BRN
BRN
85 86 85 86 85 86
BLK-22
87a 87a 87a UNUSED
87 87 87
C
BRN
BRN
ORG/RED-42 ORG/RED
BRN
RED-27
RED-27P
Z-45/25 DC • Z-45/25J DC
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
BRN
ORG
ORG
B
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN
87a 87a 87a 87a
86 85 86 85 86 85 86 85
BLK-22
30 30 30
WHT
30
A
HORN RELAY BRAKE RELEASE PLATFORM LEVEL PLATFORM LEVEL

WHT
CR4 RELAY CR5 CUTOUT UP RELAY CUTOUT DOWN

CR10B RELAY CR10A
WHT
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
6 - 46
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 47
TERMINAL BASE (TB)
D C B A
RED
RED RED-1
1 PRIMARY BOOM UP 1
RED/BLK BLK
RED/BLK RED/BLK-2
A
SPARE
RED/WHT
PLUGGED
RED/WHT-3
#3
M.H.
WHT
WHT WHT-4

WHT/BLK
WHT/BLK WHT/BLK-5
WHT/RED
WHT/RED GRN/WHT
BLK
B
BLK BLK-7
BLK/WHT
BLK/WHT BLK/WHT-8
CABLE #4
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
LIMIT SWITCH (LS4)

SECONDARY BOOM
BLU BLU-10
SECONDARY
BLU/BLK BLK
BLU/BLLK BLU/BLK-11

BLU/WHT WHT-12
C
M.H.
EXT.
WHT BLU/WHT-12
CABLE #6
BLU/RED
BLK
BOOM EXTEND
ORG
LIMIT SWITCH (LS1)

ORG-14
ORG/BLK
ENABLE
ORG/BL-15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
CABLE #5
GRN
D
GRN GRN-17
17 PLATFORM ROTATE RIGHT/JIB DOWN 17
GRN/BLK
PRIMARY BOOM
GRN/BLK GRN/BLK-18
LIMIT SWITCH (LS2)

18 PLATFORM ROTATE LEFT/JIB UP 18
GRN/WHT GRN/WHT
PRIMARY
GRN/WHT GRN/WHT-19
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
WHT-12
#3
E
WHT-21 WHT-21
CABLE #7
BLK
SWITCH (LS3)
BLK BLK-22
DRIVE ENABLE LIMIT

WHT RED-ALARM
RED/WHT-23 WHT-23
WHT-23
BOOM
CABLE #3
24 (UNUSED) 24
#2
25 (UNUSED) 25
ENABLE
PRIMARY
F
May 2005
Part No. 106726

EXTENTION
26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
RED-27
#1 27 AUXILIARY PUMP SELECT 27
CHASSIS HARNESS
RED/BLK
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
G
WHT/BLK-31
31 REVERSE 31
BASE BOX HARNESS
WHT/RED
BOOM
CABLE #2
WHT/RED-32
BLK
BLK-33
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
BLK/RED
LED
BLK/RED-35
35 HIGH/LOW RPM 35
FAULT
BLU
STATUS
H
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
ORG
BOOM
CABLE #1
ORG-40 RED
ORG/BLK
I
ORG/BLK-41
GRN
#2
#1
43 (SPARE) 43
GRN/BLK
ENABLE
PRIMARY
44 (SPARE) 44
EXTENSION
GRN/WHT
GRN/WHT-19
SECONDARY
HARNESS
GRN/WHT-45
MANIFOLD
FUNCTION
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
J
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
GROUND
RED/WHT-48 RED/WHT-48 CONTROL
48 BRAKE RELEASE 48
BLK BOX
RED HARNESS
BLK
RED
(TO
K
SWITCH
PANEL)
ORG/RED-42 LED
ORG/BLK ORG/BLK
ORG ORG
WHT WHT-40
RED-27 RED-27P
CHASSIS
L
HARNESS
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
M
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
REV A
N
N
REV A
M
L
P1 TS51
AUXILIARY
K
EMERGENCY KS1
STOP KEY SWITCH PUMP
RED RED-POWER
ON
RED
NC NO BLK-22
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
I
1 2
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21 TS61
PRIMARY TS63
BOOM PRIMARY
BOOM
HOUR METER EXTEND/
H.M. RETRACT
H
BLK
BASE BOX HARNESS RED
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
BLK-22
G
BLK
RED
BLU/BLK-11 TS62
RED TURNTABLE
BLU-10 ROTATE
TS60 RED
SECONDARY RED
BOOM
BLK
F
BLK
GRN-17
RED
RED
RED
RED
ORG-14
BLK BLK
May 2005
GRN-17
RED RED
RED-20
BLK
RED
ORG
RED
Part No. 106726
ORG/BLK
TS55 CB1
RED
FUNCTION CIRCUIT ORG/BLK-15 RED

BLK
ENABLE BREAKER 1
E
RED RED TS59 TS57

PLATFORM PLATFORM
ROTATE
GRN/BLK-18
RED LEVEL RED

BLK BLK
ORG
D
ORG/BLK
ORG/RED-R2
RED/WHT-3 CR2
RED/WHT-3 48V DC BRN
CR1 POWER CR3
48V DC POWER RELAY RELAY AUXILIARY CONTROL
RELAY
30 30 30
BRN
BRN
BRN
BLK-22
87a 87a 87a UNUSED

86 85 86 85 86 85
C
87 87 87
BRN
BRN
ORG/RED-42 ORG/RED
BRN
RED-27
Z-45/25 DC • Z-45/25J DC
RED-27P
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
B
BRN
ORG
ORG
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN 85 86 85 86 85 86 85 86
87a 87a 87a 87a
BLK-22
30 30 30
WHT
30
A
CR4 CR5 CR10B CR10A

WHT

RELAY CUTOUT UP RELAY WHT CUTOUT DOWN RELAY
6 - 48
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 49
TERMINAL BASE (TB)
D C B A
RED
RED-1 RED-1
1 PRIMARY BOOM UP 1
SPARE PLUGGED RED/BLK BLK
A
RED/BLK-2 RED/BLK-2
RED/WHT
RED/WHT-3
#3
M.H.
WHT
WHT-4 WHT-4
WHT/BLK
WHT/BLK-5 WHT/BLK-5
WHT/RED
WHT/RED-6 GRN/WHT
B
BLK
BLK-7 BLK-7
BLK/WHT
BLK/WHT-8 BLK/WHT-8
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
SECONDARY BLU-10 BLU-10
SECONDARY
LIMIT SWITCH (LS4) BLU/BLK BLK
CABLE #4 BLU/BLK-11 BLU/BLK-11

C
BLU/WHT WHT-12
M.H.
EXT.
WHT BLU/WHT-12
BLU/RED
BLK
ORG
A ORG-14 ORG-14
BOOM EXTEND 14 PLATFORM LEVEL UP 14
LIMIT SWITCH (LS1) ORG/BLK
ENABLE
CABLE #6 A ORG/BLK-15 ORG/BLK-15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
GRN
D
GRN-17 GRN-17
GRN/BLK
PRIMARY GRN/BLK-18 GRN/BLK-18
LIMIT SWITCH (LS2) GRN/WHT GRN/WHT
CABLE #5
PRIMARY
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
20 +24 V POWER 20
E
WHT-12
#3
WHT-21 WHT-21
BLK
BLK BLK-22
DRIVE 22 +24 V TO PLATFORM 22
WHT RED-ALARM
ENABLE LIMIT
SWITCH (LS3) RED/WHT-23 WHT-23
CABLE #7 WHT-23
24 (UNUSED) 24
#2
BOOM CABLE #3 25 (UNUSED) 25
F
May 2005
ENABLE
Part No. 106726

PRIMARY
EXTENTION
26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
RED-27
#1
RED/BLK
CHASSIS HARNESS
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
29 JOYSTICK POTENTIOMETER HIGH 29
WHT
WHT-30
30 FORWARD 30
G
WHT/BLK
WHT/BLK-31
31 REVERSE 31
WHT/RED
WHT/RED-32
GROUND CONTROL HARNESS
BLK
BOOM CABLE #2 BLK-33
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
FAULT BLK/RED
STATUS BLK/RED-35
35 HIGH/LOW RPM 35
H
LED
BLU
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLK-LED
37 STEER RIGHT 37
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
ORG
ORG-40 RED
I
40 OFF-LIMIT SPEED 40
ORG/BLK
BOOM CABLE #1 ORG/BLK-41
GRN
#2
#1
43 (SPARE) 43
FUNCTION GRN/BLK
ENABLE
PRIMARY
MANIFOLD
44 (SPARE) 44
EXTENTION
HARNESS GRN/WHT
GRN/WHT-19
SECONDARY
GRN/WHT-45
J
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
BLK
HARNESS
RED
BLK
RED
K
50 LS2-LS4 JUNCTION 50 (TO SWITCH

PANEL)

ORG/RED-42 LED
ORG/BLK-15 ORG/BLK
ORG-14 ORG
WHT WHT-40
CHASSIS RED-27 RED-27P
HARNESS ORG/RED-R2 ORG/RED-R2
L
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
M
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
CUTOUT OPTION
BRN-J1
GROUND
BRN-J7
BRN
BRN
BRN
CONTROL HARNESS
BRN
A NOT USED FOR PLATFORM LEVEL
BRN
REV A
N
N
REV A
M
L
P1 TS51
EMERGENCY KS1 AUXILIARY
K

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
I
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21 TS61
PRIMARY TS63
BOOM PRIMARY
BOOM
HOUR METER EXTEND/
H.M. RETRACT
H
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
BLK-22
BLK
G
RED
BLU/BLK-11 TS62
RED TURNTABLE
BLU-10 ROTATE
TS60 RED
SECONDARY RED
BOOM
BLK
BLK
GRN-17
RED
RED
RED
F
RED
ORG-14
BLK BLK
May 2005
GRN-17
RED RED
RED-20
BLK
RED
ORG
RED
Part No. 106726
ORG/BLK
TS55 CB1
RED

BLK
ENABLE BREAKER 1
RED RED
E
TS59 TS57
PLATFORM PLATFORM
LEVEL ROTATE
GRN/BLK-18
RED RED
BLK BLK
ORG
D
ORG/BLK
ORG/RED-R2
RED/WHT-3 CR2
CR1 POWER CR3
RELAY
30 30 30
BRN
BRN
BRN
BLK-22
87a 87a 87a UNUSED

86 85 86 85 86 85
87 87 87
C
BRN
BRN
ORG/RED-42 ORG/RED
BRN
RED-27
RED-27P
Z-45/25 DC • Z-45/25J DC
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
B
BRN
ORG
ORG
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN 85 86 85 86 85 86 85 86
87a 87a 87a 87a
BLK-22
30 30 30
WHT
30
A
CR4 CR5 CR10B CR10A

WHT

6 - 50
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 51
TERMINAL BASE (TB)
D C B A
RED
RED-1 RED-1
1 PRIMARY BOOM UP 1
RED/BLK-2 RED/BLK-2
A
RED/WHT
RED/WHT-3
#3
M.H.
WHT
WHT-4 WHT-4

WHT/BLK
WHT/BLK-5 WHT/BLK-5
WHT/RED
WHT/RED-6 GRN/WHT
BLK
B
BLK-7 BLK-7
BLK/WHT
BLK/WHT-8 BLK/WHT-8
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
SECONDARY

BLU/WHT WHT-12
C
M.H.
EXT.
WHT BLU/WHT-12
BLU/RED
BLK
ORG
1 ORG-14 ORG-14
ENABLE
CABLE #6 1 ORG/BLK-15 ORG/BLK-15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
GRN
D
GRN-17 GRN-17
GRN/BLK
CABLE #5
PRIMARY
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
20 +24 V POWER 20
WHT-12
E
#3
WHT-21 WHT-21
BLK
BLK BLK-22
WHT RED-ALARM
ENABLE LIMIT
CABLE #7 WHT-23
24 (UNUSED) 24
#2
ENABLE
F
May 2005
PRIMARY
Part No. 106726

EXTENTION
26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
#1 RED-27
RED/BLK
CHASSIS HARNESS
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
G
WHT/BLK-31
31 REVERSE 31
WHT/RED
WHT/RED-32
BLK
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
FAULT BLK/RED
STATUS BLK/RED-35
LED 35 HIGH/LOW RPM 35
H
BLU
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLK-LED
37 STEER RIGHT 37
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
ORG
ORG-40 RED
I
ORG/BLK
GRN
#2
#1
43 (SPARE) 43
FUNCTION GRN/BLK
ENABLE
PRIMARY
MANIFOLD
44 (SPARE) 44
EXTENTION
HARNESS GRN/WHT
GRN/WHT-19
SECONDARY
GRN/WHT-45
J
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
BLK
HARNESS
RED
BLK
RED
K

PANEL)

ORG/RED-42 LED
ORG/BLK-15 ORG/BLK
ORG-14 ORG
WHT WHT-40
L
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
M
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
CUTOUT OPTION
BRN-J1
GROUND
BRN-J7
BRN
BRN
BRN
CONTROL HARNESS
BRN
1 NOT USED FOR PLATFORM LEVEL
BRN
REV A
N
N
REV A
M
L
P1 TS51
K

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
I
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21 TS61
PRIMARY TS63
BOOM PRIMARY
BOOM
HOUR METER EXTEND/
H.M. RETRACT
H
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
BLK-22
BLK
G
RED
BLU/BLK-11 TS62
RED TURNTABLE
BLU-10 ROTATE
TS60 RED
SECONDARY RED
BOOM
BLK
BLK
GRN-17
RED
RED
RED
F
RED
ORG-14
BLK BLK
May 2005
GRN-17
RED RED
RED-20
BLK
RED
ORG
RED
Part No. 106726
ORG/BLK
TS55 CB1
RED

BLK
ENABLE BREAKER 1
RED RED
E
TS59 TS57
PLATFORM PLATFORM
LEVEL ROTATE
GRN/BLK-18
RED RED
BLK BLK
ORG
D
ORG/BLK
ORG/RED-R2
RED/WHT-3 CR2
CR1 POWER CR3
RELAY
30 30 30
BRN
BRN
BRN
BLK-22
87a 87a 87a UNUSED

86 85 86 85 86 85
87 87 87
C
BRN
BRN
ORG/RED-42 ORG/RED
BRN
RED-27
RED-27P
Z-45/25 DC • Z-45/25J DC
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
B
BRN
ORG
ORG
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN 85 86 85 86 85 86 85 86
87a 87a 87a 87a
BLK-22
30 30 30
WHT
30
A
CR4 CR5 CR10B CR10A

WHT

6 - 52
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 53
TERMINAL BASE (TB)
D C B A
RED
RED-1 RED-1
1 PRIMARY BOOM UP 1
SPARE PLUGGED RED/BLK BLK A
RED/BLK-2 RED/BLK-2
RED/WHT
RED/WHT-3
#3
M.H.
WHT
WHT-4 WHT-4
WHT/BLK
WHT/BLK-5 WHT/BLK-5
WHT/RED
WHT/RED-6 GRN/WHT
BLK
B
BLK-7 BLK-7
BLK/WHT
BLK/WHT-8 BLK/WHT-8
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
SECONDARY
CABLE #4
C
BLU/WHT WHT-12
M.H.
EXT.
WHT BLU/WHT-12
BLU/RED
BLK
ORG
1 ORG-14 ORG-14
ENABLE
CABLE #6 1 ORG/BLK-15 ORG/BLK-15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
GRN
D
GRN-17 GRN-17
GRN/BLK
CABLE #5
PRIMARY
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
20 +24 V POWER 20
WHT-12
E
#3
WHT-21 WHT-21
BLK
BLK BLK-22
WHT RED-ALARM
ENABLE LIMIT
CABLE #7 WHT-23
24 (UNUSED) 24
#2
F
May 2005
ENABLE
Part No. 106726

PRIMARY
EXTENTION
26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
RED-27
#1
RED/BLK
CHASSIS HARNESS
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
G
WHT/BLK
WHT/BLK-31
31 REVERSE 31
WHT/RED
WHT/RED-32
BLK
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
FAULT BLK/RED
STATUS BLK/RED-35
H
BLU
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLK-LED
37 STEER RIGHT 37
BLU/WHT
38 (SPARE) 38
BLU/RED
39 (SPARE) 39
ORG
ORG-40 RED
I
ORG/BLK
GRN
#2
#1
43 (SPARE) 43
FUNCTION GRN/BLK
ENABLE
PRIMARY
MANIFOLD
44 (SPARE) 44
EXTENTION
HARNESS GRN/WHT
GRN/WHT-19
SECONDARY
GRN/WHT-45
J
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
BLK
HARNESS
RED
BLK
RED
K

PANEL)

ORG/RED-42 LED
ORG/BLK-15 ORG/BLK
ORG-14 ORG
WHT WHT-40
L
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
M
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
CUTOUT OPTION
BRN-J1
GROUND
BRN-J7
BRN
BRN
BRN
CONTROL HARNESS
BRN
1 NOT USED FOR PLATFORM LEVEL
BRN
REV A
N
N
REV A
M
L
P1 TS51
K

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
I
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21 TS61
PRIMARY TS63
BOOM PRIMARY
BOOM
HOUR METER EXTEND/
H.M. RETRACT
H
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
BLK-22
BLK
G
RED
BLU/BLK-11
TS62
RED
TURNTABLE
BLU-10 ROTATE
TS60 RED
SECONDARY RED
BOOM
BLK
BLK
GRN-17
RED
RED
RED
F
RED
ORG-14
BLK BLK
May 2005
GRN-17
RED RED
RED RED-20
BLK
RED
ORG
RED
Part No. 106726
ORG/BLK
TS55 CB1
RED

BLK
ENABLE BREAKER 1
RED RED
E
TS59 TS57
PLATFORM PLATFORM
LEVEL ROTATE
GRN/BLK-18
RED RED
BLK BLK
ORG
D
ORG/BLK
ORG/RED-R2 ORG/RED
RED/WHT-3 CR2
RED/WHT-3 48V DC BRN BRN
CR1 POWER CR3 CR20 LIFT PUMP
48V DC POWER RELAY RELAY AUXILIARY CONTROL RELAY
RELAY
30 30 30 30
BRN
BRN
BRN
BLK-22
87a 87a 87a 87a

86 85 86 85 86 85 86 85
87 87 87 87
C
BRN
BRN
ORG/RED-42 ORG/RED
GRN/WHT
BRN
RED-27
RED-27P
Z-45/25 DC • Z-45/25J DC
BRN
GRN/WHT-19
GRN/WHT-R3
GRN/WHT-R3
ORG/RED
B
BRN
ORG
ORG
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN 85 86 85 86 85 86 85 86
87a 87a 87a 87a
BLK-22
30 30 30
WHT
30
A
CR4 CR5 CR10B CR10A

WHT

6 - 54
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 55
TERMINAL BASE (TB)
D C B A
RED
RED-1 RED-1
1 PRIMARY BOOM UP 1
RED/BLK-2 RED/BLK-2
A
RED/WHT
RED/WHT-3
#3
M.H.
WHT
WHT-4 WHT-4
WHT/BLK
WHT/BLK-5 WHT/BLK-5
WHT/RED
WHT/RED-6 GRN/WHT
BLK
B
BLK-7 BLK-7
BLK/WHT
BLK/WHT-8 BLK/WHT-8
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
SECONDARY
BLU/WHT WHT-12
C
M.H.
EXT.
WHT BLU/WHT-12
BLU/RED
BLK
ORG
BOOM EXTEND ORG-14 ORG-14
ENABLE
CABLE #6 ORG/BLK-15 ORG/BLK-15
ORG/RED
Z-45/25 DC • Z-45/25J DC
RED
GRN
D
GRN-17 GRN-17
GRN/BLK
CABLE #5
PRIMARY
19 LIFT PUMP 19
19 LIFT PUMP 19
BLK-ALARM (USED ONLY FOR ALARM OPTION)
RED-20 RED-20
20 +24V DC POWER 20
WHT-12
#3
E
WHT-21 WHT-21
BLK
BLK BLK-22
DRIVE 22 +24V DC TO PLATFORM 22
WHT RED-ALARM
ENABLE LIMIT
CABLE #7 WHT-23
24 (UNUSED) 24
#2
ENABLE
F
May 2005
PRIMARY
Part No. 106726

EXTENTION
26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
#1 RED-27
RED/BLK
CHASSIS HARNESS
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
G
WHT/BLK-31
31 REVERSE 31
WHT/RED
RED-ALARM (USED ONLY FOR ALARM OPTION)
WHT/RED-32
BLK
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
FAULT BLK/RED
STATUS BLK/RED-35
BLU
H
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLK-LED
37 STEER RIGHT 37
BLU/WHT
38 (SPARE) 38
BLU/RED
39 (SPARE) 39
ORG
ORG-40 RED
I
ORG/BLK
GRN
#2
#1
43 (SPARE) 43
FUNCTION GRN/BLK
ENABLE
PRIMARY
MANIFOLD
44 JIB DESCENT ALARM 44
EXTENTION
HARNESS GRN/WHT
GRN/WHT-19
SECONDARY
GRN/WHT-45
45 JIB VALVE 45
ORG/RED-42 LED
J
CHASSIS HARNESS
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
48 BRAKE RELEASE 48
BLK
RED
BLK
RED
K
ORG/RED-42 LED
RED
BLU/WHT-12
RED-ALARM
BLK-ALARM
CHASSIS
HARNESS
L
GRN/WHT-19
RED-27 RED-27P
ORG/RED-R2 ORG/RED-R2 GROUNDCONTROL
RED/BLK-R5 RED/BLK-R5 HARNESS
NOTE:
RED-PBRK RED-POWER
RED-PISM6
BLK/RED-9 BLK/RED-R4 (TO SWITCH PANEL)
M
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3 THESE WIRES

BRN-J1 TERMINATE AT THE
GROUND
BRN-J7 SWITCH PANEL

BRN
BRN
BRN
CONTROL HARNESS
BRN
BRN
DASHED LINES INDICATE OPTION WIRES
REV A
N
N
REV A
M
L
TS51
K
P1 KS1 AUXILIARY
EMERGENCY KEY SWITCH PUMP
STOP
3 3
RED RED-POWER
NO NO
2
RED BLK-22
NC
4 4
RED RED
RED-27
WHT-23 RED
BLK-22
J
RED RED
RED
RED
BLK-22
RED
WHT-21 WHT-21
I
BLK/WHT-8
BLK/RED-7
BRN BRN
BRN RED-1
RED/BLK-2
TS63
HOUR METER TS61
PRIMARY
H.M. PRIMARY
BRN
BOOM
BOOM
EXTEND/
H
RETRACT
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19
BRN
G
BLK-22
BLK
RED
BLU/BLK-11 TS62
TURNTABLE
RED
ROTATE
BLU-10
TS60 RED
SECONDARY RED
BOOM
BLK
F
BLK
GRN-17
RED
RED
RED
RED
ORG-14
May 2005
BLK BLK
GRN-17
RED RED
RED-20
BLK
RED
Part No. 106726
RED TS59
PLATFORM
LEVEL
TS55 CB1
RED

BLK
E
ENABLE RED RED BREAKER 1

TS57
PLATFORM
ROTATE
GRN/BLK-18
RED RED
BLK BLK
D
ORG/RED-R2 ORG/RED
RED/WHT-3 BRN
RED/WHT-3 CR2 BRN CR20
CR1 48V DC POWER CR3 LIFT PUMP
48V DC POWER RELAY RELAY AUXILIARY CONTROL RELAY
RELAY
30 30 30 30
BRN
BRN
BRN
BLK-22
87a 87a 87a 87a

86 85 86 85 86 85 86 85
C
87 87 87 87
BRN
BRN
ORG/RED-42 ORG/RED
GRN/WHT
BRN
Z-45/25 DC • Z-45/25J DC
RED-27
RED-27P
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
B
BRN
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87
BRN 85 86 85 86
87a 87a
BLK-22
30 30
A
CR4 CR5
HORN RELAY BRAKE RELEASE
RELAY
6 - 56
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 57
TERMINAL BASE (TB) P20BAT RD
D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK BK-ALARM
A
C3B-2 C2PBD RD/BK RD/BK-TS61
C6B-4 C4TRL WH
C3B-4 C4TRL WH WH-TS62
C6B-5 C5TRR WH/BK
C3B-5 C5TRR WH/BK WH/BK-TS62

C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
C6B-8 C8PBR BK/WH
C3B-8 C8PBR BK/WH BK/WH-TS63
B

C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
P20BAT RD C7B-4
C6B-11 C11SBD BL/BK BK ALARM
C3B-11 C11SBD BL/BK BL/BK-TS60
C6B-12 C12DRE BL/WH C12DRE BL/WH
C3B-12 C12DRE BL/WH WH-HM
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59

C6B-17 C17PRL GR
C
C4B-5 C17PRL GR GR-TS57

C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM

C6B-38 C19PSW GR/WH GR/WH
C4B-7 C19LPMP GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 C22LS BK BK-CR4
C7B-1 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22
Z-45/25 DC • Z-45/25J DC
C6B-34 C23ALARM WH
C7B-2 P23SWBAT WH WH-KS1
RD-CR3
D
C1B-1 C27AUX RD RD-TS51

C1B-7 C33STR BK BK-TS52

33 START ENGINE 33
C7B-3
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C1B-9 C35HRPM BK/RD BK/RD-TS54

35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
C1B-11 C37STC BL/BK GR/WH-J19
E
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
C6B-22 R42BAT OR/RD OR/RD-CR1
C2B-4 R42BAT OR/RD OR/RD-LED
BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
FAULT 44 JIB DESCENT ALARM 44

STATUS
LED
GROUND
BK C6B-25 CONTROL
OR/RD-42A OR/RD HARNESS
F
May 2005
C2B-7 C45JSV GR/WH
Part No. 106726

GR/WH
BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-23 P20BAT RD
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK
G
C6B-19 R19LPMP GR/WH
C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD
C6B-39 CR5 RD/BK

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

48V DC 48V DC CR3 CR20
POWER POWER AUXILIARY CONTROL LIFT PUMP
H
RELAY RELAY RELAY RELAY
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

I
C3B-9 C9HRN BK/RD

BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
J
CR4 CR5
HORN BRAKE
RELAY RELEASE
RELAY
K
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

C45JSV GR/WH (C2B-7)
BK-7A GR/BK-18A 1
BK
BK/WH-8A GR-17A
BK WH/BK-5A
RD
PLATFORM
ROTATE
WH-4A GR
TS57
ROTATE
TABLE
TURN
TS62
RETRACT
PRIMARY
BK
EXTEND/
BOOM
TS63
RD
BK 2
RD
AUXILIARY
RD RD-27A
PUMP
TS51
RD
BK
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
3
PLATFORM
LEVEL
TS59
PRIMARY
BOOM
TS61
RD
RD
RD
RD
RD
BK
P20BAT RD (C6B-23)
P20BAT RD (C7B-4)
BL-10A RD
KEY SWITCH
BREAKER 1
BK-22A BL/BK-11A
CIRCUIT
NO
5
CB1
KS1
WH-23A GR/WH-19A BK
NO
3
SECONDARY
BOOM TS60
RD
RD RD
RD
6
RD
RD
RD
WH
BRN
BRN-HM
WH-HM
7
RD
RD
EMERGENCY 1
HOUR METER
STOP
P1
NC
FUNCTION
H.M.
ENABLE
TS55
2
BASE BOX HARNESS

Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 58


ANSI and CSA Models (from serial number 22051 to 23235)
8
7
6
5
4
3
2
1
6 - 59
C23
A
1 3 4 5 6 7 8 12
RD H6
BK 22B
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)
BRN GND
GR/BK H6
P20BAT RD
BL/WH C1-12
D C B A
C6B-1 C1PBU RD
1 PRIMARY BOOM UP 1
B
C6B-4 C4TRL WH
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
C6B-6 C6LFC WH/RD
H6
C6B-7 C7PBE BK
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
(CE OPTION ONLY)

GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C
P20BAT RD C7B-4
C6B-14 C14PLU OR
C6B-15 C15PLD OR/BK
C6B-17 C17PRL GR
Z-45/25 DC • Z-45/25J DC
C6B-18 C18PRR GR/BK
D

BK-ALARM

19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C23-4 P22BAT BK BK-KS1
C7B-2 P23SWBAT WH WH-KS1 (D2)

RD-CR3
E

33 START ENGINE 33
C7B-3
34 GLOW PLUG 34

35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F
May 2005
Part No. 106726

BK-ALARM
C6B-34 C23ALARM RD RD H6
C2B-5 C134PWR RD RD KS1
134 KEYSWEITCH POWER 134
FAULT
STATUS
LED GROUND
BK C6B-25 CONTROL
G
C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C32JSL WH/RD
H
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD
C6B-39 CR5 RD/BK

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

RELAY RELAY
I
RELAY RELAY
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

J
C3B-9 C9HRN BK/RD

BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
K
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

BK-7A GR/BK-18A 1
BK/WH-8A GR-17A
BK WH/BK-5A
RD
PLATFORM
ROTATE
WH-4A GR
TS57
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A
AUXILIARY
PUMP
RD
BK
TS51
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
PRIMARY
BOOM
TS61
WH
RD
RD
RD
RD C23-6
RD
BK
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
P20BAT RD (C5B-1) RD
BOOM
TS60
RD 134A
RD RD
RD
RD C23-7 RD 6
D2
GR/BK H6
RD
WH 23A
7
EMERGENCY
1
WH
STOP
P1
RD
RD
NC
BRN
2
BRN-HM
WH-HM
FUNCTION
ENABLE
TS55
8
BASE BOX HARNESS

HOUR METER
H.M.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 60
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,


CE Models (from serial number 22051 to 23235)
8
7
6
5
4
3
2
1
6 - 61
U33
1 3 4 5 6 7 8 12
A
RD H6
BK 22B
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)
BRN GND
GR/BK H6
P20BAT RD
BL/WH C1-12
D C B A
C6B-1 C1PBU RD
1 PRIMARY BOOM UP 1
B
C6B-4 C4TRL WH
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
C6B-6 C6LFC WH/RD
H6
C6B-7 C7PBE BK
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C
P20BAT RD C7B-4
C6B-14 C14PLU OR
C6B-15 C15PLD OR/BK
C6B-17 C17PRL GR
Z-45/25 DC • Z-45/25J DC
C6B-18 C18PRR GR/BK

D
BK-ALARM

19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C23-4 P22BAT BK BK-KS1
C7B-2 P23SWBAT WH WH-KS1 (D2)

RD-CR3
E

33 START ENGINE 33
C7B-3
34 GLOW PLUG 34

35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F
May 2005
Part No. 106726

BK-ALARM
C6B-34 C23ALARM RD RD H6
C2B-5 C134PWR RD RD KS1
134 KEYSWEITCH POWER 134
FAULT
STATUS
LED GROUND
BK C6B-25 CONTROL
G
C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
H
C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD
C6B-39 CR5 RD/BK

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

RELAY RELAY RELAY RELAY
I
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

J
C3B-9 C9HRN BK/RD

BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
K
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

BK-7A GR/BK-18A 1
BK/WH-8A GR-17A
BK WH/BK-5A
RD
PLATFORM
ROTATE
WH-4A GR
TS57
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A
AUXILIARY
PUMP
RD
BK
TS51
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
PRIMARY
BOOM
TS61
WH
RD
RD
RD
RD C23-6
RD
BK
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
P20BAT RD (C5B-1) RD
BOOM
TS60
RD 134A
RD RD
RD
RD C23-7 RD 6
D2
GR/BK H6
RD
WH 23A
7
EMERGENCY
1
WH
STOP
P1
RD
RD
NC
BRN
2
BRN-HM
WH-HM
FUNCTION
ENABLE
TS55
8
BASE BOX HARNESS

HOUR METER
H.M.
Part No. 106726 Z-45/25 DC • Z-45/25J DC 6 - 62
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J

8
7
6
5
4
3
2
1
6 - 63
TERMINAL BASE (TB)
D C B A
RED
RED RED-1
1 PRIMARY BOOM UP 1
RED/BLK BLK
RED/BLK RED/BLK-2
SPARE
A
RED/WHT
PLUGGED
RED/WHT-3
#3
M.H.
WHT
WHT WHT-4
WHT/BLK
WHT/BLK WHT/BLK-5
WHT/RED
WHT/RED GRN/WHT
BLK
BLK-7
B
BLK
BLK/WHT
BLK/WHT BLK/WHT-8
CABLE #4
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
LIMIT SWITCH (LS4)

SECONDARY BOOM
BLU BLU-10
SECONDARY
BLU/BLK BLK
BLU/BLLK BLU/BLK-11
BLU/WHT WHT-12
M.H.
EXT.
C
WHT BLU/WHT-12
CABLE #6
BLU/RED
BLK
BOOM EXTEND
ORG
LIMIT SWITCH (LS1)

ORG-14
ORG/BLK
ENABLE
ORG/BL-15
ORG/RED
RED
Z-45/25 DC • Z-45/25J DC
CABLE #5
GRN
GRN GRN-17
D

GRN/BLK
PRIMARY BOOM
GRN/BLK GRN/BLK-18
LIMIT SWITCH (LS2)

GRN/WHT GRN/WHT
PRIMARY
GRN/WHT GRN/WHT-19
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
WHT-12
#3
WHT-21 WHT-21
E
CABLE #7
BLK
SWITCH (LS3)
BLK BLK-22
DRIVE ENABLE LIMIT

WHT RED-ALARM
RED/WHT-23 WHT-23
WHT-23
BOOM
CABLE #3
24 (UNUSED) 24
#2
25 (UNUSED) 25
ENABLE
PRIMARY
F
May 2005
EXTENTION
26 (UNUSED) 26
Part No. 106726

GRN/WHT-19
SECONDARY
RED RED-27
#1 RED-27
CHASSIS HARNESS
RED/BLK
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
WHT/BLK-31
G
31 REVERSE 31
BASE BOX HARNESS
WHT/RED
BOOM
CABLE #2
WHT/RED-32
BLK
BLK-33
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
BLK/RED
LED
BLK/RED-35
35 HIGH/LOW RPM 35
FAULT
BLU
STATUS
H
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
ORG
BOOM
CABLE #1
ORG-40 RED
ORG/BLK
I
ORG/BLK-41
GRN
#2
#1
43 (SPARE) 43
GRN/BLK
ENABLE
PRIMARY
44 (SPARE) 44
EXTENSION
GRN/WHT
GRN/WHT-19
SECONDARY
HARNESS
GRN/WHT-45
MANIFOLD
FUNCTION
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
J
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
GROUND
48 BRAKE RELEASE 48
BLK BOX
RED HARNESS
BLK
RED
(TO
K
SWITCH
PANEL)
ORG/RED-42 LED
ORG/BLK ORG/BLK
ORG ORG
WHT WHT-40
RED-27 RED-27P
CHASSIS
L
HARNESS
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
M
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
REV A
N
N
REV A
M
L
EMERGENCY STOP KEY SWITCH AUXILIARY

K
P1 KS1 PUMP TS51

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
I
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21
PRIMARY
BOOM
PRIMARY EXTEND/
BOOM RETRACT
HOUR METER
TS61 TS63
H.M.
H
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19 JIB BOOM UP/DOWN
BRN
TS58
BLK-22
BLK
G
RED
BLU/BLK-11 TURNTABLE
RED RED ROTATE
TS62
BLU-10
BLK
SECONDARY RED
BLK
BOOM TS60 RED

RED RED GRN/BLK
GRN
BLK
BLK
GRN-17
RED
RED
RED
F
RED
RED
ORG-14
GRN
BLK BLK
May 2005
GRN-17
RED RED
GRN/BLK
RED RED-20
BLK
RED
ORG/BLK
BLK
RED
Part No. 106726
ORG
FUNCTION CIRCUIT
RED
ENABLE TS55 BREAKER 1 ORG/BLK-15 RED

BLK
RED RED CB1 PLATFORM

E
PLATFORM
LEVEL TS59 ROTATE TS57
GRN/BLK-18
RED RED
BLK BLK
ORG
D
ORG/BLK
ORG/RED-R2
RED/WHT-3
RED/WHT-3 48 V BRN
48 V POWER POWER AUXILIARY CONTROL
RELAY CR1 RELAY CR2 RELAY CR3
30 30 30
BRN
BRN
BRN
85 86 85 86 85 86
BLK-22
87a 87a 87a UNUSED
87 87 87
C
BRN
BRN
ORG/RED-42 ORG/RED
BRN
RED-27
RED-27P
Z-45/25 DC • Z-45/25J DC
BRN
GRN/WHT-19
GRN/WHT-R3
ORG/RED
B
BRN
ORG
ORG
WHT-40
ORG/BLK
ORG/BLK
ORG/RED
BLK/RED-9
ORG/BLK-41
BLK/RED-R4
RED/BLK-R5
RED/WHT-48
TO T.B. 27A
WIRE GOES
87 87 87 87
BRN
87a 87a 87a 87a
86 85 86 85 86 85 86 85
BLK-22
30 30 30
WHT
30
A

WHT
CR4 RELAY CR5 CUTOUT UP RELAY CUTOUT DOWN

CR10B RELAY CR10A
WHT
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
6 - 64
8
7
6
5
4
3
2
1
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J


8
7
6
5
4
3
2
1
6 - 65
TERMINAL BASE (TB)
D C B A
RED
RED RED-1
1 PRIMARY BOOM UP 1
RED/BLK BLK
RED/BLK RED/BLK-2
A
SPARE
RED/WHT
PLUGGED
RED/WHT-3
#3
M.H.
WHT
WHT WHT-4
WHT/BLK
WHT/BLK WHT/BLK-5
WHT/RED
WHT/RED GRN/WHT
BLK
B
BLK BLK-7
BLK/WHT
BLK/WHT BLK/WHT-8
CABLE #4
BLK/RED
BLK/RED-R4
9 HORN 9
BLU
LIMIT SWITCH (LS4)

SECONDARY BOOM
BLU BLU-10
SECONDARY
BLU/BLK BLK
BLU/BLLK BLU/BLK-11
BLU/WHT WHT-12
C
M.H.
EXT.
WHT BLU/WHT-12
CABLE #6
BLU/RED
BLK
BOOM EXTEND
ORG
LIMIT SWITCH (LS1)

ORG-14
ORG/BLK
ENABLE
ORG/BL-15
ORG/RED
RED
Z-45/25 DC • Z-45/25J DC
CABLE #5
GRN
GRN GRN-17
D

GRN/BLK
PRIMARY BOOM
GRN/BLK GRN/BLK-18
LIMIT SWITCH (LS2)

GRN/WHT GRN/WHT
PRIMARY
GRN/WHT GRN/WHT-19
19 LIFT PUMP 19
19 LIFT PUMP 19
RED-20 RED-20
WHT-12
#3
WHT-21 WHT-21
E
CABLE #7
BLK
SWITCH (LS3)
BLK BLK-22
DRIVE ENABLE LIMIT

WHT RED-ALARM
RED/WHT-23 WHT-23
WHT-23
BOOM
CABLE #3
24 (UNUSED) 24
#2
25 (UNUSED) 25
ENABLE
PRIMARY
F
May 2005
EXTENTION
Part No. 106726

26 (UNUSED) 26
GRN/WHT-19
SECONDARY
RED RED-27
RED-27
#1 27 AUXILIARY PUMP SELECT 27
CHASSIS HARNESS
RED/BLK
MANIFOLD HARNESS
RED/WHT
SWITCH PANEL.
RED/WHT-29
WHT
WHT-30
30 FORWARD 30
WHT/BLK
G
WHT/BLK-31
31 REVERSE 31
BASE BOX HARNESS
WHT/RED
BOOM
CABLE #2
WHT/RED-32
BLK
BLK-33
33 START ENGINE 33
BLK/WHT
BLK/WHT-34
34 GLOW PLUG 34
BLK/RED
LED
BLK/RED-35
35 HIGH/LOW RPM 35
FAULT
BLU
STATUS
H
BLU-36 GRN/WHT-J19
36 STEER LEFT 36
BLU/BLK
BLU/WHT
38 (SPARE) 38
BLU/RED
BLU/RED-39
ORG
BOOM
CABLE #1
ORG-40 RED
ORG/BLK
I
ORG/BLK-41
GRN
#2
#1
43 (SPARE) 43
GRN/BLK
ENABLE
PRIMARY
44 (SPARE) 44
EXTENSION
GRN/WHT
GRN/WHT-19
SECONDARY
HARNESS
GRN/WHT-45
MANIFOLD
FUNCTION
45 JIB VALVE 45
ORG/RED-42 LED
CHASSIS HARNESS
J
MANIFOLD HARNESS
46 (UNUSED) 46
47 (UNUSED) 47
RED/WHT-48
GROUND
48 BRAKE RELEASE 48
BLK BOX
RED HARNESS
BLK
RED
(TO
K
SWITCH
PANEL)
ORG/RED-42 LED
ORG/BLK ORG/BLK
ORG ORG
WHT WHT-40
RED-27 RED-27P
CHASSIS
L
HARNESS
RED-PBRK RED-POWER
RED-PISM6
RED-ALARM
BLK-ALARM
GRN/WHT-19
BRN
PRI.
C.H.
M.H.
EXT.
ENA.
SEC.
BRN-J3
M
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
REV A
N
N
REV A
M
L
P1 TS51
K

RED RED-POWER
ON
NO
RED BLK-22
NC
RED RED
RED-27
BLK-22
J
RED RED
RED
WHT-23
RED
BLK-22
RED
BRN
BRN BRN
1 2
I
BLK/WHT-8
BLK/RED-7
BRN
3 RED-1
RED/BLK-2
WHT-21 WHT-21 TS61
PRIMARY TS63
BOOM PRIMARY
BOOM
HOUR METER EXTEND/
H.M. RETRACT
H
BLK
BLK
RED
(TO TERMINAL STRIP)
WHT/BLK-5
WHT-4
GRN/WHT-19 TS58
BRN
JIB BOOM
BLK-22
BLK
G
RED
BLU/BLK-11 TS62
RED RED TURNTABLE
BLU-10 ROTATE
BLK
TS60 RED
BLK
SECONDARY RED
RED RED BOOM GRN/BLK
GRN
BLK
BLK
GRN-17
RED
RED
RED
F
RED
RED
ORG-14
GRN
BLK BLK
May 2005
GRN-17
RED RED
GRN/BLK
RED-20
BLK
RED
ORG
BLK
RED
Part No. 106726
ORG/BLK
TS55 CB1
RED

BLK
ENABLE BREAKER 1
RED RED
E
TS59 TS57
PLATFORM PLATFORM
LEVEL ROTATE
GRN/BLK-18
RED RED
BLK BLK
ORG
D

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Introduction August 2011

Important Serial Number Information

Contact Us: Copyright © 2011 Terex Corporation

http://www.genielift.com 106726 Rev C August 2011

"Genie" and "Z" are registered trademarks of

Printed on recycled paper

ii Z-45/25 DC • Z-45/25J DC Part No. 106726

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

Terex South Dakota, Inc.

Part No. 106726 Z-45/25 DC • Z-45/25J DC iii

This page intentionally left blank.

iv Z-45/25 DC • Z-45/25J DC Part No. 106726

Do Not Perform Maintenance

Part No. 106726 Z-45/25 DC • Z-45/25J DC v

Personal Safety Workplace Safety

Indicates a potentially hazardous Be sure to properly dispose of old oil or

Be aware of potential crushing hazards

vi Z-45/25 DC • Z-45/25J DC Part No. 106726

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 106726 Z-45/25 DC • Z-45/25J DC vii

Section 3 Rev Scheduled Maintenance Procedures, continued

viii Z-45/25 DC • Z-45/25J DC Part No. 106726

Section 4 Rev Repair Procedures

Part No. 106726 Z-45/25 DC • Z-45/25J DC ix

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

x Z-45/25 DC • Z-45/25J DC Part No. 106726

Section 6 Rev Schematics, continued

Part No. 106726 Z-45/25 DC • Z-45/25J DC xi

Section 6 Rev Schematics, continued

xii Z-45/25 DC • Z-45/25J DC Part No. 106726

Section 6 Rev Schematics, continued

Part No. 106726 Z-45/25 DC • Z-45/25J DC xiii

Section 6 Rev Schematics, continued

xiv Z-45/25 DC • Z-45/25J DC Part No. 106726

Section 6 Rev Schematics, continued

Part No. 106726 Z-45/25 DC • Z-45/25J DC xv

Section 6 Rev Schematics, continued

xvi Z-45/25 DC • Z-45/25J DC Part No. 106726

Tires and wheels Hydraulic tank 8 gallons

Overall tire diameter 28 in

For operational specifications, refer to the

Part No. 106726 Z-45/25 DC • Z-45/25J DC 2-1

Performance Specifications Boom function speeds, maximum

Turntable rotate, 359° 76 to 82 seconds

Platform rotate, 180°, Z-45/25 6 to 10 seconds

Platform rotate, 160°, Z-45/25J 6 to 10 seconds

2-2 Z-45/25 DC • Z-45/25J DC Part No. 106726

Hydraulic Specifications Function pump

Before serial number 20926 Type: Fixed displacement gear pump

Jib boom/platform rotate flow regulator 0.4 gpm

Part No. 106726 Z-45/25 DC • Z-45/25J DC 2-3

Manifold Component Machine Torque Specifications

SAE No. 10 41 ft-lbs / 55 Nm Platform rotator

Solenoid valve, N.C. poppet, 20V DC 25 to 28Ω

Solenoid valve, N.O. poppet, 20V DC 25 to 28Ω

2-4 Z-45/25 DC • Z-45/25J DC Part No. 106726

Hydraulic Hose and Fitting Seal-Lok® fittings

-16 139 ft-lbs / 188.5 Nm