Genie z45-25 PDF

Service Manual First Edition
Second Printing
Part No. 52709
From Serial number 9998 to 21179

Introduction First Edition • Second Printing
Important Contact us:

Read, understand and obey the safety rules and http://www.genielift.com
operating instructions in the e-mail: techpub@genieind.com
Genie Z-45/25 & Genie Z-45/25J Operator's
Manual before attempting any maintenance or
repair procedure.
This service manual covers the Genie Z-45/25 &
Genie Z-45/25J 2WD and 4WD models introduced
in 1998.
This manual provides detailed scheduled

maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at a Genie dealer service center. ®
Copyright © 1998 by Genie Industries

Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However, First Edition: Second Printing, September 2000
continuous improvement of our products is a Genie "Genie" and "Z" are Registered Trademarks
policy. Therefore product specifications are subject of Genie Industries in the USA and many other
to change without notice. countries.
Readers are encouraged to notify Genie of errors These machines comply with
ANSI/SIA 92.5-1992.
and send in suggestions for improvement. All
communications will be carefully considered for Printed on recycled paper
future printings of this and other manuals. Please Printed in U.S.A.
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 U.S.A.
If you have any questions, please call Genie
Industries.
ii Genie Z-45/25 & Genie Z-45/25J Part No. 52709

First Edition • Second Printing Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-45/25 &
Genie Z-45/25J Operator's Manual will result in
death or serious injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- 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. 52709 Genie Z-45/25 & Genie Z-45/25J iii

Section 1 • Safety Rules First Edition • Second Printing
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert Workplace Safety
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
Red—used to indicate the extinguisher within easy reach.
presence of an imminently
hazardous situation which, if not
avoided, will result in death or Be sure that all tools and working areas
serious injury. are properly maintained and ready for
Orange—used to indicate the use. Keep work surfaces clean and free of
presence of a potentially debris that could get into machine components and
hazardous situation which, if not cause damage.
avoided, could result in death or
serious injury.
Be sure that your workshop or work area
Yellow with safety alert symbol— is properly ventilated and well lit.
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
Be sure any forklift, overhead crane or
minor or moderate injury.
other lifting or supporting device is fully
Yellow without safety alert capable of supporting and stabilizing the
symbol—used to indicate the weight to be lifted. Use only chains or straps that
presence of a potentially are in good condition and of ample capacity.
avoided, may result in property
damage. Be sure that fasteners intended for one
Green—used to indicate operation time use (i.e., cotter pins and self-locking
or maintenance information. nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe .
iv Genie Z-45/25 & Genie Z-45/25J Part No. 52709

First Edition • Second Printing
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules ..................................................................................................... iii
Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ............................................................................................ 2 - 4
Ford LRG-425 EFI Engine Specifications ................................................................. 2 - 5
Deutz F3L 1011F Engine Specifications ................................................................... 2 - 7
Perkins 104-22 Engine Specifications ....................................................................... 2 - 8
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 9
Section Three Theory of Operation

Power Source ........................................................................................................... 3 - 1
Hydraulic System ...................................................................................................... 3 - 1
Electrical System ...................................................................................................... 3 - 1
Limit Switches ........................................................................................................... 3 - 2
Machine Controls ...................................................................................................... 3 - 2
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J v

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................ 4 - 3
A-1 Inspect the Operator's and Safety Manuals .................................................... 4 - 5
A-2 Inspect the Decals and Placards ..................................................................... 4 - 5
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4 Check the Engine Oil Level ............................................................................. 4 - 7
A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8
A-6 Check for Fuel Leaks ...................................................................................... 4 - 8
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9
A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10
A-9 Check the Tire Pressure ............................................................................... 4 - 10
A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11
A-11 Test the Platform and Ground Controls ......................................................... 4 - 11
A-12 Test the Auxiliary Power Operation ............................................................... 4 - 12
A-13 Test the Tilt Sensor ....................................................................................... 4 - 13
A-14 Test the Limit Switches ................................................................................. 4 - 14
A-15 Check the Engine Belt - Perkins Diesel Models ............................................ 4 - 18
A-16 Inspect the Engine Air Filter Element ............................................................ 4 - 19
A-17 Replace the Fuel Filters - Ford Models ......................................................... 4 - 20
A-18 Inspect the Radiator - Perkins Models .......................................................... 4 - 21
A-19 Perform 30 Day Service ................................................................................ 4 - 22
A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models ............ 4 - 23
A-21 Inspect the Fuel Filter/Water Separator - Diesel Models ............................... 4 - 24
A-22 Check and Adjust the Engine RPM - Perkins Diesel Models ......................... 4 - 26
A-23 Check the Engine Belt - Ford Models ............................................................ 4 - 28
vi Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

B-1 Check the Battery ......................................................................................... 4 - 29
B-2 Inspect the Electrical Wiring .......................................................................... 4 - 29
B-3 Check the Radiator - Ford Models ................................................................ 4 - 30
B-4 Check the Exhaust System ........................................................................... 4 - 31
B-5 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32
B-6 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32
B-7 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33
B-8 Confirm the Proper Brake Configuration ....................................................... 4 - 34
B-9 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34
B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models ............ 4 - 35
B-11 Test the Key Switch ...................................................................................... 4 - 37
B-12 Test the Emergency Stop Buttons ................................................................. 4 - 37
B-13 Test the Ground Control Override ................................................................. 4 - 38
B-14 Check the Directional Valve Linkage ............................................................. 4 - 38
B-15 Test the Platform Self-leveling ...................................................................... 4 - 39
B-16 Test the Horn ................................................................................................ 4 - 40
B-17 Test the Foot Switch ..................................................................................... 4 - 40
B-18 Test the Engine Idle Select ........................................................................... 4 - 41
B-19 Test the Fuel Select Operation - Ford Models ............................................... 4 - 42
B-20 Test the Drive Enable System ....................................................................... 4 - 43
B-21 Test the Drive Brakes ................................................................................... 4 - 44
B-22 Test the Drive Speed - Stowed Position ........................................................ 4 - 45
B-23 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J vii

TABLE OF CONTENTS

B-24 Test the Alarm Package - Optional Equipment .............................................. 4 - 47
B-25 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48
B-26 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 48
B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 49
B-28 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 51
B-29 Replace the Spark Plugs - Ford Models ........................................................ 4 - 52
B-30 Replace the Engine Air Filter Element ........................................................... 4 - 53
C-1 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55
C-2 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57
C-3 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57
C-4 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58
C-5 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 59
C-6 Replace the PCV Valve - Ford Models .......................................................... 4 - 60
D-1 Check the Boom Wear Pads ......................................................................... 4 - 61
D-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62
D-3 Check the Free-wheel Configuration ............................................................. 4 - 63
D-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 65
D-5 Replace the Drive Hub Oil ............................................................................. 4 - 66
D-6 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67
D-7 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68
D-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69
viii Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS

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

Introduction ............................................................................................................... 5 - 1
Fault Codes .............................................................................................................. 5 - 3
1 Engine Will Not Crank Over ............................................................................ 5 - 6
2 Engine Cranks Over But Will Not Start - Ford Models ..................................... 5 - 8
2A Engine Runs While Cranking Then Dies ....................................................... 5 - 10
3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 11
4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models ..... 5 - 14
5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models ..... 5 - 16
6 Engine High Idle Inoperative - Ford Models .................................................. 5 - 17
7 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 18
8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 19
9 Engine Low Idle Inoperative - Diesel Models ................................................. 5 - 21
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 22
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 23
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J ix

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 24
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 25
14 Primary Boom Up Function Inoperative ........................................................ 5 - 26
15 Primary Boom Down Function Inoperative (before serial number 13099) ..... 5 - 29
16 Primary Boom Down Function Inoperative (after serial number 13098) ........ 5 - 32
17 Secondary Boom Up Function Inoperative .................................................... 5 - 35
18 Secondary Boom Down Function Inoperative ............................................... 5 - 38
19 Primary Boom Extend Function Inoperative .................................................. 5 - 41
20 Primary Boom Retract Function Inoperative .................................................. 5 - 43
21 Turntable Rotate Left Function Inoperative ................................................... 5 - 45
22 Turntable Rotate Right Function Inoperative ................................................. 5 - 49
23 All Platform Leveling Functions Inoperative .................................................. 5 - 53
24 Platform Level Up Function Inoperative ........................................................ 5 - 54
25 Platform Level Down Function Inoperative .................................................... 5 - 56
26 Platform Rotate Left Function Inoperative ..................................................... 5 - 58
27 Platform Rotate Right Function Inoperative ................................................... 5 - 61
28 Jib Boom Up Function Inoperative, Z-45/25J Models .................................... 5 - 64
29 Jib Boom Down Function Inoperative, Z-45/25J Models ............................... 5 - 66
30 Steer Left Function Inoperative ..................................................................... 5 - 68
31 Steer Right Function Inoperative ................................................................... 5 - 69
32 Oscillate Function Inoperative ....................................................................... 5 - 70
33 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 71
34 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 74
35 Traction Function Inoperative ........................................................................ 5 - 75
36 Machine Will Not Drive At Full Speed ............................................................ 5 - 76
37 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 77
38 Drive Enable System Is Malfunctioning ......................................................... 5 - 78
39 Auxiliary Functions Inoperative ..................................................................... 5 - 79
x Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ....................................................................................... 6 - 4
Abbreviation Legend ................................................................................................. 6 - 5
Ford LRG-425 EFI Engine Harness (before serial number 13099) ........................... 6 - 7
Ford LRG-425 EFI Engine Harness (after serial number 13098) .............................. 6 - 8
Electrical Schematic - Z-45/25 Ford Models (before serial number 13099) ............. 6 - 10
Ground Control Box Wiring Diagram, Z-45/25 Ford Models
(before serial number 13099) ............................................................................. 6 - 11
Platform Control Box Wiring Diagram, Z-45/25 Ford Models
Electrical Schematic, Z-45/25 Ford Models
(from serial number 13098 to 16303) ................................................................. 6 - 14
Electrical Schematic, Z-45/25J Ford Models
Ground Control Box Wiring Diagram, Z-45/25J Ford Models
Platform Control Box Wiring Diagram, Z-45/25J Ford Models
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J xi

TABLE OF CONTENTS
Section Six Schematics, continued

Electrical Schematic, Z-45/25 Ford Models (after serial number 16303) ................. 6 - 26
(after serial number 16303) ................................................................................ 6 - 27
Electrical Schematic, Z-45/25J Ford Models (after serial number 16303) ............... 6 - 30
Electrical Schematic, Z-45/25 Deutz Models (before serial number 13099) ............ 6 - 34
Ground Control Box Wiring Diagram, Z-45/25 Deutz Models
Platform Control Box Wiring Diagram, Z-45/25 Deutz Models
Electrical Schematic, Z-45/25 Deutz Models
Electrical Schematic, Z-45/25J Deutz Models (before serial number 13099) .......... 6 - 42
Ground Control Box Wiring Diagram, Z-45/25J Deutz Models
Platform Control Box Wiring Diagram, Z-45/25J Deutz Models
Electrical Schematic, Z-45/25J Deutz Models
xii Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS

Platform Control Box Wiring Diagram - Lift Drive Select Option,
Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................ 6 - 49
Z-45/25 Deutz Models (after serial number 16303) ................................................. 6 - 54
Electrical Schematic, Z-45/25J Deutz Models (after serial number 16303) ............. 6 - 56
Z-45/25J Deutz Models (after serial number 16303) ............................................... 6 - 59
Electrical Schematic, Z-45/25 Perkins Models (before serial number 16304) ......... 6 - 61
Ground Control Box Wiring Diagram, Z-45/25 Perkins Models
Platform Control Box Wiring Diagram, Z-45/25 Perkins Models
Electrical Schematic, Z-45/25J Perkins Models (before serial number 16304) ....... 6 - 65
Ground Control Box Wiring Diagram, Z-45/25J Perkins Models
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J xiii

TABLE OF CONTENTS

Platform Control Box Wiring Diagram, Z-45/25J Perkins Models
Platform Control Box Wiring Diagram - Lift/Drive Select Option,
Z-45/25J Perkins Models (before serial number 16304) ......................................... 6 - 68
Electrical Schematic, Z-45/25 Perkins Models (after serial number 16303) ............ 6 - 70
Platform Control Box Wiring Diagram, Z-45/25 Perkins Models
Electrical Schematic, Z-45/25J Perkins Models (after serial number 16303)) ......... 6 - 74
Ground Control Box Wiring Diagram, Z-45/25J Perkins Models
Platform Control Box Wiring Diagram, Z-45/25J Perkins Models
Platform Control Box Wiring Diagram - Lift/Drive Select Option,
Z-45/25J Perkins Models (after serial number 16303) ............................................ 6 - 78
Platform Control Box Wiring Diagram- Load Sensor Option, All Models ................. 6 - 79
Hydraulic Symbols Legend ..................................................................................... 6 - 80
2WD Hydraulic Schematic ...................................................................................... 6 - 82
4WD Hydraulic Schematic ...................................................................................... 6 - 83
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 8
xiv Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS
Section Seven Repair Procedures, continued

1-3 Foot Switch ................................................................................................... 7 - 10
1-4 Toggle Switches ............................................................................................ 7 - 11
Platform Components
2-1 Platform ........................................................................................................ 7 - 13
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 14
2-3 Platform Rotator ............................................................................................ 7 - 15
Jib Boom Components, Z-45/25J Models
3-1 Jib Boom, Z-45/25J Models .......................................................................... 7 - 18
3-2 Jib Boom Lift Cylinder, Z-45/25J Models ....................................................... 7 - 19
3-3 Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models ........... 7 - 21
Primary Boom Components
4-1 Plastic Cable Track ....................................................................................... 7 - 22
4-2 Primary Boom ............................................................................................... 7 - 27
4-3 Primary Boom Lift Cylinder ........................................................................... 7 - 30
4-4 Primary Boom Extension Cylinder ................................................................. 7 - 31
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 32
Secondary Boom Components
5-1 Secondary Boom .......................................................................................... 7 - 34
5-2 Secondary Boom Lift Cylinders ..................................................................... 7 - 39
Turntable Covers
6-1 Turntable Covers .......................................................................................... 7 - 40
Deutz Engine F3L 1011F
7-1 RPM Adjustment ........................................................................................... 7 - 41
7-2 Flex Plate ...................................................................................................... 7 - 41
7-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 42
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J xv

TABLE OF CONTENTS

Perkins 104-22 Engine
8-1 RPM Adjustment ........................................................................................... 7 - 43
8-2 Flex Plate ...................................................................................................... 7 - 43
8-3 Coolant Temperature and Oil Pressure Gauages ......................................... 7 - 44
Ford LRG-425 EFI Engine
9-1 Timing Adjustment ........................................................................................ 7 - 45
9-2 RPM Adjustment ........................................................................................... 7 - 45
9-3 Flex Plate ...................................................................................................... 7 - 45
9-4 Water Temperature and Oil Pressure Gauges .............................................. 7 - 46
Ground Controls
10-1 Control Relays .............................................................................................. 7 - 48
10-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 49
10-3 Wago® Components ...................................................................................... 7 - 49
10-4 Engine Fault Codes - Ford Models ................................................................ 7 - 50
Hydraulic Pumps
11-1 Lift/Steer Pump ............................................................................................. 7 - 52
11-2 Drive Pump ................................................................................................... 7 - 53
Manifolds
12-1 Function Manifold Components ..................................................................... 7 - 56
12-2 Valve Adjustments - Function Manifold ......................................................... 7 - 62
12-3 Turntable Rotation Manifold Components ..................................................... 7 - 63
12-4 Directional Valve Manifold Components ........................................................ 7 - 65
12-5 2WD Drive Manifold Components ................................................................. 7 - 68
12-6 Valve Adjustments, 2WD Drive Manifold ....................................................... 7 - 70
12-7 4WD Drive Manifold Components ................................................................. 7 - 72
xvi Genie Z-45/25 & Genie Z-45/25J Part No. 52709

TABLE OF CONTENTS

12-8 Valve Adjustments, 4WD Drive Manifold ....................................................... 7 - 76
. Fuel and Hydraulic Tanks
13-1 Fuel Tank ...................................................................................................... 7 - 77
13-2 Hydraulic Tank .............................................................................................. 7 - 80
Turntable Rotation Components
14-1 Rotation Hydraulic Motor ............................................................................... 7 - 80
2WD Steering Axle Components
15-1 Yoke and Hub ............................................................................................... 7 - 84
15-2 Steering Cylinders ......................................................................................... 7 - 84
15-3 Tie Rod ......................................................................................................... 7 - 85
4WD Steering Axle Components
16-1 Yoke and Hub ............................................................................................... 7 - 86
16-2 Steering Cylinders, See 15-2, Steering Cylinders ......................................... 7 - 88
16-3 Tie Rod, See 15-3, Tie Rod .......................................................................... 7 - 88
Oscillating Axle Components
17-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 89
Non-steering Axle Components
18-1 Drive Motor ................................................................................................... 7 - 90
18-2 Drive Hub ...................................................................................................... 7 - 91
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J xvii

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

First Edition • Second Printing Section 2 • Specifications
Specifications
Machine Specifications Z-45/25 Z-45/25J
(non jib) (jib)
Stowed dimensions Z-45/25 Z-45/25J
(non jib) (jib) Minimum turning radius, inside
Standard Base Models 4 ft 6 in 4 ft 6 in
Length 18 ft 22 ft 3 in 1.4 m 1.4 m
5.5 m 6.8 m Narrow Base Models 5 ft 5 ft
1.5 m 1.5 m
Width
Standard Base Models 7 ft 4 in 7 ft 4 in Minimum turning radius, outside
2.2 m 2.2 m Standard Base Models 11 ft 6 in 11 ft 6 in
Narrow Base Models 5 ft 9 in 5 ft 9 in 3.5 m 3.5 m
1.8 m 1.8 m Narrow Base Models 11 ft 11 ft
3.35 m 3.35 m
Height
Standard Base Models 6 ft 10 in 6 ft 10 in Turntable rotation 359° 359°
2.1 m 2.1 m
Narrow Base Models 6 ft 7 in 6 ft 7 in Platform rotation 180° 160°
2.05 m 2.05 m Maximum capacity 500 lbs 500 lbs
Weight 6 foot platform 227 kg 227 kg
Standard Base Models 14,000 lbs 14,700 lbs Maximum allowable
6350 kg 6668 kg side force (ANSI and CSA) 150 lbs 150 lbs
Narrow Base Models 17,100 lbs 17,100 lbs 68 kg 68 kg
7756 kg 7756 kg
Platform dimensions
Ground clearance
Standard Base Models 10 in 10 in Length 72 in
25.4 cm 25.4 cm 183 cm
Narrow Base Models 7 in 7 in
Width 30 in
17.7 cm 17.7 cm
76 cm
Operational dimensions
Maximum platform height

Standard Base Models 45 ft 8 in 45 ft 6 in
13.9 m 13.8 m
Narrow Base Models 45 ft 5 in 45 ft 5 in
13.9 m 13.9 m
Maximum horizontal reach 124 ft 6 in 25 ft 3 in

17.5 m 7.7 m
Maximum turntable tailswing 0 in 0 in

0 cm 0 cm
Wheelbase 6 ft 8 in 6 ft 8 in
2m 2m
1Outreach specification with platform rotated
90 degrees.
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 2-1

Section 2 • Specifications First Edition • Second Printing
SPECIFICATIONS
Tires and wheels Rough terrain Industrial Performance Specifications

Wheel diameter 17.5 inches 14.5 inches Drive speeds, maximum
Wheel width 10.5 inches 7 inches Drive speed, stowed 4.8 mph
Wheel lugs, 4WD 9@ 5 /8 -18 All models 7.7 km/h
40 ft/5.7 sec
Wheel lugs, 2WD 12.2 m/5.7 sec
Front 8 @ 5/8 -18 8 @ 5/8 -18
Drive speed, boom 0.6 mph
Rear 9 @ 5/8 -18 9 @ 5/8 -18
raised or extended, 1 km/h
Lug nut torque 125 ft-lbs 125 ft-lbs Standard Base Models 40 ft/45 sec
169.5 Nm 169.5 Nm 12.2 m/45 sec
Tire size 14-17.5 NHS 9-14.5 LT Drive speed, boom 0.36 mph
raised or extended, 0.58 km/h
Tire ply rating 14 Tread 8 Narrow Base Models 40 ft/79 sec
Sidewall 6 12.2 m/79 sec
Tire contact area 59 sq in 43.5 sq in Gradeability 2WD 4WD

149.9 sq cm 280 sq cm
Boom Stowed Position 30% 45%
Overall tire diameter 35.8 in 28 in
90.9 cm 71 cm
Tire pressure 45 psi Foam filled

2.76 bar
Fluid capacities
Fuel tank 17 gallons
64.3 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 24 gallons
91 liters
Hydraulic system 30 gallons
(including tank) 113.6 liters
Drive torque hubs 17 fl oz
0.51 liters
Continuous improvement of our products is a Genie

policy. Product specifications are subject to change
without notice.
2-2 Genie Z-45/25 & Genie Z-45/25J Part No. 52709

SPECIFICATIONS
Boom function speeds, maximum

from platform controls
Jib boom up 38 to 42 seconds
Jib boom down 24 to 27 seconds
Primary boom up 24 to 27 seconds
Primary boom down 32 to 37 seconds
Secondary boom up 23 to 27 seconds
Secondary boom down 23 to 27 seconds
Primary boom extend 10 to 14 seconds
Primary boom retract 18 to 22 seconds
Turntable rotate - 359° 73 to 78 seconds

primary boom retracted
Platform rotate - 180° 10 to 14 seconds

Z-45/25 Models
Platform rotate - 160° 9 to 13 seconds

Z-45/25J Models
Platform level up 35 to 39 seconds
Platform level down 26 to 32 seconds

SPECIFICATIONS
Hydraulic Specifications Function manifold
Hydraulic fluid Dexron equivalent Function relief valve pressure 3200 psi
220.6 bar
Drive pump
Primary boom down 2300 psi
Type: bi-directional variable displacement piston pump relief valve pressure 158.6 bar
Displacement @ 2500 rpm 0 to 30.3 gallons per minute Secondary boom down 1800 psi
0 to 114.7 liters per minute relief valve pressure 124 bar
Maximum drive pressure 3500 psi Steer flow regulator 1.5 gpm
241.3 bar 5.7 liters/min
Charge pressure Auxiliary pump

neutral position 290 psi 20 bar
drive position 250 psi 17 bar Type: fixed displacement gear pump
Medium pressure filter 3 micron Displacement 1.75 gallons per minute

2.8 liters per minute
Medium pressure filter 50 psi
bypass pressure 3.4 bar Auxiliary pump 3200 psi
relief pressure 220.6 bar
Drive manifold
Brake 250 psi

relief pressure 17.2 bar
Steer end drive motors 4WD models
Displacement 1.53 cu in
per revolution 25 cc
Non-steer end drive motors
Displacement per revolution, variable 0.16 to 2.8 cu in

4WD (2 speed motor) 2.62 to 45.9 cc
Displacement per revolution, variable 1.1 to 2.8 cu in

2WD 18.4 to 45.9 cc
Function pump
Type: pressure balanced gear
Displacement - static 0.67 cu in

11 cc
Displacement @ 2500 rpm 0 to 2.1 gallons per minute

0 to 7.95 liters per minute
Hydraulic tank circuit 6 micron with 25 psi

return line filter (1.7 bar) bypass

SPECIFICATIONS
Ford Engine LRG-425 EFI Starter motor
Displacement 153 cu in Normal engine cranking speed 200 to 250 rpm

2.5 liters Current draw, normal load 140-200A
Number of cylinders 4 Current draw, maximum load 800A
Bore & stroke 3.78 x 3.4 in Current draw, minimum 60-80A
96.01 x 86.36 mm
Maximum circuit voltage drop 0.5V DC
Horsepower while starting (normal temperature)
gross intermittent 97 Brush length, new 0.66 in
continuous 82 16.8 mm
horsepower @ 2500 rpm 70
Brush length wear limit 0.25 in
Firing order 1-3-4-2 6.35 mm
Low idle 1600 rpm Brush spring tension 64 ounces
High idle 2500 rpm 18 Newtons
Compression ratio 9.4:1 Bolt torque 45 to 84 in-lbs

through brush 5.08 to 9.5 Nm
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be Brush mounting 15 to 20 ft-lbs
at least 75% of highest cylinder bolt torque 20 to 27 Nm
Valve clearances - 0.035 to 0.055 in Maximum commutator 0.005 in

collapsed tappet 0.889 to 1.397 mm run-out 0.127 mm
Lubrication system
Oil pressure 40 to 60 psi

(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Oil capacity 5 quarts

(including filter) 4.7 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C 5W-30
-10°F to 90°F / -23°C to 32°C 10W-30
Temperature above 10W-40 to 10W-50

-10°F / -23°C
Temperature above 20W-40 or 20W-50

20°F / -6.6°C
Use oils meeting API classification SG (labeled SG/CC

or SG/CD) as they offer improved wear protection.
Units ship with 10W-40 SG/CC.

SPECIFICATIONS
Battery
Type 12V, Group 34/78
Quantity 1
Cold cranking ampere 900A
Reserve capacity @ 25A rate 200 minutes
Electronic fuel pump
Fuel pressure, static 64 psi

4.4 bar
Fuel flow rate 0.58 gpm

2.18 L/min
Ignition System
Spark plug type Motorcraft AWSF-52C
Spark plug gap 0.042 to 0.046 in

1.07 to 1.18 mm
Engine coolant
Capacity 111/2 quarts

10.9 liters
Alternator
Output 95A, 14.5V

SPECIFICATIONS
Deutz Engine F3L 1011F Injection system
Displacement 125 cu in Injection pump make OMAP

2.05 liters Injection pump pressure 4351 psi
Number of cylinders 3 300 bar
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
Horsepower Fuel requirement diesel number 2-D
gross intermittent 44 Alternator output 55A, 14V

continuous 40 Starter motor
Current draw, no load 90A
Firing order 1-2-3
Brush length, new 0.72 in
Low idle 1400 rpm 18.5 mm
High idle 2500 rpm Brush length, minimum 0.27 in
Compression ratio 18.5:1 7 mm
Compression pressure 362 to 435 psi Battery

25 to 30 bar Type 12V, Group 34/78
Governor centrifugal mechanical Quantity 1
Valve clearance, cold Cold cranking ampere 900A
Intake 0.012 in Reserve capacity @ 25A rate 200 minutes
0.3 mm
Fan belt deflection 3 /8
to 1/2 inch
Exhaust 0.020 in 9 to 12 mm
0.5 mm
Lubrication system
Oil pressure 26 to 87 psi

1.8 to 6 bar
Oil capacity 6.5 quarts

(including filter) 6 liters
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification

CC/SG or CD/SG grades.
Units ship with 10W-40 SG/CC.

SPECIFICATIONS
Perkins Engine 104-22 Oil viscosity requirements

(KR model) below 68°F / 20°C (synthetic) 5W-20
Displacement 135 cu in 5°F to 104°F / -15°C to 40°C 10W-30

2.2 liters
above 14°F / -10°C 15W-40
Number of cylinders 4
Bore and stroke 3.31 x 3.94 inches CC/SE. API classification CD/SE or CCMC D4 can be
84 x 100 mm used, but is not recommended during the first 50 hours
nor for light load applications.
Horsepower
Injection system
gross intermittent 50
continuous 46.9 Injection pump make Zexel
Injection pressure 2133 psi
Firing order 1-3-4-2 147 bar
Low idle 1600 rpm Fuel requirement #2 Diesel
High idle 2500 rpm Alternator output 55A @ 13.8V
Compression ratio 22:1 Starter motor
Compression pressure 300 to 500 psi Current draw, no load 90A

20.7 to 34.5 bar
Pressure (psi) of lowest cylinder must be 50 psi Brush length, new 0.7480 in
(3.45 bar) of highest cylinder 19 mm
Governor centrifugal mechanical Brush length, minimum 0.5 in

12.7 mm
Valve clearance, cold
Battery
Intake 0.008 in
0.2 mm Type 12V, Group 34/78
Exhaust 0.008 in Quantity 1

0.2 mm Cold cranking ampere 900A
Lubrication system Reserve capacity @ 25A rate 200 minutes
Oil pressure 41 psi Fan belt deflection 3/8 in
(at 2600 rpm) 2.8 bar 10 mm
Oil capacity 8.6 quarts
(including filter) 8.2 liters

SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

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

SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash Installing SAE Dash
Size into... ft. lbs. Nm Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
Torque Procedure
1 Replace the O-ring. The O-ring must be 3 Be sure that the face seal O-ring is seated and
replaced anytime the seal has been broken. retained properly.
The O-ring cannot be re-used if the fitting or
4 Position the tube and nut squarely on the face
hose end has been tightened beyond finger
seal end of the fitting and tighten the nut finger
tight.
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends 5 Tighten the nut or fitting to the appropriate
are custom-size O-rings. They are torque per given size as shown in the table
standard SAE size O-rings. They above.
are available in the O-ring field 6 Operate all machine functions and inspect the
service kit hoses and fittings and related components to
(Genie part number 49612). be sure that there are no leaks.
2 Lubricate the O-ring before installation.

2 - 10 Genie Z-45/25 & Genie Z-45/25J Part No. 52709

First Edition • Second Printing Section 3 • Theory of Operation
Theory of Operation
Power Source Electrical System

The Genie Z-45/25 and Genie Z-45/25J are Boom/Steer functions are accomplished by
powered by either a gasoline/LPG engine or one of moving a toggle switch or a controller, which sends
two diesel engines. The gasoline/LPG option uses voltage to the appropriate directional control valve.
a Ford LRG-425 EFI engine rated at 70 These directional valves determine which direction
horsepower @ 2500 rpm. The diesel options the hydraulic fluid will travel. The amount of
include a Deutz F3L 1011F engine rated at 36 hydraulic fluid volume is determined by a
horsepower @ 3000 rpm, and a Perkins 104-22 proportional valve or flow regulator valve. A
KR engine rated at 41 horsepower @ 2800 rpm. proportional valve receives a variable voltage
signal and delivers more hydraulic fluid as the
Hydraulic System voltage increases. A flow regulator valve is a
mechanical valve and delivers a predetermined
All machine functions are performed by the amount of hydraulic fluid.
hydraulic system. The hydraulic system can be
divided into two groups: Boom/Steer functions and Drive forward or reverse is accomplished by
Drive functions. pressing down the foot switch in the platform and
moving the drive controller (joystick) in the
Boom/Steer functions are powered by a single- appropriate direction. When activated, the drive
section gear pump, rated at 7 gpm (26.5 L/min). controller completes a circuit to the electronic
When the engine is running, this pump supplies displacement controller (EDC). The EDC regulates
hydraulic fluid under pressure to the function drive pump displacement in direct relation to the
manifold, where the directional and flow control drive controller position. A horsepower limiter
valves are located. To protect from over- printed circuit board (located in the platform control
pressurization of the Boom/Steer system, the box) is provided to maintain engine RPM as drive
pump is provided with a pressure relief valve, set system loads become greater. This is done by
at 3500 psi (241.3 bar). sensing engine RPM (via an AC tap on the
alternator) and limiting the amount of current
Drive functions are powered by a bi-directional,
supplied to the drive controller/EDC, which
variable output piston pump rated at 0 to 30.3 gpm
destrokes the pump, reducing pump output.
(0 to 114.7 L/min) @ 2500 rpm. Two internal 3200
psi (220.6 bar) relief valves are used to prevent
over-pressurization of the closed loop drive
system.
The boom lift cylinder, boom extend cylinder,

platform leveling slave cylinder, platform rotator
and jib boom cylinder (Z-45/25J models)
incorporate counterbalance valves to prevent
movement in the event of a hydraulic line failure.

Section 3 • Theory of Operation First Edition • Second Printing
THEORY OF OPERATION
Limit switches Machine Controls

There are two types of limit switches which are
The Genie Z-45/25 and Genie Z-45/25J machines
found in various locations on the machine: drive
are equipped with operational controls which are
speed limit switches and a drive enable limit
found in two locations: the ground controls, located
switch. The function of a drive speed limit switch is
on the engine side of the machine, and the
to limit the raised or extended drive speed to 0.6
platform controls, located in the platform. All lift and
miles per hour (1 km/h) when the primary boom is
drive functions are available at the platform
raised more than 2 feet (0.6 m) OR when the
controls. Only boom functions are available at the
primary boom is extended more than
ground controls.
18 inches (45.7 cm). The function of the drive
enable limit switch is to limit the ability of the Ground controls are activated by holding the
machine to drive when the boom is rotated beyond function enable toggle switch to either side, then
the non-steer wheels. moving a boom function toggle switch in the
direction indicated on the control panel decal.
This will determine which boom function will
operate and its direction of travel.
Platform controls use toggle switches and boom
function controllers (joysticks) to operate the boom
functions. The drive controller (joystick) regulates
the drive pump displacement through the EDC in
direct relation to the drive controller position. A
thumb rocker switch on the top of the drive
controller is used for steering.
Washing electronic components is

not suggested. Instead, use
compressed air to remove debris.

First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

information and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
Red—used to indicate the
and every 2 years as specified on the
presence of an imminently
Maintenance Inspection Report.
Failure to perform each procedure avoided, will result in death or
as presented and scheduled may serious injury.
cause death, serious injury or
Orange—used to indicate the
substantial damage.
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating machine. Yellow with safety alert symbol—
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
which, if not avoided, may cause
Unless otherwise specified, perform each
minor or moderate injury.
maintenance procedure with the machine in the
following configuration: Yellow without safety alert
· Machine parked on a flat, level surface symbol—used to indicate the
presence of a potentially
· Boom in stowed position hazardous situation which, if not
· Turntable rotated with the boom between avoided, may result in property
the non-steering wheels damage.
· Turntable secured with the turntable Green—used to indicate operation
rotation lock or maintenance information.
· Key switch in the OFF position with the
Indicates that a specific result is expected after
key removed
performing a series of steps.
· Wheels chocked

Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

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

perform this procedure.
Daily or every 8 hours A
Indicates that new parts will be required Quarterly or every 250 hours A+B
to perform this procedure.
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that a cold engine will be
required to perform this procedure. Two years or every 2000 hours A+B+C+D+E
Maintenance Inspection Report

Indicates that a warm engine will be
required to perform this procedure. The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
Indicates that dealer service is required
to use for each inspection. Store completed forms
to perform this procedure.
for three years.

Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals B-1 Check the battery
Serial number A-2 Decals and placards B-2 Inspect electrical wiring
A-3 Damage and loose or B-3 Check the radiator-
Date
missing parts Ford Models
Hour meter A-4 Engine oil level B-4 Exhaust system
A-5 Engine coolant- B-5 Hydraulic return filter
Machine owner Liquid Cooled Models condition indicator
A-6 Fuel leaks B-6 Check oil cooler and fins-
Inspected by (print) A-7 Hydraulic oil level Deutz Models
A-8 Hydraulic leaks B-7 Tires and wheels
Inspector signature
A-9 Tire pressure B-8 Brake configuration
A-10 Oscillate axle B-9 Drive hub oil level
Inspector title
A-11 Platform and B-10 Engine RPM-
Inspector company ground controls Ford and Deutz Models
A-12 Auxiliary power B-11 Key switch
Instructions A-13 Tilt sensor B-12 Emergency Stop
· Make copies of both pages to use for A-14 Limit switches B-13 Ground control override
each inspection. B-14 Directional valve
A-15 Check the engine belt-
· Select the appropriate checklist(s) for Perkins Models B-15 Platform leveling
the type of inspection to be A-16 Air filter B-16 Horn
performed.
A-17 Fuel filter- Ford Models B-17 Foot switch
Daily or 8 hour A-18 Inspect the radiator- B-18 Engine idle select
Inspection: A Perkins Models B-19 Fuel select-Ford Models
Quarterly or 250 hour A-19 Perform 30 day service B-20 Drive enable system
Inspection: A+B Perform every 100 hours: B-21 Drive brakes
Six Month or 500 hour A-20 Replace oil filter- B-22 Drive speed-stowed
Inspection: A+B+C Ford and Perkins Models
B-23 Drive speed-raised
Annual or 1000 hours A-21 Inspect fuel filter/water
B-24 Alarm package
Inspection: A+B+C+D separator-Diesel Models
B-25 Hydraulic oil analysis
A-22 Check engine RPM-
2 Year or 2000 hour Perform every 250 hours:
Perkins Engine Models
Inspection: A+B+C+D+E B-26 Replace hydraulic
Perform every 200 hours:
tank return filter
· Place a check in the appropriate box A-23 Check the engine belt-
after each inspection procedure is Ford Models Perform every 400 hours:
completed. B-27 Replace fuel filter/water
· If any inspection receives an “N”, tag separator element-
and remove the machine from Perkins models
service, repair and re-inspect it. After B-28 Replace the fuel filter
repair, place a check in the “R” box. element - Perkins Models
Legend B-29 Replace spark plugs-
Ford Models
Y = yes, acceptable
N = no, remove from service B-30 Replace engine air filter
R = repaired
Comments

MAINTENANCE INSPECTION REPORT
Instructions Checklist C Y N R Checklist E Y N R

· Make copies of both pages to use for C-1 Engine belt- E-1 Hydraulic oil
each inspection. Deutz Models E-2 Engine coolant-
· Select the appropriate checklist(s) for C-2 Replace engine oil Ford Models
the type of inspection to be and filter-Deutz Models E-3 Fuel hoses
performed. C-3 Valves-Deutz Models E-4 Check the toothed belt-
C-4 Check the coolant- Deutz Models
Daily or 8 hour
Liquid Cooled Models E-5 Check the engine valve
Inspection: A
C-5 Check the valve clearance-Ford Models
Quarterly or 250 hour clearance-Perkins Models E-6 Check cylinder
Inspection: A+B
C-6 PCV valve-Ford Models compression-Ford Models
Six Month or 500 hour
E-7 Check the fuel injection
Inspection: A+B+C
Checklist D Y N R pump-Deutz Models
Annual or 1000 hours E-8 Replace timing belt
D-1 Boom wear pads
Inspection: A+B+C+D Ford Models
D-2 Turntable bearing bolts
2 Year or 2000 hour E-9 Grease the steer axle
D-3 Free-wheel configuration
Inspection: A+B+C+D+E wheel bearings, 2WD Models
D-4 Grease rotation bearing
· Place a check in the appropriate box D-5 Drive hub oil
after each inspection procedure is D-6 Drive loop hydraulic filter
completed.
D-7 Check Air/LPG mixture-
· If any inspection receives an “N”, tag Ford Models
and remove the machine from
D-8 Replace the diesel fuel
service, repair and re-inspect it. After
filter/water separator-
repair, place a check in the “R” box.
Deutz Models
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

Table A Procedures
A-1 A-2
Inspect the Operator's and Inspect the Decals
Safety Manuals and Placards
Maintaining the operator’s and safety manuals in Maintaining all of the safety and instructional
good condition is essential to safe machine decals and placards in good condition is
operation. Manuals are included with each mandatory for safe machine operation. Decals
machine and should be stored in the container alert operators and personnel to the many possible
provided in the platform. An illegible or missing hazards associated with using this machine. They
manual will not provide safety and operational also provide users with operation and maintenance
information necessary for a safe operating information. An illegible decal will fail to alert
condition. personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to be sure that the storage container is
present and in good condition. 1 Refer to the Decals section in the
Genie Z45/25 & Genie Z45/25J Operator's
2 Check to make sure that the operator's,
Manual and use the decal list and illustrations
responsibilities and safety manuals are present
to determine that all decals and placards are in
and complete in the storage container in the
place.
platform.
2 Inspect all decals for legibility and damage.
3 Examine the pages of each manual to be sure
Replace any damaged or illegible decal
that they are legible and in good condition.
immediately.
4 Always return the manuals to the storage
Contact your authorized Genie
container after use.
distributor or Genie Industries if
Contact your authorized Genie replacement decals are needed.
distributor or Genie Industries if
replacement manuals are needed.

TABLE A PROCEDURES
A-3 Check entire machine for:

Inspect for Damage and Loose or · Cracks in welds or structural components
Missing Parts · Dents or damage to machine
· Battery and connections
· Compartment covers and latches
Daily machine condition inspections are essential Be sure that all structural and other critical
to safe machine operation and good machine components are present and all associated
performance. Failure to locate and repair damage, fasteners and pins are in place and properly
and discover loose or missing parts may result in tightened.
an unsafe operating condition. After you complete each inspection, be sure that all
1 Inspect the entire machine for damage and compartment covers are in place and secured.
improperly installed or missing parts including:
· Electrical components, wiring and electrical
cables
· Hydraulic hoses, fittings, cylinders and
manifolds
· Fuel and hydraulic tanks
· Drive and turntable rotation motors and
drive torque hubs
· Axle components
· Boom components and wear pads
· Platform entry mid-rail or gate
· Tires and wheels
· Engine and related components
· Limit switches
· Alarms, horn and beacon (if equipped)
· Nuts, bolts and other fasteners

TABLE A PROCEDURES
A-4 Deutz Engine F3L 1011F 6.3 quarts

Oil capacity (including filter) 6 liters
Check the Engine Oil Level
below 60°F / 15.5°C (synthetic) 5W-30
Maintaining the proper engine oil level is essential -10°F to 90°F / -23°C to 32°C 10W-40
to good engine performance and service life.
Operating the machine with an improper oil level above -4°F / -34°C 15W-40
can damage engine components.
Check the oil level with the CC/SE, CD/SE, SF/CC or SF/CD grades.
engine off. Units ship with 10-40 CC/SG.
1 Check the oil dipstick. Add oil as needed.
Perkins Engine 104-22 8.6 quarts
Result: The oil level should be in the "safe" Oil capacity (including filter) 8.2 liters
zone.
Ford LRG-425 EFI Engine 4.5 quarts
Oil capacity (including filter) 4.3 liters below 60°F / 15.5°C 5W-20
Oil viscosity requirements -10° to 90°F / -23° to 32°C 10W-30
below 60°F / 15.5°C 5W-30 above -10°F / -23°C 15W-40
-10° to 90°F / -23° to 32°C 5W-30 above 25°F / -4°C 20W-50
above -10°F / -23°C 5W-30 Engine oil should have properties of API classification
CC/SE, CD/SE, SF/CC or SF/CD grades.
above 25°F / -4°C 10W-30 Units ship with 10-40 CC/SG.
Use oils meeting API classification SH or SG.

Units ship with 10-40 CC/SG.

TABLE A PROCEDURES
A-5 A-6
Check the Engine Coolant Level - Check for Fuel Leaks
Liquid Cooled Models
Failure to detect and correct fuel leaks will result in

Maintaining the engine coolant at the proper level an unsafe condition. An explosion or fuel fire may
is essential to engine service life. Improper coolant cause death or serious injury.
level will affect the engine's cooling capability and Explosion and fire hazard. Engine
damage engine components. Daily checks will fuels are combustible. Inspect the
allow the inspector to identify changes in coolant machine in an open, well-
level that might indicate cooling system problems. ventilated area away from heaters,
Burn hazard. Beware of hot sparks, flames and lighted
engine parts and coolant. Contact tobacco. Always have an
with hot engine parts and/or approved fire extinguisher within
coolant may result in severe easy reach.
burns. 1 Open the shutoff valve on the liquid petroleum
1 Check the fluid level in the coolant recovery gas (LPG) tank by turning it counterclockwise
tank. Add fluid as needed. (if equipped).
Result: The fluid level should be at the 2 Perform a visual inspection around the following
FULL mark.
areas.
Do not remove the radiator cap. Ford Models:
· LPG tank, hoses and fittings, solenoid shutoff

valve, LPG regulator and throttle body.
An LPG detector may be
necessary to locate LPG leaks.
· Fuel tank, manual shutoff valve, fuel
pump, fuel filters, fuel rail and fuel injectors,
hoses and fittings and throttle body.

TABLE A PROCEDURES
Deutz and Perkins Models: A-7

· Fuel tank, shutoff valve, hoses and fittings, Check the Hydraulic Oil Level
fuel pump, fuel filter, fuel injection pumps and
fuel injectors.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering Maintaining the hydraulic oil at the proper level is
the area and do not operate the essential to machine operation. Improper hydraulic
machine. Repair the leak oil levels can damage hydraulic components. Daily
immediately. checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.
1 Be sure that the boom is in the stowed position,

then visually inspect the sight gauge located on
the side of the hydraulic oil tank.
Result: The hydraulic oil level should be within
the top 2 inches (5 cm) of the sight gauge.
2 Add oil as needed.
Hydraulic oil specifications
Hydraulic oil type Dexron equivalent
Tank capacity 24 gallons 90.8 liters
Hydraulic system
(including tank) 30 gallons 113.6 liters

TABLE A PROCEDURES
A-8 A-9
Check for Hydraulic Leaks Check the Tire Pressure
Detecting hydraulic fluid leaks is essential to Bodily injury hazard. An over-

operational safety and good machine performance. inflated tire can explode and could
Undiscovered leaks can develop into hazardous result in death or serious injury.
situations, impair machine functions and damage Tip-over hazard. Do not use
machine components. temporary flat tire repair products.
1 Inspect for hydraulic oil puddles, dripping or This procedure does not need
residue on or around the following areas: to be performed on machines
· Hydraulic tank— fittings, hoses, auxiliary equipped with foam-filled
power unit, filters, and turntable surface tire.
· Engine compartment—hydraulic filters, To safeguard maximum stability, achieve

fittings, hoses, pumps, filter and turntable optimum machine handling and minimize tire
surface wear, it is essential to maintain proper pressure
in all air-filled tires.
· All hydraulic cylinders
· All hydraulic manifolds 1 Check each tire with an air pressure gauge and
add air as needed.
· Primary and jib boom
· The underside of the turntable Tire specifications 2WD Models 4WD Models
· The underside of the drive chassis
Standard base models
· Ground area under the machine Rough terrain tire 14-17.5 NHS 14-17.5 NHS
45 psi (3.1 bar) 45 psi (3.1 bar)
Narrow base models

Industrial tire Foam Filled Only N/A

TABLE A PROCEDURES
A-10 A-11
Test the Oscillate Axle Test the Platform and
(if equipped) Ground Controls
Proper axle oscillation is essential to safe machine Testing the machine functions and the Emergency
operation. If the axle oscillation system is not Stop buttons for malfunctions is essential for safe
operating correctly, the stability of the machine is machine operation. An unsafe working condition
compromised and it may tip over. exists if any function fails to operate properly or
either Emergency Stop button fails to stop all the
1 Start the engine from the platform controls. machine functions and shut off the engine. Each
2 Drive the right steer tire up onto a 6 inch function should activate, operate smoothly and be
(15.2 cm) block or curb. free of hesitation, jerking and unusual noise.
Result: The three remaining tires should stay in 1 Turn the key switch to ground control and pull
firm contact with the ground and the chassis out the Emergency Stop button to the ON
should remain level at all times. position.
3 Drive the left steer tire up onto a 6 inch 2 Start the engine from the ground controls.
(15.2 cm) block or curb.
3 Do not hold the function enable switch to either
Result: The three remaining tires should stay in side. Attempt to activate each boom and
firm contact with the ground and the chassis platform function toggle switch.
should remain level at all times.
Result: All boom and platform functions should
4 Drive both steer tires up onto a 6 inch not operate.
(15.2 cm) block or curb.
4 Hold the function enable switch to either side
Result: The non-steer tires should stay in firm and activate each boom and platform function
contact with the ground. toggle switch.
If the chassis does not remain Result: All boom and platform functions should
level during test, see Repair operate through a full cycle. Descent alarm (if
Procedure 12-4, How to Set Up equipped) should sound while the boom is
the Directional Valve Linkage lowering.
Machines equipped with Platform
Level Control Disable Function:
The platform level function will not
operate when the boom is raised
or extended past the drive speed
limit switches.
Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 - 11

TABLE A PROCEDURES
5 Push in the Emergency Stop button to the OFF A-12

position.
Test the Auxiliary Power
Result: No function should operate, the engine
should stop.
Operation
Deutz and Perkins Diesel models: Detection of auxiliary power system malfunctions is
All functions should stop essential for safe machine operation. An unsafe
immediately. The engine will working condition exists if the auxiliary powered
shut off after 2 to 3 seconds. functions do not operate in the event of a main
power loss. When operating the machine on
6 Start the engine from the platform controls. engine power, selecting auxiliary power will stop
the engine immediately. Auxiliary power is
7 Do not press down on the foot switch.
designed for short term use only,
8 Attempt to activate each machine function. and excessive use will result in battery drain
and component damage.
Result: All machine functions should not
operate. 1 Turn the key switch to ground control and pull
9 Press down on the foot switch and activate out the Emergency Stop button to the ON
each machine function. position.
Machines equipped with Platform 2 Lift the red auxiliary

Level Control Disable Function: power switch cover.
The platform level function will not 3 Simultaneously hold
operate when the boom is raised the auxiliary power
or extended past the drive speed switch ON and activate
limit switches. each boom function
Result: All machine functions should operate toggle switch.
through a full cycle.
10 Push in the Emergency Stop button to the OFF To conserve battery power, test
position at the platform controls. each function through a partial
Result: No function should operate, the engine cycle.
should stop. Result: All boom functions should operate.
As a safety feature, selecting 4 Turn the key switch to platform control.
and operating the ground
controls will override the 5 Pull out the Emergency Stop button to the ON
platform controls, including position at the platform controls.
the Emergency Stop button. 6 Press down the foot switch.
Deutz and Perkins Diesel models:
All functions should stop
immediately. The engine will
shut off after 2 to 3 seconds.

TABLE A PROCEDURES
7 Lift the red auxiliary power switch cover. A-13

8 Simultaneously hold the auxiliary power switch Test the Tilt Sensor
ON and activate each function control handle or
toggle switch. The tilt sensor sounds an alarm located in the
platform when the incline of the turntable exceeds
the rating on the serial plate.
Select a level test area. The tilt

alarm should not be sounding prior
to the test.
1 Open the engine side turntable cover.
2 Turn the key switch to platform controls and pull
out the red Emergency Stop buttons out to the
Result: All boom and steer functions should ON position at both the ground and platform
operate. Drive functions should not operate with controls.

auxiliary power. 3 Locate the tilt sensor to the right of the hydraulic
To conserve battery power, test pump.
each function through a partial 4 Press down on one side of the tilt sensor.
cycle.
Result: The alarm, located in the platform,
should sound.
Tip-over hazard. The alarm should
be heard at the ground controls. If
you can't hear the alarm at the
ground controls, replace the alarm
in the platform.

TABLE A PROCEDURES
A-14 5 Locate the secondary boom drive limit switch

located at the platform end of the lower
Test the Limit Switches secondary boom.
Drive Limit Switches
Detecting limit switch malfunctions is essential to

safe machine operation. The drive limit switches
are used to restrict drive speed when the boom is
raised or extended. An improperly functioning drive
limit switch will allow the machine to operate at an a
unsafe drive speed.
1 Remove the hose and cable cover from the rear

of the upper mid-pivot. a secondary boom drive
limit switch (LS3)
2 Locate the primary boom drive limit switch
located on the inside of the upper mid-pivot. 6 Visually inspect secondary boom drive limit
switch for the following:
3 Visually inspect primary boom drive limit switch
for the following: · Broken or missing roller or arm
· Missing fasteners
· Broken or missing roller or arm
· Loose wiring
7 Manually activate the secondary boom drive
· Loose wiring limit switch.
4 Manually activate the primary boom drive limit
switch. Result: The secondary boom drive limit switch
arm should move freely and spring return to
Result: The primary boom drive limit switch arm center. A distinct click should be felt and heard.
should move freely and spring return to center.
A distinct click should be felt and heard.
a primary boom drive limit switch (LS2)

TABLE A PROCEDURES
8 Locate the primary boom extend drive limit 13 Start the engine from the platform controls.
switch located at the pivot end of the primary
14 Move the lift/drive select switch to the lift
boom.
position (if equipped).
a
15 Press down the foot switch. Fully retract the
primary boom.
16 Move the lift/drive select switch to the drive
17 Press down the foot switch and slowly move the
drive control handle off center.
Result: The machine should move at normal
drive speeds.
a primary boom extend drive limit
switch (LS1) 19 Press down the foot switch and raise the
9 Visually inspect the boom extend drive limit primary boom approximately 2 feet (61 cm).
switch located at the pivot end of the primary 20 Move the lift/drive select switch to the drive
boom. Inspect for the following: position (if equipped).
· Broken or missing arm 21 Press down the foot switch and slowly move the
· Missing fasteners drive control handle off center.
· Loose wiring Result: The machine should move at a reduced
10 Start the engine from the ground controls and drive speed.
extend the primary boom approximately 2 feet 22 Move the lift/drive select switch to the lift
(61 cm). position (if equipped).
11 Turn the engine off. 23 Press down the foot switch and lower the
12 Manually activate the boom extend drive limit primary boom to the stowed position, then raise
switch. the secondary boom approximately
2 feet (61 cm).
Result: The boom extend drive limit switch arm
should move freely and spring return to center.

TABLE A PROCEDURES
24 Move the lift/drive select switch to the drive Drive Enable Limit Switch
A properly functioning drive enable limit switch is
25 Press down the foot switch and slowly move the essential for safe machine operation and
drive control handle off center. workplace safety. The drive enable limit switch
stops the drive function when the boom is rotated
Result: The machine should move at a reduced
past a non-steer tire and alerts the operator that
drive speed.
the machine may drive in the opposite direction
26 Move the lift/drive select switch to the lift that the drive and steer control handle is moved.
1 Start the engine from the ground controls and
27 Press down the foot switch and lower the rotate the boom between the steer and
secondary boom to the stowed position, then non-steer tires. Turn the engine off.
extend the primary boom approximately 2 feet
(0.6 m). 2 Visually inspect the drive enable limit switch for
the following:
position (if equipped). · Broken or missing roller or arm
29 Press down the foot switch and slowly move the
drive control handle off center. · Loose wiring
Result: The machine should move at a reduced a

drive speed.
Drive speed, maximum,

raised or extended

Standard Base Models 40 ft/45 sec
12.2 m/45 sec

Narrow Base Models 40 ft/79 sec
12.2 m/79 sec c b
a turntable
b drive enable limit switch (LS4)
c turntable rotation bearing

TABLE A PROCEDURES
3 Manually activate the drive enable limit switch. 12 Press down the foot switch and slowly move the
Result: The drive enable limit switch roller
should move freely and spring return to center. Result: Drive function should not operate.
13 Move and hold the drive enable toggle switch to
4 Start the engine from the platform controls. either side and slowly move the drive control
handle off center.
Result: The drive enable indicator light should
be on. Result: Drive function should operate.
5 Move the lift/drive select switch to the lift 14 Move the lift/drive select switch to the lift
position (if equipped). position (if equipped).
6 Press down the foot switch. Then rotate the 15 Press down the foot switch and rotate the
turntable until the primary boom is in between turntable to the right until the boom is past the
the non-steer tires. right non-steer wheel.
Result: The drive enable indicator light should Result: The drive enable indicator light should
be off. be on.
7 Move the lift/drive select switch to the drive 16 Rotate the turntable to the left until the boom is
position (if equipped). past the left non-steer wheel.
8 Press down the foot switch and slowly move the Result: The drive enable indicator light should
drive control handle off center. be on.
Result: The drive function should operate. 17 Move the lift/drive select switch to the drive
position (if equipped). 18 Press down the foot switch and slowly move the
10 Press down the foot switch and rotate the
turntable to the left until the boom is past the Result: Drive function should not operate.
left non-steer wheel.
19 Move and hold the drive enable toggle switch to
Result: The drive enable indicator light should either side and slowly move the drive control
be on. handle off center.
11 Move the lift/drive select switch to the drive Result: Drive function should operate.

TABLE A PROCEDURES
A-15 5 Check the engine belt for proper tension.

Check the Engine Belt -
Perkins Models
Maintaining the engine belt is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt and continued use may cause component
damage.
Bodily injury hazard. Do not

inspect while the engine is
running. Remove the key to
secure from operation.
Burn hazard. Beware of hot 6 Swing the engine back to its original position
engine components. Contact with and close the engine pivot plate latch.
hot engine components may result
in severe burns. 7 Install the engine pivot plate safety pin.
1 Remove the safety pin from the engine pivot 8 Replace the air baffle and install the air baffle
plate latch. retaining fasteners.
The engine pivot plate latch is 3/8 in to 1/2 in
Belt deflection
located under the engine turntable
9.5 mm to 12 mm
pivot plate at the counterweight
end of the machine. Engine belt - Genie part number 65537
2 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.
3 Inspect the engine belt for:
· Cracking
· Glazing
· Separation
· Breaks
4 Replace belt if any damage is found.

TABLE A PROCEDURES
A-16 3 Remove the end cap from the air cleaner

canister.
Clean the Engine Air Filter
4 Remove the air filter retaining fastener. Remove
Element the filter element.
5 Clean the inside of the canister and the gasket
with a damp cloth.
Maintaining the engine air filter in good condition is 6 Inspect the filter element. If needed, blow out
essential to good engine performance and service from inside out using low pressure dry
life. Failure to perform this procedure can lead to compressed air, or tap out dust taking care not
poor engine performance and component damage. to damage the element.
Perform this procedure with the 7 Install the end cap onto the canister. Install and
engine off. tighten the retaining ring.
All Models: 8 Swing the engine back to its original position
1 Remove the safety pin (if equipped) from the and close the engine pivot plate latch.
engine pivot plate latch. 9 Install the engine pivot plate safety pin
The engine pivot plate latch is (if equipped).
end of the machine.
machine.

TABLE A PROCEDURES
A-17 1 Locate the fuel system components mounted

underneath the engine pivot plate (viewed from
Replace the Fuel bottom of engine pivot plate).
Filters - Ford Models
a b c
Replacing the gasoline fuel filter is essential to

good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel filter in an open, well-
ventilated area away from heaters,
sparks, flames and lighted e d
tobacco. Always have an
approved fire extinguisher within
easy reach. a hose from fuel pump to regulator/filter
b hose from fuel pre-filter to fuel pump
Perform this procedure with the c hose from fuel tank to fuel pre-filter
d hose from regulator/filter to engine
engine off. e hose from regulator/filter to tank
2 At the pre-filter, disconnect and plug the fuel

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

TABLE A PROCEDURES
6 Disconnect the hoses from the pressure A-18

regulator/filter.
Inspect the Radiator -
Explosion and fire hazard.
Electronic Fuel Injection (EFI)
Perkins Models
systems operate at a very high
pressure. Fuel may be expelled
under pressure if the hoses are
removed too quickly. Loosen the Maintaining the radiator in good condition is
fuel lines very slowly to allow the essential for good engine performance. Operating
fuel pressure to dissipate a machine with a damaged or leaking radiator may
gradually. Wrap a cloth around result in engine damage. Also, restricting air flow
fuel hoses to absorb leaking fuel through the radiator (i.e., dirt or debris) will affect
before disconnecting them. the performance of the cooling system. A frequent
check allows the inspector to identify changes in
7 Remove the regulator/filter mounting fasteners. the condition of the radiator that might indicate
Then remove the regulator/filter from the engine cooling system problems.
pivot plate.
8 Install the new regulator/filter (Genie part inspect while the engine
number 58967) onto the engine pivot plate and is running. Remove the key to
install the hoses to the regulator/filter. secure from operation.
Component damage hazard. Be Burn hazard. Beware of hot
sure the correct regulator/filter is engine parts and coolant. Contact
installed or component damage with hot engine parts and/or
may occur. coolant may result in severe
9 Start the machine from the ground controls, burns.
then inspect the fuel filters and hoses for leaks. 1 Remove the safety pin from the engine pivot
Explosion and fire hazard. If a fuel plate latch.
leak is discovered, keep any The engine pivot plate latch is
additional personnel from entering located under the engine turntable
the area and do not operate the pivot plate at the counterweight
machine. Repair the leak end of the machine.
immediately.
Fuel filters - Genie part numbers engine pivot plate out and away from the
machine.
Fuel pre-filter 52179
Fuel pressure regulator/filter 58967

TABLE A PROCEDURES
3 Inspect the radiator for leaks and physical A-19

damage.
Perform 30 Day Service
4 Clean the radiator fins of debris and foreign
materials.
5 Inspect all radiator hoses and connections.
The 30 day maintenance procedure is a one time
6 Swing the engine back to its original position sequence of procedures to be performed after the
and close the engine pivot plate latch. first 30 days or 50 hours of usage. After this
7 Install the engine pivot plate safety pin. interval, refer to the maintenance tables for
continued scheduled maintenance.
1 Perform the following maintenance procedures:

• Replace the Engine Oil and Filter -
Ford/Perkins Models ............................. A-19
Deutz Diesel Models .............................. C-2
• Inspect the Tires and Wheels
(including lug nut torque) ......................... B-5
• Replace the Hydraulic Tank Return
Filter ........................................................ B-24
• Check the Turnable Rotation Bearing
Bolts ....................................................... D-2

TABLE A PROCEDURES
A-20 2 Open the engine pivot plate latch and swing the
Replace the Engine Oil and machine.
Filter - Ford and Perkins Models 3 Remove the oil filler cap located on the
valve cover.
4 Pull the oil drain hose out from underneath the
Ford and Perkins engine engine.
specifications require that this 5 Open the valve on the oil pan and allow all of
procedure be performed every 100 the oil from the engine to drain into a suitable
hours. Perform this procedure container. See capacity specifications.
more often if dusty conditions exist
or the machine is subjected to 6 Close the valve on the oil pan.
extended low idle operation. 7 Place a container under the oil filter.
Periodic replacement of the engine oil and filter 8 Use an oil filter wrench and remove the filter.
is essential to good engine performance. Operating
the machine with an improper oil level or 9 Apply a thin layer of oil to the new oil filter
neglecting periodic oil and filter changes can gasket. Then install the filter and tighten it
damage engine components. A daily check of securely by hand.
machine hours against the hours noted on the oil
filter will allow the inspector to anticipate and Oil filters - Genie part numbers
perform oil and filter changes at the 100 hour Ford LRG-425 EFI Engine 28656
interval. Perkins 104-22 Engine 65540
Perform this procedure after

warming the engine to normal 10 Use a permanent ink marker to write the date
operating temperature. and number of hours from the hour meter on
Burn hazard. Beware of hot the oil filter.
engine parts and oil. Contact with 11 Fill the engine with new oil per specifications
hot engine oil and/or engine parts and install the filler cap. See capacity
may result in severe burns. specifications.
1 Remove the safety pin (if equipped) from the 12 Start the engine from the ground controls.
engine pivot plate latch. Allow the engine to run for 30 seconds, then
The engine pivot plate latch is turn the engine off.
end of the machine.

TABLE A PROCEDURES
13 Check the oil filter and the oil pan hose for A-21
leaks.
Inspect the Fuel Filter/ Water
14 Swing the engine back to its original position
and close the engine pivot plate latch.
Separator - Diesel Models
15 Install the engine pivot plate safety pin
(if equipped).
16 Check the engine oil level dipstick. Add oil Engine specifications require that
if needed. this procedure be performed every
100 hours.
Ford LRG-425 EFI Engine 4.5 quarts Proper maintenance of the fuel filter/water
Oil capacity (including filter) 4.3 liters separator is essential for good engine
performance. Failure to perform this procedure can
Oil viscosity requirements lead to poor engine performance and component
damage.
below 60°F / 15.5°C 5W-30
-10° to 90°F / -23° to 32°C 5W-30 fuels are combustible. Perform this
procedure in an open, well-
above -10°F / -23°C 5W-30 ventilated area away from heaters,
sparks, flames and lighted
above 25°F / -4°C 10W-30 tobacco. Always have an
Use oils meeting API classification SH or SG.
easy reach.
Units ship with 10-40 CC/SG
Perform this procedure with the
Perkins 104-22 Engine 8.6 quarts engine off.
Oil capacity (including filter) 8.2 liters
Perkins Models:
1 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
below 60°F / 15.5°C 15W-40
hydraulic return filter on the bulkhead.
-10°F to 90°F / -23°C to 32°C 10W-30 2 Inspect the filter bowl for water buildup.
above -4°F / -34°C 15W-40 Result: If water is present in the filter bowl
continue with steps 3 through 7 for Perkins
Engine oil should have properties of API classification models only.
CF4 grade.

TABLE A PROCEDURES
3 Loosen the vent plug located on the fuel filter/ 7 Start the engine from the ground controls and
water separator head. check the fuel filter/water separator and vent
plug for leaks.
a
d additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
c
Deutz Models:
b
the fuel filter/water separator.
2 Remove the safety pin (if equipped) from the
engine pivot plate latch.
Fuel filter/water separator
a vent plug The engine pivot plate latch is
b drain plug located under the engine turntable
c filter bowl
d separator head
end of the machine.
4 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
machine.
Immediately tighten the drain plug.
4 Loosen the drain plug located at the bottom of
5 Tighten the vent plug.
the filter. Allow the water to drain into a suitable
If the fuel filter/water separator is container until fuel starts to come out.
completely drained, you must Immediately tighten the drain plug.
prime the fuel filter/water
separator before starting the
engine. Refer to B-27 in this
section, Replace The Fuel Filter
Element - Perkins Diesel Models,
for instructions on how to prime
the fuel filter/water separator.
a
6 Clean up any fuel that may have spilled.
b
a fuel filter/water separator

b drain plug

TABLE A PROCEDURES
4 Clean up any fuel that may have spilled. A-22

If the fuel filter is completely Check and Adjust the
drained, you must prime the fuel
filter/water separator before
Engine RPM - Perkins Diesel
starting the engine. Refer to D-8 in Models
this section, Replace The Diesel
Fuel Filter/Water Separator -
Deutz Diesel Models, for
instructions on how to prime the
Perkins specifications require that
fuel filter/water separator.
this procedure be performed every
5 Start the engine from the ground controls and 100 hours.
check the fuel filter/water separator for leaks.
Maintaining the engine rpm at the proper setting for
Explosion and fire hazard. If a fuel both low and high idle is essential to good engine
leak is discovered, keep any performance and service life. The machine will not
additional personnel from entering operate properly if the rpm is incorrect and
the area and do not operate the continued use may cause component damage.
immediately. This procedure will require two
people.
and close the engine pivot plate latch. 1 Connect a tachometer to the engine. Start the
engine from the ground controls.
(if equipped). Result: Low idle should be 1600 rpm.

TABLE A PROCEDURES
Skip to step 3 if the low idle rpm is correct. 4 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
2 Loosen the low idle lock nut and turn the low counterclockwise to increase the rpm or
idle adjustment screw clockwise to increase the clockwise to decrease the rpm. Tighten the
rpm, or counterclockwise to decrease the rpm. yoke lock nut and recheck the rpm.
Tighten the low idle lock nut and confirm the
rpm. Be sure the solenoid fully retracts
when activating high idle.
Perkins Diesel models
Low idle 1600 rpm
High idle 2500 rpm
a b c d
a solenoid boot
b high idle adjustment nut
c yoke
d low idle lock nut and adjustment
screw
3 Move the function enable toggle switch to the

high idle (rabbit symbol) position.
Result: High idle should be 2500 rpm.
If high idle rpm is correct, disregard
adjustment step 4.

TABLE A PROCEDURES
A-23 3 Inspect the engine belt for:

Check the Engine Belt - · Cracking
Ford Models · Glazing

· Separation
· Breaks
4 Replace belt if any damage is found.
Engine specifications require that
this procedure be performed every Ford LRG-425 EFI engines are
200 hours. equipped with a serpentine belt
and incorporate a self adjusting
Maintaining the engine belt is essential to good belt tensioner. No adjustment is
engine performance and service life. The machine required.
belt and continued use may cause component 5 Swing the engine back to its original position
damage. and close the engine pivot plate latch.
Bodily injury hazard. Do not 6 Install the engine pivot plate safety pin
inspect while the engine is (if equipped).
secure from operation. Engine belt - Genie part number
Ford Models 52580
Burn hazard. Beware of hot
engine components. Contact with
in severe burns.
The engine pivot plate latch is
end of the machine.
machine.

Table B Procedures
B-1 B-2
Check the Battery Inspect the Electrical Wiring
Proper battery condition is essential to good Maintaining electrical wiring in good condition is
engine performance and operational safety. essential to safe operation and good machine
Improper fluid levels or damaged cables and performance. Failure to find and replace burnt,
connections can result in engine component chafed, corroded or pinched wires could result in
damage and hazardous conditions. unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in Electrocution hazard. Contact with
death or serious injury. Remove all hot or live circuits could result in
rings, watches and other jewelry. death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 1 Open the engine side turntable cover.
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are pivot plate at the counterweight
free of corrosion. end of the machine.
3 Be sure that the battery hold downs and cable 3 Open the engine pivot plate latch and swing the
connections are tight. engine pivot plate out and away from the
machine.
The battery is a maintenance free
battery and does not require the 4 Inspect the following areas for burnt, chafed,
replenishing of electrolyte. corroded and loose wires:
Adding terminal protectors and a · Engine wiring harness
corrosion preventative sealant will · Hydraulic manifold wiring
help eliminate corrosion on the
battery terminals and cables.

TABLE B PROCEDURES
5 Open the ground controls side turntable cover. B-3

6 Inspect the following areas for burnt, chafed, Check the Radiator -
corroded and loose wires:
Ford Models
· Inside of the ground control box
Maintaining the radiator in good condition is
· Hydraulic manifold wiring essential for good engine performance. Operating
7 Start the engine from the ground controls and a machine with a damaged or leaking radiator may
raise the boom above the turntable covers. result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
8 Inspect the turntable area for burnt, chafed and the performance of the cooling system. A frequent
pinched cables. check allows the inspector to identify changes in
9 Lower the boom to the stowed position and turn the condition of the radiator that might indicate
the engine off. cooling system problems.
10 Inspect the following areas for burnt, chafed, Bodily injury hazard. Do not
corroded, pinched and loose wires: inspect while the engine
is running. Remove the key to
· Cable track on the primary boom
· Cables on the primary, and jib booms
· Jib boom/Platform rotate manifold engine parts and coolant. Contact
· Inside of the platform control box with hot engine parts and/or
coolant may result in severe
11 Swing the engine back to its original position burns.
12 Install the engine pivot plate safety pin engine pivot plate latch.
(if equipped).
end of the machine.

TABLE B PROCEDURES
2 Open the engine pivot plate latch and swing the B-4
machine. Check the Exhaust System
3 Inspect the radiator for leaks and physical Maintaining the exhaust system is essential to
damage. good engine performance and service life. Running
the engine with a damaged or leaking exhaust
4 Clean the radiator fins of debris and foreign system can cause component damage and unsafe
materials. operating conditions.
5 Inspect all radiator hoses and connections. Bodily injury hazard. Do not
6 Swing the engine back to its original position inspect while the engine is
and close the engine pivot plate latch. running. Remove the key to
(if equipped). Burn hazard. Beware of hot
8 Replace the air baffle and install the air baffle hot engine components may result
retaining fasteners. in severe burns.
1 Ford models: Remove the safety pin (if
equipped) from the engine pivot plate latch.
end of the machine.
machine to access the exhaust system.
3 All models: Be sure that all nuts and bolts are
tight.
4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
6 Ford models: Swing the engine back to its
original position and close the engine pivot
plate latch.
(if equipped).

TABLE B PROCEDURES
B-5 B-6
Check the Hydraulic Return Filter Check the Oil Cooler and Cooling
Condition Indicator Fins - Deutz Diesel Models
Maintaining the hydraulic return filter in good
condition is essential to good system performance
and safe machine operation. The filter condition
indicator will show when the hydraulic flow is Maintaining the oil cooler in good condition is
bypassing a clogged filter. If the filter is not essential for good engine performance. Operating
frequently checked and replaced, impurities will a machine with a damaged oil cooler may result in
remain in the hydraulic system and cause engine damage. Also, restricting air flow through
component damage. the oil cooler will affect the performance of the
cooling system.
1 Open the engine side turntable cover.
2 Start the engine from the platform controls. inspect while the engine
3 Move the engine RPM toggle switch to the is running. Remove the key to
maintained high idle position (rabbit symbol). secure from operation.
4 Inspect the filter condition indicator gauge. Burn hazard. Beware of hot
Result: The needle on the gauge should be hot engine components may result
operating in the green area. If the needle is in in severe burns.
the red area, this indicates that the hydraulic
filter is being bypassed and the filter should be Oil Cooler
replaced. 1 Remove the safety pin (if equipped) from the
The hydraulic filter condition engine pivot plate latch.
indicator gauge is mounted to the The engine pivot plate latch is
hydraulic return filter on the engine located under the engine turntable
side bulkhead. pivot plate at the counterweight
end of the machine.
machine.
3 Remove the fasteners from the engine side
cover, then remove the cover.

TABLE B PROCEDURES
4 Inspect the oil cooler for leaks and physical B-7

damage.
Inspect the Tires and Wheels
a b c
(including lug nut torque)
Maintaining the tires and wheels in good

condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
Bodily injury hazard. An over-

a oil cooler inflated tire can explode and could
b cylinder head cooling fins cause death or serious injury.
c fan blower fins
Tip-over hazard. Do not use
5 Clean the oil cooler of debris and foreign temporary flat tire repair products.
material.
1 Check all tire treads and sidewalls for cuts,
Cooling and Fan Blower Fins cracks, punctures and unusual wear.
6 Inspect the fan blower fins for physical damage. 2 Check each wheel for damage, bends and
7 Clean the fan blower fins of debris and foreign cracked welds.
material. 3 Check each lug nut for proper torque.
8 Inspect the head cooling passages and fins for 4 Check the pressure in each air-filled tire.
physical damage or foreign material, using a
flashlight. Tire specifications Industrial Rough terrain
9 Clean the cylinder head cooling passages of
debris and foreign material. Tire size 9-14.5 LT 14-17.5 NHS
10 Install the engine side cover. Inflation pressure Foam Filled 45 psi (3.1 bar)
11 Swing the engine back to its original position Tire ply rating (minimum) 12 14
and close the engine pivot plate latch. Wheel lugs, 4WD 8 @ 5/8 -18 9 @ 5/8 -18
12 Install the engine pivot plate safety pin Wheel lugs, 2WD
(if equipped). Front 8 @ 5/8 -18 8 @ 5/8 -18
Rear 9 @ 5/8 -18 9 @ 5/8 -18
Lug nut torque, dry 125 ft-lbs 125 ft-lbs
169.5 Nm 169.5 Nm
Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs
127.4 Nm 127.4 Nm

TABLE B PROCEDURES
B-8 B-9
Confirm the Proper Check the Oil Level
Brake Configuration in the Drive Hubs
Proper brake configuration is essential to safe Failure to maintain proper drive hub oil levels may
operation and good machine performance. cause the machine to perform poorly and
Hydrostatic brakes and hydraulically-released, continued use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully Drive Hubs
operational. 1 Drive the machine to rotate the hub until the
1 Check each drive hub disconnect cap to be plugs are located one on top and the other at
sure it is in the engaged position. 90 degrees.
brake disengage position
brake engage position
2 Be sure the free-wheel valve on the drive pump

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

always remain closed.

TABLE B PROCEDURES
3 If necessary, remove the top plug and add oil B-10

until the oil level is even with the bottom of the
side plug hole. Check and Adjust the
4 Apply pipe thread sealant to the plug, and then
Engine RPM - Ford and Deutz
install it in the drive hub. Models
5 Repeat this procedure for each drive hub.
Drive hub oil

Maintaining the engine rpm at the proper setting for
Capacity 17 fl oz both low and high idle is essential to good engine
0.5 liters performance and service life. The machine will not
operate properly if the rpm is incorrect and
Type: SAE 90 multipurpose hypoid gear oil - API service continued use may cause component damage.
classification GL5
Ford Models:
The engine rpm is controlled by
the ECM and can only be adjusted
by re-programming the ECM. If
rpm adjustment or service is
required, please contact Genie
Industries Service Department OR
your local Ford dealer.
Ford Models
Low idle 1600 rpm
High idle 2500 rpm
Deutz Diesel Models:
This procedure will require two

people.
end of the machine.

TABLE B PROCEDURES
2 Open the engine pivot plate latch and swing the If high idle rpm is correct, disregard
engine pivot plate out and away from the adjustment step 6.
machine.
6 Loosen the yoke lock nut, then turn the high idle
3 Connect an rpm gauge to the engine, and then adjustment nut and solenoid boot
start the engine from the ground controls. counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
Result: Low idle should be 1400 rpm.
yoke lock nut and recheck the rpm.
Skip to step 5 if the low idle rpm is correct.
Be sure the solenoid fully retracts
4 Loosen the low idle lock nut, then turn the low when activating high idle.
idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm. Deutz Diesel Models
Tighten the low idle lock nut and recheck the
rpm. Low idle 1400 rpm
High idle 2500 rpm
a b c d
a solenoid boot
b high idle adjustment nut
c yoke lock nut
d yoke
e low idle adjustment screw
f low idle lock nut
5 Move the function enable toggle switch to the

high idle (rabbit symbol) position at the ground
controls.
Result: High idle should be 2500 rpm.

TABLE B PROCEDURES
B-11 B-12
Test the Key Switch Test the Emergency
Proper key switch action and response is essential Stop Buttons
to safe machine operation. The machine can be Properly functioning Emergency Stop buttons
operated from the ground or platform controls and are essential for safe machine operation. An
the activation of one or the other is accomplished improperly operating Emergency Stop button
with the key switch. Failure of the key switch to will fail to shut off power and stop all machine
activate the appropriate control panel could cause functions, resulting in a hazardous situation for
a hazardous operating situation. ground and platform personnel.
1 Pull out the Emergency Stop button to the ON As a safety feature, selecting
position at both the ground and platform and operating the ground controls
controls. will override the platform controls,
2 Turn the key switch to ground control, start the including the platform Emergency
engine and then turn the key switch to platform Stop button.
control. 1 Start the engine from the ground controls.
3 Check any machine function from the ground 2 Push down the Emergency Stop button to the
controls. OFF position.
Result: The machine functions should not Result: The engine should shut off and no
operate. machine functions should operate.
4 Turn the key switch to ground control. Deutz and Perkins Diesel models:
5 Check any machine function from the platform All functions should stop
controls. immediately. The engine will
shut off after 2 to 3 seconds.
Result: The machine functions should not
operate. 3 Start the engine from the platform controls.
6 Turn the key switch to the OFF position. 4 Push down the Emergency Stop button to the
OFF position.
Result: The engine should stop and no
functions should operate. Result: The engine should shut off and no
machine functions should operate.
Deutz and Perkins Diesel models:
All functions should stop The ground Emergency Stop
immediately. The engine will button will stop all machine
shut off after 2 to 3 seconds. operation, even if the key switch
is switched to platform control.

TABLE B PROCEDURES
B-13 B-14
Test the Ground Control Override Check the Directional Valve
A properly functioning ground control override is Linkage
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the Emergency Perform this test only on models
Stop button on the platform controls is in the ON or equipped with a oscillating axle.
OFF position. This function is particularly useful if
the operator at the platform controls cannot return Proper axle oscillation is essential to safe machine
the boom to the stowed position. operation. If the directional valve linkage is not
operating correctly, the stability of the machine is
1 Push in the platform Emergency Stop button compromised and it may tip over.
to the OFF position.
1 Remove the drive chassis cover and the axle
2 Start the engine from the ground controls. covers from the non-steer end of the drive
3 At the ground controls, operate each boom chassis.
function through a partial cycle.
Result: All boom functions should operate.

TABLE B PROCEDURES
2 Locate the directional valve inside of the non- B-15

steer axle and inspect the linkage for the
following: Test the Platform Self-leveling
· Lock nut is tight against yoke
· Yoke clevis pins are installed
· Cotter pins are installed through clevis pins Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
· Linkage is properly attached to
essential for safe machine operation. The
directional valve
platform is maintained at level by the platform
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder
a
located at the base of the boom.
A platform self-leveling failure creates an unsafe
working condition for platform and
ground personnel.

lower the boom into the stowed position.
b 2 Hold the function enable toggle switch to either
side and adjust the platform to a level position
c
using the platform level toggle switch.
d
3 Raise and lower the primary boom through
a full cycle.
Result: The platform should remain level at
a directional valve all times to within ±5 degrees.
b clevis pin with cotter pin (hidden)
c yoke
d lock nut

TABLE B PROCEDURES
B-16 B-17
Test the Horn Test the Foot Switch
A functional horn is essential to safe machine A properly functioning foot switch is essential to
operation. The horn is activated at the platform safe machine operation. Machine functions should
controls and sounds at the ground as a warning to activate and operate smoothly as long as the foot
ground personnel. An improperly functioning horn switch is pressed down, and promptly stop when
will prevent the operator from alerting ground the foot switch is released. The foot switch will also
personnel of hazards or unsafe conditions. shift the engine into high idle if the idle select is
switched to the rabbit and foot switch symbol. An
1 Turn the key switch to platform control and improperly functioning foot switch can cause an
pull out the Emergency Stop button to the unsafe working condition and endanger platform
ON position at both the ground and
and ground personnel.
platform controls.
The engine should not start if the
2 Push down the horn button at the platform
foot switch is pressed down.
controls.
1 Turn the key switch to platform controls and pull
Result: The horn should sound.
out the Emergency Stop button to the ON
If necessary, the horn can be position at both the ground and platform
adjusted to obtain the loudest controls.
volume by turning the adjustment
2 Press down the foot switch and attempt to start
screw near the wire terminals on
the engine by moving the start toggle switch to
the horn.
either side.
Result: The engine should not start.
3 Do not press down the foot switch and attempt
to start the engine.
Result: The engine should start.
4 Do not press down the foot switch. Check the
machine functions.
Result: The machine functions should not
operate.
5 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.

TABLE B PROCEDURES
B-18 3 Release the function enable toggle switch.

Test the Engine Idle Select Result: The engine should return to low idle.
A properly operating engine idle select switch 4 Turn the key switch to platform controls.
is essential to good engine performance and safe 5 At the platform controls, move the engine idle
machine operation. There are three settings. control switch to high idle (rabbit symbol). Do
Low idle (turtle symbol) allows the operator to not press down the footswitch.
control individual boom functions only. Drive Result: The engine should change to high idle.
functions do not operate at low idle.
6 Move the engine idle control switch to low idle
High idle (rabbit symbol) allows the operator (turtle symbol).
to control multiple boom and/or drive functions
simultaneously. This setting maintains a Result: The engine should change to low idle.
consistent high idle and is usually selected only 7 Move the engine idle control switch to foot
when the generator option is being used. switch activated high idle (rabbit and foot switch
symbol).
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal Result: The engine should not change to
machine operation. This selection activates high high idle.
idle only when the foot switch is pressed down.
8 Press down the foot switch.
1 Pull out the Emergency Stop button to the
Result: The engine should change to high idle.
ON position at both the ground and platform
controls.
2 Start the engine from the ground controls then
move the function enable toggle switch to the
high idle (rabbit symbol) position and hold in the
ON position.
Result: The engine should change to high idle.

TABLE B PROCEDURES
B-19 3 Press down the foot switch to allow the engine

to run at high idle.
Test the Fuel Select Operation -
Result: The engine should start promptly and
Ford Models operate smoothly in low and high idle.
The ability to select and switch between 4 Release the foot switch and shut the engine off
gasoline and LPG fuels as needed is essential to by pushing the Emergency Stop button in to the
safe machine operation. A fuel selection can be OFF position.
made when the engine is running or not.
Switching malfunctions and/or the failure of the 5 Move the fuel select switch to LPG.
engine to start and run properly in both fuel
6 Restart the engine and allow it to run at
modes and through all idle speeds can indicate
low idle.
fuel system problems that could develop into a
hazardous situation. 7 Press down the foot switch to allow the engine
to run at high idle.
Perform this test after checking
the gasoline and LPG fuel levels, Result: The engine should start promptly and
and warming the engine to normal operate smoothly in low and high idle.
operating temperature. The engine may hesitate
1 Move the fuel select switch to gasoline and then momentarily and then continue
move the engine idle control switch to foot to run on the selected fuel if the
switch activated high idle (rabbit and foot switch fuel source is switched while
symbol). the engine is running.
2 Start the engine from the platform controls and

allow it to run at low idle.

TABLE B PROCEDURES
B-20 4 Hold the drive enable toggle switch to either

side and slowly move the drive control handle
Test the Drive Enable System off center.
Proper drive enable system operation is
essential to safe machine operation. When the
boom is past the non-steering wheels, drive
movement is stopped and the indicator light turns
on. The drive enable switch must be to either side
to reactivate the drive function and should inform
the operator that the machine will move in the Collsion hazard. Always use the
opposite direction that the drive and steer controls color-coded direction arrows on
are moved. An improperly functioning drive enable the platform control panel and the
system may allow the machine to be moved into drive chassis to identify which
an unsafe position. direction the machine will travel.
1 Start the engine from the platform controls. Result: The drive function should operate.
2 Rotate the turntable to the right until the boom is 5 Rotate the turntable to the left until the boom is
past the right non-steering wheel. past the left non-steering wheel.
Result: The drive enable indicator light should Result: The drive enable indicator light should
turn on. come on.
3 Slowly move the drive control handle off center. 6 Repeat steps 3 and 4.
Result: The drive function should not operate.

TABLE B PROCEDURES
B-21 5 Bring the machine to top drive speed before

reaching the test line. Release the drive joystick
Test the Drive Brakes when your reference point on the machine
crosses the test line.
6 Measure the distance between the test line and
your machine reference point.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Braking:
paved surface 4WD
noise. Hydrostatic brakes and hydraulically-
released individual wheel brakes can appear to
Stopping distance 3 to 6 ft
operate normally when they are actually not fully 0.9 to 1.8 m
operational.
Collision hazard. Be sure that the

machine is not in free-wheel or The brakes must be able to hold
partial free-wheel configuration. the machine on any slope it is able
Refer to B-8 in this section, to climb.
Confirm the Proper Brake
Configuration.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and
foot switch), then lower the boom into the
stowed position.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.

TABLE B PROCEDURES
B-22 5 Bring the machine to top drive speed before

reaching the start line. Begin timing when your
Test the Drive Speed - reference point on the machine crosses the
Stowed Position start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
Proper drive function movement is essential to
safe machine operation. The drive function should Drive speed, maximum
respond quickly and smoothly to operator control. stowed position
Drive performance should also be free of
hesitation, jerking and unusual noise over the All models 40 ft / 5.7 sec
entire proportionally controlled speed range. 12.2 m / 5.7 sec

1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and foot
switch), then lower the boom into the stowed
position.
4 Choose a point on the machine; i.e., contact
when crossing the start and finish lines.

TABLE B PROCEDURES
B-23 8 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line.
Raised or Extended Position 9 Move the lift/drive select switch to the lift
10 Press down the foot switch and lower the boom
to the stowed position.
Proper drive function movement is essential to
safe machine operation. The drive function should 11 Extend the boom 1 foot (30 cm).
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range. 13 Choose a point on the machine; i.e., contact
when crossing the start and finish lines.
14 Bring the machine to top drive speed before
1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
reference point on the machine crosses the
2 Start the engine from the platform controls. start line.
3 Move the lift/drive select switch to the lift 15 Continue at top speed and note the time when
position (if equipped). the machine reference point crosses the finish
line.
4 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch).
Press down the foot switch and raise the boom
raised or extended, 1 km/h
above horizontal. Standard Base Models 40 ft/45 sec
5 Move the lift/drive select switch to the drive 12.2 m/45 sec
6 Choose a point on the machine; i.e., contact raised or extended, 0.58 km/h
patch of a tire, as a visual reference for use Narrow Base Models 40 ft/79 sec
when crossing the start and finish lines. 12.2 m/79 sec
7 Bring the machine to top drive speed before

reference point on the machine crosses the
start line.

TABLE B PROCEDURES
B-24 3 Move the function enable switch to either side

and activate the secondary boom toggle switch
Test the Alarm Package - in the DOWN position, hold for a moment and
Optional Equipment then release it.
The alarm package includes: Result: The descent alarm should sound when
the switch is held down.
· Travel alarm
4 Turn the key switch to platform control.
· Descent alarm
· Flashing beacon Result: The flashing beacon should be ON
and flashing.
Alarms and a beacon are installed to alert
operators and ground personnel of machine 5 Press down the foot switch. Move the primary
proximity and motion. The alarm package is boom control handle to the DOWN position, hold
installed on the turntable covers. for a moment and then release it.
The alarms and beacon will Result: The descent alarm should sound when
operate with the engine the control handle is held down.
running or not running. 6 Press down the foot switch. Move the
1 Turn the key switch to ground control and pull secondary boom control handle to the DOWN
out the Emergency Stop button to the ON position, hold for a moment and then release it.
position at both the ground and platform Result: The descent alarm should sound when
controls. the control handle is held down.
Result: The flashing beacon should be ON and 7 Press down the foot switch. Move the drive
flashing. control handle off center, hold for a moment
2 Move the function enable switch to either side and then release it. Move the drive control
and activate the primary boom toggle switch in handle off center in the opposite direction, hold
the DOWN position, hold for a moment and then for a moment and then release it.
release it. Result: The travel alarm should sound when the
Result: The descent alarm should sound when drive control handle is moved off center in
the switch is held down. either direction.

TABLE B PROCEDURES
B-25 B-26
Perform Hydraulic Oil Analysis Replace the Hydraulic Tank
Return Filter
See E-1, Test or Replace the Hydraulic Oil.

Genie requires that this procedure
be performed quarterly or every
250 hours, whichever comes first.
Perform this procedure more often
if dusty conditions exist.
Replacement of the hydraulic tank filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Burn hazard. Beware of hot oil.

Contact with hot oil may result in
severe burns.
engine off.
the hydraulic return filter on the bulkhead.
2 Remove the filter with an oil filter wrench.
3 Apply a thin layer of oil to the new oil filter
gasket.
4 Install the new filter (Genie part number 65540)
and tighten it securely by hand. Clean up any
oil that may have spilled during the installation
procedure.
5 Start the engine from the ground controls.
6 Inspect the filter and related components to
be sure that there are no leaks.

TABLE B PROCEDURES
B-27 3 Loosen the vent plug located on the fuel filter/

water separator head.
Replace the Fuel Filter/ Water
Separator Element -
a
Perkins Diesel Models
f
e b
Replacing the diesel fuel filter/water separator

d
element is essential for good engine performance
and service life. A dirty or clogged filter may cause c
the engine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Fuel filter/water separator
Explosion and fire hazard. Engine a vent plug
fuels are combustible. Perform this b main fuel line
procedure in an open, well- c drain plug
ventilated area away from heaters, d filter bowl
e filter element
sparks, flames and lighted f separator head
easy reach. 4 Place a suitable container under the filter bowl.
Loosen the drain plug located at the bottom of
Perform this procedure with the the bowl. Completely drain the fuel.
engine off.
5 Rotate the filter bowl counterclockwise and
1 Open the engine side turntable cover and locate remove it from the element.
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead. 6 Rotate the filter element counterclockwise and
remove it from the filter head.
2 Disconnect and plug the fuel supply hose from
the fuel tank to the fuel filter/water separator. 7 Install the bowl onto the new filter element
(Genie part number 22942).
8 Apply a thin layer of oil onto the element gasket.
Install the filter/bowl assembly onto the filter
head. Tighten the drain plug.
10 Tighten the vent plug.

TABLE B PROCEDURES
11 Clean up any diesel fuel that may have spilled 16 Operate the starter motor for intervals of 15
during the installation procedure. seconds until the engine starts.
12 Install the fuel supply hose from the fuel tank to It is important to allow the starter
the fuel filter/water separator. Tighten the motor to cool for 30 seconds
clamp. between each 15 second interval
of operation.
Bleed the system:
If the engine runs correctly for a
13 Loosen the vent plug on top of the fuel injection
short time and then stops or runs
pump.
roughly, check for air in the fuel
system. If there is air in the fuel
system, there is probably a leak in
the low pressure side of the
a system.
c b
a vent plug
b fuel injection pump
c fuel lift pump
14 Operate the priming lever or priming bulb (if

equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug.
15 Clean up any fuel that may have spilled during
this procedure.

TABLE B PROCEDURES
B-28 2 Open the engine pivot plate latch and swing the
Replace the Fuel Filter Element - machine.
Perkins Diesel Models 3 Thoroughly clean the outside surfaces of the
fuel filter assembly.
4 Place a suitable container under the fuel filter
Replacing the diesel fuel filter element is essential element.
for good engine performance and service life. A 5 Disconnect and plug the fuel line from the fuel
dirty or clogged filter may cause the engine to pump to the fuel filter element.
perform poorly and continued use may cause
component damage. Extremely dirty conditions 6 Remove the fuel filter element with a filter
may required that the filter be replaced more often. wrench.
Explosion and fire hazard. Engine 7 Apply a thin layer of fuel to the new fuel filter
fuels are combustible. Perform this element o-ring.
procedure in an open, well- 8 Install the new fuel filter element (Genie part
ventilated area away from heaters, number 65542) and tighten it securely by hand.
sparks, flames and lighted Clean up any fuel that may have spilled during
tobacco. Always have an the installation procedure.
easy reach.
Perform this procedure with the a
engine off.
b
1 Remove the safety pin from the engine pivot
c
plate latch.
end of the machine.
a fuel line
b filter head
c fuel filter element

TABLE B PROCEDURES
Bleed the system: B-29

9 Loosen the vent plug on top of the fuel injection Replace the Spark Plugs -
pump.
Ford Models
a
Engine specifications requires that
c b this procedure be performed every
400 hours.
Periodic replacement of the spark plugs is
essential to good engine performance and
service life. Worn, loose or corroded spark plugs
will cause the engine to perform poorly and may
result in component damage.
a vent plug engine off.
b fuel injection pump
c fuel lift pump 1 Remove the safety pin (if equipped) from the
10 Operate the priming lever or priming bulb (if
equipped) of the fuel lift pump until fuel, free The engine pivot plate latch is
from air, comes from the vent plug. located under the engine turntable
11 Clean up any fuel that may have spilled during end of the machine.
this procedure.
12 Operate the starter motor for intervals of 15 engine pivot plate out and away from the
seconds until the engine starts. machine.
It is important to allow the starter 3 Label, then disconnect the plug wires from the
motor to cool for 30 seconds spark plugs by grasping the handle on the
between each 15 second interval spark plug boot. Do not pull on the plug wire.
of operation.
If the engine runs correctly for a
short time and then stops or runs
roughly, check for air in the fuel
system. If there is air in the fuel
system, there is probably a leak in
the low pressure side of the
system.

TABLE B PROCEDURES
4 Blow out any debris around spark plugs. B-30

5 Remove all the spark plugs from the engine. Replace the Engine Air Filter
6 Adjust the gap on each new spark plug. Element
7 Install the new spark plugs and torque to
specifications.
8 Connect the wires. Be sure that each spark plug Engine specifications requires that
wire is attached to the correct spark plug. this procedure be performed every
9 Swing the engine back to its original position 400 hours or annually, whichever
and close the engine pivot plate latch. comes first. Perform this
procedure more often if dusty
10 Install the engine pivot plate safety pin conditions exist.
(if equipped).
Maintaining the engine air filter in good condition is
essential to good engine performance and service
Spark plug specifications
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Spark plug type Motorcraft AWSF-52C
Spark plug gap 0.042 to 0.046 inch engine off.
1.07 to 1.18 mm
All Models:
Spark plug torque 5 to 10 ft-lbs
7 to 14 Nm 1 Remove the safety pin (if equipped) from the
end of the machine.
machine.
3 Open the engine side cover and remove the
retaining ring from the end cap of the air filter
canister.

TABLE B PROCEDURES
4 Remove the end cap from the air cleaner

canister.
5 Remove the air filter retaining fastener. Remove
the filter element.
6 Clean the inside of the canister and the gasket
with a damp cloth.
7 Install the new air filter element and install the
mounting fastener.
8 Install the end cap onto the canister. Install and
tighten the retaining ring.
(if equipped).
Air filters - Genie part numbers

All Models 27916

Table C Procedures
C-1 4 Remove the front engine access cover
mounting fasteners.
Check the Engine Belt -
5 Inspect the engine belt for:
Deutz Diesel Models
· Cracking
· Glazing
· Separation
Engine specifications require that
· Breaks
this procedure be performed every
500 hours. 6 Replace belt if any damage is found.
Maintaining the engine belt is essential to good 7 Check the engine belt for proper tension. Adjust
engine performance and service life. The machine as necessary.
belt and continued use may cause component
damage.
inspect while the engine is
engine components. Contact with Deutz Diesel engine
in severe burns. 8 Install the front engine access cover.
1 Remove the safety pin (if equipped) from the 9 Replace the air baffle and install the air baffle
engine pivot plate latch . retaining fasteners.
The engine pivot plate latch is 10 Swing the engine back to its original position
located under the engine turntable and close the engine pivot plate latch.
end of the machine.
(if equipped).
engine pivot plate out and away from the Belt deflection - 3 /8
inch to 1/2 inch
machine. 9.5 mm to 12 mm
3 Remove the air baffle retaining fasteners. Engine belt - Genie part number 32698
Remove the air baffle.

TABLE C PROCEDURES
C-2 2 Open the engine pivot plate latch and swing the
Replace the Engine Oil and machine.
Filter - Deutz Diesel Models 3 Remove the oil filler cap located above the
dipstick.
4 Pull the end of the oil drain hose out from under
Engine specifications require the engine.
that this procedure be performed 5 Remove the plug from the drain hose and allow
every 500 hours. Perform this all of the oil from the engine to drain into a
procedure more often if dusty suitable container. See capacity specifications.
conditions exist or if the machine
is operated in hot climates. 6 Install the plug on the oil drain hose.
Periodic replacement of the engine oil and 7 Place a pan under the oil filter.
filter is essential to good engine performance. 8 Use an oil filter wrench and remove the oil filter.
Operating the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A frequent check
of elapsed machine hours against the hours a
noted on the oil filter will allow the inspector to
anticipate and perform oil and filter changes at
the 500 hour interval.
Burn hazard. Beware of hot c

engine parts and oil. Contact with b
hot engine oil and/or engine parts
may result in severe burns.
Perform this procedure after
warming the engine to normal a engine oil level dipstick
operating temperature. b fuel filter/water separator
c oil filter
engine pivot plate latch. 9 Apply a thin layer of oil to the new oil filter
gasket (Genie part number 49924). Install the
The engine pivot plate latch is filter and tighten it securely by hand.
pivot plate at the counterweight 10 Use a permanent ink marker to write the date
end of the machine. and number of hours from the hour meter on
the oil filter.

TABLE C PROCEDURES
11 Fill the engine with new oil per specifications C-3

and install the oil filler cap.
Check the Engine Valve
12 Start the engine from the ground controls. Allow
the engine to run for 30 seconds then turn the
Clearances -
engine off. Deutz Diesel Models
13 Check the oil filter and oil drain hose for leaks.
14 Check the engine oil level dipstick. Add oil if
needed. Engine specifications require
that this procedure be performed
Deutz Engine F3L 1011F 6.3 quarts initially at 500 hours, at 1000
Oil capacity (including filter) 6 liters hours and every 1000 hours
thereafter.
Complete information to perform this procedure is
Temperature below 60°F / 15.5°C (synthetic) 5W-30 available in the Deutz F3L 1011F Operation
Manual, Deutz part number 0297 7343
-10°F to 90°F / -23°C to 32°C 10W-40 (Genie part number 52883).
Temperature above -4°F / -34°C 15W-40

CC/SE, CD/SE, CC/SF or CD/SF grades.
Units shipped with 10-40 CC/SG
Oil filter - Genie part number 49924

TABLE C PROCEDURES
C-4 2 Open the engine pivot plate latch and swing the
Change or Recondition the machine.
Engine Coolant - 3 Put on protective clothing and eye wear.
Liquid Cooled Models
4 Disconnect the coolant return hose at the
radiator and drain the coolant return tank into a
suitable container.
Engine specifications require 5 Slowly remove the radiator cap from the
that this procedure be performed radiator.
every 500 hours or 6 months, Bodily injury hazard. Allow any
whichever comes first. pressure to dissipate gradually
Replacing or reconditioning the engine coolant is before removing the radiator cap.
essential to good engine performance and service 6 Open the drain valve on the radiator and allow
life. Old or dirty coolant may cause the engine to all the coolant to drain into a suitable container.
engine damage. Extremely dirty conditions may 7 After all the coolant has drained, close the drain
require coolant to be changed more frequently. valve and connect the coolant return hose to
the radiator.
8 Open the drain valve on the engine block and
engine parts and coolant. Contact
allow the coolant to drain into a suitable
with hot engine parts and/or
container. After the fluid is drained, close the
coolant may result in severe
drain valve.
burns.
9 Replace all coolant hoses and clamps.
engine off and cooled. 10 Fill the radiator with the proper coolant mixture
(coolant and water) for your climate until it is
full.
11 Fill the coolant return tank to the NORMAL range.
end of the machine.

TABLE C PROCEDURES
12 Clean up any coolant that may have spilled C-5

during this procedure.
Check the Engine Valve
let it run for 30 seconds. Turn the engine off
Clearances -
and inspect for leaks. Perkins Diesel Models
14 Check the coolant level in the coolant return
tank. Add coolant if needed.
15 Swing the engine back to its original position Engine specifications require
and close the engine pivot plate latch. that this procedure be performed
16 Install the engine pivot plate safety pin every 600 hours.
(if equipped). Complete information to perform this procedure is
17 Start the engine from the ground controls available in the Perkins Workshop Manual,
and let it run until it reaches normal operating Perkins part number TPD 1378
temperature. (Genie part number 72352).
18 Turn the engine off. Allow the engine to cool.

19 Check the coolant level in the coolant return
tank. Add coolant if needed.
Coolant capacity
Ford Gasoline/LPG Engine 11.5 quarts 10.9 liters
Perkins 104-22 Engine 6.3 quarts 6 liters

TABLE C PROCEDURES
C-6 4 Locate the PCV valve on the engine under the

intake manifold. Detach the hose from the PCV
Replace the PCV Valve - valve.
Ford Models
Engine specifications require a

that this procedure be performed
every 800 hours. b
Replacement of the PCV valve is essential to good

engine performance. A malfunctioning PCV valve
can impair crankcase ventilation and may cause
engine damage.
a PCV valve
Perform this procedure with the b PCV valve hose
engine off.
5 Remove the PCV valve from the engine.
1 Open the engine side turntable cover. Discard the valve.
2 Remove the safety pin (if equipped) from the 6 Thoroughly clean the inside and outside of the
engine pivot plate latch. hose, tubes and fittings.
The engine pivot plate latch is 7 Install the new PCV valve and connect the
located under the engine turntable hose.
end of the machine.
(if equipped).
machine.
PCV Valve - Genie part number 33957

Table D Procedures
D-1 4 Extend and retract the primary boom through
the entire range of motion to check for tight
Check the Boom spots that may cause binding or scraping of the
Wear Pads boom.
Always maintain squareness
between the outer and inner
boom tubes.
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads Wear pad specifications
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving All wear pads 9/16 inch
parts. Improperly shimmed wear pads or continued 14.3 mm

use of worn out wear pads may result in
component damage and unsafe operating
conditions.
If the wear pads are not worn
below specification but are still
within tolerence, see Repair
Procedure 4-2, How to Shim the
Primary Boom.
1 Start the engine from the ground controls.
2 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot (30 cm).
3 Measure each wear pad. Replace the wear pad
if it is less than 9/16 inch. If the wear pad is not
less than 9/16 inch, shim as necessary to obtain
zero clearance and zero drag.

TABLE D PROCEDURES
D-2 5 Be sure that each turntable mounting bolt is

torqued in sequence to 210 ft-lbs (285 Nm).
Check the Turntable Rotation
Bearing Bolts
Maintaining proper torque on the turntable bearing

bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the secondary boom and place safety
chocks on the lift cylinders rods. Carefully lower
the boom onto the lift cylinders safety chocks. Bolt torque sequence
Crushing hazard. Keep hands
away from cylinders and all
moving parts when lowering the 6 Start the engine form the ground controls.
boom.
7 Rais the secondary boom and remove the
The lift cylinder safety chock is safety chocks.
available through
8 Lower the boom to the stowed position.
9 Remove drive chassis covers from both the
2 Turn the engine off.
steer end and the non-steer end of the
3 Remove the safety pin (if equipped) from the machine.
10 Remove the lower chassis cover mounting
The engine pivot plate latch is fasteners from inside of the drive chassis.
end of the machine.
machine.

TABLE D PROCEDURES
11 Remove the lower chassis cover to access the D-3

lower turntable bearing bolts under the drive
chassis. Check the Free-wheel
12 Check to ensure that each lower bearing
Configuration
mounting bolt under the drive chassis is
torqued in sequence to 210 ft-lbs
(285 Nm).
Proper use of the free-wheel configuration is
essential to safe machine operation. The
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.
Collision hazard. Select a work
site that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph (3.2 km/h).
Bolt torque sequence Non-Steer Wheels: All Models
1 Chock the steer wheels to prevent the machine

from rolling.
2 Center a lifting jack of ample capacity
(20,000 lbs/10,000 kg) under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.

TABLE D PROCEDURES
4 Disengage the drive hubs by turning over the Steer Wheels: 4WD Models
drive hub disconnect caps on each
non-steer wheel hub. 7 Chock the non-steer wheels to prevent the
machine from rolling.
disengage position
8 Center a lifting jack of ample capacity
(20,000 lbs/10,000 kg) under the drive chassis
between the steer tires.
engage position 9 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
5 Manually rotate each non-steering wheel.
10 Disengage the drive hubs by turning over the
Result: Each non-steering wheel should rotate drive hub disconnect caps on each
with minimum effort. steer wheel hub.
disengage position
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Collision hazard. Failure to engage position
re-engage the drive hubs may
cause death or serious injury and 11 Manually rotate each steer wheel.
property damage. Result: Each steer wheel should rotate with
minimum effort.

TABLE D PROCEDURES
12 Re-engage the drive hubs by turning over D-4

the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine and Grease the Turntable Rotation
remove the jack stands. Bearing and Rotate Gear
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage. Yearly application of lubrication to the turntable
bearing and rotate gear is essential to good
All Models:
machine performance and service life. Continued
13 Be sure the free-wheel valve on the drive pump use of an improperly greased bearing and gear will
is closed (clockwise). result in component damage.
The free-wheel valve is located on 1 Locate the grease fitting on the front turntable
the side of the drive pump. cover.
a b
a drive pump
b free-wheel valve
c lift pump a b c
d screwdriver
The free-wheel valve should a turntable bearing grease fitting

always remain closed. b front turntable cover
c power to platform plug
2 Pump grease into the turntable rotation bearing.

Rotate the turntable in increments of 4 to 5
inches (10 to 13 cm) at a time and repeat this
step until the entire bearing has been greased.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Grease type Multipurpose grease

TABLE D PROCEDURES
D-5 4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Replace the Drive Hub Oil Apply pipe thread sealant to the plugs, and then
install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
Oil capacity per hub 17 fl oz
replace the drive hub oil at yearly intervals may
0.5 liters
cause the machine to perform poorly and
continued use may cause component damage. Type: SAE 90 multipurpose hypoid gear oil - API
service classification GL5
Drive Hubs:
1 Select the drive hub to be serviced. Then drive

the machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.

TABLE D PROCEDURES
D-6 3 Remove the filter element from the housing.

Replace the Drive Loop 4 Inspect the housing seal and replace it if
necessary.
Hydraulic Filter
5 Install the new filter (Genie part number 20880)
and tighten the housing onto the filter securly
head by hand. Clean up any oil that may have
Replacing the drive loop hydraulic filter is essential spilled during the installation procedure.
to good machine performance and service life. A 6 Start the engine from the ground controls.
dirty or clogged filter may cause the machine to
perform poorly and continued use may cause 7 Inspect the filter assembly to be sure that there
component damage. Extremely dirty conditions are no leaks.
may require that the filter be replaced more often. 8 Clean up any oil that may have spilled during
the installation procedure.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
engine off.
the drive loop hydraulic filter mounted near the
pump.
2 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.

TABLE D PROCEDURES
D-7 4 Load the system by activating the primary boom

retract function, then move the function enable
Check and Adjust the Air/LPG toggle switch to the high idle (rabbit symbol)
Mixture - Ford Models position.
5 Adjust the high idle adjustment screw to obtain
an air-to-fuel mixture ratio of 13.0:1 to 13.2:1,
using an exhaust gas analyzer.
Maintaining the proper air-to-fuel mixture during
Preliminary setting is 1/4 inch
LPG operation is essential to good engine
(6.4mm) of threads showing.
performance.
Measure from top of lock nut to
Explosion and fire hazard. Engine top of adjustment screw.
fuels are combustible. Perform this If an exhaust gas analyzer is not
procedure in an open, well- available, adjust to obtain peak or
ventilated area away from heaters, optimum rpm.
tobacco. Always have an 6 Hold the adjustment screw and tighten the
approved fire extinguisher within lock nut.
easy reach.
7 Return the function enable toggle switch to the
The engine should be warmed to center position.
normal operating temperature
8 Locate the low idle mixture adjustment screw on
before performing this procedure.
the LPG regulator.
1 Move the fuel select toggle switch to LPG fuel
9 Adjust the low idle mixture adjustment screw to
and start the engine from the ground controls.
obtain an air-to-fuel mixture ratio of 13.0:1 to
2 Locate the high idle mixture adjustment 13.2:1.
screw on the throttle body elbow that attaches
Preliminary setting: turn low idle
to the air cleaner.
adjustment screw clockwise all the
3 Loosen the lock nut on the high idle mixture way in. Turn low idle adjustment
adjustment screw. screw counterclockwise 2 3/4
turns.

TABLE D PROCEDURES
D-8 2 Open the engine pivot plate latch and swing the
Replace the Diesel Fuel machine.
Filter/Water Separator - Deutz 3 At the fuel pump, disconnect and plug the fuel
Diesel Models hose that goes to the fuel tank.
4 Remove the fuel filter with a filter wrench.
Replacing the diesel fuel filter/water separator is

life. A dirty or clogged filter may cause the engine
to perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the filter be replaced more often. a
b
fuel filter in an open, well-
tobacco. Always have an a oil filter
approved fire extinguisher within b fuel filter/water separator
easy reach.
Prime the Fuel Pump:
engine off. 5 Fill the new filter (Genie part number 65541)
with fresh diesel fuel and apply a thin layer of oil
1 Remove the safety pin (if equipped) from the or diesel fuel to the new fuel filter gasket.
6 Install the new filter and tighten it securely by
The engine pivot plate latch is hand. Clean up any diesel fuel that might have
located under the engine turntable spilled during the procedure.
end of the machine. 7 Connect the fuel hose from the tank to the fuel
pump.
8 Start the engine from the ground controls, then
inspect the fuel filter for leaks.
additional personnel from entering
immediately.

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

essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes open closed
to be performed more often.
Component damage hazard. The
The machine uses Dexron engine must not be started with
equivalent hydraulic oil. Before the hydraulic tank shutoff valves in
replacing the hydraulic oil, the oil the CLOSED position or component
may be tested by an oil distributor damage will occur. If the tank
for specific levels of contamination valves are closed, remove the key
to verify that changing the oil is from the key switch and tag the
necessary. If the hydraulic oil is machine to inform personnel of the
not replaced at the two year condition.
inspection, test the oil quarterly.
4 Place a suitable container underneath the
Replace the oil when it fails the
hydraulic tank.
test.
5 Remove the drain plug from the hydraulic tank.
boom in the stowed position. 6 Completely drain the tank into a suitable
container. See capacity specifications.
1 Ford models: Turn the valve on the LPG tank
clockwise to the OFF position. Then slowly 7 Tag, disconnect and plug the two suction hoses
disconnect the hose from the LPG tank. that are attached to the hydraulic tank
shutoff valves.
2 Ford models: Open the clamps from the LPG
tank straps and remove the LPG tank from the 8 Disconnect and plug the return filter hydraulic
machine. hose at the hydraulic tank. Cap the fitting on the
tank.

TABLE E PROCEDURES
9 Disconnect and plug the supply hose for the 18 Install the hydraulic tank onto the machine.
auxiliary power unit through the access hole
19 Install the two suction hoses to the suction
underneath the turntable. Cap the fitting on the
strainers.
hydraulic tank.
20 Install the supply hose for the auxiliary power
10 Remove the ground controls side turntable
unit and the return filter hose.
cover. See Repair Procedure 6-1, How to
Remove a Turntable Cover. 21 Fill the tank with hydraulic oil until the level is
within the top 2 inches (5 cm) of the sight
11 Support the hydraulic tank with an appropriate
gauge. Do not overfill.
lifting device.
22 Clean up any oil that may have spilled and open
12 Remove the hydraulic tank mounting fasteners.
the hydraulic tank valves.
13 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank may become unbalanced and
fall if it is not properly supported
by the lifting device.
14 Remove the suction strainers from the tank and
clean them using a mild solvent.
15 Rinse out the inside of the tank using a mild
solvent.
16 Install the suction strainers using a thread
sealant on the threads.
17 Install the drain plug using a thread sealant on
the threads.

TABLE E PROCEDURES
23 Prime the pump. See Repair Procedure 11-2, E-2

How to Prime the Pump.
Change or Recondition the
Component damage hazard. Be
sure that the hydraulic tank shutoff
Engine Coolant -
valves are in the OPEN position Ford Models
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
the CLOSED position or component
Replacing or reconditioning the engine coolant is
damage will occur. If the tank
valves are closed, remove the key
life. Old or dirty coolant may cause the engine to
from the key switch and tag the
machine to inform personnel of the
engine damage. Extremely dirty conditions may
condition.
require coolant to be changed more frequently.
Always use pipe thread sealant
when installing the suction hose Burn hazard. Beware of hot
fittings and the drain plug. engine parts and coolant. Contact
with hot engine parts and/or
Use only Dexron equivalent coolant may result in severe
hydraulic fluid. burns.
Hydraulic system
engine off and cooled.
Hydraulic tank capacity 24 gallons 1 Put on protective clothing and eye wear.
91 liters
Hydraulic system 30 gallons engine pivot plate latch.
capacity (including tank) 114 liters
Hydraulic fluid Dexron equivalent
end of the machine.
machine.

TABLE E PROCEDURES
4 Disconnect the coolant return hose at the 13 Swing the engine back to its original position
radiator and drain the coolant return tank into a and close the engine pivot plate latch.
suitable container.
5 Slowly remove the radiator cap from the (if equipped).
radiator.
15 Start the engine from the ground controls,
Bodily injury hazard. Allow any run it for 30 seconds, and then turn it off.
pressure to dissipate gradually
16 Inspect for leaks and then check the fluid
before removing the radiator cap.
level in the coolant return tank. Add
6 Open the drain valve on the radiator and allow water if needed.
all the coolant to drain into a suitable container.
17 Start the engine from the ground controls
7 After all the coolant has drained, close the drain and let it run until it reaches normal operating
valve. Connect the coolant return hose to temperature.
the radiator.
18 Turn the engine off.
8 Open the drain valve on the engine block and
19 Allow engine to cool and check the fluid level in
allow the coolant to drain into a container.
the coolant retrun tank. Add water if needed.
After the fluid is drained, close the drain valve.
9 Replace all coolant hoses and clamps. Coolant capacity 11.5 quarts
10.9 liters
10 Pour the proper coolant mixture (anti-freeze and
water) for your climate into the radiator until it is
full.
11 Fill the radiator and then fill the coolant return
tank to the NORMAL range.
12 Clean up any coolant spilled during this
procedure.

TABLE E PROCEDURES
E-3 2 Open the engine pivot plate latch and swing the
Change the Fuel Hoses machine.
3 Place a suitable container underneath the
engine pivot plate.
Maintaining the fuel hoses in good condition is 4 Ford Models: At the pre-filter, disconnect the
essential to safe operation and good engine fuel hose to the fuel tank and drain the fuel
performance. Failure to detect a worn, cracked or tank into the container.
leaking fuel hose may cause an unsafe operating
condition. a b c

fuel hoses in an open, well-
easy reach.
Component damage hazard. Be
sure the fuel hoses are routed the
same way the original hoses were.
e d
engine off and the key switch in
the OFF position.
a hose from fuel pump to regulator/filter
1 Remove the safety pin (if equipped) from the b hose from fuel pre-filter to fuel pump
c hose from fuel tank to fuel pre-filter
engine pivot plate latch. d hose from regulator/filter to engine
e hose from regulator/filter to tank
end of the machine.

TABLE E PROCEDURES
Deutz Diesel Models: At the fuel pump, a b b b b b b b

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

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

TABLE E PROCEDURES
Explosion and fire hazard. 6 Clean up any fuel that may have spilled during
Electronic Fuel Injection (EFI) this procedure.
systems operate at a very high
pressure. Fuel may be expelled
under pressure if the hoses are
removed too quickly. Loosen the 8 Install the engine pivot plate safety pin
fuel lines very slowly to allow the (if equipped).
fuel pressure to dissipate
gradually. Wrap a cloth around 9 Start the engine from the ground controls, then
fuel hoses to absorb leaking fuel inspect the fuel filter and hoses for leaks.
before disconnecting them. Explosion and fire hazard. If a fuel
additional personnel from entering
a b c machine. Repair the leak
immediately.
e d
Ford models
a high pressure hose from fuel pump to
regulator/filter
b hose from fuel pre-filter to fuel pump
c hose from fuel tank to fuel pre-filter
d high pressure hose from regulator/
filter to engine
e hose from regulator/filter to tank

TABLE E PROCEDURES
E-4 E-7
Check the Toothed Belt - Check the Fuel Injection Pump
Deutz Diesel Models and Injectors - Deutz Diesel
Models

available in the Deutz FL 1011F Operation Manual Complete information to perform this procedure is
Deutz part number: 0297 4706 EN. available in the Deutz FL 1011F Workshop Manual
(Genie part number 29790). Deutz part number: 0297 7195.
E-5
Check the Engine Valve E-8
Clearance - Ford Models Replace the Timing Belt -
Ford Models

available in the Ford LRG-425 EFI 2.5 Liter Complete information to perform this procedure is
Industrial Engine Service Manual available in the Ford LRG-425 EFI 2.5 Liter
Ford number: FPP-194-303. Industrial Engine Service Manual
(Genie part number 52695). Ford part number: FPP-194-303.
E-6
Check the Engine Cylinder
Compression - Ford Models

available in the Ford LRG-425 EFI 2.5 Liter
Industrial Engine Service Manual
Ford number: FPP-194-303.

TABLE E PROCEDURES
E-9 Skip to step 10 if there is no movement.

Grease the Steer Axle 6 Remove the dust cap from the hub, then
remove the cotter pin from the castle nut.
Wheel Bearings, 2WD Models
7 Tighten the castle nut to 35 ft-lbs (47 Nm) to
seat the bearings.
8 Loosen the castle nut, then re-tighten to
Maintaining the steer axle wheel bearings is 8 ft-lbs (11 Nm).
essential for safe machine operation and service
9 Check for wheel bearing wear by attempting to
life. Operating the machine with loose or worn
move the wheel hub side to side, then up and
wheel bearings may cause an unsafe operating
down.
condition and continued use may result in
component damage. Extremely wet or dirty Result: If there is side to side or up and down
conditions or regular steam cleaning and pressure movement, continue to step 11 and replace the
washing of the machine may require that this wheel bearings with new ones.
procedure be performed more often.
When replacing a wheel bearing,
1 Loosen the wheel lug nuts. Do not remove both the inner and outer bearings,
them. including the pressed-in races,
must be replaced.
2 Block the non-steering wheels, then center a
lifting jack under the steer axle. Result: If there is no side to side or up and
down movement, continue with step 11 and
3 Raise the machine 6 inches (15 cm) and place
grease the wheel bearings.
blocks under the drive chassis for support.
10 Remove the dust cap from the hub, then
4 Remove the lug nuts, then remove the tire and
remove the cotter pin from the castle nut.
wheel assembly.
11 Remove the castle nut.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and 12 Pull the hub off of the spindle. The washer and
down. outer bearing should fall loose from the hub.
Result: There should be no side to side or up 13 Place the hub on a flat surface and gently pry
and down movement. the bearing seal out of the hub. Remove the
rear bearing.

TABLE E PROCEDURES
14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of the
hub.
16 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Always replace the bearing grease
seal when removing the hub.
17 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the slotted nut to 35 ft-lbs (47 Nm) to
seat the bearings.
21 Loosen the castle nut, then re-tighten to
8 ft-lbs (11 Nm).
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
125 ft-lbs (169.5 Nm).


First Edition • Second Printing Section 5 • Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie Z-45/25 and Genie Z-45/25J Operator’s
Manual.
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 appropiate flow chart 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:
Electrocution hazard. Contact
· Machine parked on a flat 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-steering wheels and other jewelry.
· Turntable secured with the turntable Bodily injury hazard. Spraying
rotation lock hydraulic oil can penetrate and
· Key switch in the OFF position with the burn skin. Loosen hydraulic
key removed connections very slowly to allow
the oil pressure to dissipate
· Wheels chocked
gradually. Do not allow oil to
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 • Troubleshooting Flow Charts First Edition • Second Printing
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.
Fault codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest
efficiency while at the same time keeping
exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code
in memory that relates to the appropriate sensor
and will turn on the Check Engine Light. See
Repair Section, How to Retrieve Engine Fault
Codes. Use the Fault Code Chart on the
following pages to aid in identifying the fault.

Fault Codes
Fault
Problem Cause Solution
Code
11 -- -- Normal operation.
Check for poor terminal

Faulty TP sensor OR sensor
Throttle Position (TP) connections or shorted wires
12 wires shorted shorted to ground
sensor low voltage. from the TP sensor to the ECM
or poor terminal connection.
OR replace the TP sensor.
Manifold Absolute Faulty MAP sensor OR sensor Check for poor terminal
14 Pressure (MAP) sensor wires shorted to ground or poor connections OR wires shorted to
low voltage. terminal connection. ground OR replace MAP sensor.
Check for obstructions in the

Engine speed exceeded Obstruction in throttle body OR throttle body that could cause
21
4000 RPM. faulty ECM. binding of the throttle assembly
OR replace ECM.
The ECM senses a signal from

the TP sensor that is greater
than 4.9V DC OR the TP
Throttle Position (TP) connections or shorted wires
22 sensor wiring is shorted to
sensor high voltage. from the TP sensor to the ECM
ground OR there is a poor
OR replace the TP sensor.
terminal connection OR the TP
sensor is bad.

Manifold Absolute Faulty MAP sensor OR sensor connections or shorted wires
24 Pressure (MAP) sensor wires shorted to ground or poor from the MAP sensor to the
high voltage. terminal connection. ECM to ground OR replace MAP
sensor.
Test the fuel pump relay, see the

Voltage to fuel pump is greater Repair Section OR check for
31 Fuel pump low voltage. than or equal to poor terminal connection from
2V DC below ignition voltage. the fuel pump relay to fuel pump
OR replace the fuel pump.
Check for water in the fuel,

Water in the fuel, misfiring
misfiring cylinder or pugged fuel
cylinder, plugged fuel filter OR
filter OR check for poor terminal
Heated Oxygen (HO2) the HO2 sensor wiring is
32 connections or shorted wires
sensor low voltage. shorted to ground OR there is a
from the HO2 sensor to the ECM
poor terminal connection OR
to ground OR replace HO2
the HO2 sensor is bad.
sensor.
Check engine coolant level OR

Engine is overheating OR
Engine Coolant check for shorted wires or poor
sensor wires shorted to ground
33 Temperature (ECT) terminal connections from the
or poor terminal connections
sensor high voltage. ECT sensor to the ECM OR
OR ECT sensor is bad
replace the ECT sensor.

FAULT CODES
Fault
Code
IAT sensor signal is greater
connections or shorted wires
Intake Air Temperature than or equal to
35 from the IAT sensor to the ECM
(IAT) sensor high voltage. 4.93V DC for at least 3
to ground OR replace IAT
seconds.
sensor.
Test the fuel pump relay, see the

Fuel pump is receiving voltage
Repair Section OR check for
when the ECM is not sending
41 Fuel pump high voltage. poor terminal connections from
the signal to the fuel pump to
the fuel pump relay to fuel pump
turn ON.
OR replace the ECM.
Test for a leaking or

A leaking or malfunctioning fuel
malfunctioning fuel injector,
injector, misfiring cylinder, faulty
misfiring cylinder or bad TP
TP sensor or contamination
sensor. Remove HO2 sensor and
from fuel OR use of improper
Heated Oxygen (HO2) check condition of sensor for
42 thread sealant on sensor
sensor high voltage. contamination OR check for poor
threads OR sensor wires
terminal connections or shorted
shorted to ground or poor
2 wires from the HO2 sensor to the
terminal connections OR HO
ECM to ground OR replace HO2
sensor is bad.
sensor.
Check engine coolant level OR

Engine Coolant ECM detects a excessively low check for shorted wires or poor
43 Temperature (ECT) signal voltage from the ECT terminal connections from the
sensor low voltage. sensor. ECT sensor to the ECM OR
replace the ECT sensor.
The IAT sensor shares the same

ground wire as the ECT and
MAP sensors. Check for shorted
ECM detects a excessively low
Intake Air Temperature wires or poor terminal
45 signal voltage from the IAT
(IAT) sensor low voltage. connections from the IAT sensor
sensor.
to the ECT and MAP sensors to
the ECM OR replace the IAT
sensor.
Check engine oil level OR check

Bad oil pressure switch, wires for shorted wires or poor
51 Low oil pressure. shorted to ground or not terminal connections from the oil
enough engine oil. pressure switch to the ECM OR
replace the oil pressure switch.

FAULT CODES
Fault
Code
The CKP and CMP sensors
work together; if one is bad, the
Check for shorted wires or poor
other one won’t work correctly
Crankshaft Position (CKP) terminal connections from the
and causes the ECM to detect
52 sensor senses extra or CKP and CMP sensors to the
a fault. The ECM uses the
missing pulses. ECM OR replace the CKP or
signal pulses from the CKP and
CMP sensor.
CMP sensors to initiate
sequential fuel injection.
The CMP and CKP sensors

work together; if one is bad, the
Check for shorted wires or poor
other one won’t work correctly
Camshaft Position (CMP) terminal connections from the
and causes the ECM to detect
53 sensor senses unknown CKP and CMP sensors to the
a fault. The ECM uses the
pattern. ECM OR replace the CKP or
signal pulses from the CKP and
CMP sensor.
CMP sensors to initiate
sequential fuel injection.
The ECM received an illegal

instruction signal from one or
ECM Fault - Illegal more of the sensors and has
54 Replace the ECM.
Operation. gone into a default program
and then return to normal
operation.
The ECM received an illegal

interruption signal from one or
more engine sensors and has
55 ECM - Illegal Interuption. Replace the ECM.
gone into a default program
and then return to normal
operation.
Under normal operation the

ECM - Computer ECM will store numbers into
56 Operating Properly (COP) memory. If this does not Replace the ECM.
failure happen, it will reset itself and
set fault code 56.
Check battery and/or alternator

condition OR check for shorted
Battery supply voltage to the
61 System voltage low. wires or poor terminal
ECM is 8V DC or less.
connections from the battery to
the ECM.
Check battery and/or alternator

condition OR check for shorted
Battery supply voltage to the
62 System voltage high. wires or poor terminal
ECM is 18V DC or more.
connections from the battery to
the ECM.

Chart 1
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Chart 2
Engine Cranks 9KK8KVGOX9KIZOUT )NKIQLUXVUUXZKXSOTGR 8KLKXZUZNKLG[RZIUJK
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CHART 2
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Chart 2A
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Chart 3
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CHART 3
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CHART 3
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Chart 4
Engine Will Not 9KK8KVGOX9KIZOUT )NKIQLUXVUUXZKXSOTGR 8KLKXZUZNKLG[RZIUJK
.U]ZU8KZXOK\K,G[RZ _KY IUTTKIZOUTY58INKIQ INGXZOTZNOYYKIZOUTLUXG
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But Will Start SKSUX_% +)3ZUZNKYKTYUXZNGZ XKVGOXY
On Gasoline - OYIG[YOTMZNKLG[RZ58
XKVRGIKZNKYKTYUX58
Ford Models IUTY[RZ-KTOK/TJ[YZXOKY
Be sure fuel select
switch is switched
to LPG.
:[XTULLZNK\GR\KUTZNK
26-ZGTQZNKT
Be sure the valve on the JOYIUTTKIZ26-Y[VVR_
LPG tank is fully ROTKLXUS26-ZGTQGTJ
opened. HRKKJVXKYY[XKLXUS
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Be sure to check
LPG fuel level.
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CHART 4
)XGTQKTMOTKLUX TU 8KVGOXUVKTOTJQMXT
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26-GJP[YZSKTZY58
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Chart 5
Engine Will 9KK8KVGOX9KIZOUT )NKIQLUXVUUXZKXSOTGR 8KLKXZUZNKLG[RZIUJK
Not Start On .U]ZU8KZXOK\K,G[RZ _KY IUTTKIZOUTY58INKIQ INGXZOTZNOYYKIZOUTLUXG
Gasoline, IUJKYZUXKJOTZNK+)3 ]OXKYZNGZMULXUSZNK GTJXKIUSSKTJKJ
But Will Start OYIG[YOTMZNKLG[RZ58
XKVRGIKZNKYKTYUX58
On LPG - IUTY[RZ-KTOK/TJ[YZXOKY
Ford Models
Be sure fuel select
switch is switched =OZNZNKQK_Y]OZIN < 8KVRGIKL[KRYKRKIZ
to gasoline. Z[XTKJZUMXU[TJIUTZXUR Y]OZIN
GTJHUZN+SKXMKTI_
Be sure to check
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gasoline fuel level. )NKIQ\URZGMKGZ26-
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Chart 6
Engine 9KK8KVGOX9KIZOUT )NKIQLUXVUUXZKXSOTGR 8KLKXZUZNKLG[RZIUJK
High Idle )UJKY/YZNKXKGLG[RZ LUXYNUXZKJUXJGSGMKJ JKYIXOVZOUTULZNKLG[RZ
Inoperative - IUJKYZUXKJOTZNK+)3 ]OXKYZNGZMULXUSZNK GTJXKIUSSKTJKJ
Ford Models OYIG[YOTMZNKLG[RZ58
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SU\KGTJNURJZNK863 ZKXSOTGRUT863YKRKIZ Y[VVR_IOXI[OZZUIKTZKX
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Chart 7
Engine Low Idle 9KK8KVGOX9KIZOUT )NKIQLUXVUUXZKXSOTGR 8KLKXZUZNKLG[RZIUJK
Inoperative - )UJKY/YZNKXKGLG[RZ LUXYNUXZKJUXJGSGMKJ JKYIXOVZOUTULZNKLG[RZ
Ford Models IUJKYZUXKJOTZNK+)3 ]OXKYZNGZMULXUSZNK GTJXKIUSSKTJKJ
OYIG[YOTMZNKLG[RZ58
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Chart 8
Engine 9ZGXZZNKKTMOTKZNKT )NKIQNOMNOJRK
Y]OZINXVSYKRKIZY]OZIN YURKTUOJ GJP[YZSKTZYKK
High Idle ZUNOMNOJRKXGHHOZ V[RRYOT 3GOTZKTGTIKYKIZOUT
Inoperative - Y_SHURGTJINKIQOL 58YKK*K[ZÙX
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Diesel Models SGT[GRYZUZXU[HRKYNUUZ
YURKTUOJ L[KROTPKIZOUTY_YZKS
Be sure mechanical JUKY
linkage is not binding TUZV[RROT
or defective.
)NKIQ\URZGMKGZHRQXKJ < )NKIQ\URZGMKUTXKJ 8KVGOXUVKTOTIOXI[OZ
Be sure 2-speed ]OXKUT863YKRKIZ ]OXKGZIKTZKXZKXSOTGRUL < Y[VVR_OTM<ZUIKTZKX
Y]OZIN:9GTJ:9 863YKRKIZY]OZIN ZKXSOTGRULY]OZIN
solenoid grounding
wires are free of <
corrosion and have full
continuity to ground. < 8KVRGIKZUMMRKY]OZIN
)NKIQ\URZGMKGZ:( < 8KVGOXUVKTOTHRQXKJ

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CHART 8
)UTZOT[KJLXUSZNK )NKIQ\URZGMKGZ < 8KVGOXUVKTOTHRQXKJ

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UNSY

Chart 9
Engine 'ZZNKVRGZLUXSIUTZXURY /YURGZKZNKVRGZLUXSGTJ
YZGXZZNKKTMOTKGTJ < MXU[TJ863Y]OZINKY
Low Idle SU\KZNK863YKRKIZ :9GTJ:9INKIQ
Y]OZIN:9ZU OTJO\OJ[GRR_GTJXKVRGIK
Inoperative - SGOTZGOTKJRU]OJRK JKLKIZO\KY]OZIN
Diesel Models Z[XZRKY_SHUR)NKIQ
\URZGMKGZHRQXKJ]OXK
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Check if mechanical
linkage from 2-speed <
solenoid to fuel
injection system is )NKIQ\URZGMKGZZNK < 8KVRGIK)8XKRG_
binding or defective. HRQXKJ]OXKUTZNK
YVKKJYURKTUOJ
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9KX\OIK*KVGXZSKTZ

Chart 10
All Functions )NKIQN_JXG[ROI RU] ,ORR]OZN*K^XUT
LR[OJRK\KR KW[O\GRKTZN_JXG[ROI
Inoperative, LR[OJ
Engine Starts UQ
and Runs
)NKIQV[SVY[IZOUTROTK IRUYKJ *UZNKV[SVYLKKR _KY /LKTMOTKNGYHKKTX[T
YN[ZULL\GR\KY/TZNK KÎKYYO\KR_NUZ% ]OZN\GR\KYIRUYKJOZ
UVKTVUYOZOUTZNK\GR\K SG_NG\KJGSGMKJUTK
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TU *KVGXZSKTZ
UVKT 5VKT\GR\KYGTJYZGXZ
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SGINOTKL[TIZOUTYLUX
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5T,UXJSUJKRYIRUYK YVROTK :XU[HRKYNUUZ

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:9ZUZNK26- L[TIZOUTYYKVGXGZKR_
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8KSU\KL[TIZOUTV[SV
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Y]OZINGTJIXGTQKTMOTK
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SGOTV[SV
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9KX\OIK*KVGXZSKTZ

Chart 11
All Lift and /TYZGRRGZU69/ :XU[HRKYNUUZKGIN

Steer Functions HGXVXKYY[XKZU
ZNKZKYZVUXZOZKS//UT
VYO
L[TIZOUTOTJO\OJ[GRR_UX
Inoperative, ZNKL[TIZOUTSGTOLURJ
9ZGXZKTMOTKSU\KZNK
9KX\OIK*KVGXZSKTZ
Drive Functions L[TIZOUTKTGHRKZUMMRK
Y]OZINZUZNKNOMN863
Operational YOJKGTJNURJZNKHUUS
XKZXGIZL[TIZOUTZUMMRK
Y]OZINGTJINKIQZNK
Be sure the hydraulic N_JXG[ROIVXKYY[XK
suction line shutoff

RKYYZNGT
valve for the lift/steer
VYO
pump is in the OPEN
position. 'JP[YZZNKL[TIZOUT

3U\KZNKL[TIZOUT
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VYOUX
\GR\KOZKS.GRRZNK NOMN863YOJKGTJNURJ
Be sure all grounding SUXK
]G_OTIRUIQ]OYK ZNKHUUSXKZXGIZY]OZIN
wires for the hydraulic IU[TZOTMZNKT[SHKXUL GTJXKGJP[YZZNKXKROKL
manifold valves are free Z[XTY3U\KZNKL[TIZOUT VXKYY[XKZUVYO
KTGHRKY]OZINZUZNK HGX
of corrosion and have NOMN863YOJKGTJNURJ
full continuity to ground. ZNKHUUSXKZXGIZZUMMRK
Y]OZINGTJXKINKIQZNK
VXKYY[XK
RKYYZNGT
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JOLLKXKTZOGRYKTYOTM\GR\K
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HGJ
8KVRGIKZNKL[TIZOUT
V[SV

Chart 12
Ground *UKYZNKKTMOTKYZGXZ _KY 9ZGXZZNKKTMOTKLXUS 8KVGOXUVKTOTXKJ]OXK
LXUSZNKMXU[TJ ZNKMXU[TJIUTZXURY < IOXI[OZLXUSQK_Y]OZINZU
Controls IUTZXURY% 3U\KZNKL[TIZOUT L[TIZOUTKTGHRKZUMMRK
Inoperative, KTGHRKZUMMRKY]OZINZU Y]OZINZUKGINL[TIZOUT
KOZNKXYOJKGTJINKIQ ZUMMRKY]OZIN
Platform ZNK\URZGMKUTZNK
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Controls VRGZLUXSXUZGZKZUMMRK
Y]OZIN:9
Operate
Normally TU <
Be sure all other :XU[HRKYNUUZKGIN

L[TIZOUTOTJO\OJ[GRR_
functions operate
normally, including
the platform
controls. 6[RRHUZN+SKXMKTI_ 8KVGOXUVKTOTXKJ]OXK
9ZUVH[ZZUTYU[ZZUZNK < IOXI[OZLXUSZNK
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Z[XTKJZUMXU[TJIUTZXUR < OTZKXTGRIGSOYGIZO\GZOTM _KY IUTZGIZLUXMXU[TJ
GTJHUZN+SKXMKTI_ MXU[TJIUTZGIZ IUTZXURY
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Chart 13
Platform *UKYKTMOTKYZGXZLXUS _KY 9ZGXZKTMOTKLXUSZNK :KYZUXXKVRGIKLUUZ
ZNKVRGZLUXSIUTZXURY% VRGZLUXSIUTZXURYZNKT < Y]OZINYKK8KVGOX
Controls VXKYYJU]TZNKLUUZ 9KIZOUT58XKVGOXUVKT
Inoperative, Y]OZINGTJINKIQ OT]NZ]OXKIOXI[OZLXUS
\URZGMKGZ:6 LUUZY]OZINZU:6
Ground
<
Controls
TU
Operate 8KVGOXUVKTOT]NZ]OXK
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Normally L[TIZOUTZUMMRKY]OZINKY
GTJL[TIZOUTIUTZXURRKXY
Be sure all cables
from ground control
)NKIQ\URZGMKGZ:( < 8KVGOXUVKTOTXKJ]OXK
box through the IOXI[OZLXUSQK_Y]OZINZU
cable track are in :(588KVRGIKZNK
good condition with VRGZLUXSIUTZXURYIUTZGIZ
< GZZNKQK_Y]OZIN
no kinks or
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:6
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]OXKUTOTV[ZYOJKUL < LXUS:6ZU
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9ZUVH[ZZUTIUTZGIZ6 6
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Z[XTKJZUVRGZLUXS 9ZUVH[ZZUTOTZKXTGRIGS _KY +SKXMKTI_9ZUVH[ZZUT
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58IUTY[RZ-KTOK
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*KVGXZSKTZ

Chart 14
Primary Boom =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ]NZ
Up Function Z[XTKJZUMXU[TJ KTGHRKY]OZINZUKOZNKX ZU ]OXKIOXI[OZLXUS:(ZU
IUTZXURYGTJHUZN YOJKGTJNURJZNK VXOSGX_HUUS[VJU]T
Inoperative +SKXMKTI_9ZUVH[ZZUTY < VXOSGX_HUUS[VZUMMRK < VXUVUXZOUTGR\GR\KIUOR
V[RRKJU[ZZUZNK54 Y]OZIN:9GZZNK OZKS2258XKVGOX
VUYOZOUTSU\KZNK MXU[TJIUTZXURYOTZNK UVKTOTHXU]TMXU[TJ
Be sure all other L[TIZOUTKTGHRKY]OZINZU [VJOXKIZOUT)NKIQ ]OXKIOXI[OZZU\GR\KIUOR
functions operate KOZNKXYOJKGTJNURJZNK \URZGMKGZ:(
VXOSGX_HUUS[VZUMMRK
normally. Y]OZIN:9GZZNK <
MXU[TJIUTZXURYOTZNK
[VJOXKIZOUTGTJINKIQ ZU
\URZGMKUTXKJ]NZ]OXK =OZNZNKQK_Y]OZIN < 8KVGOXUVKTOTXKJ]NZ
UTVXOSGX_HUUS[V Z[XTKJZUVRGZLUXS ]OXKLXUS:6ZU:(
JU]TVXUVUXZOUTGR\GR\K IUTZXURYGTJHUZN
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VUYOZOUTGIZO\GZKLUUZ
Y]OZINGTJVXOSGX_
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JOXKIZOUT)NKIQ\URZGMK
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XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 14
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ

VXK\OU[YVGMK ZUMXU[TJIUTZXURYGTJ KTGHRKZUMMRKY]OZINZU <UX ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV < KOZNKXYOJKGTJNURJZNK SUXK VXOSGX_HUUS[V
H[ZZUTYV[RRKJU[ZZUZNK VXOSGX_HUUS[VZUMMRK L[TIZOUTJOXKIZOUTGR\GR\K
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VGMK

CHART 14
)UTZOT[KJLXUSZNK *OYIUTTKIZ]OXKYZU UX

VXK\OU[YVGMK VXOSGX_HUUS[V OTLOTOZK 8KVRGIKVXOSGX_HUUS
JOXKIZOUTGR\GR\KIUOR UNSY [VJOXKIZOUTGR\GR\KIUOR
OZKS**GTJZKYZZNK OZKS**
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I_ROTJKXIU[TZKXHGRGTIK
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OTZKXTGRLG[RZ)UTY[RZ
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Chart 15
Primary Boom =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ]NZ
Down Function Z[XTKJZUMXU[TJ KTGHRKY]OZINZUKOZNKX ZU ]OXKIOXI[OZLXUS:(ZU
Inoperative +SKXMKTI_9ZUVH[ZZUTY < VXOSGX_HUUSJU]T < VXUVUXZOUTGR\GR\KIUOR
V[RRKJU[ZZUZNK54 ZUMMRKY]OZIN:9GZ OZKS2258XKVGOX
(before serial VUYOZOUTSU\KZNK ZNKMXU[TJIUTZXURYOT UVKTOTHXU]TMXU[TJ
L[TIZOUTKTGHRKY]OZINZU ZNKJU]TJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
number 13099) KOZNKXYOJKGTJNURJZNK INKIQ\URZGMKGZ:(
VXOSGX_HUUSJU]T
ZUMMRKY]OZIN:9GZ <
Be sure all other ZNKMXU[TJIUTZXURYOT
functions operate ZNKJU]TJOXKIZOUTGTJ ZU
normally. INKIQ\URZGMKUTXKJ =OZNZNKQK_Y]OZIN < 8KVGOXUVKTOTXKJ]NZ
]NZ]OXKUTVXOSGX_ Z[XTKJZUVRGZLUXS ]OXKLXUS:6ZU:(
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VXUVUXZOUTGR\GR\KIUOR +SKXMKTI_9ZUVH[ZZUTY
OZKS22 V[RRKJU[ZZUZNK54
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\URZGMKGZ:6
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VGMK

CHART 15
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJHRQ

VXK\OU[YVGMK ZUMXU[TJIUTZXURYGTJ KTGHRKY]OZINZUKOZNKX <UX ]OXKIOXI[OZLXUS:(
HUZN+SKXMKTI_9ZUV < YOJKGTJNURJZNK SUXK ZUVXOSGX_HUUSJU]T
H[ZZUTYV[RRKJU[ZZUZNK VXOSGX_HUUSJU]T L[TIZOUTJOXKIZOUTGR\GR\K
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9GZ IUOROZKS**58XKVGOX
L[TIZOUTKTGHRKY]OZINZU ZNKMXU[TJIUTZXURYOT UVKTOTHXU]TMXU[TJ
KOZNKXYOJKGTJNURJZNK ZNKJU]TJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
VXOSGX_HUUS[VZUMMRK INKIQ\URZGMKGZ:(
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OZKS** H[ZZUTYV[RRKJU[ZZUZNK SUXK IUTZXURVGTKR58XKVGOX
54VUYOZOUTGIZO\GZKZNK UVKTOTXKJHRQ ]OXK
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IUTZXURVGTKROTJU]T *KVGXZSKTZ
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VGMK

CHART 15

VXK\OU[YVGMK VXOSGX_HUUSJU]T OTLOTOZK 8KVRGIKVXOSGX_HUUS
JOXKIZOUTGR\GR\KIUOR UNSY JU]TJOXKIZOUTGR\GR\K
OZKS**GTJZKYZZNK IUOROZKS**
ZUUNSY
MG[MKGZZNKW[OIQ VXOSGX_HUUSLXUS
JOYIUTTKIZIU[VROTMUT 69/UX
SUXK SU\OTM58XKVGOX
VXOSGX_HUUSJU]T
ZUMMRKY]OZINGZZNK
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INKIQZNKVXKYY[XK
RKYYZNGT
69/
L[TIZOUT
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VXOSGX_HUUSJU]T
L[TIZOUT
L[TIZOUT
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9KIZOUTOZKS058
XKVGOXI_ROTJKXUX
\GR\K58L[TIZOUT
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*KVGXZSKTZ

Chart 16
Primary =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ]NZ
Boom Down Z[XTKJZUMXU[TJ KTGHRKY]OZINZUKOZNKX ZU ]OXKIOXI[OZLXUS:(ZU
Function +SKXMKTI_9ZUVH[ZZUTY < VXOSGX_HUUSJU]T < VXUVUXZOUTGR\GR\KIUOR
V[RRKJU[ZZUZNK54 ZUMMRKY]OZIN:9GZ OZKS2258XKVGOX
Inoperative VUYOZOUTSU\KZNK ZNKMXU[TJIUTZXURYOT UVKTOTHXU]TMXU[TJ
L[TIZOUTKTGHRKY]OZINZU ZNKJU]TJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
(after serial KOZNKXYOJKGTJNURJZNK INKIQ\URZGMKGZ:(
VXOSGX_HUUSJU]T
number ZUMMRKY]OZIN:9GZ <
ZNKMXU[TJIUTZXURYOT
13098) ZNKJU]TJOXKIZOUTGTJ ZU
INKIQ\URZGMKUTXKJ =OZNZNKQK_Y]OZIN < 8KVGOXUVKTOTXKJ]NZ
]NZ]OXKUTVXOSGX_ Z[XTKJZUVRGZLUXS ]OXKLXUS:6ZU:(
Be sure all other
HUUS[VJU]T IUTZXURYGTJHUZN
functions operate VXUVUXZOUTGR\GR\KIUOR +SKXMKTI_9ZUVH[ZZUTY
normally. OZKS22 V[RRKJU[ZZUZNK54
Y]OZINGTJVXOSGX_
(6UTVRGZLUXS
IUTZXURVGTKROTJU]T
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
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(6
8KVGOX9KIZOUT58
58IUTY[RZ-KTOK
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*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 16
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJHRQ

VXK\OU[YVGMK ZUMXU[TJIUTZXURYGTJ KTGHRKY]OZINZUKOZNKX <UX ]OXKIOXI[OZLXUS:(
HUZN+SKXMKTI_9ZUV < YOJKGTJNURJZNK SUXK ZUVXOSGX_HUUSJU]T
H[ZZUTYV[RRKJU[ZZUZNK VXOSGX_HUUSJU]T L[TIZOUTJOXKIZOUTGR\GR\K
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9GZ IUOROZKS**58XKVGOX
L[TIZOUTKTGHRKY]OZINZU ZNKMXU[TJIUTZXURYOT UVKTOTHXU]TMXU[TJ
KOZNKXYOJKGTJNURJZNK ZNKJU]TJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
VXOSGX_HUUS[VZUMMRK INKIQ\URZGMKGZ:(
Y]OZIN:9GZZNK
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HUUS[VJU]T ZUVRGZLUXSIUTZXURYGTJ JU]TL[TIZOUTZUMMRK
JOXKIZOUTGR\GR\KIUOR HUZN+SKXMKTI_9ZUV <UX Y]OZIN:9UTMXU[TJ
OZKS** H[ZZUTYV[RRKJU[ZZUZNK SUXK IUTZXURVGTKR58XKVGOX
54VUYOZOUTGIZO\GZKZNK UVKTOTXKJHRQ ]OXK
LUUZY]OZINGTJVXOSGX_ IOXI[OZLXUS:9ZU:(
HUUSL[TIZOUTIUTZXURRKX 58IUTY[RZ-KTOK
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VGMK

CHART 16

VXK\OU[YVGMK VXOSGX_HUUSJU]T OTLOTOZK 8KVRGIKVXOSGX_HUUS
JOXKIZOUTGR\GR\KIUOR UNSY JU]TJOXKIZOUTGR\GR\K
OZKS**GTJZKYZZNK IUOROZKS**
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VXOSGX_HUUSJU]T
ZUMMRKY]OZINGZZNK
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JU]TJOXKIZOUTGTJ
INKIQZNKVXKYY[XK
RKYYZNGT
69/
L[TIZOUT
\GR\KOZKS-)NKIQ
VXOSGX_HUUSJU]T
L[TIZOUT
L[TIZOUT
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\GR\KYKK8KVGOX
9KIZOUTOZKS.58
XKVGOXI_ROTJKXUX
\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 17
Secondary =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHR[]NZ
Boom Up Z[XTKJZUMXU[TJ KTGHRKZUMMRKY]OZINZU ZU ]OXKIOXI[OZLXUS:(ZU
IUTZXURYGTJHUZN KOZNKXYOJKGTJNURJZNK < YKIUTJGX_HUUS[V
Function +SKXMKTI_9ZUVH[ZZUTY < YKIUTJGX_HUUS[V JU]TVXUVUXZOUTGR\GR\K
V[RRKJU[ZZUZNK54 ZUMMRKY]OZIN:9GZ IUOROZKS(58XKVGOX
L[TIZOUTKTGHRKZUMMRK ZNK[VJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
Y]OZINZUKOZNKXYOJKGTJ INKIQ\URZGMKGZ:(
Be sure all other NURJZNKYKIUTJGX_
functions operate HUUS[VZUMMRKY]OZIN <
:9GZZNKMXU[TJ
normally.
IUTZXURYOTZNK[V ZU
JOXKIZOUTGTJINKIQ =OZNZNKQK_Y]OZIN < 8KVGOXUVKTOTHR[]NZ
\URZGMKUTHR[]NZ]OXK Z[XTKJZUVRGZLUXS ]OXKLXUS:6ZU:(
UTYKIUTJGX_HUUS[V IUTZXURYGTJHUZN
JU]TVXUVUXZOUTGR\GR\K +SKXMKTI_9ZUVH[ZZUTY
IUOROZKS( V[RRKJU[ZZUZNK54
Y]OZINGTJYKIUTJGX_
(6UTVRGZLUXS
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JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
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8KVGOX9KIZOUT58
58IUTY[RZ-KTOK
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VGMK

CHART 17
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHR[

VXK\OU[YVGMK ZUMXU[TJIUTZXURYGTJ KTGHRKY]OZINZUKOZNKX <UX ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV YOJKGTJNURJZNK SUXK YKIUTJGX_HUUS[V
H[ZZUTYV[RRKJU[ZZUZNK < YKIUTJGX_HUUS[V L[TIZOUTJOXKIZOUTGR\GR\K
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L[TIZOUTKTGHRKZUMMRK ZNKMXU[TJIUTZXURYOT UVKTOTHXU]TMXU[TJ
Y]OZINZUKOZNKXYOJKGTJ ZNK[VJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
NURJZNKYKIUTJGX_ INKIQ\URZGMKGZ:(
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UTYKIUTJGX_HUUS[V ZUVRGZLUXSIUTZXURYGTJ YKIUTJGX_HUUS[V
JU]TJOXKIZOUTGR\GR\K HUZN+SKXMKTI_9ZUV L[TIZOUTZUMMRKY]OZIN
IUOROZKS// H[ZZUTYV[RRKJU[ZZUZNK <UX :9UTMXU[TJ
54VUYOZOUTGIZO\GZKZNK SUXK IUTZXURVGTKR58XKVGOX
LUUZY]OZINGTJ UVKTOTHR[ ]OXK
YKIUTJGX_HUUS IOXI[OZLXUS:9ZU
L[TIZOUTIUTZXURRKX(6 :(58IUTY[RZ-KTOK
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VGMK

CHART 17
*OYIUTTKIZ]OXKYZU UX
)UTZOT[KJLXUSZNK YKIUTJGX_HUUS[V OTLOTOZK 8KVRGIKYKIUTJGX_
VXK\OU[YVGMK JOXKIZOUTGR\GR\KIUOR UNSY HUUS[VJOXKIZOUTGR
OZKS//GTJZKYZZNK \GR\KIUOROZKS//
ZUUNSY
MG[MKGZZNKW[OIQ YKIUTJGX_HUUSLXUS
SUXK SU\OTM58XKVGOX
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OZKS11GTJYZGXZZNK IU[TZKXHGRGTIK\GR\KY
L[TIZOUTKTGHRKZUMMRK /TJ[YZXOKY9KX\OIK
Y]OZINZUKOZNKXYOJKGTJ *KVGXZSKTZ
NURJZNKYKIUTJGX_
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GZZNKMXU[TJIUTZXURYOT
ZNK[VJOXKIZOUTGTJ
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9KIZOUTOZKS+58
XKVGOXI_ROTJKXYUX
\GR\KY58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 18
Secondary =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHR[]NZ
Boom Down Z[XTKJZUMXU[TJ KTGHRKZUMMRKY]OZINZU ZU ]OXKIOXI[OZLXUS:(ZU
IUTZXURYGTJHUZN KOZNKXYOJKGTJNURJZNK < YKIUTJGX_HUUS[V
Function +SKXMKTI_9ZUVH[ZZUTY < YKIUTJGX_HUUSJU]T JU]TVXUVUXZOUTGR\GR\K
V[RRKJU[ZZUZNK54 ZUMMRKY]OZIN:9GZ IUOROZKS(58XKVGOX
L[TIZOUTKTGHRKZUMMRK ZNKJU]TJOXKIZOUTGTJ ]OXKIOXI[OZZU\GR\KIUOR
Y]OZINZUKOZNKXYOJKGTJ INKIQ\URZGMKGZ:(
Be sure all other NURJZNKYKIUTJGX_
functions operate HUUSJU]TZUMMRK <
Y]OZIN:9GZZNK
normally.
MXU[TJIUTZXURYOTZNK ZU
JU]TJOXKIZOUTGTJ =OZNZNKQK_Y]OZIN < 8KVGOXUVKTOTHR[]NZ
INKIQ\URZGMKUTHR[]NZ Z[XTKJZUVRGZLUXS ]OXKLXUS:6ZU:(
]OXKUTYKIUTJGX_HUUS IUTZXURYGTJHUZN
[VJU]TVXUVUXZOUTGR +SKXMKTI_9ZUVH[ZZUTY
\GR\KIUOROZKS( V[RRKJU[ZZUZNK54
Y]OZINGTJYKIUTJGX_
(6UTVRGZLUXS
IUTZXURVGTKROTJU]T
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
<
OTHXU]TMXU[TJ]OXK
(6
<UXSUXK 8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
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)UTZOT[KJUTZNKTK^Z
VGMK

CHART 18
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHR[HRQ

VXK\OU[YVGMK ZUMXU[TJIUTZXURYGTJ KTGHRKZUMMRKY]OZINZU ]OXKIOXI[OZLXUS
HUZN+SKXMKTI_9ZUV KOZNKXYOJKGTJNURJZNK <UX :(ZUYKIUTJGX_
H[ZZUTYV[RRKJU[ZZUZNK < YKIUTJGX_HUUSJU]T SUXK HUUSJU]TL[TIZOUT
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9GZ JOXKIZOUTGR\GR\KIUOR
L[TIZOUTKTGHRKZUMMRK ZNKMXU[TJIUTZXURYOT OZKS//58XKVGOXUVKT
Y]OZINZUKOZNKXYOJKGTJ ZNKJU]TJOXKIZOUTGTJ OTHXU]TMXU[TJ]OXK
NURJZNKYKIUTJGX_ INKIQ\URZGMKGZ:( IOXI[OZZU\GR\KIUOR
HUUSJU]TZUMMRK
Y]OZIN:9GZZNK <
MXU[TJIUTZXURYOTZNK
JU]TJOXKIZOUTGTJ
INKIQ\URZGMKUTHR[ =OZNQK_Y]OZINZ[XTKJ :XU[HRKYNUUZZNK
]OXKUTYKIUTJGX_ ZUVRGZLUXSIUTZXURYGTJ YKIUTJGX_HUUSJU]T
HUUS[VJU]T HUZN+SKXMKTI_9ZUV L[TIZOUTZUMMRKY]OZIN
JOXKIZOUTGR\GR\KIUOR H[ZZUTYV[RRKJU[ZZUZNK <UX :9UTMXU[TJ
OZKS// 54VUYOZOUTGIZO\GZKZNK SUXK IUTZXURVGTKR58XKVGOX
LUUZY]OZINGTJ UVKTOTHR[HRQ ]OXK
YKIUTJGX_HUUS IOXI[OZLXUS:9ZU
L[TIZOUTIUTZXURRKX(6 :(58IUTY[RZ-KTOK
UTVRGZLUXSIUTZXUR /TJ[YZXOKY9KX\OIK
VGTKROTJU]TJOXKIZOUT *KVGXZSKTZ
GTJINKIQ\URZGMK
:(
< <UX
SUXK 8KVGOXUVKTOTXKJ]OXK
'IZO\GZKLUUZY]OZINGTJ LXUS:6ZU:(
YKIUTJGX_HUUS
L[TIZOUTIUTZXURRKX(6
UTVRGZLUXSIUTZXUR
VGTKROTJU]TJOXKIZOUT
GTJINKIQ\URZGMKGZ
:6
<UXSUXK <
OTHXU]TMXU[TJ]OXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 18

VXK\OU[YVGMK YKIUTJGX_HUUSJU]T OTLOTOZK 8KVRGIKYKIUTJGX_
JOXKIZOUTGR\GR\KIUOR UNSY HUUSJU]TJOXKIZOUTGR
OZKS//GTJZKYZZNK \GR\KIUOROZKS//
ZUUNSY
MG[MKGZZNKW[OIQ YKIUTJGX_HUUSLXUS
SUXK SU\OTM58XKVGOX
ZNKL[TIZOUTSGTOLURJ I_ROTJKXYUXI_ROTJKX
OZKS11GTJYZGXZZNK IU[TZKXHGRGTIK\GR\KY
Y]OZINZUKOZNKXYOJKGTJ *KVGXZSKTZ
NURJZNKYKIUTJGX_
HUUSJU]TZUMMRK
Y]OZINGZZNKMXU[TJ
IUTZXURYOTZNKJU]T
JOXKIZOUTGTJINKIQZNK
VXKYY[XK
RKYYZNGT
69/
L[TIZOUT
\GR\KOZKS)]OZNGROQK XKM[RGZUX\GR\K
\GR\KOZKS-)NKIQ
YKIUTJGX_HUUS[V
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
'JP[YZYKIUTJGX_HUUS
9KIZOUTOZKS+58
XKVGOXI_ROTJKXYUX
\GR\KY58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 19
Primary Boom =OZNQK_Y]OZINZ[XTKJ =OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOTHRQ]OXK
ZUMXU[TJIUTZXURYGTJ ZUVRGZLUXSIUTZXURYGTJ LXUS:9ZU:6ZU
Extend HUZN+SKXMKTI_9ZUV HUZN+SKXMKTI_9ZUV :(
Function H[ZZUTYV[RRKJU[ZZUZNK H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTSU\KZNK 54VUYOZOUTGIZO\GZKZNK
Inoperative L[TIZOUTKTGHRKZUMMRK < LUUZY]OZINGTJZNK
Y]OZINZUKOZNKXYOJK VXOSGX_HUUSK^ZKTJ
ZNKTSU\KZNKVXOSGX_ XKZXGIZZUMMRKY]OZIN
Be sure all other HUUSK^ZKTJXKZXGIZ :9GZZNKVRGZLUXS
functions operate ZUMMRKY]OZIN:9GZ IUTZXURYOTZNKK^ZKTJ
normally. ZNKMXU[TJIUTZXURYOT JOXKIZOUTGTJINKIQ
ZNKK^ZKTJJOXKIZOUTGTJ \URZGMKGZZNKHRGIQ]OXK
INKIQ\URZGMKGZ:( UTZNKVXOSGX_HUUS
K^ZKTJXKZXGIZZUMMRK
Y]OZIN:9
<
< 8KVGOXUVKTOTXKJ
VU]KXY[VVR_IOXI[OZZU
:9GTJ:958
XKVRGIKZUMMRKY]OZINKY
VXOSGX_HUUSK^ZKTJ OTLOTOZK 8KVRGIKVXOSGX_HUUS
JOXKIZOUTGR\GR\KIUOR UNSY K^ZKTJJOXKIZOUTGR\GR\K
OZKS2GTJZKYZZNK IUOROZKS2
ZUUNSY
MG[MKGZZNKW[OIQ 69/UX VXOSGX_HUUSLXUS
JOYIUTTKIZIU[VROTMUT SUXK K^ZKTJOTM58XKVGOX
ZNKHUUSL[TIZOUT I_ROTJKXUXI_ROTJKX
SGTOLURJGTJYZGXZZNK IU[TZKXHGRGTIK\GR\KY
Y]OZINZUZNKNOMNXVS *KVGXZSKTZ
VUYOZOUTGTJNURJZNK
VXOSGX_HUUSK^ZKTJ
ZUMMRKY]OZINGZZNK
MXU[TJIUTZXURYOTZNK
K^ZKTJJOXKIZOUTGTJ
INKIQZNKVXKYY[XK
RKYYZNGT
69/
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 19
8KVRGIKLRU]XKM[RGZUX L[TIZOUT
)UTZOT[KJLXUSZNK \GR\KOZKS3)NKIQ UVKXGZKY 8KVRGIKLG[RZ_LRU]
VXK\OU[YVGMK VXOSGX_HUUSK^ZKTJ XKM[RGZUX\GR\K
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
'JP[YZY_YZKSXKROKL
\GR\KYKK8KVGOX
9KIZOUTOZKS.58
XKVGOXI_ROTJKXUX
\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 20
Primary Boom =OZNQK_Y]OZINZ[XTKJ =OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOTHRQ]NZ
ZUMXU[TJIUTZXURYGTJ ZUVRGZLUXSIUTZXURYGTJ ]OXKLXUS:9ZU:6
Retract HUZN+SKXMKTI_9ZUV HUZN+SKXMKTI_9ZUV ZU:(
H[ZZUTYV[RRKJU[ZZUZNK H[ZZUTYV[RRKJU[ZZUZNK
Function 54VUYOZOUTSU\KZNK 54VUYOZOUTGIZO\GZKZNK
Inoperative L[TIZOUTKTGHRKZUMMRK < LUUZY]OZINGTJZNK
Y]OZINZUKOZNKXYOJK VXOSGX_HUUSK^ZKTJ
ZNKTSU\KZNKVXOSGX_ XKZXGIZZUMMRKY]OZIN
Be sure all other HUUSK^ZKTJXKZXGIZ :9GZZNKVRGZLUXS
functions operate ZUMMRKY]OZIN:9GZ IUTZXURYOTZNKXKZXGIZ
normally. ZNKMXU[TJIUTZXURYOT JOXKIZOUTGTJINKIQ
ZNKXKZXGIZJOXKIZOUTGTJ \URZGMKGZZNKHRGIQ]NZ
INKIQ\URZGMKGZ:( ]OXKUTZNKVXOSGX_
HUUSK^ZKTJXKZXGIZ
ZUMMRKY]OZIN:9
<
< 8KVGOXUVKTOTXKJ
VU]KXY[VVR_IOXI[OZZU
:9GTJ:958
XKVRGIKZUMMRKY]OZINKY
VXOSGX_HUUSXKZXGIZ OTLOTOZK 8KVRGIKVXOSGX_HUUS
JOXKIZOUTGR\GR\KIUOR UNSY XKZXGIZJOXKIZOUTGR\GR\K
ZUUNSY
SUXK XKZXGIZOTM58XKVGOX
ZNKHUUSL[TIZOUT I_ROTJKXUXI_ROTJKX
SGTOLURJGTJYZGXZZNK IU[TZKXHGRGTIK\GR\KY
ZNKNOMNXVSVUYOZOUT *KVGXZSKTZ
GTJNURJZNKVXOSGX_
HUUSK^ZKTJXKZXGIZ
ZUMMRKY]OZINGZZNK
MXU[TJIUTZXURYOTZNK
XKZXGIZJOXKIZOUTGTJ
INKIQZNKVXKYY[XK
RKYYZNGT
69/
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 20
8KVRGIKLRU]XKM[RGZUX L[TIZOUT
)UTZOT[KJLXUSZNK \GR\KOZKS3)NKIQ UVKXGZKY 8KVRGIKLG[RZ_LRU]
VXK\OU[YVGMK VXOSGX_HUUSXKZXGIZ XKM[RGZUX\GR\K
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
'JP[YZY_YZKSXKROKL
\GR\KYKK8KVGOX
9KIZOUTOZKS.58
XKVGOXI_ROTJKXUX
\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 21
Turntable =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZXKJ
Rotate Left ZUMXU[TJIUTZXURGTJ KTGHRKZUMMRKY]OZINZU ZU ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV KOZNKXYOJKGTJNURJZNK < Z[XTZGHRKXUZGZKRKLZXOMNZ
Function H[ZZUTYV[RRKJU[ZZUZNK < Z[XTZGHRKXUZGZKZUMMRK VXUVUXZOUTGR\GR\KIUOR
54VUYOZOUTSU\KZNK Y]OZIN:9UTMXU[TJ OZKS'58XKVGOXUVKT
Inoperative L[TIZOUTKTGHRKZUMMRK VGTKROTZNKRKLZJOXKIZOUT OTHXU]TMXU[TJ]OXK
Y]OZINZUKOZNKXYOJKGTJ GTJINKIQ\URZGMKGZ IOXI[OZZU\GR\KIUOR
NURJZNKZ[XTZGHRKXUZGZK :(
Be sure all other ZUMMRKY]OZIN:9UT
functions operate MXU[TJVGTKROTZNKRKLZ
JOXKIZOUTGTJINKIQ
normally.
\URZGMKUT]NZXKJ]OXK
UTZ[XTZGHRKXUZGZKRKLZ
XOMNZVXUVUXZOUTGR\GR\K <
IUOROZKS'
ZU
=OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOT]NZXKJ
ZUVRGZLUXSIUTZXURGTJ ]OXKLXUS:6ZU:(
HUZN+SKXMKTI_9ZUV
H[ZZUTYV[RRKJU[ZZUZNK
UTVUYOZOUTGIZO\GZKLUUZ
Y]OZINGTJZ[XTZGHRK
XUZGZKRKLZXOMNZ
VXUVUXZOUTGRIUTZXURRKX
(6UTVRGZLUXS
IUTZXURVGTKROTZNKRKLZ
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
<
< INKIQ\URZGMKGZ Y[VVR_IOXI[OZLXUS:6
OTHXU]TMXU[TJ]OXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 21
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZHRQ

VXK\OU[YVGMK ZUMXU[TJIUTZXURGTJ KTGHRKZUMMRKY]OZINZU <UX ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV KOZNKXYOJKGTJNURJZNK SUXK Z[XTZGHRKXUZGZKRKLZ
H[ZZUTYV[RRKJU[ZZUZNK < Z[XTZGHRKXUZGZKRKLZXOMNZ L[TIZOUTJOXKIZOUTGR\GR\K
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9UT IUOROZKS,,58XKVGOX
L[TIZOUTKTGHRKZUMMRK MXU[TJVGTKROTZNKRKLZ UVKTOTHXU]TMXU[TJ
Y]OZINZUKOZNKXYOJKGTJ JOXKIZOUTGTJINKIQ ]OXKIOXI[OZZU\GR\KIUOR
NURJZNKZ[XTZGHRKXUZGZK \URZGMKGZ:(
RKLZXOMNZZUMMRKY]OZIN
:9UTMXU[TJVGTKR <
OTZNKRKLZJOXKIZOUTGTJ
INKIQ\URZGMKUT
]NZHRQ]OXKUTHUUS =OZNQK_Y]OZINZ[XTKJ :XU[HRKYNUUZZ[XTZGHRK
L[TIZOUTJOXKIZOUTGR\GR\K ZUVRGZLUXSIUTZXURGTJ XUZGZKRKLZXOMNZL[TIZOUT
IUOROZKS,, HUZN+SKXMKTI_9ZUV <UX ZUMMRKY]OZIN:9UT
H[ZZUTYV[RRKJU[ZZUZNK SUXK MXU[TJIUTZXURVGTKR58
54VUYOZOUTGIZO\GZKLUUZ XKVGOXUVKTOT]NZHRQ
Y]OZINGTJZ[XTZGHRK ]OXKIOXI[OZLXUS:9ZU
XUZGZKRKLZXOMNZ :(58IUTY[RZ-KTOK
VXUVUXZOUTGRIUTZXURRKX /TJ[YZXOKY9KX\OIK
(6UTVRGZLUXS *KVGXZSKTZ
JOXKIZOUTGTJINKIQ
\URZGMK:(
<
<UX
'IZO\GZKLUUZY]OZINGTJ SUXK 8KVGOXUVKTOT]NZHRQ
Z[XTZGHRKXUZGZKRKLZXOMNZ ]OXKLXUS:6ZU:(
(6UTVRGZLUXS
JOXKIZOUTGTJINKIQ
\URZGMK:6
< <
OTHXU]TMXU[TJ]OXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 21

VXK\OU[YVGMK Z[XTZGHRKXUZGZKRKLZ OTLOTOZK 8KVRGIKZ[XTZGHRKXUZGZK
JOXKIZOUTGR\GR\KIUOR UNSY RKLZJOXKIZOUTGR\GR\KIUOR
OZKS,,GTJZKYZZNK OZKS,,
ZUUNSY
/TYZGRRGZU69/
HGXVXKYY[XK
MG[MKGZZNKW[OIQ 69/UX +ÎNGTMKLRU]XKM[RGZUX L[TIZOUT
JOYIUTTKIZIU[VROTMUT SUXK \GR\KOZKS-]OZNGROQK UVKXGZKY 8KVRGIKLG[RZ_LRU]
ZNKHUUSL[TIZOUT \GR\KOZKS/)NKIQ XKM[RGZUX\GR\K
SGTOLURJGTJYZGXZZNK Z[XTZGHRKXUZGZKRKLZ
KTMOTK3U\KZNK L[TIZOUT
Y]OZINOTZNKNOMNXVS L[TIZOUT
VUYOZOUTGTJNURJZNK OTUVKXGZO\K
Z[XTZGHRKXUZGZKRKLZ
ZUMMRKY]OZINGZZNK 8KVGOXUXXKVRGIKZNK
MXU[TJIUTZXURYOTZNK Z[XTZGHRKXUZGZOUTSUZUX
RKLZJOXKIZOUTGTJINKIQ 58L[TIZOUTSGTOLURJ
ZNKVXKYY[XK IU[RJNG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
RKYYZNGT
69/
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 21
)UTZOT[KJLXUSZNK 6R[SHGZUVYO :[XTZGHRKXUZGZOUT

VXK\OU[YVGMK ZUHGXVXKYY[XK RKYYZNGT SGTOLURJIU[RJNG\KGT
MG[MKOTZUZNKNUYK VYO OTZKXTGRLG[RZ58ZNK
LXUSZNKZ[XTZGHRK UXOLOIKSG_HK
XUZGZOUTSGTOLURJZUZNK VR[MMKJ58IUTY[RZ
Z[XTZGHRKXUZGZOUTHXGQK -KTOK/TJ[YZXOKY9KX\OIK
3U\KZNKL[TIZOUT *KVGXZSKTZ
KTGHRKY]OZINZUKOZNKX
YOJKGTJGIZO\GZKZNK
Z[XTZGHRKXUZGZKRKLZ
L[TIZOUT
VYOUX
SUXK
+ÎNGTMKZ[XTZGHRK
XUZGZKRKLZGTJXOMNZ L[TIZOUT
IU[TZKXHGRGTIK\GR\KY UVKXGZKY 8KVRGIKLG[RZ_
OZKSY44GTJ55GZ IU[TZKXHGRGTIK\GR\K
ZNKZ[XTZGHRKXUZGZOUT
SUZUXIU[TZKXHGRGTIK
\GR\KSGTOLURJ'IZO\GZK
Z[XTZGHRKXUZGZKRKLZ
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKXUZGZKRKLZ
L[TIZOUTLXUSUVKXGZOTM
58XKVRGIKYN[ZZRK\GR\K
OZKS3358IUTY[RZ
*KVGXZSKTZ

Chart 22
Turntable =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZXKJ
Rotate Right ZUMXU[TJIUTZXURGTJ KTGHRKZUMMRKY]OZINZU ZU ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV KOZNKXYOJKGTJNURJZNK < Z[XTZGHRKXUZGZKRKLZXOMNZ
Function H[ZZUTYV[RRKJU[ZZUZNK < Z[XTZGHRKXUZGZKZUMMRK VXUVUXZOUTGR\GR\KIUOR
54VUYOZOUTSU\KZNK Y]OZIN:9UTMXU[TJ OZKS'58XKVGOXUVKT
Inoperative L[TIZOUTKTGHRKZUMMRK VGTKROTZNKXOMNZ OTHXU]TMXU[TJ]OXK
Y]OZINZUKOZNKXYOJKGTJ JOXKIZOUTGTJINKIQ IOXI[OZZU\GR\KIUOR
Be sure all other ZUMMRKY]OZIN:9UT
functions operate MXU[TJVGTKROTZNKXOMNZ
JOXKIZOUTGTJINKIQ
normally.
\URZGMKUT]NZXKJ]OXK
UTZ[XTZGHRKXUZGZKRKLZ
XOMNZVXUVUXZOUTGR\GR\K <
IUOROZKS'
ZU
=OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOT]NZXKJ
ZUVRGZLUXSIUTZXURGTJ ]OXKLXUS:6ZU:(
HUZN+SKXMKTI_9ZUV
UTVUYOZOUTGIZO\GZKLUUZ
Y]OZINGTJZ[XTZGHRK
XUZGZKRKLZXOMNZ
(6UTVRGZLUXS
IUTZXURVGTKROTZNKXOMNZ
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
<
< INKIQ\URZGMKGZ Y[VVR_IOXI[OZLXUS:6
OTHXU]TMXU[TJ]OXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 22
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZHRQ

VXK\OU[YVGMK ZUMXU[TJIUTZXURGTJ KTGHRKZUMMRKY]OZINZU <UX ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV KOZNKXYOJKGTJNURJZNK SUXK Z[XTZGHRKXUZGZKXOMNZ
H[ZZUTYV[RRKJU[ZZUZNK < Z[XTZGHRKXUZGZKRKLZXOMNZ L[TIZOUTJOXKIZOUTGR\GR\K
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9UT IUOROZKS,,58XKVGOX
L[TIZOUTKTGHRKZUMMRK MXU[TJVGTKROTZNKXOMNZ UVKTOTHXU]TMXU[TJ
Y]OZINZUKOZNKXYOJKGTJ JOXKIZOUTGTJINKIQ ]OXKIOXI[OZZU\GR\KIUOR
RKLZXOMNZZUMMRKY]OZIN
:9UTMXU[TJVGTKR <
OTZNKXOMNZJOXKIZOUTGTJ
INKIQ\URZGMKUT
]NZ]OXKUTHUUS =OZNQK_Y]OZINZ[XTKJ :XU[HRKYNUUZZ[XTZGHRK
L[TIZOUTJOXKIZOUTGR\GR\K ZUVRGZLUXSIUTZXURGTJ XUZGZKRKLZXOMNZL[TIZOUT
IUOROZKS,, HUZN+SKXMKTI_9ZUV <UX ZUMMRKY]OZIN:9UT
H[ZZUTYV[RRKJU[ZZUZNK SUXK MXU[TJIUTZXURVGTKR58
54VUYOZOUTGIZO\GZKLUUZ XKVGOXUVKTOT]NZ]OXK
Y]OZINGTJZ[XTZGHRK IOXI[OZLXUS:9ZU:(
XUZGZKRKLZXOMNZ 58IUTY[RZ-KTOK
VXUVUXZOUTGRIUTZXURRKX /TJ[YZXOKY9KX\OIK
(6UTVRGZLUXS *KVGXZSKTZ
JOXKIZOUTGTJINKIQ
\URZGMK:(
<
<UX
'IZO\GZKLUUZY]OZINGTJ SUXK 8KVGOXUVKTOT]NZ]OXK
Z[XTZGHRKXUZGZKRKLZXOMNZ LXUS:6ZU:(
(6UTVRGZLUXS
JOXKIZOUTGTJINKIQ
\URZGMK:6
< <
OTHXU]TMXU[TJ]OXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 22

VXK\OU[YVGMK Z[XTZGHRKXUZGZKXOMNZ OTLOTOZK 8KVRGIKZ[XTZGHRKXUZGZK
JOXKIZOUTGR\GR\KIUOR UNSY XOMNZJOXKIZOUTGR\GR\K
OZKS,,GTJZKYZZNK IUOROZKS,,
ZUUNSY
/TYZGRRGZU69/
HGXVXKYY[XK
MG[MKGZZNKW[OIQ +ÎNGTMKLRU]XKM[RGZUX L[TIZOUT
SUXK \GR\KOZKS-]OZNGROQK UVKXGZKY 8KVRGIKLG[RZ_LRU]
ZNKHUUSL[TIZOUT \GR\KOZKS/)NKIQ XKM[RGZUX\GR\K
SGTOLURJGTJYZGXZZNK Z[XTZGHRKXUZGZKXOMNZ
KTMOTK3U\KZNK L[TIZOUT
Y]OZINOTZNKNOMNXVS L[TIZOUT
VUYOZOUTGTJNURJZNK OTUVKXGZO\K
Z[XTZGHRKXUZGZKXOMNZ
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MXU[TJIUTZXURYOTZNK Z[XTZGHRKXUZGZOUTSUZUX
XOMNZJOXKIZOUTGTJINKIQ 58L[TIZOUTSGTOLURJ
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LG[RZ)UTY[RZ-KTOK
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RKYYZNGT
69/
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 22
)UTZOT[KJLXUSZNK 6R[SHGZUVYO :[XTZGHRKXUZGZOUT

VXK\OU[YVGMK ZUHGXVXKYY[XK RKYYZNGT SGTOLURJIU[RJNG\KGT
MG[MKOTZUZNKNUYK VYO OTZKXTGRLG[RZ58ZNK
LXUSZNKZ[XTZGHRK UXOLOIKSG_HK
XUZGZOUTSGTOLURJZUZNK VR[MMKJ58IUTY[RZ
Z[XTZGHRKXUZGZOUTHXGQK -KTOK/TJ[YZXOKY9KX\OIK
3U\KZNKL[TIZOUT *KVGXZSKTZ
KTGHRKZUMMRKY]OZINZU
KOZNKXYOJKGTJGIZO\GZK
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L[TIZOUT
VYOUX
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IU[TZKXHGRGTIK\GR\KY UVKXGZKY 8KVRGIKLG[RZ_
OZKSY44GTJ55GZ IU[TZKXHGRGTIK\GR\K
ZNKZ[XTZGHRKXUZGZOUT
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L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
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XKYZXOIZOUTYQKKVOTM
L[TIZOUTLXUSUVKXGZOTM
58XKVRGIKYN[ZZRK\GR\K
OZKS3358IUTY[RZ
*KVGXZSKTZ

Chart 23
All Platform 8KSU\KHUZNN_JXG[ROI 8KVRGIKZNK
NUYKYLXUSZNKL[TIZOUT _KY IU[TZKXHGRGTIK\GR\KY
Leveling SGTOLURJVUXZY62 UTL[TIZOUTSGTOLURJ
Functions 626R[MZNKNUYKY OZKSY67
GTJIGVZNKSGTOLURJ
Inoperative LOZZOTMY3U\KZNK
Y]OZINZUKOZNKXYOJKGTJ
Be sure all other GIZO\GZKZNKVXOSGX_
functions operate HUUS[VL[TIZOUTGTJ
normally. INKIQZUYKKOLVRGZLUXS
RK\KRY
TU
6R[SHGZUVYO )NKIQLUXSKINGTOIGR

ZUHGXVXKYY[XK 69/ XKYZXOIZOUTY58XKVRGIK
MG[MKOTZUSGYZKX ZNKYRG\KI_ROTJKX
I_ROTJKXXUJKTJ IU[TZKXHGRGTIK\GR\KY
N_JXG[ROINUYKNUYK
IUTTKIZKJZUVUXZ62
[YOTMGZKKLOZZOTM
'IZO\GZKVXOSGX_HUUS
[VL[TIZOUTGTJINKIQ
ZNKVXKYY[XK
RKYYZNGT
69/
/TYZGRRGZUVYO RKYYZNGT
ZUHGXVXKYY[XK 69/ 8KVGOXUXXKVRGIKZNK
MG[MKOTZUZNKHGXXKR SGYZKXI_ROTJKX
KTJN_JXG[ROINUYKLXUS
ZNKSGYZKXI_ROTJKXGTJ
XGOYKZNKVXOSGX_HUUS
UTKOTINGZGZOSK
)UTZOT[GRR_SUTOZUXZNK
VXKYY[XKMG[MKJ[XOTM
HUUS[V*UTUZGRRU]
ZNKVXKYY[XKZUKÎKKJ
69/
69/UX
SUXK
8KVGOXUXXKVRGIKZNK
YRG\KI_ROTJKX

Chart 24
Platform Level =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVGOXUVKTOTUXM]OXK
Z[XTKJZUMXU[TJ KTGHRKZUMMRKY]OZINZU <UX LXUS:(ZUVRGZLUXS
Up Function IUTZXURYGTJHUZN KOZNKXYOJKGTJGIZO\GZK SUXK RK\KR[VJOXKIZOUTGR\GR\K
Inoperative +SKXMKTI_9ZUVH[ZZUTY ZNKVRGZLUXSRK\KRZUMMRK IUOROZKS958XKVGOX
V[RRKJU[ZZUZNK54 Y]OZIN:9OTZNK[V UVKTOTHXU]TMXU[TJ
VUYOZOUTSU\KZNK < JOXKIZOUTGTJINKIQZNK ]OXKIOXI[OZZU\GR\KIUOR
Be sure all other L[TIZOUTKTGHRKZUMMRK \URZGMKGZ:(
functions operate Y]OZINZUKOZNKXYOJKGTJ
GIZO\GZKZNKVRGZLUXS <
normally. RK\KRZUMMRKY]OZIN:9
OTZNK[VJOXKIZOUTGTJ
INKIQZNK\URZGMKGZUXM =OZNZNKQK_Y]OZIN :XU[HRKYNUUZVRGZLUXS
]OXKUTVRGZLUXSRK\KR[V Z[XTKJZUVRGZLUXS RK\KRZUMMRKY]OZINKY
L[TIZOUTJOXKIZOUTGR\GR\K IUTZXURYGTJHUZN :9GTJ:9UT
OZKS9 +SKXMKTI_9ZUVH[ZZUTY MXU[TJGTJVRGZLUXS
V[RRKJU[ZZUZNK54 < IUTZXURVGTKRY58XKVGOX
VUYOZOUTGIZO\GZKZNK UVKTOTXKJVU]KX]OXK
LUUZY]OZINGTJZNK IOXI[OZZU:9GTJ:9
VRGZLUXSRK\KRZUMMRK 58XKVGOXUVKTOTUXM
Y]OZIN:9OTZNK[V ]OXKIOXI[OZLXUS:9
JOXKIZOUTGTJINKIQZNK GTJ:9ZU:(58
\URZGMKGZ:( IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
<UXSUXK
:XU[HRKYNUUZVRGZLUXS
RK\KRZUMMRKY]OZIN:9
UTMXU[TJIUTZXURVGTKR
58XKVGOXUVKTOTXKJ
VU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
UXM]OXKIOXI[OZLXUS
:9ZU:(58
<UXSUXK 9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 24
)UTZOT[KJLXUSZNK *OYIUTTKIZZNK]OXKY UX

VXK\OU[YVGMK LXUSZNKVRGZLUXSRK\KR OTLOTOZK 8KVRGIKZNKVRGZLUXS
[VJOXKIZOUTGR\GR\KIUOR UNSY RK\KR[VJOXKIZOUTGR\GR\K
IUOR
ZUUNSY
+ÎNGTMKVRGZLUXSRK\KR L[TIZOUT
[VGTJJU]TJOXKIZOUTGR UVKXGZKY 8KVRGIKZNKLG[RZ_
\GR\KIUORYGTJGIZO\GZK JOXKIZOUTGR\GR\KIUOR
ZNKVRGZLUXSRK\KR[V
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
[VGTJJU]T UVKXGZKY 8KVRGIKZNKLG[RZ_
IU[TZKXHGRGTIK\GR\KY IU[TZKXHGRGTIK\GR\K
OZKSY7GTJ8GTJ
GIZO\GZKZNKVRGZLUXS
RK\KR[VL[TIZOUT
L[TIZOUT
OTUVKXGZO\K
/TYZGRRGZU )NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK VYO XKYZXOIZOUTYQKKVOTM
MG[MKGZZNKW[OIQ VRGZLUXSRK\KR[V
JOYIUTTKIZIU[VROTMUT UXSUXK L[TIZOUTLXUSUVKXGZOTM
ZNKL[TIZOUTSGTOLURJ 58XKVRGIKYRG\K
GTJGIZO\GZKZNKVRGZLUXS I_ROTJKX58XKVRGIK
RK\KR[VL[TIZOUT YRG\KI_ROTJKX
IU[TZKXHGRGTIK\GR\KY
58IUTY[RZ-KTOK
RKYYZNGT /TJ[YZXOKY9KX\OIK
VYO *KVGXZSKTZ
8KVRGIKLRU]XKM[RGZUX
\GR\KOZKS458ZKYZ
SGYZKXI_ROTJKXYKK
)NGXZ58XKVGOXUX
XKVRGIKYRG\KI_ROTJKXUX
YRG\KI_ROTJKX
58L[TIZOUTSGTOLURJ
SG_NG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Chart 25
Platform Level =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVGOXUVKTOTUXMHRQ
Down Function Z[XTKJZUMXU[TJ KTGHRKZUMMRKY]OZINZU <UX ]OXKLXUS:(ZU
IUTZXURYGTJHUZN KOZNKXYOJKGTJGIZO\GZK SUXK VRGZLUXSRK\KRJU]T
Inoperative +SKXMKTI_9ZUVH[ZZUTY ZNKVRGZLUXSRK\KRZUMMRK JOXKIZOUTGR\GR\KIUOR
V[RRKJU[ZZUZNK54 Y]OZIN:9OTZNKJU]T OZKS958XKVGOXUVKT
VUYOZOUTSU\KZNK < JOXKIZOUTGTJINKIQZNK OTHXU]TMXU[TJ]OXK
Be sure all other L[TIZOUTKTGHRKZUMMRK \URZGMKGZ:( IOXI[OZZU\GR\KIUOR
GIZO\GZKZNKVRGZLUXS <
normally. RK\KRZUMMRKY]OZIN:9
OTZNKJU]TJOXKIZOUT
GTJINKIQZNK\URZGMKGZ =OZNZNKQK_Y]OZIN :XU[HRKYNUUZVRGZLUXS
UXMHRQ]OXKUTVRGZLUXS Z[XTKJZUVRGZLUXS RK\KRZUMMRKY]OZINKY
RK\KRJU]TL[TIZOUT IUTZXURYGTJHUZN :9GTJ:9UT
JOXKIZOUTGR\GR\K +SKXMKTI_9ZUVH[ZZUTY MXU[TJGTJVRGZLUXS
OZKS9 V[RRKJU[ZZUZNK54 < IUTZXURVGTKRY58XKVGOX
VUYOZOUTGIZO\GZKZNK UVKTOTXKJVU]KX]OXK
LUUZY]OZINGTJZNK IOXI[OZZU:9GTJ:9
VRGZLUXSRK\KRZUMMRK 58XKVGOXUVKTOTUXM
Y]OZIN:9OTZNKJU]T HRQ]OXKIOXI[OZLXUS
JOXKIZOUTGTJINKIQZNK :9GTJ:9ZU:(
\URZGMKGZ:( 58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
<UXSUXK
:XU[HRKYNUUZVRGZLUXS
RK\KRZUMMRKY]OZIN:9
UTMXU[TJIUTZXURVGTKR
58XKVGOXUVKTOTXKJ
VU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
UXMHRQ]OXKIOXI[OZLXUS
:9ZU:(58
<UXSUXK 9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 25
)UTZOT[KJLXUSZNK *OYIUTTKIZZNK]OXKY UX

VXK\OU[YVGMK LXUSZNKVRGZLUXSRK\KR OTLOTOZK 8KVRGIKZNKVRGZLUXS
JU]TJOXKIZOUTGR\GR\K UNSY RK\KRJU]TJOXKIZOUTGR
IUOROZKS9GTJZKYZZNK \GR\KIUOROZKS9
IUOR
ZUUNSY
JU]TGTJ[VJOXKIZOUTGR UVKXGZKY 8KVRGIKZNKLG[RZ_
\GR\KIUORYGTJGIZO\GZK JOXKIZOUTGR\GR\KIUOR
ZNKVRGZLUXSRK\KRJU]T
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
JU]TGTJ[V UVKXGZKY 8KVRGIKZNKLG[RZ_
OZKSY7GTJ8GTJ
GIZO\GZKZNKVRGZLUXS
RK\KRJU]TL[TIZOUT
L[TIZOUT
OTUVKXGZO\K
/TYZGRRGZU )NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK VYO XKYZXOIZOUTYQKKVOTM
MG[MKGZZNKW[OIQ VRGZLUXSRK\KRJU]T
JOYIUTTKIZIU[VROTMUT UXSUXK L[TIZOUTLXUSUVKXGZOTM
ZNKL[TIZOUTSGTOLURJ 58XKVRGIKYRG\K
GTJGIZO\GZKZNKVRGZLUXS I_ROTJKX58XKVRGIK
RK\KRJU]TL[TIZOUT YRG\KI_ROTJKX
58IUTY[RZ-KTOK
RKYYZNGT /TJ[YZXOKY9KX\OIK
VYO *KVGXZSKTZ
8KVRGIKLRU]XKM[RGZUX
\GR\KOZKS458ZKYZ
SGYZKXI_ROTJKXYKK
)NGXZ58XKVGOXUX
XKVRGIKYRG\KI_ROTJKXUX
YRG\KI_ROTJKX
58L[TIZOUTSGTOLURJ
SG_NG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Chart 26
Platform Rotate =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXT]NZ
Left Function Z[XTKJZUMXU[TJ < ]OXKLXUS:9ZU:(
IUTZXURYGTJHUZN ZU:658ZKYZZUMMRK
Inoperative +SKXMKTI_9ZUVH[ZZUTY Y]OZIN9KK8KVGOX
V[RRKJU[ZZUZNK54 9KIZOUT
VUYOZOUTSU\KZNK
Be sure all other L[TIZOUTKTGHRKZUMMRK
GIZO\GZKZNKVRGZLUXS
normally. XUZGZKZUMMRKY]OZIN
:9OTZNKRKLZJOXKIZOUT
GTJINKIQ\URZGMKGZ
MXT]NZ]OXKGZ:6GZ
ZNKVRGZLUXSIUTZXURY
<
=OZNQK_Y]OZINZ[XTKJ < )NKIQ\URZGMKUTIKTZKX < 8KVGOXUVKTOTXKJ
ZUVRGZLUXSIUTZXURYGTJ ZKXSOTGRUL:9 VU]KX]OXKIOXI[OZ
HUZN+SKXMKTI_9ZUV ZNXU[MNIUTZXURRKXYGTJ
H[ZZUTYV[RRKJU[ZZUZNK L[TIZOUTZUMMRKY]OZINKY
54VUYOZOUTGIZO\GZKLUUZ ZU:9
Y]OZINGTJVRGZLUXS
XUZGZKZUMMRKY]OZIN:9
INKIQ\URZGMKGZZNKMXT <
]NZ]OXKGZZNKPOHJKRG_
IGVGIOZUX
=OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOTMXT]NZ

ZUVRGZLUXSIUTZXURGTJ ]OXKLXUS:6ZUPOH
HUZN+SKXMKTI_9ZUV JKRG_IGVGIOZUX
54VUYOZOUTGIZO\GZKLUUZ
Y]OZINGTJVRGZLUXS
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Y]OZIN:9OTZNKRKLZ
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)UTZOT[KJUTZNKTK^Z XKVRGIKVRGZLUXSXUZGZK
VGMK ZUMMRKY]OZIN:9

CHART 26
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 8KVRGIKZNKPOHJKRG_

VXK\OU[YVGMK ZUVRGZLUXSIUTZXURGTJ < IGVGIOZUX58XKVGOX
HUZN+SKXMKTI_9ZUV UVKTOTHXU]TMXU[TJ
H[ZZUTYV[RRKJU[ZZUZNK ]OXKLXUSIGVGIOZUXZU
54VUYOZOUTGIZO\GZKLUUZ MXU[TJ
Y]OZINGTJVRGZLUXS
INKIQ\URZGMKGZZNKXKJ
]OXKGZZNKPOHJKRG_
IGVGIOZUX
<
'IZO\GZKLUUZY]OZINGTJ < 8KVGOXUVKTOTXKJ]OXK

VRGZLUXSXUZGZKZUMMRK LXUSPOHJKRG_IGVGIOZUX
Y]OZIN:9OTZNKRKLZ ZU)8
JOXKIZOUTGTJINKIQ
\URZGMKUTZNKXKJ]OXK
GZZKXSOTGR UT
)8
<
'IZO\GZKLUUZY]OZINGTJ 8KVRGIKXKRG_)858
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Y]OZIN:9OTZNKRKLZ Y[VVR_LXUS6ZU)8
JOXKIZOUTGTJINKIQ 58XKVGOXUVKTOTHXU]T
\URZGMKUTZNKXKJGTJ MXU[TJ]OXKZU)8
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<
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Y]OZIN:9OTZNKRKLZ ]OXKYLXUS)8ZUPOH
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< UX
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ZNK\GR\KIUORY IUOR
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VGMK

CHART 26
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK HXU]TMXU[TJ]OXKYUT IUTZOT[OZ_ MXU[TJ]OXKIOXI[OZZU
\GR\KIUORYZUMXU[TJ \GR\KIUORY
IUTZOT[OZ_
+ÎNGTMKPOHHUUS L[TIZOUT 8KVGOXUVKTOTHXU]T

VRGZLUXSXUZGZKYKRKIZ UVKXGZKY MXU[TJ]OXKIOXI[OZZU
\GR\KYOZKS'< \GR\KIUORY
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L[TIZOUT
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\GR\K)NKIQVRGZLUXS SG_HKJKLKIZO\K
XUZGZKRKLZL[TIZOUT
L[TIZOUT
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SGTOLURJOYVR[MMKJ58
POHSGTOLURJSG_NG\K
GTOTZKXTGRLG[RZ)UTY[RZ
*KVGXZSKTZ

Chart 27
Platform Rotate =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXT]NZ
Right Function Z[XTKJZUMXU[TJIUTZXUR < ]OXKLXUS:9ZU:(
GTJHUZN+SKXMKTI_ ZU:658ZKYZZUMMRK
Inoperative 9ZUVH[ZZUTYV[RRKJU[Z Y]OZIN9KK8KVGOX
ZUZNK54VUYOZOUTSU\K 9KIZOUT
ZNKL[TIZOUTKTGHRK
Be sure all other ZUMMRKY]OZINZUKOZNKX
functions operate YOJKGTJGIZO\GZKZNK
VRGZLUXSXUZGZKZUMMRK
normally. Y]OZIN:9OTZNKXOMNZ
JOXKIZOUTGTJINKIQ
\URZGMKGZMXT]NZ]OXK
GZ:6GZZNKVRGZLUXS
IUTZXURY
<
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ZUVRGZLUXSIUTZXURGTJ ZKXSOTGRUL:9 VU]KX]OXKIOXI[OZ
HUZN+SKXMKTI_9ZUV ZNXU[MNIUTZXURRKXYGTJ
H[ZZUTYV[RRKJU[ZZUZNK L[TIZOUTZUMMRKY]OZINKY
54VUYOZOUTGIZO\GZKLUUZ ZU:9
Y]OZINGTJVRGZLUXS
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]NZ]OXKGZZNKPOHJKRG_
IGVGIOZUX
=OZNQK_Y]OZINZ[XTKJ < 8KVGOXUVKTOTMXT]NZ

ZUVRGZLUXSIUTZXURGTJ ]OXKLXUS:6ZUPOH
HUZN+SKXMKTI_9ZUV JKRG_IGVGIOZUX
54VUYOZOUTGIZO\GZKLUUZ
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XKVRGIKVRGZLUXSXUZGZK
)UTZOT[KJUTZNKTK^Z ZUMMRKY]OZIN:9
VGMK

CHART 27
)UTZOT[KJLXUSZNK =OZNQK_Y]OZINZ[XTKJ 8KVRGIKZNKPOHJKRG_

VXK\OU[YVGMK ZUVRGZLUXSIUTZXURGTJ < IGVGIOZUX58XKVGOX
HUZN+SKXMKTI_9ZUV UVKTOTHXU]TMXU[TJ
H[ZZUTYV[RRKJU[ZZUZNK ]OXKLXUSIGVGIOZUXZU
54VUYOZOUTGIZO\GZKLUUZ MXU[TJ
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JOXKIZOUTGTJINKIQ
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<
'IZO\GZKLUUZY]OZINGTJ 8KVGOXUVKTOTIGHRK
VRGZLUXSXUZGZKZUMMRK < IUTZGOTOTMXKJGTJHRGIQ
Y]OZIN:9OTZNKXOMNZ ]OXKYLXUS)8ZUPOH
JOXKIZOUTGTJINKIQ HUUSVRGZLUXSXUZGZK
\URZGMKUTZNKXKJGTJ YKRKIZ\GR\KY
HRGIQ]OXKYGZZNKPOH
\GR\KYOZKS'<
< UX
OTLOTOZK
:KYZZNKXKYOYZGTIKUL UNSY 8KVRGIKLG[RZ_\GR\K
ZNK\GR\KIUORY IUOR
ZU
UNSY
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 27
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK HXU]TMXU[TJ]OXKYUT IUTZOT[OZ_ MXU[TJ]OXKIOXI[OZZU
\GR\KIUORYZUMXU[TJ \GR\KIUORY
IUTZOT[OZ_
+ÎNGTMKPOHHUUS L[TIZOUT 8KVGOXUVKTOTHXU]T

VRGZLUXSXUZGZKYKRKIZ UVKXGZKY MXU[TJ]OXKIOXI[OZZU
\GR\KYOZKS'< \GR\KIUORY
'IZO\GZKLUUZY]OZINGTJ
VRGZLUXSXUZGZKXOMNZ
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
'IZO\GZKVRGZLUXSXUZGZK 8KVGOXUVKTOTMXTHRQ
XOMNZL[TIZOUTGTJINKIQ < ]OXKLXUS:(ZU
ZNK\URZGMKUTZNKMXT VRGZLUXSXUZGZKPOHHUUS
HRQ]OXKGZZNKVRGZLUXS JOXKIZOUTGR\GR\KIUOR
XUZGZKPOHHUUS OZKS**
JOXKIZOUTGR\GR\K
OZKS((
<
+ÎNGTMKZNKZ]U\GR\K L[TIZOUT 8KVRGIKZNKLG[RZ_\GR\K

IUORYUTZNKJOXKIZOUTGR UVKXGZKY IUOR58\GR\KIGXZXOJMK
\GR\K)NKIQVRGZLUXS SG_HKLG[RZ_
XUZGZKXOMNZL[TIZOUT
L[TIZOUT
OTUVKXGZO\K
8KVGOXUXXKVRGIK
VRGZLUXSXUZGZUX58
UXOLOIKOTPOH
SGTOLURJOYVR[MMKJ58
POHSGTOLURJSG_NG\K
GTOTZKXTGRLG[RZ)UTY[RZ
*KVGXZSKTZ

Chart 28
Jib Boom Up =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTMXT]OXK
Function Z[XTKJZUMXU[TJIUTZXUR KTGHRKZUMMRKY]OZINZU LXUS:(ZUPOHHUUS
GTJHUZN+SKXMKTI_ < KOZNKXYOJKGTJGIZO\GZK < [VJOXKIZOUTGR\GR\K58
Inoperative, 9ZUVH[ZZUTYV[RRKJU[Z ZNKPOHHUUSZUMMRK XKVGOXUVKTOTHXU]T
ZUZNK54VUYOZOUTSU\K Y]OZIN:9OTZNK[V MXU[TJ]OXKIOXI[OZZU
Z-45/25J ZNKL[TIZOUTKTGHRK JOXKIZOUTGTJINKIQ JOXKIZOUTGR\GR\K
ZUMMRKY]OZINZUKOZNKX \URZGMKGZ:(
Models YOJKGTJGIZO\GZKZNKPOH
HUUSZUMMRKY]OZIN <
:9OTZNK[VJOXKIZOUT
Be sure all other GTJINKIQ\URZGMKGZZNK
functions operate MXT]OXKUTZNKPOHHUUS 8KVGOXUVKTOTXKJ
normally. [VJOXKIZOUTGR\GR\K VU]KX]OXKIOXI[OZLXUS
OZKS(( QK_Y]OZINZU:958
XKVRGIKZUMMRKY]OZIN
:9
<
=OZNZNKQK_Y]OZIN 'IZO\GZKZNKLUUZY]OZIN < 8KVGOXUVKTOTMXT]OXK

Z[XTKJZUVRGZLUXS < GTJZNKPOHHUUSZUMMRK LXUS:6ZU:(
IUTZXURGTJHUZN Y]OZIN:9OTZNK[V
+SKXMKTI_9ZUVH[ZZUTY JOXKIZOUTGTJINKIQ
V[RRKJU[ZZUZNK54 \URZGMKGZ:6
VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJZNKPOH
HUUSZUMMRKY]OZIN:9 <
OTZNK[VJOXKIZOUTGTJ
INKIQ\URZGMKGZ:(
=OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXT]OXK
Z[XTKJZUVRGZLUXS < LXUS:9ZU:658
IUTZXURGTJHUZN XKVRGIKPOHHUUSZUMMRK
+SKXMKTI_9ZUVH[ZZUTY Y]OZIN:9
V[RRKJU[ZZUZNK54
VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJINKIQ
ZNK\URZGMKUTZNK
IKTZKXZKXSOTGRULZNKPOH
HUUSZUMMRKY]OZIN:9
<
< )NKIQZNK\URZGMKGZ < 8KVGOXUVKTOTXKJ]OXK
ZKXSOTGR UT)8 LXUS(6ZU)858
XKVGOXUVKTOTHXU]T
MXU[TJ]OXKIOXI[OZZU
< )8
)NKIQZNK\URZGMKGZ < 8KVRGIK)8

ZKXSOTGR GUT)8
<
)UTZOT[KJUTZNKTK^Z 8KVGOXUVKTOTXKJ]OXK
VGMK LXUSZKXSOTGR GUT
)8ZU:958
9KX\OIK*KVGXZSKTZ

CHART 28
)UTZOT[KJLXUSZNK 'IZO\GZKLUUZY]OZINGTJ < 8KVRGIK)8

VXK\OU[YVGMK POHHUUSZUMMRKY]OZIN
:9OTZNK[VJOXKIZOUT
GTJINKIQ\URZGMKUT
ZNKXKJGTJHRGIQ]OXKY
GZZNKPOHVRGZLUXSXUZGZK
YKRKIZ\GR\KYOZKS'<
<
/TYZGRRGZUVYO +ÎNGTMKPOHHUUS L[TIZOUT

ZUHGXVXKYY[XK VRGZLUXSXUZGZKYKRKIZ UVKXGZKY 8KVRGIKLG[RZ_\GR\K
MG[MKGZZNKW[OIQ VYO \GR\KYOZKS'<
JOYIUTTKIZIU[VROTMUT 'IZO\GZKLUUZY]OZINGTJ
ZNKL[TIZOUTSGTOLURJ POHHUUS[VL[TIZOUT
GTJGIZO\GZKZNKPOH
HUUS[VL[TIZOUT L[TIZOUT
OTUVKXGZO\K
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTMPOH
HUUS[VL[TIZOUTLXUS
UVKXGZOTM58XKVGOXUX
XKVRGIKPOHHUUS
I_ROTJKX58XKVRGIK
IU[TZKXHGRGTIK\GR\K
RKYYZNGT 58UXOLOIKSG_
VYO HKVR[MMKJ58POH
HUUSVRGZLUXSXUZGZK
YKRKIZSGTOLURJNGYGT
OTZKXTGRLG[RZ58IUTY[RZ
*KVGXZSKTZ
L[TIZOUT
+ÎNGTMKPOHHUUS UVKXGZKY 8KVRGIKLG[RZ_
GTJGIZO\GZKPOHHUUS[V
L[TIZOUT
L[TIZOUT
OTUVKXGZO\K
9KX\OIK*KVGXZSKTZ

Chart 29
Jib Boom Down =OZNZNKQK_Y]OZIN 3U\KZNKL[TIZOUT 8KVGOXUVKTOTMXTHRQ
Function Z[XTKJZUMXU[TJIUTZXUR KTGHRKZUMMRKY]OZINZU ]OXKLXUS:(ZUPOH
GTJHUZN+SKXMKTI_ < KOZNKXYOJKGTJGIZO\GZK < HUUSJU]TJOXKIZOUTGR
Inoperative, 9ZUVH[ZZUTYV[RRKJU[Z ZNKPOHHUUSZUMMRK \GR\K58XKVGOXUVKTOT
ZUZNK54VUYOZOUTSU\K Y]OZIN:9OTZNKJU]T HXU]TMXU[TJ]OXK
Z-45/25J ZNKL[TIZOUTKTGHRK JOXKIZOUTGTJINKIQ IOXI[OZZUJOXKIZOUTGR
ZUMMRKY]OZINZUKOZNKX \URZGMKGZ:( \GR\K
Models YOJKGTJGIZO\GZKZNKPOH
HUUSZUMMRKY]OZIN <
:9OTZNKJU]T
Be sure all other JOXKIZOUTGTJINKIQ
functions operate \URZGMKGZZNKMXTHRQ 8KVGOXUVKTOTXKJ
normally. ]OXKUTZNKPOHHUUS VU]KX]OXKIOXI[OZLXUS
JU]TJOXKIZOUTGR\GR\K QK_Y]OZINZU:958
OZKS(( XKVRGIKZUMMRKY]OZIN
:9
<
=OZNZNKQK_Y]OZIN 'IZO\GZKZNKLUUZY]OZIN < 8KVGOXUVKTOTMXTHRQ

Z[XTKJZUVRGZLUXS < GTJZNKPOHHUUSZUMMRK ]OXKLXUS:6ZU:(
IUTZXURGTJHUZN Y]OZIN:9OTZNKJU]T
+SKXMKTI_9ZUVH[ZZUTY JOXKIZOUTGTJINKIQ
V[RRKJU[ZZUZNK54 \URZGMKGZ:6
VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJZNKPOH
HUUSZUMMRKY]OZIN:9 <
OTZNKJU]TJOXKIZOUT
GTJINKIQ\URZGMKGZ
:( =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXT]OXK
Z[XTKJZUVRGZLUXS < LXUS:9ZU:658
IUTZXURGTJHUZN XKVRGIKPOHHUUSZUMMRK
+SKXMKTI_9ZUVH[ZZUTY Y]OZIN:9
V[RRKJU[ZZUZNK54
VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJINKIQ
ZNK\URZGMKUTZNK
IKTZKXZKXSOTGRULZNKPOH
HUUSZUMMRKY]OZIN:9
<
< )NKIQZNK\URZGMKGZ < 8KVGOXUVKTOTXKJ]OXK
ZKXSOTGR UT)8 LXUS(6ZU)858
XKVGOXUVKTOTHXU]T
MXU[TJ]OXKIOXI[OZZU
< )8
)NKIQZNK\URZGMKGZ < 8KVRGIK)8

ZKXSOTGR GUT)8
<
)UTZOT[KJUTZNKTK^Z 8KVGOXUVKTOTXKJ]OXK
VGMK LXUSZKXSOTGR GUT
)8ZU:958
9KX\OIK*KVGXZSKTZ

CHART 29
)UTZOT[KJLXUSZNK 'IZO\GZKLUUZY]OZINGTJ < 8KVRGIK)8

VXK\OU[YVGMK POHHUUSZUMMRKY]OZIN
:9OTZNKJU]T
JOXKIZOUTGTJINKIQ
\URZGMKUTZNKXKJGTJ
HRGIQ]OXKYGZZNKPOH
\GR\KYOZKS'<
<
/TYZGRRGZUVYO +ÎNGTMKPOHHUUS L[TIZOUT

ZUHGXVXKYY[XK UVKXGZKY 8KVRGIKLG[RZ_\GR\K
MG[MKGZZNKW[OIQ VYO VRGZLUXSXUZGZKYKRKIZ
\GR\KYOZKS'<
JOYIUTTKIZIU[VROTMUT 'IZO\GZKLUUZY]OZINGTJ
ZNKL[TIZOUTSGTOLURJ POHHUUS[VL[TIZOUT
GTJGIZO\GZKZNKPOH
HUUSJU]TL[TIZOUT L[TIZOUT
OTUVKXGZO\K
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTMPOH
HUUSJU]TL[TIZOUT
LXUSUVKXGZOTM58
XKVGOXUXXKVRGIKPOH
HUUSI_ROTJKX58
RKYYZNGT XKVRGIKIU[TZKXHGRGTIK
VYO \GR\K58UXOLOIK
SG_HKVR[MMKJ58POH
HUUSVRGZLUXSXUZGZK
YKRKIZSGTOLURJNGYGT
OTZKXTGRLG[RZ58IUTY[RZ
*KVGXZSKTZ
L[TIZOUT
+ÎNGTMKPOHHUUS UVKXGZKY 8KVRGIKLG[RZ_
GTJGIZO\GZKPOHHUUS
JU]TL[TIZOUT
L[TIZOUT
OTUVKXGZO\K
9KX\OIK*KVGXZSKTZ

Chart 30
Steer Left =OZNQK_Y]OZINZ[XTKJ 'IZO\GZKLUUZY]OZINGTJ <UX 8KVGOXUVKTOTHR[
Function ZUVRGZLUXSIUTZXURGTJ YZKKXXUIQKXY]OZINUT SUXK ]OXKIOXI[OZLXUSJXO\K
HUZN+SKXMKTI_9ZUV JXO\KIUTZXURRKX*6OT IUTZXURRKX*6ZU:6
Inoperative H[ZZUTYV[RRKJU[ZZUZNK RKLZJOXKIZOUTGTJINKIQ ZNKTZU:(
54VUYOZOUTGIZO\GZKLUUZ < \URZGMKGZZNKIUTZXURRKX
Y]OZINGTJYZKKXXUIQKX ZKXSOTGR]OZNZNKHR[
Be sure all other Y]OZINUTJXO\K ]OXKGZZGINKJ
functions operate IUTZXURRKX*6OTRKLZ
JOXKIZOUTGTJINKIQ <
normally. \URZGMKUT:(
8KVGOXUXXKVRGIKYZKKX
SOIXUY]OZINUTJXO\K
IUTZXURRKX)UTY[RZ
<UXSUXK -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
'IZO\GZKLUUZY]OZINGTJ 8KVGOXUVKTOTHR[
YZKKXXUIQKXY]OZINUT < ]OXKIOXI[OZZNGZX[TY
JXO\KIUTZXURRKX*6OT LXUS:(ZUYZKKXRKLZ
RKLZJOXKIZOUTGTJINKIQ JOXKIZOUTGR\GR\KIUORUT
\URZGMKUTHR[ ]OXK L[TIZOUTSGTOLURJ
UTYZKKXJOXKIZOUTGR
\GR\KIUOROZKS--UT
L[TIZOUTSGTOLURJ
<UXSUXK
*OYIUTTKIZ]OXKYZU UX 8KVRGIKYZKKXRKLZ
YZKKXRKLZJOXKIZOUTGR OTLOTOZK JOXKIZOUTGR\GR\KIUOR
\GR\KIUOROZKS--UT UNSY OZKS--58XKVGOX
L[TIZOUTSGTOLURJGTJ UVKTOTHXU]TMXU[TJ
ZKYZZNKXKYOYZGTIKULZNK ]OXKZUYZKKXRKLZ\GR\K
\GR\KIUOR IUOR
ZUUNSY
ZUHGXVXKYY[XK XKYZXOIZOUTYQKKVOTM
MG[MKGZZNKW[OIQ YZKKXRKLZL[TIZOUTLXUS
JOYIUTTKIZIU[VROTMUT 69/ UVKXGZOTM58XKVGOXUX
ZNKHUUSL[TIZOUT XKVRGIKYZKKXI_ROTJKX
SGTOLURJGTJGIZO\GZK 58XKVRGIKLRU]
ZNKYZKKXRKLZL[TIZOUT XKM[RGZUX\GR\KOZKS,
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
RKYYZNGT
69/
I_ROTJKX58YZKKX
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 31
Steer Right =OZNQK_Y]OZINZ[XTKJ 'IZO\GZKLUUZY]OZINGTJ <UX 8KVGOXUVKTOTHR[
Function ZUVRGZLUXSIUTZXURGTJ YZKKXXUIQKXY]OZINUT SUXK ]OXKIOXI[OZLXUSJXO\K
HUZN+SKXMKTI_9ZUV JXO\KIUTZXURRKX*6OT IUTZXURRKX*6ZU:6
Inoperative H[ZZUTYV[RRKJU[ZZUZNK XOMNZJOXKIZOUTGTJINKIQ ZNKTZU:(
54VUYOZOUTGIZO\GZKLUUZ < \URZGMKGZZNKIUTZXURRKX
Y]OZINGTJYZKKXXUIQKX ZKXSOTGR]OZNZNKHR[HRQ
Be sure all other Y]OZINUTJXO\K ]OXKGZZGINKJ
functions operate IUTZXURRKX*6OTXOMNZ
JOXKIZOUTGTJINKIQ <
normally. \URZGMKUT:(
SOIXUY]OZINUTJXO\K
IUTZXURRKX)UTY[RZ
<UXSUXK -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
'IZO\GZKLUUZY]OZINGTJ 8KVGOXUVKTOTHR[HRQ
YZKKXXUIQKXY]OZINUT < ]OXKIOXI[OZZNGZX[TY
JXO\KIUTZXURRKX*6OT LXUS:(ZUYZKKXXOMNZ
XOMNZJOXKIZOUTGTJINKIQ JOXKIZOUTGR\GR\KIUORUT
\URZGMKUTHR[HRQ L[TIZOUTSGTOLURJ
]OXKUTYZKKXJOXKIZOUTGR
\GR\KIUOROZKS--UT
L[TIZOUTSGTOLURJ
<UXSUXK
*OYIUTTKIZ]OXKYZU UX 8KVRGIKYZKKXXOMNZ
YZKKXXOMNZJOXKIZOUTGR OTLOTOZK JOXKIZOUTGR\GR\KIUOR
\GR\KIUOROZKS--UT UNSY OZKS--58XKVGOX
L[TIZOUTSGTOLURJGTJ UVKTOTHXU]TMXU[TJ
ZKYZZNKXKYOYZGTIKULZNK ]OXKZUYZKKXXOMNZ\GR\K
\GR\KIUOR IUOR
ZUUNSY
ZUHGXVXKYY[XK XKYZXOIZOUTYQKKVOTM
MG[MKGZZNKW[OIQ 69/ YZKKXXOMNZL[TIZOUTLXUS
JOYIUTTKIZIU[VROTMUT UVKXGZOTM58XKVGOXUX
ZNKHUUSL[TIZOUT XKVRGIKYZKKXI_ROTJKX
SGTOLURJGTJGIZO\GZK 58XKVRGIKLRU]
ZNKYZKKXXOMNZL[TIZOUT XKM[RGZUX\GR\KOZKS,
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
RKYYZNGT
69/
I_ROTJKX58YZKKX
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ

Chart 32
Oscillate 8KSU\KZNKINGYYOY HGJ 8KGJP[YZUXXKVRGIK
IU\KXGTJZNKG^RK ROTQGMK
Function IU\KXYLXUSZNKTUT
Inoperative YZKKXKTJULZNK
SGINOTK)NKIQZNK
ROTQGMKLUXJGSGMKUX
Be sure all other OSVXUVKXROTQGMK
function operate GJP[YZSKTZ9KK8KVGOX
normally. YKIZOUT.U]ZU9KZ
;VZNK*OXKIZOUTGR<GR\K
2OTQGMK
MUUJ
/TYZGRRGZUVYO 'JP[YZZNKINGXMK
ZUHGXVXKYY[XK RKYYZNGT VXKYY[XKXKROKL\GR\K
MG[MKGZZNKW[OIQ 9KK8KVGOXVXUIKJ[XK
JOYIUTTKIZIU[VROTMUT VYO .U]ZU'JP[YZZNK
ZNKJXO\KSGTOLURJ9ZGXZ 5YIORRGZK9KW[KTIOTM
ZNKKTMOTKGTJINKIQ <GR\K6XKYY[XK58
ZNKVXKYY[XK IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
VYO
9KX\OIK*KVGXZSKTZ

Chart 33
All Drive =OZNZNKQK_Y]OZIN RKYY
Z[XTKJZUVRGZLUXS ZNGT )NKIQIUTZOT[OZ_UL 8KVGOXUVKTOTVU]KX
Functions IUTZXURGTJHUZN < HXU]TMXU[TJ]OXKLXUS IUTZOT[OZ_ Y[VVR_IOXI[OZLXUS:6
Inoperative, +SKXMKTI_9ZUVH[ZZUTY ZKXSOTGR UT*6ZU ZUZKXSOTGR UTJXO\K
V[RRKJU[ZZUZNK54 MXU[TJ PU_YZOIQ*6
All Other VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJINKIQ TUIUTZOT[OZ_
Functions ZNK\URZGMKGZZKXSOTGR
UTZNKJXO\KPU_YZOIQ
Operate *6 8KVGOXUVKTOTHXU]T
MXU[TJ]OXKIOXI[OZLXUS
Normally MXU[TJZU*6
<UXSUXK
Be sure the rpm toggle
switch is in the
footswitch activated 'IZO\GZKZNKLUUZY]OZIN RKYY )NKIQIUTZOT[OZ_UL 8KVGOXUVKTOTVU]KX
high idle position. GTJINKIQZNK\URZGMKGZ ZNGT
< HXU]TMXU[TJ]OXKLXUS IUTZOT[OZ_ Y[VVR_IOXI[OZLXUS:6
ZKXSOTGR UTZNK ZKXSOTGR UTZNK ZUZKXSOTGR UTZNK
NUXYKVU]KXROSOZKX NUXYKVU]KXROSOZKX NUXYKVU]KXROSOZKX
Be sure the hydraulic IOXI[OZHUGXJ IOXI[OZHUGXJZUMXU[TJ IOXI[OZHUGXJ
tank shut off valves are
in the OPEN position. TUIUTZOT[OZ_
Be sure machine is 8KVGOXUVKTOTHXU]T
not in the free wheel MXU[TJ]OXKIOXI[OZLXUS
configuration. <UXSUXK MXU[TJZUZKXSOTGR UT
ZNKNUXYKVU]KXROSOZKX
IOXI[OZHUGXJ
9ZGXZZNKKTMOTKZNKT 'IZO\GZKZNKLUUZY]OZIN ZU< 8KVRGIKNUXYKVU]KX

GIZO\GZKZNKLUUZY]OZIN < GTJINKIQZNK\URZGMKGZ ROSOZKXHUGXJ
GTJNURJZNKJXO\K ZKXSOTGR UTZNK
PU_YZOIQOTZNKL[RR NUXYKVU]KXROSOZKX
LUX]GXJVUYOZOUTGTJ HUGXJ
INKIQZNK\URZGMKGZ
ZKXSOTGR UTZNK <
NUXYKVU]KXROSOZKX
HUGXJ
'IZO\GZKZNKLUUZY]OZIN 8KVGOXUVKTOTUXMHRQ
GTJINKIQZNK\URZGMK ZU< ]OXKLXUSGRZKXTGZUX
UTZNKUXMHRQ ]OXK ZU:(ZU:6ZU
UTZNKGRZKXGZUX ZKXSOTGR UT
NUXYKVU]KXROSOZKX
< HUGXJ
ZU<
8KVGOXUXXKVRGIK
GRZKXTGZUX
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 33
)UTZOT[KJLXUSZNK 'IZO\GZKZNKLUUZY]OZIN 8KVGOXUVKTOT]OXKLXUS

VXK\OU[YVGMK GTJNURJZNKJXO\K < ZKXSOTGR UT
PU_YZOIQOTZNKL[RR NUXYKVU]KXROSOZKX
LUX]GXJVUYOZOUTGTJ HUGXJZUZKXSOTGR UT
INKIQZNK\URZGMKGZ ZNKJXO\KPU_YZOIQ
ZKXSOTGR UTZNKJXO\K
PU_YZOIQIUTZXURRKX
ZU<
)UTTKIZZNKVUYOZ\K )NKIQIUTZOT[OZ_LXUS TU
RKGJLXUSG\URZSKZKXZU < ZKXSOTGR UTJXO\K IUTZOT[OZ_ 8KVGOXUVKTOTHXU]T
ZKXSOTGR UTZNK PU_YZOIQZUMXU[TJ ZKXSOTGR UTJXO\K
PU_YZOIQGTJZNKTKMGZO\K PU_YZOIQZUMXU[TJ
RKGJZUZKXSOTGR UT IUTZOT[OZ_
ZNKPU_YZOIQ'IZO\GZKZNK
LUUZY]OZINGTJNURJZNK
JXO\KPU_YZOIQOTZNKL[RR 8KVRGIKJXO\KPU_YZOIQ
LUX]GXJVUYOZOUTGTJ IUTZXURRKX58IUTY[RZ
INKIQZNK\URZGMK -KTOK/TJ[YZXOKY9KX\OIK
GIXUYYZNK GTJ *KVGXZSKTZ
ZKXSOTGRYUTZNKJXO\K
PU_YZOIQIUTZXURRKX
<
)UTTKIZZNKVUYOZ\K )NKIQIUTZOT[OZ_LXUS TU
RKGJLXUSG\URZSKZKXZU < ZKXSOTGR UTJXO\K IUTZOT[OZ_ 8KVGOXUVKTOTHXU]T
ZKXSOTGR UTZNK PU_YZOIQZUMXU[TJ ZKXSOTGR UTJXO\K
PU_YZOIQGTJZNKTKMGZO\K PU_YZOIQZUMXU[TJ
RKGJZUZKXSOTGR UT IUTZOT[OZ_
ZNKPU_YZOIQ'IZO\GZKZNK
LUUZY]OZINGTJNURJZNK
JXO\KPU_YZOIQOTZNKL[RR 8KVRGIKJXO\KPU_YZOIQ
XK\KXYKVUYOZOUTGTJ IUTZXURRKX58IUTY[RZ
INKIQZNK\URZGMK -KTOK/TJ[YZXOKY9KX\OIK
GIXUYYZNK GTJ *KVGXZSKTZ
ZKXSOTGRYUTZNKJXO\K
PU_YZOIQIUTZXURRKX
<
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 33
)UTZOT[KJLXUSZNK 'IZO\GZKZNKLUUZY]OZIN =OZNZNKLUUZY]OZIN 8KVGOXUVKTOT]NZ]OXK

VXK\OU[YVGMK GTJNURJZNKJXO\K GIZO\GZKJGTJZNKJXO\K LXUSZKXSOTGR UT
PU_YZOIQOTZNKL[RR PU_YZOIQOTZNKL[RR JXO\KPU_YZOIQZU:9ZU
LUX]GXJVUYOZOUTGTJ < LUX]GXJVUYOZOUTSU\K < :6ZU:(ZNXU[MN
INKIQZNK\URZGMK ZNKJXO\KKTGHRKZUMMRK JXO\KKTGHRKROSOZY]OZIN
GIXUYYZNK]NZ ]OXK Y]OZIN:9ZUKOZNKX 29ZU:(ZU]NZ
GTJZNK]NZHRQ ]OXK YOJKGTJINKIQZNK ]OXKUT+*)W[OIQ
UT+*) \URZGMKGIXUYYZNK]NZ JOYIUTTKIZVR[M
]OXKGTJZNK]NZHRQ
UT+*)
<
)UTTKIZZNKVUYOZ\K 8KVGOXUVKTOTHR[]NZ
RKGJLXUSG\URZSKZKXZU < ]OXKLXUS:9ZU:6
ZKXSOTGR UTZNK ZU:(
PU_YZOIQGTJ]OZNZNKLUUZ
Y]OZINGIZO\GZKJGTJZNK
JXO\KPU_YZOIQOTZNKL[RR
LUX]GXJVUYOZOUTSU\K
ZNKJXO\KKTGHRKZUMMRK
Y]OZIN:9ZUKOZNKX
YOJKGTJNURJZNK
TKMGZO\KRKGJLXUSZNK
\URZSKZKXUTZUZNK
HR[]NZ]OXKUT:9
GTJINKIQZNK\URZGMK
<
<
)UTTKIZZNKVUYOZ\K 8KVGOXUVKTOT]OXKLXUS
RKGJLXUSG\URZSKZKXZU ZKXSOTGR LXUSJXO\K
ZKXSOTGR UTZNK PU_YZOIQ*6ZUJXO\K
PU_YZOIQGTJ]OZNZNKLUUZ < KTGHRKZUMMRKY]OZIN
Y]OZINGIZO\GZKJGTJZNK :958XKVRGIKJXO\K
JXO\KPU_YZOIQOTZNKL[RR PU_YZOIQIUTZXURRKX58
LUX]GXJVUYOZOUTNURJ IUTY[RZ-KTOK/TJ[YZXOKY
ZNKTKMGZO\KRKGJULZNK 9KX\OIK*KVGXZSKTZ
\URZSKZKXUTZUZNK
IKTZKXZKXSOTGRULZNK
JXO\KKTGHRKZUMMRK
Y]OZIN:9GTJINKIQ
ZNK\URZGMK
<
8KVRGIKJXO\KKTGHRK
ZUMMRKY]OZIN:9
:XU[HRKYNUUZJXO\K
LUX]GXJGTJJXO\K
XK\KXYKL[TIZOUTY
YKVGXGZKR_58XKVRGIK
V[SV58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Chart 34
Drive Forward *OYIUTTKIZZNK+*) \URZGMKXKGJOTMYJOLLKXKTZ 8KVGOXUXXKVRGIKZNK
]OXKIUTTKIZUXLXUSZNK JXO\KIUTZXURRKX*6
Or Reverse JXO\KV[SVYZGXZ
Function KTMOTKSU\KZNKJXO\K
IUTZXURRKXZUL[RRLUX]GXJ
Inoperative VUYOZOUTGTJTUZKZNK
\URZGMKGIXUYYZNK]NZ
GTJZNK]NZHRQ
Be sure all other ]OXKZKXSOTGRYUTZNK
functions operate +*)8K\KXYKZNK\URZ
normally including SKZKXRKGJYGTJSU\K
ZNKJXO\KIUTZXURRKXZUL[RR
drive in opposite XK\KXYKVUYOZOUTGTJ
direction of TUZKZNK\URZGMK
malfunction.
\URZGMKXKGJOTMY
ZNKYGSK
UX
OTLOTOZK
)NKIQZNKXKYOYZGTIKUL UNSY 8KVRGIKZNK+*)
ZNK+*)
ZUUNSY
'JP[YZZNKJXO\KV[SV ,G[RZ_9[TJYZXGTJJXO\K
T[RRTK[ZXGR)UTY[RZ TUOSVXU\KSKTZ V[SVIUTZGIZ
-KTOK/TJ[YZXOKY9KX\OIK 9[TJYZXGTJG[ZNUXO`KJ
*KVGXZSKTZ XKVGOXLGIOROZ_
Y_SVZUSYOSVXU\K
8KGJP[YZJXO\KPU_YZOIQ
IUTZXURRKX58OLVXUHRKS
YZORRVKXYOYZYIUTY[RZ
*KVGXZSKTZ

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

Chart 36
Machine Will =OZNZNKHUUSOTZNK 8KVGOXYNUXZZUMXU[TJ
Not Drive At YZU]KJVUYOZOUTINKIQ IUTZOT[OZ_ OT]NZ]OXKYZUROSOZ
IUTZOT[OZ_LXUS:(ZU Y]OZINKY2929GTJ
Full Speed MXU[TJ 2958XKVGOXUX
XKVRGIKVXOSGX_HUUSROLZ
JXO\KROSOZY]OZIN
Be sure all other YKIUTJGX_HUUSJXO\K
functions operate ROSOZY]OZINUXVXOSGX_
TUIUTZOT[OZ_ HUUSK^ZKTJROSOZ
normally. Y]OZIN
Be sure the machine
is not raised above or
extended beyond the =OZNZNKHUUSOTZNK 8KVGOXYNUXZZUMXU[TJ
drive limit switches. YZU]KJVUYOZOUTINKIQ OTUXGTMK]OXKLXUS
ZKXSOTGR UT IUTZOT[OZ_ :(ZU:6ZU
Be sure the primary NUXYKVU]KXROSOZKX ZKXSOTGR UT
HUGXJLUXIUTZOT[OZ_ZU NUXYKVU]KXROSOZKX
boom drive limit MXU[TJ IOXI[OZHUGXJ
switch is clear of any
debris and is not TUIUTZOT[OZ_
activated when the
boom is in the stowed 8KGJP[YZUXXKVRGIK
NUXYKVU]KXROSOZKX
position.
HUGXJ58INKIQLUX
SOYGROMTSKTZULROSOZ
Be sure the Y]OZINKY2929GTJ
secondary boom drive 2958IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
limit switch is clear of
*KVGXZSKTZ
any debris and is not
activated when the
boom is in the stowed
position.
Be sure that the
primary boom extend
drive limit switch arm
is being activated
when the boom is
fully retracted.
Be sure the wiring to

limit switches is intact
and show no sign of
damage or corrosion.
Be sure the free-

wheel valve is closed
on the drive pump.

Chart 37
Machine Drives +^ZKTJZNKHUUSVGYZ 8KVRGIKNUXYKVU]KX
ZNKJXO\KROSOZY]OZINGTJ ROSOZKXHUGXJ58XK
At Full Speed INKIQIUTZOT[OZ_LXUS IUTZOT[OZ_ GJP[YZNUXYKVU]KX
MXU[TJZUZKXSOTGR UT ROSOZKXHUGXJ58IUTY[RZ
With Platform ZNKNUXYKVU]KXROSOZKX -KTOK/TJ[YZXOKY9KX\OIK
Raised or HUGXJ *KVGXZSKTZ
Extended TUIUTZOT[OZ_
Be sure primary boom )NKIQIUTZOT[OZ_LXUS IUTZOT[OZ_ 8KVGOXUVKTOTUXM]OXK
drive limit switch is MXU[TJZU:( IOXI[OZLXUS:(ZU
being activated by the :6ZUZKXSOTGR UT
NUXYKVU]KXROSOZKX
cam on the primary IOXI[OZHUGXJ
boom when the primary TUIUTZOT[OZ_
boom is raised.
Be sure secondary :KYZROSOZY]OZINKY9KK HGJ 8KVRGIKLG[RZ_ROSOZ

boom drive limit switch VXUIKJ[XK'OTZNK Y]OZINIUTZGIZ58
is being activated by the 3GOTZKTGTIK9KIZOUT XKVRGIKROSOZY]OZIN
cam on the
MUUJ
compression link when
the secondary boom is 8KVGOXUVKTLXUS]NZ
raised. ]OXKYGZ:(ZUJXO\K
ROSOZY]OZINKY2929
Be sure that the primary GTJ29ZNKTLXUS
HXU]TMXU[TJ]OXKYZU
boom extend drive limit MXU[TJ
switch is not being held
down or being activated
when the primary boom
is extended.
Be sure the wiring to

limit switches is intact
and show no sign of
damage or corrosion.

Chart 38
Drive Enable =OZNQK_Y]OZINOT 'IZO\GZKLUUZY]OZINGTJ < 8KVGOXUVKTOTVU]KX
VRGZLUXSVUYOZOUTGTJ JXO\KIUTZXURRKXOT Y[VVR_IOXI[OZLXUS
System Is HUZN+SKXMKTI_9ZUV TU LUX]GXJJOXKIZOUTGTJ :6
Malfunctioning H[ZZUTYV[RRKJU[ZZUZNK INKIQ\URZGMKGZ
54VUYOZOUTGTJZNK ZKXSOTGR UTJXO\K
HUUSXUZGZKJHKZ]KKT IUTZXURRKX*6
Be sure the boom is in ZNKTUTYZKKXZOXKY
the stowed position. GIZO\GZKLUUZY]OZINGTJ <UXSUXK
JXO\KIUTZXURRKXOT
LUX]GXJJOXKIZOUT=ORR
[TOZJXO\K% 8KVGOXUVKTLXUS
ZKXSOTGR UT*6ZU
IKTZKXZKXSOTGRUT:9
58XKLKXZU)NGXZ58
_KY 9KX\OIK*KVGXZSKTZ
=OZNQK_Y]OZINOT .URJZNKJXO\KKTGHRK :NKSGINOTKOY

VRGZLUXSVUYOZOUTGTJ Y]OZIN:9ZUKOZNKX UVKXGZOTMIUXXKIZR_/L
HUZN+SKXMKTI_9ZUV TU YOJKGTJGIZO\GZKZNK _KY SGINOTKJUKYTUZ
H[ZZUTYV[RRKJU[ZZUZNK LUUZY]OZINGTJJXO\K UVKXGZKVXUVKXR_
54VUYOZOUTGTJZNK LUX]GXJL[TIZOUT=ORR IUTY[RZ-KTOK/TJ[YZXOKY
HUUSXUZGZKJHKZ]KKT [TOZJXO\K% 9KX\OIK*KVGXZSKTZ
ZNKYZKKXKTJZOXKY
GIZO\GZKLUUZY]OZINGTJ TU
JXO\KIUTZXURRKXOT
LUX]GXJJOXKIZOUT=ORR
[TOZJXO\K% 8KVGOXUVKTOTHR[]NZ
]OXKLXUSJXO\KKTGHRK
ZUMMRKY]OZIN:9ZU
:6ZU:(58
XKVRGIKJXO\KKTGHRK
_KY ZUMMRKY]OZIN:9
)NKIQLUXIUTZOT[OZ_ IUTZOT[OZ_ 'IZO\GZKROSOZY]OZINH_ 8KVRGIKJXO\KKTGHRK

LXUS:(ZU:( NGTJGTJINKIQ IUTZOT[OZ_ ROSOZY]OZINIUTZGIZ58
IUTZOT[OZ_LXUS:(ZU XKVRGIKJXO\KKTGHRK
:( ROSOZY]OZIN29
TUIUTZOT[OZ_
TUIUTZOT[OZ_
8KVGOXUVKTLXUS:( 6RKGYKHKMOT
ZU29ZNKTLXUS29ZU ZXU[HRKYNUUZOTMLXUS
:( HKMOTTOTMULINGXZ58
9KX\OIK*KVGXZSKTZ

Chart 39
Auxiliary 2OLZZNKXKJG[ÔROGX_ /TYZGRRGZUVYO 8KIUTTKIZVXKYY[XK
V[SVY]OZINIU\KXOL SUZUX ZUHGXVXKYY[XK ROTKGTJINKIQHGZZKX_
Functions KW[OVVKJNURJG[ÔROGX_ UVKXGZKY MG[MKOTZUZNKVXKYY[XK VYO IUTJOZOUT:NKXKOY
Y]OZINGTJROYZKTLUX VUXZULZNKG[ÔROGX_ VUYYOHR_TUZKTU[MN
Inoperative YU[TJULG[ÔROGX_V[SV V[SVGTJNURJZNK HGZZKX_IGVGIOZ_ZU
SUZUXUVKXGZOTM G[ÔROGX_VU]KXZUMMRK UVKXGZKHUZNG[^V[SV
Be sure all other Y]OZINGTJTUZKZNK GTJL[TIZOUT\GR\KY
functions operate VXKYY[XK
normally. RKYYZNGT
VYO
Be sure key switch
is in the appropriate )NKIQLUXGVUYOZO\K 8KVGOXUXXKVRGIKV[SV
IUTTKIZOUTHKZ]KKT MUUJ 58XKVRGIKXKROKL\GR\K
position and both KRKIZXOISUZUXGTJZNK )UTY[RZ-KTOK/TJ[YZXOKY
Emergency Stop V[SVH_XKSU\OTMZNK 9KX\OIK*KVGXZSKTZ
buttons are pulled V[SVLXUSZNKSUZUX
H[ZRKG\KGRRZNKNUYKY
out to the ON SUZUXJUKY
IUTTKIZKJ<OY[GRR_
position. TUZUVKXGZK
INKIQIU[VROTM
IUTTKIZOUT
Be sure engine is
not running when HGJ
using auxiliary
power. 8KVRGIKZNKG[ÔROGX_
VU]KX[TOZ
Note: Operating
auxiliary power with
the engine running
=OZNZNKQK_Y]OZIN 'IZO\GZKZNKG[ÔROGX_ <UX 8KVGOXUVKTLXUS:(
should immediately Z[XTKJZUMXU[TJIUTZXUR < V[SVZUMMRKY]OZINGTJ SUXK ZU6858XKVGOXUVKT
kill the engine. GTJHUZN+SKXMKTI_ INKIQZNK\URZGMKGZ OTHXU]TMXU[TJ]OXK
9ZUVH[ZZUTYV[RRKJU[Z :( IOXI[OZZU6858
ZUZNK54VUYOZOUT XKVRGIK68
GIZO\GZKZNKG[ÔROGX_
<
V[SVZUMMRKY]OZINGTJ
INKIQZNK\URZGMKUTZNK
XKJIGHRKUTZNK 'IZO\GZKZNKG[ÔROGX_ 8KVGOXUVKTOTXKJ
G[ÔROGX_VU]KX[TOZ V[SVZUMMRKY]OZINGTJ < VU]KXY[VVR_]OXKLXUS
INKIQZNK\URZGMKGZZNK QK_Y]OZIN19ZU
IKTZKXZKXSOTGRUL:9 G[ÔROGX_ZUMMRKY]OZIN
:9
<UXSUXK
< 8KVGOXUVKTOTXKJ
]OXKLXUS:9ZU:(
58XKVRGIK:9
)NKIQIUTZOT[OZ_LXUS 8KVRGIKTKMGZO\KIGHRK
HGJ
TKMGZO\KZKXSOTGRUT LXUSG[ÔROGX_V[SVZU
G[ÔROGX_VU]KX[TOZZU MXU[TJ
MXU[TJ
MUUJ
8KVRGIKG[ÔROGX_V[SV
SUZUX


First Edition • Second Printing Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

electrically charged circuits may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
Genie Z-45/25 & Genie Z-45/25J General Repair Process
Operator's Manual.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics First Edition • Second Printing
Electrical Components
Item Description Genie Manufacturer Manufacturer Qty

Part Number Part Number
BAT ................ Battery, 900 CCA, 12V DC .... 36872 ........... Delco .................................... 34DT78 .......................... 1
BP1 ................ Joystick controller, Dual axis . 53073 ........... OEM Controls ...................... EJS5DM11179 ............... 1
CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2
CR1,2,4,5,7,8
CR7, 8,
(Gas/LPG) ...... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 6
CR1through 5,
CR7, 8,
(Diesel) ........... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 7
CR7,12,13 and 14
(Diesel) ........... Relay, SPDT, 12V DC ........... 19274 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 2
Diode
(Gas/LPG) ...... Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 25
Diode
(Diesel) ........... Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 25
DP1 ................ Joystick controller - Drive ...... 20424 ........... OEM Controls ...................... MCH1159AD1386 .......... 1
FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400A-GEN ................... 1
FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1
H1 .................. Alarm, Warble tone ................ 19270 ........... Floyd Bell Inc. ...................... MW-09-616-Q ................ 1
H2 .................. Horn, 12V DC, 130 dB ........... 56264 ........... Wolo Industries. ................... 300ST - 12 GEN ............ 1
H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q .................. 1
H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1
HM ................. Hourmeter .............................. 56100 ........... Curtis Instruments ............... 17305666 ....................... 1
KS1 ................ Contact - Keyswitch, N.O. ..... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 2
L1,2,3,4
(Gas/LPG) ...... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 4
L1,2,3
(Diesel) ........... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 3
LS1, 2, 3 ........ Contact - Limit switch,

N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2051 ..................... 3
This list continues on the next page.

ELECTRICAL COMPONENTS
Item Description Genie Manufacturer Manufacturer Qty

Part Number Part Number
Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36 ............................... 1
P1, P2 ............ Contact, N.C. ......................... 29732 ........... Telemecanique .................... ZB2-BE102 .................... 4
P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 1
PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ............................ 1
R1 .................. Resistor, 50Ω 5 watt .............. 49866 ........... Dale ..................................... RH5- 50R-1% ................ 1
R2 .................. Resistor, 100Ω 25 watt .......... 27116 ........... Dale ..................................... RH25-100R-1% ............. 1
R3 .................. Resistor, 250Ω 5 watt ............ 27117 ........... Dale ..................................... RH5- 250R-1% .............. 1
R4, (before serial number 13099)

Resistor, 15Ω 25 watt ............ 45836 ........... Dale ..................................... RH25-15R-1% ............... 1
R4, (after serial number 13098)

Resistor, 10Ω 25 watt ............ 54516 ........... Dale ..................................... D25K10R ....................... 1
R5 .................. Resistor, 10Ω 25 watt ............ 27287 ........... Dale ..................................... RH25-10R-1% ............... 1
TS1, TS51, TS64

(Gas/LPG) ...... Toggle switch, DPST
2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 3
TS1, TS51
(Diesel) ........... Toggle switch, DPST
TS2, 3, 9,13,15, 52,54

58, 59, 63
(Gas/LPG) ...... Toggle switch, SPDT
TS2,8, 9,13,15,52,54,58,
59, 63
(Diesel) ........... Toggle switch, SPDT
3 position momentary ............ 13037 ........... Microswitch Control Inc. ...... 1NT1-7 ......................... 10
TS14 .............. Toggle switch, DPST

2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 1
TS4 ................ Toggle switch, DPDT

3 position maintained ............ 13038 ........... Microswitch Control Inc. ...... 2NT1-1 ........................... 1
TS7, 57,
60, 61, 62, ...... Toggle switch, DPDT

Electrical Symbols Legend

Abbreviation Legend
LABEL DESCRIPTION
BAT ............. Battery
BP ............... Boom Proportional controller
CB ............... Circuit breaker
CR ............... Control relay
DP ............... Drive proportional controller
FB ................ Flashing beacon
FS ................ Foot switch
H .................. Horn or Alarm
HM ............... Hour meter
KS ............... Keyswitch
L .................. LED
LS ................ Limit switch
P .................. Power switch
PR ............... Power relay
R .................. Resistor
TB ................ Terminal base location
TP ................ Terminal platform location
TS ................ Toggle switch


Ford LRG-425 EFI Engine Wire Harness

(before serial number 13099)
Section 6 • Schematics Service Manual

A B C D E F G H I J K L M N
1 FORD WIRING HARNESS WIRE COLOR CODE

THROTTLE ACTUATOR/
POSITION SENSOR POWER FUEL PUMP STARTER CODE COLOR CODE COLOR CODE COLOR
CR-FA CR-FB CR-FC
FUEL INJECTOR VALVES BL BLUE GY GREY P PURPLE
87A
87A
87A
#4 #3 #2 #1
30
30
30
BK BLACK LB LIGHT BLUE R RED
87
87
87
WATER TEMP. BR BROWN LG LIGHT GREEN T TAN
SWITCH (NO)
86
85
86
85
86
85
DB DARK BLUE N NATURAL W WHITE
DG DARK GREEN O ORANGE Y YELLOW

2
GN GREEN PK PINK
787APK/BK16
570DBK/W18
351BBR/W18
359CGY/R18
558BR/LB18
926ALB/O16
355GY/W18
570BK/W12
557BR/Y18
264W/LB18
32ADKBL16
342LG/P16
16BR/LG18
32R/LB16
16R/LG16
361BR14
361AR14
361DR14
361CR14
361JR14
361ER16
39RW20
361R12
556W18
FORD ENGINE CONTROL MODULE (ECM)
37AY12
555T18
37CY16
QUICK DISCONNECTS
MATING FACE
(TO ECM)
SHOWN
95TW18 X1 IGNITION COIL 1

F1 NOT USED
K1 VPWR A
361LR18
37BY18 F2 KEEP ALIVE PWR B
H1 NOT USED
3 349DB18
A3
G1
NOT USED
CRANKSHAFT SENSOR RETURN (+)
C
350GY18 H2 CRANKSHAFT SENSOR RETURN (-) D
282DB/O18 J1 CAMSHAFT SENSOR FEED (+)
355GY/W18 C1 THROTTLE POSITION SENSOR INPUT E
238ADG/Y18 F3 FUEL PUMP MONITOR
Y3 NOT USED
Y2 NOT USED
FORD 42 PIN QUICK DISCONNECT W3 NOT USED
ENGINE HARNESS #2 555T18 S3 FUEL INJECTOR #1
556W18 S2 FUEL INJECTOR #2 F
(SEE PAGE 1) 557BR/Y18 S1 FUEL INJECTOR #3 G
558BR/LB18 T1 FUEL INJECTOR #4
TACH LEAD 2 11T/Y20 351BR/W18 A2 VREF H
RED 10awg KEEP ALIVE PWR * 1 16AR/LG16 77DB/Y18 R2 DRY FUEL MODULATOR
YELLOW 10awg KEEP ALIVE PWR * 8 37BY18 B3 NOT USED J
4 WATER TEMP. SWITCH
VPWR *
16
9
39RW20
37Y12 570BK/W18
C2
X2
NOT USED
POWER GROUND K
PINK/BLK 16awg FUEL PUMP OUTPUT 5 767PK/BK16 570ABK/W18 X3 POWER GROUND
VREF 31 351DBR/W20 570BBK/W18 W1 POWER GROUND 1 2 3
BLK/WHT 10awg BATT. - 34 570CBK/W12 570HBK/W18 W2 POWER GROUND
BLK/WHT 10awg BATT. - 42 570EBK/W12 C3 NOT USED
DATA LINK 22 107P20 E3 NOT USED
DRIVE BY WIRE SIGNAL INPUT 14 151LB/BK20 G2 NOT USED
AUXILARY INPUT 37 198DG/O20 G3 NOT USED
WHT/PUR 18awg SELF TEST INPUT * 18 209W/P20 107P20 M1 DATA LINK 1 2 3
TAN/LB 18awg GOV. SPD. CONT. 24 306T/LB20 151LB/BK20 A1 DRIVE BY WIRE
BLK/Y 18awg GOV. SPD. CONT. 25 307BK/Y20 198DG/O20 L1 AUXILLARY INPUT L
PINK/LG 18awg FAULT LT. * 6 658PK/LG20 209W/P20 H3 SELF TEST INPUT
BRN/WHT 20awg FUEL SELECT * 7 674BR/W20 306T/LB20 J2 GOVERNOR SELECT #1 M
DATA LINK CONNECTOR (+) 11 914T/O20 307BK/Y20 K2 GOVERNOR SELECT #2
DATA LINK CONNECTOR (-) 3 915PK/LB20 658PK/LG20 R3 MALFUNCTION INDICATOR LAMP N
5 DB/BL 16awg STARTER INPUT
DRIVE BY WIRE SIGNAL RETURN
15
33
32ADKBL16
359LGY/Y20
674BR/W20
914T/O20
K3
M2
FUEL SELECT
DATA LINK CONNECTOR (+) P
RED/LB 16awg STARTER OUTPUT 13 32R/LB16 915PK/LB20 N2 DATA LINK CONNECTOR (-) R
OIL PRESSURE SWITCH * 26 253DG/W20 926ALB/O16 P3 FUEL PUMP RELAY CONTROL
L2 NOT USED
NOTE: * SHOWS USED WIRES M3 NOT USED
359FGY/R20 B2 SINGLE RETURN
N1 NOT USED
N3 NOT USED S
P1 NOT USED
743GY20 D1 INTAKE AIR TEMP SENSOR T
358LG/BK20 B1 MAP SENSOR INPUT
354LG/R18 D2 ECT SENSOR W
9 42 T2 NO USAGE
342LG/P16 L3 STARTER LOCKOUT X
E1 NOT USED Y
6 264W/LB18
225BK/Y20
R1
D3
IDLE AIR CONTROL
DRY FUEL SENSOR
253BDG/W20 J3 OIL PRESSURE
57BK18 T3 GROUND
242DG18 P2 DRYFUEL LOCKOFF MATING FACE
96T/O18 Y1 IGNITION COIL 2 SHOWN
74GY/LB18 E2 HO2S SENSOR SIDE
1 34
354LG/R18
89AO18
34LB/O18
359DGY/Y20
209W/P20
74GY/LB18
349DB18
107P20
350GY18
77DB/Y18
359MGY/Y20
359AGY/R18
359JGY/R18
570NBK/W18
915PK/LB20
253ADG/W20
96T/O18
351CBR/W20
361NR18
282DB/O18
743GY20
359KGY/Y20
658PK/LG20
914T/O20
358LG/BK20
570BK/W20
57BK18
361PR18
225BK/Y20
95AT/W18
16CR/LG16
242DG18
7 MATING FACE
SHOWN
NOTES:
1. WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE
EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE
CR4
(LOCATED INSIDE THE DIAGNOSTIC 2. INTERNAL SPLICES ARE NOT SHOWN
87 87A
GROUND CONTROL BOX) CONNECTOR

30
OIL PRESSURE
SWITCH (NC)
ENGINE
86
85
G G
HEATED COOLANT
8 OXYGEN TEMPERATURE
INTAKE AIR
TEMPERATURE
SENSOR COIL SENSOR MANIFOLD SENSOR
(HO2S) (ECT) ABSOLUTE (IAT)
SYSTEM
IGNITION
(CMP)
SENSOR
POSITION
CAMSHAFT
(CKP)
SENSOR
POSITION
CRANKSHAFT
PRESSURE
SENSOR
(MAP)
LPG LOCKOUT RELAY
AND VALVE


(after serial number 13098)
N M L K J I H G F E D C B A
THROTTLE ACTUATOR/ FORD WIRING HARNESS WIRE COLOR CODE 1

POSITION SENSOR POWER FUEL PUMP STARTER CODE COLOR CODE COLOR CODE COLOR
CR-FA CR-FB CR-FC
FUEL INJECTOR VALVES BL BLUE GY GREY P PURPLE
87A
87A
87A
#4 #3 #2 #1
30
30
30
BK BLACK LB LIGHT BLUE R RED
87
87
87
WATER TEMP. BR BROWN LG LIGHT GREEN T TAN
SWITCH (NO)
86
85
86
85
86
85
DB DARK BLUE N NATURAL W WHITE
DG DARK GREEN O ORANGE Y YELLOW
GN GREEN PK PINK 2
787APK/BK16
570DBK/W18
351BBR/W18
359CGY/R18
558BR/LB18
926ALB/O16
355GY/W18
570BK/W12
557BR/Y18
264W/LB18
32ADKBL16
342LG/P16
16BR/LG18
32R/LB16
16R/LG16
361BR14
361AR14
361DR14
361CR14
361JR14
361ER16
39RW20
361R12
556W18
FORD ENGINE CONTROL MODULE (ECM)
37AY12
555T18
37CY16
QUICK DISCONNECTS
MATING FACE
(TO ECM)
SHOWN
95TW18 X1 IGNITION COIL 1

F1 NOT USED
K1 VPWR A
361LR18
37BY18 F2 KEEP ALIVE PWR B
H1 NOT USED
349DB18
A3
G1
NOT USED
CRANKSHAFT SENSOR RETURN (+)
C 3
350GY18 H2 CRANKSHAFT SENSOR RETURN (-) D
282DB/O18 J1 CAMSHAFT SENSOR FEED (+)
355GY/W18 C1 THROTTLE POSITION SENSOR INPUT E
238ADG/Y18 F3 FUEL PUMP MONITOR
Y3 NOT USED
Y2 NOT USED
FORD 42 PIN QUICK DISCONNECT W3 NOT USED
ENGINE HARNESS #2 555T18 S3 FUEL INJECTOR #1
556W18 S2 FUEL INJECTOR #2 F
557BR/Y18 S1 FUEL INJECTOR #3 G
558BR/LB18 T1 FUEL INJECTOR #4
T/Y TACH LEAD 2 11T/Y20 351BR/W18 A2 VREF H
R/GN KEEP ALIVE PWR * 1 16AR/LG16 77DB/Y18 R2 DRY FUEL MODULATOR
Y KEEP ALIVE PWR * 8 37BY18 B3 NOT USED J
R/W WATER TEMP. SWITCH
Y VPWR *
16
9
39RW20
37Y12 570BK/W18
C2
X2
NOT USED
POWER GROUND K 4
PK/BK FUEL PUMP OUTPUT * 5 787PK/BK16 570ABK/W18 X3 POWER GROUND
VREF 31 351DBR/W20 570BBK/W18 W1 POWER GROUND 1 2 3
BK/W BATT. - * 34 570CBK/W12 570HBK/W18 W2 POWER GROUND
BK/W BATT. - * 42 570EBK/W12 C3 NOT USED
P DATA LINK 22 107P20 E3 NOT USED
DB/BK DRIVE BY WIRE SIGNAL INPUT 14 151LB/BK20 G2 NOT USED
GN/O AUXILARY INPUT 37 198DG/O20 G3 NOT USED
W/P SELF TEST INPUT * 18 209W/P20 107P20 M1 DATA LINK 1 2 3
T/LB GOV. SPD. CONT. * 24 306T/LB20 151LB/BK20 A1 DRIVE BY WIRE
BK/Y GOV. SPD. CONT. 25 307BK/Y20 198DG/O20 L1 AUXILLARY INPUT L
PK/LG FAULT LT. * 6 658PK/LG20 209W/P20 H3 SELF TEST INPUT
Y/BK FUEL SELECT * 7 674Y/BK20 306T/LB20 J2 GOVERNOR SELECT #1 M
T/O DATA LINK CONNECTOR (+) 11 914T/O20 307BK/Y20 K2 GOVERNOR SELECT #2
PK/LB DATA LINK CONNECTOR (-) 3 915PK/LB20 658PK/LG20 R3 MALFUNCTION INDICATOR LAMP N
BL STARTER INPUT
GY/R DRIVE BY WIRE SIGNAL RETURN
15
33
32ADKBL16
359LG/Y20
674BR/W20
914T/O20
K3
M2
FUEL SELECT
DATA LINK CONNECTOR (+) P 5
R/LB STARTER OUTPUT 13 32R/LB16 915PK/LB20 N2 DATA LINK CONNECTOR (-) R
GN/W OIL PRESSURE SWITCH 26 253DG/W20 926ALB/O16 P3 FUEL PUMP RELAY CONTROL
L2 NOT USED
NOTE: * SHOWS USED WIRES M3 NOT USED
359FGY/R20 B2 SINGLE RETURN
N1 NOT USED
N3 NOT USED S
P1 NOT USED
743GY20 D1 INTAKE AIR TEMP SENSOR T
358LG/BK20 B1 MAP SENSOR INPUT
354LG/R18 D2 ECT SENSOR W
9 42 T2 NO USAGE
342LG/P16 L3 STARTER LOCKOUT X
E1 NOT USED
264W/LB18 R1
D3
IDLE AIR CONTROL
DRY FUEL SENSOR
Y
6
225BK/Y20
253BDG/W20 J3 OIL PRESSURE
57BK18 T3 GROUND
242DG18 P2 DRY FUEL LOCKOFF MATING FACE
96T/O18 Y1 IGNITION COIL 2 SHOWN
74GY/LB18 E2 HO2S SENSOR SIDE
1 34
354LG/R18
89AO18
34LB/O18
359DGY/Y20
209W/P20
74GY/LB18
349DB18
107P20
350GY18
77DB/Y18
359MGY/Y20
359AGY/R18
359JGY/R18
570NBK/W18
915PK/LB20
253ADG/W20
96T/O18
351CBR/W20
361NR18
282DB/O18
743GY20
359KGY/Y20
658PK/LG20
914T/O20
358LG/BK20
570BK/W20
57BK18
361PR18
225BK/Y20
95AT/W18
16CR/LG16
242DG18
MATING FACE 7
SHOWN
NOTES:
1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE
EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE
2. INTERNAL SPLICES ARE NOT SHOWN
CR4
DIAGNOSTIC
87A
(LOCATED INSIDE THE
GROUND CONTROL BOX) CONNECTOR
30
OIL PRESSURE 87
SWITCH (NC)
ENGINE
8
86
85
G G
HEATED COOLANT INTAKE AIR
OXYGEN TEMPERATURE TEMPERATURE
SENSOR COIL SENSOR MANIFOLD SENSOR
(HO2S) CRANKSHAFT IGNITION (ECT) ABSOLUTE (IAT)
POSITION SYSTEM PRESSURE CAMSHAFT
SENSOR SENSOR POSITION
(CKP) (MAP) SENSOR
LPG LOCKOUT RELAY (CMP)
AND VALVE


N
WHT
WHT
ORG/BLK
RED
RED
BRN
M
SELECTOR
TS50
LIFT/DRIVE SELECTOR
OPTION
DRIVE
OPTION (REQUIRED
LIFT/
CE MODELS)
BLK/RED-1
LOW RPM
TS54
TP35
FOOTSW. H/L
ENGINE
SPEED
HIGH RPM LOW RPM

TS4
FUNCTION
HIGH RPM ENABLE BRN/BLU
L
TB35
OFF
GENERATOR GRN/WHT#45-E.H.#1
GRN/WHT-1 GENERATOR
ON
TS47
OPTION
K
TP45
TB45
RED/WHT#23-E.H.#1 FLASHING BEACON

FB
OPTION
TB39
TP39
TS3
BLU/RED-1
J
LP
FUEL
GAS
TS53
LP
3
FUEL WHT#21
2
1
HM
TP38
GAS HOUR METER

L3
BLU/WHT-1
L2
CHECK ENGINE
ENGINE
TB38
CHECK
BLU/WHT#38 LED
I
ENGINE
CHECK
IGN./START
MODULE
RUN/TEST SWITCH
TP33
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
10 ENG. FAULT
BLK-1
7 KEY PWR.
TEST
6 BATTERY
TS2
5 GROUND
4 AUX. ON
TEST
ENGINE RUN
TS64
TS52
START
ENGINE
START
H
BLK
TB33
POWER RELAY
CR2
FORD 42 PIN QUICK DISCONNECT

PINK/LG FEH(658) PIN6
TB21
TB25
WT/PUR FEH(209) PIN18
ENGINE HARNESS #2
RD/LG FEH(16A) PIN1
G
BR/WT FEH(674) PIN7

CR2
NO
BRN/BLU FEH(253) PIN24

Y FEH(37B) PIN8
Y FEH(37) PIN9
(GND) BLK/WT FEH(570C) PIN34
(GND) BLK/WT FEH(570E) PIN42
F
CR1
Part No. 52709

IGNITION./START RELAY
BLK#R1-E.H.#1
WHT
WHT
RED
CR1
NO
STARTER
STARTER MOTOR
E
TS51
TP25
TP21
TB27
TS1
AUXILIARY
PUMP RED#27-C.H. AUXILIARY POWER
TP27
AUXILIARY
RED RELAY
PR1
PUMP
RED
RED-1
TP24
PUMP
AUX
AUXILIARY PUMP
RED
PR1
NO
TB28
TP28
FS1
D
WHT RED/BLK-1 RED/BLK#28-C.H.

BLK
TILT ALARM
WHT-2 RED/WHT#23-C.H.
LEVEL SENSOR
BLK
Genie Z-45/25 & Genie Z-45/25J

TP23
TB23
TP26
BLK
HORN
TB9
TP9
P3
P2
BLK BLK/RED-3 BLK/RED#9 HORN

TP22
RELAY
CR5
TB22
C
BLK-2 BLK/RED#R5-C.H.
HORN
CR5
NO
GRND
PLAT
KS1
RED
P1
B
WHT#21-E.H.#1
500
RED-E.H.#1
TP41
TB41
ORG/BLK-1 ORG/BLK#41-C.H.
RED
RED
Section 6 • Schematics
STA.
A
S
I
ALTERNATOR
REGULATOR
15AMP.
15AMP.
FLD.
A
CB1
CB2
GRD.
BAT.
FUSE
LINK
TB20
RED#20-C.H.
-
RED
12 V
DC
6-9
1
8
1
8
6 - 10
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
A
BLU/RED-3 BLU/RED#13-C.H.
BRN DRIVE ENABLE
TP30
TB30
LIMIT SWITCH
WHT-1 WHT#30-C.H. ORG/RED#16-C.H.
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16
DRIVE ENABLE DRIVE ENABLE SWITCH

ORG/RED-3
TB31
WHT/BLK-1 WHT/BLK#31-C.H.
DRIVE EDC
TB32
TP32

B
WHT/RED-1 WHT/RED#32-C.H.
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
TP37
TB37
BLU/BLK-1 BLU/BLK#37-M.H.
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
3
4
5
2
6
7
8
C
DP1
RED
TB29
TP29
RED/WHT-1 RED/WHT#29-C.H.
MOTOR STROKE
HIGH (2WD)
D
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1
WHT#40-6 BRN-6 PRIMARY BOOM EXTEND

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO
Part No. 52709
ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP

DRIVE LIMIT SWITCH
TP40
LS2
NO
WHT#40-5 BRN-5 PRIMARY BOOM UP

DRIVE LIMIT SWITCH
10
1
2
3
HORSE- 4
POWER 5
LIMITER 6
BOARD 7
8
9
F
TP7
TS13
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
RETRACT BLK/WHT#8-M.H.
TS63
BOOM RETRACT
TB8
TP6
G
WHT/RED-3
TP5
WHT/BLK-3
WHT-3
TB4
TP4
WHT#4-M.H.
TURNTABLE ROTATE RIGHT
RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT/BLK#5-M.H.
TS62
R
-
A
X
+
TURNTABLE ROTATE LEFT

TB5
15
WHT/RED#6-M.H.
H
TURNTABLE ROTATE
R4
FLOW CONTROL
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2
DOWN BOOM RED/BLK#2-M.H.

TS61
PRIMARY BOOM DOWN

PWM
R
-
X
A
+
TB3
10
RED/WHT#3-M.H. PRIMARY BOOM
R5
TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
J
BLU-3
TB10
BLU BLU#10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
R
-
A
X
+
BLU/BLK BLU/BLK#11-M.H.
TS60
SECONDARYBOOM DOWN
BP2
TB11
TB12
BLU/WHT BLU/WHT#12-M.H. SECONDARY BOOM
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
TB14
DOWN LEVEL ORG/BLK-3
TS9
TS59
ORG#14-M.H.
TP15
PLAT LEVEL UP
UP PLATFORM
DOWN LEVEL ORG/BLK#15-M.H.
PLAT LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP17
L
GRN-3
RIGHT
PLAT ROTATE
TB17
LEFT GRN/BLK-3
TS7
TS57
GRN#17-M.H.
TP18
PLATFORM ROTATE LEFT
RIGHT
PLAT ROTATE
LEFT GRN/BLK#18-M.H.
PLATFORM ROTATE RIGHT
TB18
M
DESCENT ALARM OPTION

N
ORG/BLK
RED
RED
WHT
WHT
BRN
BRN

Ground Control Box Wiring Diagram-

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

LABEL DESCRIPTION
P1 EMERGENCY STOP BUTTON
1 KS1 KEY SWITCH
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL TS51 AUXILIARY SWITCH
TS52 START ENGINE SWITCH
TS53 FUEL SELECT SWITCH
STACKED CONTACTS TS55 FUNCTION ENABLE SWITCH
TS57 PLATFORM ROTATE SWITCH
BLK-R1#86 KS1 TS59 PLATFORM LEVEL SWITCH
1 START RELAY
ORG/BLK-41A
TACHOMETER
TS60 SECONDARY BOOM UP/DOWN SWITCH
2
NO
NO
TS61 PRIMARY BOOM UP/DOWN SWITCH
2 M.H.
BLK-33D
3 START INPUT
TS62 TURNTABLE ROTATE SWITCH
RED-27B
4 AUX. ON
BRN-GRD. TST. SW. TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
5 GROUND
RED-20C
IGN./START TS64 RUN/TEST SWITCH
6 BATTERY
WHT-TST. SW. MODULE CB1 CIRCUIT BREAKER, ENGINE, 15A
7 KEY PWR.
CB2 CIRCUIT BREAKER, CONTROLS, 15A
EXT#6 8 KEY BYPASS P1 KS1
WHT-R2#86 WIRING AUXILIARY PUMP HM HOUR METER
9 IGN./FUEL ON
HARNESS: R4 TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS
SEC.#4 BASE TERMINATION TO BASE NC
ENG. FAULT
NO
10
NO
BLOCK CONTROL BOX R5 BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS
D C B A CONNECTIONS
3 RED-M.H RED-3 1 RED-S.P. PRI. BOOM UP
WHT #23
NC TS51 L2
CR1
CHECK ENGINE LED
IGNITION / START RELAY
RED/BLK-M.H RED/BLK-3 2 RD/BK-S.P. PRI. BOOM DOWN STOP SPLICE
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRI. BOOM F.C. BLK #22 CR2 INGITION POWER RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURN. ROT. R RED #27 BLU/WHT #38
PRIM.#5 WHT/BLK-M.H WHT/BLK-3 TURN. ROT. L CR4 LPG LOCKOUT RELAY
5 WT/BLK-S.P.
BRN TO R4 HORN RELAY
W/R-M.H WHT/RED-3 6 WT/RD-S.P. TURN. ROT. F.C. CR5
BLK-M.H BLK-3 7 BLK-S.P. BOOM EXTEND BRN TO GRD
RED
WHT #21 BLU/RED #39 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. BOOM RETRACT L2 TS53
BLK/RED-C.H BLK/RED-3 9 BK/RD-R5 HORN WHT#21TO R2 RED/WHT #3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BLU-M.H BLU-3 10 BLU-S.P. SEC. BOOM UP 1 2 CHECK
RED/BLK #2
BLU/BLK-M.H BLU/BLK-3 11 BU/BK-S.P. SEC. BOOM DN ENGINE FUEL SELECT BRN TO H.M.
3 BLU/WT-S.P. HOUR METER RED #1
BLU/WHT-M.H BLU/WHT-3 12 SEC. BOOM F.C. LIGHT
BLK/RED-9
4 BL/RED#13-C.H.
ORG-M.H.
BLU/RED-3
ORG-3
13
14 ORG-S.P
DRV. ENA. LT. SW.
PLAT. LEVEL. UP
3 BLK #7
BLK-22
WHT/PRP EH2 OR/BK-M.H. ORG/BLK-3 15 OG/BK-S.P PLAT. LEVEL DN. BLK/WHT #8
TS61 WHT-R2
ORG/RED-CH ORG/RED-3 16 WHT#12-C.H. DRV. ENA. BLU/WHT #12 TS63
GRN-M.H GRN-3 17 GRN-S.P. PLAT. ROT. L. PRIMARY RED-CB1
GRN/BLK-M.H GRN/BLK-3 18 GR/BK-S.P. PLAT. ROT. R.
BOOM EXTEND/
PRIMARY RETRACT CR1 CR2 CR5 CR4
2 GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 R5 TS60 BOOM
WHT #4
RED-C.H. RED-ISM#6 20 RED-S.P. 12V BATT. SUPPLY BLK-R1 TO ISM#1
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION PWR. TS52 UP/DOWN WHT/BLK #5
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. PWR. TO PLAT. WHT/RED #6

TS62 BLK-R1 TO E.H.#1
WHT 23B RD/WT-C.H. WHT-2 23 WHT-TEST SW WHT-S.P. KEYSWITCH PWR.
TURNTABLE RED-R4
24 BLK/RED #35 WHT-21
RD/GRN-EH#1 25 BLK-TEST SW OIL PRESSURE SENDER START ROTATE BLK/RED-R5 BLK-R4
5 1
RED-C.H. RED-1
26
RED-S.P.
WATER TEMP. SENDER SEC. BOOM
GREEN-R4
27 RED-ISM#4 AUX. PWR.
WHT-40
RD/BK-C.H. RED/BLK-1 28 TILT ALARM TS54 CB1 CB2
RD/WT-C.H. R/W-1 29 2WD/4WD (DRIVE RANGE) GRN/WHT #19
WHT ISM7 TS59 ORG ORG/BLK
WHT#30-C.H. WHT-1 30 E.D.C.
GRN/BLK #18
WT/BK-C.H.. WHT/BLK-1 31 E.D.C.
RUN/TEST
WHT/RED-1 BRAKE GRN #17 CR7 CR8

WT/RD-C.H. 32 BLU #10 HIGH/LOW RPM
BLK-ISM#3 BLK-1 33 BLK-S.P. START
EH2 BLU/BLK #11 PLAT. TS57
BLK/WHT-1 34 GLOW PLUG
TS64 LEVEL PLATFORM
BR/BLU-EH2 BLK/RED-1 35 RPM BK/RD-S.P. RED #20
BRN-GRD.
BLU-M.H. BLU-1 36 STEER RIGHT ROTATE ORG #14

WHT#40-R7 BLU/BLK-1 STEER LEFT
RED-R1
BU/BK-M.H. 37
WHT-PRIM.#5
BLU/WHT-1 TEST LIGHT ORG/BLK #15
6 PK/GR-EH#2
BRN/WHT-EH2 BLU/RED-1
38
39
BU/WT-S.P.
BU/RD-S.P. L.P. (FUEL SELECT)
RED TO EH2
ORG/BLK-15
ORG-1 40 WHT-SEC.#4 WHT-EXT.#6 LIMIT SWITCH SIG. BLK #33
ORG-14
CH+EH1 OG/BK-C.H. ORG/BLK-1 41 OG/BK-ISM#2 PULSE PICKUP PLATFORM LEVEL CUTOUT
BLACK-SEC.#4 ORG/RED-1 42 SPARE (CE MODLES ONLY)
GRN-1 43 SPARE
GRN/BLK-1 44 SPARE
GRN/WHT-C.H GRN/WHT-1 45 GEN. OPTION
GROUND STUD
(-12 VOLTS)
7
RED-E.H.#1 RED-R4
GRN-E.H.#1 GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
BLK/RED-E.H.#1 BLK/RED-R5
ORANGE-M.H. ORG-R7
ORG/BLK-M.H. ORG/BLK-R8
WIRE CONNECTION ABBREVIATION KEY: ENGINE HARNESS # 2, FORD EFI,

8 EH#1 ENGINE HARNESS #1 42 PIN INTERCHANGE
EH#2 ENGINE HARNESS #2 (FORD EFI HARNESS) PIN/#: TO:
C.H. CHASSIS HARNESS RED/GRN #1 - 25D
M.H. MANIFOLD HARNESS PNK/GRN #6 - 38D
BRN/WHT #7 - 39D
S.P. SWITCH PANEL YEL (18GA) #8 - CB2
R or CR RELAY YEL (12GA) #9 - CB2
ISM IGNITION/START MODULE WHT/PRP #18 - TST SW
BRN/BLU #26 - 35D
H.M. HOUR METER

Platform Control Box Wiring Diagram-

1
PLATFORM CONTROL BOX
LABEL DESCRIPTION
P3 HORN SWITCH
WHT-24 TS1 AUXILIARY SWITCH
2
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DN.
PRIMARY F.C.
SWING LEFT
SWING RIGHT
SWING F.C.
EXTEND
RETRACT
HORN
SEC.BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRV. ENA. LT.
PLAT. LVL. UP
PLAT. LVL. DN.
DRV. ENA.
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
OPTION WIRE
PWR. TO PLAT.
PWR. FRM PLAT.
PWR. (CONT.)
PWR. (START)
PWR. TO F.S.
AUX. PWR.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START
GLOW PLG. OPT.
RPM
STEER LEFT
STEER RIGHT
ENGINE FAULT
L.P.
LIMIT SWITCH
PULSE PICKUP
SPARE
SPARE
SPARE
GEN. (OPTION)
OG/BK-41
HORSE-
POWER TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
ORG-40 LIMITER TS11 PRIMARY BOOM UP/DOWN SWITCH
BOARD TS12 TURNTABLE ROTATE SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
TS9 PLATFORM LEVEL SWITCH
21
31
41
4
6
2
3
7
8
9
1
TS50 LIFT/DRIVE SELECT SWITCH

RED-10
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
R1 EFI RESISTOR 3
R2 LOW SPEED RESISTOR
L1 DRIVE ENABLE LED
L3 CHECK ENGINE LED
GRD. STUD BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE
CR12
BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
RED/BLK-28
EFI RELAY CR12 EFI RELAY

50
H.P.L. HORSEPOWER LIMITER BOARD
R1 H1 TILT ALARM 4
CABLE CABLE CABLE
H1
+ TILT
_ #3 #2 #1
110 F.S.
ALARM
BLU/RED-13
BLU/WHT-38
ORG/RED-16
RED-25
BLK/RED-35
BLK-33
BLU/BLK-37
BLU-36
BRN TO GRD.
WHT-24 TO H.P.L.
BLU/RED-39
WHT/BLK-31
WHT-30
WHT/RED-32
BLK-22
BLK-26
WHT-23
BLK/RED-9
ORG-14
ORG/BLK-15
WHT/RED-6
WHT/BLK-5
WHT-4
RED/BLK-2
RED/WHT-3
RED-1
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN-17
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
GEN.
OPT.
PRIMARY SEC.BOOM 6
8
NC NO BOOM BP2 L1
EXTEND/
7
R
R
A
RETRACT
6
+
NC
- X
5
- X
BP1 TS13
-
4
NC
+
3
NO NO
R
A
2
TURNTABLE PRIMARY BOOM
7
1
ROTATE UP/DOWN
PLATFORM DRIVE
ROTATE
PLATFORM
TS7 R2 R3 DRV.ENA
LEVEL
TS15
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
HORN DRIVE CHECK TS4
HIGH/LOW FUEL SELECT
8
SPEED TS14 ENGINE RPM
HIGH/LOW (2WD/4WD) EMERGENCY STOP
P2
PLATFORM CONTROL SWITCH PANEL



(from serial number 13099 to 16303)
SEE NOTE 1 SEE NOTE 2
ORG/BLK
1 P2 FS1 RED RED TP25 RED WHT
TP22 TP26
BLK BLK BLK
WHT
TS50
TP21 WHT WHT
TP24 LIFT/
DRIVE
SELECTOR
TS2 TS47 TS4 OPTION
TS1 TS3
CHECK
L3
HIGH RPM
LOW RPM
BLK-2
WHT
ON
OFF
START
ENGINE
POWER
AUXILIARY
GAS
LP
2
FOOTSW. H/L
GENERATOR
P3
FUEL
HORN
ENGINE
BLK
TP41
ENGINE
CB1 TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 SPEED
KS1
P1
15AMP. RED RED PLAT TP35 RED
GRND RED
WHT-2
BLU/WHT-1
ORG/BLK-1
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLU/RED-1
GRN/WHT-1
BLK/RED-1
3 TS53
TS51 TS52 TS54
HIGH RPM
LOW RPM
START
GAS
LP
POWER
AUXILIARY
RED
TB39 TB45
FUEL
ENGINE
FUNCTION ENA.
BLK
TB27 TB33
TB28
4
RED
TB9
TB41 TB23
1 START RELAY
2 TACHOMETER
CB2 3 START INPUT
RED/WHT#23-E.H.#1
4 AUX. ON TB35
TB20 15AMP. 5 GROUND IGN./START
RED MODULE
6 BATTERY
RED#20-C.H.
7 KEY PWR.
8 KEY BYPASS
TAN/BLU
CR1 CR1 9 IGN./FUEL ON
CR2 CR2 10 ENG. FAULT
NO
NO
TB21
5
ORG/BLK#41-C.H.
WHT#21-E.H.#1
BLK#22
BLK/RED#9
RED/WHT#23-C.H.
RED/BLK#28-C.H.
RED#27-C.H.
BLK#R1-E.H.#1
RED-E.H.#1
WHT#21
WHT
ALTERNATOR TS64 CHECK
FUSE L2
GRN/WHT#45-E.H.#1
ENGINE
BAT. FB
BLU/WHT#38
PK/BLK
LINK
TEST
RUN
TEST
GRD. CR5 PR1 TB25
PR1
500 AMP
CR5
NO NO
STA.
RED
WHT
BLK/RED#R5-C.H.
6
FLD.
PINK/BLK FEH(787) PIN5
Y FEH(37) PIN9
Y FEH(37B) PIN8
TAN/BLU FEH(306) PIN24
YEL/BLK FEH(674) PIN7
RD/LG FEH(16A) PIN1
TB38
12 V REGULATOR
A FUEL
DC
+ S PUMP
I
1
BLK
AUX STARTER 3
HM
BLK
PUMP
- 2
BRN
BRN
7
OPTION
RELAY
RELAY
STARTER MOTOR
OPTION
FLASHING BEACON
HORN
HORN
LEVEL SENSOR
TILT ALARM
AUXILIARY POWER
IGNITION/START RELAY
FUEL PUMP
RUN/TEST SWITCH
HOUR METER
CHECK ENGINE
GENERATOR
CE MODELS)
OPTION (REQUIRED FOR
LIFT/DRIVE SELECTOR
POWER RELAY
AUXILIARY PUMP
LED
ENGINE HARNESS #2
8
NOTE:
1) The connection to TP24 is for units without generator option.
2) The foot switch power is connected to both white wires without the lift/drive selector option.
3) All switches and contacts are shown with the boom in the stowed position and the key switch off.

1
8

6 - 14
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
A
BRN-7 DRIVE ENABLE

TP30
TB30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE

B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
D
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK#5-M.H.
TP4

RIGHT TURNTABLE
PWM
LEFT ROTATE WHT#4-M.H.

TS62
-
R
A
X
+

R4
10
TB4
WHT/RED#6-M.H. TURNTABLE ROTATE

FLOW CONTROL
H
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP
TB2
PRIMARY
TS61
PRIMARY BOOM DOWN

PWM
R
X
A
-
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU#10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
R
A
X
+
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
UP
K
PLATFORM
TB14
TS9
TS59
ORG#14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
GRN/BLK-3
L
RIGHT
PLATFORM ROTATE
TB18
TS7
LEFT GRN-3
TS57
GRN/BLK#18-M.H.
TP17
RIGHT
PLATFORM ROTATE
LEFT GRN#17-M.H.
TB17
M

ORG/BLK
N
RED
RED
WHT
WHT
BRN
BRN


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

LABEL DESCRIPTION
1 KS1 KEY SWITCH
BASE CONTROL BOX BASE CONTROL SWITCH PANEL TS51 AUXILIARY SWITCH
KS1 TS57 PLATFORM ROTATE SWITCH
BLK-R1#86
START RELAY
1
NO
NO
ORG/BLK-41A TS60 SECONDARY BOOM UP/DOWN SWITCH
2 TACHOMETER
BLK-33D TS61 PRIMARY BOOM UP/DOWN SWITCH
2 M.H.
RED-27B
3 START INPUT
P1
AUXILIARY PUMP TS62 TURNTABLE ROTATE SWITCH
4 AUX. ON
BRN-GRD. TST. SW. TS51 TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
5 GROUND IGN./START NC TS64 RUN/TEST SWITCH
RED-20C
6 BATTERY MODULE CB1 CIRCUIT BREAKER, ENGINE, 15A
WHT-TST. SW.
KEY PWR. NC KS1
7
EXT#6 8 KEY BYPASS
WIRING STOP HM HOUR METER
NO
NO
WHT-R2#86
9 IGN./FUEL ON
HARNESS: R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
SEC.#4 BASE TERMINATION TO BASE
10 ENG. FAULT
BLOCK CONTROL BOX L2 CHECK ENGINE LED
D C B A CONNECTIONS CR1 IGNITION / START RELAY
3 RED-M.H
RED/BLK-M.H
RED-3
RED/BLK-3
1 RED-S.P.
RD/BK-S.P.
PRIMARY BOOM UP
PRIMARY BOOM DOWN
WHT #23 SPLICE
CR2 INGITION POWER RELAY
2
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNTION CONTROL BLK #22 CR4 LPG LOCKOUT RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURNTABLE ROTATE LEFT RED #27 BLU/WHT #38
PRIM.#5 WHT/BLK-M.H WHT/BLK-3 TURNTABLE ROTATE RIGHT CR5 HORN RELAY
5 WT/BLK-S.P.
W/R-M.H WHT/RED-3 WT/RD-S.P.
BRN TO R4 BLU/RED #39
6 TURNTABLE ROTATE FUNCTION CTRL CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK-M.H BLK-3 7 BLK-S.P. PRIMARY BOOM EXTEND BRN TO GRD
CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT #21 +
RED/WHT #3
LED
BLK/RED-C.H BLK/RED-3 9 BK/RD-R5 HORN
WHT#21TO R2 L2 TS53
BLU-M.H BLU-3 10 BLU-S.P. SECONDARY BOOM UP
RED/BLK #2
BLU/BLK-M.H BLU/BLK-3 11 BU/BK-S.P. SECONDARY BOOM DOWN FUEL SELECT
3 1 2 CHECK BRN TO H.M.
BLU/WHT-3 12 BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL RED #1
BLU/RED-3
ENGINE BLK/RED-9
HOUR METER
4 BLK-ENA.
ORG-M.H. ORG-3
13
14 ORG-S.P
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
BLK #7
BLK-22
WHT/PRP EH2 OR/BK-M.H ORG/BLK-3 15 OG/BK-S.P PLATFORM LEVEL DOWN 3 BLK/WHT #8
TS61 WHT-R2
RED-ENA. ORG/RED-3 16 WHT#12-C.H. DRIVE ENABLE RELAY COIL TS63
GRN-M.H GRN-3 17 GRN-S.P. PLATFORM ROTATE LEFT PRIMARY RED-CB1
BLU/WHT #12 BOOM EXTEND/
GRN/BLK-M.H GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT TS60 PRI. BOOM RETRACT WHT #4 CR1 CR2 CR5 CR4
2 GRN/WHT-3 19 GR/WT-S.P. JIB VALVE
RED-C.H. RED-ISM#6 20 RED-S.P. +12 V POWER UP/DOWN BLK-R1 TO ISM#1
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION POWER R4 WHT/BLK #5
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. +12 V TO PLATFORM TS62 WHT/RED #6 BLK-R1 TO E.H.#1
WHT-2 WHT-S.P. KEYSWITCH POWER
TS52
WHT 23B RD/WT-C.H. 23 WHT-TEST SW
TURNTABLE RED-R4
24 (UNUSED) WHT-21
SECONDARY ROTATE
RD/GRN-EH#1 25 BLK-TEST SW ECM KEEP ALIVE POWER BLK/RED-R5 BLK-R4
BOOM
5 1
RED-C.H. RED-1
26
27 RED-ISM#4 RED-S.P.
(UNUSED)
AUXILIARY PUMP SELECT BLK/RED #35
START
GREEN-R4
WHT-40
RD/BK-C.H. RED/BLK-1 28 TILT ALARM
RD/WT-C.H. R/W-1 29 2WD/4WD PLATFORM GRN/WHT #19 ORG/BLK
WHT ISM7 WHT-ENA. WHT-1 E.D.C. ORG
30 TS54 CB1 CB2 LEVEL GRN/BLK #18
WT/RD-C.H.
RUN/TEST
32
BLK-ISM#3 BLK-1 33 BLK-S.P. START ENGINE
EH2 TS59 TS57
TS64 BR/BLU-EH2 BLK/RED-1 HIGH/LOW RPM BK/RD-S.P. HIGH/LOW RPM PLATFORM
35
BRN-GRD.
STEER LEFT
BLU #10 ROTATE
BLU-M.H. BLU-1 36 ORG #14
WHT#40-R7
WHT-PRIM.#5
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT BLU/BLK #11
BLU/WHT-1 38 (SPARE) ORG/BLK #15
6 PK/GR-EH#2
YEL/BLK-EH2 BLU/RED-1 39
BU/WT-S.P.
BU/RD-S.P. LIQUID PROPANE FUEL
RED #20 ORG/BLK-15
ORG-1 40 WHT-SEC.#4 WHT-EXT.#6 OFF-LIMIT SPEED RED-R1 ORG-14
CH+EH1 OG/BK-C.H. ORG/BLK-1 41 OG/BK-ISM#2 ALTERNATOR PULSE PICKUP PLATFORM LEVEL CUTOUT
RED TO EH2
ORG/RED-1 42 (SPARE) (CE MODELS ONLY)
GRN-1 43 (SPARE) BLK #33
GRN/BLK-1 44 (SPARE)
GRN/WHT-C.H GRN/WHT-1 45 GENERATOR OPTION
GROUND STUD
(-12 VOLTS)
7
RED-E.H.#1 RED-R4
GRN-E.H.#1 GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
ORANGE-M.H. ORG-R7
WIRE CONNECTION ABBREVIATION KEY:

ENGINE HARNESS # 2, FORD EFI,
8 EH#1 ENGINE HARNESS #1 42 PIN INTERCHANGE
YEL/BLK #7 - 39D
S.P. SWITCH PANEL
YEL (18GA) #8 - CB2
H.M. HOUR METER TAN/BLU #24 - 35D


PLATFORM CONTROL BOX 1

LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. L.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
PLAT. LEVEL DN.
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
+12 V TO PLAT.
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
AUX. PUMP SEL.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
L.P. GAS
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
TS9 PLATFORM LEVEL SWITCH 2
HORSE-
POWER TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
R1 EFI RESISTOR ( FORD AND PERKINS ONLY )
ORG-40 R2 LOW SPEED RESISTOR
CR12 LOW SPEED RESISTOR
RED-10
R3 3
L1 DRIVE ENABLE LED
WHT-24 L3 CHECK ENGINE LED
R1 BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
RED/BLK-28
50
CR12 EFI RELAY
RED-10 HORSEPOWER LIMITER BOARD
H.P.L.
LIMITING RELAY
T1 TIME DELAY ( JIB ONLY )
H1 TILT ALARM
CABLE CABLE CABLE
110 F.S. 4
#3 #2 #1
H1
+ TILT
_
ALARM
WHT-23
WHT/RED-32
BLK-22
BLK-26
RED/BLK-2
WHT-24 TO H.P.L.
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED/WHT-3
RED-1
BLK/RED-35
BLU/RED-39
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
RED-25
BLU/WHT-38
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/
7
6
R
R
A
RETRACT
6
+
NC
- X
5
- X
- X
BP1
4
NC
+
+
3
NO NO
TS13
R
A
2
1
ROTATE UP/DOWN
DRIVE
PLATFORM
DP1 7
PLATFORM ROTATE R2 R3 DRV.ENA
LEVEL TS7
TS15
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
SPEED TS14 HIGH/LOW
ENGINE FUEL SELECT
RPM
P2
8


N
WHT
WHT
BRN
RED
ORG/BLK
RED
RED
BRN
CR13
RED
JIB CUTOUT RELAY (CR13)
CR14
JIB CUTOUT RELAY

SEE NOTE 2
JIB VALVE RELAY JIB VALVE RELAY (CR-14)

CR14
JIB VALVES JIB VALVES

NO
M
SELECTOR
TS50
LIFT/DRIVE SELECTOR
OPTION
DRIVE

LIFT/
CE MODELS)
BLK/RED-1
HIGH RPM
TS54
TP35
LOW RPM
ENGINE
FOOTSW. H/L LOW RPM

SPEED
TS4
FUNCTION
HIGH RPM ENABLE BRN/BLU
L
TB35
OFF
GENERATOR GRN/WHT#45-E.H.#1
GRN/WHT-1 GENERATOR
ON
TS47
OPTION
K
TP45
TB45
RED/WHT#23-E.H.#1 FLASHING BEACON

FB
OPTION
TB39
TP39
TS3
BLU/RED-1
J
LP
FUEL
GAS
WHT
TS53
LP
3
FUEL WHT#21
2
1
HM
TP38
GAS HOUR METER

L3
BLU/WHT-1
L2
CHECK ENGINE
ENGINE
TB38
CHECK
BLU/WHT#38 LED
I
ENGINE
CHECK
IGN./START
MODULE
RUN/TEST SWITCH
TP33
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
10 ENG. FAULT
BLK-1
7 KEY PWR.
TEST
6 BATTERY
TS2
5 GROUND
4 AUX. ON
TEST
ENGINE RUN
TS64
TS52
START
ENGINE
START
H
BLK
TB33
POWER RELAY
CR2

TB21
TB25
ENGINE HARNESS #2
RD/LG FEH(16A) PIN1
G
BR/WT FEH(674) PIN7

CR2
NO
BRN/BLU FEH(253) PIN24

Y FEH(37B) PIN8
Y FEH(37) PIN9
F
CR1
Part No. 52709

BLK#R1-E.H.#1
WHT
WHT
RED
CR1
NO
STARTER
STARTER MOTOR
SEE NOTE 1
TS51
TP25
TP21
E
TB27
TS1
AUXILIARY
AUXILIARY PUMP RED#27-C.H. AUXILIARY POWER
TP27
PUMP RED RELAY
PR1
RED
RED-1
TP24
PUMP
AUX
AUXILIARY PUMP
RED
PR1
NO
TB28
TP28
FS1
WHT RED/BLK-1 RED/BLK#28-C.H.

BLK
TILT ALARM
D
WHT-2 RED/WHT#23-C.H.
LEVEL SENSOR
BLK
TP23
TB23
TP26

BLK
HORN
TB9
TP9
P3
P2
BLK BLK/RED-3 BLK/RED#9 HORN

TP22
RELAY
CR5
TB22
BLK-2 BLK#22 BLK/RED#R5-C.H.
C
HORN
CR5
NO
GRND
PLAT
KS1
RED
P1
WHT#21-E.H.#1
B
500
RED-E.H.#1
TP41
TB41
ORG/BLK-1 ORG/BLK#41-C.H.
RED
RED
STA.
A
S
I
ALTERNATOR
REGULATOR
15AMP.
15AMP.
FLD.
CB1
CB2
GRD.
BAT.
A
FUSE
LINK
TB20
RED#20-C.H.
-
RED
12 V
DC
6 - 17
1
8
1
8
6 - 18
BRN-2
GROUND
TB13
TP30 TP13
L1
NCHO
LS4
BRN DRIVE ENABLE
A
TB30
LIMIT SWITCH
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
3
5
4
6
2
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
D
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
HORSE- 4
POWER 5
LIMITER 6
BOARD 7
8
9
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB4
TP4
WHT#4-M.H.
RIGHT TURNTABLE
PWM
LEFT ROTATE WHT/BLK#5-M.H.

TS62
R
A
X
-
+

TB5
15
R4
FLOW CONTROL
H
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
X
A
-
+
TB3
10
R5
TP1
FLOW CONTROL
RED-3
TP2
I
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU#10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
-
R
A
X
+
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
UP PLATFORM
K
DOWN LEVEL
TB14
ORG/BLK-3
TS9
TS59
ORG#14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP17
CR13
GRN-3
NC
L
UP
JIB BOOM
TB17
LEFT GRN/BLK-3
TS8
TS58
GRN#17-M.H.
TP18
PLATFORM ROTATE LEFT/
UP JIB BOOM UP
JIB BOOM
PLATFORM ROTATE RIGHT/
JIB BOOM DOWN
TB18
TS57
RIGHT RIGHT
PLAT ROTATE PLAT ROTATE
LEFT LEFT
TS7
M
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
ORG/BLK
N
RED
RED
WHT
WHT
RED
BRN
BRN


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

LABEL DESCRIPTION
1 KS1 KEY SWITCH
BLK-R1#86 KS1 TS58 JIB BOOM UP/DOWN
1 START RELAY
ORG/BLK-41A TS59 PLATFORM LEVEL SWITCH
2 TACHOMETER
NO
NO
BLK-33D TS60 SECONDARY BOOM UP/DOWN SWITCH
2 M.H.
RED-27B
3 START INPUT
4 AUX. ON
BRN-GRD. TST. SW. IGN./START TS62 TURNTABLE ROTATE SWITCH
5 GROUND
RED-20C MODULE TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY
WHT-TST. SW.
TS64 RUN/TEST SWITCH
7 KEY PWR.
CB1 CIRCUIT BREAKER, ENGINE, 15A
EXT#6 8 KEY BYPASS P1 KS1
WHT-R2#86 WIRING AUXILIARY PUMP CB2 CIRCUIT BREAKER, CONTROLS, 15A
9 IGN./FUEL ON
HARNESS: HM HOUR METER
SEC.#4 BASE TERMINATION TO BASE NC
NO
10 ENG. FAULT
NO
BLOCK CONTROL BOX R4 TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS
D C B A CONNECTIONS NC TS51 R5 BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS
3 RED-M.H
RED/BLK-M.H
RED-3
RED/BLK-3
1
2
RED-S.P.
RD/BK-S.P.
PRI. BOOM UP
PRI. BOOM DOWN
WHT #23
STOP SPLICE L2 CHECK ENGINE LED
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRI. BOOM F.C. BLK #22 CR1 IGNITION / START RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURN. ROT. R RED #27 BLU/WHT #38
PRIM.#5 WHT/BLK-M.H WHT/BLK-3
CR2 INGITION POWER RELAY
5 WT/BLK-S.P. TURN. ROT. L
BRN TO R4 LPG LOCKOUT RELAY
W/R-M.H WHT/RED-3 6 WT/RD-S.P. TURN. ROT. F.C. CR4
BLK-M.H BLK-3 7 BLK-S.P. BOOM EXTEND BRN TO GRD
HORN RELAY
RED
WHT #21 BLU/RED #39 CR5
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. BOOM RETRACT L2 TS53
BLK/RED-C.H BLK/RED-3 9 BK/RD-R5 HORN WHT#21TO R2 RED/WHT #3 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLU-M.H BLU-3 10 BLU-S.P. SEC. BOOM UP 1 2 CHECK CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
RED/BLK #2
BLU/BLK-M.H BLU/BLK-3 11 BU/BK-S.P. SEC. BOOM DN ENGINE FUEL SELECT BRN TO H.M.
3 BLU/WT-S.P. HOUR METER RED #1
BLU/WHT-M.H BLU/WHT-3 12 SEC. BOOM F.C. LIGHT
BLU/RED-3 13 DRV. ENA. LT. SW.
BLK/RED-9
BL/RED#13-C.H. BLK #7
3
4 ORG-M.H.
OR/BK-M.H.
ORG-3
ORG/BLK-3
14
15
ORG-S.P
OG/BK-S.P
PLAT. LEVEL. UP
PLAT. LEVEL DN. BLK/WHT #8
BLK-22
WHT/PRP EH2 TS61 WHT-R2
ORG/RED-CH ORG/RED-3 16 WHT#12-C.H. DRV. ENA. BLU/WHT #12 TS63
GRN-M.H GRN-3 17 GRN-S.P. PLAT. ROT. L. PRIMARY RED-CB1
GRN/BLK-M.H GRN/BLK-3 18 GR/BK-S.P. PLAT. ROT. R.
BOOM EXTEND/
PRI. BOOM RETRACT CR1 CR2 CR5 CR4
2 GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 R5 TS60 UP/DOWN
WHT #4
RED-C.H. RED-ISM#6 20 RED-S.P. 12V BATT. SUPPLY BLK-R1 TO ISM#1
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION PWR. TS52 WHT/BLK #5
TS58
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. PWR. TO PLAT. WHT/RED #6 BLK-R1 TO E.H.#1

WHT-2 WHT-S.P. KEYSWITCH PWR.
TS62
WHT 23B RD/WT-C.H. 23 WHT-TEST SW RED-R4
24 BLK/RED #35 TURNTABLE
WHT-21
RD/GRN-EH#1 25 BLK-TEST SW OIL PRESSURE SENDER START ROTATE BLK/RED-R5 BLK-R4
1 26 WATER TEMP. SENDER SEC. BOOM JIB
5 RED-C.H.
RD/BK-C.H.
RED-1
RED/BLK-1
27
28
RED-ISM#4 RED-S.P. AUX. PWR.
TILT ALARM
WHT-40
GREEN-R4
TS54 CB1 CB2

RD/WT-C.H. R/W-1 29 2WD/4WD (DRIVE RANGE) GRN/WHT #19
WHT ISM7 TS59 ORG ORG/BLK
WHT#30-C.H. WHT-1 30 E.D.C.
GRN/BLK #18
WHT/RED-1 GRN #17 CR7 CR8
WT/RD-C.H. 32 BRAKE BLU #10 HIGH/LOW RPM
EH2 BLU/BLK #11 PLAT. TS57
LEVEL PLATFORM
BR/BLU-EH2 BLK/RED-1 35 RPM BK/RD-S.P. RED #20
BRN-GRD.
BLU-M.H. BLU-1 36 STEER RIGHT ROTATE ORG #14

WHT#40-R7 BLU/BLK-1 STEER LEFT
RED-R1
BU/BK-M.H. 37
WHT-PRIM.#5
PK/GR-EH#2 BLU/WHT-1 38 BU/WT-S.P. TEST LIGHT RED TO EH2 ORG/BLK #15
BRN/WHT-EH2 BLU/RED-1 39 BU/RD-S.P. L.P. (FUEL SELECT) ORG/BLK-15
6 ORG-1 40 WHT-SEC.#4 WHT-EXT.#6 LIMIT SWITCH SIG. BLK #33
ORG-14
CH+EH1 OG/BK-C.H. ORG/BLK-1 41 OG/BK-ISM#2 PULSE PICKUP PLATFORM LEVEL CUTOUT
BLACK-SEC.#4 ORG/RED-1 42 SPARE (CE MODELS ONLY)
GRN-1 43 SPARE
GRN/BLK-1 44 SPARE
GRN/WHT-C.H GRN/WHT-1 45 GEN. OPTION
GROUND STUD
(-12 VOLTS)
7 RED-E.H.#1
GRN-E.H.#1
RED-R4
GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
ORANGE-M.H. ORG-R7

42 PIN INTERCHANGE
8 EH#1 ENGINE HARNESS #1 PIN/#: TO:
RED/GRN #1 - 25D
EH#2 ENGINE HARNESS #2 (FORD EFI HARNESS) PNK/GRN #6 - 38D
C.H. CHASSIS HARNESS BRN/WHT #7 - 39D
M.H. MANIFOLD HARNESS YEL (18GA) #8 - CB2
YEL (12GA) #9 - CB2
S.P. SWITCH PANEL
WHT/PRP #18 - TST SW
R or CR RELAY BRN/BLU #26 - 35D
ISM IGNITION/START MODULE
H.M. HOUR METER



LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DN.
PRIMARY F.C.
SWING LEFT
SWING RIGHT
SWING F.C.
EXTEND
RETRACT
HORN
SEC.BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRV. ENA. LT.
PLAT. LVL. UP
PLAT. LVL. DN.
DRV. ENA.
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
OPTION WIRE
PWR. TO PLAT.
PWR. FRM PLAT.
PWR. (CONT.)
PWR. (START)
PWR. TO F.S.
AUX. PWR.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START
GLOW PLG. OPT.
RPM
STEER LEFT
STEER RIGHT
ENGINE FAULT
L.P.
LIMIT SWITCH
PULSE PICKUP
SPARE
SPARE
SPARE
GEN. (OPTION)
OG/BK-41
HORSE-
TS8 JIB BOOM UP/DOWN
2
POWER
RED FROM CR14

LIMITER TS9 PLATFORM LEVEL SWITCH
ORG-40 BOARD TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-10 RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
R1 EFI RESISTOR
R2 LOW SPEED RESISTOR 3
L1 DRIVE ENABLE LED
GRD. STUD L3 CHECK ENGINE LED
CR12
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE
RED/BLK-28
EFI RELAY BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN

50
WHT JIB CABLE CR12 EFI RELAY
R1 BLK JIB CABLE CR13 JIB CUTOUT RELAY
CR14 JIB VALVE RELAY
CABLE CABLE CABLE
110
JIB
F.S. H.P.L. HORSEPOWER LIMITER BOARD 4
#3 #2 #1 CABLE
H1 T1 TIME DELAY
+ TILT _ H1 TILT ALARM
ALARM
5
RED-1
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
WHT-24 TO H.P.L.
RED TO JIB CABLE
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED-25
BLK/RED-35
BLU/RED-39
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
BLU/WHT-38
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
RED/BLK-2
RED/WHT-3
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13 6
7
R
R
A + -
RETRACT
CR14
6
NC JIB
VALVE
5
X
BP1 TS13 RELAY

X
4
A + -
A + -
NC
JIB CUTOUT
3
NO NO
RELAY
R
2
GRN/WHT +
1
ROTATE UP/DOWN RED OUTPUT
BRN
PLATFORM DRIVE
TIME DELAY T1
7
ROTATE
PLATFORM
TS7 R2 R3 DRV.ENA
LEVEL JIB
TS8 TS15
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
SPEED TS14 HIGH/LOW FUEL SELECT
ENGINE
RPM
P2
8



ORG/BLK
1 P2 FS1 WHT
TP22 TP26 RED RED TP25 RED
BLK BLK BLK
WHT BRN
TS50
TP21 WHT WHT
TP24 LIFT/
DRIVE
TS47 TS4 SELECTOR

TS2
TS1 TS3 OPTION CR13
JIB VALVES
JIB VALVE RELAY
JIB CUTOUT RELAY

CHECK
L3
BLK-2
WHT
OFF
START
ON
FOOTSW. H/L
LOW RPM
HIGH RPM
ENGINE
PUMP
AUXILIARY
GAS
2
LP
RED
P3
FUEL
GENERATOR
HORN
ENGINE
RED
BLK
TP41
ENGINE CR14
CB1 TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 SPEED NO
KS1
P1 RED
15AMP. RED PLAT TP35 CR14 RED
GRND RED
WHT-2
BLU/WHT-1
ORG/BLK-1
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLU/RED-1
GRN/WHT-1
BLK/RED-1
3
TS53
TS51 TS52 TS54
HIGH RPM ENABLE

LOW RPM FUNCTION
START
PUMP
GAS
AUXILIARY
LP
RED
TB39 TB45
FUEL
ENGINE
BLK
TB27 TB33
TB28
4
RED
TB9
TB41 TB23
1 START RELAY
2 TACHOMETER
CB2 3 START INPUT TB35
RED/WHT#23-E.H.#1
4 AUX. ON IGN./START
TB20 15AMP. 5 GROUND MODULE
RED
6 BATTERY
RED#20-C.H.
7 KEY PWR.
8 KEY BYPASS
TAN/BLU
NO
NO
TB21
5
ORG/BLK#41-C.H.
WHT#21-E.H.#1
BLK#22
BLK/RED#9
RED/WHT#23-C.H.
RED/BLK#28-C.H.
RED#27-C.H.
BLK#R1-E.H.#1
RED-E.H.#1
WHT#21
WHT
FUSE L2
GRN/WHT#45-E.H.#1
ENGINE
BAT. FB
BLU/WHT#38
PK/BLK
LINK
TEST
RUN
TEST
GRD. CR5 PR1 TB25
PR1
500
CR5
NO NO
STA.
RED
WHT
BLK/RED#R5-C.H.

6 FLD.
Y FEH(37) PIN9
Y FEH(37B) PIN8
RD/LG FEH(16A) PIN1
TB38
12 V REGULATOR
A
DC FUEL
S PUMP
+
I
1
BLK
AUX STARTER 3
HM
BLK
PUMP
- 2
BRN
BRN
7
STARTER MOTOR
LED
FLASHING BEACON
HORN
RELAY
HORN
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
FUEL PUMP
RUN/TEST SWITCH
HOUR METER
CHECK ENGINE
OPTION
OPTION
GENERATOR
CE MODELS)
LIFT/DRIVE SELECTOR
JIB BOOM VALVES
JIB BOOM VALVE RELAY (CR-14)
JIB BOOM CUTOUT RELAY (CR13)

POWER RELAY
AUXILIARY PUMP

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

1
8

6 - 22
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
A
TP30
TB30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
D
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
HORSE- 4
POWER 5
LIMITER 6
BOARD 7
8
9
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
TP4
WHT/BLK#5-M.H.
RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT#4-M.H.
TS62
A
R
+

-
R4
10
TB4

FLOW CONTROL
H
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
A
R
-
X
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
TP10
BLU BLU#10-M.H.
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
R
+
A
X
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
UP PLATFORM
K
TB14
TS9
TP15
TS59
ORG#14-M.H.
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
CR13
GRN/BLK-3
L
NC
DOWN
JIB BOOM
TB18
UP
TS8
GRN-3
TS58
TP17 GRN/BLK#18-M.H.
PLATFORM ROTATE RIGHT / JIB DOWN
DOWN
JIB BOOM
UP GRN#17-M.H.
PLATFORM ROTATE LEFT / JIB UP
TB17
TS57
RIGHT RIGHT
LEFT LEFT
M
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
ORG/BLK
N
RED
RED
WHT
WHT
RED
BRN
BRN


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

LABEL DESCRIPTION
1 KS1 KEY SWITCH
STACKED CONTACTS
TS55 FUNCTION ENABLE SWITCH
BLK-R1#86 TS58 JIB BOOM UP/DOWN
1 START RELAY
NO
NO
ORG/BLK-41A
2 TACHOMETER
BLK-33D TS60 SECONDARY BOOM UP/DOWN SWITCH
2 M.H.
RED-27B
3 START INPUT
AUX. ON P1
AUXILIARY PUMP TS61 PRIMARY BOOM UP/DOWN SWITCH
4
BRN-GRD. TST. SW.
5 GROUND IGN./START NC
TS51
RED-20C
TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY MODULE TS64 RUN/TEST SWITCH
WHT-TST. SW.
KEY PWR. NC KS1
7
EXT#6 8 KEY BYPASS
STOP CB2 CIRCUIT BREAKER, CONTROLS, 15A
WIRING
NO
NO
WHT-R2#86
9 IGN./FUEL ON
HARNESS: HM HOUR METER
10 ENG. FAULT R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
BLOCK CONTROL BOX
D C B A CONNECTIONS L2 CHECK ENGINE LED
3 RED-M.H
RED/BLK-M.H
RED-3
RED/BLK-3
1
2
RED-S.P.
RD/BK-S.P.
PRIMARY BOOM UP
PRIMARY BOOM DOWN
WHT #23 SPLICE CR1 IGNITION / START RELAY
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNTION CONTROL BLK #22 CR2 INGITION POWER RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURNTABLE ROTATE LEFT RED #27 BLU/WHT #38 LPG LOCKOUT RELAY
PRIM.#5 WHT/BLK-M.H WHT/BLK-3
CR4
5 WT/BLK-S.P. TURNTABLE ROTATE RIGHT
W/R-M.H WHT/RED-3 WT/RD-S.P. TURNTABLE ROTATE FUNCTION CTRL
BRN TO R4 BLU/RED #39 CR5 SERVICE HORN RELAY
6
CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT #21 + CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
RED/WHT #3
LED
WHT#21TO R2 L2 TS53
RED/BLK #2
BLU/WHT-3 12 BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL RED #1
BLU/RED-3
ENGINE BLK/RED-9
DRIVE ENABLE LIGHT HOUR METER
4 BLK-ENA.
ORG-M.H. ORG-3
13
14 ORG-S.P PLATFORM LEVEL UP
BLK #7
BLK-22
OR/BK-M.H ORG/BLK-3 15 OG/BK-S.P PLATFORM LEVEL DOWN 3 BLK/WHT #8
GRN-M.H GRN-3 17 GRN-S.P. PLATFORM ROTATE LEFT/JIB UP PRIMARY RED-CB1
BLU/WHT #12 BOOM EXTEND/
GRN/BLK-M.H GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN TS60 PRI. BOOM RETRACT WHT #4 CR1 CR2 CR5 CR4
RED-C.H. RED-ISM#6 20 RED-S.P. +12 V POWER UP/DOWN BLK-R1 TO ISM#1
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION POWER R4 TS58 WHT/BLK #5
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. +12 V TO PLATFORM WHT/RED #6 BLK-R1 TO E.H.#1

TS52 TS62
24 (UNUSED) TURNTABLE
SECONDARY WHT-21
RD/GRN-EH#1 25 BLK-TEST SW ECM KEEP ALIVE POWER ROTATE BLK/RED-R5 BLK-R4
BOOM
5 1
RED-C.H. RED-1
26
(SPARE)
AUXILIARY PUMP SELECT BLK/RED #35
START JIB
GREEN-R4
WHT-40
RD/WT-C.H. R/W-1 29 2WD/4WD GRN/WHT #19
WHT ISM7 ORG ORG/BLK
WHT-ENA. WHT-1 30 E.D.C. TS54 CB1 CB2 GRN/BLK #18
WT/RD-C.H. 32
EH2 TS59 TS57
RUN/TEST

35
BRN-GRD.
STEER LEFT
BLU #10 ROTATE
BLU-M.H. BLU-1 36 ORG #14
WHT#40-R7
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT BLU/BLK #11 PLAT.
WHT-PRIM.#5
PK/GR-EH#2 BLU/WHT-1 38 BU/WT-S.P. (SPARE) LEVEL ORG/BLK #15
6 YEL/BLK-EH2 BLU/RED-1 39 BU/RD-S.P. LIQUID PROPANE FUEL
RED #20 ORG/BLK-15
ORG-1 40 WHT-SEC.#4 WHT-EXT.#6 OFF-LIMIT SPEED RED-R1 ORG-14
RED TO EH2
ORG/RED-1 42 (SPARE) (CE VERSION ONLY)
GRN-1 43 (SPARE) BLK #33
GRN/WHT-C.H GRN/WHT-1 45 GENERATOR OPTION
GROUND STUD
(-12 VOLTS)
7
RED-E.H.#1 RED-R4
GRN-E.H.#1 GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
ORANGE-M.H. ORG-R7

EH#1 ENGINE HARNESS #1
8 EH#2 ENGINE HARNESS #2 (FORD EFI HARNESS)
42 PIN INTERCHANGE
PIN/#: TO:
S.P. SWITCH PANEL YEL/BLK #7 - 39D
YEL (18GA) #8 - CB2



1
LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
L.P. GAS
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
TS8 JIBBOOM UP/DOWN
HORSE- 2
RED FROM CR14

POWER TS9 PLATFORM LEVEL SWITCH
ORG-40 LIMITER TS10 SECONDARY BOOM UP/DOWN SWITCH
BOARD TS11 PRIMARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
ORG-40 R1 EFI RESISTOR
CR12 R2 LOW SPEED RESISTOR
RED-10
WHT-24 L1 DRIVE ENABLE LED
R1 BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE
RED/BLK-28
50
BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
RED-10 CR12 EFI RELAY
WHT JIB CABLE
LIMITING RELAY
BLK JIB CABLE CR13 JIB CUTOUT RELAY
CABLE CABLE CABLE JIB H.P.L. HORSEPOWER LIMITER BOARD
H1
#3 #2 #1
110
CABLE
F.S.
T1 TIME DELAY
4
ALARM
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
RED/BLK-2
WHT-24 TO H.P.L.
RED TO JIB CABLE
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED/WHT-3
RED-1
BLK/RED-35
BLU/RED-39
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
RED-25
BLU/WHT-38
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
R
R
A
RETRACT
CR14 6
6
+
NC JIB
VALVE
- X
5
- X
- X
BP1 RELAY
4
NC
+
JIB CUTOUT
3
NO TS13 NO
RELAY
R
A
2
GRN/WHT +
1
BRN
DRIVE
PLATFORM TIME DELAY T1 7
LEVEL TS7 JIB
TS8 TS15
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
SPEED TS14 HIGH/LOW
ENGINE FUEL SELECT
HIGH/LOW (2WD/4WD) RPM
EMERGENCY STOP
P2
8



LOAD SENSE OPTION (SEE DETAIL)
ORG/BLK
1 TP22
P2
TP26
FS1 RED-(FS) TP25 RED RED
BLK BLK-(FS)
WHT-(FS) TP24 WHT WHT WHT
TS2 TS47 TS4

TS1 TS3
CHECK
L3
ON
OFF
BLK-2
WHT
START
LOW RPM
FOOTSW. H/L
HIGH RPM
ENGINE
PUMP
GAS
LP
GENERATOR
2 P3
AUXILIARY
FUEL
HORN
ENGINE
BLK
TP41
ENGINE
CB1 TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 SPEED
KS1
P1
GRND RED
WHT-2
BLU/WHT-1
ORG/BLK-1
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLU/RED-1
GRN/WHT-1
BLK/RED-1
3 TS51 TS52
TS53
TS54
HIGH RPM ENABLE

LOW RPM FUNCTION
PUMP
START
GAS
LP
RED
AUXILIARY
TB39 TB45
FUEL
ENGINE
BLK
TB27 TB33
TB28
4
RED
TB9
TB41 TB23
1 START RELAY
2 TACHOMETER
RED/WHT-23-E.H.#1
TB20 15AMP. 5 GROUND MODULE
RED
6 BATTERY
RED#20-C.H.
7 KEY PWR.
8 KEY BYPASS
TAN/BLU
NO
NO
TB21
5
ORG/BLK-41-C.H.
BLK-22
WHT-21-E.H.#1
BLK/RED-9
RED/WHT-23-C.H.
RED/BLK-28-C.H.
RED-27-C.H.
BLK-R1-E.H.#1
RED-E.H.#1
WHT-21
WHT
FUSE L2
GRN/WHT-45-E.H.#1
ENGINE
BAT. FB
BLU/WHT-38
PK/BLK
LINK
TEST
RUN
TEST
GRD. CR5 PR1 TB25
PR1
500
CR5

NO NO
STA.
RED
WHT
BLK/RED-R5-C.H.
FLD.
6

Y FEH(37) PIN9
Y FEH(37B) PIN8

RD/LG FEH(16A) PIN1
TB38
12 V REGULATOR
A FUEL
DC
S PUMP
+
I
1
STARTER
BLK
AUX 3
HM
BLK
PUMP
2
-
BRN
BRN
CHECK ENGINE
STARTER MOTOR
FLASHING BEACON
LED
TILT ALARM
FUEL PUMP
HORN
RELAY
HORN
LEVEL SENSOR
RELAY
AUXILIARY POWER
RUN/TEST SWITCH
HOUR METER
OPTION
OPTION
GENERATOR
POWER RELAY
AUXILIARY PUMP
LOAD SENSE OPTION
P2 FS1 RED-(FS)
TP22
BLK-26 BLK-(FS) LOAD
TP26 WHT-(FS) C SENSOR
BOX TP24
BLK-26 LOAD B+
WHT-LOAD WHT-24 FORD 42 PIN QUICK DISCONNECT
GND 8 ENGINE HARNESS #2
(SEE PAGE 6)
ORG-LOAD

1
8

6 - 26
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
LIMIT SWITCH
A
WHT-1 WHT-7 RED-7

WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
WHT/BLK-1 WHT/BLK-31-C.H.
DRIVE EDC
TB32
TP32
WHT/RED-1 WHT/RED-32-C.H.
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
BLU/BLK-1 BLU/BLK-37-M.H.
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
RED/WHT-1 RED/WHT-29-C.H.
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
250
D
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1
WHT-40-6 BRN-6 PRIMARY BOOM EXTEND

50
DRIVE LIMIT SWITCH

CR12
E
TB40
LS3
NO
ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO
WHT-40-5 BRN-5 PRIMARY BOOM UP

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
TP7
TS13
BLK-3
F
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
RETRACT BLK/WHT-8-M.H.
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
TP4
WHT/BLK-5-M.H.
RIGHT
TURNTABLE
PWM

TS62
A
+
X

-
R4
10
TB4
WHT/RED-6-M.H. TURNTABLE ROTATE

FLOW CONTROL
H
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2
DOWN BOOM RED/BLK-2-M.H.

TS61
PRIMARY BOOM DOWN

PWM
R
A
+
X
-
TB3
RED/WHT-3-M.H. PRIMARY BOOM

FLOW CONTROL
TP1
RED-3
I
TP2
RED/BLK-3
REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
TP10
BLU BLU-10-M.H.
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
A
X
+
-
BLU/BLK BLU/BLK-11-M.H.
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
BLU/WHT BLU/WHT-12-M.H. SECONDARY BOOM
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP
PLATFORM LEVEL
TB14
DOWN ORG/BLK-3
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN ORG/BLK-15-M.H.
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
L
GRN/BLK-3
RIGHT
PLAT ROTATE
TB18
TS7
LEFT GRN-3
TS57
TP17 GRN/BLK-18-M.H.
RIGHT
PLAT ROTATE
LEFT GRN-17-M.H.
TB17
M

N
ORG/BLK
RED
RED
WHT
BRN
BRN


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

1 LABEL DESCRIPTION
KS1 KEY SWITCH
STACKED CONTACTS
BLK-R1#86
1 START RELAY
2
NO
NO
ORG/BLK-41A
TACHOMETER
2
3 START INPUT
M.H. AUXILIARY PUMP TS62 TURNTABLE ROTATE SWITCH
RED-27B P1
4 AUX. ON
BRN-GRD. TST. SW. TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
5 GROUND TS51
IGN./START NC TS64 RUN/TEST SWITCH
RED-20C
6 BATTERY MODULE
WHT-TST. SW. KS1 CB1 CIRCUIT BREAKER, ENGINE, 15A
7 KEY PWR. NC
EXT#6 8 KEY BYPASS
WIRING STOP HM HOUR METER
NO
NO
WHT-R2#86
9 IGN./FUEL ON
HARNESS: R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
10 ENG. FAULT
L2 CHECK ENGINE LED
3 D
BLOCK
C B A
CONTROL BOX
CONNECTIONS CR1 IGNITION / START RELAY
RED-M.H RED-3 1 RED-S.P. PRIMARY BOOM UP SPLICE
RED/BLK-M.H RED/BLK-3 RD/BK-S.P.
WHT-23 CR2 INGITION POWER RELAY
2 PRIMARY BOOM DOWN
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNTION CONTROL BLK-22 CR4 LPG LOCKOUT RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURNTABLE ROTATE LEFT RED-27 BLU/WHT-38
PRIM.#5 WHT/BLK-M.H WHT/BLK-3 CR5 HORN RELAY
5 WT/BLK-S.P. TURNTABLE ROTATE RIGHT
BRN TO R4 BLU/RED-39
W/R-M.H WHT/RED-3 6 WT/RD-S.P. TURNTABLE ROTATE FUNCTION CTRL CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT-21 +
RED/WHT-3
LED
WHT-21TO R2 L2 TS53
RED/BLK-2
BLU/WHT-3 12 BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL RED-1
4 BLK-ENA. BLU/RED-3 13 DRIVE ENABLE LIGHT HOUR METER
ENGINE
BLK-7
BLK/RED-9
ORG-M.H. ORG-3 14 ORG-S.P PLATFORM LEVEL UP BLK-22
OR/BK-M.H ORG/BLK-3 15 OG/BK-S.P PLATFORM LEVEL DOWN 3 BLK/WHT-8
GRN-M.H GRN-3 17 GRN-S.P. PLATFORM ROTATE LEFT/JIB UP PRIMARY RED-R1
BLU/WHT-12 BOOM EXTEND/
GRN/BLK-M.H GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN TS60 PRIMARY BOOM RETRACT WHT-4 CR1 CR2 CR5 CR4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE
2 UP/DOWN
RED-C.H. RED-ISM#6 20 RED-S.P. +12 V POWER BLK-R1 TO ISM#1
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION POWER R4 WHT/BLK-5
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. +12 V TO PLATFORM WHT/RED-6 BLK-R1 TO E.H.#1

TS52 TS62
24 (UNUSED) TURNTABLE
SECONDARY WHT-21
RD/GRN-EH#1 25 BLK-TEST SW ECM KEEP ALIVE POWER ROTATE BLK/RED-R5 BLK-R4
BOOM
5 1
RED-C.H. RED-1
26
(SPARE)
AUXILIARY PUMP SELECT BLK/RED-35
START
WHT-40
GREEN-R4
RUN/TEST
RD/WT-C.H. R/W-1 29 2WD/4WD GRN/WHT-19

WHT ISM7 ORG ORG/BLK
WHT-ENA. WHT-1 30 E.D.C. TS54 CB1 CB2
WT/BK-C.H.. WHT/BLK-1
GRN/BLK-18
31 E.D.C.
WHT/RED-1 BRAKE GRN-17 CR7 CR8
WT/RD-C.H. 32
EH2 TS59 TS57
35
BRN-GRD.
BLK/RED-35GEN
STEER LEFT
BLU-10 ROTATE
BLU-M.H. BLU-1 36 ORG-14
WHT#40-R7
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT BLU/BLK-11 PLAT.
WHT-PRIM.#5
PK/GR-EH#2 BLU/WHT-1 38 BU/WT-S.P. (SPARE) LEVEL ORG/BLK-15
BLU/RED-1 LIQUID PROPANE FUEL
RED-20 ORG/BLK-15
BU/RD-S.P.
6 YEL/BLK-EH2
ORG-1
39
40 WHT-SEC.#4 WHT-EXT.#6 OFF-LIMIT SPEED RED-R1 ORG-14
RED TO EH2
ORG/RED-1 42 (SPARE) (CE VERSION ONLY)
GRN-1 43 (SPARE) BLK-33
GRN/WHT-C.H GRN/WHT-1 45 BLK/RED-35GEN GENERATOR OPTION
GROUND STUD
(-12 VOLTS)
RED-E.H.#1 RED-R4
7 GRN-E.H.#1 GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
ORANGE-M.H. ORG-R7

42 PIN INTERCHANGE
EH#1 ENGINE HARNESS #1 PIN/#: TO:
8 EH#2 ENGINE HARNESS #2 (FORD EFI HARNESS)
RED/GRN #1 - 25D
PNK/GRN #6 - 38D
C.H. CHASSIS HARNESS YEL/BLK #7 - 39D
M.H. MANIFOLD HARNESS YEL (18GA) #8 - CB2
YEL (12GA) #9 - CB2
S.P. SWITCH PANEL
WHT/PRP #18 - TST SW
R or CR RELAY TAN/BLU #24 - 35D
H.M. HOUR METER



COMPONENT INDEX
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
DRIVE ENA. LT.
+12 V TO PLAT.
KEYSW. PWR.
PULSE PICKUP
GEN. (OPTION)
GLOW PLUG
STEER RIGHT
LIMIT SWITCH
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. L.
TURN ROT. R.
TURN. ROT. F.C.
SEC. BOOM UP
SEC. BOOM DN.
PLAT. LEVEL UP
PLAT. LEVEL DN.
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
STEER LEFT
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM F.C.
JIB VALVE
AUX. PUMP SEL.
2WD/4WD
E.D.C.
E.D.C.
BRAKE
L.P. GAS
START ENGINE
HIGH/LOW RPM
(SPARE)
(SPARE)
(SPARE)
(SPARE)
TILT ALARM
OPTION WIRE
(UNUSED)
ORG/BLK-41
HORSE-
POWER
LIMITER TS10 SECONDARY BOOM UP/DOWN SWITCH
ORG-40 BOARD TS11 PRIMARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
25
20
22
23
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
TS47 GENERATOR SWITCH ( OPTION )
RED (F.S.)
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
BLK-2
WHT-2
WHT (F.S.)
BLK (F.S.)
RED-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
RED/BLK-1
WHT
R1 EFI RESISTOR
ORG-40 R2 LOW SPEED RESISTOR
RED-10 L1 DRIVE ENABLE LED 3
WHT-24 L3 CHECK ENGINE LED
GRD. STUD BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATE
R1
RED/BLK-28

RED-TILT
50 CR12 EFI RELAY

RED-10
LIMITING RELAY DP1 DRIVE PROPORTIONAL JOYSTICK
H1 TILT ALARM
CABLE CABLE CABLE
110 F.S.
H1 #3 #2 #1 4
+ TILT _
ALARM
GRN/WHT-45
WHT-4
RED/BLK-2
ORG-14
BLK-7
BLK/WHT-8
GRN/BLK-18
RED-27
BLU/WHT-12
BLU/RED-13
RED-10 TO H.P.L.
BLU-10
BLU/BLK-11
RED/WHT-29
ORG/BLK-15
BLK/RED-35
WHT/BLK-5
GRN/WHT-19
GRN-17
BLK/RED-9
RED/WHT-3
RED-25
ORG/RED-16
WHT/RED-6
RED-1
BLU/WHT-38
BLK-33
SIDE VIEW OF DP1
BLU/BLK-37
WHT-30
BLU-36
WHT/RED-32
5
WHT-24 TO H.P.L.
BLK-26
BRN TO GRD.
BLU/RED-39
WHT/BLK-31
BLK-22
WHT-23
RED-TILT
WHT TO PLATFORM ROTATE
GEN.
OPT.
8
PRIMARY SEC.BOOM TS47
7
8
NC NO BOOM BP2 L1 6
RED-GEN
EXTEND/
7
R
R
A
RETRACT
5
6
+
NC
4 6
- X
5
- X
- X
BP1
4
NC 3
+
3
NO NO
TS13
R
A
SEE 2
2
TURNTABLE PRIMARY BOOM SIDE VIEW
1
1
ROTATE UP/DOWN DP1
DP1
DRIVE
PLATFORM
PLATFORM ROTATE
R2 R3 DRV.ENA
LEVEL TS7
TS15 7
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
SPEED TS14 HIGH/LOW
ENGINE FUEL SELECT
EMERGENCY STOP
P2
8


N
WHT
BRN
RED
ORG/BLK
RED
RED
BRN
CR13
RED
CR14
JIB CUTOUT RELAY JIB BOOM CUTOUT RELAY (CR13)

JIB VALVE RELAY JIB BOOM VALVE RELAY (CR-14)
CR14
JIB VALVES JIB BOOM VALVES

NO
M
BLK/RED-1
FOOTSW. H/L
TS54
TP35
LOW RPM
ENGINE
HIGH RPM
SPEED
LOW RPM
TS4
FUNCTION ENA.
L
HIGH RPM TAN/BLU

TB35
OFF
GENERATOR GRN/WHT-45-E.H.#1
ON GRN/WHT-1 GENERATOR
K
TS47
OPTION
WHT
RED
TP45
TB45
RED/WHT-23-E.H.#1 FLASHING BEACON

FB
OPTION
TB39
TP39
J
TS3
BLU/RED-1
LP
FUEL
GAS
WHT
TS53
HM 3
LP
FUEL WHT-21
2
1
TP38
GAS HOUR METER

L3
BLU/WHT-1
L2
CHECK ENGINE
ENGINE
TB38
CHECK
BLU/WHT-38 LED
I
ENGINE
CHECK
IGN./START
MODULE
RUN/TEST SWITCH
TP33
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
10 ENG. FAULT
BLK-1
7 KEY PWR.
TEST
6 BATTERY
TS2
5 GROUND
4 AUX. ON
TEST
ENGINE RUN
TS64
TS52
START
ENGINE
H
START
BLK
TB33
POWER RELAY
CR2

TB21
TB25
ENGINE HARNESS #2
RD/LG FEH(16A) PIN1
G
(SEE PAGE 6)
CR2
NO

Y FEH(37B) PIN8
Y FEH(37) PIN9
F
CR1
PUMP
FUEL
PK/BLK BLK
FUEL PUMP
Part No. 52709

BLK-R1-E.H.#1
WHT
RED
CR1
NO
STARTER
STARTER MOTOR
E
TS51
TP25
TP24
TB27
TS1
AUXILIARY
PUMP RED-27-C.H. AUXILIARY POWER
AUXILIARY
TP27
RED RELAY
PR1
PUMP RED-1
WHT-(FS)
RED-(FS)
PUMP
AUX
AUXILIARY PUMP
LOAD SENSE OPTION (SEE DETAIL)
PR1
NO
TB28
TP28
FS1
WHT RED/BLK-1 RED/BLK-28-C.H. WHT

D
TILT ALARM
BLK-(FS)
WHT-2 RED/WHT-23-C.H. RED BLK BRN

LEVEL SENSOR
TP23
TB23

TP26
BLK
HORN
TB9
TP9
P3
P2
BLK BLK/RED-3 BLK/RED-9 HORN

RELAY
CR5
WHT-24
TP22
TB22
C
BLK-2 BLK-22 BLK/RED-R5-C.H.

HORN
TP24
CR5
NO
GRND
WHT-LOAD
PLAT
KS1
RED
SENSOR
P1
LOAD
ORG-LOAD
BOX
8
LOAD SENSE OPTION
B
GND
WHT-21-E.H.#1
500
RED-E.H.#1
TP41
TB41
B+
C
ORG/BLK-1 ORG/BLK-41-C.H.
WHT-(FS)
RED-(FS)
RED
RED
BLK-26 LOAD
STA.
A
S
I
ALTERNATOR
REGULATOR
FS1
BLK-(FS)
15AMP.
15AMP.
FLD.
CB1
CB2
GRD.
TP26
BAT.
A
BLK-26
FUSE
LINK
TB20
P2
-
+
RED RED#20-C.H.
TP22
12 V
DC
6 - 29
1
8

6 - 30
BRN-2
GROUND
TB13
TP13
L1
NCHO
A
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
B
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
C
1
2
3
4
5
6
7
8
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
D
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO
Part No. 52709

DRIVE LIMIT SWITCH
TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
HORSE- 3
4
POWER 5
LIMITER 6
7
8
9
BOARD
F
TP7
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
TS13
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
G
WHT/RED-3
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK-5-M.H.
TP4

RIGHT TURNTABLE
PWM

TS62
R
A
X
+
-

R4
10
TB4
H
WHT/RED-6-M.H.
TURNTABLE ROTATE
FLOW CONTROL
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
X
A
-
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
J
BLU-3
TB10
BLU BLU-10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
BOOM
R
A
X
+
-
DOWN BLU/BLK BLU/BLK-11-M.H.

TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
DOWN LEVEL
TB14
ORG/BLK-3
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
DOWN LEVEL ORG/BLK-15-M.H.
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
L
CR13
GRN/BLK-3
NC
DOWN
JIB BOOM
TB18
TS8
UP GRN-3
TS58
PLATFORM ROTATE RIGHT /
DOWN JIB BOOM DOWN
JIB BOOM
UP GRN-17-M.H.
PLATFORM ROTATE LEFT /
JIB BOOM UP
TB17
TS57
RIGHTPLATFORM RIGHT PLATFORM
M
LEFT ROTATE LEFT ROTATE

WHT
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
N
ORG/BLK
RED
RED
WHT
RED
BRN
BRN


Z-45/25J Ford Models (after serial number 16303)

LABEL DESCRIPTION
1 P1 EMERGENCY STOP BUTTON
KS1 KEY SWITCH
STACKED CONTACTS
1 START RELAY
NO
NO
2 TACHOMETER
2 M.H.
BLK-33D
3 START INPUT
AUXILIARY PUMP
TS60
TS61
SECONDARY BOOM UP/DOWN SWITCH
PRIMARY BOOM UP/DOWN SWITCH
RED-27B P1
4 AUX. ON
BRN-GRD. TST. SW. IGN./START TS51 TS62 TURNTABLE ROTATE SWITCH
5 GROUND NC
RED-20C TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY MODULE
WHT-TST. SW. KS1 TS64 RUN/TEST SWITCH
7 KEY PWR. NC
EXT#6 8 KEY BYPASS
WIRING STOP CB2 CIRCUIT BREAKER, CONTROLS, 15A
NO
NO
WHT-R2#86
9 IGN./FUEL ON HARNESS:
SEC.#4 HM HOUR METER
BASE TERMINATION 10 ENG. FAULT TO BASE
BLOCK CONTROL BOX R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
D C B A CONNECTIONS L2 CHECK ENGINE LED
3 RED-M.H
RED/BLK-M.H
RED-3 1 RED-S.P.
RD/BK-S.P.
PRIMARY BOOM UP
PRIMARY BOOM DOWN
WHT-23 SPLICE
CR1 IGNITION / START RELAY
RED/BLK-3 2
R/W-M.H RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNTION CONTROL BLK-22 CR2 INGITION POWER RELAY
WHT-M.H WHT-3 4 WHT-S.P. TURNTABLE ROTATE LEFT RED-27 BLU/WHT-38
PRIM.#5 WHT/BLK-M.H WHT/BLK-3 5 WT/BLK-S.P. TURNTABLE ROTATE RIGHT CR4 LPG LOCKOUT RELAY
BRN TO R4 BLU/RED-39
W/R-M.H WHT/RED-3 6 WT/RD-S.P. TURNTABLE ROTATE FUNCTION CTRL CR5 HORN RELAY
BLK/WHT-M.H BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT-21 +
RED/WHT-3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
LED
WHT-21TO R2 L2 TS53
BLU-M.H 10 BLU-S.P. SECONDARY BOOM UP
BLU-3 RED/BLK-2
3 1 2 CHECK RED-1
BRN TO H.M.
BLU/WHT-3 12 BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL
ENGINE BLK/RED-9
BLK-ENA. BLU/RED-3 13 DRIVE ENABLE LIGHT HOUR METER BLK-7
4 ORG-M.H.
OR/BK-M.H
ORG-3
ORG/BLK-3
14
15
ORG-S.P
OG/BK-S.P
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN 3 BLK/WHT-8
BLK-22
GRN-M.H GRN-3 17 GRN-S.P. PLATFORM ROTATE LEFT/JIB UP PRIMARY RED-R1
GRN/BLK-M.H
BLU/WHT-12 BOOM EXTEND/
GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN TS60 PRI. BOOM RETRACT WHT-4 CR1 CR2 CR5 CR4
RED-C.H. 20 RED-S.P. +12 V POWER UP/DOWN BLK-R1 TO ISM#1
RED-ISM#6
RED-EXT.#6 21 WHT-E.H.#1 WHT-S.P. IGNITION POWER R4 WHT/BLK-5
BRN ISM5
BLK 25B BLK-2 22 BLK-S.P. +12 V TO PLATFORM WHT/RED-6 BLK-R1 TO E.H.#1

TS52 TS58 TS62
24 (UNUSED) TURNTABLE WHT-21
SECONDARY ROTATE
RD/GRN-EH#1 25 BLK-TEST SW ECM KEEP ALIVE POWER BLK/RED-R5 BLK-R4
BOOM
1 26 (SPARE) START JIB
GREEN-R4
5 RED-C.H.
RD/BK-C.H.
RED-1
RED/BLK-1
27
28
RED-ISM#4 RED-S.P. AUXILIARY PUMP SELECT
TILT ALARM
BLK/RED-35
WHT-40
RUN/TEST
RD/WT-C.H. R/W-1 29 2WD/4WD GRN/WHT-19 ORG/BLK

WHT ISM7 WHT-ENA. E.D.C. ORG
WHT-1 30 TS54 CB1 CB2 GRN/BLK-18
BRAKE GRN-17 CR7 CR8
WT/RD-C.H. WHT/RED-1 32
EH2 TS59 TS57
TS64 BLK/RED-1 HIGH/LOW RPM BK/RD-S.P. HIGH/LOW RPM PLATFORM
BR/BLU-EH2 35
BRN-GRD.
BLK/RED-35GEN
STEER LEFT
BLU-10 ROTATE
BLU-M.H. BLU-1 36 ORG-14
WHT#40-R7
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT BLU/BLK-11 PLAT.
WHT-PRIM.#5
PK/GR-EH#2 BLU/WHT-1 38 BU/WT-S.P. (SPARE) LEVEL ORG/BLK-15
LIQUID PROPANE FUEL
RED-20 ORG/BLK-15
YEL/BLK-EH2 BLU/RED-1 39 BU/RD-S.P.
6 CH+EH1 OG/BK-C.H.
ORG-1
ORG/BLK-1
40
41
WHT-SEC.#4 WHT-EXT.#6
OG/BK-ISM#2
OFF-LIMIT SPEED
ALTERNATOR PULSE PICKUP
RED-R1 ORG-14
PLATFORM LEVEL CUTOUT
RED TO EH2
ORG/RED-1 42 (SPARE) (CE MODELS ONLY)
GRN-1 43 (SPARE) BLK-33
GRN/WHT-C.H GRN/WHT-1 45 BLK/RED-35GEN GENERATOR OPTION
GROUND STUD
(-12 VOLTS)
RED-E.H.#1 RED-R4
7 GRN-E.H.#1 GRN-R4
BLK-E.H.#1 BLK-R4
BLK-E.H.#1 BLK-1
ORANGE-M.H. ORG-R7

EH#1 ENGINE HARNESS #1 42 PIN INTERCHANGE
8 C.H. CHASSIS HARNESS RED/GRN #1 - 25D
PNK/GRN #6 - 38D
M.H. MANIFOLD HARNESS
YEL/BLK #7 - 39D
S.P. SWITCH PANEL
YEL (18GA) #8 - CB2


COMPONENT INDEX
P2 EMERGENCY STOP BUTTON 1
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. L.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
PLAT. LEVEL DN.
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
+12 V TO PLAT.
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
AUX. PUMP SEL.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
L.P. GAS
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
HORSE-
POWER
RED FROM CR14

ORG-40 BOARD TS10 SECONDARY BOOM UP/DOWN SWITCH
2
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
WHT/RED-3
ORG-40 R1 EFI RESISTOR
CR12 LOW SPEED RESISTOR
R2
RED-10 LOW SPEED RESISTOR
R3
GRD. STUD
L3 CHECK ENGINE LED 3
R1
RED-TILT
RED/BLK-28
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATE

50 BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
RED-10
WHT JIB CABLE CR12 EFI RELAY
LIMITING RELAY
CABLE CABLE CABLE JIB
110 F.S. DP1 DRIVE PROPORTIONAL JOYSTICK
#3 #2 #1 CABLE
H1 H.P.L. HORSEPOWER LIMITER BOARD
+ TILT _
T1 TIME DELAY
ALARM
H1 TILT ALARM
4
SIDE VIEW FOR DP1

BLK/RED-9
ORG-14
ORG/BLK-15
WHT/RED-6
WHT/BLK-5
WHT-4
RED/BLK-2
RED/WHT-3
RED-1
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN-17
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
BLU/RED-13
BLU/WHT-38
ORG/RED-16
RED-25
BLK/RED-35
BLK-33
GRN/WHT-45
RED TO JIB CABLE

RED JUMP
RED TIM.DEL.
RED-TILT
RED-STP
BLU/BLK-37
BLU-36
BRN TO GRD.
WHT-24 TO H.P.L.
BLU/RED-39
WHT/BLK-31
WHT-30
WHT/RED-32
BLK-22
BLK-26
WHT-23
RED-STP
5
GEN.
OPT.
8
PRIMARY SEC.BOOM
TS47 7
8
NC NO BOOM BP2 L1 6
RED-GEN
EXTEND/ CR13
7
R
R
A
RETRACT
CR14 5
6
+
NC JIB
VALVE
4
- X
5
- X
- X
BP1 RELAY 6
4
NC 3
+
JIB CUTOUT
3
NO NO
TS13 RELAY
2
R
A
SEE SIDE
2
GRN/WHT +
TURNTABLE PRIMARY BOOM VIEW DP1
1
1
DP1 BRN
DRIVE
PLATFORM TIME DELAY T1
LEVEL JIB
TS7
TS8 TS15 7
TS9
250
100
P3 NO TS1 NC NC
L3 TS2 START
AUXILIARY PUMP TS3
SPEED TS14 HIGH/LOW
ENGINE FUEL SELECT
EMERGENCY STOP
P2
8


Z-45/25J Ford Models (after serial number
N
WHT
WHT
ORG/BLK
RED
RED
BRN
SELECTOR
M
LIFT/DRIVE SELECTOR
TS50
OPTION

DRIVE
LIFT/
CE MODELS)
BLK/RED-1
LOW RPM
TS54
TP35
FOOTSW. H/L
CR4
ENGINE
CR3
SPEED
HIGH RPM LOW RPM

NO
FUNCTION
TS4
HIGH RPM ENABLE BLK/RED

HIGH IDLE RELAY
L
TB35
HIGH IDLE CUTOUT

RELAY
CR3
BLK/RED#R4-E.H.
RPM SOLENOID
CR4
NO
OFF
GENERATOR
ON GRN/WHT-1 GRN/WHT#45-E.H. GENERATOR
TS47
K
OPTION
TB45
TP45
RED/WHT#23-E.H. FLASHING BEACON

FB
OPTION
J
PR2
TB34
TP34
BLK/WHT#34-E.H.
TS6
BLK-1
GLOW
GLOW PLUG OPTION
TS56
PLUG
GLOW
PLUG
PR2
NO
BLK
I
TEMP.
L3
OIL
WHT/RED
OIL TEMPERATURE LED
PRES.
L2
OIL
WHT/BLK
OIL PRESSURE LED
IGN./START
MODULE
H
OTS
NO
TP33
TB26
IGN./FUEL ON
2 TACHOMETER
KEY BYPASS
1 START RELAY
KEY PWR.
3 START INPUT
10 ENG. FAULT
BATTERY
GROUND
BLK-1
4 AUX. ON
TS2
WHT/RED#26 E.H.
OIL TEMPERATURE
ENGINE SWITCH
TS52
TB25
TB24
START
WHT/BLK#25 E.H.
5
8
6
9
7
OIL PRESSURE
ENGINE
START SWITCH
OPS
BLK
NC
TB33
G
CR2
POWER RELAY
TB21
FUEL SOLENOID
CR2
NO
WHT
3
F
2
WHT#21
1
HM
HOUR METER
CR1
Part No. 52709

BLK#R1-E.H.
WHT
WHT
RED
CR1
NO
STARTER
STARTER MOTOR
E
TS51
TP25
TP21
TB27
TS1
AUXILIARY
PUMP RED#27-E.H.
TP27
AUXILIARY AUXILIARY POWER

PUMP RED RELAY
PR1
RED
RED-1
TP24
PUMP
AUX
AUXILIARY PUMP
RED
PR1
NO
TB28
TP28
FS1
D
RED/BLK-1 RED/BLK#28-E.H.
BLK
WHT TILT ALARM

WHT-2 RED/WHT#23-E.H.
LEVEL SENSOR
BLK

TB23
TP23
TP26
BLK
CR5
HORN
TB9
TP9
P3
P2
BLK BLK/RED-3 BLK/RED HORN

RELAY
TP22
TB22
CR5
C
NO
BLK-2 BLK#22 BLK/RED#R5-E.H.
HORN
GRND
PLAT
KS1
RED
P1
B
TB41
TP41
ORG/BLK-1 ORG/BLK#41-E.H.
EXCT.
WHT#21-E.H.
STA.
BAT.
IND.
RED
RED
-
ALTERNATOR
REG.
15AMP.
15AMP.
A
CB2
CB1
BAT.
+
TB20
-
RED RED#20-E.H.
12 V
6 - 33
DC
1
8
6 - 34
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BRN DRIVE ENABLE
TP30
TB30
A
LIMIT SWITCH
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
D
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1

DRIVE LIMIT SWITCH
E
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
HORSE- 4
POWER 5
LIMITER 6
BOARD 7
8
9
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB4
TP4
WHT#4-M.H.
RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT/BLK#5-M.H.
TS62
R
A
X
+

-
TB5
15
R4
FLOW CONTROL
H
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2
DOWN BOOM
RED/BLK#2-M.H.
TS61
PRIMARY BOOM DOWN

PWM
R
X
A
+
-
TB3
10
R5
TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU#10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
R
A
X
+
-
TS60
SECONDARYBOOM DOWN
BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
UP
K
PLATFORM LEVEL
TB14
DOWN ORG/BLK-3
TS9
TS59
ORG#14-M.H.
TP15
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN ORG/BLK#15-M.H.
PLATFORM LEVEL DOWN
PLATFORM LEVEL
TB15
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP17
L
GRN-3
RIGHT
PLATFORM ROTATE
TB17
LEFT GRN/BLK-3
TS8
TS58
GRN#17-M.H.
TP18 PLATFORM ROTATE LEFT
RIGHT
PLATFORM ROTATE
TB18
M

N
ORG/BLK
RED
RED
WHT
WHT
BRN
BRN


Z-45/25 Deutz Models (before serial number 13099)

LABEL DESCRIPTION
KS1 KEY SWITCH
KS1
BLK-R1#86
1 START RELAY TS60 SECONDARY BOOM UP/DOWN SWITCH
2
NO
NO
ORG/BLK-41A
M.H. 2 TACHOMETER TS61 PRIMARY BOOM UP/DOWN SWITCH
BLK-33D TS62 TURNTABLE ROTATE SWITCH
3 START INPUT
RED-27B TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
4 AUX. ON
BRN-GRD.
5 GROUND CB1 CIRCUIT BREAKER, ENGINE, 15A
RED-R2 # 30
6 BATTERY
IGN./START CB2 CIRCUIT BREAKER, CONTROLS, 15A
WHT-23A HM HOUR METER
7 KEY PWR. MODULE
8 KEY BYPASS AUXILIARY R4 TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS
SECON.4
P1 KS1
WHT-R2#86 R5 BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS
3 EXT.6
WHT-24D
9 IGN./FUEL ON
NC L2 OIL PRESSURE LED
NO
10 ENG. FAULT
NO
BASE TERMINATION BLOCK L3 OIL TEMPERATURE LED
D C B A NC TS51 CR1 IGNITION / START RELAY
RED-4 RED-3 1 RED-S.P. PRI. BOOM UP WHT #23
RED/BLK-4 RED/BLK-3 2 RD/BK-S.P. PRI. BOOM DOWN STOP CR2 POWER RELAY
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRI. BOOM F.C. WHT/BLK # 25
PRIM.5 BLK #22 CR3 HIGH IDLE CUTOUT RELAY
WHT-4 WHT-3 4 WHT-S.P. TURN. ROT. R
WHT/BLK-4 WHT/BLK-3 WT/BK-S.P. TURN. ROT. L
RED #27 CR4 RPM SOLENOID RELAY
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN TO R4 WHT/RED #26
6 TURN. ROT. F.C. CR5 HORN RELAY
BRN TO GRD
RED
BLK-4 BLK-3 7 BLK-S.P. BOOM EXTEND
WHT #21 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
4 BLK/WHT-4 BLK/WHT-3
BLK/RED-3
8
9
BK/WT-S.P.
BK/RD-R5
BOOM RETRACT
HORN WHT#21TO R2
L2
RED/WHT #3
1 2 OIL PRESS
3
BLU-4 BLU-3 10 BLU-S.P. SEC. BOOM UP RED/BLK #2
BLU/BLK-4 BLU/BLK-3 11 BU/BK-S.P. SEC. BOOM DN
BLU/WHT-4 BLU/WHT-3 BLU/WT-S.P.
HOUR METER RED #1
12 SEC. BOOM F.C.
BLU/RED-C.H BLU/RED-3 13 DRV. ENA. LT. BLK #7 BLK/RED#35B
3
ORG-4/R7 ORG-3 14 ORG-SP PLAT. LEVEL. UP
RED
ORG/BLK-3
BLK/WHT #8 RED-ISM#6
ORG/BLK-4/R8 15 OG/BK-SP PLAT. LEVEL DN.
BLU/WHT #12 L3 TS61 TS63 WHT-ISM#9
ORG/RED-C.H ORG/RED-3 16 WHT#12-E.H.1 DRV. ENA.
GRN-4 GRN-3 GRN-S.P. PLAT. ROT. L. OIL TEMP. RED-CB1
17 EXTEND
2 GRN/BLK-4 GRN/BLK-3 18 GR/BK-S.P. PLAT. ROT. R.
RETRACT CR1 CR2 CR3 CR4
GRN/WHT-3 GR/WT-S.P. JIB VALVE R4 R5 PRIMARY BOOM WHT #4
5 RED-C.H.
19
20 RED-S.P. 12V BATT. SUPPLY TS60
TS62 WHT/BLK #5 BLK-ISM#1
WHT-E.H.1 RED-EXT.#6 21 WHT-S.P. IGNITION PWR. TS52
BLK-2 22 BLK-S.P. PWR. TO PLAT. WHT/RED #6
BLK#R1-E.H
RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM#7 KEYSWITCH PWR.
BLK/RED #35 TURNTABLE
WHT-ISM#10 24 ENGINE FAULT WHT#21
START ROTATE
1 WHT/BLK-EH.1 25 WHT/BLK-SP OIL PRESSURE SENDER BLK/RED#R4-EH
WATER TEMP. SENDER
SEC. BOOM
WT/RD-E.H.1 26 WHT/RED-SP
RED-C.H RED-1 27 RED-ISM#4 RED-S.P. AUX. PWR. WHT-40B
RED/BLK-C.H RED/BLK-1 28 TILT ALARM TS54 CB1 CB2 BLK/RED#R5-AH
RED/WHT-C.H R/W-1 29 2WD/4WD GRN/WHT #19
TS59 ORG-4 ORG/BLK-4
WHT-30 C.H WHT-1 30 E.D.C. GRN/BLK #18
6 WT/BK-E.H.1 WHT/BLK-1 31 E.D.C.
GRN #17 CR5 CR7 CR8
WHT/RED-C.H WHT/RED-1 32 BRAKE BLU #10 FUNCTION ENABLE
BLU/BLK #11 PLAT. TS57 BRN GRND H.M
BLK/WHT-E.H.1 BLK/WHT-1 34 GLOW PLUG PLATFORM
BLK/RED-1 RPM RED #20 LEVEL
35 BK/RD-R3#35 BK/RD-SP ROTATE
BLU-M.H. BLU-1 36 STEER RIGHT RED-R1 ORG #14 BLK#22
WHT#40-R7 BU/BK-M.H. BLU/BLK-1 STEER LEFT
37
WHT-PRIM.#5 BLK #33 ORG/BLK #15 BLK/RED-9A
BLU/WHT-1 38 TEST LIGHT
BLU/RED-1 39 L.P. PLATFORM LEVEL CUTOUT
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 LIMIT SWITCH SIG. (CE MODELS ONLY)
CH+EH1 OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 PULSE PICKUP
7 BLK-SEC#4 ORG/RED-1 42 SPARE
SPARE
GRN-1 43
GRN/BLK-1 44 SPARE
GR/WT-C.H GRN/WHT-1 45 GEN. OPTION
ORG/BLK-15
GRD-HOLE
ORG-14
BLK/RED-EH BLK/RED-R4 WIRE CONNECTION ABBREVIATION KEY:

8 BLK/RED-EH
EH ENGINE HARNESS
BLK/RED-R5
C.H. CHASSIS HARNESS
BLK-E.H BLK-R1 M.H. MANIFOLD HARNESS
S.P. SWITCH PANEL
ORG-M.H ORG-R7
R or CR RELAY
ORG/BLK-M.H ORG/BLK-R8 ISM IGNITION/START MODULE
H.M. HOUR METER

1
8
6 - 36
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE
A
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN

PRIMARY BOOM EXTEND/RETRACT SWITCH
B

HORSEPOWER LIMITER BOARD

TURNTABLE ROTATE SWITCH
PLATFORM ROTATE SWITCH
LIFT/DRIVE SELECT SWITCH

EMERGENCY STOP BUTTON
PLATFORM LEVEL SWITCH

DESCRIPTION
START ENGINE SWITCH
LOW SPEED RESISTOR

LOW SPEED RESISTOR
GLOW PLUG OPTION
DRIVE ENABLE LED

AUXILIARY SWITCH
C
HORN SWITCH
TIME DELAY
TILT ALARM
EFI RELAY
LABEL
H.P.L.
CR12
TS11
TS13
TS10
TS12
TS50
BP1
TS1
BP2
TS2
TS6
TS9
TS7
H1
T1
R3
R2
L1
P3
P2
D
WHT-23
BLK-26
EMERGENCY STOP
BLK-22
NC
E
P2
Part No. 52709

NC
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 TO H.P.L.
BRN TO GRD.
F
DRIVE
BLU-36
DP1
8 7 6 5 4 3 2 1
BLU/BLK-37
HIGH/LOW
RPM
G
TS4
GEN.
OPT.
GEN. (OPTION) 45 GRN/WHT-1

SPARE 44 GRN/BLK-1
BLK-33
SPARE 43 GRN-1
TS2 START
SPARE 42 ORG/RED-1 BLK/RED-35
41 RED-25
PULSE PICKUP ORG/BLK-1
LIMIT SWITCH 40 ORG-1 ORG/RED-16
DRV.ENA
H
TS15
L.P. 39 BLU/RED-1
ENGINE FAULT 38 BLU/WHT-1
L1

STEER RIGHT 37 BLU/BLK-1
BLU/RED-13
STEER LEFT 36 BLU-1
RPM 35 BLK/RED-1
GLOW PLG. OPT. 34 BLK/WHT-1
R3
START 33 BLK-1 250
HIGH/LOW (2WD/4WD)
BRAKE 32 WHT/RED-1
R2
E.D.C. 31 WHT/BLK-1 RED/WHT-29
100
I
TS14
E.D.C. 30 WHT-1
NO
NC
BLU/BLK-11
2WD/4WD 29 RED/WHT-1
SEC.BOOM
TILT ALARM 28 RED/BLK-1
SPEED
DRIVE
+
BP2
R - X A
AUX. PWR. 27 RED-1
PWR. TO F.S. 26 BLK (F.S.)
BLU-10
F.S.
PWR. (START) 25 RED (F.S.)

PWR. (CONT.) 24 WHT (F.S.)
BLU/WHT-12
PWR. FRM PLAT. 23 WHT-2
AUXILIARY PUMP
RED-27
22
J
PWR. TO PLAT. BLK-2

OPTION WIRE 21 WHT
20 RED-10 TO H.P.L.
TS1
JIB VALVE 19 GRN/WHT-3 GRN/BLK-18
PLAT. ROT. R. 18 GRN/BLK-3 GRN-17
PLAT. ROT. L. 17 GRN-3 GRN/WHT-19

DRV. ENA. 16 ORG/RED-3
RETRACT
PRIMARY
EXTEND/
PLAT. LVL. DN. 15 ORG/BLK-3
BOOM
PLAT. LVL. UP 14 ORG-3
TS13
K
DRV. ENA. LT. 13 BLU/RED-3

110
SEC. BOOM F.C. 12 BLU/WHT-3 BLK/WHT-8
SEC. BOOM DN. 11 BLU/BLK-3 BLK-7
SEC.BOOM UP 10 BLU-3 RED-1
TS7
PLATFORM
HORN 9 BLK/RED-3
ROTATE
RETRACT 8 BLK/WHT-3 RED/WHT-3
7
CABLE
EXTEND BLK-3
#1
SWING F.C. 6 WHT/RED-3
PRIMARY BOOM
SWING RIGHT 5 WHT/BLK-3 A + - X R
UP/DOWN
L
SWING LEFT 4 WHT-3

RED/BLK-2
PRIMARY F.C. 3 RED/WHT-3
NO
TS9
NC
PLATFORM
PRIMARY DN. 2 RED/BLK-3
NO
LEVEL
1
BP1
PRIMARY UP RED-3 WHT-4
CABLE
#2
NC
TURNTABLE
WHT/BLK-5
LIMITER
HORSE-
POWER
ROTATE
BOARD
R - X + A
M
CABLE
1 2 3 4 5 6 7 8 9 10
#3
WHT/RED-6
NO
HORN
OG/BK-41
RED-10
WHT-24
RED/BLK-28
ORG-40
ORG/BLK-15
GRD. STUD
+ TILT _
P3
ALARM
ORG-14
H1
BLK/RED-9
N


1 ORG/BLK
P2 FS1 RED RED TP25 RED WHT

TP22 TP26
BLK BLK BLK
WHT TS50
TP21 WHT WHT
TP24
LIFT/
DRIVE
TS2 TS47 TS4 SELECTOR
TS6
TS1
OPTION
OFF
HIGH RPM
FOOTSW. H/L
ON
LOW RPM
WHT
BLK-2
START
PLUG
2
GLOW
PUMP
AUXILIARY
GENERATOR
P3
HORN
ENGINE
BLK
TP41
ENGINE
CB1 TB22 TP9 TP33 TP34
KS1 TP23 TP28 TP27 SPEED
P1 TP45
GRND RED
WHT-2
BLK-1
BLK/RED-1
BLK-1
GRN/WHT-1
RED/BLK-1
RED-1
BLK/RED-3
ORG/BLK-1
TS51 TS52 TS56 TS54
LOW RPM
HIGH RPM ENABLE
START
PUMP
PLUG
AUXILIARY
GLOW
RED
TB45
ENGINE
BLK
BLK
FUNCTION
TB28 TB27
TB33 TB34
4
RED
TB9 TB23
TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT#23-E.H.
TB20 15AMP. 5 GROUND MODULE OIL
RED
6 BATTERY
7 KEY PWR.
PRES.
RED#20-E.H.
8 KEY BYPASS
BLK/RED
CR1 9 IGN./FUEL ON L3
CR1
CR2 10 ENG. FAULT OIL
N.O.
N.O. TEMP.
CR2
TB21
5
BLK/WHT#34-E.H.
CR3
N.O.
WHT/BLK
WHT/RED
BLK#22
RED/BLK#28-E.H.
RED#27-E.H.
BLK#R1-E.H.
BLK/RED
RED/WHT#23-E.H.
TB24 CR3
WHT
WHT#21
WHT#21-E.H.
ORG/BLK#41-E.H.
CR4
CR4
GRN/WHT#45-E.H.
.NO.
FB
BLK/RED#R4-E.H.
CR5 PR1 TB25
N.O. CR5 PR1
PR2
WHT/BLK#25 E.H.
ALTERNATOR N.O. PR2
TB26 N.O.
RED
WHT
BLK/RED#R5-E.H.
EXCT.
6
WHT/RED#26 E.H.
12 V BAT. BAT.
+ -
DC
+
STA.
1 OPS
AUX STARTER 3
HM
BLK
REGULATOR PUMP N.C. OIL

IND. 2 TEMPERATURE
-
SWITCH
BRN
N.O.
BRN
7
GLOW PLUG
TILT ALARM
CE MODELS)
LIFT/DRIVE SELECTOR
OPTION
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED

FUEL SOLENOID
OIL TEMPERATURE LED

AUXILIARY PUMP
RELAY
AUXILIARY POWER
STARTER MOTOR
HOUR METER
POWER RELAY
FLASHING BEACON
OPTION
GENERATOR
RELAY
HORN
HORN
LEVEL SENSOR
8 NOTE:
1) The connection to TP24 is for units without the generator option.

6 - 38
BRN-2
GROUND
N.C.H.O.
TB13
TP13
L1
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TB30
TP30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
A
N.O.H.C.
TS15
TB16
WHT#12-C.H.
TP16

ORG/RED-3
TB31
TP31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
DP1
C
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
D
RANGE
DRIVE
R2
BLK
RED
100
N.C.H.O.
LS1

DRIVE LIMIT SWITCH
N.O.
TB40
LS3

E
DRIVE LIMIT SWITCH

TP40
Part No. 52709

N.O.
LS2

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
TP7
TS13
BLK-3
EXTEND
BOOM
F
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
TP5
WHT/BLK-3
G
WHT-3
TB5
WHT/BLK#5-M.H.
TP4

RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT#4-M.H.
TS62
+
-

R
A
R4
10
TB4

FLOW CONTROL
TB6
BP1
TB1
H
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
+
A
TB3

TP1
FLOW CONTROL
RED-3
TP2
RED/BLK-3
I
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
TP10
BLU BLU#10-M.H.
SECONDARY BOOM UP
UP
J
SECONDARY
PWM
+
-
R
A
DOWN BOOM BLU/BLK BLU/BLK#11-M.H.

TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12

FLOW CONTROL
TP14
CR7
NC
ORG-3
UP PLATFORM
DOWN LEVEL TB14
ORG/BLK-3
TS9
K
TS59
ORG#14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
GRN/BLK-3
RIGHT
PLAT ROTATE
TB18
LEFT
TS7
GRN-3
L
TS57
TP17
GRN/BLK#18-M.H.
RIGHT
PLAT ROTATE
LEFT GRN#17-M.H.
TB17
M
ORG/BLK
RED
RED
WHT
WHT
BRN
BRN
N


Z-45/25 Deutz Models (from serial number 13099 to 16303)

LABEL DESCRIPTION
KS1 KEY SWITCH
TS56 GLOW PLUG
BLK-R1#86
1 START RELAY TS59 PLATFORM LEVEL SWITCH
NO
2 ORG/BLK-41A
NO
M.H. 2 TACHOMETER TS60 SECONDARY BOOM UP/DOWN SWITCH
3 START INPUT
RED-27B TS62 TURNTABLE ROTATE SWITCH
4 AUX. ON
BRN-GRD.
GROUND
5
IGN./START
RED-R2 # 30
6 BATTERY CB1 CIRCUIT BREAKER, ENGINE, 15A
MODULE
WHT-23A
7 KEY PWR. CB2 CIRCUIT BREAKER, CONTROLS, 15A
8 KEY BYPASS AUXILIARY
HM HOUR METER
SECON.4 P1 KS1
WHT-R2#86 R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
EXT.6 9 IGN./FUEL ON
3 WHT-24D
ENG. FAULT
NO
10
NO
RED-4 RED-3 1 RED-S.P. PRIMARY BOOM UP
WHT #23 CR2 POWER RELAY
RED/BLK-4 RED/BLK-3 2 RD/BK-S.P. PRIMARY BOOM DOWN STOP
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK # 25
PRIM.5 BLK #22 CR3 HIGH IDLE CUTOUT RELAY
WHT-4 WHT-3 4 WHT-S.P. TURNTABLE ROTATE LEFT
WHT/BLK-4 WHT/BLK-3 5 WT/BK-S.P. TURNTABLE ROTATE RIGHT
W/R-4 WT/RD-S.P. BRN TO R4 WHT/RED #26
WHT/RED-3 6 TURNTABLE ROTATE FUNCTION CTRL
+ CR5 SERVICE HORN RELAY
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN TO GRD
LED
7
BLK/WHT-4 BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT #21 L2 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/RED-3 9 BK/RD-R5 HORN WHT#21TO R2 RED/WHT #3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
4 3
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP 1 2 OIL PRESS
RED/BLK #2
BLU/BLK-4 BLU/BLK-3 11 BU/BK-S.P. SECONDARY BOOM DOWN
BLU/WHT-3 SECONDARY BOOM FUNCTION CTRL
HOUR METER RED #1
12 BLU/WT-S.P. BLK/RED#35B
BLK-ENA. BLU/RED-3 13 DRIVE ENABLE LIGHT
3 BLK #7
ORG-4/R7 ORG-3 14 ORG-SP PLATFORM LEVEL UP RED-ISM#6
RED
OG/BK-SP PLATFORM LEVEL DOWN
BLK/WHT #8
ORG/BLK-4/R8 ORG/BLK-3 15 WHT-ISM#9
RED-ENA. DRIVE ENABLE RELAY COIL BLU/WHT #12 L3 TS61 TS63
ORG/RED-3 16 WHT#12-E.H.1
BLK/WHT-34 OIL TEMP. RED-CB1
GRN-4 GRN-3 17 GRN-S.P. PLATFORM ROTATE LEFT/JIB UP
2 EXTEND
GRN/BLK-4 GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN CR1 CR2 CR3 CR4
PRIMARY RETRACT WHT #4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4
RED-C.H. 20 RED-S.P. +12 V POWER
TS60 BOOM WHT/BLK #5 BLK-ISM#1
TS56
5 WHT-E.H.1 RED-EXT.#6
BLK-2
21
22
WHT-S.P.
BLK-S.P.
IGNITION POWER
+12 V TO PLATFORM
TS52 TS62
WHT/RED #6 BLK#R1-E.H.
RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM#7 KEYSWITCH POWER
ENGINE FAULT
TURNTABLE
WHT-ISM#10 24
ROTATE WHT#21
1 WHT/BLK-EH.1 25 WHT/BLK-SP OIL PRESSURE SWITCH
BLK/RED #35 GLOW PLUG START SEC. BOOM BLK/RED#R4-EH
WT/RD-E.H.1 26 WHT/RED-SP OIL TEMPERATURE SWITCH
RED-C.H RED-1 27 RED-ISM#4 RED-S.P. AUXILARY PUMP SELECT WHT-40B
RED/BLK-C.H RED/BLK-1 28 TILT ALARM
RED/WHT-C.H R/W-1 29 2WD/4WD TS54 CB1 CB2 GRN/WHT #19
BLK/RED#R5-AH. ORG-4 ORG/BLK-4
WHT-ENA. WHT-1 E.D.C. TS59
30 GRN/BLK #18
WT/BK-E.H.1 WHT/BLK-1 31 E.D.C. CR5
GRN #17 CR7 CR8
WHT/RED-C.H WHT/RED-1 32 BRAKE
6 BLK-ISM#3 BLK-1 33 BLK-S.P.
BLK/WHT-34
START ENGINE
GLOW PLUG BLU #10 FUNCTION ENABLE PLAT. TS57 BRN GRND H.M
BLK/WHT-E.H.1 BLK/WHT-1 34 PLAT.
BK/RD-SP HIGH/LOW RPM LEVEL
BLK/RED-1 35 BK/RD-R3#35 BLU/BLK #11
BLU-M.H. BLU-1 36 STEER LEFT ROTATE ORG #14 BLK#22
WHT#40-R7
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT RED #20
WHT-PRIM.#5
ORG/BLK #15 BLK/RED-9A PLATFORM LEVEL
BLU/WHT-1 38 (SPARE) RED-R1 CUTOUT
BLU/RED-1 39 (SPARE)
BLK #33 (CE VERSION ONLY)
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 OFF-LIMIT SPEED
CH+EH1 OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 ALTERNATOR PULSE PICKUP
ORG/RED-1 42 (SPARE)
GRN-1 43 (SPARE)
GRN/BLK-1
7 GR/WT-C.H GRN/WHT-1
44
45
(SPARE)
GENERATOR OPTION
ORG/BLK-15
GRD-HOLE
ORG-14
BLK/RED-EH-r.male r.fem-BLK/RED-R4
BLK/RED-EH-r.fem r.male-BLK/RED-R5
8 BLK-E.H-r.fem r.male-BLK-R1
EH ENGINE HARNESS
ORG-M.H.-r.male r.fem-ORG-R7 C.H. CHASSIS HARNESS
ORG/BLK-M.H.-r.male r.fem-ORG/BLK-R8 M.H. MANIFOLD HARNESS
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER

1
8
6 - 40
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE
A

B




DESCRIPTION
START ENGINE SWITCH
LOW SPEED RESISTOR

LOW SPEED RESISTOR
FUEL SELECT SWITCH
CHECK ENGINE LED

DRIVE ENABLE LED
AUXILIARY SWITCH
C
HORN SWITCH
GLOW PLUG
TILT ALARM
LABEL
H.P.L.
TS11
TS13
TS10
TS12
TS50
BP1
TS1
BP2
TS3
TS2
TS6
TS9
TS7
R3
H1
R2
L1
P3
P2
L3
D
WHT-23
BLK-26
EMERGENCY STOP
BLK-22
NC
E
P2
NC
Part No. 52709
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 TO H.P.L.
BRN TO GRD.
F
DRIVE
BLU-36
8 7 6 5 4 3 2 1
BLU/BLK-37
HIGH/LOW
RPM
G
TS4
GENERATOR
OPTION

(SPARE) 44 GRN/BLK-1
BLK-33
(SPARE) 43 GRN-1
TS2 START
(SPARE) 42 ORG/RED-1 BLK/RED-35
41 RED-25
LIMIT SWITCH 40 ORG-1 ORG/RED-16 DRV.ENA
H
TS15
(SPARE) 39 BLU/RED-1 BLK/WHT-34
(SPARE) 38 BLU/WHT-1
L1
GLOW PLUG
BLU/RED-13
STEER LEFT 36 BLU-1
HIGH/LOW RPM 35 BLK/RED-1
TS6
GLOW PLUG 34 BLK/WHT-1
R3
START ENGINE 33 BLK-1

250
HIGH/LOW (2WD/4WD)
BRAKE 32 WHT/RED-1
R2
100
I
TS14
E.D.C. 30 WHT-1
NO
NC
BLU/BLK-11
SEC.BOOM
SPEED
DRIVE
+
BP2
R - X A
AUX. PUMP SEL. 27 RED-1
BLU-10
F.S.
F.S. UP POWER 25 RED (F.S.)

BLU/WHT-12
KEYSW. PWR. 23 WHT-2
AUXILIARY PUMP
RED-27
+12 V TO PLAT. 22 BLK-2
J
OPTION WIRE 21 WHT

20 RED-10 TO H.P.L.
(UNUSED)
TS1
DRIVE ENABLE 16 ORG/RED-3
RETRACT
TS13
PRIMARY
EXTEND/
PLAT. LEVEL DN. 15 ORG/BLK-3
BOOM
PLAT. LEVEL UP 14 ORG-3
K
DRIVE ENA. LT. 13 BLU/RED-3 110

SEC. BOOM UP 10 BLU-3 RED-1
TS7
PLATFORM
HORN 9 BLK/RED-3
ROTATE
BOOM RETRACT 8 BLK/WHT-3 RED/WHT-3
7
CABLE
BOOM EXTEND BLK-3
#1
TURN. ROT. F.C. 6 WHT/RED-3
PRIMARY BOOM
TURN ROT. R. 5 WHT/BLK-3 A + - X R
UP/DOWN
L
TURN ROT. L. 4 WHT-3

RED/BLK-2
NO
TS9
NC
PLATFORM
PRIMARY DOWN 2 RED/BLK-3
NO
LEVEL
1
BP1
CABLE
#2
NC
TURNTABLE
WHT/BLK-5
LIMITER
HORSE-
ROTATE
POWER
BOARD
R - X + A
M
CABLE
1 2 3 4 5 6 7 8 9 10
#3
WHT/RED-6
NO
ORG/BLK-41
HORN
ORG-40
WHT-24
RED/BLK-28
RED-10
ORG/BLK-15
GRD. STUD
P3
ALARM
ORG-14
+ TILT
H1
BLK/RED-9
N

N
WHT
WHT
BRN
RED
ORG/BLK
RED
RED
BRN
CR13
RED
JIB BOOM CUTOUT RELAY
CR14
(CR-13)
JIB BOOM VALVE RELAY
(CR-14)
CR14
JIB VALVES JIB BOOM VALVES

NO
SELECTOR
M
LIFT/DRIVE SELECTOR
TS50
OPTION

DRIVE
LIFT/
CE MODELS)
BLK/RED-1
LOW RPM
TS54
TP35
FOOTSW. H/L
CR4
ENGINE
CR3
SPEED
HIGH RPM LOW RPM FUNCTION

NO
TS4

HIGH IDLE RELAY
L
TB35
HIGH IDLE CUTOUT

RELAY
CR3
BLK/RED#R4-E.H.
RPM SOLENOID
CR4
NO
OFF
GENERATOR
ON GRN/WHT-1 GRN/WHT#45-E.H. GENERATOR
TS47
OPTION
K
TB45
TP45
RED/WHT#23-E.H. FLASHING BEACONS

FB
OPTION
J
PR2
TB34
TP34
BLK/WHT#34-E.H.
TS6
BLK-1
GLOW
GLOW PLUG OPTION
TS56
PLUGS
GLOW
PLUGS
PR2
NO
BLK
I
TEMP.
L3
OIL
WHT/RED
OIL TEMPERATURE LED
PRES.
L2
OIL
WHT/BLK
OIL PRESSURE LED
IGN./START
MODULE
H
OTS
NO
TP33
10ENG. FAULT
2 TACHOMETER
1 START RELAY
TB26
3 START INPUT
IGN./FUEL ON
KEY BYPASS
KEY PWR.
BATTERY
GROUND
BLK-1
4 AUX. ON
TS2
WHT/RED#26 E.H.
OIL TEMPERATURE
ENGINE SWITCH
TS52
TB25
TB24
START
WHT/BLK#25 E.H.
5
6
7
8
9
OIL PRESSURE
ENGINE
START SWITCH
OPS
BLK
NC
TB33
G
CR2
POWER RELAY
TB21
FUEL SOLENOID
CR2
NO
WHT
2
1
WHT#21
HM
F
HOUR METER
CR1
Part No. 52709

BLK#R1-E.H.
WHT
WHT
RED
CR1
NO
STARTER
STARTER MOTOR
TS51
TP25
TP21
E
TB27
TS1
AUXILIARY
PUMP RED#27-E.H.
TP27
AUXILIARY AUXILIARY POWER

RED RELAY
PR1
RED
PUMP RED-1
PUMP
TP24
AUX
AUXILIARY PUMP
RED
PR1
NO
TB28
TP28
FS1
RED/BLK-1 RED/BLK#28-E.H.
BLK
WHT TILT ALARM

D
WHT-2 RED/WHT#23-E.H.
LEVEL SENSOR
BLK
TB23
TP23
TP26

BLK
CR5
HORN
TB9
TP9
TP22
P3

RELAY
P2
TB22
BLK-2 BLK#22 BLK/RED#R5-E.H.
C
HORN
CR5
NO
GRND
PLAT
KS1
RED
P1
TB41
TP41
B
ORG/BLK-1 ORG/BLK#41-E.H.
EXCT.
WHT#21-E.H.
STA.
BAT.
IND.
RED
RED
-
ALTERNATOR
REG.
15AMP.
15AMP.
CB2
CB1
BAT.
A
+
TB20
-
RED RED#20-E.H.
12 V
DC
6 - 41
1
8
6 - 42
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BRN DRIVE ENABLE
TP30
TB30
LIMIT SWITCH
A
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
DP1
C
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
D
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1

DRIVE LIMIT SWITCH

TB40
LS3
NO
E

DRIVE LIMIT SWITCH
Part No. 52709
TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
HORSE- 4
POWER 5
LIMITER 6
BOARD 7
8
9
TP7
TS13
BLK-3
F
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
TP5
G
WHT/BLK-3
WHT-3
TB4
TP4
WHT#4-M.H.
RIGHT
TURNTABLE
PWM
LEFT ROTATE WHT/BLK#5-M.H.

TS62
-
R
A

X
+
TB5
15
R4
FLOW CONTROL
TB6
H
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
-
A
X
+
TB3
10
R5
TP1
FLOW CONTROL
RED-3
TP2
I
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU#10-M.H.
TP10
SECONDARY BOM UP
UP SECONDARY
PWM
DOWN BOOM
R
A
X
+
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
UP PLATFORM
K
TB14
TS9
TS59
ORG#14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP17
CR13
GRN/BLK-3
L
NC
UP
JIB BOOM
TB17
DOWN
TS8
GRN-3
TS58
GRN/BLK#18-M.H.
TP18
PLATFORM ROTATE LEFT/
UP JIB BOOM UP
JIB BOOM
DOWN GRN#17-M.H.
PLATFORM ROTATE RIGHT/
JIB BOOM DOWN
TB18
TS57
RIGHT RIGHT
LEFT LEFT
M
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
ORG/BLK
N
RED
RED
WHT
WHT
RED
BRN
BRN


Z-45/25J Deutz Models (before serial number 13099)

LABEL DESCRIPTION
1 KS1 KEY SWITCH
KS1 TS59 PLATFORM LEVEL SWITCH
BLK-R1#86 TS60 SECONDARY BOOM UP/DOWN SWITCH
1 START RELAY
NO
ORG/BLK-41A TS61 PRIMARY BOOM UP/DOWN SWITCH
NO
2 M.H.
BLK-33D
2 TACHOMETER
3 START INPUT
RED-27B
4 AUX. ON TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
BRN-GRD. CB1 CIRCUIT BREAKER, ENGINE, 15A
5 GROUND IGN./START
RED-R2 # 30
BATTERY
6
MODULE
WHT-23A
7 KEY PWR.
HM HOUR METER
R4 TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS
SECON.4
8 KEY BYPASS P1 KS1 AUXILIARY
WHT-R2#86 R5 BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS
EXT.6 9 IGN./FUEL ON
3 WHT-24D
ENG. FAULT
NO
10
NO
RED-4 RED-3 1 RED-S.P. PRI. BOOM UP
RED/BLK-4 RED/BLK-3 2 RD/BK-S.P. PRI. BOOM DOWN STOP
R/W-4 RED/WHT-3 RD/WT-S.P. PRI. BOOM F.C. WHT/BLK # 25 HIGH IDLE CUTOUT RELAY
PRIM.5
3 BLK #22 CR3
WHT-4 WHT-3 4 WHT-S.P. TURN. ROT. R
WHT/BLK-4 WHT/BLK-3 WT/BK-S.P. TURN. ROT. L
5
BRN TO R4 WHT/RED #26 HORN RELAY
W/R-4 WHT/RED-3 6 WT/RD-S.P. TURN. ROT. F.C. CR5
BRN TO GRD
RED
BLK-4 BLK-3 7 BLK-S.P. BOOM EXTEND
BLK/WHT-4 BLK/WHT-3 8 BK/WT-S.P. BOOM RETRACT WHT #21 L2
RED/WHT #3
4 BLU-4
BLK/RED-3 9 BK/RD-R5 HORN WHT#21TO R2
1 2 OIL PRESS
BLU-3 10 BLU-S.P. SEC. BOOM UP RED/BLK #2
3
BLU/BLK-4 BLU/BLK-3 11 BU/BK-S.P. SEC. BOOM DN
BLU/WHT-4 BLU/WHT-3 12 BLU/WT-S.P. SEC. BOOM F.C.
HOUR METER RED #1
BLU/RED-C.H BLU/RED-3 13 DRV. ENA. LT. BLK #7 BLK/RED#35B
3
ORG-4/R7 ORG-3 14 ORG-SP PLAT. LEVEL. UP
RED
ORG/BLK-4/R8 ORG/BLK-3 PLAT. LEVEL DN.
BLK/WHT #8 RED-ISM#
15 OG/BK-SP
BLU/WHT #12 L3 TS61 TS63 WHT-ISM#9
ORG/RED-C.H ORG/RED-3 16 WHT#12-E.H.1 DRV. ENA.
OIL TEMP. RED-CB1
GRN-4 GRN-3 17 GRN-S.P. PLAT. ROT. L.
2 GRN/BLK-4 GRN/BLK-3 GR/BK-S.P. PLAT. ROT. R.
EXTEND
18 CR1 CR2 CR3 CR4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 R5 PRIMARY RETRACT WHT #4
BOOM TS62
5 RED-C.H.
WHT-E.H.1
20
21
RED-S.P.
WHT-S.P.
12V BATT. SUPPLY
IGNITION PWR. TS52
TS60 TS58
WHT/BLK #5 BLK-ISM#1
RED-EXT.#6
BLK-2 22 BLK-S.P. PWR. TO PLAT. WHT/RED #6 BLK#R1-E.H
RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM#7 KEYSWITCH PWR.
TURNTABLE
WHT-ISM#10 24 ENGINE FAULT BLK/RED #35 WHT#21
START ROTATE
1 WHT/BLK-EH.1 25 WHT/BLK-SP OIL PRESSURE SENDER BLK/RED#R4-EH
WHT/RED-SP WATER TEMP. SENDER SEC. BOOM JIB
WT/RD-E.H.1 26
RED-C.H RED-1 27 RED-ISM#4 RED-S.P. AUX. PWR. WHT-40B
RED/BLK-C.H RED/BLK-1 28 TILT ALARM TS54 CB1 CB2
RED/WHT-C.H R/W-1 29 2WD/4WD GRN/WHT #19
BLK/RED#R5-AH ORG-4 ORG/BLK-4
WHT-30 C.H WHT-1 E.D.C. TS59
30 GRN/BLK #18
6 WT/BK-E.H.1
WHT/RED-C.H
WHT/BLK-1
WHT/RED-1
31
32
E.D.C.
BRAKE BLU #10 FUNCTION ENABLE
GRN #17 CR5 CR7 CR8
BLU/BLK #11 PLAT. TS57 BRN GRND H.M
BLK/WHT-E.H.1 BLK/WHT-1 34 GLOW PLUG
LEVEL PLATFORM
BLK/RED-1 35 BK/RD-R3#35 BK/RD-SP RPM RED #20 ROTATE
BLU-M.H. BLU-1 36 STEER RIGHT ORG #14 BLK#22
WHT#40-R7 BU/BK-M.H. BLU/BLK-1
RED-R1
37 STEER LEFT
WHT-PRIM.#5 BLK/RED-9A PLATFORM LEVEL
BLU/WHT-1 38 TEST LIGHT BLK #33 ORG/BLK #15
CUTOUT
BLU/RED-1 39 L.P. (CE MODELS ONLY)
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 LIMIT SWITCH SIG.
CH+EH1 OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 PULSE PICKUP
7 BLK-SEC#4 ORG/RED-1
GRN-1
42
43
SPARE
SPARE
GRN/BLK-1 44 SPARE
GR/WT-C.H GRN/WHT-1 45 GEN. OPTION
ORG/BLK-15
GRD-HOLE
ORG-14

BLK/RED-EH BLK/RED-R4
EH ENGINE HARNESS
8 BLK/RED-EH BLK/RED-R5 C.H. CHASSIS HARNESS
BLK-E.H BLK-R1 M.H. MANIFOLD HARNESS
S.P. SWITCH PANEL
ORG-M.H. ORG-R7 R or CR RELAY
ORG/BLK-M.H. ORG/BLK-R8 ISM IGNITION/START MODULE
H.M. HOUR METER


1
LABEL DESCRIPTION
P3 HORN SWITCH
2
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DN.
PRIMARY F.C.
SWING LEFT
SWING RIGHT
SWING F.C.
EXTEND
RETRACT
HORN
SEC.BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRV. ENA. LT.
PLAT. LVL. UP
PLAT. LVL. DN.
DRV. ENA.
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
OPTION WIRE
PWR. TO PLAT.
PWR. FRM PLAT.
PWR. (CONT.)
PWR. (START)
PWR. TO F.S.
AUX. PWR.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START
GLOW PLG. OPT.
RPM
STEER LEFT
STEER RIGHT
ENGINE FAULT
L.P.
LIMIT SWITCH
PULSE PICKUP
SPARE
SPARE
SPARE
GEN. (OPTION)
TS6 GLOW PLUG OPTION
OG/BK-41
HORSE- TS8 JIB BOOM UP/DOWN
POWER
RED FROM CR14

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

RED-10
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
TS50 LIFT/DRIVE SELECT SWITCH 3
L1 DRIVE ENABLE LED
GRD. STUD BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
CR12 EFI RELAY
RED/BLK-28
CR13 JIB CUTOUT RELAY

WHT JIB CABLE CR14 JIB VALVE RELAY 4
BLK JIB CABLE H.P.L. HORSEPOWER LIMITER BOARD
T1 TIME DELAY
110 F.S. H1 TILT ALARM
H1 #3 #2 #1 CABLE
+ TILT _
ALARM
5
RED-1
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
WHT-24 TO H.P.L.
RED TO JIB CABLE
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED-25
BLK/RED-35
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
RED/BLK-2
RED/WHT-3
GEN.
PRIMARY
OPT. 6
SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
R
R
A
RETRACT
CR14
6
+
NC JIB
VALVE
- X
5
- X
- X
BP1 TS13 RELAY
4
NC
+
+
JIB CUTOUT
3
NO NO
RELAY
R
A
2
GRN/WHT +
1
DRIVE BRN
PLATFORM DP1
TIME DELAY T1
ROTATE
PLATFORM
LEVEL TS7 JIB R2 R3 DRV.ENA
TS8 TS15
TS9
250
100
P3 NO TS1 NC NC
AUXILIARY PUMP
TS2 START 8
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2



ORG/BLK
P2 FS1
1 TP22
BLK
TP26
BLK BLK
RED RED TP25
TP21
RED WHT
WHT TS50
TP24 WHT WHT
LIFT/
DRIVE
TS6
TS1
OPTION
BLK-2
WHT
START
PLUG
GLOW
GENERATOR
PUMP
AUXILIARY
2 P3
HORN
ENGINE
BLK
ENGINE
CB1 TP41 TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 TP35
KS1 SPEED
P1
15AMP. RED RED PLAT RED
GRND RED
WHT-2
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLK-1
GRN/WHT-1
BLK/RED-1
ORG/BLK-1
3 TS51 TS52 TS56 TS54
LOW RPM
HIGH RPM
START
PUMP
PLUG
AUXILIARY
GLOW
RED
TB45
ENGINE
BLK
BLK
ENABLE
FUNCTION
TB28 TB27
TB33 TB34
RED
TB9
4 TB41
TB23
1 START RELAY
2 TACHOMETER
L2
RED/WHT#23-E.H.
4 AUX. ON
TB20 15AMP. IGN./START
RED 5 GROUND OIL
6 BATTERY MODULE
7 KEY PWR. PRES.
RED#20-E.H.
8 KEY BYPASS
BLK/RED
CR1
NO
NO TEMP.
CR2
TB21
BLK/WHT#34-E.H.
CR3
NO
5
WHT/BLK
WHT/RED
BLK#22
BLK/RED
RED/WHT#23-E.H.
RED/BLK#28-E.H.
RED#27-E.H.
BLK#R1-E.H.
TB24 CR3
WHT#21
WHT
WHT#21-E.H.
ORG/BLK#41-E.H.
CR4
CR4
GRN/WHT#45-E.H.
NO
FB
BLK/RED#R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK#25 E.H.
ALTERNATOR NO PR2
TB26 NO
RED
WHT
BLK/RED#R5-E.H.
EXCT.
WHT/RED#26 E.H.
6 12 V
DC
BAT.
+
BAT.
-
+
STA.
1 OPS
AUX STARTER 3
HM
BLK
REGULATOR PUMP NC OIL

- IND. 2 TEMPERATURE
SWITCH
BRN
NO
BRN
STARTER MOTOR
OPTION
FLASHING BEACON
HORN
RELAY
HORN
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
HOUR METER
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
OIL TEMPERATURE LED
OPTION
GENERATOR
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY
CE MODELS)
LIFT/DRIVE SELECTOR
AUXILIARY PUMP
GLOW PLUG
NOTE:
8 3) All switches and contacts are shown with the boom in the stowed position and the key switch off.

6 - 46
A
BRN-2
GROUND
TB30 TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
TS15
TB16
NOHC
WHT#12-C.H.
TP16

ORG/RED-3
TP31
TB31
B
DRIVE EDC
TP32
TB32
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
TP37
TB37
STEER RIGHT
TP36
TB36
BLU-1 BLU#36-M.H.
C
STEER LEFT
1
2
3
4
5
6
7
8
DP1
RED
TB29
TP29
D
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
E

DRIVE LIMIT SWITCH
Part No. 52709
TB40
LS3
TP40
NO

DRIVE LIMIT SWITCH
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
F
TP7
TS13
BLK-3
EXTEND
TP8
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
BOOM EXTEND
EXTEND
BOOM
TB8
TS63
BOOM RETRACT
G
TP6
WHT/RED-3
TP4 TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK#5-M.H.
RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT#4-M.H.
TS62
+

A
-
X
R4
10
TB4
H

FLOW CONTROL
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
+
-
R
A
TB3

FLOW CONTROL
TP1
I
RED-3
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP10 TP11
BLU/BLK-3
J
BLU-3
TB10
BLU BLU#10-M.H.
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
+
R
A
X
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP
TP15
PLATFORM
TB14
TS9
TS59
ORG#14-M.H.
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
L
CR13
GRN/BLK-3
NC
DOWN
TP17
JIB BOOM
TB18
UP
TS8
GRN-3
TS58
GRN/BLK#18-M.H.
JIB BOOM DOWN
DOWN
JIB BOOM
UP GRN#17-M.H.
JIB BOOM UP
TB17
TS57
RIGHT RIGHT
M
LEFT LEFT
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
N
ORG/BLK
RED
RED
WHT
WHT
RED
BRN
BRN


Z-45/25J Deutz Models (from serial number 13099 to 16303)

LABEL DESCRIPTION
1 KS1 KEY SWITCH
TS56 GLOW PLUG
1 START RELAY
NO
NO
M.H. 2 TACHOMETER
2 BLK-33D
3 START INPUT TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
RED-27B TS61 PRIMARY BOOM UP/DOWN SWITCH
BRN-GRD.
5 GROUND
MODULE
RED-R2 # 30 TS60 SECONDARY BOOM UP/DOWN SWITCH
6 BATTERY
WHT-23A CB1 CIRCUIT BREAKER, ENGINE, 15A
7 KEY PWR.
SECON.4
WHT-R2#86 HM HOUR METER
9 IGN./FUEL ON
EXT.6
WHT-24D NC R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
ENG. FAULT
NO
10
NO
L2 OIL PRESSURE LED
3 BASE TERMINATION BLOCK
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK # 25 HIGH IDLE CUTOUT RELAY
PRIM.5 BLK #22 CR3
WHT/BLK-4 WHT/BLK-3 WT/BK-S.P. TURNTABLE ROTATE RIGHT
5
WT/RD-S.P. BRN TO R4 WHT/RED #26 HORN RELAY
W/R-4 WHT/RED-3 6 TURNTABLE ROTATE FUNCTION CTRL CR5
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN TO GRD +
LED
7
BLK/WHT-4 BLK/WHT-3 BK/WT-S.P. PRIMARY BOOM RETRACT WHT #21 L2 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
8
BLK/RED-3 9 BK/RD-R5 HORN WHT#21TO R2 RED/WHT #3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
1 2 OIL PRESS
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP RED/BLK #2
3
4 BLU/BLK-4 BLU/BLK-3
BLU/WHT-3
11 BU/BK-S.P.
BLU/WT-S.P.
SECONDARY BOOM DOWN
SECONDARY BOOM FUNCTION CTRL
HOUR METER RED #1
12 BLK/RED#35B
3 BLK #7
RED
ORG/BLK-3
BLK/WHT #8
ORG/BLK-4/R8 15 OG/BK-SP PLATFORM LEVEL DOWN
BLU/WHT #12 L3 TS61 WHT-ISM#9
RED-ENA. ORG/RED-3 16 WHT#12-E.H.1 DRIVE ENABLE RELAY COIL TS63
2
EXTEND
GRN/BLK-4 GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN
PRIMARY RETRACT WHT #4 CR1 CR2 CR3 CR4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4
RED-C.H. RED-S.P.
TS60 BOOM WHT/BLK #5
20 +12 V POWER BLK-ISM#1
WHT-S.P. IGNITION POWER TS56
WHT-E.H.1 RED-EXT.#6 21 TS52
BLK-2 22 BLK-S.P. +12 V TO PLATFORM TS58 WHT/RED #6 BLK#R1-E.H.
5 RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM#7 KEYSWITCH POWER
TS62
TURNTABLE
WHT-ISM#10 24 ENGINE FAULT
ROTATE WHT#21
BLK/RED #35 GLOW PLUG START SEC. BOOM JIB BLK/RED#R4-EH
TS59 BLK/RED#R5-AH. ORG-4 ORG/BLK-4
WHT-ENA. WHT-1 30 E.D.C. GRN/BLK #18
GRN #17 CR7 CR8
PLAT. TS57 BRN GRND H.M
GLOW PLUG BLU #10 FUNCTION ENABLE PLATFORM
6 BLK/WHT-E.H.1 BLK/WHT-1
BLK/RED-1
34
35 BK/RD-R3#35
BLK/WHT-34
BK/RD-SP HIGH/LOW RPM BLU/BLK #11
LEVEL ROTATE
BLU-M.H. BLU-1 36 STEER LEFT ORG #14 BLK#22
WHT#40-R7 BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT RED #20
WHT-PRIM.#5 BLK/RED-9A
BLU/WHT-1 38 (SPARE) RED-R1 ORG/BLK #15
BLU/RED-1 39 (SPARE) PLATFORM LEVEL
OFF-LIMIT SPEED
BLK #33 CUTOUT
ORG-1 40 WHT-SEC#4 WHT-EXT.#6
CH+EH1 OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 ALTERNATOR PULSE PICKUP (CE MODELS ONLY)
GRN-1 43 (SPARE)
GR/WT-C.H GRN/WHT-1 45 GENERATOR OPTION
7 ORG/BLK-15
GRD-HOLE
ORG-14
r.male-BLK-R1 WIRE CONNECTION ABBREVIATION KEY:
BLK-E.H-r.fem
8 EH ENGINE HARNESS
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER


1
LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(SPARE)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41 TS6 GLOW PLUG
TS8 JIB UP/DOWN
HORSE- 2
RED FROM CR14

ORG-40 POWER TS10 SECONDARY BOOM UP/DOWN SWITCH
LIMITER TS11 PRIMARY BOOM UP/DOWN SWITCH
|BOARD
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
RED-10 TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
L1 DRIVE ENABLE LED 3
RED/BLK-28

WHT JIB CABLE H.P.L. HORSEPOWER LIMITER BOARD
BLK JIB CABLE T1 TIME DELAY
H1 TILT ALARM
110 F.S.
H1 #3 #2 #1 CABLE 4
+ TILT _
ALARM
5
RED-1
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
BLK/WHT-34
WHT-24 TO H.P.L.
RED TO JIB CABLE
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
BLK/RED-35
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
RED-25
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
RED/BLK-2
RED/WHT-3
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
R
R
A
RETRACT
CR14
6
6
+
NC JIB
VALVE
- X
5
- X
- X
BP1 RELAY
4
NC
+
+
JIB CUTOUT
3
NO NO
TS13 RELAY
R
A
2
GRN/WHT +
1
BRN
DRIVE
PLATFORM ROTATE
7
LEVEL JIB R2 R3 DRV.ENA
TS7
TS8 TS15
TS9 TS6
250
100
P3 NO TS1 NC NC
TS2 START
AUXILIARY PUMP
HORN DRIVE GLOW PLUG TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2 8


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,


1
LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(SPARE)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
TS6 GLOW PLUG
ORG/BLK-41
HORSE- TS8 JIB UP/DOWN
2
RED FROM CR14

ORG-40 TS10
LIMITER SECONDARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-10
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
L1 DRIVE ENABLE LED 3
L3 CHECK ENGINE LED
RED/BLK-28

WHT JIB CABLE CR14 JIB VALVE RELAY
BLK JIB CABLE H.P.L. HORSEPOWER LIMITER BOARD
T1 TIME DELAY
CABLE CABLE CABLE JIB H1
110 F.S. TILT ALARM
H1 #3 #2 #1 CABLE 4
+ TILT _
ALARM
RED-1
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
BLK/WHT-34
WHT-24 TO H.P.L.
WHT-21
RED TO JIB CABLE
5
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
BLK/RED-35
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
RED-25
ORG/RED-16
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
RED/BLK-2
RED/WHT-3
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
R
R
A
RETRACT
CR14
+
6
NC JIB
VALVE
6
- X
5
- X
- X
BP1 RELAY
4
NC JIB CUTOUT
+
+
3
NO NO RELAY LIFT/
TS13
R
A
DRIVE
2
SEL. GRN/WHT +
1
BRN
TS50 DRIVE
PLATFORM ROTATE
DRV.ENA
7
LEVEL TS7 JIB R2 R3
TS8 TS15
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2
8

Platform Control Box Wiring Diagram- Lift/Drive Select Option,


LOAD SENSE OPTION (SEE DETAIL BELOW)
ORG/BLK
1 TP22
P2
BLK
TP26
BLK-(FS)
FS1 RED-(FS) TP25 RED
WHT-(FS) TP24 WHT WHT
WHT
TS2 TS47 TS4

TS6
TS1
ON
OFF
BLK-2
WHT
GLOW PLUG
FOOT SW H/L
HIGH RPM
START
LOW RPM
PUMP
GENERATOR
2
AUAXILIARY
P3
HORN
ENGINE
BLK
TP41
ENGINE
P1 KS1 TP23 TP28 TP27 SPEED
15AMP. TP45
RED RED PLAT TP35 RED
GRND RED
WHT-2
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLK-1
GRN/WHT-1
BLK/RED-1
ORG/BLK-1
3 TS51 TS52 TS56 TS54
GLOW PLUG
LOW RPM FUNCTION

HIGH RPM ENABLE
PUMP
START
AUAXILIARY
RED
TB45
ENGINE
BLK
BLK
TB28 TB27
TB33 TB34
4
RED
TB9 TB23
TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT-23-E.H.
4 AUX. ON
TB20 15AMP. IGN./START
RED 5 GROUND
MODULE
OIL
6 BATTERY
7 KEY PWR. PRES.
RED-20-E.H.
8 KEY BYPASS
BLK/RED
CR1
NO
NO TEMP.
CR2
TB21
BLK/WHT-34-E.H.
CR3
5 NO
WHT/BLK
WHT/RED
BLK-22
BLK/RED
RED/WHT-23-E.H.
RED/BLK-28-E.H.
RED-27-E.H.
BLK-R1-E.H. TB24 CR3
WHT-21
WHT
WHT-21-E.H.
ORG/BLK-41-E.H.
CR4
CR4
GRN/WHT-45-E.H.
NO
FB
BLK/RED-R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK-25 E.H.
ALTERNATOR NO PR2
TB26 NO
RED
WHT
BLK/RED-R5-E.H.
EXCT.
WHT/RED-26 E.H.
6 12 V BAT. BAT.
DC + -
+
STA.
1 OPS
AUX STARTER 3 NC
HM
BLK
REGULATOR PUMP
OTS
IND. 2
- NO
BRN
BRN
7
STARTER MOTOR
OPTION
FLASHING BEACON
HORN
RELAY
HORN
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
HOUR METER
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
OIL TEMPERATURE LED
OPTION
GENERATOR
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG OPTION

LOAD SENSE OPTION
P2 FS1 RED-(FS)
TP22
BOX TP24
WHT-LOAD WHT-24
BLK-26 LOAD B+
GND 8
ORG-LOAD

6 - 51
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
A
LIMIT SWITCH
WHT-1 WHT-7 RED-7
WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
D
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1

DRIVE LIMIT SWITCH
E
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
HORSE- 3
4
POWER 5
LIMITER 6
BOARD 7
8
9
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK-5-M.H.
TP4

RIGHT TURNTABL
PWM
LEFT E ROTATE WHT#4-M.H.

TS62
R
A
+
-
X

R4
10
TB4

FLOW CONTROL
H
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2
DOWN BOOM
RED/BLK-2-M.H.
TS61
PRIMARY BOOM DOWN

PWM
A
R
X
-
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU-10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
BOOM
A
-
X
R
+

TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
LEVEL
TB14
DOWN ORG/BLK-3
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
L
GRN/BLK-3
RIGHT PLATFORM
TB18
LEFT ROTATE
TS7
GRN-3
TS57
GRN/BLK-18-M.H.
TP17
RIGHT PLATFORM
LEFT ROTATE GRN-17-M.H.
TB17
M

N
ORG/BLK
RED
RED
WHT
BRN
BRN
Electrical Schematic- Z-45/25 Deutz Models


Z-45/25 Deutz Models (after serial number 16303)

1 LABEL DESCRIPTION
KS1 KEY SWITCH
TS56 GLOW PLUG
2 BLK-R1-86
NO
NO
M.H. 2 TACHOMETER
3 START INPUT
RED-27B
4 AUX. ON TS62 TURNTABLE ROTATE SWITCH
BRN-GRD.
5 GROUND IGN./START TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
RED-R2#30
6 BATTERY MODULE CB1 CIRCUIT BREAKER, ENGINE, 15A
WHT-23A
KEY PWR. CB2 CIRCUIT BREAKER, CONTROLS, 15A
7
8 KEY BYPASS
HM HOUR METER
P1 KS1
SECON.4 AUXILIARY R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
3 EXT.6
WHT-R2#86
WHT-24D
9 IGN./FUEL ON
NO
10 ENG. FAULT
NO
WHT-23 CR2 POWER RELAY
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK-25
PRIM.5 BLK-22 CR3 HIGH IDLE CUTOUT RELAY
RED-27 CR4 RPM SOLENOID RELAY
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN-(R5) WHT/RED-26
6 TURNTABLE ROTATE FUNCTION CTRL CR5 SERVICE HORN RELAY
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN-(GRND) +
LED
7
BLK/WHT-4 BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT-21 L2 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
4 BLK/RED-3 9 BK/RD-R5 HORN WHT-21 (R2)
1 2 OIL PRESS
RED/WHT-3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
3
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP RED/BLK-2
BLU/WHT-3 BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL
HOUR METER RED-1
12 BLK/RED-35B
3 BLK-7 RED-R2
ORG-4/R7 ORG-3 14 ORG-SP PLATFORM LEVEL UP
RED
ORG/BLK-3
BLK/WHT-8
BLU/WHT-12 L3 TS61 TS63 WHT-R2
RED-ENA. ORG/RED-3 16 WHT-12-E.H.1 DRIVE ENABLE RELAY COIL
GRN-4 GRN-3 GRN-S.P. BLK/WHT-34 OIL TEMP. RED-R1
17 PLATFORM ROTATE LEFT/JIB UP
2 GRN/BLK-4 GRN/BLK-3 GR/BK-S.P.
EXTEND
18 PLATFORM ROTATE RIGHT/JIB DOWN CR1 CR2 CR3 CR4
GRN/WHT-3 PRIMARY RETRACT WHT-4
19 GR/WT-S.P. JIB VALVE R4
RED-C.H. 20 RED-S.P. +12 V POWER TS60 BOOM WHT/BLK-5 BLK-R1
5 WHT-E.H.1 RED-EXT.-6
BLK-2
21 WHT-S.P.
BLK-S.P.
IGNITION POWER
+12 V TO PLATFORM
TS56 TS52
WHT/RED-6
22 BLK-R1-E.H.
RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM-7 KEYSWITCH POWER
TS62 TURNTABLE
WHT-ISM-10 24 ENGINE FAULT
ROTATE WHT-21
BLK/RED-35 GLOW PLUG START SEC. BOOM BLK/RED-R4
RED-C.H RED-1 27 RED-ISM-4 RED-S.P. AUXILARY PUMP SELECT WHT-40B
RED/WHT-C.H R/W-1 29 2WD/4WD TS54 CB1 CB2 GRN/WHT-19
TS59 BLK/RED-R5 ORG-4 ORG/BLK-4
WHT-ENA. WHT-1 30 E.D.C. GRN/BLK-18
GRN-17 CR7 CR8
6 BLK-ISM-3 BLK-1
BLK/WHT-E.H.1 BLK/WHT-1
33 BLK-S.P. START ENGINE
GLOW PLUG BLU-10 FUNCTION ENABLE PLAT. TS57 BRN-(GRND H.M)
34 LEVEL PLATFORM
BLK/RED-35GEN BLK/RED-1 35 BK/RD-R3#35 BK/RD-SP HIGH/LOW RPM BLU/BLK-11 ROTATE
BLU-M.H. BLU-1 36 STEER LEFT ORG-14 BLK-22
WHT#40-R7 BU/BK-M.H. BLU/BLK-1 STEER RIGHT
RED-20
37
WHT-PRIM.#5 ORG/BLK-15 BLK/RED-9A
BLU/WHT-1 38 (SPARE) RED-R1
BLU/RED-1 (SPARE)
PLATFORM LEVEL
39
OFF-LIMIT SPEED
BLK-33 CUTOUT
ORG-1 40 WHT-SEC#4 WHT-EXT.#6
CH+EH1
(CE MODELS ONLY)
OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 ALTERNATOR PULSE PICKUP
GRN-1 43 (SPARE)
7 GR/WT-C.H GRN/WHT-1 45 BLK/RED-35GEN GENERATOR OPTION
ORG/BLK-15
GRD-HOLE ORG-14
8 BLK-E.H-r.fem r.male-BLK-R1
EH ENGINE HARNESS
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER



COMPONENT INDEX 1
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
AUX. PUMP SEL.

TURN ROT. L.
PLAT. LEVEL DN.
(UNUSED)
(UNUSED)
OPTION WIRE
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
START ENGINE
HIGH/LOW RPM
(SPARE)
(SPARE)
(SPARE)
(SPARE)
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM F.C.
JIB VALVE
BRAKE
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
STEER LEFT
SEC. BOOM UP
SEC. BOOM DN.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
GLOW PLUG
DRIVE ENA. LT.
KEYSW. PWR.
STEER RIGHT
LIMIT SWITCH
PULSE PICKUP
GEN. (OPTION)
ORG/BLK-41
TS6 GLOW PLUG OPTION (DIESEL ONLY)
HORSE-
TS8 JIB UP/DOWN (JIB OPTION ONLY)
ORG-40
POWER 2
BOARD TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
14
12
13
15
16
17
18
10
19
34
44
24
26
27
28
30
32
33
35
36
37
38
40
42
43
45
20
22
23
25
29
39
11
31
41
21
4
6
2
3
7
8
9
1
RED-10
WHT
RED/BLK-1
BLK (F.S.)
RED-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
BLK-2
WHT-2
WHT (F.S.)
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
RED (F.S.)
GRD. STUD L1 DRIVE ENABLE LED
RED-TILT
L3 CHECK ENGINE LED

RED/BLK-28
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE

BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
CR12 EFI RELAY ( FORD AND PERKINS ONLY )
CR13 JIB CUTOUT RELAY ( JIB ONLY )
CABLE CABLE CABLE JIB VALVE RELAY ( JIB ONLY )
110 F.S. CR14
#3 #2 #1
DP1 DRIVE PROPORTIONAL JOYSTICK
TILT H.P.L. HORSEPOWER LIMITER BOARD
4
ALARM T1 TIME DELAY ( JIB ONLY )
TILT ALARM
GRN/WHT-45
SIDE VIEW DP1
WHT-4
RED/BLK-2
GRN/WHT-19
RED/WHT-3
BLK/WHT- 34
BLU/RED-13
RED-10 TO H.P.L.
BLU-10
BLU/BLK-11
RED/WHT-29
BLK-7
BLK/WHT-8
GRN/BLK-18
RED-27
BLU/WHT-12
BLK/RED-35
ORG-14
WHT/BLK-5
GRN-17
RED-25
ORG/RED-16
ORG/BLK-15
BLK-33
RED-1
BLK/RED-9
BLU-36
RED-TILT
WHT/RED-6
BLU/BLK-37
BLK-22
WHT-23
WHT/BLK-31
BRN TO GRD.
WHT-24 TO H.P.L.
BLK-26
WHT-30
WHT/RED-32
5
8
PRIMARY SEC.BOOM
GENERATOR
OPTION
7
8
NC BOOM
NO BP2 L1 TS47 6
RED-GEN
EXTEND/
7
R
R
A
RETRACT
5
+
6
NC 6
4
-
5
- X
+ - X
BP1
X
4
NC 3
+
3
NO NO
TS13
2
R
A
SEE
2
1
1
ROTATE UP/DOWN DP1
DP1
DRIVE
PLATFORM
PLATFORM
LEVEL
ROTATE
DRV.ENA
7
TS7
TS15
TS9
250
100
P3 NO TS1 TS6 TS2 NC NC

GLOW PLUG START
AUXILIARY PUMP
DRIVE TS4
HORN HIGH/LOW
SPEED TS14
EMERGENCY STOP
P2
8



1
COMPONENT INDEX
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(UNUSED)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
TS6 GLOW PLUG
ORG/BLK-41
HORSE-
POWER TS10 SECONDARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
RED-10 TS47 GENERATOR SWITCH ( OPTION )
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
L1 DRIVE ENABLE LED
L3 CHECK ENGINE LED 3
RED-TILT
RED/BLK-28

H1 TILT ALARM
CABLE CABLE CABLE

H1 #3 #2 #1
110 F.S. 4
+ TILT -
ALARM
GRN/WHT-45
WHT-4
RED/BLK-2
BLK/WHT- 34
ORG-14
BLU/RED-13
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED/WHT-3
BLK/RED-35
ORG/BLK-15
WHT/BLK-5
GRN-17
RED-25
ORG/RED-16
BLK/RED-9
BLK-33
RED-1
WHT/RED-6
BLU/BLK-37
BLU-36
RED-TILT
WHT-30
BRN TO GRD.
WHT-24 TO H.P.L.
WHT/BLK-31
WHT/RED-32
BLK-22
BLK-26
WHT-23
SIDE VIEW FOR DP1

8
PRIMARY SEC.BOOM
GENERATOR
OPTION
7
8
NC NO BOOM BP2 L1 TS47
6
RED-GEN
EXTEND/
7
R
R
A
RETRACT
5 6
+
6
NC
4
-
5
- X
+ - X
BP1
X
4
NC 3
+
3
NO NO
TS13
2
R
A
SEE
2
1
1
ROTATE UP/DOWN DP1
DP1
DRIVE
PLATFORM TS15 7
PLATFORM ROTATE
R2 R3 DRIVE
LEVEL TS7 ENABLE
TS9 TS6
250
100
P3 NO TS1 NC
TS2 NC
GLOW PLUG START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2
8


WHT
BRN
RED
ORG/BLK
RED
RED
N
BRN
CR13
RED
CR14
JIB CUTOUT RELAY (CR-13)

JIB VALVE RELAY JIB BOOM VALVE RELAY
(CR-14)
CR14
JIB BOOM VALVES

NO
JIB VALVES
M
BLK/RED-1
FOOTSW. H/L
TS54
TP35
CR4
LOW RPM
ENGINE
CR3
SPEED
LOW RPM FUNCTION

NO
TS4
HIGH RPM
HIGH IDLE RELAY
TB35
L
HIGH IDLE CUTOUT

RELAY
CR3
BLK/RED-R4-E.H.
RPM SOLENOID
CR4
NO
OFF
GENERATOR
ON GRN/WHT-1 GRN/WHT-45-E.H. GENERATOR
TS47
OPTION
TB45
TP45
K
RED/WHT-23-E.H. FLASHING BEACON

FB
OPTION
J
TB34
PR2
TP34
BLK/WHT-34-E.H.
TS6
BLK-1
GLOW PLUG OPTION
GLOW
TS56
PLUG
GLOW
PLUG
PR2
NO
BLK
I
WHT/RED
OIL TEMPERATURE LED
TEMP.
PRES.
OIL
L2
L3
OIL
WHT/BLK
OIL PRESSURE LED
IGN./START
MODULE
TP33
2 TACHOMETER
OTS
1 START RELAY
9 IGN./FUEL ON
TB26
3 START INPUT
H
NO
8 KEY BYPASS
10 ENG. FAULT
BLK-1
7 KEY PWR.
WHT/RED-26 E.H.
6 BATTERY
TS2
5 GROUND
4 AUX. ON
OIL TEMPERATURE
ENGINE SWITCH
TB25
TS52
TB24
START
WHT/BLK-25 E.H. OIL PRESSURE
ENGINE
START SWITCH
OPS
BLK
NC
TB33
CR2
G
POWER RELAY
TB21
FUEL SOLENOID
CR2
NO
WHT
2
WHT-21
1
HM
HOUR METER
CR1
F
Part No. 52709

WHT
WHT
RED
BLK-R1-E.H.
CR1
NO
STARTER
STARTER MOTOR
TS51
TP25
TP24
TB27
TS1
AUXILIARY
E
PUMP RED-27-E.H.
TP27
AUXILIARY POWER
AUXILIARY
RED RELAY
PR1
RED-1
PUMP
WHT-(FS)
RED-(FS)
PUMP
AUX
AUXILIARY PUMP
PR1
NO
TB28
TP28
FS1
WHT RED/BLK-1 RED/BLK-28-E.H. WHT

TILT ALARM
BLK-(FS)
RED/WHT-23-E.H. RED BLK BRN

WHT-2
LEVEL SENSOR
D
TP23
TB23
TP26
BLK

WHT-24
CR5
HORN
TB9
TP9
P3
P2
TP24
RELAY
TB22
CR5
NO
TP22
BLK-2 BLK-22 BLK/RED-R5-E.H.
WHT-LOAD
HORN
GRND
C
PLAT
KS1
SENSOR
RED
ORG-LOAD
LOAD
8
BOX
P1
TB41
TP41
GND
LOAD SENSE OPTION
ORG/BLK-1 ORG/BLK-41-E.H.
B+
C
B
EXCT.
WHT-21-E.H.
STA.
BAT.
IND.
RED
RED
WHT-(FS)
-
RED-(FS)
ALTERNATOR
BLK-26 LOAD
REGULATOR
15AMP.
15AMP.
CB1
CB2
FS1
BAT.
+
BLK-(FS)
TP26
TB20
A
-
+
RED RED-20-E.H.
BLK-26
12 V
DC
P2
TP22
6 - 55
1
8
6 - 56
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
A
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32

B
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
D
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1

DRIVE LIMIT SWITCH
E
TB40
LS3
NO
Part No. 52709

DRIVE LIMIT SWITCH
TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
F
TP7
TS13
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
G
WHT/RED-3
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK-5-M.H.
TP4

RIGHT
TURNTABLE
PWM

TS62
A
R
-
+

R4
10
TB4

H
FLOW CONTROL
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
X
A
-
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
J
BLU-3
TB10
BLU BLU-10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
-
R
+
A
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
TB14
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
L
CR13
GRN/BLK-3
NC
DOWN
JIB BOOM
TB18
UP
TS8
GRN-3
TS58
DOWN
JIB BOOM JIB BOOM DOWN
UP GRN-17-M.H.
JIB BOOM UP
TB17
TS57
RIGHT RIGHT
M
LEFT LEFT
WHT
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
N
ORG/BLK
RED
RED
WHT
RED
BRN
BRN
Electrical Schematic- Z-45/25J Deutz Models


Z-45/25J Deutz Models (after serial number 16303)

LABEL DESCRIPTION
1 KS1 KEY SWITCH
TS56 GLOW PLUG
BLK-R1-86 TS58 JIB UP/DOWN
1 START RELAY
NO
NO
M.H.
ORG/BLK-41A
2 TACHOMETER TS59 PLATFORM LEVEL SWITCH
2 BLK-33D
RED-27B
3 START INPUT TS60
4 AUX. ON
BRN-GRD.
5 GROUND IGN./START TS62 TURNTABLE ROTATE SWITCH
RED-R2#30 TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY MODULE
7 KEY PWR.
SECON.4 HM HOUR METER
WHT-R2#86
9 IGN./FUEL ON
EXT.6
NO
10 ENG. FAULT
NO
BASE TERMINATION BLOCK L2 OIL PRESSURE LED
3 D
RED-4
C
RED-3 1
B A
RED-S.P. PRIMARY BOOM UP
NC TS51 L3 OIL TEMPERATURE LED
WHT-23 CR1 IGNITION / START RELAY
RED/WHT-3 RD/WT-S.P. WHT/BLK-25
PRIM.5
R/W-4 3 PRIMARY BOOM FUNCTION CONTROL
BLK-22 CR2 POWER RELAY
RED-27 CR3 HIGH IDLE CUTOUT RELAY
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN-(R5) WHT/RED-26 RPM SOLENOID RELAY
6 TURNTABLE ROTATE FUNCTION CTRL
+ CR4
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN-(GRND)
LED
7
BK/WT-S.P. WHT-21 L2 CR5 HORN RELAY
BLK/WHT-4 BLK/WHT-3 8 PRIMARY BOOM RETRACT
BK/RD-R5 RED/WHT-3 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/RED-3 9 HORN WHT-21 (R2) OIL PRESS
1 2
3
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP RED/BLK-2 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
HOUR METER RED-1
4 BLK-ENA.
BLU/WHT-3
BLU/RED-3
12
13
BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL
DRIVE ENABLE LIGHT BLK-7
BLK/RED-35B
3 RED-R2
RED
BLK/WHT-8
ORG/BLK-4/R8 ORG/BLK-3 15 OG/BK-SP PLATFORM LEVEL DOWN
EXTEND
18 PLATFORM ROTATE RIGHT/JIB DOWN PRIMARY CR1 CR2 CR3 CR4
GRN/WHT-3
RETRACT WHT-4
19 GR/WT-S.P. JIB VALVE R4 BOOM
RED-C.H. 20 RED-S.P. +12 V POWER TS60 WHT/BLK-5 BLK-R1
TS56 TS58
WHT-E.H.1 RED-EXT.-6 21 WHT-S.P. IGNITION POWER TS52
BLK-2 22 BLK-S.P. +12 V TO PLATFORM WHT/RED-6 BLK-R1-E.H.
TS62 TURNTABLE
ENGINE FAULT
5 1
WHT-ISM-10
WHT/BLK-EH.1
24
25 WHT/BLK-SP OIL PRESSURE SWITCH
BLK/RED-35 GLOW PLUG START SEC. BOOM
ROTATE WHT-21
BLK/RED-R4
WT/RD-E.H.1 26 WHT/RED-SP OIL TEMPERATURE SWITCH JIB
GRN-17 CR7 CR8
BLK-ISM-3 BLK-1 33 BLK-S.P. START ENGINE PLAT. TS57 BRN-(GRND H.M)
BLK/WHT-E.H.1 BLK/WHT-1 34 GLOW PLUG BLU-10 FUNCTION ENABLE
LEVEL PLATFORM
6 WHT#40-R7
WHT-PRIM.#5
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT
RED-20
ORG/BLK-15
BLU/WHT-1 38 (SPARE) RED-R1 BLK/RED-9A PLATFORM LEVEL
BLU/RED-1 39 (SPARE) CUTOUT
BLK-33
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 OFF-LIMIT SPEED (CE MODELS ONLY)
GRN-1 43 (SPARE)
GR/WT-C.H GRN/WHT-1 45 BLK/RED-35GEN GENERATOR OPTION
ORG/BLK-15
7 GRD-HOLE ORG-14
r.male-BLK-R1 WIRE CONNECTION ABBREVIATION KEY:
BLK-E.H-r.fem
EH ENGINE HARNESS
8 ORG/BLK-M.H.-r.male r.fem-ORG/BLK-R8 M.H. MANIFOLD HARNESS
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER



1
COMPONENT INDEX
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
AUX. PUMP SEL.

TURN ROT. L.
PLAT. LEVEL DN.
(UNUSED)
(UNUSED)
OPTION WIRE
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
START ENGINE
HIGH/LOW RPM
(SPARE)
(SPARE)
(SPARE)
(SPARE)
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM F.C.
JIB VALVE
BRAKE
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
STEER LEFT
SEC. BOOM UP
SEC. BOOM DN.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
GLOW PLUG
DRIVE ENA. LT.
KEYSW. PWR.
STEER RIGHT
LIMIT SWITCH
PULSE PICKUP
GEN. (OPTION)
ORG/BLK-41
TS6 GLOW PLUG OPTION (DIESEL ONLY) 2
HORSE-
RED FROM CR14

TS8 JIB UP/DOWN (JIB OPTION ONLY)
ORG-40 POWER
BOARD TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
26
27
28
30
32
33
35
36
37
38
40
42
43
45
25
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-10
WHT
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
BLK-2
WHT-2
WHT (F.S.)
BLK (F.S.)
RED-1
BLU/BLK-3
RED (F.S.)
3
RED-TILT
RED/BLK-28
L3 CHECK ENGINE LED

BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
WHT JIB CABLE BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
BLK JIB CABLE CR12 EFI RELAY ( FORD AND PERKINS ONLY )
CR13 JIB CUTOUT RELAY ( JIB ONLY ) 4
CABLE CABLE CABLE JIB JIB VALVE RELAY ( JIB ONLY )
110 F.S. CR14
#3 #2 #1 CABLE
TILT H.P.L. HORSEPOWER LIMITER BOARD
ALARM T1 TIME DELAY ( JIB ONLY )
TILT ALARM
GRN/WHT-45
RED-TILT
RED-STP
RED JUMP
RED TO JIB CABLE
RED TIM.DEL.
WHT-4
RED/BLK-2
GRN/WHT-19
RED/WHT-3
SIDE VIEW DP1
BLU/RED-13
RED-10 TO H.P.L.
BLU-10
BLU/BLK-11
RED/WHT-29
BLK-7
BLK/WHT-8
GRN/BLK-18
RED-27
BLU/WHT-12
BLK/WHT-34
BLK/RED-35
ORG-14
WHT/BLK-5
GRN-17
RED-25
ORG/BLK-15
ORG/RED-16
BLK/RED-9
BLK-33
RED-1
WHT/RED-6
BLU-36
BLU/BLK-37
WHT-30
RED-STP
BLK-22
WHT-23
WHT/BLK-31
BRN TO GRD.
WHT-24 TO H.P.L.
BLK-26
WHT/RED-32
GEN.
OPT.
8
PRIMARY SEC.BOOM
TS47 7
8
NC NO BOOM BP2 L1 6 6
RED-GEN
EXTEND/ CR13
7
R
R
A + - X
RETRACT
CR14 5
6
NC JIB
VALVE
4
5
A + - X
A + - X
BP1 RELAY
4
NC
JIB CUTOUT
3
3
NO TS13 NO
RELAY
2
R
SEE
2
GRN/WHT +
1
1
ROTATE UP/DOWN DP1 RED OUTPUT
DP1 BRN 7
DRIVE
PLATFORM ROTATE
LEVEL JIB DRV.ENA
TS7
TS8 TS15
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW 8
EMERGENCY STOP
P2




1
COMPONENT INDEX
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(UNUSED)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
TS6 GLOW PLUG
HORSE- 2
RED FROM CR14

ORG-40 POWER
BOARD TS10 SECONDARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
RED-10 1
RED-3 TS12 TURNTABLE ROTATE SWITCH
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
L1 DRIVE ENABLE LED
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN,TURNTABLE ROTATE
RED-TILT
RED/BLK-28

WHT JIB CABLE CR13 JIB CUTOUT RELAY
BLK JIB CABLE CR14 JIB VALVE RELAY
CABLE CABLE CABLE JIB H.P.L. HORSEPOWER LIMITER BOARD
110 F.S.
H1 #3 #2 #1 CABLE
T1 TIME DELAY
4
+ TILT - H1 TILT ALARM
ALARM
GRN/WHT-45
RED-TILT
RED-STP
WHT-4
RED/BLK-2
RED JUMP
RED TIM.DEL.
RED TO JIB CABLE
ORG-14
BLU/RED-13
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
RED/WHT-3
BLK/WHT-34
BLK/RED-35
ORG/BLK-15
WHT/BLK-5
GRN-17
SIDE VIEW FOR DP1
RED-25
ORG/RED-16
BLK/RED-9
BLK-33
RED-1
WHT/RED-6
BLU/BLK-37
BLU-36
WHT-30
BRN TO GRD.
WHT-24 TO H.P.L.
WHT/BLK-31
WHT/RED-32
BLK-22
BLK-26
WHT-23
RED-STP
GEN.
OPT.
8
PRIMARY SEC.BOOM
TS47 7
8
NC NO BOOM BP2 L1 6
RED-GEN
EXTEND/ CR13
7
R
R
A + - X
RETRACT
CR14 5 6
6
NC JIB
VALVE
4
5
A + - X
A + - X
BP1 RELAY
4
NC
JIB CUTOUT
3
3
NO TS13 NO
RELAY
2
R
SEE
2
GRN/WHT +
1
1
ROTATE UP/DOWN DP1 RED OUTPUT
DP1 BRN
DRIVE
PLATFORM TS15 TIME DELAY T1 7
PLATFORM ROTATE
DRIVE
LEVEL TS7 JIB R2 R3
TS8 ENABLE
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2 8


Electrical Schematic, Z-45/25 Perkins Models

ORG/BLK
1 TP22
P2
BLK
TP26
BLK
FS1
BLK
RED RED TP25 RED WHT
WHT TS50
TP21 WHT WHT
TP24
LIFT/
DRIVE
TS6
TS1
OPTION
OFF
ON
LOW RPM
ENGINE
HIGH RPM
BLK-2
WHT
ON
START
FOOTSW. H/L
2
PUMP
GLOW
PLUG
GENERATOR
P3
AUXILIARY
HORN
BLK
TP41
ENGINE
CB1 TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 TP35
KS1 SPEED
P1
RED RED PLAT RED
15AMP. GRND RED
3
WHT-2
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLK-1
GRN/WHT-1
BLK/RED-1
ORG/BLK-1
TS51 TS52 TS56 TS54
LOW RPM
PUMP
HIGH RPM
ENGINE
ON GLOW
START
AUXILIARY
PLUG
RED
TB45
BLK
BLK
ENABLE
FUNCTION
4
TB28 TB27
TB33 TB34
RED
TB9 TB23
TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT#23-E.H.
RED
6 BATTERY
7 KEY PWR. PRES.
RED#20-E.H.
8 KEY BYPASS
BLK/RED
CR1
5 NO
NO TEMP.
CR2
TB21
BLK/WHT#34-E.H.
CR3
NO
WHT/BLK
WHT/RED
BLK#22
BLK/RED
RED/WHT#23-E.H.
RED/BLK#28-E.H.
RED#27-E.H.
BLK#R1-E.H.
TB24 CR3
WHT#21
WHT
WHT#21-E.H.
ORG/BLK#41-E.H.
CR4
CR4
GRN/WHT#45-E.H.
NO
FB
BLK/RED#R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK#25 E.H.
ALTERNATOR NO PR2
TB26 NO
WHT
RED
BLK/RED#R5-E.H.
EXCT.
WHT/RED#26 E.H.
BAT. BAT.
12 V + -
DC
+
OIL
STA. W PRESSURE
7 AUX
STARTER
1
3
SWITCH
NC
HM
BLK
REGULATOR PUMP OIL

IND. 2 TEMPERATURE
- SWITCH
NO
BRN
BRN
STARTER MOTOR
GLOW PLUG
OPTION
FLASHING BEACON
HORN
RELAY
HORN
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
HOUR METER
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
OIL TEMPERATURE LED
OPTION
GENERATOR
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY
CE MODELS)
LIFT/DRIVE SELECTOR
AUXILIARY PUMP
NOTE:
1) The connection to TP24 is for units without the generator option
3) All switches and contacts are shown with the boom in the stowed position and the key switch off


6 - 61
BRN-2
GROUND
TP13
TB13
L1
NCHO
LS4
BLU/RED-3 BLK-7
A
BRN-7 DRIVE ENABLE

TP30
TB30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
TS15
TB16
NOHC
WHT#12-C.H.
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
B
BRAKE RELEASE VALVE

TRAVEL ALARM OPTION
TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU#36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
D
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
WHT#40-6
R1
BRN-6 PRIMARY BOOM EXTEND

50
DRIVE LIMIT SWITCH

E
CR12
Part No. 52709

TB40
LS3
NO

DRIVE LIMIT SWITCH
TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
F
TP7
TS13
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
TP8
BLK#7-M.H.
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
G
TP6
WHT/RED-3
TP5
WHT/BLK-3
WHT-3
TB5
TP4
WHT/BLK#5-M.H.
RIGHT
TURNTABLE ROTATE
PWM
LEFT WHT#4-M.H.
TS62

R
A
R4
X
+
-
TB4
H

FLOW CONTROL
TB6
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP
TB2
PRIMARY BOOM
DOWN RED/BLK#2-M.H.
TS61
PRIMARY BOOM DOWN

PWM
R
A
X
+
-
TB3

FLOW CONTROL
TP1
I
RED-3
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP10 TP11
J
BRN
BLU/BLK-3
BLU-3
TB10
BLU BLU#10-M.H.
SECONDARY BOOM UP
UP
PWM
SECONDARY BOOM
R
A
X
+
-
DOWN BLU/BLK BLU/BLK#11-M.H.

TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
K
TP14
CR7
NC
ORG-3
UP
PLATFORM LEVEL
TB14
DOWN ORG/BLK-3
TS9
TP15
TS59
ORG#14-M.H.
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN ORG/BLK#15-M.H.
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
L
CR8
NC
TP18
GRN-3
RIGHT
PLATFORM ROTATE
TB18
LEFT GRN/BLK-3
TS7
TP17
TS57
GRN/BLK#18-M.H.
RIGHT
PLATFORM ROTATE
LEFT GRN#17-M.H.
M
TB17
DESCENT ALARM
(OPTION)
ORG/BLK
N
RED
RED
WHT
WHT
BRN



LABEL DESCRIPTION
KS1 KEY SWITCH
TS56 GLOW PLUG
BLK-R1#86
NO
NO
2 M.H.
BLK-33D
2 TACHOMETER
3 START INPUT
RED-27B
4 AUX. ON
IGN./START
BRN-GRD. TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
5 GROUND
MODULE CIRCUIT BREAKER, ENGINE, 15A
RED-R2 # 30
6 BATTERY
CB1
WHT-23A CB2 CIRCUIT BREAKER, CONTROLS, 15A
7 KEY PWR.
HM HOUR METER
SECON.4
WHT-R2#86 R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
9 IGN./FUEL ON
EXT.6
WHT-24D NC L2 OIL PRESSURE LED
NO
10 ENG. FAULT
NO
3 BASE TERMINATION BLOCK L3 OIL TEMPERATURE LED
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK # 25 HIGH IDLE CUTOUT RELAY
PRIM.5 BLK #22 CR3
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN TO R4 WHT/RED #26 HORN RELAY
6 TURNTABLE ROTATE FUNCTION CTRL CR5
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN TO GRD +
LED
7
BLK/WHT-4 BLK/WHT-3 BK/WT-S.P. PRIMARY BOOM RETRACT WHT #21 L2 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
8
BLK/RED-3 BK/RD-R5 RED/WHT #3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
9 HORN WHT#21TO R2 OIL PRESS
1 2
3
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP RED/BLK #2
BLU/WHT-3
11
12
BU/BK-S.P.
BLU/WT-S.P.
SECONDARY BOOM DOWN
HOUR METER RED #1
BLK/RED#35B
3 BLK #7
RED
BLK/WHT #8
BLU/WHT #12 L3 TS61 WHT-ISM#9
RED-ENA. ORG/RED-3 16 WHT#12-E.H.1 DRIVE ENABLE RELAY COIL TS63
GRN-4 GRN-3 GRN-S.P. BLK/WHT-34 OIL TEMP. RED-CB1
17 PLATFORM ROTATE LEFT EXTEND
2 GRN/BLK-4 GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT
RETRACT WHT #4 CR1 CR2 CR3 CR4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 PRIMARY
RED-C.H. 20 RED-S.P. +12 V POWER TS60 BOOM WHT/BLK #5 BLK-ISM#1
WHT-E.H.1 RED-EXT.#6 21 WHT-S.P. IGNITION POWER TS56 TS52
BLK-2 22 BLK-S.P. +12 V TO PLATFORM TS62 WHT/RED #6
BLK#R1-E.H.
5 RD/WT-C.H.
WHT-ISM#10
WHT-2 23
24
WHT-S.P. WHT-ISM#7 KEYSWITCH POWER
ENGINE FAULT
TURNTABLE
ROTATE
1 WHT/BLK-EH.1 25 WHT/BLK-SP OIL PRESSURE SWITCH WHT#21
BLK/RED #35 GLOW PLUG START SEC. BOOM BLK/RED#R4-EH
RED/BLK-C.H RED/BLK-1 28 TILT ALARM TS57
GRN #17 CR7 CR8
BLK-ISM#3 BLK-1 33 BLK-S.P. START ENGINE PLAT. BRN GRND H.M
BLK/WHT-1 GLOW PLUG BLU #10 FUNCTION ENABLE
BLK/WHT-E.H.1 34 BLK/WHT-34 PLATFORM
BLK/RED-1 HIGH/LOW RPM BLU/BLK #11 LEVEL
6 BLU-M.H. BLU-1
35
36
BK/RD-R3#35 BK/RD-SP
STEER LEFT
RED #20
ROTATE
ORG #14 BLK#22
37
WHT-PRIM.#5 ORG/BLK #15 BLK/RED-9A
BLU/WHT-1 38 (SPARE) RED-R1 PLATFORM LEVEL
BLU/RED-1 39 (SPARE) CUTOUT
BLK #33
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 OFF-LIMIT SPEED (CE VERSION ONLY)
GRN-1 43 (SPARE)
ORG/BLK-15
7 GRD-HOLE
ORG-14
BLK-E.H-r.fem r.male-BLK-R1 WIRE CONNECTION ABBREVIATION KEY:
ORG-M.H.-r.male r.fem-ORG-R7
EH ENGINE HARNESS
8 C.H. CHASSIS HARNESS
ORG/BLK-M.H.-r.male r.fem-ORG/BLK-R8
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER

Z-45/25 Perkins Models (before serial number 16304)
8
6 - 63
BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN, TURNTABLE ROTATE
A

B




DESCRIPTION
START ENGINE SWITCH
LOW SPEED RESISTOR

LOW SPEED RESISTOR
C
DRIVE ENABLE LED

AUXILIARY SWITCH
HORN SWITCH
GLOW PLUG
TILT ALARM
EFI RELAY
H.P.L.
LABEL
CR12
TS11
TS13
TS10
TS12
TS50
BP1
TS1
BP2
TS2
TS6
TS9
TS7
R3
R2
L1
P3
P2
H1
D
WHT-23
BLK-26
EMERGENCY STOP
BLK-22
NC
E
P2
Part No. 52709

NC
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 TO H.P.L.
BRN TO GRD.
F
DRIVE
BLU-36
8 7 6 5 4 3 2 1
BLU/BLK-37
HIGH/LOW
RPM
G
TS4
GENERATOR
OPTION

(SPARE) 44 GRN/BLK-1
BLK-33
(SPARE) 43 GRN-1
BLK/RED-35 TS2 START
(SPARE) 42 ORG/RED-1
41 RED-25
LIMIT SWITCH 40 ORG-1 ORG/RED-16
DRV.ENA
H
TS15
(SPARE) 39 BLU/RED-1 BLK/WHT-34
(SPARE) 38 BLU/WHT-1
L1
GLOW PLUG
BLU/RED-13
STEER LEFT 36 BLU-1
HIGH/LOW RPM 35 BLK/RED-1
TS6
GLOW PLUG 34 BLK/WHT-1
R3
START ENGINE 33 BLK-1

250
HIGH/LOW (2WD/4WD)
BRAKE 32 WHT/RED-1
R2
100
I
TS14
E.D.C. 30 WHT-1
NO
NC
BLU/BLK-11
SEC.BOOM
SPEED
DRIVE
BP2
R - X + A
AUX. PUMP SEL. 27 RED-1
BLU-10
F.S.
F.S. UP POWER 25 RED (F.S.)

BLU/WHT-12
KEYSW. PWR. 23 WHT-2
AUXILIARY PUMP
RED-27
22
J
+12 V TO PLAT. BLK-2

OPTION WIRE 21 WHT
20 RED-10 TO H.P.L.
(UNUSED)
TS1
DRIVE ENABLE 16 ORG/RED-3
RETRACT
PRIMARY
EXTEND/
PLAT. LEVEL DN. 15 ORG/BLK-3
BOOM
PLAT. LEVEL UP 14 ORG-3
TS13
K
DRIVE ENA. LT. 13 BLU/RED-3

110
SEC. BOOM UP 10 BLU-3 RED-1
TS7
PLATFORM
HORN 9 BLK/RED-3
ROTATE
BOOM RETRACT 8 BLK/WHT-3 RED/WHT-3
7
CABLE
BOOM EXTEND BLK-3
#1
TURN. ROT. F.C. 6 WHT/RED-3
PRIMARY BOOM
TURN ROT. R. 5 WHT/BLK-3 A + - X R
UP/DOWN
L
TURN ROT. L. 4 WHT-3

RED/BLK-2
NO
TS9
NC
PLATFORM
PRIMARY DOWN 2 RED/BLK-3
NO
LEVEL
1
BP1
CABLE
#2
LIMITING RELAY
NC
TURNTABLE
WHT/BLK-5
LIMITER
HORSE-
ROTATE
POWER
BOARD
CR12
RED-10
R - X + A
50
M
R1
CABLE
1 2 3 4 5 6 7 8 9 10
ORG-40
WHT-24
RED-10
#3
WHT/RED-6
NO
ORG/BLK-41
HORN
WHT-24
RED/BLK-28
ORG-40
ORG/BLK-15
GRD. STUD
P3
ALARM
ORG-14
+ TILT
H1
BLK/RED-9
N

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

ORG/BLK
1 P2 FS1 RED RED TP25 RED WHT
TP22 TP26
BLK BLK BLK
WHT BRN
TS50
TP21 WHT WHT
TP24
LIFT/
DRIVE
TS6
TS1 CR13
JIB VALVE RELAY
JIB CUTOUT RELAY

OPTION
JIB VALVES
HIGH RPM
LOW RPM
WHT
BLK-2
OFF
START
ON
PLUGS
GLOW
FOOTSW. H/L
2 RED
PUMP
AUXILIARY
P3
GENERATOR
HORN
ENGINE
RED
BLK
TP41 CR14
ENGINE
CB1 TB22 TP9 TP33 TP34 NO
KS1 TP23 TP28 TP27 SPEED
P1 TP45 CR14
GRND RED
BLK-1
WHT-2
BLK/RED-1
BLK-1
GRN/WHT-1
RED/BLK-1
RED-1
BLK/RED-3
ORG/BLK-1
3
TS51 TS52 TS56 TS54
LOW RPM
HIGH RPM ENABLE
START
PUMP
AUXILIARY
PLUGS
GLOW
RED
TB45
ENGINE
BLK
BLK
FUNCTION
TB28 TB27
TB33 TB34
4
RED
TB9 TB23
TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT#23-E.H.
RED
6 BATTERY
7 KEY PWR.
PRES.
RED#20-E.H.
8 KEY BYPASS
BLK/RED
CR1
NO
NO TEMP.
CR2
TB21
5
BLK/WHT#34-E.H.
CR3
NO
WHT/BLK
WHT/RED
BLK#22
RED/BLK#28-E.H.
BLK#R1-E.H.
RED#27-E.H.
BLK/RED
RED/WHT#23-E.H.
TB24 CR3
WHT
WHT#21
WHT#21-E.H.
ORG/BLK#41-E.H.
CR4
CR4
GRN/WHT#45-E.H.
NO
FB
BLK/RED#R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK#25 E.H.
ALTERNATOR NO PR2
TB26 NO
RED
WHT
BLK/RED#R5-E.H.
EXCT.
6
WHT/RED#26 E.H.
12 V BAT. BAT.
DC
+ -
+
STA. W
1 OPS
AUX STARTER 3
HM
BLK
REGULATOR PUMP NC OIL

- IND. 2 TEMPERATURE
SWITCH
BRN
NO
BRN
7
(CR-14)
OPTION
STARTER MOTOR
TILT ALARM
CE MODELS)
LIFT/DRIVE SELECTOR
JIB BOOM VALVES
(CR-13)
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

FUEL SOLENOID
OIL TEMPERATURE LED
FLASHING BEACON
RELAY
AUXILIARY POWER
HOUR METER
POWER RELAY
OPTION
GENERATOR
RELAY
HORN
HORN
LEVEL SENSOR
AUXILIARY PUMP
GLOW PLUGS
NOTE:
8


6 - 65
BRN-2
GROUND
TP13
TB30 TB13
L1
NCHO
A
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
LIMIT SWITCH
WHT-1 WHT-7 RED-7
TS15
TB16
NOHC
WHT#12-C.H.
TP16

ORG/RED-3
TB31
TP31
DRIVE EDC
TB32
TP32
B
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
TP37
TB36 TB37
STEER RIGHT
TP36
BLU-1 BLU#36-M.H.
STEER LEFT
C
1
2
3
4
5
6
7
8
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
D
R3
LOW (4WD) RED

TS14
250
(2WD/4WD)
CE OPTION ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TP40
Part No. 52709

TB40
LS3
NO

DRIVE LIMIT SWITCH
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
F
TP7
TS13
BLK-3
EXTEND
TP8
BOOM
RETRACT BLK/WHT-3
TB7
BLK#7-M.H.
BOOM EXTEND
EXTEND
TB8
BOOM
TS63
BOOM RETRACT
TP6
G
WHT/RED-3
TP4 TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK#5-M.H.
RIGHT TURNTABLE
PWM

TS62
R
+
-
A

R4
10
TB4
TB6

H
FLOW CONTROL
BP1
TB1
RED#1-M.H.
PRIMARY BOOM UP
UP
TB2
PRIMARY
TS61
PRIMARY BOOM DOWN

PWM
R
A
+
X
-
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP10 TP11
BLU/BLK-3
J
BLU-3
TB10
BLU BLU#10-M.H.
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
A
X
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP
TP15
PLATFORM
LEVEL
TB14
DOWN ORG/BLK-3
TS9
TS59
ORG#14-M.H.
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
L
CR13
GRN/BLK-3
NC
DOWN
TP17
JIB BOOM
TB18
UP
TS8
GRN-3
TS58
GRN/BLK#18-M.H.
JIB BOOM DOWN
DOWN
JIB BOOM
UP GRN#17-M.H.
JIB BOOM UP
TB17
TS57
RIGHT RIGHT
LEFT
M
LEFT
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
ORG/BLK
N
RED
RED
WHT
WHT
RED
BRN
BRN


Z-45/25J Perkins Models (before serial number 16304)

1
LABEL DESCRIPTION
KS1 KEY SWITCH
TS56 GLOW PLUG
2 BLK-R1#86
START RELAY TS58 JIB BOOM UP/DOWN
1
NO
NO
M.H. 2 TACHOMETER
BLK-33D
3 START INPUT TS60 SECONDARY BOOM UP/DOWN SWITCH
RED-27B
4 AUX. ON
BRN-GRD. TS62 TURNTABLE ROTATE SWITCH
5 GROUND IGN./START
RED-R2 # 30 TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY
MODULE CIRCUIT BREAKER, ENGINE, 15A
WHT-23A
KEY PWR.
CB1
7
SECON.4
3 EXT.6
WHT-R2#86
9 IGN./FUEL ON
HM
R4
HOUR METER
SPEED LIMITING VARIABLE RESISTOR 10 OHMS
WHT-24D NC
ENG. FAULT
NO
10
NO
BASE TERMINATION BLOCK L2 OIL PRESSURE LED
D C B A NC TS51 L3 OIL TEMPERATURE LED
WHT #23 CR1 IGNITION / START RELAY
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK # 25 CR2 POWER RELAY
PRIM.5
WHT-4 WHT-3 TURNTABLE ROTATE LEFT
BLK #22
4 WHT-S.P.
RED #27 CR3 HIGH IDLE CUTOUT RELAY
5
BRN TO R4 WHT/RED #26 RPM SOLENOID RELAY
W/R-4 WHT/RED-3 6 WT/RD-S.P. TURNTABLE ROTATE FUNCTION CTRL
+ CR4
BLK-4 BLK-3 BLK-S.P. PRIMARY BOOM EXTEND BRN TO GRD
LED
7 HORN RELAY
BLK/WHT-3 PRIMARY BOOM RETRACT WHT #21 L2 CR5
BLK/WHT-4 8 BK/WT-S.P.
RED/WHT #3
4 BLU-4
BLK/RED-3
BLU-3
9
10
BK/RD-R5
BLU-S.P.
HORN
SECONDARY BOOM UP
WHT#21TO R2
1 2 OIL PRESS
RED/BLK #2
3 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
HOUR METER RED #1
BLU/WHT-3 12 BLU/WT-S.P. BLK/RED#35B
3 BLK #7
RED
BLK/WHT #8
L3 TS61 WHT-ISM#9
RED-ENA. ORG/RED-3 16 WHT#12-E.H.1 DRIVE ENABLE RELAY COIL BLU/WHT #12 TS63
2 GRN/BLK-4 PLATFORM ROTATE RIGHT/JIB DOWN
EXTEND
GRN/BLK-3 18 GR/BK-S.P. CR1 CR2 CR3 CR4
PRIMARY RETRACT WHT #4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 BOOM
RED-C.H. 20 RED-S.P. +12 V POWER TS60 WHT/BLK #5 BLK-ISM#1
IGNITION POWER TS56 TS58
WHT-E.H.1 RED-EXT.#6 21 WHT-S.P. TS52
5 BLK-2 22 BLK-S.P. +12 V TO PLATFORM
TS62 WHT/RED #6 BLK#R1-E.H.
RD/WT-C.H. WHT-2 23 WHT-S.P. WHT-ISM#7 KEYSWITCH POWER
ENGINE FAULT
TURNTABLE
WHT-ISM#10 24
ROTATE WHT#21
BLK/RED #35 GLOW PLUG START SEC. BOOM JIB BLK/RED#R4-EH
GRN #17 CR7 CR8
PLAT. TS57 BRN GRND H.M
BLU #10 FUNCTION ENABLE
6 BLK/WHT-E.H.1 BLK/WHT-1
BLK/RED-1
34
35 BK/RD-R3#35
BLK/WHT-34
BK/RD-SP
GLOW PLUG
HIGH/LOW RPM BLU/BLK #11
LEVEL PLATFORM
ROTATE
BLU-M.H. BLU-1 36 STEER LEFT ORG #14 BLK#22
WHT#40-R7
BU/BK-M.H. BLU/BLK-1 37 STEER RIGHT RED #20
WHT-PRIM.#5 BLK/RED-9A PLATFORM LEVEL
BLU/WHT-1 38 (SPARE) RED-R1 ORG/BLK #15
CUTOUT
BLK #33 (CE MODELS ONLY)
GRN-1 43 (SPARE)
7 ORG/BLK-15
GRD-HOLE
ORG-14
BLK-E.H-r.fem r.male-BLK-R1
EH ENGINE HARNESS
8 ORG-M.H.-r.male r.fem-ORG-R7
C.H. CHASSIS HARNESS
ORG/BLK-M.H.-r.male r.fem-ORG/BLK-R8
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER


1
LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

DRIVE ENA. LT.
KEYSW. PWR.
GEN. (OPTION)
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
SEC. BOOM UP
SEC. BOOM DN.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
GLOW PLUG
STEER RIGHT
LIMIT SWITCH
PULSE PICKUP
STEER LEFT
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM F.C.
JIB VALVE
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
HIGH/LOW RPM
(SPARE)
(SPARE)
(SPARE)
(SPARE)
TILT ALARM
OPTION WIRE
(UNUSED)
(SPARE)
ORG/BLK-41
TS6 GLOW PLUG
HORSE-
POWER
TS7 PLATFORM ROTATE SWITCH 2
RED FROM CR14

ORG-40 LIMITER
BOARD TS9 PLATFORM LEVEL SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
25
20
22
23
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
RED (F.S.)
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
BLK-2
WHT-2
WHT (F.S.)
BLK (F.S.)
RED-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
RED/BLK-1
WHT
ORG-40 TS50 LIFT/DRIVE SELECT SWITCH
CR12 R1 EFI RESISTOR ( FORD AND PERKINS ONLY )
RED-10
WHT-24 R3 LOW SPEED RESISTOR
R1
RED/BLK-28
L3 CHECK ENGINE LED

50
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE
RED-10 BP2 BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
WHT JIB CABLE
LIMITING RELAY
BLK JIB CABLE CR12 EFI RELAY ( FORD AND PERKINS ONLY )
CABLE CABLE CABLE JIB JIB VALVE RELAY
110 F.S. CR14
H1 #3 #2 #1 CABLE
4
+ TILT _ T1 TIME DELAY
ALARM
H1 TILT ALARM
5
RED-1
RED TIM.DEL.
WHT/RED-32
WHT-23
RED JUMP
BLK-22
BLK-26
WHT-24 TO H.P.L.
ORG-14
RED TILT AL.

RED TO STOP SW
RED TO JIB CABLE
WHT-30
BLK-7
BLK/WHT-8
GRN/BLK-18
RED-27
BLU/WHT-12
BLU/RED-13
BLU/BLK-37
BRN TO GRD.
RED-10 TO H.P.L.
BLU-10
BLU/BLK-11
RED/WHT-29
ORG/BLK-15
BLK/WHT-34
BLK/RED-35
BLU-36
WHT/BLK-5
GRN/WHT-19
GRN-17
BLK/RED-9
RED-25
ORG/RED-16
WHT/BLK-31
WHT/RED-6
BLK-33
WHT-4
RED/BLK-2
RED/WHT-3
GENERATOR
OPTION
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
R
R
A
RETRACT
CR14 6
6
+
NC JIB
VALVE
- X
5
- X
- X
BP1 RELAY
4
NC
+
JIB CUTOUT
3
NO NO
TS13 RELAY
R
A
2
GRN/WHT +
1
DRIVE BRN
DP1
PLATFORM TIME DELAY T1 7
PLATFORM ROTATE
LEVEL JIB R2 R3 DRV.ENA
TS7
TS8 TS15
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2 8



1
LABEL DESCRIPTION
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
+12 V TO PLAT.
TURN ROT. L.
PLAT. LEVEL DN.
AUX. PUMP SEL.

PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(SPARE)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
TS6 GLOW PLUG 2
HORSE-
RED FROM CR14

ORG-40 POWER
BOARD TS10 SECONDARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-3 TS12 TURNTABLE ROTATE SWITCH
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
ORG-40 TS50 LIFT/DRIVE SELECT SWITCH
CR12 R1 EFI RESISTOR ( FORD AND PERKINS ONLY ) 3
RED-10
WHT-24 R3 LOW SPEED RESISTOR
R1 BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE
RED/BLK-28
50
RED-10 CR12 EFI RELAY ( FORD AND PERKINS ONLY )
WHT JIB CABLE
LIMITING RELAY
CABLE CABLE CABLE
110
JIB
F.S. H.P.L. HORSEPOWER LIMITER BOARD
4
H1 #3 #2 #1 CABLE
T1 TIME DELAY
ALARM
5
RED-1
WHT-23
RED TIM.DEL.
WHT/RED-32
RED JUMP
BLK-22
BLK-26
RED TILT AL.
RED TO STOP SW
BLK/WHT-34
ORG/RED-16
RED-25
BLK/RED-35
WHT-24 TO H.P.L.
WHT-21
RED TO JIB CABLE
BLU-36
BRN TO GRD.
WHT-30
ORG-14
BLU/RED-13
BLU/BLK-37
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
WHT/BLK-31
ORG/BLK-15
WHT/BLK-5
GRN-17
BLK/RED-9
BLK-33
WHT/RED-6
WHT-4
RED/BLK-2
RED/WHT-3
GEN.
OPT.
PRIMARY SEC.BOOM
8
NC NO BOOM BP2 L1
EXTEND/ CR13
7
6
R
R
A
RETRACT
CR14
6
+
NC JIB
VALVE
- X
5
X
- X
BP1 RELAY
+-
4
NC
+
JIB CUTOUT
3
NO NO LIFT/
TS13 RELAY
R
A
DRIVE
2
SEL. GRN/WHT +
1
DRIVE BRN
PLATFORM
TS50 DP1
TIME DELAY T1 7
PLATFORM ROTATE
DRV.ENA
LEVEL TS7 JIB R2 R3
TS8 TS15
TS6
TS9
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2
8




ORG/BLK
1 P2 FS1 RED-(FS) TP25
TP22 TP26 RED
BLK BLK-(FS)
WHT
TS2 TS47 TS4

TS6
TS1
ON
OFF
BLK-2
WHT
START
HIGH RPM
FOOTSW. H/L
LOW RPM
PLUGS
GLOW
PUMP
AUXILIARY
GENERATOR
2 P3
HORN
ENGINE
BLK
TP41
ENGINE
15AMP. TP45
GRND RED
WHT-2
BLK/RED-3
RED/BLK-1
RED-1
BLK-1
BLK-1
GRN/WHT-1
BLK/RED-1
ORG/BLK-1
3 TS51 TS52 TS56 TS54
LOW RPM
HIGH RPM ENABLE
PUMP
START
AUXILIARY
PLUGS
GLOW
RED
TB45
ENGINE
BLK
BLK
FUNCTION
TB28 TB27
TB33 TB34
RED
TB9 TB23
4 TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT-23-E.H.
RED
6 BATTERY
7 KEY PWR. PRES.
RED-20-E.H.
8 KEY BYPASS
BLK/RED
CR1
NO
NO TEMP.
CR2
TB21
BLK/WHT-34-E.H.
CR3
NO
WHT/BLK
WHT/RED
BLK-22
BLK/RED
RED/WHT-23-E.H.
RED/BLK-28-E.H.
RED-27-E.H.
BLK-R1-E.H.
TB24 CR3
WHT-21
WHT
WHT-21-E.H.
ORG/BLK-41-E.H.
5 CR4
CR4
GRN/WHT-45-E.H.
NO
FB
BLK/RED-R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK-25 E.H.
ALTERNATOR NO PR2
TB26 NO
RED
WHT
BLK/RED-R5-E.H.
EXCT.
WHT/RED-26 E.H.
12 V BAT. BAT.
+ -
DC
6 +
STA. W
OPS
1
AUX STARTER 3
HM
BLK
REGULATOR PUMP NC
IND. 2 OTS
-
NO
BRN
BRN
STARTER MOTOR
OPTION
FLASHING BEACON
HORN
RELAY
HORN
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
HOUR METER
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
OIL TEMPERATURE LED
OPTION
GENERATOR
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUGS
7
LOAD SENSE OPTION
P2 FS1 RED-(FS)
TP22
BOX TP24
WHT-LOAD WHT-24
BLK-26 LOAD B+
GND 8
ORG-LOAD

1
8

6 - 70
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
A
LIMIT SWITCH
WHT-1 WHT-7 RED-7
WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
D
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK-5-M.H.
TP4

RIGHT
TURNTABLE
PWM

TS62
R
A
X
-
+

R4
10
TB4

FLOW CONTROL
H
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP PRIMARY
TB2

TS61
PRIMARY BOOM DOWN

PWM
R
X
A
-
+
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU-10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
BOOM
R
A
X
-
+

TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
TB14
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
L
GRN/BLK-3
RIGHT
PLAT ROTATE
TB18
LEFT
TS7
GRN-3
TS57
GRN/BLK-18-M.H.
TP17
RIGHT
PLAT ROTATE
LEFT GRN-17-M.H.
TB17
M

N
ORG/BLK
RED
RED
WHT
BRN
BRN


Z-45/25 Perkins Models (after serial number 16303)

LABEL DESCRIPTION
1 KS1 KEY SWITCH
GROUND CONTROL SWITCH PANEL TS51 AUXILIARY SWITCH
GROUND CONTROL BOX TS52 START ENGINE SWITCH
TS56 GLOW PLUG
BLK-R1-86 TS59 PLATFORM LEVEL SWITCH
1 START RELAY
NO
NO
ORG/BLK-41A
M.H. 2 TACHOMETER TS60
2 BLK-33D
RED-27B
3 START INPUT TS61 PRIMARY BOOM UP/DOWN SWITCH
4 AUX. ON TS62 TURNTABLE ROTATE SWITCH
BRN-GRD. TS63
5 GROUND PRIMARY BOOM EXTEND/RETRACT SWITCH
RED-R2#30 IGN./START CB1 CIRCUIT BREAKER, ENGINE, 15A
6 BATTERY
WHT-23A MODULE CB2 CIRCUIT BREAKER, CONTROLS, 15A
7 KEY PWR.
8 KEY BYPASS AUXILIARY HM HOUR METER

SECON.4
P1 KS1
WHT-R2#86
IGN./FUEL ON
R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
EXT.6 9
WHT-24D NC L2 OIL PRESSURE LED
NO
10 ENG. FAULT
NO
3 D
RED-4
C
RED-3 1
B A
RED-S.P. PRIMARY BOOM UP
NC TS51 CR1 IGNITION / START RELAY
WHT-23 CR2 POWER RELAY
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK-25
PRIM.5 BLK-22 CR3 HIGH IDLE CUTOUT RELAY
RED-27 CR4 RPM SOLENOID RELAY
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN-(R5) WHT/RED-26
+ CR5 HORN RELAY
LED
7
BLK/WHT-4 BLK/WHT-3 8 BK/WT-S.P. PRIMARY BOOM RETRACT WHT-21 L2 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
BLK/RED-3 BK/RD-R5 RED/WHT-3 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
9 HORN WHT-21 (R2)
2 OIL PRESS CR8
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP 1 RED/BLK-2
3
HOUR METER RED-1
4 BLK-ENA.
BLU/WHT-3
BLU/RED-3
12
13
BLU/WT-S.P. SECONDARY BOOM FUNCTION CTRL
DRIVE ENABLE LIGHT
3 BLK-7
BLK/RED-35B
RED-R2
RED
ORG/BLK-3
BLK/WHT-8
EXTEND
18 PLATFORM ROTATE RIGHT/JIB DOWN CR1 CR2 CR3 CR4
GRN/WHT-3 PRIMARY RETRACT WHT-4
19 GR/WT-S.P. JIB VALVE R4 TS60
RED-C.H. 20 RED-S.P. +12 V POWER BOOM WHT/BLK-5 BLK-R1
WHT-E.H.1 RED-EXT.-6 21 WHT-S.P. IGNITION POWER TS56 TS52
TS62
TURNTABLE
WHT-ISM-10 24 ENGINE FAULT
5 1 WHT/BLK-EH.1 25 WHT/BLK-SP OIL PRESSURE SWITCH BLK/RED-35 GLOW PLUG START SEC. BOOM
ROTATE WHT-21
BLK/RED-R4
RED/BLK-C.H RED/BLK-1 28 TILT ALARM TS57
GRN-17 CR7 CR8
BLK-ISM-3 BLK-1 33 BLK-S.P. START ENGINE PLAT. BRN-(GRND H.M)
BLK/WHT-E.H.1 BLK/WHT-1 34 GLOW PLUG BLU-10 FUNCTION ENABLE
LEVEL PLATFORM
RED-20
6 WHT#40-R7
WHT-PRIM.#5
BU/BK-M.H. BLU/BLK-1
BLU/WHT-1
37
38
STEER RIGHT
(SPARE) RED-R1 ORG/BLK-15 BLK/RED-9A
BLU/RED-1 39 (SPARE) PLATFORM LEVEL
BLK-33
ORG-1 40 WHT-SEC#4 WHT-EXT.#6 OFF-LIMIT SPEED CUTOUT
CH+EH1 OG/BK-E.H.1 ORG/BLK-1 41 OG/BK-IM2 ALTERNATOR PULSE PICKUP (CE MODELS ONLY)
GRN-1 43 (SPARE)
ORG/BLK-15
ORG-14
7 GRD-HOLE
BLK-E.H-r.fem r.male-BLK-R1
EH ENGINE HARNESS
8 S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER



COMPONENT INDEX
1
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
TURN ROT. L.
+12 V TO PLAT.
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(SPARE)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
PLAT. LEVEL DN.
AUX. PUMP SEL.

ORG/BLK-41
TS6 GLOW PLUG OPTION
HORSE-
POWER TS7 PLATFORM ROTATE SWITCH
LIMITER TS9 PLATFORM LEVEL SWITCH 2
ORG-40 BOARD TS10 SECONDARY BOOM UP/DOWN SWITCH
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
6
2
3
7
8
9
1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
ORG-40 R1 EFI RESISTOR ( FORD AND PERKINS ONLY )
RED-10 LOW SPEED RESISTOR
WHT-24
R3 3
L1 DRIVE ENABLE LED
GRD. STUD BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN,TURNTABLE ROTATE
R1
RED-TILT
RED/BLK-28

50 CR12 EFI RELAY ( FORD AND PERKINS ONLY )
RED-10
LIMITING RELAY
H1 TILT ALARM
CABLE CABLE CABLE
110 F.S.
H1 #3 #2 #1 4
+ TILT _
ALARM
5
BLK/RED-9
ORG-14
ORG/BLK-15
WHT/RED-6
WHT/BLK-5
WHT-4
RED/BLK-2
RED/WHT-3
RED-1
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN-17
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
BLU/BLK-11
RED/WHT-29
BLU/RED-13
BLK/WHT-34
ORG/RED-16
RED-25
BLK/RED-35
BLK-33
GRN/WHT-45
BLU/BLK-37
BLU-36
BRN TO GRD.
WHT-24 TO H.P.L.
WHT/BLK-31
WHT-30
WHT/RED-32
BLK-22
BLK-26
WHT-23
RED-TILT
SIDE VIEW FOR DP1

8
PRIMARY SEC.BOOM
GENERATOR
OPTION
7
8
NC NO BOOM BP2 L1 6
RED-GEN
EXTEND/
7
R
R
A + - X
RETRACT TS47
5 6
6
NC
4
5
A + - X
A + - X
BP1
4
NC 3
3
NO TS13 NO
2
R
SEE
2
1
1
ROTATE UP/DOWN DP1
DP1
DRIVE
PLATFORM
PLATFORM
ROTATE
7
LEVEL R2 R3 DRV.ENA
TS7
TS15
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
REMOVE FOR LIFT/ HIGH/LOW (2WD/4WD) RPM
EMERGENCY STOP
DRIVE SELECT VERSION P2
8




COMPONENT INDEX 1
P3 HORN SWITCH
1 2 3 4 5 6 7 8 9 10
PRIMARY UP
PRIMARY DOWN
PRIMARY F.C.
TURN ROT. L.
TURN ROT. R.
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
HORN
SEC. BOOM UP
SEC. BOOM DN.
SEC. BOOM F.C.
DRIVE ENA. LT.
PLAT. LEVEL UP
PLAT. LEVEL DN.
DRIVE ENABLE
PLAT. ROT. L.
PLAT. ROT. R.
JIB VALVE
(UNUSED)
OPTION WIRE
+12 V TO PLAT.
KEYSW. PWR.
PWR. (CONT.)
F.S. UP POWER
PWR. TO F.S.
AUX. PUMP SEL.
TILT ALARM
2WD/4WD
E.D.C.
E.D.C.
BRAKE
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
(SPARE)
LIMIT SWITCH
PULSE PICKUP
(SPARE)
(SPARE)
(SPARE)
GEN. (OPTION)
ORG/BLK-41
TS6 GLOW PLUG OPTION (DIESEL ONLY)
HORSE- TS7 PLATFORM ROTATE SWITCH
ORG-40
LIMITER TS10 SECONDARY BOOM UP/DOWN SWITCH 2
14
10
12
13
15
16
17
18
19
24
34
44
20
22
23
25
26
27
28
30
32
33
35
36
37
38
40
42
43
45
29
39
11
21
31
41
4
6
2
3
7
8
9
1
RED-3
RED/BLK-3
RED/WHT-3
WHT-3
WHT/BLK-3
WHT/RED-3
BLK-3
BLK/WHT-3
BLK/RED-3
BLU-3
BLU/BLK-3
BLU/WHT-3
BLU/RED-3
ORG-3
ORG/BLK-3
ORG/RED-3
GRN-3
GRN/BLK-3
GRN/WHT-3
WHT
BLK-2
WHT-2
WHT (F.S.)
RED (F.S.)
BLK (F.S.)
RED-1
RED/BLK-1
RED/WHT-1
WHT-1
WHT/BLK-1
WHT/RED-1
BLK-1
BLK/WHT-1
BLK/RED-1
BLU-1
BLU/BLK-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
ORG/RED-1
GRN-1
GRN/BLK-1
GRN/WHT-1
ORG-40 R1 EFI RESISTOR ( FORD AND PERKINS ONLY )
RED-10 R3 LOW SPEED RESISTOR
GRD. STUD 3
BP1 BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DN,TURNTABLE ROTATE
R1
RED-TILT
RED/BLK-28

50
CR12 EFI RELAY ( FORD AND PERKINS ONLY )
RED-10
LIMITING RELAY DP1 DRIVE PROPORTIONAL JOYSTICK
H1 TILT ALARM
CABLE CABLE CABLE
110 F.S.
H1 #3 #2 #1
+ TILT _
ALARM
4
BLU/BLK-11
RED/WHT-29
BLU/RED-13
BLK/WHT-34
ORG/RED-16
RED-25
BLK/RED-35
BLK-33
GRN/WHT-45
BLU/BLK-37
BLU-36
BRN TO GRD.
WHT-24 TO H.P.L.
WHT/BLK-31
WHT-30
WHT/RED-32
BLK-22
BLK-26
WHT-23
RED-TILT
BLK/RED-9
ORG-14
ORG/BLK-15
WHT/RED-6
WHT/BLK-5
WHT-4
RED/BLK-2
RED/WHT-3
RED-1
BLK-7
BLK/WHT-8
GRN/WHT-19
GRN-17
GRN/BLK-18
RED-10 TO H.P.L.
RED-27
BLU/WHT-12
BLU-10
SIDE VIEW FOR DP1
5
8
PRIMARY SEC.BOOM
7
8
NC NO BOOM GENERATOR
BP2 L1 6
RED-GEN
EXTEND/ OPTION
7
R
R
A + - X
RETRACT
5
6
NC TS47
4 6
5
A + - X
A + - X
BP1
4
NC 3
3
NO NO
TS13
2
R
SEE
2
1
1
ROTATE UP/DOWN DP1
DP1
DRIVE
PLATFORM
PLATFORM ROTATE
DRV.ENA
LEVEL TS7 R2 R3
TS15 7
TS9 TS6
250
100
P3 NO TS1 NC NC
GLOW PLUG TS2 START
AUXILIARY PUMP
HORN DRIVE TS4
SPEED TS14 HIGH/LOW
EMERGENCY STOP
P2
8



ORG/BLK
1 TP22
P2
BLK
TP26
BLK-(FS)
FS1
RED-(FS) TP25 RED BRN
WHT
TS2 TS47 TS4

TS6
TS1 CR13
JIB VALVE RELAY
JIB CUTOUT RELAY

JIB VALVES
OFF
WHT
BLK-2
ON
HIGH RPM
LOW RPM
FOOTSW. H/L
START
PLUG
GLOW
PUMP
RED
GENERATOR
2
AUXILIARY
P3
HORN
ENGINE
RED
BLK
TP41 CR14
ENGINE
CB1 TB22 TP9 TP33 TP34 NO
15AMP. TP45 CR14
GRND RED
WHT-2
BLK-1
BLK/RED-1
RED/BLK-1
RED-1
BLK-1
GRN/WHT-1
BLK/RED-3
ORG/BLK-1
3 TS51 TS52 TS56 TS54
LOW RPM FUNCTION

HIGH RPM ENABLE
PUMP
PLUG
START
GLOW
AUXILIARY
RED
TB45
ENGINE
BLK
BLK
TB28 TB27
TB33 TB34
RED
TB9 TB23
4 TB41 1 START RELAY
2 TACHOMETER
L2
RED/WHT-23-E.H.
4 AUX. ON
TB20 15AMP. 5 GROUND IGN./START OIL
RED MODULE
6 BATTERY
7 KEY PWR. PRES.
RED-20-E.H.
8 KEY BYPASS
BLK/RED
CR1
NO
NO TEMP.
CR2
TB21
BLK/WHT-34-E.H.
CR3
NO
WHT/BLK
WHT/RED
BLK-22
RED/BLK-28-E.H.
RED-27-E.H.
BLK-R1-E.H.
BLK/RED
RED/WHT-23-E.H.
TB24 CR3
5
WHT
WHT-21
WHT-21-E.H.
ORG/BLK-41-E.H.
CR4
CR4
GRN/WHT-45-E.H.
NO
FB
BLK/RED-R4-E.H.
CR5 PR1 TB25
NO CR5 PR1
PR2
WHT/BLK-25 E.H.
ALTERNATOR NO PR2
TB26 NO
RED
WHT
BLK/RED-R5-E.H.
EXCT.
WHT/RED-26 E.H.
12 V BAT. BAT.
+ -
6 DC
+
STA. W
1 OPS
AUX STARTER 3
HM
BLK
REGULATOR PUMP NC
IND. 2 OTS
-
NO
BRN
BRN
(CR-14)
STARTER MOTOR
JIB BOOM VALVES

OPTION
TILT ALARM
FLASHING BEACON
FUEL SOLENOID
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OIL PRESSURE LED
OIL TEMPERATURE LED
(CR-13)
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

RELAY
AUXILIARY POWER
HOUR METER
POWER RELAY
HORN
RELAY
HORN
LEVEL SENSOR
OPTION
GENERATOR
AUXILIARY PUMP
GLOW PLUGS
7 LOAD SENSE OPTION
P2 FS1 RED-(FS)
TP22
BOX TP24
WHT-LOAD WHT-24
BLK-26 LOAD B+
GND 8
ORG-LOAD


6 - 75
BRN-2
GROUND
TB13
TP13
L1
NCHO
LS4
BLU/RED-3 BLK-7
BRN-7 DRIVE ENABLE
TP30
TB30
A
LIMIT SWITCH
WHT-1 WHT-7 RED-7
WHT-12-C.H.
TS15
TB16
NOHC
TP31 TP16

ORG/RED-3
TB31
DRIVE EDC
TB32
TP32
BRAKE RELEASE VALVE
B
TRAVEL ALARM OPTION

TP37
TB37
STEER RIGHT
TB36
BLU-1 BLU-36-M.H.
STEER LEFT
TP36
1
2
3
4
5
6
7
8
C
DP1
RED
TB29
TP29
MOTOR STROKE
HIGH (2WD)
R3
LOW (4WD) RED

TS14
D
250
(2WD/4WD)
CE MODELS ONLY
RANGE
DRIVE
R2
BLK
RED
100
NCHO
LS1
R1

50
DRIVE LIMIT SWITCH

E
CR12
TB40
LS3
NO

Part No. 52709
DRIVE LIMIT SWITCH

TP40
LS2
NO

DRIVE LIMIT SWITCH
10
1
2
3
4
5
6
7
8
9
LIMITER
HORSE-
POWER
BOARD
TP7
TS13
F
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TB7
BLK-7-M.H.
TP8
BOOM EXTEND
EXTEND
BOOM
TS63
BOOM RETRACT
TB8
TP6
WHT/RED-3
G
TP5
WHT/BLK-3
WHT-3
TB5
WHT/BLK-5-M.H.
TP4

RIGHT TURNTABLE
ROTATE
PWM
LEFT WHT#4-M.H.
TS62
R
A
X
+

R4
-
10
TB4

FLOW CONTROL
H
TB6
BP1
TB1
RED-1-M.H.
PRIMARY BOOM UP
UP
TB2
PRIMARY
TS61
PRIMARY BOOM DOWN

PWM
R
X
A
+
-
TB3

TP1
FLOW CONTROL
RED-3
I
TP2
RED/BLK-3
TP3
RED/WHT-3
TP12
BLU/WHT-3
TP11
BLU/BLK-3
BLU-3
TB10
J
BLU BLU-10-M.H.
TP10
SECONDARY BOOM UP
UP SECONDARY
PWM
DOWN BOOM
R
A
X
+
-
TS60
SECONDARY BOOM DOWN

BP2
TB11
TB12
FLOW CONTROL
TP14
CR7
NC
ORG-3
K
UP PLATFORM
DOWN LEVEL
TB14
ORG/BLK-3
TS9
TS59
ORG-14-M.H.
TP15
PLATFORM LEVEL UP
UP PLATFORM
PLATFORM LEVEL DOWN
TB15
PLATFORM LEVEL
MODELS ONLY)
CUTOUT (CE
CR8
NC
TP18
WHT
CR13
L
GRN/BLK-3
NC
DOWN
JIB BOOM
TB18
UP
TS8
GRN-3
TS58
DOWN
JIBBOOM DOWN
JIB BOOM
UP GRN-17-M.H.
JIBBOOM UP
TB17
TS57
RIGHT PLATFORM RIGHT PLATFORM
LEFT ROTATE LEFT ROTATE
M
WHT
TS7
CR9
NC
TP19
BRN GRN/WHT-3
TB19
+
CR9
TI
N
ORG/BLK
RED
RED
WHT
RED
BRN
BRN


Z-45/25J Perkins Models (after serial number 16303)

LABEL DESCRIPTION
KS1 KEY SWITCH
TS56 GLOW PLUG
BLK-R1-86 TS58 JIB BOOM UP/DOWN (JIB OPTION ONLY)
1 START RELAY
NO
NO
2 M.H.
BLK-33D
2 TACHOMETER
3 START INPUT
RED-27B
4 AUX. ON
BRN-GRD. TS62 TURNTABLE ROTATE SWITCH
5 GROUND IGN./START
RED-R2#30 TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
6 BATTERY MODULE
7 KEY PWR.
8 KEY BYPASS P1 KS1
SECON.4 HM HOUR METER
WHT-R2#86 AUXILIARY
9 IGN./FUEL ON
EXT.6
NO
10 ENG. FAULT
NO
3 BASE TERMINATION BLOCK L2 OIL PRESSURE LED
D C B A NC TS51 L3 OIL TEMPERATURE LED
WHT-23 CR1 IGNITION / START RELAY
R/W-4 RED/WHT-3 3 RD/WT-S.P. PRIMARY BOOM FUNCTION CONTROL WHT/BLK-25 CR2 POWER RELAY
PRIM.5 BLK-22
RED-27 CR3 HIGH IDLE CUTOUT RELAY
5
W/R-4 WHT/RED-3 WT/RD-S.P. BRN-(R5) WHT/RED-26 RPM SOLENOID RELAY
+ CR4
LED
7
BLK/WHT-4 BLK/WHT-3 BK/WT-S.P. WHT-21 L2 CR5 HORN RELAY
8 PRIMARY BOOM RETRACT
BLK/RED-3 BK/RD-R5 RED/WHT-3 CR7 PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)
9 HORN WHT-21 (R2) OIL PRESS
1 2
3
BLU-4 BLU-3 10 BLU-S.P. SECONDARY BOOM UP RED/BLK-2 CR8 PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BLU/WHT-3
11
12
BU/BK-S.P.
BLU/WT-S.P.
SECONDARY BOOM DOWN
HOUR METER RED-1
BLK/RED-35B
3 BLK-7 RED-R2
RED
ORG/BLK-3
BLK/WHT-8
17 PLATFORM ROTATE LEFT/JIB UP EXTEND
2 GRN/BLK-4 GRN/BLK-3 18 GR/BK-S.P. PLATFORM ROTATE RIGHT/JIB DOWN
PRIMARY RETRACT CR1 CR2 CR3 CR4
GRN/WHT-3 19 GR/WT-S.P. JIB VALVE R4 WHT-4
BOOM
RED-C.H. 20 RED-S.P. +12 V POWER TS60 WHT/BLK-5 BLK-R1
TS56 TS58
WHT-E.H.1 RED-EXT.-6 21 WHT-S.P. IGNITION POWER TS52
TS62
5 RD/WT-C.H.
WHT-ISM-10
WHT-2 23
24
WHT-S.P. WHT-ISM-7 KEYSWITCH POWER
ENGINE FAULT
TURNTABLE
ROTATE WHT-21
BLK/RED-35 GLOW PLUG START SEC. BOOM JIB BLK/RED-R4
GRN-17 CR7 CR8
BLK-ISM-3 BLK-1 33 BLK-S.P. START ENGINE PLAT. TS57 BRN-(GRND H.M)
BLK/WHT-E.H.1 BLK/WHT-1 GLOW PLUG BLU-10 FUNCTION ENABLE
34 LEVEL PLATFORM
BLK/RED-35GEN BLK/RED-1 BLU/BLK-11
6 BLU-M.H. BLU-1
35
36
BK/RD-R3#35 BK/RD-SP HIGH/LOW RPM
STEER LEFT
ROTATE
ORG-14 BLK-22
RED-20
37
WHT-PRIM.#5 ORG/BLK-15 BLK/RED-9A
BLU/WHT-1 38 (SPARE) RED-R1 PLATFORM LEVEL
BLK-33 CUTOUT
(CE MODELS ONLY)
GRN-1 43 (SPARE)
ORG/BLK-15
7
GRD-HOLE ORG-14
BLK-E.H-r.fem r.male-BLK-R1 WIRE CONNECTION ABBREVIATION KEY:
EH ENGINE HARNESS
ORG-M.H.-r.male r.fem-ORG-R7
8 C.H. CHASSIS HARNESS
S.P. SWITCH PANEL
R or CR RELAY
H.M. HOUR METER



COMPONENT INDEX 1

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Genie z45-25 PDF

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Service Manual First Edition

From Serial number 9998 to 21179

Important Contact us:

This manual provides detailed scheduled

Copyright © 1998 by Genie Industries

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

Many of the hazards identified in the operator's

Do Not Perform Maintenance

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

Personal Safety Be sure to wear protective eye wear and

Be sure to properly dispose of old oil or

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

Section One Safety Rules

Section Two Specifications

Section Three Theory of Operation

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

Section Four Scheduled Maintenance Procedures

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

Section Four Scheduled Maintenance Procedures, continued

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

Section Four Scheduled Maintenance Procedures, continued

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

Section Four Scheduled Maintenance Procedures, continued

Section Five Troubleshooting Flow Charts

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

Section Five Troubleshooting Flow Charts, continued

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

Section Six Schematics

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

Section Six Schematics, continued

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

Section Six Schematics, continued

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

Section Six Schematics, continued

Section Seven Repair Procedures

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

Section Seven Repair Procedures, continued

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

Section Seven Repair Procedures, continued

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

Section Seven Repair Procedures, continued

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

This page intentionally left blank.

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

Maximum platform height

Maximum horizontal reach 124 ft 6 in 25 ft 3 in

Maximum turntable tailswing 0 in 0 in

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

Tires and wheels Rough terrain Industrial Performance Specifications

Tire contact area 59 sq in 43.5 sq in Gradeability 2WD 4WD

Tire pressure 45 psi Foam filled

Continuous improvement of our products is a Genie

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

Boom function speeds, maximum

Jib boom up 38 to 42 seconds

Jib boom down 24 to 27 seconds

Primary boom up 24 to 27 seconds

Primary boom down 32 to 37 seconds

Secondary boom up 23 to 27 seconds

Secondary boom down 23 to 27 seconds

Primary boom extend 10 to 14 seconds

Primary boom retract 18 to 22 seconds

Turntable rotate - 359° 73 to 78 seconds