Manual de Servicio Z45 PDF

Service Manual
Serial Number Range
Z-45/25 Deutz models: from 23041 to 34010

Ford models: from 23190 to 34010
Perkins models: from 23009 to 34010
Z-45/25J All models: from A34011 to A47000

All models: from B101 to B3300
IC Power
Part No. 107846

Rev C5
June 2012
Introduction June 2012
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie Z-45/25 and Manuals for these models:
Genie Z-45/25J Operator's Manual before
attempting any maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled
Z-45/25 and Z-45/25J Service Manual ................. 52709
maintenance information for the machine owner
From serial number 9998 to 21179
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service Z-45/25 and Z-45/25J Service Manual ................. 77809
professionals. Deutz models: from 21180 to 23040
Basic mechanical, hydraulic and electrical skills Ford models: from 21180 to 23189
Perkins models: from 21180 to 23008
are required to perform most procedures.
However, several procedures require specialized
Z-45/25 and Z-45/25J Service Manual ............... 107846
skills, tools, lifting equipment and a suitable Deutz models: from 23041 to 34010
workshop. In these instances, we strongly Ford models: from 23190 to 34010
recommend that maintenance and repair be Perkins models: from 23009 to 34010
performed at an authorized Genie dealer service All models: from A34011 to A47000
center. All models: from B101
Compliance Z-45/25 and Z-45/25J Service Manual ............... 219418

From serial number 13A-47001
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper opeation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors Copyright © 2011 Terex Corporation
and send in suggestions for improvement. All 107846 Rev C August 2006
communications will be carefully considered for Third Edition, Third Printing
future printings of this and all other manuals. "Genie" and "Z" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Contact Us:
Printed on recycled paper
http://www.genielift.com
Printed in U.S.A.
e-mail: awp.techpub@terex.com
ii Z-45/25 • Z-45/25J Part No. 107846

June 2012
INTRODUCTION
Serial Number Legend
Serial number: Z452506-12345

Model year: 2006 Manufacture date: 04/12/06
Electrical schematic number: ES0274
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg Z4525 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 45 ft 6 in/ 13.8 m
Model Sequence
Maximum platform reach : 25 ft 3 in/ 7.7 m
number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries Serial label

18340 NE 76th Street (located under cover)
Redmond, WA 98052 Serial number

USA stamped on chassis
PN - 77055
Part No. 107846 Z-45/25 • Z-45/25J iii

June 2012
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iv Z-45/25 • Z-45/25J Part No. 107846

June 2012 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-45/25 and
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. 107846 Z-45/25 • Z-45/25J v

Section 1 • Safety Rules June 2012
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:
Workplace Safety
Be sure to keep sparks, flames and
Safety alert symbol—used to alert
lighted tobacco away from flammable
personnel to potential personal
and combustible materials like battery
injury hazards. Obey all safety
gases and engine fuels. Always have an approved
messages that follow this symbol
fire extinguisher within easy reach.
to avoid possible injury or death.
Be sure that all tools and working areas
Used to indicate the presence of
are properly maintained and ready for
an imminently hazardous situation
use. Keep work surfaces clean and free
which, if not avoided, will result in
death or serious injury. of debris that could get into machine components
and cause damage.
Used to indicate the presence of a
potentially hazardous situation Be sure any forklift, overhead crane or
which, if not avoided, could result other lifting or supporting device is fully
in death or serious injury. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
With safety alert symbol—used to are in good condition and of ample capacity.
indicate the presence of a
potentially hazardous situation Be sure that fasteners intended for one
which, if not avoided, may result in time use (i.e., cotter pins and self-locking
minor or moderate injury. nuts) are not reused. These components
may fail if they are used a second time.
Without safety alert symbol—used
to indicate the presence of a Be sure to properly dispose of old oil or
potentially hazardous situation other fluids. Use an approved container.
which, if not avoided, may result in Please be environmentally safe.
property damage.
Be sure that your workshop or work area
Used to indicate operation or is properly ventilated and well lit.
maintenance information.
vi Z-45/25 • Z-45/25J Part No. 107846

June 2012
Table of Contents
Introduction
Important Information .................................................................................................. ii
Serial Number Information ........................................................................................... ii
Serial Number Legend ................................................................................................ iii
Section 1 Safety Rules

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

H Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-2011 / D2011 L03i Engine Specifications .............................................. 2 - 8
Perkins 404-22 Engine Specifications .................................................................. 2 - 10
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14
Part No. 107846 Z-45/25 • Z-45/25J vii

June 2012
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
D Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 7
A-2 Perform Function Tests ................................................................................ 3 - 7
A-3 Perform Engine Maintenance ....................................................................... 3 - 8
A-4 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9
A-5 Test the Oscillate Axle (if equipped) ............................................................. 3 - 9
A-6 Perform 30 Day Service ............................................................................. 3 - 10
A-7 Perform Engine Maintenance - Ford Models ............................................... 3 - 10
A-8 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11
A-9 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-10 Perform Engine Maintenance - Ford Models ............................................... 3 - 13
C Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 14
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 15
B-3 Check the Exhaust System ....................................................................... 3 - 16
B-4 Inspect the Engine Air Filter ....................................................................... 3 - 17
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 17
B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 18
B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 19
B-8 Check the Oil Level in the Drive Hubs ........................................................ 3 - 19
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June 2012
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B-9 Check and Adjust the Engine RPM - All Models ........................................ 3 - 20
B-10 Test the Ground Control Override .............................................................. 3 - 22
B-11 Check the Directional Valve Linkage ......................................................... 3 - 23
B-12 Test the Platform Self-leveling ................................................................... 3 - 23
B-13 Test the Engine Idle Select ........................................................................ 3 - 24
B-14 Test the Fuel Select Operation - Ford Models ........................................... 3 - 25
B-15 Test the Drive Brakes ................................................................................ 3 - 26
B-16 Test the Drive Speed - Stowed Position .................................................... 3 - 26
B-17 Test the Drive Speed - Raised or Extended Position ................................. 3 - 27
B-18 Test the Alarm Package (if equipped) ........................................................ 3 - 28
B-19 Perform Hydraulic Oil Analysis .................................................................. 3 - 29
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ...................... 3 - 29
B-21 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 30
B-22 Perform Engine Maintenance - Perkins Models ......................................... 3 - 32
B-23 Replace the Engine Air Filter Element - Ford Models ................................ 3 - 32
B-24 Perform Engine Maintenance - Ford Models .............................................. 3 - 33
D Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34
C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 34
C-3 Test the Platform Overload System (if equipped) ...................................... 3 - 35
C-4 Replace the Fuel Filter/Water Separator - Perkins Models ........................ 3 - 38
C-5 Replace the Engine Air Filter Element - Deutz and Perkins Models ........... 3 - 40
C-6 Perform Engine Maintenance - Perkins Models ......................................... 3 - 40
C-7 Perform Engine Maintenance - Ford Models .............................................. 3 - 41
Part No. 107846 Z-45/25 • Z-45/25J ix

June 2012
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 42
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42
D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 44
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 46
D-5 Check the Free-wheel Configuration ........................................................... 3 - 46
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 48
D-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 49
D Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52
E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 53
E-4 Perform Engine Maintenance - Deutz Models ............................................. 3 - 54
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
B Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
C Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 7
2-2 Platform Rotator ........................................................................................... 4 - 8
2-3 Platform Overload System ......................................................................... 4 - 10
x Z-45/25 • Z-45/25J Part No. 107846

June 2012
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

B Jib Boom Components, Z-45/25J
3-1 Jib Boom .................................................................................................... 4 - 12
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 13
B Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 15
4-2 Primary Boom ............................................................................................ 4 - 19
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 21
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 23
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 24
B Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 27
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 32
B Engines
6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 33
6-2 RPM Adjustment - Perkins Models ............................................................. 4 - 33
6-3 Flex Plate ................................................................................................... 4 - 33
6-4 Engine Fault Codes - Ford Models ............................................................. 4 - 37
B Hydraulic Pumps
7-1 Lift/Steer Pump .......................................................................................... 4 - 38
7-2 Drive Pump ................................................................................................ 4 - 39
Part No. 107846 Z-45/25 • Z-45/25J xi

June 2012
TABLE OF CONTENTS

E Manifolds
8-1 Function Manifold Components
(before serial number 27001) ..................................................................... 4 - 42
8-2 Valve Adjustments - Function Manifold
8-3 Function Manifold Components
(after serial number 27000) ........................................................................ 4 - 48
8-4 Valve Adjustments - Function Manifold
8-5 Jib Boom / Platform Rotate Manifold Components
8-6 Jib Boom / Platform Rotate Manifold Components
8-7 Turntable Rotation Manifold Components
8-8 Turntable Rotation Manifold Components
8-9 Directional Valve Manifold Components .................................................... 4 - 57
8-10 Traction Manifold Components, 2WD
8-12 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 64
8-15 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 70
8-16 Valve Coils ................................................................................................. 4 - 70
xii Z-45/25 • Z-45/25J Part No. 107846

June 2012
TABLE OF CONTENTS

C Turntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 72
C Axle Components
10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 73
10-2 Oscillate Lock-out Cylinders ....................................................................... 4 - 74
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
A Fault Codes - Control System ................................................................................ 5 - 2
B Fault Codes - Ford LRG-425 EFI Models ............................................................... 5 - 6
A Fault Codes - Ford DSG-423 EFI Models ............................................................. 5 - 12
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
A Ford Engine Relay Layout ...................................................................................... 6 - 4
Ford models
A Ford LRG-425 EFI Engine Harness ........................................................................ 6 - 5
A Ford DSG-423 EFI Engine Harness ....................................................................... 6 - 6
C Electrical Schematic, Z-45/25
Ford LRG-425 EFI (before serial number 30142) ........................................ 6 - 7
A Electrical Schematic, Z-45/25
Ford DSG-423 EFI (after serial number 30141) ........................................... 6 - 9
Part No. 107846 Z-45/25 • Z-45/25J xiii

June 2012
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Ford models, continued
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 11
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 12
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 13
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 14
C Electrical Schematic, Z-45/25J
Ford LRG-425 EFI (before serial number 30142) ...................................... 6 - 15
A Electrical Schematic, Z-45/25J
Ford DSG-423 EFI (after serial number 30141) ......................................... 6 - 17
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 19
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 20
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 21
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 22
Deutz F3L-2011 models
C Electrical Schematic, Z-45/25 .............................................................................. 6 - 23
C Electrical Schematic, Z-45/25
CE models ........................................................................................................... 6 - 25
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 27
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 28
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 29
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 30
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 31
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 32
xiv Z-45/25 • Z-45/25J Part No. 107846

June 2012
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Deutz F3L-2011 models, continued
C Electrical Schematic, Z-45/25J ............................................................................ 6 - 33
C Electrical Schematic, Z-45/25J
CE models ........................................................................................................... 6 - 35
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 37
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 38
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 39
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 40
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 41
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 42
Perkins 404-22 models
C Electrical Schematic, Z-45/25 .............................................................................. 6 - 44
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 ................................ 6 - 48
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................. 6 - 49
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 52
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 53
C Electrical Schematic, Z-45/25J ............................................................................ 6 - 56
B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J .............................. 6 - 60
B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J ................................ 6 - 61
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 63
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 65
Hydraulic Schematics
D Hydraulic Schematic, 2WD Models (before serial number 27001) ......................... 6 - 67
B Hydraulic Schematic, 2WD Models (after serial number 27000) ........................... 6 - 69
C Hydraulic Schematic, 4WD Models (before serial number 27001) ......................... 6 - 71
B Hydraulic Schematic, 4WD Models (after serial number 27000) ........................... 6 - 73
Part No. 107846 Z-45/25 • Z-45/25J xv

June 2012
xvi Z-45/25 • Z-45/25J Part No. 107846

January 2011 Section 2 • Specifications
REV H
Specifications
Machine Specifications Tires and wheels Hi-flotation
(option)
Tires and wheels Rough terrain Industrial
Tire size 33/16LL500
Tire size 355/55 D625 9-14.5 LT
Tire ply rating 10
Tire ply rating 14 Tread 8
Sidewall 6 Overall tire diameter 33 in
84 cm
Tire weight,
new foam-filled (minimum) 390 lbs 175 lbs Wheel diameter 19.5 inches
177 kg 79 kg 49.5 cm
Overall tire diameter 36.9 in 28 in Wheel width 14 inches

93.7 cm 71 cm 35.6 cm
Wheel diameter 24.5 inches 14.5 inches Wheel lugs 9 @ 5/8 -18
62.2 cm 36.8 cm Lug nut torque
Wheel width 11.75 inches 7 inches (lubricated) 94 ft-lbs
29.8 cm 17.8 cm 127.4 Nm
(dry) 125 ft-lbs
Wheel lugs 9@ 5/8 -18 9@ 5/8 -18 169.5 Nm
Lug nut torque Tire pressure 38 psi

(lubricated) 94 ft-lbs 94 ft-lbs 2.6 bar
127.4 Nm 127.4 Nm
(dry) 125 ft-lbs 125 ft-lbs
169.5 Nm 169.5 Nm
Tire pressure (air-filled tires) 50 psi 100 psi

3.45 bar 6.9 bar
For operational specifications, refer to the

Operator's Manual.
Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.
Part No. 107846 Z-45/25 • Z-45/25J 2-1

Section 2 • Specifications January 2011
SPECIFICATIONS REV H
Fluid capacities Performance Specifications

LPG tank 33.5 pounds
Drive speed, maximum
15.2 kg
Fuel tank 17 gallons Stowed position 4.8 mph
64.4 liters 7.7 km/h
40 ft / 5.7 sec
Hydraulic tank 24 gallons 12.2 m / 5.7 sec
91 liters
Raised or extended position 0.6 mph
Hydraulic system 30 gallons 0.98 km/h
(including tank) 113.6 liters 40 ft / 45 sec
Drive hubs, 2WD models 17 fl oz 12.2 m / 45 sec
(before serial number 24690) 0.5 liters Raised or extended position 0.38 mph
Drive hubs, 2WD models 24 fl oz (narrow models) 0.6 km/h
(after serial number 24689) 0.7 liters 40 ft / 70 sec
12.2 m / 70 sec
Drive hubs - Steer end, 4WD models 17 fl oz
0.5 liters Gradeability See Operator's Manual
Drive hubs, 48:1, 17 fl oz Braking distance, maximum
Non-steer end, 4WD models 0.5 liters
(before serial number 23812) High range on paved surface 3 to 6 ft
Drive hubs with brake, 57:1, 24 fl oz 0.9 to 1.8 m
Non-steer end, 4WD models 0.7 liters Boom function speeds, maximum
(after serial number 23811) from platform controls
Drive hub oil type:
Primary boom up 24 to 28 seconds
SAE 90 multipurpose hypoid gear oil API service
classification GL5 Primary boom down 24 to 28 seconds
Secondary boom up 24 to 28 seconds
Secondary boom down 38 to 42 seconds

(before serial number 27001)
Secondary boom down 24 to 28 seconds

(after serial number 27000)
Turntable rotate, 359° 62 to 68 seconds

primary boom retracted

Genie policy. Product specifications are subject
to change without notice.
2-2 Z-45/25 • Z-45/25J Part No. 107846

REV H SPECIFICATIONS
Hydraulic Specifications Drive pump
Hydraulic Oil Specifications Type: bi-directional, variable

displacement piston pump
Hydraulic oil type Chevron Rykon MV equivalent
Viscosity grade Multi-viscosity Flow rate @ 2500 rpm 32 gpm
Viscosity index 200 121 L/min
Cleanliness level, minimum 15/13 Drive pressure, maximum 3500 psi

241 bar
Water content, maximum 200 ppm
Charge pump
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Type: gear
Genie specifications require hydraulic oils which are Displacement 0.84 cu in
designed to give maximum protection to hydraulic 13.76 cc
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index Flow rate @ 2500 rpm 9.1 gpm
greater than 140. They should provide excellent 34.4 L/min
antiwear, oxidation, corrosion inhibition, seal
conditioning, and foam and aeration suppression Charge pressure @ 2500 rpm 315 psi
properties. 21.7 bar
Optional fluids Function pump
Biodegradable Petro Canada Environ MV46 Type: gear

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S Displacement 0.67 cu in
11 cc
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822 Flow rate @ 2500 rpm 7.25 gpm
27.4 L/min
Mineral based Shell Tellus T32
Shell Tellus T46 Auxiliary pump
Chevron Aviation A Type: gear, fixed displacement
Displacement per revolution 0.067 cu in

Use Chevron Aviation A hydraulic 1.1 cc
oil when in ambient temperatures
Auxiliary pump relief pressure 3200 psi
consistently below 0°F / -18°C.
220.6 bar
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use. Continuous improvement of our products is a
Part No. 107846 Z-45/25 • Z-45/25J 2-3

Function manifold Hydraulic filters
System relief valve pressure 3200 psi High pressure filter Beta 3 ≥ 200
220.6 bar
High pressure filter 100 psi
Secondary boom down 2100 psi bypass pressure 6.89 bar
relief valve pressure 145 bar
Medium pressure filter Beta 3 ≥ 200
Platform level relief valve pressure 2500 psi
172 bar Medium pressure filter 50 psi
bypass pressure 3.4 bar
Steer flow regulator 1.5 gpm
5.7 L/min Hydraulic return filter 10 micron with
25 psi / 1.7 bar bypass
Boom extend flow regulator 2 gpm
7.6 L/min
Jib boom / platform rotate flow regulator 0.4 gpm

1.5 L/min
Drive manifold
Hot oil relief pressure 250 psi

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 0.12 to 2.14 cu in

4WD (2 speed motor) 1.97 to 35 cc

4WD (2 speed motor) 1.61 to 30 cc

2WD (before serial number 24690) 22.5 to 35 cc

2WD (after serial number 24689) 16.2 to 30 cc

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

Manifold Component
Specifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
Valve Coil Resistance Specification
Proportional directional solenoid valve, 10V DC 6 to 8Ω

(schematic items A, C, D, BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω

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

(schematic items E, G, CA, CC, AD, OO,
XX, AF, AG, AI and AK)

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

Ford LRG-425 EFI Engine Electronic fuel pump
Displacement 153 cu in Fuel pressure, static 63 psi

2.5 liters 4.3 bar
Number of cylinders 4 Fuel flow rate 0.58 gpm

2.2 L/min
Bore & stroke 3.78 x 3.4 inches
96.01 x 86.36 mm
Horsepower 70 @ 2500 rpm Fuel requirement

52 kW @ 2500 rpm For fuel requirements, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.
Low function idle (computer controlled) 1600 rpm Ignition system

27 Hz Spark plug type Motorcraft AGSF-32-FM
High function idle (computer controlled) 2500 rpm Spark plug gap 0.042 to 0.046 inches
42 Hz 1.07 to 1.17 mm
Compression ratio 9.4:1 Engine coolant
Compression pressure (approx.) Capacity 11.5 quarts
Pressure (psi or bar) of lowest cylinder must be 10.9 liters
at least 75% of highest cylinder
Coolant temperature switch
Valve clearances - 0.035 to 0.055 inches
collapsed tappet 0.889 to 1.397 mm Temperature switch point 230°F
110°C
Lubrication system
Starter motor
Oil pressure 40 to 60 psi
(operating temperature @ 2500 rpm) 2.75 to 4.1 bar Normal engine cranking speed 200 to 250 rpm
Oil capacity 4.5 quarts Current draw, normal load 140-200A
(including filter) 4.3 liters
Current draw, maximum load 800A
Oil pressure switch
Alternator
Oil pressure switch point 7.5 psi
0.51 bar Output 95A, 14.5V DC
Oil viscosity requirements Battery
Extreme operating temperatures may require the use of Type 12V DC, Group 34/78
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Quantity 1
Cold cranking ampere @ 0°F 900A
Reserve capacity @ 25A rate 200 minutes

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

Ford DSG-423 EFI Engine Electronic fuel pump
Displacement 140.4 cu in Fuel pressure, static 64 psi

2.3 liters 4.4 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm Fuel requirement
Horsepower 59 @ 2500 rpm For fuel requirements, refer to the engine Operator's
44 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Ignition system
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FEC
27 Hz Spark plug gap 0.044 to 0.045 inches
High function idle (computer controlled) 2500 rpm 1.125 to 1.135 mm
42 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 4 quarts Starter motor
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Current draw, normal load 140-200A
Oil pressure switch point 7.5 psi
0.51 bar Current draw, maximum load 800A
Extreme operating temperatures may require the use of Alternator
Engine Operator Handbook on your machine. Output 95A, 13.8V DC
Battery
Type 12V DC, Group 34/78
Quantity 1
Cold cranking ampere @ 0°F 900A

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

Deutz F3L 2011 Engine Lubrication system

Deutz D2011L03i Oil pressure 20 to 44 psi
1.4 to 3 bar
Displacement 142 cu in
2.33 liters Oil capacity 8.5 quarts
(including filter) 8 liters
Number of cylinders 3 (Deutz F3L 2011 Engine)
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011L03i Engine)
Horsepower 48 @ 2800 rpm
36 kW @ 2800 rpm Oil viscosity requirements
Firing order 1-2-3 -22° F to 86° F/ -30° C to 30° C 5W-30

(synthetic)
Low idle 1500 rpm
25 Hz -4° F to 90° F / -20° C to 32° C 10W-40
High idle 2500 rpm Above 23° F / -5° C 20W-50

42 Hz
Units ship with 15W-40.
Compression ratio 19:1 Extreme operating temperatures may require the use of
Compression pressure 362 to 435 psi Engine Operator Handbook on your machine.
25 to 30 bar
Oil temperature switch
Governor centrifugal mechanical
Temperature switch point 300°F
Valve clearance, cold 149°C
Intake 0.012 in Oil pressure switch
0.3 mm
Oil pressure switch point 7 psi
Exhaust 0.020 in (Deutz F3L 2011 Engine) 0.5 bar
0.5 mm
Oil pressure switch point 22 psi
(Deutz D2011L03i Engine) 1.5 bar

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

Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's

Manual on your machine.
Starter motor
Current draw, no load 90A
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
Battery
Quantity 1
Cold cranking ampere 900A
Alternator output 60A @ 14V DC
Fan belt deflection 3/8to 1/2 inch

9 to 12 mm

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

Perkins 404-22 Engine Lubrication system
Displacement 134 cu in Oil pressure, cold 60 psi

2.2 liters (at 2500 rpm) 4.1 bar
Number of cylinders 4 Oil capacity 9.3 quarts

Bore and stroke 3.31 x 3.94 inches
84 x 100 mm Oil viscosity requirements
Horsepower 51 @ 2500 rpm Below 86°F / 30°C 5W-20

38 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Low idle 1300 rpm Units ship with 15W-40.
22 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
42 Hz Engine Operator Handbook on your machine.
Compression ratio 23.3:1 Oil pressure sending unit
Compression pressure 426 psi Oil pressure switch point 14.2 psi
29.4 bar 1 bar
Pressure (psi) of lowest cylinder must Fuel injection system
be within 50 psi / 3.45 bar of highest cylinder
Injection pump make Zexel
Governor centrifugal mechanical
Injection pressure 2133 psi
Valve clearance, cold 147 bar
Intake 0.008 in Fuel requirement
0.2 mm
For fuel requirements, refer to the engine Operator's
Exhaust 0.008 in Manual on your machine.
0.2 mm
Alternator output 55A @ 12V DC
Fan belt deflection 3/8 in

10 mm
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in

19 mm
Brush length, minimum 0.5 in

12.7 mm

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

Battery
Quantity 1
Cold cranking ampere 900A
Engine coolant
Capacity 7.7 quarts

7.3 liters
Coolant temperature sending unit
Temperature switch point 221° F

105° C

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

Machine Torque Specifications

Platform rotator
3 /4 -10 center bolt, GR 8 380 ft-lbs
515 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs

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

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

108 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs

244 Nm
Drive motor mounting bolts, lubricated 55 ft-lbs

75 Nm

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

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
field service kit (Genie part
SAE Dash size Torque
number 49612).
-4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-8 40 ft-lbs / 54.2 Nm
4 Position the tube and nut squarely on the face
-10 69 ft-lbs / 93.6 Nm
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.
-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-20 172 ft-lbs / 233.2 Nm
6 Operate all machine functions and inspect the
-24 208 ft-lbs / 282 Nm hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm
-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm
-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm
-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm
Part No. 107846 Z-45/25 • Z-45/25J 2 - 13

SAE FASTENER TORQUE CHART

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

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

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2 - 14 Z-45/25 • Z-45/25J Part No. 107846

August 2006 Section 3 • 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
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
Used to indicate the presence of
and every 2 years as specified on the
Maintenance Inspection Report.
Failure to perform each procedure death or serious injury.
as presented and scheduled may
cause death, serious injury or
potentially hazardous situation
substantial damage.
which, if not avoided, could result
Immediately tag and remove from service a in death or serious injury.
damaged or malfunctioning machine.
With safety alert symbol—used to
Repair any machine damage or malfunction indicate the presence of a
before operating machine. potentially hazardous situation
which, if not avoided, may cause
Keep records on all inspections for three years. minor or moderate injury.
Unless otherwise specified, perform each Without safety alert symbol—used
maintenance procedure with the machine in the to indicate the presence of a
following configuration: potentially hazardous situation
· Machine parked on a firm, level surface which, if not avoided, may result in
property damage.
· Boom in stowed position
Used to indicate operation or
· Turntable rotated with the boom between
maintenance information.
the non-steer wheels
· Turntable secured with the turntable Indicates that a specific result is expected after
rotation lock performing a series of steps.
· Key switch in the off position with the Indicates that an incorrect result has occurred
key removed after performing a series of steps.
· Wheels chocked
· All external AC power disconnected
from the machine
Part No. 107846 Z-45/25 • Z-45/25J 3-1

Section 3 • Scheduled Maintenance Procedures August 2006
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

The following symbols have been The pre-delivery preparation report contains
used in this manual to help checklists for each type of scheduled inspection.
communicate the intent of the
instructions. When one or more of Make copies of the Pre-delivery Preparation report
the symbols appear at the to use for each inspection. Store completed forms
beginning of a maintenance as required.
procedure, it conveys the meaning Maintenance Schedule
below.
There are five types of maintenance inspections
that must be performed according to a schedule—
Indicates that tools will be required to daily, quarterly, every six months, annual and
perform this procedure. two years. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
Indicates that new parts will be required
group(s) of procedures are required to perform a
to perform this procedure.
scheduled inspection.
Indicates that a cold engine will be Inspection Table or Checklist

required to perform this procedure.
Daily or every 8 hours A
Quarterly or every 250 hours A+B

Indicates that a warm engine will be
required to perform this procedure. Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D
Indicates that dealer service is required Two years or every 2000 hours A+B+C+D+E
to perform this procedure.
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3-2 Z-45/25 • Z-45/25J Part No. 107846

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from If any inspection receives an N, remove the machine from
service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed in Comments
the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.

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

Maintenance Inspection Report

Model Checklist A - Rev D Y N R Checklist B - Rev C Y N R
A-1 Pre-operation B-1 Battery
Serial number inspection B-2 Electrical wiring
Date A-2 Functions tests B-3 Exhaust system
A-3 Engine maintenance B-4 Inspect air filter
Hour meter A-4 Filter condition indicator B-5 Oil cooler and fins-
A-5 Oscillate axle Deutz models
Machine owner
Perform after 40 hours: B-6 Tires and wheels
Inspected by (print) A-6 30 day service B-7 Brake configuration
Perform every 100 hours: B-8 Drive hub oil level
Inspector signature
A-7 Engine maintenance - B-9 Engine RPM -
Ford models All models
Inspector title
A-8 Fuel filter/separator - B-10 Ground control override
Inspector company Diesel models B-11 Directional valve
A-9 Rotation bearing B-12 Platform leveling
Instructions Perform every 200 hours: B-13 Engine idle select
· Make copies of both pages to use A-10 Engine maintenance - B-14 Fuel select -
for each inspection. Ford models Ford models
· Select the appropriate checklist(s)
B-15 Drive brakes
for the type of inspection to be
performed. B-16 Drive speed -
stowed position
Daily or 8 hour B-17 Drive speed -
Inspection: A raised position
Quarterly or 250 hour B-18 Alarm package
Inspection: A+B B-19 Hydraulic oil analysis
Six Month or 500 hour B-20 Fuel and hydraulic
Inspection: A+B+C tank cap venting
Annual or 1000 hours B-21 Replace fuel filter -
Inspection: A+B+C+D Perkins models
2 Year or 2000 hour B-22 Engine maintenance -
Inspection: A+B+C+D+E Perkins models
B-23 Air filter - Ford models
· Place a check in the appropriate box
after each inspection procedure is Perform every 400 hours:
completed. B-24 Engine maintenance -
· Use the step-by-step procedures in Ford models
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend Comments
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 107846 Z-45/25 • Z-45/25J 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C - Rev D Y N R Checklist D - Rev D Y N R

C-1 Engine maintenance - D-1 Boom wear pads
Serial number Deutz models D-2 Turntable bearing bolts
Date C-2 Grease platform D-3 Turntable bearing wear
overload (if equipped)
D-4 Drive hub oil
Hour meter C-3 Test platform overload
D-5 Free-wheel
(if equipped)
configuration
Machine owner C-4 Fuel filter/separator -
D-6 Hydraulic filters
Perkins models
Inspected by (print) D-7 Engine maintenance -
C-5 Air filter - Deutz and
Deutz models
Perkins models
Inspector signature
Perform every 600 hours:
Checklist E - Rev D Y N R
Inspector title C-6 Engine maintenance -
Perkins models E-1 Hydraulic oil
Inspector company Perform every 800 hours: E-2 Grease steer axle
wheel bearings,
C-7 Engine maintenance -
Instructions 2WD models
Ford models
· Make copies of both pages to use Perform every 3000 hours:
for each inspection. E-3 Engine maintenance -
· Select the appropriate checklist(s) Deutz models
for the type of inspection to be Perform every 12,000 hours:
performed. E-4 Engine maintenance -
Deutz models
Daily or 8 hour
Inspection: A
Quarterly or 250 hour
Inspection: A+B
Six Month or 500 hour
Inspection: A+B+C
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour Comments
Inspection: A+B+C+D+E
· Place a check in the appropriate box

after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 Z-45/25 • Z-45/25J Part No. 107846

REV D
Checklist A Procedures
A-1 A-2
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a pre-operation inspection is essential machine operation. Function tests are designed to
to safe machine operation. The pre-operation discover any malfunctions before the machine is
inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The pre-operation inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the appropriate operator's manual. Refer
procedures are required. to the Operator's Manual on your machine.
Complete information to perform this procedure is
available in the appropriate operator's manual. Refer
to the Operator's Manual on your machine.
Part No. 107846 Z-45/25 • Z-45/25J 3-7

CHECKLIST A PROCEDURES REV D
A-3 To access the engine:

Perform Engine Maintenance 1 Remove the safety pin from the engine pivot
plate latch.
The engine pivot plate latch is
located under the engine turntable
Engine specifications require that pivot plate at the counterweight
this procedure be performed daily end of the machine.
or every 8 hours, whichever comes
first. 2 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
Proper engine maintenance, following the engine machine.
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional

engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) OR the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020) OR the
Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929) OR the
Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S).

Genie part number 84792



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

REV D CHECKLIST A PROCEDURES
A-4 A-5
Check the High Pressure Test the Oscillate Axle
Hydraulic Filter Condition (if equipped)
Indicator
Genie specifications require that
this procedure be performed daily Genie specifications require that
or every 8 hours, whichever comes this procedure be performed daily
first. or every 8 hours, whichever comes
Maintaining the high pressure hydraulic filter in first.
good condition is essential to good system Proper axle oscillation is essential to safe machine
performance and safe machine operation. The filter operation. If the axle oscillation system is not
condition indicator will show when the hydraulic flow operating correctly, the stability of the machine is
is bypassing a clogged filter. If the filter is not compromised and it may tip over.
frequently checked and replaced, impurities will
remain in the hydraulic system and cause 1 Start the engine from the platform controls.
component damage.
2 Drive the right steer tire up onto a
1 Open the engine side turntable cover. 6 inch / 15 cm block or curb.
2 Start the engine from the ground controls. Result: The three remaining tires should stay in
firm contact with the ground and the chassis
3 Change the engine idle to high rpm (rabbit should remain level at all times.
symbol).
3 Drive the left steer tire up onto a
4 Visually inspect the filter condition indicator. 6 inch / 15 cm block or curb.
Result: The filter condition indicator should be Result: The three remaining tires should stay in
operating with the plunger in the green area. firm contact with the ground and the chassis
Result: If the indicator displays the plunger in should remain level at all times.
the red area, this indicates that the hydraulic 4 Drive both steer tires up onto a
filter is being bypassed and the filter should be 6 inch / 15 cm block or curb.
replaced. See D-6, Replace the Hydraulic
Filters. Result: The non-steer tires should stay in firm
contact with the ground.
If the chassis does not remain
level during test, refer to Repair
Procedure 8-9, How to Set Up the
Directional Valve Linkage.
Part No. 107846 Z-45/25 • Z-45/25J 3-9

A-6 A-7
Perform 30 Day Service Perform Engine Maintenance -
Ford Models
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
Engine specifications require that
first 30 days or 40 hours of usage, whichever
this procedure be performed every
comes first. After this interval, refer to the
100 hours. Perform this procedure
maintenance checklist for continued scheduled
more often if dusty conditions exist
maintenance.
or the machine is subjected to
1 Perform the following maintenance procedures: extended low idle operation.
Proper engine maintenance, following the engine
• A-9 Grease the Turntable Rotation Bearing manufacturer's maintenance schedule, is essential
and Rotate Gear to good engine performance and service life. Failure
• A-10 Perform Engine Maintenance - to perform the maintenance procedures can lead to
Ford Models poor engine performance and component damage.
• B-6 Inspect the Tires, Wheels and Required maintenance procedures and additional
Lug Nut Torque engine information are available in the
• B-8 Check the Oil Level in the Drive Hubs Ford LRG-425 EFI Operator Handbook
• C-1 Perform Engine Maintenance -
Deutz Models
(EDI part number 1060020).
• D-2 Check the Turnable Rotation Bearing
Bolts Ford LRG-425 EFI Operator Handbook
• D-6 Replace the Hydraulic Filters Genie part number 84792

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

A-8 4 Open the engine pivot plate latch and swing the
Inspect the Fuel Filter/ Water machine.
Separator - Diesel Models 5 Locate the fuel filter/water separator mounted to
the rear engine mounting bracket.
6 Visually inspect the filter bowl for water buildup.
Genie specifications require that Result: If water is present in the filter bowl,
this procedure be performed every continue with steps 7 through 11.
100 hours or monthly, whichever
comes first. 7 Loosen the vent plug located on the fuel filter/
water separator head.
Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
perform this procedure can lead to poor engine a
performance and/or hard starting, and continued
use may result in component damge. Extremely d
dirty conditions may require this procedure be
performed more often.
Explosion and fire hazard. Engine c

fuels are combustible. Perform this
b
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach. a vent plug
b drain plug
Perform this procedure with the
c filter bowl
engine off. d separator head
Perkins models: 8 Loosen the drain plug located at the bottom of
1 Put on protective clothing and eye wear. the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
2 Open the engine side turntable cover. Immediately tighten the drain plug.
3 Remove the safety pin from the engine pivot 9 Tighten the vent plug.
plate latch.
If the fuel filter/water separator is
The engine pivot plate latch is completely drained, you must
located under the engine turntable prime the fuel filter/water separator
pivot plate at the counterweight before starting the engine.
end of the machine. See C-4, Replace The Fuel Filter/
Water Separator Element - Perkins
Models, for instructions on how to
prime the fuel filter/water
separator.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 11

10 Clean up any fuel that may have spilled. 5 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
11 Start the engine from the ground controls and
container until fuel starts to come out.
check the fuel filter/water separator and vent
Immediately tighten the drain plug.
plug for leaks.
Do not completely drain the filter.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
12 Swing the engine back to its original position
and close the engine pivot plate latch. a
13 Install the engine pivot plate safety pin.

b
Deutz models:
1 Put on protective clothing and eye wear.
2 Remove the safety pin from the engine pivot a fuel filter/water separator
b drain valve
plate latch.
The engine pivot plate latch is 6 Clean up any fuel that may have spilled.
located under the engine turntable 7 Start the engine from the ground controls and
pivot plate at the counterweight check the fuel filter/water separator for leaks.
end of the machine.
Explosion and fire hazard. If a fuel
3 Open the engine pivot plate latch and swing the leak is discovered, keep any
engine pivot plate out and away from the additional personnel from entering
machine. the area and do not operate the
4 Locate the fuel filter/water separator next to the machine. Repair the leak
oil filter. immediately.
and close the engine pivot plate latch.
3 - 12 Z-45/25 • Z-45/25J Part No. 107846

A-9 A-10
Grease the Turntable Rotation Perform Engine Maintenance -
Bearing and Rotate Gear Ford Models
Genie specifications require that Engine specifications require that

this procedure be performed every this procedure be performed every
100 hours of operation. Perform 200 hours.
this procedure more often if dusty Proper engine maintenance, following the engine
conditions exist. manufacturer's maintenance schedule, is essential
Frequent application of lubrication to the turntable to good engine performance and service life. Failure
bearing and rotate gear is essential to good to perform the maintenance procedures can lead to
machine performance and service life. Continued poor engine performance and component damage.
use of an improperly greased bearing and gear will
result in component damage.
1 Before serial number 27001: Locate the grease Ford LRG-425 EFI Operator Handbook
fitting on the front turntable cover. (Ford part number FPP 194-302) OR the
After serial number 27000: Locate the grease (EDI part number 1060020).
fitting near the ground control box.
2 Pump grease into the turntable rotation bearing. Ford LRG-425 EFI Operator Handbook
Rotate the turntable in increments of 4 to 5 Genie part number 84792
inches / 10 to 13 cm at a time and repeat this
step until the entire bearing has been greased. Ford DSG-423 EFI Operator Handbook
3 Apply grease to each tooth of the drive gear,
located under the turntable.
To access the engine:
Grease Specification
1 Remove the safety pin from the engine pivot
Chevron Ultra-duty grease, EP NLGI 2 (lithium based) plate latch.
or equivalent
pivot plate at the counterweight
end of the machine.
2 Open the engine pivot plate latch and swing the
machine.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 13

Checklist B Procedures REV C
B-1 4 Be sure that the battery separator wire

connections are tight (if equipped).
Inspect the Battery
5 Fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check the
Genie specifications require that specific gravity of each battery cell with a
this procedure be performed every hydrometer. Note the results.
250 hours or quarterly, whichever 7 Check the ambient air temperature and adjust
comes first. the specific gravity reading for each cell as
Proper battery condition is essential to good engine follows:
performance and operational safety. Improper fluid • Add 0.004 to the reading of each cell for
levels or damaged cables and connections can every 10° / 5.5° C above 80° F / 26.7° C.
result in engine component damage and hazardous
conditions. • Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Electrocution hazard. Contact with
hot or live circuits could result in Result: All battery cells display an adjusted
death or serious injury. Remove all specific gravity of 1.277 or higher. The battery
rings, watches and other jewelry. is fully charged. Proceed to step 11.
Bodily injury hazard. Batteries Result: One or more battery cells display a
contain acid. Avoid spilling or specific gravity of 1.217 or below. Proceed to
contacting battery acid. Neutralize step 8.
battery acid spills with baking soda 8 Perform an equalizing charge OR fully charge
and water. the battery(s) and allow the battery(s) to rest at
1 Put on protective clothing and eye wear. least 6 hours.
2 Be sure that the battery cable connections are 9 Remove the battery vent caps and check the
free of corrosion. specific gravity of each battery cell with a
hydrometer. Note the results.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
3 Be sure that the battery hold downs and cable
connections are tight.
3 - 14 Z-45/25 • Z-45/25J Part No. 107846

REV C CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for Genie specifications require that
every 10° / 5.5° C below 80° F / 26.7° C. this procedure be performed every
Result: All battery cells display a specific 250 hours or quarterly, whichever
comes first.
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 13. Maintaining electrical wiring in good condition is
essential to safe operation and good machine
Result: The difference in specific gravity
performance. Failure to find and replace burnt,
readings between cells is greater than 0.1 OR
chafed, corroded or pinched wires could result in
the specific gravity of one or more cells is less
unsafe operating conditions and may cause
than 1.177. Replace the battery.
component damage.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm Electrocution hazard. Contact with
below the bottom of the battery fill tube. Do not hot or live circuits could result in
overfill. death or serious injury. Remove all
rings, watches and other jewelry.
12 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Open the engine side turntable cover.
plate latch.
end of the machine.
machine.
4 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Engine wiring harness
· Hydraulic manifold wiring
Part No. 107846 Z-45/25 • Z-45/25J 3 - 15

CHECKLIST B PROCEDURES REV C
5 Open the ground controls side turntable cover. B-3

6 Inspect the following areas for burnt, chafed, Check the Exhaust System
corroded and loose wires:
· Ground control box wire harnesses this procedure be performed every
· Inside of the ground control box 250 hours or quarterly, whichever
comes first.
· Hydraulic manifold wiring
7 Inspect for a liberal coating of dielectric grease Maintaining the exhaust system is essential to
at the following location: good engine performance and service life. Running
the engine with a damaged or leaking exhaust
· All wire harnesses connectors to the system can cause component damage and unsafe
ground control box operating conditions.
Bodily injury hazard. Do not
raise the secondary boom above the turntable
inspect while the engine is running.
covers.
Remove the key to secure from
9 Remove the center turntable cover retaining operation.
fasteners. Remove the center turntable cover
Burn hazard. Beware of hot engine
from the machine.
components. Contact with hot
10 Inspect the turntable area for burnt, chafed and engine components may result in
pinched cables. severe burns.
11 Lower the boom to the stowed position and turn Ford models:
the engine off.
12 Inspect the following areas for burnt, chafed, plate latch.
corroded, pinched and loose wires:
· Cable track on the primary boom located under the engine turntable
· Cables on the primary, and jib booms pivot plate at the counterweight
end of the machine.
· Jib boom/Platform rotate manifold
· Inside of the platform control box
13 Inspect for a liberal coating of dielectric grease machine to access the exhaust system.
at the following location:
All models:
· All wire harnesses connectors to the
platform control box 3 Be sure that all nuts and bolts are tight.
14 Swing the engine back to its original position 4 Inspect all welds for cracks.
and close the engine pivot plate latch. 5 Inspect for exhaust leaks; i.e., carbon buildup
15 Install the engine pivot plate safety pin. around seams and joints.
16 Install the center turntable cover and tighten the Ford models:
retaining fasteners.
3 - 16 Z-45/25 • Z-45/25J Part No. 107846

B-4 B-5
Inspect the Engine Air Filter Check the Oil Cooler and
Cooling Fins - Deutz Models

this procedure be performed every Engine specifications require that
250 hours or quarterly, whichever this procedure be performed every
comes first. 250 hours or quarterly, whichever
Maintaining the engine air filter in good condition is comes first.
essential to good engine performance and service Maintaining the oil cooler in good condition is
life. Failure to perform this procedure can lead to essential for good engine performance. Operating a
poor engine performance and component damage. machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
Perform this procedure with the the oil cooler will affect the performance of the
engine off. cooling system.
1 Release the latches from the air cleaner canister
Bodily injury hazard. Do not
end cap. Remove the end cap.
inspect while the engine
2 Remove the filter element. is running. Remove the key to
secure from operation.
3 Clean the inside of the canister and the end cap
with a damp cloth. Burn hazard. Beware of hot engine
components. Contact with hot
4 Inspect the air filter element. If needed, blow
engine components may result in
from the inside out using low pressure dry
severe burns.
compressed air, or carefully tap out dust.
Replace the filter if needed. Oil cooler:
5 Install the filter element. 1 Remove the safety pin from the engine pivot
plate latch.
6 Install the air filter canister end cap and secure
the end cap latches. The engine pivot plate latch is
Be sure the discharge valve is
pointing down when the cap is
end of the machine.
instaled.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 17

2 Open the engine pivot plate latch and swing the B-6
machine. Inspect the Tires, Wheels and
3 Remove the fasteners from the engine side
Lug Nut Torque
cover, then remove the cover.
4 Inspect the oil cooler for leaks and physical
damage. Genie specifications require that
a b c this procedure be performed every
250 hours or quarterly, whichever
comes first.
Maintaining the tires and wheels, including proper
wheel fastener torque, 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-

inflated tire can explode and could
cause death or serious injury.
a oil cooler
b cylinder head cooling fins Tip-over hazard. Do not use
c fan blower fins
temporary flat tire repair products.
5 Clean the oil cooler of debris and foreign The tires on some machines are
material. foam-filled and do not need air
Cooling and fan blower fins: added to them.
6 Inspect the fan blower fins for physical damage. 1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
7 Clean the fan blower fins of debris and foreign
material. 2 Check each wheel for damage, bends and
cracked welds.
8 Inspect the head cooling passages and fins for
physical damage or foreign material, using a 3 Check each lug nut for proper torque.
flashlight. Refer to Section 2, Specifications.
9 Clean the cylinder head cooling passages of 4 Check the pressure in each air-filled tire.
debris and foreign material. Refer to Section 2, Specifications.
10 Install the engine side cover.

3 - 18 Z-45/25 • Z-45/25J Part No. 107846

B-7 B-8
Confirm the Proper Check the Oil Level
Brake Configuration in the Drive Hubs
Genie specifications require that Genie specifications require that

250 hours or quarterly, whichever 250 hours or quarterly, whichever
comes first. comes first.
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 continued
Hydrostatic brakes and hydraulically-released, use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully 1 Drive the machine to rotate the hub until the
operational. plugs are located one on top and the other at
90 degrees.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position. a
brake disengaged position
brake engaged position
a drive hub plugs
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 19

B-9 Deutz models:

Check and Adjust the This procedure will require two
Engine RPM - All Models people.
plate latch.
Genie specifications require that located under the engine turntable
this procedure be performed every pivot plate at the counterweight
250 hours or quarterly, whichever end of the machine.
comes first.
Maintaining the engine rpm at the proper setting for engine pivot plate out and away from the
both low and high idle is essential to good engine machine.
performance and service life. The machine will not
operate properly if the rpm is incorrect and 3 Connect a tachometer to the engine, and then
continued use may cause component damage. start the engine from the ground controls and
check the rpm. Refer to Section 2,
Ford LRG-425 EFI models: Specifications.
The engine rpm is controlled by the Skip to step 5 if the low idle rpm is correct.
ECM and can only be adjusted by
re-programming the ECM. If rpm 4 Loosen the low idle lock nut, then turn the low
adjustment or service is required, idle adjustment screw clockwise to increase the
please contact the Genie rpm or counterclockwise to decrease the rpm.
Industries Service Department OR Tighten the low idle lock nut and recheck the
your local Ford dealer. rpm.
Ford DSG-423 EFI models:

The engine rpm is controlled by the
ECM and can only be adjusted by
re-programming the ECM. If rpm f
adjustment or service is required,
e
please contact your local EDI
distributor. Refer to the engine
operator's handbook on your
machine for EDI distributor
locations.
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
3 - 20 Z-45/25 • Z-45/25J Part No. 107846

5 Move the function enable/rpm select toggle 5 Loosen the low idle lock nut and turn the low idle
switch to the high idle (rabbit symbol) position at adjustment screw clockwise to increase the
the ground controls and check the rpm. Refer to rpm, or counterclockwise to decrease the rpm.
Section 2, Specifications. Tighten the low idle lock nut and confirm the
rpm.
If high idle rpm is correct, disregard adjustment
step 6.
6 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Be sure the solenoid fully retracts
when activating high idle.
Perkins models:
This procedure will require two

people. a b c d
1 Open the engine side turntable cover. a solenoid boot

b high idle adjustment nut
2 Remove the safety pin from the engine pivot c yoke
plate latch. d low idle lock nut and adjustment
screw
located under the engine turntable 6 Move the function enable toggle switch to the
pivot plate at the counterweight high idle (rabbit symbol) position. Refer to
end of the machine. Section 2, Specifications.
3 Open the engine pivot plate latch and swing the If high idle rpm is correct, disregard adjustment
engine pivot plate out and away from the step 7.
machine.
4 Connect a tachometer to the engine. Start the
engine from the ground controls. Refer to
Section 2, Specifications.
Skip to step 6 if the low idle rpm is correct.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 21

7 Loosen the yoke lock nut, then turn the high idle B-10
adjustment nut and solenoid boot
counterclockwise to increase the rpm or Test the Ground Control
clockwise to decrease the rpm. Tighten the Override
yoke lock nut and recheck the rpm.
Be sure the solenoid fully retracts this procedure be performed every
when activating high idle. 250 hours or quarterly, whichever
8 Swing the engine back to its original position comes first.
and close the engine pivot plate latch. A properly functioning ground control override is
9 Install the engine pivot plate safety pin. 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 red Emergency Stop
button on the platform controls is in the on or off
position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop button

to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
3 - 22 Z-45/25 • Z-45/25J Part No. 107846

B-11 B-12
Check the Oscillate Directional Test the Platform Self-leveling
Valve Linkage

Genie specifications require that this procedure be performed every
this procedure be performed every 250 hours or quarterly, whichever
250 hours or quarterly, whichever comes first.
comes first. Automatic platform self-leveling throughout
Perform this test only on models the full cycle of boom raising and lowering is
equipped with an oscillating axle. essential for safe machine operation. The
platform is maintained at level by the platform
Proper axle oscillation is essential to safe machine leveling slave cylinder which operates in a closed
operation. If the oscillate directional valve linkage is loop hydraulic circuit with the master cylinder
not operating correctly, the stability of the machine located at the base of the boom.
is compromised and it may tip over. A platform self-leveling failure creates an unsafe
working condition for platform and ground
1 Remove the drive chassis cover and the axle personnel.
covers from the non-steer end of the drive
chassis. 1 Start the engine from the ground controls and
lower the boom into the stowed position.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for 2 Hold the function enable toggle switch to either
the following: side and adjust the platform to a level position
using the platform level toggle switch.
· Lock nut is tight against yoke
· Yoke clevis pins are installed 3 Raise and lower the primary boom through
a full cycle.
· Cotter pins are installed through clevis pins
Result: The platform should remain level at
· Linkage is properly attached to
all times to within ±5 degrees.
directional valve
Part No. 107846 Z-45/25 • Z-45/25J 3 - 23

B-13 5 Move the engine idle control switch to foot

switch activated high idle (rabbit and foot switch
Test the Engine Idle Select symbol).
Genie specifications require that Result: The engine should not change to
this procedure be performed every high idle.
comes first. 6 Press down the foot switch.
A properly operating engine idle select switch Result: The engine should change to high idle.
is essential to good engine performance and safe 7 Move the engine idle control switch to foot
machine operation. There are two settings. switch activated low idle (turtle symbol).
Foot switch activated low idle (turtle symbol) Result: The engine should change to low idle.
allows the operator to control individual boom
functions. Drive functions will operate at low idle,
but at reduced performance.
Foot switch activated high idle (rabbit symbol)
should be used for normal machine operation. This
selection activates high idle only when the foot
switch is pressed down.
1 Pull out the red Emergency Stop button to the

on position at both the ground and platform
controls.
2 Start the engine from the ground controls then
move the function enable toggle switch to the
high idle (rabbit symbol) position and hold in the
on position.
Result: The engine should change to high idle.
3 Release the function enable toggle switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
3 - 24 Z-45/25 • Z-45/25J Part No. 107846

B-14 4 Release the foot switch and shut the engine off
by pushing in the red Emergency Stop button in
Test the Fuel Select Operation - to the off position.
Ford Models 5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at
low idle.
Genie specifications require that 7 Press down the foot switch to allow the engine
this procedure be performed every to run at high idle.
comes first. Result: The engine should start promptly and
operate smoothly in low and high idle.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to The engine may hesitate
safe machine operation. A fuel selection can be momentarily and then continue
made when the engine is running or not. to run on the selected fuel if the
Switching malfunctions and/or the failure of the fuel source is switched while
engine to start and run properly in both fuel the engine is running.
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
Perform this test after checking

the gasoline and LPG fuel levels,
and warming the engine to normal
operating temperature.
1 At the platform controls, move the fuel select
switch to gasoline and then move the engine
idle control switch to foot switch activated high
idle (rabbit and foot switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 25

B-15 B-16
Test the Drive Brakes Test the Drive Speed -
Stowed Position

comes first.
Proper brake action is essential to safe machine comes first.
operation. The drive brake function should operate
Proper drive function movement is essential to safe
smoothly, free of hesitation, jerking and unusual
machine operation. The drive function should
noise. Hydrostatic brakes and hydraulically-
respond quickly and smoothly to operator control.
released individual wheel brakes can appear to
Drive performance should also be free of hesitation,
operate normally when they are actually not fully
jerking and unusual noise over the entire
operational.
proportionally controlled speed range.
Collision hazard. Be sure that the
Select a test area that is firm, level
machine is not in free-wheel or
and free of obstructions.
partial free-wheel configuration.
See B-7, Confirm the Proper Brake 1 Create start and finish lines by marking two lines
Configuration. on the ground 40 feet / 12.2 m apart.
Select a test area that is firm, level 2 Start the engine from the platform controls.
3 Move the engine idle control switch to
1 Mark a test line on the ground for reference. foot switch activated high idle (rabbit and foot
switch symbol), then lower the boom into the
2 Start the engine from the platform controls.
stowed position.
3 Move the engine idle control switch to
4 Choose a point on the machine; i.e., contact
foot switch activated high idle (rabbit and
patch of a tire, as a visual reference for use
foot switch symbol), then lower the boom into
when crossing the start and finish lines.
the stowed position.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
when crossing the test line.
start line.
6 Continue at full speed and note the time when
reaching the test line. Release the drive joystick
the machine reference point crosses the finish
when your reference point on the machine
line. Refer to Section 2, Specifications.
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
The brakes must be able to hold
the machine on any slope it is able
to climb.
3 - 26 Z-45/25 • Z-45/25J Part No. 107846

B-17 7 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line. Refer to Section 2, Specifications.
Raised or Extended Position 8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
250 hours or quarterly, whichever 10 Bring the machine to top drive speed before
comes first. reaching the start line. Begin timing when your
Proper drive function movement is essential to safe
start line.
machine operation. The drive function should
respond quickly and smoothly to operator control. 11 Continue at top speed and note the time when
Drive performance should also be free of hesitation, the machine reference point crosses the finish
jerking and unusual noise over the entire line. Refer to Section 2, Specifications.
proportionally controlled speed range.
Select a test area that is firm, level
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 select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
4 Press down the foot switch and raise the
primary boom above horizontal.
reaching the start line. Begin timing when your
start line.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 27

B-18 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
(if equipped) then release it.
Genie specifications require that Result: The descent alarm should sound when
this procedure be performed every the switch is held down.
250 hours or quarterly, whichever 4 Z-45/25J: Move the function enable toggle
comes first. switch to either side and activate the jib boom
The alarm package includes: toggle switch in the down position, hold for a
moment and then release it.
· Travel alarm
Result: The descent alarm should sound when
· Descent alarm
the switch is held down.
· Flashing beacon
5 Turn the key switch to platform control.
Alarms and a beacon are installed to alert operators
and ground personnel of machine proximity and Result: The flashing beacon should be on
motion. The alarm package is installed on the and flashing.
turntable covers. 6 Press down the foot switch. Move the primary
The alarms and beacon will boom control handle to the down position, hold
operate with the engine for a moment and then release it.
running or not running. Result: The descent alarm should sound when
1 Turn the key switch to ground control and pull the control handle is held down.
out the red Emergency Stop button to the on 7 Press down the foot switch. Move the
position at both the ground and platform secondary boom control handle to the down
controls. position, hold for a moment and then release it.
Result: The flashing beacon should be on and Result: The descent alarm should sound when
flashing. the control handle is held down.
2 Move the function enable switch to either side 8 Z-45/25J: Press down the foot switch. Activate
and activate the primary boom toggle switch in the jib boom toggle switch in the down position,
the down position, hold for a moment and then hold for a moment and then release it.
release it.
Result: The descent alarm should sound when
Result: The descent alarm should sound when the switch is held down.
the switch is held down.
9 Press down the foot switch. Move the drive
control handle off center, hold for a moment and
then release it. Move the drive control handle off
center in the opposite direction, hold for a
moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in either
direction.
3 - 28 Z-45/25 • Z-45/25J Part No. 107846

B-19 B-20
Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic
Tank Cap Venting Systems

Genie requires that this procedure
be performed every 250 hours or
comes first.
quarterly, whichever comes first.
Replacement or testing of the hydraulic oil is Perform this procedure more often
essential for good machine performance and if dusty conditions exist.
service life. Dirty oil and a clogged suction strainer
Free-breathing fuel and hydraulic tank caps are
may cause the machine to perform poorly and
essential for good machine performance and
continued use may cause component damage.
service life. A dirty or clogged tank cap may cause
Extremely dirty conditions may require oil changes
the machine to perform poorly and continued use
to be performed more often. For hydraulic oil
may cause component damage. Extremely dirty
specifications, refer to Section 2, Specifications.
conditions may require that the caps be inspected
Before replacing the hydraulic oil, more often.
the oil may be tested by an oil
distributor for specific levels of Explosion and fire hazard. Engine
contamination to verify that fuels are combustible. Perform this
changing the oil is necessary. If procedure in an open, well-
the hydraulic oil is not replaced ventilated area away from heaters,
at the two year inspection, test sparks, flames and lighted
the oil quarterly. Replace the oil tobacco. Always have an approved
when it fails the test. fire extinguisher within easy reach.
See E-1, Test or Replace the Perform this procedure with the
Hydraulic Oil. engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank
cap venting, air should pass freely
through the cap.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 29

3 Using a mild solvent, carefully wash the cap B-21

venting system. Dry using low pressure
compressed air. Repeat this procedure Replace the Fuel Filter Element -
beginning with step 2. Perkins Models
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank. Engine specifications require that
6 Check for proper venting. this procedure be performed every
Result: Air passes through the fuel tank cap. comes first.
Proceed to step 8.
Replacing the diesel fuel filter element is essential
Result: If air does not pass through the cap, for good engine performance and service life. A
clean or replace the cap. Proceed to step 7. dirty or clogged filter may cause the engine to
When checking for positive tank perform poorly and continued use may cause
cap venting, air should pass freely component damage. Extremely dirty conditions
through the cap. may required that the filter be replaced more often.
7 Using a mild solvent, carefully wash the cap Explosion and fire hazard. Engine
venting system. Dry using low pressure fuels are combustible. Perform this
compressed air. Repeat this procedure procedure in an open, well-
beginning with step 6. ventilated area away from heaters,
8 Install the breather cap onto the hydraulic tank. tobacco. Always have an approved
engine off.
plate latch.
end of the machine.
machine.
3 - 30 Z-45/25 • Z-45/25J Part No. 107846

3 Thoroughly clean the outside surfaces of the Prime the fuel system:
fuel filter assembly.
10 Loosen the vent plug on top of the fuel injection
4 Place a suitable container under the fuel filter pump.
element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
a
c b
a
a vent plug
b fuel injection pump
c fuel lift pump
a fuel line
b filter head
11 Operate the priming lever or priming bulb (if
c fuel filter element equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
6 Remove the fuel filter element with a filter vent plug.
wrench.
12 Clean up any fuel that may have spilled during
7 Apply a thin layer of fuel to the new fuel filter this procedure.
element O-ring.
13 Operate the starter motor for intervals of 15
8 Install the new fuel filter element and tighten it seconds until the engine starts.
securely by hand. Clean up any fuel that may
have spilled during the installation procedure. It is important to allow the starter
motor to cool for 30 seconds
9 Use a permanent ink marker to write the date between each 15 second interval
and number of hours from the hour meter on the of operation.
fuel filter housing.
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.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 31

B-22 B-23
Perform Engine Maintenance - Replace the Engine Air Filter
Perkins Models Element - Ford Models
Engine specifications require that Engine specifications require that

250 hours. 400 hours.
Proper engine maintenance, following the engine Maintaining the engine air filter in good condition is
manufacturer's maintenance schedule, is essential essential to good engine performance and service
to good engine performance and service life. Failure life. Failure to perform this procedure can lead to
to perform the maintenance procedures can lead to poor engine performance and component damage.
Required maintenance procedures and additional engine off.
1 Locate the engine air filter assembly.
(Perkins part number TPD 1443S). 2 Release the latches from the air cleaner canister
end cap. Remove the end cap.
Perkins 400 Series Operation Manual 3 Remove and discard the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Install the new filter element.
6 Install the air filter canister end cap and secure
the end cap latches.
Be sure the discharge valve is
instaled.
3 - 32 Z-45/25 • Z-45/25J Part No. 107846

B-24
Perform Engine Maintenance -
Ford Models

400 hours.



Part No. 107846 Z-45/25 • Z-45/25J 3 - 33

Checklist C Procedures REV D
C-1 C-2
Perform Engine Maintenance - Grease the Platform Overload
Deutz Models Mechanism (if equipped)
Deutz engine specifications require Genie specifications require

that this procedure be performed that this procedure be performed
every 500 hours. every 500 hours or 6 months,
Proper engine maintenance, following the engine whichever comes first. Perform
manufacturer's maintenance schedule, is essential this procedure more often if dusty
to good engine performance and service life. Failure conditions exist.
to perform the maintenance procedures can lead to Application of lubrication to the platform overload
poor engine performance and component damage. mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
(Deutz part number 0297-9929).
1 Locate the grease fittings on each pivot pin of
Deutz FL 2011 Operation Manual the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.

Grease Specification
plate latch. Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
end of the machine.
machine.
3 - 34 Z-45/25 • Z-45/25J Part No. 107846

REV D CHECKLIST C PROCEDURES
C-3 The platform support subassembly utilizes two load

support arms that are opposed in a full
Test the Platform Overload parallelogram link. This isolates platform loads into
System (if equipped) a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
supports this purely compressive load regardless of
where the load is placed in the platform.
Genie specifications require that As weight is added to the platform, the spring will
this procedure be performed every compress until, when the platform is overloaded,
500 hours or six months, the lower arm contacts a limit switch and thereby
whichever comes first. activating the overload signal. When adjusted
correctly, the platform overload system will
Testing the platform overload system regularly is
deactivate normal boom operation at platform
essential to safe machine operation. Continued use
capacity.
of an improperly operating platform overload
system could result in the system not sensing an Perform this procedure with the
overloaded platform condition. Machine stablity machine on a firm, level surface.
could be compromised resulting in the machine
tipping over. 1 Turn the key switch to platform control. Start the
engine and level the platform.
The platform overload system is designed to detect
an overloaded platform and prevent machine 2 Determine the maximum platform capacity.
operation anytime the machine is turned on. When Refer to the machine serial plate.
activated, the system halts all normal boom 3 Remove all weight, tools and accessories from
operation, giving visual and audible warning to the the platform.
operator.
Failure to remove all weight, tools
Models equipped with the platform overload option and accessories from the platform
are provided with additional machine components: will result in an inaccurate test.
an adjustable spring-loaded platform support
subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
power, and an audio/visual warning indication to
alert the operator of the overload.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 35

CHECKLIST C PROCEDURES REV D
4 Using a suitable lifting device, place a test 6 Using a suitable lifting device, place an
weight equal to that of the available capacity additional 50 lbs / 23 kg of weight onto the
one of the locations shown. platform.
Refer to Illustration 1.
Result: The alarm should sound.
Result: The platform overload indicator lights The platform overload indicator lights should be
should be off at both the ground and platform flashing at both the ground and platform
controls and the alarm should not sound. controls.
Result: The platform overload indicator lights are Result: The alarm does not sound and the
on and the alarm is sounding. Calibrate the platform overload indicator lights are not
platform overload system. Refer to Repair flashing. Calibrate the platform overload
Proceedure 2-3, How to Calibrate the Platform system. Refer to Repair Proceedure 2-3,
Overload System (if equipped). How to Calibrate the Platform Overload System
(if equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1. There may be a 2 second delay
before the overload indicator lights
Result: The platform overload indicator lights
flash and the alarm sounds.
should be off at both the ground and platform
controls and the alarm should not sound. 7 Carefully move the test weights to each
remaining location on the platform.
Result: The platform overload indicator lights are
Refer to Illustration 1.
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm should sound.
Proceedure 2-3, How to Calibrate the Platform The platform overload indicator lights should be
Overload System (if equipped). flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload
System (if equipped).
There may be a 2 second delay
flash and the alarm sounds.
Illustration 1
3 - 36 Z-45/25 • Z-45/25J Part No. 107846

8 Test all machine functions from the platform 15 Turn the key switch to platform control.
controls.
16 Test all machine functions from the platform
Result: All platform control functions should not controls.
operate.
Result: All platform control functions should
9 Turn the key switch to ground control. operate.
10 Test all machine functions from the ground If the platform overload system is
controls. not operating properly, Refer
to Repair Procedure 2-3, How to
Result: All ground control functions should not
Calibrate the Platform Overload
operate.
System (if equipped).
11 Activate the auxiliary power toggle switch.
17 Using a suitable lifting device, remove the
The engine will turn off when the remaining test weights from the platform.
auxiliary power is activated.
12 Using auxiliary power, test all machine functions
from the ground controls.
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
There may be an 2 second delay
and alarm turn off.
14 Start the engine and test all machine functions
from the ground controls.
Result: All ground control functions should
operate normally.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 37

C-4 4 Open the engine pivot plate latch and swing the
Replace the Fuel Filter/Water machine.
Separator - Perkins Models 5 Locate the fuel filter/water separator mounted to
the rear engine mounting bracket.
6 Disconnect and plug the fuel supply hose from
Genie specifications require that the fuel tank to the fuel filter/water separator.
this procedure be performed every 7 Loosen the vent plug located on the fuel filter/
500 hours or six months, water separator head.
whichever comes first.
Regular replacement of the fuel filter/water
a
separator is essential for good engine performance.
Failure to perform this procedure can lead to poor f
engine performance and/or hard starting, and
continued use may result in component damge. e b
Extremely dirty conditions may require this
procedure be performed more often. d
Explosion and fire hazard. Engine c

fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
tobacco. Always have an approved a vent plug
b main fuel line
c drain plug
Perform this procedure with the d filter bowl
e filter element
engine off. f separator head
1 Put on protective clothing and eye wear. 8 Place a suitable container under the filter bowl.
2 Open the engine side turntable cover. Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel.
plate latch. 9 Rotate the filter bowl counterclockwise and
remove it from the element.
end of the machine.
3 - 38 Z-45/25 • Z-45/25J Part No. 107846

10 Rotate the filter element counterclockwise and 17 Operate the priming lever or priming bulb (if
remove it from the filter head. equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
11 Install the bowl onto the new filter element.
vent plug.
12 Apply a thin layer of oil onto the element gasket.
18 Clean up any fuel that may have spilled during
Install the filter/bowl assembly onto the filter
this procedure.
head. Tighten the drain plug and vent plug.
19 Operate the starter motor for intervals of 15
Component damage hazard. The
seconds until the engine starts.
drain plug and vent plug can be
damaged if they are overtightened. It is important to allow the starter
motor to cool for 30 seconds
13 Clean up any diesel fuel that may have spilled
between each 15 second interval
during the installation procedure.
of operation.
14 Install the fuel supply hose from the fuel tank to
If the engine runs correctly for a
the fuel filter/water separator. Tighten the
short time and then stops or runs
clamp.
roughly, check for air in the fuel
15 Use a permanent ink marker to write the date system. If there is air in the fuel
and number of hours from the hour meter on the system, there is probably a leak in
filter element housing. the low pressure side of the
system.
Prime the fuel system:
16 Loosen the vent plug on top of the fuel injection and close the engine pivot plate latch.
pump.
c b
a vent plug
b fuel injection pump
c fuel lift pump
Part No. 107846 Z-45/25 • Z-45/25J 3 - 39

C-5 C-6
Replace the Engine Air Filter Perform Engine Maintenance -
Element - Deutz and Perkins Perkins Models
Models

Genie specifications require that this procedure be performed every
this procedure be performed every 600 hours.
500 hours or six months, Proper engine maintenance, following the engine
whichever comes first. manufacturer's maintenance schedule, is essential
Maintaining the engine air filter in good condition is to good engine performance and service life. Failure
essential to good engine performance and service to perform the maintenance procedures can lead to
life. Failure to perform this procedure can lead to poor engine performance and component damage.
poor engine performance and component damage. Required maintenance procedures and additional
Perform this procedure with the engine information are available in the
engine off. Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S).
1 Locate the engine air filter assembly.
2 Release the latches from the air cleaner canister Perkins 400 Series Operation Manual
end cap. Remove the end cap. Genie part number 94890
3 Remove and discard the filter element.

4 Clean the inside of the canister and the end cap To access the engine:
with a damp cloth.
5 Install the new filter element. plate latch.
6 Install the air filter canister end cap and secure The engine pivot plate latch is
the end cap latches. located under the engine turntable
Be sure the discharge valve is end of the machine.
instaled. 2 Open the engine pivot plate latch and swing the
machine.
3 - 40 Z-45/25 • Z-45/25J Part No. 107846

C-7
Ford Models

800 hours.




plate latch.
end of the machine.
machine.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 41

Checklist D Procedures REV D
D-1 D-2
Check the Boom Wear Pads Check the Turntable Rotation
Bearing Bolts

this procedure be performed every Genie specifications require that
1000 hours or annually, whichever this procedure be performed every
comes first. 1000 hours or annually, whichever
Maintaining the boom wear pads in good condition comes first.
is essential to safe machine operation. Wear pads Maintaining proper torque on the turntable bearing
are placed on boom tube surfaces to provide a low bolts is essential to safe machine operation.
friction, replaceable wear pad between moving Improper bolt torque could result in an unsafe
parts. Improperly shimmed wear pads or continued operating condition and component damage.
use of worn wear pads may result in component
damage and unsafe operating conditions. 1 Raise the secondary boom and place a safety
chock on the lift cylinder rods. Carefully lower
1 Measure each wear pad. Replace the wear pad the boom onto the lift cylinder safety chock.
once it reaches the minimum allowable
thickness. If the wear pad is still within Crushing hazard. Keep hands
specification, shim as necessary to obtain away from the cylinder and all
minimum clearance with zero binding. moving parts when lowering the
boom.
2 Extend and retract the primary boom through the
entire range of motion to check for tight spots The lift cylinder safety chock is
that may cause binding or scraping of the boom. available through the Genie
Service Parts Department.
Always maintain squareness
between the outer and inner 2 Turn the engine off.
boom tubes.
plate latch.
Primary boom wear
pad specifications Minimum The engine pivot plate latch is
Top, bottom and side wear pads 5 /8
inch pivot plate at the counterweight
(platform end of boom) 15.9 mm end of the machine.
Side and bottom wear pads 1/2 inch

(pivot end of boom) 12.7 mm
Top wear pads 5 /8

inch
(pivot end of boom) 15.9 mm
3 - 42 Z-45/25 • Z-45/25J Part No. 107846

REV D CHECKLIST D PROCEDURES

engine pivot plate out and away from the Counterweight
machine. 18 6 13
3 10
5 Remove the center turntable cover retaining 11 1
fasteners. Remove the center turntable cover
from the machine. 8 15
6 Be sure that each turntable mounting bolt is

torqued in sequence to specification. Refer to 16 7
Section 2, Specifications. 2 12
9 4
14 5 17
Bolt torque sequence


8 Raise the secondary boom and remove the
safety chocks.
9 Lower the boom to the stowed position.
10 Remove drive chassis covers from both the
steer end and the non-steer end of the machine.
(before serial number 23332) 11 Remove the lower chassis cover mounting
fasteners from inside of the drive chassis (if
10 1 15 equipped).
13 19
6 12 Remove the lower chassis cover to access the
7
lower turntable bearing bolts under the drive
18 12 chassis.
3 4
11 17
8 5
20 14
16 2 9
(from serial number 23332 to 27000)
Part No. 107846 Z-45/25 • Z-45/25J 3 - 43

CHECKLIST D PROCEDURES REV D
13 Check to ensure that each lower bearing D-3

mounting bolt under the drive chassis is torqued
in sequence to specification. Refer to Section 2, Inspect for Turntable Bearing
Specifications. Wear

1000 hours or annually, whichever
comes first.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
Bolt torque sequence operating condition, resulting in death or serious
(before serial number 23332) injury and component damage.
10 1 Perform this procedure with the

15
13 machine on a firm, level surface
7
and the boom in the stowed
6 4 position.
11 12 1 Grease the turntable bearing. See A-10, Grease

the Turntable Bearing and Rotate Gear.
3 5
2 Torque the turntable bearing bolts to
8 14 specification. See D-2, Check the Turntable
16 2 9 Rotation Bearing Bolts.
Bolt torque sequence 3 Start the machine from the ground controls and
(after serial number 23331) raise the primary and secondary booms to full
height. Do not extend the primary boom.
3 - 44 Z-45/25 • Z-45/25J Part No. 107846

4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator.
and the turntable at a point that is directly
Result: The measurement is less than
under, or inline with, the boom and no more than
0.055 inch / 1.4 mm. The bearing is good.
1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
To obtain an accurate
0.055 inch / 1.4 mm. The bearing is worn and
measurement, place the dial
needs to be replaced.
indicator no more than 1 inch /
2.5 cm from the turntable rotation 8 Fully retract the primary boom. Raise the
bearing. primary and secondary booms to full height.
Visually inspect the the dial indicator to be sure
the needle returns to the "zero" position.
a 9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
b bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the primary and secondary booms to the
c stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
d
a turntable
b dial indicator
c drive chassis
d turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the

indicator.
6 Lower the secondary boom to the stowed
position and lower the primary boom to a
horizontal position. Fully extend the primary
boom.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 45

D-4 D-5
Replace the Drive Hub Oil Check the Free-wheel
Configuration

this procedure be performed every Genie specifications require that
1000 hours or annually, whichever this procedure be performed every
comes first. 1000 hours or annually, whichever
Replacing the drive hub oil is essential for good comes first.
machine performance and service life. Failure to Proper use of the free-wheel configuration is
replace the drive hub oil at yearly intervals may essential to safe machine operation. The
cause the machine to perform poorly and continued free-wheel configuration is used primarily for towing.
use may cause component damage. A machine configured to free-wheel without operator
1 Select the drive hub to be serviced. Then drive knowledge may cause death or serious injury and
the machine until one of the two plugs is at the property damage.
lowest point. Collision hazard. Select a work site
2 Remove both plugs and drain the oil. that is firm and level.
3 Drive the machine until one plug is at the top Component damage hazard. If the
and the other is at 90 degrees. machine must be towed, do not
exceed 2 mph / 3.2 km/h.
a 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.
a drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
6 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
3 - 46 Z-45/25 • Z-45/25J Part No. 107846

4 Disengage the drive hubs by turning over the 10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each drive hub disconnect caps on each
non-steer wheel hub. steer wheel hub.
disengaged position disengaged position
engaged position engaged position
5 Manually rotate each non-steer wheel. 11 Manually rotate each steer wheel.
Result: Each non-steer wheel should rotate with Result: Each steer wheel should rotate with
minimum effort. minimum effort.
6 Re-engage the drive hubs by turning over 12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine, check for engagement. Raise the machine,
remove the jack stands and lower the machine. remove the jack stands and lower the machine.
Collision hazard. Failure to Collision hazard. Failure to
re-engage the drive hubs could re-engage the drive hubs could
result in death or serious injury and result in death or serious injury and
property damage. property damage.
Steer wheels: 4WD models
7 Chock the non-steer wheels to prevent the

machine from rolling.
8 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the steer tires.
9 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 47

D-6 5 Install the new filter element into the filter

housing.
Replace the Hydraulic Filters
6 Push the filter element down to be sure the
O-ring on the element is fully seated into the
housing.
Genie requires that this procedure 7 Rotate the filter element clockwise to lock it in
be performed yearly or every 1000 place.
hours, whichever comes first.
8 Install the filter housing cap.
Perform this procedure more often
if dusty conditions exist. 9 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
Replacement of the hydraulic filters is essential for
oil filter housing.
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform Medium and high pressure filters
poorly and continued use may cause component
damage. Extremely dirty conditions may require The medium pressure filter is for
that the filters be replaced more often. the charge pump and the high
pressure filter is for all machine
Bodily injury hazard. Beware of hot functions except the drive circuit
oil. Contact with hot oil may cause and oscillating axle circuit.
severe burns.
10 Open the engine side turntable cover and locate
Perform this procedure with the the medium and high pressure filters.
engine off.
The medium pressure filter is
Hydraulic return filter mounted near the pump. The high
pressure filter, with filter condition
1 Open the ground controls side turntable cover indicator, is mounted to the
and locate the hydraulic return filter housing on bulkhead.
top of the hydraulic tank.
11 Place a suitable container under each filter.
2 Remove the cap from the filter housing.
12 Remove the filter housings by using a wrench on
3 Lift the handle on the filter element and rotate
the nut provided on the bottom of the housings.
the element counterclockwise to release the
element from the housing. 13 Remove the filter elements from the housings.
4 Remove the filter element from the filter 14 Inspect the housing seals and replace them if
housing. necessary.
3 - 48 Z-45/25 • Z-45/25J Part No. 107846

15 Install the new filter elements into the housings D-7

and tighten them securely.
The medium and high pressure
filters use the same elements.
Deutz Models
16 Clean up any oil that may have spilled during the
installation procedure.
17 Use a permanent ink marker to write the date Engine specifications require that
and number of hours from the hour meter on the this procedure be performed every
oil filter housings. 1000 hours.
18 Start the engine from the ground controls. Proper engine maintenance, following the engine
19 Inspect the filter housings and related to good engine performance and service life. Failure
components to be sure that there are no leaks. to perform the maintenance procedures can lead to



plate latch.
end of the machine.
machine.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 49

Checklist E Procedures REV D
E-1 1 Ford models: Turn the valve on the LPG tank

clockwise to the off position (if equipped). Then
Test or Replace the Hydraulic Oil slowly disconnect the hose from the LPG tank.
2 Ford models: Open the clamps from the LPG
tank straps and remove the LPG tank from the
machine (if equipped).
Genie requires that this procedure
be performed every 2000 hours or 3 Models with hydraulic tank shut-off valves:
every two years, whichever comes Locate the two hydraulic tank valves at the
first. Perform this procedure more hydraulic tank through the access hole
often if dusty conditions exist. underneath the turntable. Close the valves.
Replacement or testing of the hydraulic oil is Component damage hazard. The

essential for good machine performance and engine must not be started with the
service life. Dirty oil and suction strainers may hydraulic tank shut-off valves in
cause the machine to perform poorly and continued the closed position or component
use may cause component damage. Extremely damage will occur. If the tank
dirty conditions may require oil changes to be valves are closed, remove the key
performed more often. from the key switch and tag the
machine to inform personnel of the
Before replacing the hydraulic oil, condition.
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test.
open closed
When removing a hose assembly
or fitting, the O-ring (if equipped)
4 Remove the drain plug from the hydraulic tank
on the fitting and/or the hose end
and completely drain the tank into a container of
must be replaced. All connections
suitable capacity. Refer to Section 2,
must be torqued to specification
Specifications.
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
boom in the stowed position.
3 - 50 Z-45/25 • Z-45/25J Part No. 107846

REV D CHECKLIST E PROCEDURES
5 Tag, disconnect and plug the two suction hoses 16 Install the hydraulic return filter housing onto the
and supply hose for the auxiliary pump from the hydraulic tank.
hydraulic tank. Cap the fittings on the tank.
17 Install the hydraulic tank onto the machine.
The hoses can be accessed
18 Install the two suction hoses to the suction
through the access hole under the
strainers.
turntable.
19 Install the supply hose for the auxiliary power
6 Disconnect and plug the return filter hydraulic
unit and the return filter hose.
hose at the return filter. Cap the fitting on the
filter housing. 20 Models with hydraulic tank shut-off valves:
Open the two hydraulic tank valves at the
7 Remove the ground controls side turntable
hydraulic tank.
cover.
21 Fill the tank with the proper hydraulic oil for your
8 Support the hydraulic tank with an appropriate
machine until the level is within the top
lifting device.
2 inches / 5 cm of the sight gauge. Do not
9 Remove the hydraulic tank mounting fasteners. overfill. Refer to Section 2, Specifications.
10 Remove the hydraulic tank from the machine. 22 Clean up any oil that may have spilled.
Crushing hazard. The hydraulic 23 Prime the pump. Refer to Repair Procedure 7-2,
tank could become unbalanced How to Prime the Pump.
and fall if not properly supported
Always use pipe thread sealant
when removed from the machine.
when installing the suction hose
11 Remove the hydraulic return filter housing fittings and the drain plug.
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
12 Remove the suction strainers from the tank and
clean them using a mild solvent.
13 Rinse out the inside of the tank using a mild
solvent.
14 Install the suction strainers using a thread
sealant on the threads.
15 Install the drain plug using a thread sealant on
the threads.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 51

CHECKLIST E PROCEDURES REV D
E-2 6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
Grease the Steer Axle
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to
Wheel Bearings, 2WD Models seat the bearings.
8 Loosen the castle nut and re-tighten to
8 ft-lbs / 11 Nm.
Genie requires that this procedure 9 Check for wheel bearing wear by attempting to
be performed every 2000 hours or move the wheel hub side to side, then up and
every two years, whichever comes down.
first. Perform this procedure more
Result: If there is no side to side or up and
often if dusty conditions exist.
down movement, continue with step 11 and
Maintaining the steer axle wheel bearings is grease the wheel bearings.
essential for safe machine operation and service
life. Operating the machine with loose or worn Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings may cause an unsafe operating
wheel bearings with new ones.
condition and continued use may result in
component damage. Extremely wet or dirty When replacing a wheel bearing,
conditions or regular steam cleaning and pressure both the inner and outer bearings,
washing of the machine may require that this including the pressed-in races,
procedure be performed more often. must be replaced.
1 Loosen the wheel lug nuts. Do not remove them. 10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
2 Block the non-steer wheels, then center a lifting
jack under the steer axle. 11 Remove the castle nut.
3 Raise the machine 6 inches / 15 cm and place 12 Pull the hub off of the spindle. The washer and
blocks under the drive chassis for support. outer bearing should fall loose from the hub.
4 Remove the lug nuts. Remove the tire and wheel 13 Place the hub on a flat surface and gently pry
assembly. the bearing seal out of the hub. Remove the rear
bearing.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and 14 Pack both bearings with clean, fresh grease.
down.
15 Place the large inner bearing into the rear of the
Result: There should be no side to side or up hub.
and down movement.
Skip to step 10 if there is no movement.
3 - 52 Z-45/25 • Z-45/25J Part No. 107846

REV D CHECKLIST E PROCEDURES
16 Install a new bearing grease seal into the hub by E-3

pressing it evenly into the hub until it is flush.
17 Slide the hub onto the yoke spindle.
Deutz Models
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur. Engine specifications require that
18 Place the outer bearing into the hub. this procedure be performed every
3000 hours.
19 Install the washer and castle nut.
20 Tighten the slotted nut to 35 ft-lbs / 47 Nm to manufacturer's maintenance schedule, is essential
seat the bearings. to good engine performance and service life. Failure
21 Loosen the castle nut and re-tighten to to perform the maintenance procedures can lead to
8 ft-lbs / 11 Nm. poor engine performance and component damage.
22 Install a new cotter pin. Bend the cotter pin Required maintenance procedures and additional
to lock it in. engine information are available in the
Always use a new cotter pin when (Deutz part number 0297-9929).
installing a castle nut.
23 Install the dust cap, then the tire and wheel Deutz FL 2011 Operation Manual
assembly. Torque the wheel lug nuts to Genie part number 84794
specification. Refer to Section 2, Specifications.

plate latch.
end of the machine.
machine.
Part No. 107846 Z-45/25 • Z-45/25J 3 - 53

CHECKLIST E PROCEDURES REV D
E-4
Deutz Models

12,000 hours.



plate latch.
end of the machine.
machine.
3 - 54 Z-45/25 • Z-45/25J Part No. 107846

August 2006 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
Repair procedures shall be completed by a
perform the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
injury hazards. Obey all safety
Repair any machine damage or malfunction
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
Read, understand and obey the safety rules and
operating instructions in the appropriate death or serious injury.
Operator's Manual on your machine.
Be sure that all necessary tools and parts are potentially hazardous situation
available and ready for use. which, if not avoided, could result
Read each procedure completely and adhere in death or serious injury.
to the instructions. Attempting shortcuts may With safety alert symbol—used to
produce hazardous conditions. indicate the presence of a
potentially hazardous situation
Unless otherwise specified, perform each
which, if not avoided, may cause
repair procedure with the machine in the
minor or moderate injury.
following configuration:
Machine parked on a firm, level surface Without safety alert symbol—used
to indicate the presence of a
Boom in stowed position potentially hazardous situation
Turntable rotated with the boom between which, if not avoided, may result in
the non-steer wheels property damage.
Turntable secured with the turntable Used to indicate operation or
rotation lock 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
Indicates that an incorrect result has occurred
All external AC power disconnected after performing a series of steps.
from the machine
Part No. 107846 Z-45/25 • Z-45/25J 4-1

Section 4 • Repair Procedures August 2006
Platform Controls REV B
The platform control box contains one printed 1-1

circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that When the ALC-500 circuit board is
particular machine function will operate. See 1-2, replaced, the joystick controllers
How to Calibrate a Joystick. will need to be calibrated. See 1-2,
Each joystick controller should operate smoothly How to Calibrate a Joystick.
and provide proportional speed control over its
entire range of motion.
How to Remove the ALC-500
Circuit Board
a
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to the
inside of the platform control box.
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
d c b
a ALC-500 circuit board

b drive/steer joystick controller
c secondary boom up/down
joystick controller
d primary boom up/down and
turntable rotate left/right
joystick controller
4-2 Z-45/25 • Z-45/25J Part No. 107846

REV B PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 1-2

screw inside the platform control box.
Joysticks
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
How to Calibrate a Joystick
components. Maintain firm contact The joysticks on this machine utilize digital Hall
with a metal part of the machine Effect technology for proportional control. If a
that is grounded at all times when joystick is disconnected or replaced, it must be
handling printed circuit boards OR calibrated before that particular machine function
use a grounded wrist strap. will operate.
5 Carefully disconnect the wire connectors from The joystick must be calibrated
the circuit board. before the threshold, max-out or
6 Remove the ALC-500 circuit board mounting ramp rate can be set.
fasteners. Perform this procedure with the
7 Carefully remove the ALC-500 circuit board from engine off.
the platform control box. 1 Open the platform control box.
on position at both the ground and platform
controls.
3 Turn the key switch to platform control. Do not
start the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from the
joystick for approximately 10 seconds or until
the alarm sounds. Connect the wire harness
connector to the joystick.
6 Move the joystick full stroke in either direction
and hold for 5 seconds.
7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds and
return the joystick to the neutral position.
Result: The alarm should sound indicating
successful joystick calibration.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
No machine fuction should operate
while performing the joystick
calibration procedure.
Part No. 107846 Z-45/25 • Z-45/25J 4-3

PLATFORM CONTROLS REV B
How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Max-out Setting
9 Start a timer and activate the machine function
The max-out setting of a joystick controls the that needs to be adjusted. Record the time it
maximum speed of a joystick-controlled machine takes for that function to complete a full cycle
function. Whenever a hydraulic cylinder, drive (ie; boom up).
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum 10 Compare the machine function time with the
performance. The max-out settings on the joystick function times listed in Section 2,
can be changed to compensate for hydraulic pump Specifications. Determine whether the function
wear to maintain peak performance from the time needs to increase or decrease.
machine. 11 While the joystick is activated, adjust the max-
Perform this procedure with the out setting to achieve the proper function cycle
boom in the stowed position. time. Momentarily move the drive enable toggle
switch in the right direction to increase the
1 Pull out the red Emergency Stop button to the function speed or momentarily move the drive
on position at both the ground and platform enable toggle switch in the left direction to
controls. decrease the function speed.
2 Turn the key switch to platform control. Do not Each time the drive enable toggle
start the engine. switch is momentarily moved, the
function speed will change in 2%
3 Push in the platform controls red Emergency
increments.
Stop button to the off position.
12 Repeat steps 9 through 11 for each joystick
4 Do not press down the foot switch.
controlled machine function.
5 Move and hold the drive enable toggle switch in
13 Return the joystick to the neutral position and
the right position and pull out the red
wait for approximately 10 seconds to allow the
Emergency Stop button to the on position.
settings to be saved.
6 When the alarm sounds, release the drive
Result: The alarm should sound indicating that
enable toggle switch.
the settings have been saved in memory.
7 Momentarily activate the drive enable toggle
Do not operate any machine
switch in the right direction 4 times.
function during the 10 second
Result: There should be a pause and the alarm waiting time.
should sound 4 times indicating that the
machine is in max-out calibration mode.
4-4 Z-45/25 • Z-45/25J Part No. 107846

REV B PLATFORM CONTROLS
How to Adjust the Joystick 10 Compare the function ramp rate time with the
table below and determine whether the ramp
Ramp Rate Setting rate time needs to increase or decrease.
The ramp rate setting of a joystick controls the time 11 While the joystick is activated, set the ramp
at which it takes for the joystick to reach maximum rate. Momentarily move the drive enable toggle
output, when moved out of the neutral position. The switch in the right direction to increase the time
ramp rate settings of a joystick can be changed to or momentarily move the drive enable toggle
compensate for hydraulic pump wear to maintain switch in the left direction to decrease the time.
peak performance from the machine.
Each time the drive enable toggle
Perform this procedure with the switch is momentarily moved, the
boom in the stowed position. time will change in 10%
increments.
on position at both the ground and platform 12 Repeat steps 9 through 11 for each joystick
controls. controlled machine function.
2 Turn the key switch to platform control. Do not 13 Return the joystick to the neutral position and
start the engine. wait for approximately 10 seconds to allow the
Stop button to the off position. Result: The alarm should sound indicating that
waiting time.
6 When the alarm sounds, release the drive Ramp rate (factory settings)
Primary boom up/down
7 Momentarily activate the drive enable toggle accelerate 4 seconds
switch in the right direction 6 times. decelerate 0.5 second
Result: There should be a pause and the alarm Secondary boom up/down
should sound 6 times indicating that the accelerate 2 seconds
machine is in ramp rate calibration mode. decelerate 0.5 second
8 Start the engine from the platform controls and Turntable rotate
press down the foot switch. accelerate 2 seconds
decelerate 0.5 second
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how Drive
long it takes the function to reach maximum accelerate 3.3 seconds
speed. This is the ramp rate. accelerate (narrow models) 3.8 seconds
decelerate to neutral 0.5 second
decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
decelerate, braking 1 second
decelerate, shift from low to high speed 1 second
decelerate, shift from high to low speed 2 seconds
Part No. 107846 Z-45/25 • Z-45/25J 4-5

PLATFORM CONTROLS REV B
How to Adjust the Joystick 10 Slowly move the joystick off center in either
direction just until the function begins to move.
Threshold Setting
11 Slowly move the joystick back to the neutral
The threshold setting of a joystick is the minimum position. Just before the function stops moving,
output at which a function proportional valve can move the drive enable toggle switch to either
open and allow the function to operate. side to set the threshold.
Perform this procedure with the Result: The alarm should sound indicating a
boom in the stowed position. successful calibration.
1 Pull out the red Emergency Stop button to the 12 Repeat steps 9 through 11 for each boom
on position at both the ground and platform joystick controlled machine function (boom up/
controls. down, boom extend/retract and turntable rotate).
2 Turn the key switch to platform control. Do not 13 Return the joystick to the neutral position and
start the engine. wait for approximately 10 seconds to allow the
Stop button to the off position. Result: The alarm should sound indicating that
waiting time.
6 When the alarm sounds, release the drive
7 Momentarily activate the drive enable toggle
switch in the right direction 8 times.
Result: There should be a pause and the alarm
should sound 8 times indicating that the
machine is in threshold calibration mode.
8 Start the engine from the platform controls and
press down the foot switch.
9 Select a boom function joystick to set the
threshold.
4-6 Z-45/25 • Z-45/25J Part No. 107846

REV C
Platform Components
2-1 3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
Platform Leveling Slave Cylinder platform.
The slave cylinder and the rotator pivot are the Do not rest the entire weight of the
two primary supports for the platform. The slave boom on the blocks.
cylinder keeps the platform level through the 4 Tag, disconnect and plug the hydraulic hoses
entire range of boom motion. It operates in a from the slave cylinder at the unions and
closed-circuit hydraulic loop with the master connect them together using a connector.
cylinder. The slave cylinder is equipped with Connect the hoses from the cylinder together
counterbalance valves to prevent movement in using a connector.
the event of a hydraulic line failure.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Leveling Slave Cylinder connections very slowly to allow
Before cylinder removal is the oil pressure to dissipate
considered, bleed the slave gradually. Do not allow oil to
cylinder to be sure there is no squirt or spray.
air in the closed loop. 5 Remove the pin retaining fastener from the slave
When removing a hose assembly cylinder rod-end pivot pin. Do not remove the
or fitting, the O-ring (if equipped) pin.
on the fitting and/or the hose end 6 Z-45/25J: Remove the external snap rings from
must be replaced. All connections the slave cylinder barrel-end pivot pin. Do not
must be torqued to specification remove the pin.
Section 2, Hydraulic Hose and Z-45/25: Remove the pin retaining fastener from
Fitting Torque Specifications.. the slave cylinder barrel-end pivot pin. Do not
remove the pin.
1 Z-45/25J: Extend the primary boom until the
slave cylinder barrel-end pivot pin is accessible. 7 Place a block under the slave cylinder for
support. Protect the cylinder rod from damage.
2 Raise the primary boom slightly and place
blocks under the platform for support.
Part No. 107846 Z-45/25 • Z-45/25J 4-7

PLATFORM COMPONENTS REV C
8 Z-45/25: Support the platform rotator with a 2-2

suitable lifting device.
Platform Rotator
9 Use a soft metal drift to drive the rod-end pivot
pin out.
How to Bleed the Platform
Crushing hazard. The platform Rotator
could fall when the slave cylinder
rod-end pivot pin is removed if not This procedure will require two
properly supported. people. Do not start the engine.
Use auxiliary power for this
procedure.
slave cylinder rod may become
damaged if it is allowed to fall if 1 Move the function enable toggle switch to either
not properly supported by the lifting side and activate the platform rotate toggle
device. switch to the right then the left through two
platform rotation cycles, then hold the switch to
10 Use a soft metal drift and drive the barrel-end
the right position until the platform is fully
pin out.
rotated to the right.
11 Carefully pull the cylinder out of the primary
Before serial number 24304:
boom.
2 Connect a clear hose to the top bleed valve.
How to Bleed the Slave Cylinder Place the other end of the hose in a container to
1 Simultaneously activate the boom up function collect any drainage. Secure the container to
and the platform level up function until the boom the boom.
is fully raised. 3 Open the top bleed valve on the rotator, but do
2 Simultaneously activate the boom down function not remove it.
a
and the platform level down function until the
boom is fully lowered.
d c b
a top bleed valve

b bottom bleed valve
c container
d clear hose
4-8 Z-45/25 • Z-45/25J Part No. 107846

REV C PLATFORM COMPONENTS
4 Move the function enable toggle switch to either 4 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch side and hold the platform rotate toggle switch
to the left position until the platform is fully to the left position until the platform is fully
rotated to the left. Continue holding the toggle rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed switch until air stops coming out of the bleed
valve. Close the bleed valve. screw. Close the bleed screw.
Crushing hazard. Keep clear of the Crushing hazard. Keep clear of the
platform during rotation. platform during rotation.
5 Connect the clear hose to the bottom bleed 5 Open the bottom bleed screw on the rotator, but
valve and open the valve. Do not remove the do not remove it.
bleed valve.
6 Move the function enable toggle switch to either hydraulic oil can penetrate and
side and hold the platform rotate toggle switch burn skin. Loosen hydraulic
to the right position until the platform is fully connections very slowly to allow
rotated to the right. Continue holding the toggle the oil pressure to dissipate
switch until air stops coming out of the bleed gradually. Do not allow oil to
valve. Close the bleed valve. squirt or spray.
Crushing hazard. Keep clear of the 6 Move the function enable toggle switch to either
platform during rotation. side and hold the platform rotate toggle switch
to the right position until the platform is fully
7 Remove the hose from the bleed valve and
rotated to the right. Continue holding the toggle
clean up any hydraulic oil that may have spilled.
switch until air stops coming out of the bleed
8 Rotate the platform fully in both directions and screw. Close the bleed screw.
inspect the bleed valves for leaks.
Crushing hazard. Keep clear of the
After serial number 24303: platform during rotation.
2 Place a suitable container underneath the 7 Clean up any hydraulic oil that may have spilled.
platform rotator. 8 Rotate the platform fully in both directions and
3 Open the top bleed screw on the rotator, but do inspect the bleed screws for leaks.
not remove it.
hydraulic oil can penetrate and
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 107846 Z-45/25 • Z-45/25J 4-9

PLATFORM COMPONENTS REV C
2-3 5 Move the platform up and down by hand, so it

bounces approximately 2.5 to 5 cm / 1 to 2
Platform Overload System inches. Allow the platform to settle.
Result: The overload indicator lights are off and
How to Calibrate the Platform the alarm does not sound. Proceed to step 6.
Overload System
Result: The overload indicator lights are flashing
Calibration of the platform overload system is at the platform and ground controls, and the
essential to safe machine operation. Continued use alarm is sounding. Slowly tighten the load spring
of an improperly calibrated platform overload adjustment nut in a clockwise direction in 10°
system could result in the system failing to sense increments until the overload indicator light
an overloaded platform. The stability of the turns off, and the alarm does not sound.
machine is compromised and it could tip over. Proceed to step 8.
Perform this procedure with the The platform will need to be moved
machine on a firm, level surface. up and down and allowed to settle
between each adjustment.
1 Turn the key switch to platform control. Start the
engine and level the platform. There may be a 2 second delay
before the platform overload
2 Determine the maximum platform capacity. indicator light and alarm responds.
Refer to the machine serial plate.
6 Move the platform up and down by hand, so it
3 Remove all weight, tools and accessories from bounces approximately 2.5 to 5 cm / 1 to 2
the platform. inches. Allow the platform to settle.
Failure to remove all weight, tools Result: The overload indicator lights are off at
and accessories from the platform the platform and ground controls, and the alarm
will result in an incorrect does not sound. Slowly loosen the load spring
calibration. adjustment nut in a counterclockwise direction
4 Using a suitable lifting device, place a test in 10° increments until the overload indicator
weight equal to the maximum platform capacity light flashes at both the platform and ground
at the center of the platform floor. controls, and the alarm sounds.
Proceed to step 7.
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.
The platform will need to be moved
up and down and allowed to settle
between each adjustment.
indicator lights and alarm
responds.
4 - 10 Z-45/25 • Z-45/25J Part No. 107846

REV C PLATFORM COMPONENTS
7 Move the platform up and down by hand, so it 10 Turn the key switch to ground control.
bounces approximately 2.5 to 5 cm / 1 to 2
11 Test all machine functions from the ground
inches. Allow the platform to settle.
controls.
Result: The overload indicator lights are off and
Result: All ground control functions should not
the alarm does not sound. Proceed to step 8.
operate.
12 Using a suitable lifting device, lift the test weight
at the platform and ground controls, and the
off the platform floor.
alarm is sounding. Repeat this procedure
beginning with step 5. Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
indicator light and alarm responds. There may be a 2 second delay
8 Add an additional 10 lb / 4.5 kg test weight to
and alarm turn off.
the platform.
13 Test all machine functions from the ground
Result: The overload indicator light is flashing at
controls.
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9. Result: All ground control functions should
operate normally.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm 14 Turn the key switch to platform control.
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure 15 Test all machine functions from the platform
beginning with step 6. controls.
There may be a 2 second delay Result: All platform control functions should
before the platform overload operate normally.
indicator light and alarm responds.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 11

Jib Boom Components, Z-45/25J REV B
3-1 5 Attach a lifting strap from an overhead crane to

the platform rotator for support.
Jib Boom
6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
How to Remove the Jib Boom remove the pin.
Perform this procedure with the 7 Remove the pin retaining fasteners from both
boom in the stowed position. platform rotator pivot pins. Do not remove the
When removing a hose assembly pins.
or fitting, the O-ring (if equipped) 8 Use a soft metal drift to remove the leveling arm
on the fitting and/or the hose end pivot pin and let the leveling arms hang down.
must be torqued to specification 9 Use a soft metal drift to remove the platform
during installation. Refer to rotator pivot pin and remove the platform rotator
Section 2, Hydraulic Hose and from the machine.
10 Slide both of the jib boom leveling arms off of
1 Remove the platform. the jib boom cylinder rod-end pivot pin.
2 Disconnect the electrical connector from the jib 11 Remove the hose and cable cover from the side
boom/platform rotate select valve manifold of the jib boom. Remove the hose and cable
mounted to the platform support. separators.
3 Tag, disconnect and plug all of the hydraulic 12 Attach a lifting strap from an overhead crane to
hoses from the jib boom/platform rotate select the jib boom.
valve manifold. Cap the fittings on the manifold
13 Support the barrel end of the jib boom lift
and pull the hoses out through the platform
cylinder with a suitable lifting device.
rotator.
14 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to burn skin. Loosen hydraulic
squirt or spray. connections very slowly to allow
4 Remove the platform mounting weldment.
squirt or spray.
4 - 12 Z-45/25 • Z-45/25J Part No. 107846

REV B JIB BOOM COMPONENTS, Z-45/25J
15 Remove the pin retaining fastener from the jib 3-2

boom lift cylinder barrel-end pivot pin.
Jib Boom Lift Cylinder
16 Use a soft metal drift to remove the pin and let
the cylinder hang down.
How to Remove the Jib Boom
Crushing hazard. The jib boom Lift Cylinder
could fall when when the barrel-end
pivot pin is removed if not properly Perform this procedure with the
supported by the overhead crane. boom in the stowed position.
17 Remove the pin retaining fastener from the jib When removing a hose assembly
boom pivot pin. Use a soft metal drift to remove or fitting, the O-ring (if equipped)
the pin, then remove the jib boom from the on the fitting and/or the hose end
bellcrank. must be replaced. All connections
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane. 1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
18 Attach a lifting strap from an overhead crane to
lower the jib boom until the platform is resting
the lug on the rod end of the jib boom lift
on the blocks just enough to support the
cylinder.
platform.
19 Use a soft metal drift to remove the jib boom lift
Do not rest the entire weight of the
cylinder rod-end pivot pin, then remove the jib
boom on the blocks.
boom lift cylinder from the bellcrank.
2 Tag, disconnect and plug the jib boom lift
Crushing hazard. The jib boom lift
cylinder could become unbalanced
cylinder.
and fall when removed from the
machine if not properly attached to Bodily injury hazard. Spraying
the overhead crane. hydraulic oil can penetrate and
squirt or spray.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 13

JIB BOOM COMPONENTS, Z-45/25J REV B
3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a suitable
lifting device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
Crushing hazard. The jib boom
could fall when the barrel-end pivot
pin is removed if not properly
supported by the overhead crane.
7 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the jib boom lift
cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
4 - 14 Z-45/25 • Z-45/25J Part No. 107846

REV B
Primary Boom Components
4-1 5 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located above the
Cable Track primary boom lift cylinder. Cap the fittings on
the unions.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
Z-45/25 from the "V1" and "V2" ports on the
counterbalance valve manifold located on the
When removing a hose assembly platform rotator. Cap the fittings on the
or fitting, the O-ring (if equipped) manifold.
must be replaced. All connections Bodily injury hazard. Spraying
must be torqued to specification hydraulic oil can penetrate and
during installation. Refer to burn skin. Loosen hydraulic
Section 2, Hydraulic Hose and connections very slowly to allow
Fitting Torque Specifications. the oil pressure to dissipate
1 Locate the cables from the primary boom cable squirt or spray.
track to the platform control box. Number each
cable and its entry location at the platform 7 Tag, disconnect and plug the hydraulic hoses
control box. from the platform leveling master cylinder. Cap
the fittings on the cylinder.
2 Disconnect the cables from the platform control
box. Bodily injury hazard. Spraying
3 Pull all of the electrical cables out of the plastic burn skin. Loosen hydraulic
cable track. Do not pull out the hydraulic hoses. connections very slowly to allow
4 Raise the primary boom to a horizontal position. the oil pressure to dissipate
squirt or spray.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 15

PRIMARY BOOM COMPONENTS REV B
8 Tag and disconnect the hydraulic hoses from 15 Remove the cable track from the machine and
the platform leveling slave cylinder and connect place it on a structure capable of supporting it.
them together using a connector. Cap the
Crushing hazard. The cable track
fittings on the cylinder.
Bodily injury hazard. Spraying if not properly attached to the
hydraulic oil can penetrate and overhead crane.
Cables and hoses can be damaged
if they are kinked or pinched.
squirt or spray. How to Remove the Cable Track,
9 Pull the four hydraulic hoses toward the platform Z-45/25J
to clear the rod end of the primary boom lift
cylinder. When removing a hose assembly
10 Place blocks in between the upper and lower on the fitting and/or the hose end
cable tracks and secure the upper and lower must be replaced. All connections
tracks together. must be torqued to specification
Crushing hazard. If the upper and during installation. Refer to
lower cable tracks are not properly Section 2, Hydraulic Hose and
secured together, the cable track Fitting Torque Specifications.
could become unbalanced and fall 1 Locate the cables from the primary boom cable
when removed from the machine. track to the platform control box. Number each
11 Remove all hose and cable clamps from the cable and its entry location at the platform
underside of the primary boom. control box.
12 Attach a strap from an overhead crane to the 2 Disconnect the cables from the platform control
cable track. box.
13 Remove the mounting fasteners from the upper 3 Remove the hose and cable cover from the side
cable track at the platform end of the extension of the jib boom. Remove the hose and cable
boom. separators.
14 Remove the cable track mounting fasteners that 4 Remove the hose clamp on the primary boom
attach the lower cable track to the primary bellcrank.
boom. 5 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
4 - 16 Z-45/25 • Z-45/25J Part No. 107846

REV B PRIMARY BOOM COMPONENTS
6 Tag, disconnect and plug the hydraulic hoses 9 Tag, disconnect and plug the platform rotator
from the "V1" and "V2" ports on the hydraulic hoses at the union located above the
counterbalance valve manifold located on the primary boom lift cylinder. Cap the fittings on
platform rotator. Cap the fittings on the the unions.
manifold.
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.
10 Tag, disconnect and plug the hydraulic hoses
7 Tag and disconnect the hydraulic hoses from from the platform leveling master cylinder. Cap
the platform leveling slave cylinder at the union the fittings on the cylinder.
and connect them together using a connector.
Connect the hoses from the cylinder together
using a connector.
Bodily injury hazard. Spraying connections very slowly to allow
hydraulic oil can penetrate and the oil pressure to dissipate
burn skin. Loosen hydraulic gradually. Do not allow oil to
connections very slowly to allow squirt or spray.
11 Raise the boom to a horizontal position.
squirt or spray. 12 Place blocks between the upper and lower cable
tracks and secure the upper and lower tracks
8 Tag, disconnect and plug the hydraulic hoses
together.
from the jib boom/platform rotate manifold. Cap
the fittings on the manifold. Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
when removed from the machine.
the oil pressure to dissipate 13 Attach a lifting strap from an overhead 5 ton /
gradually. Do not allow oil to 5,000 kg capacity crane to the platform end of
squirt or spray. the primary boom for support. Do not lift it.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 17

14 Remove all hose and cable clamps from the 25 Remove the cable track from the machine and
underside of the primary boom. place it on a structure capable of supporting it.
15 Support the rod end of the primary boom lift Crushing hazard. The cable track
cylinder with a suitable lifting device. could become unbalanced and fall
if not properly attached to the
16 Remove the pin retaining fasteners from the
overhead crane.
primary boom lift cylinder rod-end pivot pin. Do
not remove the pin. Component damage hazard.
Cables and hoses can be damaged
17 Raise the primary boom slightly with the
if they are kinked or pinched.
overhead crane to relieve the pressure on the
primary boom lift cylinder rod-end pivot pin. How to Repair the Primary Boom
18 Use a soft metal drift to remove the primary Cable Track
boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary primary boom cable track can be
boom lift cylinder could become damaged if it is twisted.
unbalanced and fall if not properly
supported by the lifting device. A 7 link repair section of cable
track is available through
19 Lower the rod end of the primary boom lift the Genie Industries Service Parts
cylinder approximately 12 inches / 30 cm. Department.
20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
primary boom lift cylinder.
21 Raise the rod end of the primary boom lift
cylinder back into position and install the rod- a
end pivot pin. Install the pin retaining fasteners.
22 Attach a strap from an overhead crane to the b
cable track.
23 Remove the mounting fasteners from the upper a link separation point
cable track at the platform end of the extension b lower clip
boom.
1 Use a slotted screwdriver to pry down on the
24 Remove the cable track mounting fasteners that lower clip.
attach the lower cable track to the primary
2 To remove a single link, open the lower clip
boom.
and then use a screw driver to pry the link to the
side.
3 Repeat steps 1 and 2 for each link.
4 - 18 Z-45/25 • Z-45/25J Part No. 107846

4-2 4 Raise the primary boom to a horizontal position.

Primary Boom 5 Remove the hose and cable cover from the
upper pivot.
How to Remove the Primary 6 Remove the pin retaining fastener from the
Boom master cylinder barrel-end pivot pin. Use a soft
metal drift to remove the pin. Then lower the
Bodily injury hazard. This cylinder and let it hang down.
procedure requires specific repair
skills, lifting equipment and a
When lowering the master cylinder
suitable workshop. Attempting this
down, be sure not to damage the
procedure without these skills and
master cylinder hoses or fittings.
tools could result in death or
serious injury and significant 7 Locate the primary boom drive speed limit
component damage. Dealer switch inside of the upper pivot.
service is strongly recommended.
8 Remove the primary boom drive speed limit
Perform this procedure with the switch mounting fasteners. Do not disconnect
boom in the stowed position. the wiring.
When removing a hose assembly 9 Locate the primary extension boom drive speed
or fitting, the O-ring (if equipped) limit switch inside of the extension boom.
must be replaced. All connections 10 Remove the primary extension boom drive
must be torqued to specification speed limit switch mounting fasteners. Do not
during installation. Refer to disconnect the wiring.
Section 2, Hydraulic Hose and 11 Pull the limit switch and the wiring out of the
Fitting Torque Specifications. extension tube and move it out of the way.
1 Remove the platform. 12 Tag, disconnect and plug the primary boom
2 Z-45/25: Remove the platform rotator and extension cylinder hydraulic hoses. Cap the
platform mounting weldment. fittings on the cylinder.
Z-45/25J: Remove the jib boom. Bodily injury hazard. Spraying

See 3-1, How to Remove the Jib Boom. hydraulic oil can penetrate and
3 Remove the cable track. See 4-1, How to connections very slowly to allow
Remove the Cable Track. the oil pressure to dissipate
squirt or spray.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 19

13 Remove the hose clamp at the pivot end of the How to Disassemble the Primary
boom.
Boom
14 Attach a 5 ton / 5,000 kg overhead crane to the
center point of the primary boom. Complete disassembly of the
boom is only necessary
15 Attach a similar lifting device to the primary if the outer or inner boom tube
boom lift cylinder. must be replaced. The extension
16 Place support blocks under the primary boom lift cylinder can be removed without
cylinder. completely disassembling the
boom. See 4-4, How to Remove
17 Remove the pin retaining fasteners from the the Primary Boom Extension
primary boom lift cylinder rod-end pivot pin. Use Cylinder.
a soft metal drift to remove the pin.
1 Remove the primary boom. See How to Remove
Crushing hazard. The boom lift the Primary Boom.
cylinder and primary boom will fall
if not properly supported. 2 Place blocks under the barrel end of the primary
boom extension cylinder for support.
18 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the 3 Remove the pin retaining fastener from the
cylinder rod from damage. extension cylinder barrel-end pivot pin at the
pivot end of the primary boom. Use a soft metal
19 Remove the pin retaining fasteners from the drift to remove the pin.
primary boom pivot pin.
4 Remove and label the location of the wear pads
20 Remove the primary boom pivot pin with a soft from the platform end of the primary boom.
metal drift, then carefully remove the primary
boom from the machine and place it on a Pay careful attention to the
structure capable of supporting it. location and amount of shims used
with each wear pad.
Crushing hazard. The primary
boom could become unbalanced 5 Support and slide the extension tube and
and fall when removed from the extension cylinder assembly out of the boom
machine if not properly attached to tube.
the overhead crane. Crushing hazard. The primary
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
4 - 20 Z-45/25 • Z-45/25J Part No. 107846

6 Remove the external snap rings from the 4-3

extension cylinder rod-end pivot pin at the
platform end of the extension tube. Use a soft Primary Boom Lift Cylinder
metal drift to remove the pin.
The primary boom lift cylinder raises and lowers the
7 Support and slide the extension cylinder out of primary boom. The primary boom lift cylinder is
the base end of the extension tube. Place the equipped with a counterbalance valve to prevent
extension cylinder on blocks for support. movement in the event of a hydraulic line failure.
Crushing hazard. The extension
cylinder could become unbalanced How to Remove the Primary
and fall when removed from Boom Lift Cylinder
primary boom extension tube if not
properly supported. Bodily injury hazard. This
During removal, the overhead skills, lifting equipment and a
crane strap will need to be suitable workshop. Attempting this
carefully adjusted for proper procedure without these skills and
balancing. tools could result in death or
serious injury and significant
component damage. Dealer
1 Raise the primary boom to a horizontal position.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above
the turntable covers.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 21

4 Raise the primary boom with the overhead crane 10 Remove the primary boom lift cylinder barrel-end
slightly to take the pressure off the primary pivot pin retaining fasteners. Do not remove the
boom lift cylinder pivot pins. pin.
5 Support the rod end and the barrel end of the 11 Use a slide hammer to remove the barrel-end
primary boom lift cylinder with a second pivot pin. Carefully remove the primary boom lift
overhead crane or similar lifting device. cylinder from the machine.
6 Tag, disconnect and plug the primary boom lift Crushing hazard. The lift cylinder
cylinder hydraulic hoses. Cap the fittings on the could become unbalanced and fall
cylinder. if not properly supported and
secured to the lifting device.
squirt or spray.
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
boom will fall if not properly
supported when the primary boom
rod-end pivot pin is removed.
8 Place a support block across both turntable
covers under the primary boom lift cylinder.
9 Lower the rod end of the lift cylinder onto the
block. Protect the cylinder rod from damage.
boom lift cylinder could fall if not
properly supported.
4 - 22 Z-45/25 • Z-45/25J Part No. 107846

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

extension cylinder hydraulic hoses. Cap the
Primary Boom Extension fittings on the cylinder.
Cylinder Bodily injury hazard. Spraying
The primary boom extension cylinder extends and burn skin. Loosen hydraulic
retracts the primary boom extension tube.The connections very slowly to allow
primary boom extension cylinder is equipped with the oil pressure to dissipate
counterbalance valves to prevent movement in the gradually. Do not allow oil to
event of a hydraulic line failure. squirt or spray.
How to Remove the Primary 5 At the platform end of the boom, remove the
external snap rings from the extension cylinder
Boom Extension Cylinder rod-end pivot pin. Use a soft metal drift to
Bodily injury hazard. This remove the pin.
6 Remove the barrel-end pivot pin retaining
skills, lifting equipment and a
fasteners.
suitable workshop. Attempting this
procedure without these skills and 7 Place a rod through the barrel-end pivot pin and
tools could result in death or twist to remove the pin.
serious injury and significant
8 Support and slide the extension cylinder out of
the upper pivot.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
must be torqued to specification Component damage hazard. Be
during installation. Refer to careful not to damage the
Section 2, Hydraulic Hose and counterbalance valves on the
Fitting Torque Specifications. primary boom extension cylinder
when removing the cylinder from
1 Raise the primary boom to a horizontal position.
the primary boom.
2 Extend the primary boom until the primary boom
Component damage hazard. Hoses
extension cylinder rod-end pivot pin is
and cables can be damaged if the
accessible in the primary boom extension tube.
primary boom extension cylinder is
3 Remove the hose and cable guard from the dragged across them.
upper pivot.
Note the length of the cylinder after
removal. The cylinder must be at
the same length for installation.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 23

4-5 4 Remove the pin retaining fasteners from the

master cylinder barrel-end pivot pin.
Platform Leveling
5 Place a rod through the barrel-end pivot pin and
Master Cylinder twist to remove the pin.
The master cylinder acts as a pump for the slave 6 Remove the pin retaining fastener from the rod-
cylinder. It’s part of the closed circuit hydraulic loop end pivot pin.
that keeps the platform level through the entire
7 Place a rod through the rod-end pivot pin and
range of boom motion. The master cylinder is
twist to remove the pin.
located at the base of the primary boom.
8 Remove the master cylinder from the machine.
How to Remove the Platform
Crushing hazard. The master
Leveling Master Cylinder cylinder could become unbalanced
and fall if not properly attached to
the overhead crane.
1 Raise the secondary boom until both the rod-end
and barrel-end pivot pins on the master cylinder
are accessible.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
3 Attach overhead crane or similar lifting device to
the master cylinder.
4 - 24 Z-45/25 • Z-45/25J Part No. 107846

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

Secondary Boom Components REV B
a b c
h d
f
Secondary Boom components
a upper secondary boom

(number 1 arm)
b upper tension link
(number 2 arm)
c lower tension link
(number 3 arm)
d mid-pivot
e compression link
f secondary boom lift cylinder (2)
g lower secondary boom
(number 4 arm)
h turntable pivot
i boom rest
j upper pivot
4 - 26 Z-45/25 • Z-45/25J Part No. 107846

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

to the lug on the rod end of the primary boom lift
Secondary Boom cylinder. Then raise the primary boom lift
cylinder with the crane, to a vertical position.
How to Disassemble the 6 Tag, disconnect and plug the hydraulic hoses at
Secondary Boom the primary boom lift cylinder. Cap the fittings
on the cylinder.
Bodily injury hazard. The
procedures in this section require Bodily injury hazard. Spraying
specific repair skills, lifting hydraulic oil can penetrate and
equipment and a suitable burn skin. Loosen hydraulic
workshop. Attempting this connections very slowly to allow
procedure without these skills and the oil pressure to dissipate
tools could result in death or gradually. Do not allow oil to squirt
serious injury and significant or spray.
7 Remove the pin retaining fastener from the
service is required.
primary boom lift cylinder barrel-end pivot pin.
Follow the disassembly steps to the point required
8 Use a slide hammer to remove the pin. Remove
to complete the repair. Then re-assemble the
the primary boom lift cylinder from the machine.
secondary boom by following the disassembly
steps in reverse order. Crushing hazard. The primary
boom lift cylinder could become
When removing a hose assembly unbalanced and fall if not properly
or fitting, the O-ring (if equipped) supported by the overhead crane.
must be replaced. All connections 9 Tag, disconnect and plug the hydraulic hoses
must be torqued to specification on both of the secondary boom lift cylinders.
during installation. Refer to Cap the fittings on the cylinders.
1 Remove the platform. burn skin. Loosen hydraulic
2 Z-45/25J: Remove the jib boom. the oil pressure to dissipate
See 3-1, How to Remove the Jib Boom. gradually. Do not allow oil to squirt
3 Remove the primary boom. See 3-2, How to or spray.
Remove the Primary Boom.
4 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 27

SECONDARY BOOM COMPONENTS REV B
10 Remove the pin retaining fasteners from both 17 Attach a lifting strap from a second overhead
sides of the secondary boom lift cylinder rod- crane to the number 1 arm at the mid-point
end pivot pin and barrel-end pivot pin. Do not between the upper pivot and mid-pivot.
remove the pins.
11 Attach a strap from an overhead crane to the lug number 1 arm pivot pins at the mid-pivot and
on the rod end of one of the secondary boom lift the upper pivot. Do not remove the pins.
cylinders for support. Do not apply any lifting
19 Use a soft metal drift to drive both pins out.
pressure.
20 Remove the number 1 arm from the machine.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of Crushing hazard. The number 1
the secondary boom lift cylinder and let it hang arm could become unbalanced and
down. fall when removed from the
machine if not properly attached to
the overhead crane.
pin half way out.
Crushing hazard. The upper pivot
14 Remove the secondary boom lift cylinder from
could fall when the number 1 arm
the machine.
is removed from the machine if not
15 Repeat steps 11 through 14 for the other properly supported by the overhead
secondary boom lift cylinder. crane.
Crushing hazard. The secondary 21 Using the overhead crane attached to the upper
boom lift cylinder could become pivot, raise the secondary boom assembly
unbalanced and fall when removed approximately 30 inches / 76 cm.
from the machine if not properly
22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
attached to the overhead crane.
between the number 2 arm and the boom rest.
Component damage hazard. When Then lower the secondary boom assembly onto
removing a secondary boom lift the block.
cylinder from the machine, be
Crushing hazard. The secondary
careful not to damage the
boom assembly could fall if not
counterbalance valve at the barrel
properly supported by the
end of the cylinder.
4 x 4 x 11 inch / 10 x 10 x
16 Attach a lifting strap from an overhead crane to 28 cm block.
the upper pivot for support. Do not lift it.
4 - 28 Z-45/25 • Z-45/25J Part No. 107846

23 Pull all of the cables and hoses out through the 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
upper pivot. block between the number 3 arm and the
number 4 arm at the mid-pivot end.
Cables and hoses can be 32 Attach a lifting strap from the overhead crane to
damaged if they are kinked or the mid-pivot for support. Do not lift it.
pinched.
24 Remove the hose and cable covers from the top number 2, 3 and 4 arm pivot pins at the
of the number 2 arm. mid-pivot. Do not remove the pins.
25 Pull all of the hoses and cables out of the upper 34 Use a soft metal drift to drive each pin out. Then
pivot and out through the mid-pivot. Lay the remove the mid-pivot from the secondary boom
hoses and cables on the ground. assembly.
Component damage hazard. Crushing hazard. The mid-pivot
Cables and hoses can be could become unbalanced and fall
damaged if they are kinked or when removed from the secondary
pinched. boom assembly if not properly
26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use a 35 Attach the lifting strap from an overhead crane
soft metal drift to remove the pin. to the center point of the number 2 arm for
support. Do not lift it.
27 Remove the upper pivot from the machine.
36 Remove the pin retaining fasteners from both
Crushing hazard. The upper pivot
compression link pivot pins. Do not remove the
pins.
when removed from the machine if
not properly attached to the 37 Use a soft metal drift to remove the lower
overhead crane. compression link pivot pin at the number 3 arm.
28 Attach the lifting strap from an overhead crane 38 Support the compression link with an appropriate
to the number 2 arm at the upper pivot end. lifting device.
29 Raise the number 2 arm slightly and remove the
4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest pad.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 29

39 Use a soft metal drift to remove the upper 43 Open the ground controls side turntable cover.
compression link pivot pin from the number 2
44 Remove the fuel tank filler cap.
arm. Remove the compression link from the
machine. 45 Using an approved hand-operated pump, drain
the fuel tank into a container of suitable
Crushing hazard. The number 2
capacity. Refer to Section 2, Specifications.
arm could fall when the
compression link is disconnected Explosion and fire hazard. Engine
from the number 2 arm if not fuels are combustible. Perform this
properly supported by the overhead procedure in an open, well-
crane. ventilated area away from heaters,
Crushing hazard. The compression
tobacco. Always have an approved
link may fall if not properly
supported when removed from the
secondary boom assembly. Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
Crushing hazard. The number 2 machine and pump or container.
arm could become unbalanced and
Be sure to only use a hand-
fall when removed from the
operated pump suitable for use
secondary boom assembly if not
with gasoline and diesel fuel.
properly supported by the overhead
crane. 46 Tag, disconnect and plug the fuel hoses from
the fuel tank. Clean up any fuel that may have
41 Remove the upper and lower hose and cable
spilled.
covers from the number 3 arm.
47 Remove the fuel tank mounting fasteners.
42 Pull all of the cables and hoses from the number
Carefully remove the fuel tank from the
3 arm and lay them over the turntable
machine.
counterweight.
fuel tank is plastic and may
Cables and hoses can be
become damaged if allowed to fall.
damaged if they are kinked or
pinched. Clean the fuel tank and inspect for
cracks and other damage before
installing it onto the machine.
4 - 30 Z-45/25 • Z-45/25J Part No. 107846

48 Remove the retaining fastener from the ground 57 Remove the pin retaining fasteners from the
control box and function manifold pivot plate. number 4 arm at the turntable riser. Do not
remove the pin.
49 Lower the ground control box and function
manifold pivot plate to access the number 3 arm 58 Attach a lifting strap from the overhead crane to
pivot pin. the center point of the number 4 arm. Do not
lift it.
50 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for 59 Use a slide hammer to remove the number 4
support. Do not lift it. arm from the turntable riser through the ground
controls side bulkhead.
51 Remove the mounting fasteners from the cover
located in the boom storage area to access the 60 Remove the number 4 arm from the machine.
number 3 and number 4 arm pivot pin retaining
fasteners at the turntable riser.
52 Remove the pin retaining fasteners from the fall when removed from the
number 3 arm at the turntable riser. Do not machine if not properly supported
remove the pin. by the overhead crane.
53 Use a slide hammer to remove the number 3
arm pivot pin from the turntable pivot through
the access hole behind the ground control box.
fall when removed from the
machine if not properly supported
by the overhead crane.
55 Remove the upper and lower hose and cable
covers from the number 3 arm.
56 Remove the secondary boom drive speed limit
switch mounting fasteners from the number 4
arm at the mid-pivot end. Do not disconnect the
wiring.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 31

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

on the secondary boom lift cylinder.
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders hydraulic oil can penetrate and
incorporated in the structure of the secondary boom burn skin. Loosen hydraulic
assembly. These cylinders operate in parallel and connections very slowly to allow
require hydraulic pressure to extend and retract. the oil pressure to dissipate
Each secondary boom lift cylinder is equipped with gradually. Do not allow oil to squirt
a counterbalance valve to prevent movement in the or spray.
event of a hydraulic line failure. 4 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin
How to Remove a Secondary and barrel-end pivot pin. Do not remove the
Boom Lift Cylinder pins.
Bodily injury hazard. This 5 Attach a strap from an overhead crane to the lug
procedure requires specific repair on the rod end of the secondary boom lift
skills, lifting equipment and a cylinder for support. Do not apply any lifting
suitable workshop. Attempting this pressure.
procedure without these skills and 6 Use a soft metal drift to drive the barrel-end
tools could result in death or pivot pin half way out. Lower the barrel end of
serious injury and significant the secondary boom lift cylinder and let it hang
component damage. Dealer down.
When removing a hose assembly pin half way out.
on the fitting and/or the hose end 8 Remove the secondary boom lift cylinder from
must be replaced. All connections the machine.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when removed
1 Lower the secondary boom to the stowed attached to the overhead crane.
position.
Component damage hazard. When
2 Raise the primary boom so that it is above the removing a secondary boom lift
secondary boom lift cylinder rod-end pivot pin. cylinder from the machine, be
careful not to damage the
counterbalance valve at the barrel
end of the cylinder.
4 - 32 Z-45/25 • Z-45/25J Part No. 107846

REV B
Engines
6-1 6-3
RPM Adjustment - Ford and Flex Plate
Deutz Models
The flex plate acts as a coupler between the engine
Refer to Maintenance Procedure B-9, Check and and the pump. It is bolted to the engine flywheel
Adjust the Engine RPM - All Models. and has a splined center to drive the pump.
How to Remove the Flex Plate

1 Disconnect the positive battery cable from the
6-2 battery.
RPM Adjustment - Perkins Electrocution hazard. Contact with
Models electrically charged circuits could
Refer to Maintenance Procedure B-9, Check and Remove all rings, watches and
Adjust the Engine RPM - All Models. other jewelry.
2 Disconnect the electrical connectors at the
electrical proportional controller, located on the
drive pump.
Ford LRG-425 EFI and Perkins models:
3 Remove the engine starter mounting fasteners.

Remove the starter from the engine. Do not
disconnect the wiring.
4 Support the drive pump with an appropriate
lifting device. Then remove all of the bell
housing to engine mounting bolts. Leave the
pump connected to the bell housing.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 33

ENGINES REV B
5 Carefully pull the pump and bell housing away 11 Remove the engine mounting plate to bell
from the engine and secure it from moving. housing fasteners.
Component damage hazard. Hoses 12 Raise the engine slightly using the overhead
can be damaged if they are kinked crane and place a block of wood under the oil
or pinched. pan for support.
6 Remove the flex plate mounting fasteners, 13 Remove all of the engine bell housing retaining
then remove the flex plate from the engine fasteners.
flywheel.
14 Carefully remove the bell housing from the
Ford DSG-423 EFI models: engine.
3 Support the drive pump assembly with an 15 Remove the flex plate mounting fasteners.
overhead crane or other suitable lifting device. Remove the flex plate from the flywheel.
Do not apply any lifting pressure.
4 Remove the drive pump retaining fasteners.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
6 Disconnect the electrical connector from the
oxygen sensor at the tailpipe. Do not remove
the oxygen sensor.
7 Support the muffler and bracket assembly with a
suitable lifting device.
8 Remove the exhaust pipe fasteners at the
muffler.
9 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the
muffler and bracket assembly from the engine.
10 Support the engine with an overhead crane or
other suitable lifting device. Do not lift it.
4 - 34 Z-45/25 • Z-45/25J Part No. 107846

REV B ENGINES
How to Install the Flex Plate 3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
1 Install the flex plate onto the engine flywheel appropriate gap between coupler and pump end
with the raised spline towards the pump. plate for your engine.
2 Ford models: Torque the flex plate mounting
a b c d e
bolts in sequence to 14 ft-lbs / 19 Nm.
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
Deutz models: Torque the flex plate mounting
bolts in sequence to 28 ft-lbs / 38 Nm.
Then torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm. f
Perkins models: Torque the flex plate mounting a pump
bolts in sequence to 49 ft-lbs / 66 Nm. b pump shaft
Then torque the flex plate mounting bolts in c pump coupler
sequence to 70 ft-lbs / 95 Nm. d flex plate with raised spline
e engine flywheel
f 3/16 inch / 4.8 mm gap - Diesel Models
1
1/16 inch / 1.5 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
6 3
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
4 5
2
Ford and Deutz models
2 3
Perkins models
Part No. 107846 Z-45/25 • Z-45/25J 4 - 35

ENGINES REV B
5 Install the pump and bell housing assembly. 6

1 B
Ford LRG-425 and Deutz models: Torque the B
3
bell housing mounting bolts labeled "C" in A
sequence to 28 ft-lbs / 38 Nm. Then torque the
bell housing mounting bolts labeled "C" in
sequence to 40 ft-lbs / 54 Nm. A
4
Ford DSG-423 models: Torque the bell housing
mounting bolts labeled "A" and "B" in sequence
C C
to 28 ft-lbs / 38 Nm and the mounting bolts
7 5
labeled "C" to 49 ft-lbs / 66 Nm. Then torque the B
bell housing mounting bolts labeled "A" and "B" 2

in sequence to 40 ft-lbs / 54 Nm and the Ford DSG-423 EFI models
mounting bolts labeled "C" to 70 ft-lbs / 95 Nm.
Perkins models: Torque the bell housing
6 1
mounting bolts labeled "B" in sequence to
28 ft-lbs / 38 Nm and the mounting bolts labeled 10 C C 8
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
C C
housing mounting bolts labeled "B" in sequence
to 40 ft-lbs / 54 Nm and the mounting bolts 4 3
labeled "A" to 70 ft-lbs / 95 Nm. C C
Component damage hazard. When

installing the pump, do not force C C
11 12
the pump coupler into the flexplate
or damage to the pump shaft seal C C
may occur.
7 C C 5
Component damage hazard. Do
not force the drive pump during 2 9
installation or the flex plate teeth Deutz models
may become damaged.
6 1
1 6 A A
C C
7 8
C C
9
C 4
3 C B
B
4 5
B
C
C C B B
9
5 2 8 B B 7
Ford LRG-425 EFI models 2 3

Perkins models
4 - 36 Z-45/25 • Z-45/25J Part No. 107846

REV B ENGINES
6-4
Engine Fault Codes -
Ford Models
How to Retrieve Engine 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.
Refer to Section 5, How to Retrieve Engine Fault

Codes for your specific model of engine. Use the
Fault Code Chart within Section 5 to aid in
identifying the fault.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 37

Hydraulic Pumps REV B
7-1 2 Tag, disconnect and plug the lift/steer pump

hydraulic hoses. Cap the fittings on the pump.
Lift/Steer Pump
How to Remove the burn skin. Loosen hydraulic
Lift/Steer Pump connections very slowly to allow
squirt or spray.
must be replaced. All connections 3 Remove the pump mounting bolts. Carefully
must be torqued to specification remove the pump.
Models without hydraulic tank shut-off valves:
Fitting Torque Specifications. Component damage hazard. Be
1 Models without hydraulic tank shut-off sure to fill the hydraulic tank to
valves: Remove the drain plug from the specification and prime the pump
hydraulic tank and completely drain the tank after installing the pump.
into a container of suitable capacity. Refer to Models with hydraulic tank shut-off valves:
Component damage hazard. Be
Models with hydraulic tank shut-off valves: sure to open the two hydraulic tank
Locate the two hydraulic tank valves at the valves and prime the pump after
hydraulic tank through the access hole installing the pump.
underneath the turntable. Close the valves.
engine must not be started with the
hydraulic tank shut-off valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open closed
4 - 38 Z-45/25 • Z-45/25J Part No. 107846

REV B HYDRAULIC PUMPS
7-2 2 Models without hydraulic tank shut-off

valves: Remove the drain plug from the
Drive Pump hydraulic tank and completely drain the tank
into a suitable container. See capacity
The drive pump is a bi-directional variable specifications.
displacement piston pump. The pump output is
controlled by the electro-proportional controller, Models with hydraulic tank shut-off valves:
located on the pump. The only adjustment that can Locate the two hydraulic tank valves at the
be made to the pump is the neutral or null hydraulic tank through the access hole
adjustment. Any internal service to the pump underneath the turntable. Close the valves.
should only be performed at an authorized Eaton Component damage hazard. The
Hydraulics center. Call Genie Industries Service engine must not be started with the
Department to locate your local authorized service hydraulic tank shut-off valves in
center. the closed position or component
damage will occur. If the tank
How to Remove the Drive Pump valves are closed, remove the key
Component damage hazard. The from the key switch and tag the
work area and surfaces where this machine to inform personnel of the
procedure will be performed must condition.
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
on the fitting and/or the hose end open closed
must be torqued to specification 3 Tag and disconnect and plug the hydraulic
during installation. Refer to hoses from the drive and lift/steer pumps. Cap
Section 2, Hydraulic Hose and the fittings on the pumps.
1 Disconnect the electrical connectors at the hydraulic oil can penetrate and
electrical proportional controller located on the burn skin. Loosen hydraulic
drive pump. connections very slowly to allow
squirt or spray.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 39

HYDRAULIC PUMPS REV B
4 Support the pump with a lifting device and How to Prime the Pump
remove the two drive pump mounting fasteners.
1 Connect a 0 to 600 psi / 0 to 41 bar pressure
5 Carefully pull the drive pump out until the pump gauge to the test port on the drive pump.
coupler separates from the flex plate.
2 Remove the safety pin (if equipped) from the
6 Remove the drive pump from the machine. engine pivot plate latch.
Component damage hazard. The The engine pivot plate latch is
hydraulic pump may become located under the engine turntable
unbalanced and fall if not properly pivot plate at the counterweight
supported. end of the machine.
Component damage hazard. When 3 Open the engine pivot plate latch and swing the
installing the pump, do not force engine pivot plate out and away from the
the pump coupler into the flexplate machine.
or damage to the pump shaft seal
may occur. 4 Ford models: Close the valve on the LPG tank
then disconnect the hose from the tank. Then
Models without hydraulic tank shut-off valves: move the fuel select switch to the LPG position.
Component damage hazard. Be Perkins models: Disconnect the engine wiring
sure to fill the hydraulic tank to harness from the fuel solenoid at the injector
specification and prime the pump pump.
after installing the pump.
Deutz models: Hold the manual fuel shutoff
Models with hydraulic tank shut-off valves: valve clockwise to the closed position.
Component damage hazard. Be
a
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
a manual fuel shutoff valve
4 - 40 Z-45/25 • Z-45/25J Part No. 107846

REV B HYDRAULIC PUMPS
5 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.
6 Ford models: Connect the LPG hose to the
LPG tank and open the valve on the tank.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
check for hydraulic leaks.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 41

Section 4 • Repair Procedures June 2012
Manifolds REV E
8-1
Function Manifold Components (before serial number 27001)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque
1 Proportional directional
solenoid valve, 3 position 4 way ....... A ........... Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm
2 Solenoid valve, 3 position 4 way ...... B ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm
solenoid valve, 3 position 4 way ....... C ........... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm
solenoid valve, 3 position 4 way ....... D ........... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm
5 Solenoid valve, 2 position 3 way ...... E ........... Primary boom extend .................................. 20 ft-lbs / 27 Nm
6 Solenoid valve, 3 position 4 way ...... F ........... Platform rotate left/right and
jib boom up/down (Z-45/25J) ...................... 25 ft-lbs / 34 Nm
7 Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 4 way ...... H ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm
9 Check valve, dual pilot operated ...... I ............ Platform level circuit .................................... 20 ft-lbs / 27 Nm
10 Check valve ....................................... J ............ Differential sensing circuit,
platform rotate right and
jib boom up (Z-45/25J) ..................... 12-14 ft-lbs / 16-19 Nm
11 Check valve ....................................... K ........... Differential sensing circuit,
platform rotate left and
jib boom down (Z-45/25J) ................ 12-14 ft-lbs / 16-19 Nm
12 Differential sensing valve .................. L ........... Meters flow to functions ............................... 25 ft-lbs / 34 Nm
13 Check valve ....................................... M .......... Differential sensing circuit,
secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm
14 Check valve ....................................... N ........... Differential sensing circuit,
secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve,
1.5 gpm / 5.7 L/min ............................ O ........... Steer circuit .................................................. 25 ft-lbs / 34 Nm
16 Relief valve, 3200 psi / 220.6 bar ..... P ........... System relief ................................................ 20 ft-lbs / 27 Nm
17 Flow regulator valve,
0.1 gpm / 0.38 L/min .......................... Q ........... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm
18 Shuttle valve ...................................... R ........... Primary boom circuit .................................. 4-5 ft-lbs / 5-7 Nm
2 gpm / 7.6 L/min ............................... S ........... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm
0.4 gpm / 1.5 L/min ............................ T ........... Jib boom and platform
rotate circuit ................................................. 20 ft-lbs / 27 Nm
This list continues. Please turn the page.
4 - 42 Z-45/25 • Z-45/25J Part No. 107846

June 2012 Section 4 • Repair Procedures
REV E MANIFOLDS
1 2 3 4 5 6 7
A B C D E F G
AC
29
H
8
I
9
AB
28
AA
27
Z J
26 10
K
11
L
Y 12
25
X
24
W
23
V
22
M
13
N
14
U T S R Q P O
21 20 19 18 17 16 15
Part No. 107846 Z-45/25 • Z-45/25J 4 - 43

MANIFOLDS REV E
Function Manifold Components

(before serial number 27001), continued
Index Schematic
21 Needle valve ..................................... U ........... Platform level flow control ........................... 20 ft-lbs / 27 Nm
22 Relief valve, 2500 psi / 172 bar ........ V ........... Platform level circuit .................................... 25 ft-lbs / 34 Nm
23 Check valve ....................................... W .......... Differential sensing circuit,
platform level up ............................... 12-14 ft-lbs / 16-19 Nm
24 Check valve ....................................... X ........... Differential sensing circuit,
platform level down .......................... 12-14 ft-lbs / 16-19 Nm
25 Shuttle valve ...................................... Y ........... Platform level circuit .................................. 4-5 ft-lbs / 5-7 Nm
26 Check valve ....................................... Z ........... Differential sensing circuit,
boom retract ...................................... 12-14 ft-lbs / 16-19 Nm
27 Check valve ....................................... AA ......... Differential sensing circuit,
turntable rotate right ......................... 12-14 ft-lbs / 16-19 Nm
28 Check valve ....................................... AB ......... Differential sensing circuit,
turntable rotate left ............................ 12-14 ft-lbs / 16-19 Nm
29 Relief valve, 2100 psi / 145 bar ........ AC ........ Secondary boom down ............................... 25 ft-lbs / 34 Nm
4 - 44 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3 4 5 6 7
A B C D E F G
AC
29
H
8
I
9
AB
28
AA
27
Z J
26 10
K
11
L
Y 12
25
X
24
W
23
V
22
M
13
N
14
U T S R Q P O
21 20 19 18 17 16 15
Part No. 107846 Z-45/25 • Z-45/25J 4 - 45

MANIFOLDS REV E
8-2 How to Adjust the Secondary

Valve Adjustments - Boom Down Relief Valve
Function Manifold Perform this procedure with the
(before serial number 27001) boom in the stowed position.
How to Adjust the System gauge to the TEST1 port on the function manifold.
Relief Valve 2 Start the engine from the ground controls.
Perform this procedure with the 3 Hold the function enable switch to the high rpm
boom in the stowed position. position and activate and hold the secondary
boom down switch with the secondary boom
fully lowered.
gauge to the TEST1 port on the function manifold.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
3 Hold the function enable switch to the high rpm
5 Turn the engine off. Use a wrench to hold the
position and activate and hold the primary boom
relief valve and remove the cap (item AC).
retract switch with the boom fully retracted.
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
5 Turn the engine off. Use a wrench to hold the cap.
relief valve and remove the cap (item P).
Tip-over hazard. Do not adjust
6 Adjust the internal hex socket. Turn it clockwise the relief valve higher than
to increase the pressure or counterclockwise to specified.
7 Repeat steps 2 through 5 and recheck relief
cap.
valve pressure.
8 Remove the pressure gauge.
the relief valve higher than
specified.
valve pressure.
4 - 46 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
Part No. 107846 Z-45/25 • Z-45/25J 4 - 47

MANIFOLDS REV E
8-3
Function Manifold Components (after serial number 27000)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
1 Solenoid valve, 3 position 4 way ...... BM ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm
2 Solenoid valve, 3 position 4 way ...... CG ........ Platform rotate left/right and
jib boom up/down ........................................ 25 ft-lbs / 34 Nm
2 gpm / 7.6 L/min ............................... BZ ......... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm
4 Solenoid valve, 2 position 3 way ...... CA ........ Primary boom extend .................................. 20 ft-lbs / 27 Nm
solenoid valve, 3 position 4 way ....... BY ......... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm
6 Differential sensing valve
160 psi / 11 bar ................................. BG ........ Meters flow to functions ............................... 25 ft-lbs / 34 Nm
solenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm
solenoid valve, 3 position 4 way ....... BU ........ Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm
9 Solenoid valve, 3 position 4 way ...... BF ......... Steer left/right ............................................... 25 ft-lbs / 34 Nm
10 Relief valve, 2100 psi / 145 bar ........ BV ......... Secondary boom down ............................... 20 ft-lbs / 27 Nm
11 Orifice, 0.046 inch / 1.17 mm ............ CF ......... Secondary boom down circuit
12 Check valve, 5psi / 0.3 bar ................ BT ......... Differential sensing circuit,
secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm
13 Check valve, 5psi / 0.3 bar ................ BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm
14 Check valve, 5psi / 0.3 bar ................ BS ......... Differential sensing circuit,
secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve,
1.5 gpm / 5.7 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm
16 Relief valve, 3200 psi / 220.6 bar ..... BA ......... System relief ................................................ 20 ft-lbs / 27 Nm
17 Shuttle valve ...................................... BO ........ Turntable rotate circuit ...................... 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5psi / 0.3 bar ................ BQ ........ Differential sensing circuit,
turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5psi / 0.3 bar ................ CB ........ Differential sensing circuit,
primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5psi / 0.3 bar ................ BC ........ Differential sensing circuit,
platform rotate left and
jib boom up .................................................. 25 ft-lbs / 34 Nm
This list continues. Please turn the page.
4 - 48 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3 4 5 6 7 8
BM CG BZ CA BY BG BP BU
BJ
33
BI
32
CC BF
31 9
BL BV
30 10
BK
29
CF
11
BH
28
BN
27
BE
26
CE
25
BT
BR 12
24
CD
23
BX
22
BW
13
BD BC CB BQ BO BA BB BS
21 20 19 18 17 16 15 14
Part No. 107846 Z-45/25 • Z-45/25J 4 - 49

MANIFOLDS REV E
Function Manifold Components

(after serial number 27000), continued
Index Schematic
21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit,
platform rotate right and
jib boom down ............................................. 25 ft-lbs / 34 Nm
0.1 gpm / 0.38 L/min .......................... BX ......... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm
23 Counterbalance valve,
3000 psi / 207 bar ............................. CD ........ Primary boom down circuit ............... 30-35 ft-lbs / 45-50 Nm
24 Pressure compensator valve,
80 psi / 5.5 bar ................................... BR ........ Turntable rotate circuit ................................. 25 ft-lbs / 34 Nm
25 Shuttle valve ...................................... CE ........ Differential sensing circuit,
primary boom up/down ..................... 12-14 ft-lbs / 16-19 Nm
0.4 gpm / 1.5 L/min ............................ BE ......... Jib boom and platform
rotate circuit ................................................. 20 ft-lbs / 27 Nm
27 Needle valve ..................................... BN ........ Platform level flow control ........................... 20 ft-lbs / 27 Nm
28 Relief valve, 2500 psi / 172 bar ........ BH ........ Platform level circuit .................................... 20 ft-lbs / 27 Nm
29 Check valve, 5psi / 0.3 bar ................ BK ......... Differential sensing circuit,
platform level up ............................... 12-14 ft-lbs / 16-19 Nm
30 Check valve, 5psi / 0.3 bar ................ BL ......... Differential sensing circuit,
platform level down .......................... 12-14 ft-lbs / 16-19 Nm
31 Solenoid valve, 2 position 3 way ...... CC ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm
32 Shuttle valve ...................................... BI .......... Platform level circuit ......................... 12-14 ft-lbs / 16-19 Nm
33 Check valve, dual pilot operated,
135 psi / 9.3 bar ................................. BJ ......... Platform level circuit .................................... 20 ft-lbs / 27 Nm
4 - 50 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3 4 5 6 7 8
BM CG BZ CA BY BG BP BU
BJ
33
BI
32
CC BF
31 9
BL BV
30 10
BK
29
CF
11
BH
28
BN
27
BE
26
CE
25
BT
BR 12
24
CD
23
BX
22
BW
13
BD BC CB BQ BO BA BB BS
21 20 19 18 17 16 15 14
Part No. 107846 Z-45/25 • Z-45/25J 4 - 51

MANIFOLDS REV E
8-4 How to Adjust the Secondary

Valve Adjustments - Boom Down Relief Valve
Function Manifold Perform this procedure with the
(after serial number 27000) boom in the stowed position.
How to Adjust the System gauge to the TEST1 port on the function manifold.
Relief Valve 2 Start the engine from the ground controls.
Perform this procedure with the 3 Hold the function enable switch to the high rpm
boom in the stowed position. position and activate and hold the secondary
boom down switch with the secondary boom
fully lowered.
gauge to the TEST1 port on the function manifold.
3 Hold the function enable switch to the high rpm
5 Turn the engine off. Use a wrench to hold the
position and activate and hold the primary boom
relief valve and remove the cap (item BV).
retract switch with the boom fully retracted.
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
5 Turn the engine off. Use a wrench to hold the cap.
relief valve and remove the cap (item BA).
6 Adjust the internal hex socket. Turn it clockwise the relief valve higher than
to increase the pressure or counterclockwise to specified.
cap.
valve pressure.
the relief valve higher than
specified.
valve pressure.
4 - 52 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
8-5
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
1 Solenoid valve, 2 position 3 way ..... AD ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
AD
Part No. 107846 Z-45/25 • Z-45/25J 4 - 53

MANIFOLDS REV E
8-6
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
4 - 54 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
8-7
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function
1 Counterbalance valve .................... MM .......... Turntable rotate right

2 Counterbalance valve .................... NN ........... Turntable rotate left
1 2
MM NN
Part No. 107846 Z-45/25 • Z-45/25J 4 - 55

MANIFOLDS REV E
8-8
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function
1 Counterbalance valve ...................... L ............ Turntable rotate right

2 Counterbalance valve ...................... J ............ Turntable rotate left
1 2
L J
4 - 56 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
8-9
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ...................................................... Directional control
Part No. 107846 Z-45/25 • Z-45/25J 4 - 57

MANIFOLDS REV E
How to Set Up the Directional 8 Verify that the ground and drive chassis are
completely level.
Valve Linkage
9 Tighten the nuts on both sides of the urethane
Adjustment of the directional valve cushions until they are snug. Tighten the
linkage is only necessary when the locknuts.
linkage or valve has been
replaced. 10 Check to be sure the drive chassis is
completely level.
1 Lower the boom to the stowed position.
11 Measure the distance between the drive chassis
2 Use a "bubble type" level to be sure the floor is and the non-steer axle on both sides (from the
completely level. inside of the drive chassis).
Tip-over hazard. Failure to perform If the distance is not equal and the
this procedure on a level floor adjustment to the linkage was
could compromise the stability of completed with the ground and
the machine resulting in the drive chassis level, repeat steps 6
machine tipping over. through 10 OR consult Genie
3 Check the tire pressure in all four tires and add Industries Service Department.
air if needed to meet specification.
4 Remove the drive chassis cover and the non-
steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
loosen the lock nuts on both sides of the
urethane cushions.
7 Push up or pull down on the threaded rod until
the machine is completely level.
4 - 58 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
Part No. 107846 Z-45/25 • Z-45/25J 4 - 59

MANIFOLDS REV E
8-10
Traction Manifold Components, 2WD (before serial number 27001)
The traction manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index Schematic
1 Solenoid valve, 2 position 3 way ...... XX ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm
2 Relief valve, 250 psi / 17.2 bar ......... PP ......... Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
3 Flow divider/combiner valve ............. QQ ........ Controls flow to drive motors
in forward and reverse ..................... 25-30 ft-lbs / 34-41 Nm
4 Orifice, 0.070 in / 1.78 mm ................ RR ........ Drive circuit
5 Check valve ....................................... SS ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
6 Check valve ....................................... TT ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
7 Shuttle valve, 3 position 3 way ......... UU ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump and allows
low pressure flow path for
brake release and 2-speed
motor shift ......................................... 15-18 ft-lbs / 20-24 Nm
8 Diagnostic fitting ................................ VV ......... Testing
9 Orifice, 0.030 in / 0.76 mm ................ WW ....... Brake circuit
10 Solenoid valve, 2 position 3 way ...... OO ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
4 - 60 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3
XX PP QQ
OO
10
RR
4
SS
5
WW
9
TT
6
VV UU
8 7
Part No. 107846 Z-45/25 • Z-45/25J 4 - 61

MANIFOLDS REV E
8-11
Traction Manifold Components, 2WD (after serial number 27000)
Index Schematic
1 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm
2 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
3 Flow divider/combiner valve ............. U ........... Controls flow to drive motors
in forward and reverse ..................... 25-30 ft-lbs / 34-41 Nm
4 Orifice, 0.070 in / 1.78 mm ................ AL ......... Drive circuit
5 Check valve ....................................... S ........... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
6 Check valve ....................................... AA ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
7 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit that
8 Diagnostic fitting ............................................... Testing
9 Orifice, 0.030 in / 0.76 mm ................ AE ......... Brake circuit
10 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
4 - 62 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3
AF AD U
AG
10
AL
4
S
5
AE
9
AA
6
8 7
Part No. 107846 Z-45/25 • Z-45/25J 4 - 63

MANIFOLDS REV E
8-12
Valve Adjustments, 2WD
Traction Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port on the drive pump.
2 Hold the charge pressure relief valve and
remove the cap (item PP or AD).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 Start the engine and move and hold the function
enable/rpm select toggle switch to the high rpm
(rabbit symbol) position. Note the reading on the
pressure gauge.
5 Turn the engine off.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
remove the cap (item PP or AD).
8 Start the engine and move and hold the function
enable/rpm select toggle switch to the high rpm
(rabbit symbol) position.
9 Adjust the internal hex socket until the pressure
reading on the gauge is 40 psi / 2.8 bar less
than the pressure reading on the pump. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
10 Turn the engine off and remove the pressure
gauge.
4 - 64 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
Part No. 107846 Z-45/25 • Z-45/25J 4 - 65

MANIFOLDS REV E
8-13
Traction Manifold Components, 4WD (before serial number 27001)
Index Schematic
1 Flow divider/combiner valve .............. AB ......... Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
2 Bi-directional flow control valve,
2 gpm / 7.6 L/min ............................... AC ........ Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm
1 gpm / 3.8 L/min ............................... AD ........ Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm
4 Directional control valve ................... AE ......... 2 speed motor shift circuit/
High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm
5 Diagnostic fitting ................................ AF ......... Testing
6 Shuttle valve, 3 position 3 way ......... AG ........ Charge pressure circuit that
7 Relief valve, 250 psi / 17.2 bar ......... AH ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
8 Solenoid valve, 2 position 3 way ...... AI .......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
9 Orifice, 0.030 inch / 0.76 mm ............ AJ ......... Brake and 2-speed motor shift circuit
10 Solenoid valve, 2 position 3 way ...... AK ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... AL ......... 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm
12 Orifice, 0.025 inch / 0.64 mm ............ AM ........ 2 speed motor shift circuit
13 Flow divider/combiner valve ............. AN ........ Controls flow to flow
divider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm
14 Check valve ....................................... AO ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
15 Orifice, 0.052 in / 1.32 mm ................ AP ......... Drive circuit
16 Check valve ....................................... AQ ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
17 Flow divider/combiner valve ............. AR ........ Controls flow to steer end
18 Check valve ....................................... AS ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
19 Check valve ....................................... AT ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
4 - 66 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3 4 5 6 7 8 9
AB AC AD AE AF AG AH AI AJ
AK
10
AT
19
AS
18
AR
17
AL
11
AM
12
AN
13
AO
14
AP
15
AQ
16
Part No. 107846 Z-45/25 • Z-45/25J 4 - 67

MANIFOLDS REV E
8-14
Traction Manifold Components, 4WD (after serial number 27000)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Flow divider/combiner valve ............. U ........... Controls flow to non-steer end
2 gpm / 7.6 L/min ............................... Z ........... Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm
1 gpm / 3.8 L/min ............................... X ........... Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm
4 Directional control valve ................... AV ......... 2 speed motor shift circuit/
High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm
5 Diagnostic fitting ............................................... Testing
6 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit that
7 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
8 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
9 Orifice, 0.030 inch / 0.76 mm ............ AE ......... Brake and 2-speed motor shift circuit
10 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... AH ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm
12 Orifice, 0.025 inch / 0.64 mm ............ AI .......... 2 speed motor shift circuit
13 Flow divider/combiner valve ............. V ........... Controls flow to flow
divider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm
14 Check valve ....................................... AC ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
15 Orifice, 0.052 in / 1.32 mm ................ Y ........... Drive circuit
16 Check valve ....................................... T ........... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
17 Flow divider/combiner valve ............. W .......... Controls flow to steer end
18 Check valve ....................................... S ........... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
19 Check valve ....................................... AA ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
4 - 68 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
1 2 3 4 5 6 7 8 9
U Z X AV R AD AG AE
AF
10
AA
19
S
18
W
17
AH
11
AI
12
V
13
AC
14
Y
15
T
16
Part No. 107846 Z-45/25 • Z-45/25J 4 - 69

MANIFOLDS REV E
8-15 8-16
Valve Adjustments, 4WD Valve Coils
Traction Manifold
How to Test a Coil
How to Adjust the Charge A properly functioning coil provides an
Pressure Relief Valve electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
1 Connect a 0 to 600 psi / 0 to 50 bar pressure within the coil that provides this force field.
gauge to the test port on the drive pump.
2 Hold the charge pressure relief valve and electrically charged circuits could
remove the cap (item AH or AD). result in death or serious injury.
3 Turn the internal hex socket clockwise fully until Remove all rings, watches and
it stops. Install the cap. other jewelry.
4 Start the engine and move and hold the function 1 Tag and disconnect the wiring from the coil to be
enable/rpm select toggle switch to the high rpm tested.
(rabbit symbol) position. Note the reading on the 2 Test the coil resistance.
pressure gauge.
Result: The resistance should be within
5 Turn the engine off.
specification, plus or minus 30%.
6 Remove the pressure gauge from the drive
Result: If the resistance is not within
pump. Connect the gauge to the test port
located on the traction manifold. specification, plus or minus 30%, replace the
coil.
remove the cap (item AH or AD). Valve Coil Resistance Specification
8 Start the engine and move and hold the function (before serial number 27001)
enable/rpm select toggle switch to the high rpm Proportional directional solenoid valve, 10V DC 6 to 8Ω
(rabbit symbol) position. (schematic items A, C and D)
9 Adjust the internal hex socket until the pressure 3 position 4 way directional valve, 10V DC 6 to 8Ω
reading on the gauge is 40 psi / 2.8 bar less (schematic items B, F and H)
than the pressure reading on the pump. Turn it
clockwise to increase the pressure or 2 position 3 way solenoid valve, 10V DC 6 to 8Ω
counterclockwise to decrease the pressure. (schematic items E, G, AD, OO, XX, AI and AK)
Install the valve cap.
Valve Coil Resistance Specification
10 Turn the engine off and remove the pressure (after serial number 27000)
gauge.
Proportional directional solenoid valve, 10V DC 6 to 8Ω
(schematic items BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω

(schematic items BF, BM and CG)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω

(schematic items CA, CC, AF and AG)
4 - 70 Z-45/25 • Z-45/25J Part No. 107846

REV E MANIFOLDS
COIL
a
How to Test a Coil Diode d
MULTI
METER
Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes. c -
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
+
b
to a coil. Faulty diodes can fail to protect the 10 W 9V
RESISTOR BATTERY
electrical system, resulting in a tripped circuit
+
breaker or component damage.
c - b
a multimeter
result in death or serious injury. b 9V DC battery
Remove all rings, watches and c 10Ω resistor
other jewelry. d coil
1 Test the coil for resistance. See, How to Test a Note: Dotted lines in illustration indicate a
reversed connection as specified in
Coil. step 6
2 Connect a 10Ω resistor to the negative terminal
3 Set a multimeter to read DC current.
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the The multimeter, when set to read
coil. DC current, should be capable of
reading up to 800 mA.
Ω
Resistor, 10Ω 4 Connect the negative lead to the other terminal
on the coil.
5 Momentarily connect the positive lead from the
The battery should read 9V DC or multimeter to the positive terminal on the 9V DC
more when measured across the battery. Note and record the current reading.
terminals.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 71

Turntable Rotation Components REV C
9-1 3 Remove the safety pin from the engine pivot

plate latch.
Turntable Rotation Assembly
How to Remove the Turntable pivot plate at the counterweight
Rotation Assembly end of the machine.
When removing a hose assembly 4 Remove the center turntable cover retaining
or fitting, the O-ring (if equipped) fasteners. Remove the center turntable cover
on the fitting and/or the hose end from the machine.
machine.
Fitting Torque Specifications. 6 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor manifold. Cap
1 Raise the secondary boom until the upper pivot
the fittings on the manifold.
is above the turntable covers. Turn the machine
off. Bodily injury hazard. Spraying
2 Secure the turntable from rotating with the
turntable rotation lock.
Tip-over hazard. The machine the oil pressure to dissipate
could tip over when the turntable gradually. Do not allow oil to squirt
rotation assembly is removed if the or spray.
turntable rotation lock is not in the
7 Attach a lifting strap from and overhead crane or
locked position.
other suitable lifting device to the turntable
rotator assembly.
8 Remove the turntable rotation assembly
mounting fasteners.
9 Carefully remove the turntable rotation assembly
from the machine.
Unlocked position
Tip-over hazard. The machine
could tip over when the turntable
rotation assembly is removed if the
turntable rotation lock is not in the
locked position.
Crushing hazard. The turntable
rotation assembly could become
unbalanced and fall when removed
Locked position
4 - 72 Z-45/25 • Z-45/25J Part No. 107846

REV C
Axle Components
10-1 How to Install the Hub and
Hub and Bearings, 2WD Models Bearings, 2WD Models
When replacing a wheel bearing,
How to Remove the both the inner and outer bearings
Hub and Bearings, 2WD Models including the pressed-in races
must be replaced.
1 Loosen the wheel lug nuts. Do not remove them.
1 Be sure that both bearings are packed
2 Block the non-steer wheels and place a lifting with clean, fresh grease.
jack of ample capacity under the steer axle.
2 Place the large inner bearing into the rear
3 Raise the machine 6 inches / 15 cm and place of the hub.
blocks under the chassis for support.
3 Press the bearing seal evenly into the hub
Crushing hazard. The machine until it is flush.
may fall if not properly supported.
4 Slide the hub onto the yoke spindle.
4 Remove the lug nuts. Remove the tire and wheel
assembly. Component damage. Do not
apply excessive force or damage
5 Remove the dust cap, cotter pin and to the lip of the seal may occur.
castle nut.
5 Place the outer bearing into the hub.
Always use a new cotter pin when
installing a castle nut. 6 Install the washer and castle nut.
6 Pull the hub off the spindle. The washer and 7 Tighten the castle nut to 35 ft-lbs / 47 Nm to
outer bearing should fall loose from the hub. seat the bearing.
7 Place the hub on a flat surface and gently pry 8 Fully loosen the castle nut, then re-tighten to
the bearing seal out of the hub. 8 ft-lbs / 11 Nm.
8 Remove the rear bearing. 9 Install a new cotter pin. Bend the cotter pin
to secure the castle nut.
Always use a new cotter pin when
installing a castle nut.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
Part No. 107846 Z-45/25 • Z-45/25J 4 - 73

AXLE COMPONENTS REV C
10-2 2 Remove the pin retaining fasteners from the

rod-end pivot pin. Use a soft metal drift to
Oscillating Axle remove the pin.
Lock-out Cylinders 3 Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
The oscillating axle cylinders extend and retract
between the drive chassis and the oscillating axle. 4 Remove the pin retaining fasteners from the
The cylinders are equipped with counterbalance barrel-end pivot pin. Use a soft metal drift to
valves to prevent movement in the event of a remove the pin.
hydraulic line failure. The valves are not adjustable.
Crushing hazard. The oscillate
cylinder may become unbalanced
How to Remove an Oscillating and fall when removed from the
Axle Cylinder machine if not properly attached to
the overhead crane.
Perform this procedure on a firm,
level surface with the boom in 5 Remove the oscillate cylinder from the machine.
the stowed position.
1 Tag, disconnect and plug the oscillating axle
oscillate cylinder.
gradually. Do not allow oil to squirt
or spray.
4 - 74 Z-45/25 • Z-45/25J Part No. 107846

August 2006 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie Z-45/25 and Genie Z-45/25J Operator’s
Manual on your machine.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropiate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing
before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
Electrocution hazard. Contact
· Machine parked on a firm, level surface
with electrically charged circuits
· Boom in stowed position could result in death or serious
· Turntable rotated with the boom between injury. Remove all rings, watches
the non-steer 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
· Wheels chocked gradually. Do not allow oil to
· All external AC power disconnected squirt or spray.
from the machine
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 107846 Z-45/25 • Z-45/25J 5-1

Section 5 • Fault Codes August 2006
FAULT CODES REV A
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once per
Fault Codes second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
At least one fault code is present
when the alarm at the platform When the red LED is flashing the
controls produces two short beeps code, the yellow LED will be on
every 30 seconds for 10 minutes. solid.
Perform this procedure with the 4 Determine the error type: The yellow LED
engine off, the key switch turned to indidates the error type and will flash two
platform controls and the red separate codes. The first code will indicate the
Emergency Stop button pulled out first digit of the two digit code, flashing once per
to the on position at both the second. It will then pause for 1.5 seconds and
ground and platform controls. flash the second digit once per 0.5 second.
1 Open the platform control box lid. When the yellow LED is flashing
the code, the red LED will be on
Electrocution hazard. Contact solid.
with electrically charged circuits
could result in death or serious 5 Use the fault code table on the following pages
injury. Remove all rings, watches to aid in troubleshooting the machine by
and other jewelry. pinpointing the area or component affected.
2 Locate the red and yellow fault LEDs on the

ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.
5-2 Z-45/25 • Z-45/25J Part No. 107846

REV A FAULT CODES
Error Source Error Type Condition Solution

ID Name ID Name
21 Boom 1 Joystick 11 Limited speed and
Value at 5V
(primary boom up/ 12 direction frozen at Power up
Value too high
down) 15 zero and neutral. controller with
Value too low
16 Alarm sounds problem corrected.
Value at 0V
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate joystick.
zero and neutral.
Initiate 1-second beep Self-clearing.
18 Just calibrated
of alarm. (transient)
22 Boom 1 directional Limited speed and
valves direction frozen at Power up
21 Fault zero and neutral. controller with
Alarm sounds problem corrected.
indicating fault.
23 Boom 1 flow Limited speed and
control valve direction frozen at Power up
12 Value too high
zero and neutral. controller with
15 Value too low
indicating fault.
Normal function Calibrate valve
17 Not calibrated
except threshold for thresholds.
one or both directions Self-clearing.
18 Just calibrated
is zero. (transient)
31 Boom 2 Joystick 11 Value at 5V Limited speed and
(secondary boom 12 Value too high direction frozen at Power up
up/down or 15 Value too low zero and neutral. controller with
primary boom 16 Value at 0V Alarm sounds problem corrected.
extend/retract) indicating fault.
Joystick speed and
zero and neutral.
Initiate 1 second beep Self-clearing.
18 Just calibrated
32 Boom 2 directional Limited speed and
indicating fault.
Continued on next page
Part No. 107846 Z-45/25 • Z-45/25J 5-3

FAULT CODES REV A

ID Name ID Name
33 Boom 2 flow Limited speed and
control valve direction frozen at Power up
12 Value too high
15 Value too low
indicating fault.
Normal function
except threshold for Calibrate valve
17 Not calibrated one or both directions thresholds.
is zero.
Self-clearing.
18 Just calibrated
(transient)
41 Turntable rotate 11 Value at 5V Limited speed and
joystick 12 Value too high direction frozen at Power up
15 Value too low zero and neutral. controller with
16 Value at 0V Alarm sounds problem corrected.
indicating fault.
Joystick speed and
zero and neutral.
18 Just calibrated
42 Turntable rotate Limited speed and
directional valves direction frozen at Power up
indicating fault.
43 Turntable rotate Limited speed and
flow control valve direction frozen at Power up
12 Value too high
15 Value too low
indicating fault.
17 Not calibrated
except threshold for thresholds.
18 Just calibrated
44 Drive enable Enable override Power up
override switches 21 Fault direction is frozen at controller with
neutral. problem corrected.
5-4 Z-45/25 • Z-45/25J Part No. 107846

REV A FAULT CODES

ID Name ID Name
51 Drive joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate joystick
zero and neutral.
18 Just calibrated
53 Drive flow valve Limited speed and
(EDC) direction frozen at Power up
12 Value too high
15 Value too low
indicating fault.
17 Not calibrated
except threshold for thresholds
18 Just calibrated
54 Drive brake valve Limited speed and
direction frozen at Power up
indicating fault.
55 High speed drive Motor speed frozen in
Power up
motor Valve the low state. Alarm
21 Fault controller with
sounds indicating
problem corrected.
fault.
61 Steer joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate Joystick
zero and neutral.
18 Just calibrated
62 Steer directional Limited speed and
indicating fault.
Part No. 107846 Z-45/25 • Z-45/25J 5-5

FAULT CODES REV B
Ford LRG-425 EFI Engine 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Before the fault codes are
displayed, the check engine light
Fault Codes will blink a code 123 three times.
The ECM constantly monitors the engine by the After the fault codes, the check
use of sensors on the engine. The ECM also uses engine light will blink a code 123
signals from the sensors to initiate sequential fuel three times again indicating the
injection and make constant and instantaneous end of the stored codes.
changes to ignition timing, fuel delivery and throttle If any fault codes are present, the
position to maintain the engine's running condition ECM will blink a three digit code
at its highest efficiency while at the same time three times for each code stored in
keeping exhaust emissions to a minimum. When a memory. It will blink the first digit
sensor fails or returns signals that are outside of of a three digit code, pause, blink
set parameters, the ECM will store a fault code in the second digit, pause, and then
memory that relates to the appropriate sensor and blink the third digit. For example:
will turn on the Check Engine Light. the check engine light blinks 5
Perform this procedure with the consecutive times, blinks 3 times
key switch in the off position. and then 1 time. That would
indicate code 531.
1 Locate the run/test toggle switch on the side of
the ground control box. Once a fault code has been
retrieved and the repair has been
2 Pull out the red Emergency Stop button to the completed, the ECM memory must
on position at both the ground and platform be reset to clear the fault code
controls. from the ECM. See How to Clear
3 Quickly activate and release the start toggle Engine Fault Codes from the ECM.
switch/button. Do not start the engine.
How to Clear Engine Fault
4 Move and hold the run/test toggle switch to the Codes from the ECM
test position.
Result: The check engine light should turn on. engine off and the key switch in
The check engine light should begin to blink. the off position.
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
other jewelry.
3 Connect the negative battery cable to the
battery.
5-6 Z-45/25 • Z-45/25J Part No. 107846

REV B FAULT CODES
Code Problem Cause Solution

Heated oxygen sensor wiring and/or connections
Closed loop multiplier high Repair wiring and/or connections OR replace
111 (LPG)
open or shorted OR sensor is faulty OR there are
sensor OR repair vacuum and exhaust leaks.
vacuum leaks or exhaust leaks.
HO2S open/inactive Heated oxygen sensor wiring and/or connections Repair wiring and/or connections OR replace
112 (bank 1) open or shorted OR sensor is faulty. sensor.
HO2S open/inactive Heated oxygen sensor wiring and/or connections Repair wiring and/or connections OR replace
113 (bank 2) open or shorted OR sensor is faulty. sensor.
The post cat heated oxygen sensor wiring and/or
Post-cat oxygen sensor connections are open or shorted OR sensor is Repair wiring and/or connections OR replace
114 open cold, non-responsive or inactive for 60 seconds or the post cat oxygen sensor.
longer.
Repair wiring and/or connections OR replace
open or shorted OR sensor is faulty OR there are
Closed loop multiplier high sensor OR repair any vacuum and exhaust
121 (gasoline)
vacuum leaks or exhaust leaks OR fuel pressure
leaks OR test the fuel pressure OR clean or
is low OR the fuel injectors need cleaning or
replace the fuel injectors.
replacing.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
Closed loop multiplier low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair
122 (gasoline) injectors are stuck open OR there is electro- fuel injectors.
magnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Closed loop multiplier low open or shorted OR sensor is faulty OR fuel
124 (LPG) quality is poor OR fuel system components may
sensor OR replace fuel OR test and repair the
fuel system components.
be faulty.
Repair exhaust leaks OR there is an
There are exhaust leaks OR the catalyst system
133 Gasoline cat monitor
efficiency is below the acceptable level.
emissions compliance issue. Contact Ford
Power Products for assistance.
134 LPG cat monitor
135 NG cat monitor
Heated oxygen sensor wiring and/or connections Repair heated oxygen sensor wiring and/or
open or shorted OR sensor is faulty OR there are connections OR replace sensor OR repair
Adaptive lean fault - High
141 limit (Gasoline)
vacuum or exhaust leaks OR one or more fuel vacuum and exhaust leaks OR test the fuel
injectors faulty or stuck closed OR fuel quality is pressure OR clean or replace the fuel
poor OR fuel pressure is too low. injectors.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
Adaptive rich fault - Low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair
142 limit (Gasoline) injectors are stuck closed OR there is electro- fuel injectors.
magnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
open or shorted OR sensor is faulty OR there are sensor OR repair any vacuum and exhaust
143 Adaptive learn high (LPG)
vacuum leaks or exhaust leaks OR fuel quality is leaks OR replace fuel OR test and repair the
poor OR fuel system components may be faulty. fuel system components.
Engine wire harness may have an intermittent
Repair short in engine wire harness OR test
144 Adaptive learn low (LPG) short to 5V DC or 12V DC OR fuel system
and repair the fuel system components.
components may be faulty.
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair
161 System voltage low
battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
Alternator is overcharging the battery when
162 System voltage high
engine RPM is greater than 1500 rpm.
Repair or replace the alternator.
IAT sensor wiring and/or connections are open or
211 IAT high voltage shorted OR sensor is faulty OR engine intake air
sensor OR direct warmer air into air intake.
temperature is too cold.
IAT sensor wiring and/or connections are open or
212 IAT low voltage shorted OR sensor is faulty OR engine intake air
sensor OR direct cooler air into air intake.
temperature is too hot.
Part No. 107846 Z-45/25 • Z-45/25J 5-7

FAULT CODES REV B

Air intake temperature is greater than 200° F with Check air intake system for damage and
IAT higher than expected
213 (1)
the engine greater than 1000 rpm OR air intake proper routing of air intake components OR
system has leaks OR IAT sensor is faulty. replace the IAT sensor.
Air intake temperature is greater than 210° F with Check air intake system for damage and
IAT higher than expected
214 (2)
the engine greater than 1000 rpm OR air intake proper routing of air intake components OR
system has leaks OR IAT sensor is faulty. replace the IAT sensor.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair sensor
215 Oil pressure low and/or connections open or shorted OR engine oil wiring and/or connections OR fill engine oil
level too low. level to specification.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR
221 CHT/ECT high voltage sensor wires and/or connections open or shorted repair open or shorted wiring to sensor OR
OR sensor is faulty. replace sensor.
Engine cooling system is malfunctioning and Repair engine cooling system problems OR
overheating the engine OR sensor wires and/or repair open or shorted wiring to sensor OR
222 CHT/ECT low voltage
connections open or shorted OR sensor is faulty replace sensor OR fill engine coolant level to
OR coolant level is low. specification.
Coolant temperature at the cylinder head is 240°
Repair engine cooling system problems OR
F. Engine cooling system is malfunctioning and
CHT higher than expected repair open or shorted wiring to sensor OR
223 (1)
overheating the engine OR sensor wires and/or
replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty
specification.
OR coolant level is low.
Coolant temperature at the cylinder head is 250°
Repair engine cooling system problems OR
F. Engine cooling system is malfunctioning and
CHT higher than expected repair open or shorted wiring to sensor OR
224 (2)
overheating the engine OR sensor wires and/or
replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty
specification.
OR coolant level is low.
Open or shorted wiring and/or connections to Repair wiring and/or connections to sensor OR
231 MAP high pressure
MAP sensor OR sensor is faulty. replace MAP sensor.
Open or shorted wiring and/or connections to Repair wiring and/or connections to sensor OR
232 MAP low voltage
MAP sensor OR sensor is faulty. replace MAP sensor.
234 BP high pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.
235 BP low pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.
Crankshaft position sensor wiring and/or Be sure system ground connections are in
242 Crank sync noise connections open or shorted OR there is a poor place and secure OR repair wiring and/or
system ground connection OR sensor is faulty. connections to sensor OR replace sensor.
Crankshaft position sensor wiring and/or Be sure system ground connections are in
243 Never crank synced at start connections open or shorted OR there is a poor place and secure OR repair wiring and/or
Camshaft position sensor wiring and/or Be sure system ground connections are in
244 Camshaft sensor loss connections open or shorted OR there is a poor place and secure OR repair wiring and/or
Camshaft position sensor wiring and/or Be sure system ground connections are in
245 Camshaft sensor noise connections open or shorted OR there is a poor place and secure OR repair wiring and/or
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock
253 Knock sensor open
shorted OR sensor is faulty. sensor OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR
254 Excessive knock signal shorted OR there is excessive engine vibration repair wiring and/or connections to knock
OR sensor is faulty. sensor OR replace knock sensor.
Repair wiring and/or connections to fuel
Open wiring and/or connections to fuel injector #1
311 Injector driver #1 open
OR fuel injector #1 is faulty OR ECM is faulty.
injector #1 OR replace fuel injector #1 OR
replace the ECM.
Wiring and/or connections to fuel injector #1 Repair wiring and/or connections to fuel
312 Injector driver #1 shorted shorted OR fuel injector #1 is faulty OR ECM is injector #1 OR replace fuel injector #1 OR
faulty. replace the ECM.
replace the ECM.
5-8 Z-45/25 • Z-45/25J Part No. 107846

REV B FAULT CODES

replace the ECM.
replace the ECM.
Open wiring and/or connections to fuel pump OR
Fuel pump loop open or Repair wiring and/or connections to fuel pump
351 high side short to ground
fuel pump power shorted to ground OR fuel pump
OR replace fuel pump.
is faulty.
Fuel pump high side Wiring and/or connections to fuel pump shorted to Repair wiring and/or connections to fuel pump
352 shorted to power power OR fuel pump is faulty. OR replace fuel pump.
Fuel pressure too high OR LPG lockoff not
Check fuel pressure OR repair LPG lockoff OR
MegaJector delivery sealing correctly OR the line between the
repair the line between the MegaJector and
353 pressure higher than MegaJector and carburetor is kinked or restricted
carburetor OR repair engine cooling system
expected or is leaking OR engine cooling system is not
OR replace MegaJector.
operating properly OR MegaJector is faulty.
Fuel pressure too low OR LPG lockoff not
Check fuel pressure OR repair LPG lockoff OR
Megajector delivery opening completely OR the line between the
repair the line between the MegaJector and
354 pressure lower than MegaJector and carburetor is kinked or restricted
carburetor OR repair engine cooling system
expected or is leaking OR engine cooling system is not
OR replace the MegaJector.
operating properly OR MegaJector is faulty.
The ECM doesn’t get any response from the Check CAN circuits for continuity and shorts to
MegaJector communication
355 lost
MegaJector, or an incorrect response for 500ms power or ground and for continuity and repair
period or longer. as necessary OR replace the MegaJector.
The MegaJector detects voltage greater than 18
MegaJector voltage supply Repair charging system OR replace the
361 high
volts for 5 seconds anytime the engine is
MegaJector.
cranking or running.
The MegaJector detects voltage less than 9.5 Repair VBAT power or ground circuit to ECM
MegaJector voltage supply
362 low
volts for 5 seconds anytime the engine is and MegaJector OR replace battery OR repair
cranking or running. charging system OR replace the MegaJector.
Check power, ground and CAN circuits at
MegaJector and all connections and repair as
Megajector internal The MegaJector detects an internal fault. Open or
363 actuator fault detection short in power, ground or CAN circuits.s
necessary OR MegaJector has an internal
fault. Contact Ford Power Products for
assistance.
Check power, ground and CAN circuits at
The MegaJector detects an internal circuitry MegaJector and all connections and repair as
Megajector internal circuitry
364 fault detection
failure. Open or short in power, ground or CAN necessary OR MegaJector has an internal
circuits. fault. Contact Ford Power Products for
assistance.
Check Power, Ground and CAN circuits at
MegaJector internal The MegaJector detects an internal MegaJector and all connections and repair as
365 communication fault communications failure. Open or short in power, necessary OR MegaJector has an internal
detection ground or CAN circuits. fault. Contact Ford Power Products for
assistance.
Open wiring and/or connections to ignition coil #1 Repair wiring and/or connections to ignition
411 Coil driver #1 open
OR ignition coil #1 is faulty. coil #1 OR replace ignition coil #1.
Wiring and/or connections to ignition coil #1 Repair wiring and/or connections to ignition
412 Coil driver #1 shorted
shorted OR ignition coil #1 is faulty. coil #1 OR replace ignition coil #1.
Open wiring and/or connections to ignition coil #2 Repair wiring and/or connections to ignition
413 Coil driver #2 open
OR ignition coil #2 is faulty. coil #1 OR replace ignition coil #1.
Wiring and/or connections to ignition coil #2 Repair wiring and/or connections to ignition
414 Coil driver #2 shorted
shorted OR ignition coil #2 is faulty. coil #2 OR replace ignition coil #2.
Part No. 107846 Z-45/25 • Z-45/25J 5-9

FAULT CODES REV B

If this fault appears on your machine, contact
511 FPP1 high voltage Not used.
Genie Industries Service Department.
512 FPP1 low voltage Not used.
513 FPP1 higher than IVS Limit Not used.
514 FPP1 lower than IVS Limit Not used.
521 FPP2 high voltage Not used.
522 FPP2 low voltage Not used.
The #1 throttle position sensor wiring and/or Be sure system ground connections are in
connections open or shorted OR there is a poor place and secure OR repair wiring and/or
531 TPS1 (signal voltage) high
system ground connection OR throttle position connections to sensor OR replace throttle
sensor #1 is faulty. position sensor #1.
532 TPS1 (signal voltage) low
533 TPS2 (signal voltage) high
534 TPS2 (signal voltage) low
The throttle position sensor wiring and/or
Be sure engine harness wiring and
connections for either TPS1 or TPS2 open or
connections are in place and secure OR repair
535 TPS1 higher than TPS2 shorted OR there is a poor system ground
wiring and/or connections to one or both TPS
connection OR one or both throttle position
sensors OR replace one or both TPS sensors.
sensors are faulty.
The throttle position sensor wiring and/or
Be sure engine harness wiring and
connections for either TPS1 or TPS2 open or
connections are in place and secure OR repair
536 TPS1 lower than TPS2 shorted OR there is a poor system ground
wiring and/or connections to one or both TPS
connection OR one or both throttle position
sensors OR replace one or both TPS sensors.
sensors are faulty.
Governor actuator is stuck closed OR wiring
Repair wiring and/or connections to governor
537 Throttle unable to open and/or connections open or shorted OR governor
actuator OR replace the governor actuator.
actuator is faulty.
Governor actuator is stuck open OR wiring and/or
Repair wiring and/or connections to governor
538 Throttle unable to close connections open or shorted OR governor
actuator OR replace the governor actuator.
actuator is faulty.
Engine harness wiring and/or connections open
Repair wiring and/or connections in engine
545 Governor interlock failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
Max governor speed
551 override
sticking open OR there are air leaks between the operation OR repair any air leaks between the
throttle body and cylinder head. throttle body and cylinder head.
552 Fuel rev limit sticking open OR there are air leaks between the operation OR repair any air leaks between the
553 Spark rev limit sticking open OR there are air leaks between the operation OR repair any air leaks between the
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
611 COP failure
faulty.
damage or shorts to ECM to be sure they are
secure OR replace ECM.
612 Invalid interrupt
faulty.
613 A/D loss
faulty.
5 - 10 Z-45/25 • Z-45/25J Part No. 107846

REV B FAULT CODES

614 RTI 1 loss
faulty.
615 Flash checksum invalid
faulty.
616 RAM failure
faulty.
External 5V DC ref lower damage or shorts OR locate and troubleshoot
631 than expected
or shorted to ground OR there is a faulty engine
or repair faulty engine sensor OR replace
sensor OR ECM is faulty.
ECM.
External 5V DC ref higher damage or shorts OR locate and troubleshoot
632 than expected
or shorted to ground OR there is a faulty engine
or repair faulty engine sensor OR replace
sensor OR ECM is faulty.
ECM.
655 RTI 2 loss
faulty.
656 RTI 3 loss
faulty.
Part No. 107846 Z-45/25 • Z-45/25J 5 - 11

FAULT CODES REV A
Ford DSG-423 EFI Engine 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Before the fault codes are
displayed, the check engine light
Fault Codes will blink a code 123 three times.
The ECM constantly monitors the engine by the After the fault codes, the check
use of sensors on the engine. The ECM also uses engine light will blink a code 123
signals from the sensors to initiate sequential fuel three times again indicating the
injection and make constant and instantaneous end of the stored codes.
changes to ignition timing, fuel delivery and throttle If any fault codes are present, the
position to maintain the engine's running condition ECM will blink a three digit code
at its highest efficiency while at the same time three times for each code stored in
keeping exhaust emissions to a minimum. When a memory. It will blink the first digit
sensor fails or returns signals that are outside of of a three digit code, pause, blink
set parameters, the ECM will store a fault code in the second digit, pause, and then
memory that relates to the appropriate sensor and blink the third digit. For example:
will turn on the Check Engine Light. the check engine light blinks 5
Perform this procedure with the consecutive times, blinks 3 times
key switch in the off position. and then 1 time. That would
indicate code 531.
1 Locate the run/test toggle switch on the side of
the ground control box. Once a fault code has been
retrieved and the repair has been
2 Pull out the red Emergency Stop button to the completed, the ECM memory must
on position at both the ground and platform be reset to clear the fault code
controls. from the ECM. See How to Clear
3 Quickly activate and release the start toggle Engine Fault Codes from the ECM.
switch/button. Do not start the engine.
How to Clear Engine Fault
4 Move and hold the run/test toggle switch to the Codes from the ECM
test position.
Result: The check engine light should turn on. engine off and the key switch in
The check engine light should begin to blink. the off position.
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
other jewelry.
3 Connect the negative battery cable to the
battery.
5 - 12 Z-45/25 • Z-45/25J Part No. 107846

REV A FAULT CODES
Code Description Code Description

111 CL (Closed Loop) high LPG IAT (Intake Air Temperature) high
211 voltage
112 EGO open / lazy pre-cat 1
IAT (Intake Air Temperature) low
113 EGO open / lazy pre-cat 2/post-cat 1 212 voltage
114 EGO open / lazy post-cat 1 IAT (Intake Air Temperature) higher
213 than expected 1
115 EGO open / lazy post-cat 2
IAT (Intake Air Temperature) higher
121 CL (Closed Loop) high gasoline bank 1 214 than expected 2
122 CL (Closed Loop) low gasoline bank 1 215 Oil pressure low
124 CL (Closed Loop) low LPG ECT / CHT (Engine/Cylinder Head
221 Coolant Temperature) high voltage
133 Gasoline catalyst monitor 1
ECT / CHT (Engine/Cylinder Head
134 LPG catalyst monitor 222 Coolant Temperature) low voltage
AL (Adaptive Learn) high gasoline bank1 223 CHT higher than expected 1
141
224 CHT higher than expected 2
142 AL (Adaptive Learn) low gasoline bank 1 225 ECT higher than expected 1
143 AL (Adaptive Learn) high LPG 226 ECT higher than expected 2
MAP (Manifold Absolute Pressure) high
144 AL (Adaptive Learn) low LPG 231 pressure
161 Battery Voltage high MAP (Manifold Absolute Pressure) low
232 voltage
162 Battery Voltage low
AUX analog PD1 high BP (Barometric Pressure) high
163 234 pressure
164 AUX analog PD1 low
235 BP (Barometric Pressure) low pressure
165 AUX analog PU3 high
166 AUX analog PU3 low 242 Crank sync noise
167 AUX analog PUD1 high 243 Never crank synced at start
168 AUX analog PUD1 low 244 Cam loss
171 AUX analog PUD2 high 245 Cam sync noise
172 AUX analog PUD2 low 246 Crank loss
173 AUX analog PUD3 high 253 Knock1/2 sensor open 1
174 AUX analog PUD3 low 254 Knock1/2 excessive signal 1
181 AUX DIG1 high

182 AUX DIG1 low For further engine fault code troubleshooting and
183 AUX DIG2 high diagnostic information, refer to the Ford DSG-423
AUX DIG2 low EFI Service Manual (EDI part number 1060040).
184
185 AUX DIG3 high Ford DSG 423 EFI Service Manual
186 AUX DIG3 low Genie part number 119494
Part No. 107846 Z-45/25 • Z-45/25J 5 - 13

FAULT CODES REV A

261 FP (Fuel Pressure) high voltage Primary Loop Open or Low-Side Short
413 to Ground 2
262 FP (Fuel Pressure) low voltage
FT (Fuel Temperature) gasoline high
414 Primary Coil Shorted 2
271 voltage Primary Loop Open or Low-Side Short
415 to Ground 3
FT (Fuel Temperature) gasoline low
272 voltage 416 Primary Coil Shorted 3
FT (Fuel Temperature) gaseous fuel Primary Loop Open or Low-Side Short
273 high voltage
421 to Ground 4
FT (Fuel Temperature) gaseous fuel 422 Primary Coil Shorted 4
274 low voltage TPS1 (Throttle Position Sensor) high
Injector Loop Open or Low-Side Short 531 voltage
311 to Ground 1 TPS1 (Throttle Position Sensor) Low
312 Injector Coil Shorted 1 532 voltage
Injector Loop Open or Low-Side Short TPS2 (Throttle Position Sensor) high
313 to Ground 2 533 voltage
314 Injector Coil Shorted 2 TPS2 (Throttle Position Sensor) low
534 voltage
Injector Loop Open or Low-Side Short
315 to Ground 3 TPS1 (Throttle Position Sensor) higher
535 than TPS2
316 Injector Coil Shorted 3
TPS1 (Throttle Position Sensor) lower
Injector Loop Open or Low-Side Short 536
321 to Ground 4
than TPS2
Unable to reach higher TPS (Throttle
322 Injector Coil Shorted 4 537 Position Sensor)
FPump motor loop open or high-side Unable to reach lower TPS (Throttle
351 shorted to ground 538 Position Sensor)
FPump motor high-side shorted to
352 power
539 TPS1/2 simultaneous voltages
EPR delivery pressure higher than 541 AUX analog PU1 high
353 expected 542 AUX analog PU1 low
EPR delivery pressure lower than
354 expected
543 AUX analog PU2 high
355 EPR comm lost 544 AUX analog PU2 low
359 Fuel run-out longer than expected 551 Max govern speed override
361 EPR voltage supply high 552 Fuel rev limit
362 EPR voltage supply low 553 Spark rev limit
363 EPR internal actuator fault detection For further engine fault code troubleshooting and
364 EPR internal circuitry fault detection diagnostic information, refer to the Ford DSG-423
365 EPR internal comm fault detection EFI Service Manual (EDI part number 1060040).
Primary Loop Open or Low-Side Short
411 to Ground 1
Ford DSG 423 EFI Service Manual
412 Primary Coil Shorted 1
5 - 14 Z-45/25 • Z-45/25J Part No. 107846

REV A FAULT CODES

611 COP failure 736 PWM3-Gauge3 short to power
612 Invalid interrupt 741 PWM4 open / ground short
613 A/D loss 742 PWM4 short to power
614 RTI 1 loss 743 PWM5 open / ground short
615 Flash checksum invalid 744 PWM5 short to power
616 RAM failure MIL (Malfunction Indicator Light) control
761 ground short
631 5VE1 low voltage
632 5VE1 high voltage 762 MIL (Malfunction Indicator Light) open
633 5VE2 high voltage MIL (Malfunction Indicator Light) control

763 short to power
634 5VE2 low voltage
771 Tach output ground short
635 5VE1/2 simultaneous out-of-range
772 Tach output short to power
641 Rx Inactive
1629 J1939 TSC1 message receipt lost
642 Rx Noise
1630 J1939 ETC message receipt lost
643 Invalid Packet Format
644 Shutdown Request For further engine fault code troubleshooting and
646 CAN Tx failure diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
647 CAN Rx failure
648 CAN address conflict failure Ford DSG 423 EFI Service Manual
655 RTI 2 loss Genie part number 119494
656 RTI 3 loss

711 Relay control ground short
712 Relay coil open
713 Relay coil short to power
714 FPump relay control ground short
715 Fpump relay coil open
716 Fpump relay coil short to power
721 Start relay control ground short
722 Start relay coil open
723 Start relay coil short to power
731 PWM1-Gauge1 open / ground short
732 PWM1-Gauge1 short to power
734 PWM2-Gauge2 short to power
Part No. 107846 Z-45/25 • Z-45/25J 5 - 15

5 - 16 Z-45/25 • Z-45/25J Part No. 107846

August 2006 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

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.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules and gradually. Do not allow oil to squirt
operating instructions in the appropriate or spray.
Operator's Manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 107846 Z-45/25 • Z-45/25J 6-1

Section 6 • Schematics August 2006
Electrical Symbols Legend

REV A
FS1
BLK
BLK
P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START
Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value
Diode Hour meter

TS6
DOWN
UP
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
KS1
25A A B C
CB1
PULL IN
Fuse
HOLD
CR4
15A with amperage N.O. Key switch
Circuit breaker
with amperage
Control relay contact Fuel or RPM
normally open solenoid
Starting aid:
glow plug or
flame ignitor
Coil
6-2 Z-45/25 • Z-45/25J Part No. 107846

Hydraulic Symbols Legend

REV A
25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size
Solenoid operated
Solenoid operated 3 position, 3 position, 4 way,
Filter with 4 way, directional valve proportional directional valve
bypass valve
relief setting
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve
o
Brake
Pump Solenoid operated 2 position,

bi-directional, 3 way, directional valve
variable displacement Directional valve
(mechanically activated)
3000 psi
(206.8 bar)
Shut off valve
3:1
50% 50%
Flow divider/combiner valve

Motor with pressure balancing orifice
bi-directional Counterbalance valve
and flow percentages with pressure and pilot ratio
Pilot operated 3 position,

3 way, shuttle valve
Motor
2-speed,
bi-directional
2 position, 2 way
solenoid valve
E
Pump prime mover
(engine or motor)
Differential
sensing valve
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Solenoid operated
proportional valve
Part No. 107846 Z-45/25 • Z-45/25J 6-3

Ford Engine Relay Layout

REV A
Ford LRG-425 EFI (before serial number 30142)
F5-15A
Power
F4-15A F3-20A
Relay
F2-5A F1-30A
Starter Fuel Pump

Relay Relay
Ford DSG-423 EFI (after serial number 30141)
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A
6-4 Z-45/25 • Z-45/25J Part No. 107846

Ford LRG-425 EFI Engine Wire Harness

Ford LRG-425 EFI Engine Wire Harness REV A
A B C D E F G H I J K L M N
6 361 R 16 361 R 16 361 R 16 361 R 16 361 R 16
1
INJ +
INJ 1
7 555 T 16 555 T 16 FORD
8 557 BR-Y 16 557 BR-Y 16
INJ 3
INJ 4
9 558 BR-LB 16 558 BR-LB 16 42 PIN
10 556 W 16 556 W 16
INJ 2
INJ 5
11 743 GY 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2
570 BK-W 16 39 R-W 18
CONNECTOR
12 359 GY-R 18 16 WATER TEMP
INJ 6
31
AUX OUT 2
EGR
21 18 O-Y 18 WATER
19 198 DG-O 18 ACT TEMP
AUX ANA PD1
20 358 LG-BK 18
MAP
15 151 LB-BK 18 151 LB-BK 151 LB-BK
FPP 1 14 FPP1
2 IAT
27
28
743 GY 18
354 LG-R 18
307 BK-Y 18
354 LG-R 18 359 GY-R 18
307 BK-Y 18
25 IVS
ECT
17 307 BK-Y 18 570 BK-W 16
IVS F1 30A
18 150 DG-W 18 570 BK-W 16 570 BK-W 12 570 BK-W 12 34 GROUND
AUX ANA PU1
16 114 LB-Y 18
ECT 570 BK-W 16
FPP 2
22 352 BR-LG 18 F2 5A
EGR PWM 16 R-LG 18 16 R-LG 18
23 360 BR-PK 18 1 VSW
EGR RECIRC
1 570 BK-W 16 570 BK-W 16
POWER GROUND
2 570 BK-W 16 570 BK-W 16 MAP_CONN
POWER GROUND F3 20A
13 359 GY-R 18 570 BK-W 16 361 R 14 361 R 14 361 R 12
ANA_RTN 9 VBATT
14 351 BR-W 18 351 BR-W 18 351 BR-W 18 TWR
5 VOLT REF C
3 VSW
3
33
16 R-LG 18
350 GY 18
16 R-LG 18
358 LG-BK 18 358 LG-BK 18
361 R 14
CRANK - B
32 349 DB 18 359 GY-R 18 359 GY-R 18
CRANK + A
35 452 GY-R 18 18 O-Y 18 18 O-Y 18
CAM - 38 EGR ANA IN
34 282 DB-O 18 198 DG-O 18 198 DG-O 18
CAM + 32 ANA AUX PD1
4 361 R 16 150 DG-W 18 150 DG-W 18
VBAT CAM CRANK 37 ANA AUX PU1
5 361 R 16 361 R 14 114 LB-Y 18 114 LB-Y 18
VBAT 12 FPP2
25 392 R-LG 18 352 BR-LG 18 352 BR-LG 18
EGO 2 40 EGR PWM
24 74 GY-LB 18 360 BR-PK 18 360 BR-PK 18
EGO 1 41 EGR REC
EGO 3
26 O2 SENSOR 361 R 14
29
KNK + 359 GY-R 18 359 GY-R 18
4 KNK -
30
351 BR-W 18 351 BR-W 18
33 ANA RTN
31 VREF
J1 BLACK 361A R 16 361A R 16 O2 MTRTWR6 MTRSHD6

TWR SHD
THROTTLE
FUEL PUMP
16 R-LG 18 32 R-LB 16
13 STARTER CONTROL
570 BK-W 16 570 BK-W 16 SENSOR 355 GY-W 18
A A
355 GY-W 18
6
86 30 STARTER
357 Y-W 18 357 Y-W 18 RELAY RELAY
74 GY-LB 18 392 R-LG 18 B B 5
151 LB-BK 18 151 LB-BK 18
C C 4 85 87 87A
359 GY-R 18 359 GY-R 18 317 GY-O 18 317 GY-O 18 86 30 32 R-LB 16
D D 1 15 STARTER IN (INTERUPT)
359 GY-R 18 351 BR-W 18 32 R-LB 16
E E 3 39 STARTER IN (AUTOCRANK)
J2 GREY TWR 342 LG-P 18
351 BR-W 18
F F
359 GY-R 18
2
85 87 87A
342 LG-P 18
4 570 BK-W 16 242 DG 18
SPK PWR GROUND A
5 COIL 1
1
2
850 Y-BK 18
851 Y-R 18
1 COIL 1
1 2 3
F4 15A
COIL 2
361A R 16
2 VBAT B
361A R 16 359 GY-R 18 D FPP_COMM 787A PK-BK 16 787A PK-BK 16
3 RTN 5 FUEL PUMP
COIL 3 3 COIL 2 351 BR-W 18 C
13 5V
COIL 4 LOCKOFF SOLENOID 669 DG-W 18 B
24 TX
COIL 5 458 O-BK 18 A
25 RX 86 30 POWER
COIL 6 TWR
STARTER LOCKOUT
22 342 LG-P 18 RELAY
23 242 DG 18
FUEL LOCKOFF 85 87 87A
9 926A LB-O 18 926A LB-O 18
FUEL PUMP F5 15A
32 15 R-Y 18 15 R-Y 18 361 R 16 361 R 16
RELAY CONTROL
30 355 GY-W 18
TPS1
6 TPS2
31
28
357 Y-W 18
151 LB-BK 18 OIL PRESSURE
253 DG-W 18
DBW +
29 317 GY-O 18
DBW -
6 511 LG-R 18 511 LG-R 18 511 LG-R 18
BRAKE SWITCH 4 BRAKE
7 253 DG-W 18 253 DG-W 18 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 11 T-Y 18
TACH 2 TACH
27 658 PK-LG 18 658 PK-LG 18 658 PK-LG 18
MIL 6 MIL
10 238 DG-Y 18 238 DG-Y 18
FUEL PUMP MON
5 71 O-LG 18 71 O-LG 18 71 O-LG 18
AUX OUT 1 21 AUX OUT1
14 72 Y-BK 18 72 Y-BK 18 72 Y-BK 18
FUEL SELECT 7 FUEL SELECT
15 148 Y-R 18 148 Y-R 18 148 Y-R 18
AUX ANA PU2 10 AUX ANA PU2
7 GOV SELECT 1
16
17
306 T-LB 18 306 T-LB 18 306 T-LB 18
24 GOV SELECT 1
307 BK-Y 18 307 BK-Y 18 307 BK-Y 18
GOV SELECT 2 23 GOV SELECT 2
11 169 LG-BK 18 169 LG-BK 18 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18
GASEOUS TRIM
33 349A DB 18 349A DB 18 349A DB 18
OVERSPEED 30 OVERSPEED
18 662 DG-P 18 662 DG-P 18 662 DG-P 18
CAN + 28 CAN +
19 459 O-LG 18 459 O-LG 18 459 O-LG 18
CAN - 29 CAN -
20 642 DG-O 18 642 DG-O 18 642 DG-O 18
RS 485 + 11 RS 485+
21 461 O 18 461 O 18 461 O 18
RS 485 - 3 RS 485-
34 669 DG-W 18 669 DG-W 18 669 DG-W 18
RS 232 TX 20 RS 232+
8 RS 232 RX
35 458 O-BK 18 458 O-BK 18 458 O-BK 18
18 RS 232-
TWR SHD
570 BK-W 16
TRIM VALVE A A PLUG (GROUND)
TWR 361A R 16
77 DB-Y 18 B B PLUG (RELAY POWER)
A 459 O-LG 18
361A R 16 361A R 16 C C PLUG (CAN -)
B 662 DG-P 18
D D PLUG (CAN +)
WPTWR2_GY MTRTWR4 MTRSHD4
6-5 Z-45/25 • Z-45/25J Part No. 107846

REV A Ford DSG-423 EFI Engine Wire Harness
N M L K J I H G F E D C B A
IGNITION COILS HO2S #1
ENGINE ECM Y/BK 18
R 16 R 16 R 16 HO2S #2
SHD
1
CONNECTOR W/PK 18 BK/LG 18 GY/R 18
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
8 CYL #2 CYL #3 CYL #4 CYL #1 TWR
UEGOS
9
GY/R 18 GASOLINE
A
UEGOC LG/W 18 SENSOR
UEGOP
10 CAM BR/W 18 B
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1 W/LG 18
13 FORD
(FRP) AUX ANA PD2
CAN1 +
CAN1 -
14
15
DG/P 18
O/LG 18
DG/P 18
O/LG 18
MTRTWR4 42 PIN
CONNECTOR
2
16
CAN2 - BR/W 18
17
CAN2 + LG/R 18 LG/R 18
18
AUX ANA PD3 BR/W 18
19
5V EXT 1 GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
5V EXT 2
5V RTN 2
31
32
33
LG/W
DG/BK
LB/R 18
LB/R 18
LG/BK 18
36 ROADSPEED -
3
PULSE IN 35 ROADSPEED +
34 T/LB 18 T/LB 18 T/LB 18
GOV 1 24 GOV SELECT 1 C128 RPM
35 DG/W 18
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2 BK/O 18
(IVS) AUX ANA PU3
40 F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW P23 BAT
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2 P/LB 18 F3
46
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
TPS 1
(FUELSELECT)AUX DIG1
TPS 2
48
49
50
Y/W 18
Y/DB 18 10A ECM 4
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2 C35 RPM
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63 R 14
INJ HS T 16
64
INJ1 LS
INJ2 LS
INJ3 LS
65
66
67
BR/Y 16
BR/LB 16
W 16
BK/LG 18
GY/W 18
BOSCH THROTTLE
GY/W 18
BATT(+) R 12 R 12
ALTERNATOR 5
INJ4 LS Y/W 18 Y/W 18 6 RING
68 R 16
INJ5 LS BK/W 16 LB/DG 18 LB/DG 18 5 3
69
GROUND BR/W 18 BR/W 18 4 2
70 R/LG 18
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER R/Y 18 1
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND
AUX PWM5 REC

DBW -
82
83
84
GY/O 18
R/BK 18
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5 6
AUX PWM5 16 AUX PWM 4
85 O/LG 18
AUX PWM1 R/W 18 BK/O 18
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC C41 RPM
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC C10 BESL
90 BK/R 16 BK/R 16 BK/R 16
FUEL PUMP AUX PWM3 18 FUEL PUMP - C21 IGN
O/LG 18 O/LG 18
39 AUX OUT1 C135 FP
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT C39 LP
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232- C127 TSW
A
INJECTOR CYL #2 FUEL PUMP
R 16 BN/LB 16
GY/R 18
B
F4
LB/PK 16
W/PK 16
15 START IN INTERUPT R33 STR 7
LPG PK/BK 16 PK/BK 16
19 START IN AUTOCRANK
PK/BK 16 5 FUEL PUMP + C135 FP+
TEMPERATURE
GY/R 18 1
ANA RTN 15A
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
A 5 FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18
B
DG/P 18
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
Y/R 18 UNUSED 85
LPG DG/P 18 7 R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8
CAN - PK/BK 16 87 LB/PK 16 30 CONNECTOR
KNOCK R/LG 18 87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON
INJECTOR CYL #3
LG/P 18 85
FPP
DG/P 18
O/LG 18
BK/W 18
3
1
6
CAN +
CAN - 8
GROUND
PK/BK 16 PK/BK 16 4
R 16 T 16 UNUSED
5
UNUSED
8
UNUSED
F1
R16 R/LB 16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A EPR EPR
INJECTOR CYL #1 R 16 30
R 16 R 16 R 16
F5 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
Part No. 107846 Z-45/25 • Z-45/25J 6-6

Ford DSG-423 EFI Engine Wire Harness

N
REV C
RD
RD
C22LS RD
BRN
P24FS WH
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
C1P-9 C35RPM BK/RD C1B-9

FOOTSW. HIGH
FOOTSW. LOW C2P-4 C128RPM OR/RD C2B-4
TS4
TB42
TS54
ENGINE
SPEED
TB35
LOW RPM
M
FUNCTION ENA.
BL/RD
HIGH RPM
TS47
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR OPTION

WH
RD
L
FUSE 10A (ONLY ON WORKLIGHTS)
CR23
TS48
C3P-4 DLITE WH C3B-4

DRIVE LIGHT
L29
LIGHTS
WORK LIGHT C4B-12 RD DRIVE LIGHT OPTION
L29
RD
RD
L30
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
CR23
NO
WORK LIGHTS OPTION

K
PBOX GND
C2P-11 C2P-9
FB1
P134BAT RD C6-34
L30
FLASHING BEACONS
OPTION
C128RPM OR/RD
TS3
C2P-1 C39LP BL/RD C2B-1

LP FUEL
TB39
GAS SELECT C21IGN WH

HM
HOUR METER
TS53
J
_
L2
LP FUEL CHECK ENGINE LED

GAS SELECT C108ESL BL/WH
ENGINE
CHECK
C35RPM BK/RD
C39LP BL/RD
TB38
BR
C1P-7 C33STR BK C1B-7
TS2
TEST RUN/TEST SWITCH

I
ENGINE
TS64
START
TS52
C5-13
CR39
C5-9
C5-8
ENGINE
TB33
START
C5-19 P23BAT WH FEH(16) PIN1 AUXILLARY POWER
RELAY
NC
CR39
C5-11 C21IGN WH FEH(71) PIN21

CR2
H
C127TSW GR
OR/RD FEH(306) PIN24

TB21
FORD 42 PIN QUICK DISCONNECT

BL/WH FEH(658) PIN6
ENGINE HARNESS #2
GR FEH(458) PIN18
CR2
NO
WH
C5-10 BL/RD FEH(72) PIN7

C5-18 BK/RD FEH(307A) PIN23
P24BAT RD
C28TTA RD/BK
P20BAT RD FEH(361) PIN9

G
(GND) BR FEH(570) PIN34

C5-2 C41RPM OR/BK FEH(11) PIN2
CR1
IGNITION/START
C5-5 R33STR BK FEH(32) PIN15 RELAY
C33STR BK FEH(32) PIN13
CR1
NO
TB24
C135FP BL/WH FEH(787A) PIN5
M4
P134BAT RD
PUMP
FUEL
BL/WH BK
P26ESTP BK
FUEL PUMP
P24FS WH
P25FS RD
F
C33STR BK
August 2006
Part No. 107846

M3
C5-3
C9P-2
C9P-3
STARTER
BAT-RD
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1
POWER C6-27 C27AUX RD AUXILIARY POWER

WH-(FS)
RD-(FS)
AUXILIARY RELAY
PR1
E
POWER C27AUX RD C1P-1

C1P-1
PUMP
BAT-RD
AUX
C28TTA RD/BK AUXILIARY PUMP
PR1
NO
L4
FS1
M2
BK-(FS)
Ford LRG-425 EFI Models (before serial number 30142)
C
WH C1P-2 C28TTA RD/BK C1P-2 C5-24 C28TTA RD/BK WH
TILT ALARM
H1
RD C2P-5 C134PWR GR C2B-5 C5-17 P134TTS RD RD BK BRN

LEVEL SENSOR
C9P-1 BK
TB134
HORN
B
A
D
S8
P3
BK C3P-9 C46HRN BK/RD C3B-9 C46HRN BK/RD

HORN RELAY
P2
CR5
C7P-2 P23BAT WH C7B-2
TB23
Z-45/25 • Z-45/25J
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK/RD C6-9
HORN
1) All switches and contacts are shown with the boom

TB22
H2
CR5
NO
C
GRND
in the stowed position and the keyswitch off.

PLAT
C41RPM OR/BK
KS1
Electrical Schematic, Z-45/25
R16
RD
P1
C107AF WH
510
TB41
BAT-RD
C41RPM OR/BK C2B-3
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
FLD.
Section 6 • Schematics
CB2
CB1
15A
15A
GND.
D1
BAT.
NOTE:
FUSE
LINK
TB20
A
-
P20BAT RD C7B-4
12 V
DC
B1
6-7
1
8
1
8

6-8
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C1P-4 C30FWD WH C1B-4 C5-21 C30FWD WH BK RD BRN
15 15 DRIVE EDC FORWARD
C1P-5 C31REV WH/BK C1B-5 C5-20 C31REV WH/BK RD BK BRN
TS14
16 DRIVE EDC REVERSE

C28TTA RD/BK
DRIVE MODE
8
H4
RD/WH C6-33 C32TA WH/RD TRAVEL ALARM OPTION

B
L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
CDE1 BL C1P-6 C32BRK WH/RD C1B-6 C6-32 C32BRK WH/RD

TS15
7 19 BRAKE RELEASE VALVE

LEFT
DRIVE ENABLE
C28-1 C28-2
Z-45/25 • Z-45/25J
RIGHT
6
CDE2 BL/BK C1P-3 C29MS RD/WH C1B-3 C6-29 C29MS RD/WH
20 MOTOR STROKE
P26ESTP BK
P24FS WH
C
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
BL C37SCW BL/BK C37SCW BL/BK
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
BRN C1P-10 C36SCC BL C1B-10 C6-36 C36SCC BL
GND 2 14 18 STEER LEFT
1 C24-1 C24-2
C3P-6 C6TRF WH/RD C3B-6
11
D
9
CR33
C3P-5 C5TRR WH/BK C3B-5 TURNTABLE ROTATE

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

TURNTABLE ROTATE TURNTABLE ROTATE RIGHT
87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TURNTABLE ROTATE LEFT
TB6
6
C6-4
20
C14-1 C14-2
7
R4
PRIMARY BOOM UP/DOWN &
14
6
CR32
TURNTABLE ROTATE
E
BK
TB1
YOUT PRIMARY BOOM

5 2
Part No. 107846
SELECT RELAY
86
85
RD
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2
OR PRIMARY BOOM PRIMARY BOOM UP

87a 87
PWR 11 DOWN
August 2006
3
30
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
C3P-1 C1PBU RD C3B-1
6
F
C3P-2 C2PBD RD/BK C3B-2

7
C3P-3 C3PBF RD/WH C3B-3
8
7
SECONDARY BOOM UP/DOWN
C3P-12 C12SBF BL/WH C3B-12

6 14
YEL
OUT 5 3
C3P-11 C11SBD BL/BK C3B-11
13
JC1
4
J1
OR
PWR 3 9 C3P-10 C10SBU BL C3B-10
CR37
12
G
TB10
BRN
GND 2 10 SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
SECONDARY BOOM SECONDARY BOOM UP
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
U13 JOYSTICK CONTROL CARD
2
P24FS WH
J3
LS3
4
C4P-4 C16PDRE OR/RD C4B-4 C6-16 BK-6 WH-6 C6-13
3
H
LS3 - DRIVE ENABLE

13
14
P26ESTP BK
2
3 LIMIT SWITCH
C2P-2 LS1 - PRIMARY BOOM EXTEND
LS1
4 DRIVE LIMIT SWITCH

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2
C11-4 WH-7 BK-7 C11-3 LS2 - PRIMARY BOOM UP

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
C2B-2 C6-40 OR C10-3 BK-4 WH-4 C10-4 BK C10-1 BK-5 LS4 - SECONDARY BOOM UP
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
C3P-7 C7PBE BK C3B-7
EXTEND
BOOM
RETRACT C3P-8 C8PBR BK/WH C3B-8
TS13
TB7 C16-1 C16-2

TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
RETRACT C6-8 C8PBR BK/WH
BOOM RETRACT
J
TB8
C17-1 C17-2
C4P-2 C14PLU OR C4B-2
TS9
DOWN
PLATFORM LEVEL
UP C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
UP C6-15 C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
K
WH
C4P-6 C18JD GR/BK C4B-6

RIGHT
PLATFORM
LEFT ROTATE
C4P-5 C17JU GR C4B-5
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
PLATFORM ROTATE RIGHT /
RIGHT JIB BOOM DOWN
PLATFORM
LEFT ROTATE
C6-17 C17 JU GR
PLATFORM ROTATE LEFT /
JIB BOOM UP
TB17
C22-1 C22-2
L
C5-25
C129DA BK C6-19
DESCENT ALARM OPTION
H3
ROTATED PAST EITHER NON-STEER
WITH BOOM IN STOWED POSITION
1. ALL LIMIT SWITCHES SHOWN
2 SWITCH SHOWN WITH BOOM

M
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK

N
REV A
RD
RD
C22LS RD
BRN
P24FS WH
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK

FOOTSW. HIGH
TS4
TB42
TS54
ENGINE
SPEED
TB35
LOW RPM
M
FUNCTION ENA.
BL/RD
HIGH RPM
TS47

WH
RD
L
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
L29
RD
RD
L30
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
CR23
NO
WORK LIGHTS OPTION

K
PBOX GND
C2P-11 C2P-9
FB1
P134BAT RD C6-34
L30
FLASHING BEACONS
OPTION
C128RPM OR/RD
TS3

+
C21IGN WH
HM
LP FUEL HOUR METER

TB39
GAS SELECT
TS53
J
CHECK ENGINE LED

L2
LP FUEL
GY/RD
SELECT A
GAS C108ESL BL/WH
FORD ENGINE
GY/YL
B GASOLINE SENSOR
HARNESS
RD
C
ENGINE
BK/BL
CHECK
D
C35RPM BK/RD
C39LP BL/RD
TB38
RD/GN
WH/BK LPG LOCKOUT
BR
TS2

I
ENGINE
TS64
START
TS52
C5-13
CR39
C5-9
C5-8
ENGINE
TB33
START
RELAY
NC
CR39

CR2
H
C127TSW GR

TB21

BL/WH FEH(658) PIN6
ENGINE HARNESS #2
GR FEH(458) PIN3
CR2
NO
WH

P24BAT RD
C28TTA RD/BK
G

CR1
IGNITION/START
CR1
NO
TB24
M4
P134BAT RD
PUMP
FUEL
BL/WH BK PIN18
P26ESTP BK
FUEL PUMP
P24FS WH
P25FS RD
F
START (FEH)
August 2006
Part No. 107846

M3
C9P-2
C9P-3
STARTER
BAT-RD
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1

WH-(FS)
RD-(FS)
AUXILIARY RELAY
PR1
E

C1P-1
PUMP
BAT-RD
AUX
PR1
NO
L4
FS1
M2
BK-(FS)
C
Ford DSG-423 EFI Models (after serial number 30141)
TILT ALARM
H1

LEVEL SENSOR
C9P-1 BK
TB134
HORN
B
A
D
S8
P3

HORN RELAY
P2
CR5
TB23
Z-45/25 • Z-45/25J
HORN

TB22
H2
CR5
NO
C
GRND

PLAT
C41RPM OR/BK
KS1
RD
P1
ALTERNATOR
FIELD (FEH)
TB41
BAT-RD
C41RPM OR/BK C2B-3
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
FLD.
CB2
CB1
15A
15A
GND.
D1
BAT.
NOTE:
FUSE
LINK
A
TB20
-
P20BAT RD C7B-4
12 V
DC
B1
6-9
1
8
8
6 - 10
C7P-3 BATGND C7B-3

GROUND
A
C41RPM OR/BK
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
B
8
H4

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

Z-45/25 • Z-45/25J
LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
C
P26ESTP BK
P24FS WH
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
D
11
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
E
14
6
Part No. 107846
CR32
TURNTABLE ROTATE
BK
TB1
YOUT PRIMARY BOOM

5 2
SELECT RELAY
86
85
RD
C12-1 C12-2
JC2
XOUT
August 2006
4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
F
6
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
G
OR
CR37
12
TB10
BRN
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
H

3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

I
21
22
CE
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
J

BOOM RETRACT
TB8
C17-1 C17-2
TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
K
TB15
C21-1 C21-2
WH

RIGHT
PLATFORM
LEFT ROTATE
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
RIGHT JIB BOOM DOWN
PLATFORM
LEFT ROTATE
C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
L
C5-25
C129DA BK C6-19
H3
M
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

NOTES:
WHEEL.
C41RPM OR/BK
REV A
C28TTA RD/BK
P26ESTP BK
N
P24FS WH
BRN
RD
RD
BK

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

Ford Models
8
7
6
5
4
3
2
1
6 - 11
30
D C TERMINAL BASE (TB) B A
85
86
CR32 #86 RD
87A
C3B-1 RD RD-TS61
Ford Models
A
1 PRIMARY BOOM UP 1
87
BK
C3B
C3B-2 RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
CR32 #30 RD/WH
C3B-3 RD/WH RD/WH-TS61
87 = NO
87A = NC
3 PRIMARY BOOM FUNCTION CONTROL 3
4 4
CR33 #86 WH/BK
86 = COIL POSITIVE
85 = COIL NEGATIVE
BK
C3B-5 WH/BK WH/BK-TS62

5 TURNTABLE ROTATE RIGHT 5
CR33 #30 WH/RD
B
30 = COMMON (12V DC IN)

C3B-6 WH/RD WH/RD-TS62
6 TURNTABLE ROTATE FUNCTION CTRL 6
C6-7 BK
C3B
C3B-7 BK BK-TS63
7 PRIMARY BOOM EXTEND 7
C6-8 BK/WH
C3B-8 BK/WH BK/WH-TS63

8 PRIMARY BOOM RETRACT 8
CR37 #86 BL
C6
C3B-10 BL BL-TS60
10 SECONDARY BOOM UP 10
BK
C3B-11 BL/BK BL/BK-TS60

11 SECONDARY BOOM DOWN 11
C
CR37 #30 BL/WH
C3B-12 BL/WH BL/WH-TS60

12 SECONDARY BOOM FUNCTION CTRL 12
C6-14 OR
C4B-2 OR OR-TS59
14 PLATFORM LEVEL UP 14
C6-15 OR/BK
C4B
Z-45/25 • Z-45/25J
C4B-3 OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6-17 GR
C7B
C4B-5 GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C3B
C6-18 GR/BK
BK-ALARM
C4B-6 GR/BK GR/BK-TS57

18 PLATFORM ROTATE RIGHT/JIB DOWN 18
D
CR23 RD RD-CB2
12V DCTO PLAT

C7B-4 RD RD-CB1
20 +12 VOLT POWER 20
WH-CR2 BRN
C5-3 WH WH-HM
21 IGNITION POWER 21
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
22 +12 VOLT TO PLATFORM 22
C6
C7B-2 WH WH-KS
23 KEYSWITCH POWER 23
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
RD-CB1
E
FUNCTIONS
24 CB1 POWER 24
C7B-3
25 (UNUSED) 25
26 (UNUSED) 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-CR39
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
27 AUXILIARY PUMP 27
C1B-6 WH/RD
Part No. 107846

August 2006
C4B
C6-32 WH/RD WH/RD-ALARM C6-33
32 BRAKE 32
C4B-4
BK-CR1
F
C1B-7 BK BK-33 TS52
C3B
33 START ENGINE 33
C3B
34 (UNUSED) 34
C5-18 BK/RD
C2B-2
C1B-3
C1B-11
C1B-10
C1B-9 BK/RD BK/RD-TS54
C5
35 HIGH RPM 35
C2B
C2B
C5-13 BL/WH BL/WH-L2 (-)
19/18 CABLES
38 CHECK ENGINE LED 38
C5-10 BL/RD
C2B-1 BL/RD BL/RD-TS53
C1B
39 LIQUID PROPANE FUEL 39

C2B-3 OR/BK
G
C1B
C5-2 OR/BK OR/BK-IS2
41 ALTERNATOR PULSE PICKUP 41
C5-9 OR/RD
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD OR/RD-TS54
42 LOW RPM 42
BK-ALARM

44 JIB DOWN DESCENT ALARM 44
C3B
BRN
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
H
C4B
C43DLITE GR
RD-24B
CR2
CR1
RELAY
RELAY
FUNCTION
POWER
ENGINE HARNESS
CR39
IGNITION
P20DLITE RD
AUXILLARY
START RELAY
RELAY BRN
BRN
HARNESS
HARNESS
CR23
I
C5-20
C5-21
C5-24
C5-12
BRN
BRN
DRIVE LIGHT
C5-5 BK
OPTION RELAY
BRN
C5
RD-27B
WH-21C
C5-11 WH
BRN-GND
C5-8
BK-33B
ENGINE
R27AUX C5-6 RD
C3B
C4B
GROUND CONTROL HARNESS
C6-39 R43DLITE2 RD
F19
C127TSW
C6-38 R43DLITE1 RD
10A FUSE
J
RD
BRN
GR
BATGND BRN
C6-10 BL
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
TS64
C6-1 RD
SWITCH
C6-2 RD/BK
RUN/TEST
C3B-9 BK/RD
C6-9 BK/RD
CR37
CR33
K
CR32
BOOM
RELAY
RELAY
BOOM
RELAY
ROTATE
PRIMARY
TURNTABLE
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
BRN-TS
BL-10B
BRN
BRN
BRN
BL/WH-12B
CR5
WH/BK-5B
HORN
RELAY
L
C6
WH/RD-6B
C4B
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

C6-33 WH/RD-ALARM WH/RD-32A
C5-19 BK-ALARM BK-ALARM

C7B3 BRN
M
C4B-7 GR/WH C19JSV GR/WH TS57

F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES

REV A
N
REV B Ground Control Box Switch Panel Wiring Diagram, Z-45/25

Ford Models
PLATFORM
LABEL DESCRIPTION
RD RD
1
ROTATE
TS57
EXTEND/RETRACT
CB1 CIRCUIT BREAKER, ENGINE, 15A
BK/WH-8A RD
PRIMARY BOOM
CB2 CIRCUIT BREAKER, CONTROLS, 15A RD RD RD
BK-7A
CR1 IGNITION / START RELAY
RD
TS63
CR2 INGITION POWER RELAY
GR/BK-18
RD
TURNTABLE
RD
C19JSV GR/WH
CR4 HIGH IDLE RELAY RD
ROTATE
RD
TS62
D4 RD
CR5 HORN RELAY
WH/RD-6A
WH/BK-5A
GR-17
HM HOUR METER D3
2
RD
RD
AUXILIARY
RD
POWER
KS1 KEY SWITCH
TS51
RD
L2 CHECK ENGINE LED
P1 RED EMERGENCY STOP BUTTON
UP/DOWN
R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS
PRIMARY
RD
RD
RD
RD
RD
RD-27
BOOM
TS61
R14 UP/DOWN SPEED RESISTER 7.5 OHMS
TS51 AUXILIARY TOGGLE SWITCH
RD
TS52 ENGINE START TOGGLE SWITCH
3
PLATFORM
TS53 FUEL SELECT TOGGLE SWITCH
LEVEL
TS59
TS54 FUNCTION ENABLE TOGGLE SWITCH
SELECT
FUEL
TS53
TS57 PLATFORM ROTATE TOGGLE SWITCH
C4B-7 GR/WH
OR/BK-15A
GR/BK-18A
TS59 PLATFORM LEVEL TOGGLE SWITCH
BL/RD-39A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
RD/BK-2A
GR-17A
OR-14A
RD-27A
RD-1A
BK-7A
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
WH
RD
RD
RD
RD
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS62 TURNTABLE ROTATE TOGGLE SWITCH RD RD
BK-22A 4
RD 134A
WH-23A
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH RD
RD
RD
RD
BL/WH-12A
BL/WH-38
BL/BK-11A
TS64 RUN/TEST TOGGLE SWITCH
BL-10A
KS1
RD
CIRCUIT BREAKER
P-BOX
BOOM UP/DOWN
RD
CONTROLS 15A
SECONDARY
WH-23
TS60
CB2
+
-
ENGINE
CHECK
5
RD
RD
RD
LED
G-BOX
L2
R14
RD
RD
RD-20B
D2
RD
RD
RD RD
6
RD
RD
RD-24A
BK-33A
C32-7
RD C23-7
RD
RD
OR/RD-42A
BK/RD-35A
CIRCUIT BREAKER
WH-CR2
TS52
BRN
ENGINE 15A
SWITCH
ENGINE
START
WH-21A
7
BRN
RD-20A
CB1
RD
CONTROL VARIABLE
FUNCTION SPEED
RESISTER, 20
RD
RD
RD
SWITCH
HOUR METER
RD
STOP
P1
RD
(TO TERMINAL STRIP)
BASE BOX HARNESS
RD
FUNCTION
ENABLE
RD
TS54
R4
RD RD
RD
14
Part No. 107846 Z-45/25 • Z-45/25J 6 - 12

Ground Control Box Switch Panel Wiring Diagram, Z-45/25

Ford Models
Platform Control Box Wiring Diagram, Z-45/25

Ford Models
N
REV A
12V DC PLATFORM POWER CONNECTOR
CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD POWER CONNECTOR
PLATFORM CONTROL
(TO SWITCH PANEL)
CONTROL BOARD INPUT CONNECTOR

HARNESS
CONTROL RELAY (CE OPTION)

FOOT SWITCH CONNECTOR
LOAD SENSE LIMIT SWITCH

48 PIN CONNECTOR BLOCK
ALC-500 CONTROL BOARD
RD-P2
DESCRIPTION
M
RD-H1
TILT ALARM
Y
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
L
CE LIFT/DRIVE OPTION
OPT.
TS7
CR27
BRN
C32BRK WH/RD C1P-6

K
C32BRK WH/RD J2-19

CE OPTION
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
I
C9HRN BK/RD C3P-9

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
H
C3P
F.S.
CWLITE RD C2P-11
C45GEN GR/WH C2P-7
C9
C128LS OR/RD C2P-4

C39LP BL/RD C2P-1
P26ESTP BK
G
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
P24FS WH C41RPM OR/BK C2P-3
F
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
August 2006
Part No. 107846

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2

C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C32BRK WH/RD C1P-6 C4P(BR)
E
C5TRR WH/BK C3P-5

ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9
C33STR BK C1P-7
D
C27AUX RD C1P-1
C2P(BK)
J1
C1P
9
JC1-3 OR
Platform Box Wiring Diagram, Z-45/25
Z-45/25 • Z-45/25J
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C
C7P
JC2-2 BRN
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
DRE A BL/WH C28TTA RD/BK H1
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
B
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
A
Ford Models
RED-TILT RED-TILT C2P-5
RED - LS18
BRN
BRN
BRN BRN
6 - 13
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25

Ford Models
TS47 PLATFORM CONTROL

GENERATOR HARNESS
(OPTION) (TO CONTROL BOX)
JC2 JC3
GR/WH DRIVE
PRIMARY BOOM
UP/DOWN 7 JC1 7 BK RD FORWARD/REVERSE
7
& TURNTABLE ROTATE SECONDARY BOOM & STEER LEFT/RIGHT
LEFT/RIGHT UP/DOWN TS15 2
6 6 DRIVE
ENABLE 6
5 5 + 5
RD
BK
GR/WH
L48
4 TS13 4 TILT ALARM LED 4
BK
PRIMARY TS48
BOOM
3 EXTEND/ 3 DRIVE LIGHTS/
WORK LIGHTS
3 3
RETRACT (OPTION)
RD
2 2 2
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED
4
RD
F18
FUSE 10A
C45GEN GR/WH C2P-7
GENERATOR OPTION
C8PBR BK/WH C3P-8
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
BL/RD-DE3 J1-16
C3P-4 DLITE WH
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
5
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
BL J1-5
BK
RD
RD
BK
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C17PRL GR C4P-5
C27AUX RD C1P-1
C29MS RD/WH J1-8
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9
C128LS OR/RD C2P-4
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
RD
BK
6
BK BK
WH WH TS3
FUEL
7
SELECT 2 2 2
3
NO
4
DRIVE P2
EMERGENCY NC NC NC
SPEED
STOP
TS7 TS14 TS2 TS4 1 1 1
P3 WH PLATFORM HIGH/LOW ENGINE HIGH/LOW RD
TS9 TS1
HORN ROTATE (2WD/4WD) START RPM
PLATFORM AUXILIARY PUMP
RD
LEVEL WH-24
8
RD RD RD RD RD RD
Part No. 107846 Z-45/25 • Z-45/25J 6 - 14

Platform Control Box Switch Panel Wiring Diagram, Z-45/25

Ford Models
REV C
RD
RD
C22LS RD
BRN
P24FS WH
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK

HIGH RPM
ENGINE
SPEED
LOW RPM C2P-4 C128RPM OR/RD C2B-4
TS4
TB42
TS54
M
TB35
LOW RPM
FUNCTION
ENABLE
HIGH RPM
BL/RD
TS47
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH
GENERATOR OPTION
WH
RD
L
CR23
TS48

DRIVE LIGHTS
L29
WORK LIGHTS C4B-12 RD

DRIVE LIGHT OPTION
L29
RD
RD
L30
C4B-11 RD
FUSE 10A
K
C2P-12 C2P-10
NO
CR23
WORK LIGHT OPTION

C2P-11 C2P-9
PBOX GND
FB1
P134BAT RD C6-34
L30
FLASHING BEACONS OPTION

C128RPM OR/RD
TS3
LP
J
FUEL SELECT
TB39
GAS C21IGN WH
HOUR METER
TS53
_
L2
LP
CHECK ENGINE LED
FUEL SELECT
GAS C108ESL BL/WH
ENGINE
CHECK
TB38
C35RPM BK/RD
C39LP BL/RD
BR
I
C1P-7 C33STR BK C1B-7 RUN/TEST SWITCH

TS2
TEST
ENGINE
TS64
START
TS52
C5-13
C5-9
CR39
C5-8
ENGINE
START
TB33
C5-19 P23BAT WH FEH(16) PIN1 AUXILLARY RELAY

NC
CR39
H

CR2

C127TSW GR
TB21
BL/WH FEH(658) PIN6

GR FEH(458) PIN18
CR2
NO

ENGINE HARNESS #2
WH

P24BAT RD
G
C28TTA RD/BK
P20BAT RD FEH(361) PIN9

CR1
C5-5 R33STR BK FEH(32) PIN15 IGNITION/START

RELAY
C33STR BK FEH(32) PIN13
CR1
NO
TB24
M4
PUMP
FUEL
BL/WH BK
F
FUEL PUMP
P134BAT RD
P26ESTP BK
P24FS WH
P25FS RD
August 2006
Part No. 107846

C33STR BK
M3
C5-3
C9P-2
C9P-3
BAT-RD
STARTER MOTOR
TS51
TB27
AUXILIARY POWER
E
TS1
C6-27 C27AUX RD
AUXILIARY POWER RELAY
AUXILIARY POWER
WH-(FS)
RD-(FS)
PR1
C1P-1 C27AUX RD C1P-1
PUMP
BAT-RD
AUX
PR1
NO
L4
FS1
M2
BK-(FS)
C
TILT ALARM
H1
B
D

LEVEL SENSOR
C4B & C4P - BROWN

C9P-1 BK
C3B & C3P - GREEN

A
C2B & C2P - BLACK

TB134
HORN
C1B & C1P - GRAY

S8
P3

HORN RELAY
P2
Z-45/25 • Z-45/25J
CR5
TB23
HORN
H2
TB22
CR5
NO
C
boom in the stowed position and the keyswitch off.

Electrical Schematic, Z-45/25J
1) All switches and contacts are shown with the

GRND
PLAT
KS1
C41RPM OR/BK
R16
RD
C107AF WH
P1
510
B
TB41
BAT-RD
C41RPM OR/BK C2B-3
RD
S
RD
STA.
I
ALTERNATOR
REGULATOR
ALTERNATOR
FLD.
15AMP.
15AMP.
CB2
CB1
D1
GND.
BAT.
A
NOTE:
FUSE
LINK
TB20
-
P20BAT RD C7B-4
12V DC
B1
6 - 15
1
8
1
8
6 - 16
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

B
L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
Z-45/25 • Z-45/25J

20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
PRIMARY BOOM
E
YOUT 5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
C6-1
August 2006
BRN
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
F
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
G
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3
H
LIMIT SWITCH
LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
BOOM RETRACT
TB8
J
C17-1 C17-2
TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
K
GR/BK-44 C2P-6 C129DA GR/BK C2B-6

WH
CR13
NC

DOWN
JIB BOOM
UP C4P-5 C17JU GR C4B-5
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
DOWN JIB BOOM DOWN
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
TS57
RIGHT
PLATFORM C5-25
L
LEFT ROTATE RIGHT

PLATFORM
LEFT ROTATE
TS7
WH
C129DA BK C6-19
H3
C4P-7 C19JSV GR/WH C4B-7

CR13

C19JSV GR/WH
M
BRN
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

BK WH
JIB BOOM VALVE
JIB BOOM VALVE
NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
N
RD
RD
BK

N
REV A
RD
RD
C22LS RD
BRN
P24FS WH
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK

FOOTSW. HIGH
TS4
TB42
TS54
ENGINE
SPEED
TB35
LOW RPM
M
FUNCTION ENA.
BL/RD
HIGH RPM
TS47

WH
RD
L
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
L29
RD
RD
L30
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
CR23
NO
WORK LIGHTS OPTION

K
PBOX GND
C2P-11 C2P-9
FB1
P134BAT RD C6-34
L30
FLASHING BEACONS
OPTION
C128RPM OR/RD
TS3

+
C21IGN WH
HM
LP FUEL HOUR METER

TB39
GAS SELECT
TS53
J
CHECK ENGINE LED

L2
LP FUEL
GY/RD
SELECT A
GAS C108ESL BL/WH
FORD ENGINE
GY/YL
B GASOLINE SENSOR
HARNESS
RD
C
ENGINE
BK/BL
CHECK
D
C35RPM BK/RD
C39LP BL/RD
TB38
RD/GN
WH/BK LPG LOCKOUT
BR
TS2

I
ENGINE
TS64
START
TS52
C5-13
CR39
C5-9
C5-8
ENGINE
TB33
START
RELAY
NC
CR39

CR2
H
C127TSW GR

TB21

BL/WH FEH(658) PIN6
ENGINE HARNESS #2
GR FEH(458) PIN3
CR2
NO
WH

P24BAT RD
C28TTA RD/BK
G

CR1
IGNITION/START
CR1
NO
TB24
M4
P134BAT RD
PUMP
FUEL
BL/WH BK PIN18
P26ESTP BK
FUEL PUMP
P24FS WH
P25FS RD
F
START (FEH)
August 2006
Part No. 107846

M3
C9P-2
C9P-3
STARTER
BAT-RD
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1

WH-(FS)
RD-(FS)
AUXILIARY RELAY
PR1
E

C1P-1
PUMP
BAT-RD
AUX
PR1
NO
L4
FS1
M2
BK-(FS)
C
TILT ALARM
H1

LEVEL SENSOR
C9P-1 BK
TB134
HORN
B
A
D
S8
P3

HORN RELAY
P2
CR5
TB23
Z-45/25 • Z-45/25J
HORN

TB22
H2
CR5
NO
C
GRND

PLAT
C41RPM OR/BK
KS1
RD
P1
ALTERNATOR
FIELD (FEH)
TB41
BAT-RD
C41RPM OR/BK C2B-3
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
FLD.
CB2
CB1
15A
15A
GND.
D1
BAT.
NOTE:
FUSE
LINK
A
TB20
-
P20BAT RD C7B-4
12 V
DC
B1
6 - 17
1
8
8
6 - 18
C7P-3 BATGND C7B-3

GROUND
A
C41RPM OR/BK
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
B
8
H4

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

Z-45/25 • Z-45/25J
LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
C
P26ESTP BK
P24FS WH
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
D
11
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
E
14
6
Part No. 107846
CR32
TURNTABLE ROTATE
BK
TB1
YOUT PRIMARY BOOM

5 2
SELECT RELAY
86
85
RD
C12-1 C12-2
JC2
XOUT
August 2006
4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
F
6
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
G
OR
CR37
12
TB10
BRN
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
H

3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

I
21
22
CE
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
J

BOOM RETRACT
TB8
C17-1 C17-2
TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
K
TB15
TB44
C21-1 C21-2
WH
CR13
NC

DOWN
JIB BOOM
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
DOWN JIB BOOM DOWN
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
L
TS57
RIGHT
PLATFORM C5-25
LEFT ROTATE RIGHT
PLATFORM
LEFT ROTATE
TS7
WH
C129DA BK C6-19
H3

CR13

M

C19JSV GR/WH
BRN
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

BK WH
JIB BOOM VALVE
JIB BOOM VALVE
NOTES:
WHEEL.
C41RPM OR/BK
REV A
C28TTA RD/BK
P26ESTP BK
N
P24FS WH
BRN
RD
RD
BK

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

Ford Models
8
7
6
5
4
3
2
1
6 - 19
30
85
86
CR32 #86 RD
87A
C3B-1 RD RD-TS61
Ford Models
A
1 PRIMARY BOOM UP 1
87
BK
C3B
CR32 #30 RD/WH
87 = NO
87A = NC
4 4
CR33 #86 WH/BK
86 = COIL POSITIVE
85 = COIL NEGATIVE
BK

CR33 #30 WH/RD
B

C3B-6 WH/RD WH/RD-TS62
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
C3B-10 BL BL-TS60
BK

C
CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
Z-45/25 • Z-45/25J
C6-17 GR
C7B
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
BK-ALARM

D
CR23 RD RD-CB2
12V DCTO PLAT

C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
C6
C7B-2 WH WH-KS
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
RD-CB1
E
FUNCTIONS
24 CB1 POWER 24
C7B-3
25 (UNUSED) 25
26 (UNUSED) 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-CR39
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
Part No. 107846

August 2006
C4B
32 BRAKE 32
C4B-4
BK-CR1
F
C1B-7 BK BK-33 TS52
C3B
33 START ENGINE 33
C3B
34 (UNUSED) 34
C5-18 BK/RD
C2B-2
C1B-3
C1B-11
C1B-10
C5
35 HIGH RPM 35
C2B
C2B
C5-13 BL/WH BL/WH-L2 (-)
19/18 CABLES
38 CHECK ENGINE LED 38
C5-10 BL/RD
C1B
39 LIQUID PROPANE FUEL 39

C2B-3 OR/BK
G
C1B
C5-9 OR/RD
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD OR/RD-TS54
42 LOW RPM 42
BK-ALARM

C3B
BRN
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
H
C4B
C43DLITE GR
RD-24B
CR2
CR1
RELAY
RELAY
FUNCTION
POWER
ENGINE HARNESS
CR39
IGNITION
P20DLITE RD
AUXILLARY
START RELAY
RELAY BRN
BRN
HARNESS
HARNESS
CR23
I
C5-20
C5-21
C5-24
C5-12
BRN
BRN
DRIVE LIGHT
C5-5 BK
OPTION RELAY
BRN
C5
RD-27B
WH-21C
C5-11 WH
BRN-GND
C5-8
BK-33B
ENGINE
R27AUX C5-6 RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C127TSW
C6-38 R43DLITE1 RD
10A FUSE
J
RD
BRN
GR
BATGND BRN
C6-10 BL
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
TS64
C6-1 RD
SWITCH
C6-2 RD/BK
RUN/TEST
C3B-9 BK/RD
C6-9 BK/RD
CR37
CR33
K
CR32
BOOM
RELAY
RELAY
BOOM
RELAY
ROTATE
PRIMARY
TURNTABLE
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
BRN-TS
BL-10B
BRN
BRN
BRN
BL/WH-12B
CR5
WH/BK-5B
HORN
RELAY
L
C6
WH/RD-6B
C4B
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS


C7B3 BRN
M

F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH

REV A
N
REV B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

Ford Models
PLATFORM
LABEL DESCRIPTION RD RD GR/BK
1
ROTATE
TS57
EXTEND/RETRACT
BK/WH-8A RD
PRIMARY BOOM
CB2 CIRCUIT BREAKER, CONTROLS, 15A RD RD RD
BK-7A
CR1 IGNITION / START RELAY
RD
TS63
CR2 INGITION POWER RELAY
GR/BK-18
RD
TURNTABLE
RD
C19JSV GR/WH
CR4 HIGH IDLE RELAY RD
ROTATE
GR
RD
TS62
D4 RD
CR5 HORN RELAY
WH/RD-6A
GR/BK
WH/BK-5A
GR-17
HM HOUR METER 2
RD
D3
RD
RD
AUXILIARY
RD
POWER
KS1 KEY SWITCH
TS51
RD
L2 CHECK ENGINE LED
GR/BK GR/BK
UP/DOWN
PRIMARY
RD RD
RD
RD
RD
RD
GR
RD
RD-27
BOOM
TS61
R14 UP/DOWN SPEED RESISTER 7.5 OHMS GR GR
TS51 AUXILIARY TOGGLE SWITCH
RD
3
PLATFORM
TS53 FUEL SELECT TOGGLE SWITCH
UP/DOWN
JIB BOOM
LEVEL
TS59
TS58
SELECT
FUEL
TS53
C4B-7 GR/WH
GR/BK-44A
OR/BK-15A
GR/BK-18A
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
BL/RD-39A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
RD/BK-2A
GR-17A
OR-14A
RD-27A
RD-1A
BK-7A
WH
RD
RD
RD
RD

BK-22A
RD RD
4
RD 134A
WH-23A
TS62 TURNTABLE ROTATE TOGGLE SWITCH RD
RD
RD
RD
BL/WH-12A
BL/WH-38
BL/BK-11A
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
BL-10A
TS64 RUN/TEST TOGGLE SWITCH
KS1
RD
CIRCUIT BREAKER
P-BOX
BOOM UP/DOWN
RD
CONTROLS 15A
SECONDARY
WH-23
TS60
CB2
+
-
ENGINE
5
CHECK
RD
RD
RD
LED
G-BOX
L2
R14
RD
RD
RD-20B
D2
RD
RD
RD RD
6
RD
RD
RD-24A
BK-33A
C32-7
RD C23-7
RD
RD
OR/RD-42A
BK/RD-35A
CIRCUIT BREAKER
WH-CR2
TS52
BRN
ENGINE 15A
SWITCH
ENGINE
7
START
WH-21A
BRN
RD-20A
CB1
RD
CONTROL VARIABLE
FUNCTION SPEED
RESISTER, 20
RD
RD
RD
SWITCH
HOUR METER
RD
STOP
P1
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS
RD
FUNCTION
ENABLE
RD
TS54
R4
RD RD
RD
14
Part No. 107846 Z-45/25 • Z-45/25J 6 - 20

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

Ford Models
Platform Control Box Wiring Diagram, Z-45/25J

Ford Models
N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


RD-P2
DESCRIPTION
M
RD-H1
TILT ALARM
Y
C19JSV WH
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
L
OPT.
TS7
CR27
JIB
BRN
C32BRK WH/RD C1P-6

K
C32BRK WH/RD J2-19

CE OPTION
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18JD GR/BK C4P-6
JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
I
C9HRN BK/RD C3P-9

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
H
C3P
F.S.
CWLITE RD C2P-11
JIB
C45GEN GR/WH C2P-7

C44JDALARM GR/BK C2P-6
C9
C128LS OR/RD C2P-4

C39LP BL/RD C2P-1
P26ESTP BK
G
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
F
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
August 2006
Part No. 107846

C31REV WH/BK C1P-5 JIB BK
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2

C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
E
C5TRR WH/BK C3P-5

ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9

C33STR BK C1P-7
D
C27AUX RD C1P-1
C2P(BK)
J1
C1P
9
JC1-3 OR
Z-45/25 • Z-45/25J
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C
C7P
JC2-2 BRN
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
B
JIB BK
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
A
Ford Models
RED - LS18
BRN
BRN
BRN BRN
6 - 21
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J

Ford Models
1
TS47 PLATFORM CONTROL
GENERATOR HARNESS
(OPTION) (TO CONTROL BOX)
JC2 JC3
GR/WH DRIVE
PRIMARY BOOM
UP/DOWN 7 JC1 7 BK RD FORWARD/REVERSE
7
& TURNTABLE ROTATE SECONDARY BOOM & STEER LEFT/RIGHT
LEFT/RIGHT UP/DOWN TS15
6 6 DRIVE
6 2
ENABLE
5 5 + 5
RD
BK
GR/WH
L48
4 TS13 4 TILT ALARM LED 4
BK
PRIMARY TS48
BOOM
3 EXTEND/ 3 DRIVE LIGHTS/
WORK LIGHTS
3 3
RETRACT (OPTION)
RD
2 CR13
2 2
JIB BOOM
1 RELAY
1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED 4
RD
F18
FUSE 10A
C45GEN GR/WH C2P-7
GENERATOR OPTION
C8PBR BK/WH C3P-8
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
BL/RD-DE3 J1-16
C3P-4 DLITE WH
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
5
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
WH-JIB
BL J1-5
BL J1-5
BRN
BK
RD
RD
BK
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
P24FS WH
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C19JSV GR/WH
C17PRL GR C4P-5
GR/BK-44 C2P-6
WH-JIB
C27AUX RD C1P-1
C29MS RD/WH J1-8
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9
C128LS OR/RD C2P-4
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
RD
BK
6
BK BK
WH WH TS3
FUEL
2 2 2
7
GR SELECT
3
NO
4
DRIVE P2
EMERGENCY NC NC NC
SPEED
STOP
TS7 TS8 TS14 TS2 TS4 1 1 1
P3 WH PLATFORM JIB HIGH/LOW ENGINE HIGH/LOW RD
TS9 TS1
HORN ROTATE GR/BK BOOM (2WD/4WD) START RPM
PLATFORM AUXILIARY PUMP
RD
LEVEL WH-24
RD RD RD RD RD RD 8
Part No. 107846 Z-45/25 • Z-45/25J 6 - 22

Platform Control Box Switch Panel Wiring Diagram, Z-45/25J

Ford Models
Electrical Schematic, Z-45/25 REV C

Deutz F3L-2011 Models
C28TTA RD/BK C28TTA RD/BK
1 C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
P2
RD-(FS) C9P-3 P25FS RD
C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24FS WH P24FS WH
FS1
C7P-1
FUSE 10A (ONLY FOR WORKLIGHTS)
C2P-5
TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
2
LOW RPM
HIGH RPM
TS1
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
6
GENERATOR
POWER
AUXILIARY
L48
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
KS1 TB22 TS51 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
C32 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
4
C7B-2
C2B-3
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
TB20 5 GROUND OIL TB34
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
3MF CR1 9 IGN./FUEL ON
5 NO CR2
NO CR2
10 ENG. FAULT
OIL
TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
6 CR4
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3
BRN
NO U32
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
IGNITION/START RELAY
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
OIL TEMPERATURE SWITCH
OIL PRESSURE LED
OIL TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
8
1. All switches and contacts are shown with the boom
in the stowed position and the keyswitch off. C1B & C1P = GRAY
C2B & C2P = BLACK
5 Add D40 only if unit has L4 and L48. C3B & C3P = GREEN
6 ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN
6 - 23 Z-45/25 • Z-45/25J Part No. 107846

6 - 24
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

L1
B
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
Z-45/25 • Z-45/25J
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
PRIMARY BOOM
E
YOUT 5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
C6-1
August 2006
BRN
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
F
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
G
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
H

LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
TB8 BOOM RETRACT
C17-1 C17-2
J

TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
K
WH

RIGHT
PLATFORM
LEFT ROTATE
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
RIGHT JIB BOOM DOWN
PLATFORM
LEFT ROTATE
C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
C5-25
L
C129DA BK C6-19
H3

M
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK
N

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

C41RPM OR/BK C41RPM OR/BK

1 P26ESTP BK P26ESTP BK
P2
C9P-1 BK BK-(FS)
FS1
C7P-1
LS18 FUSE 10A (ONLY FOR WORKLIGHTS)
C2P-5
C1P-12
4 TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
LOW RPM
HIGH RPM
2 L4
TS1
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
GENERATOR
POWER
AUXILIARY
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
D39 C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
U33 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
C7B-2
4
C2B-3
H6 L45
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
CR2 OIL
10 ENG. FAULT
5 NO
NO CR2 TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
CR4
6
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3 U32
BRN
NO
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
LOAD SENSE MODULE
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
OIL PRESSURE LED
OIL TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
8 1. All switches and contacts are shown with the boom
C2B & C2P = BLACK
4 CE and platform overload option
C3B & C3P = GREEN
5 Add D40 only if unit has L4 and L48. C4B & C4P = BROWN
6 - 25 Z-45/25 • Z-45/25J Part No. 107846

Electrical Schematic, Z-45/25, CE Models
6 - 26
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

L1
B
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
Z-45/25 • Z-45/25J
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
PRIMARY BOOM
E
YOUT 5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
C6-1
August 2006
BRN
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
F
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
G
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
H

LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
BOOM RETRACT
TB8
C17-1 C17-2
J

TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
K
WH

RIGHT
PLATFORM
LEFT ROTATE
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
RIGHT JIB BOOM DOWN
PLATFORM
LEFT ROTATE
C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
C5-25
L
C129DA BK C6-19
H3

M
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK
N
Electrical Schematic, Z-45/25, CE Models


8
7
6
5
4
3
2
1
6 - 27
Genie Industries 4 5 6 7
BK-R1
1 TO REMOVE: 1 START RELAY
30
OR/BK-41A
85
86
2 Push gently 2 TACHOMETER
A
BK-33B C32
3 and lift 3 START INPUT
87A
RD-27B
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 7 TO KEY SW (DIESEL ONLY) RD TS51
RD TS52
BK C7B-1
BRN GND
GR/BK H6
8 8 JUMP TO 7 (GAS ONLY)
BK/WH C1B-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
10 10 TEMP OR PRESS FAULT
87A = NC
B
I.S.M.
12/24 Volt IGNITON/START MODULE P/N 56057
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B
RD 134B CR32 #30 RD/WH

C
H6
4 4
GR/BK C32-8 CR33 #86 WH/BK
BK

GR/BK L45 CR33 #30 WH/RD
Z-45/25 • Z-45/25J
(CE OPTION ONLY)
GR/BK C4B-1 C3B-6 WH/RD WH/RD-TS62
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
D
C3B-10 BL BL-TS60
I.S.M.
BK
CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
E
C3B
C6-18 GR/BK
BK-ALARM

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
Part No. 107846

August 2006

WH-IS7
C7B-2 WH WH-KS
C6
F
C6-16
C6-40
C6-37
C6-36
C6-29
C6 RD-CR2
RD-CB1
FUNCTIONS
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD
WH-IS10 WH/BK-L42 (-)

WH/BK-L42-
25 OIL PRESSURE SWITCH 25
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
26 OIL TEMPERATURE SWITCH 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
32 BRAKE 32
C4B-4
BK-IS3
G
C1B-7 BK BK-33 TS52

C3B
33 START ENGINE 33
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-CR4
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN

H
C1B
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
I
C43DLITE GR
RD-24B
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
J
BRN
DRIVE LIGHT
C5
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
L
WH/RD-ALARM
BL-10B
BRN
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

M

I.S.M.
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV A
N

LABEL DESCRIPTION 1
TURNTABLE
ROTATE
PLATFORM
OVERLOAD
(CE models)
PLATFORM
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD
CB2 CIRCUIT BREAKER, CONTROLS, 15A
TS57
BOOM
LED
L45
TS63
CR1 IGNITION / START RELAY BK/WH-8 RD
RD RD RD RD
CR2 IGNITION POWER RELAY
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
RD RD
2
RD
HM HOUR METER RD RD
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
WH-4
AUXILIARY
RD RD
POWER
RD
L42 OIL PRESSURE LED
TS51
RD
L43 OIL TEMPERATURE LED
L45 PLATFORM OVERLOAD
UP/DOWN
PRIMARY
BOOM
TS61
RD-27
RD
RD
RD
RD
R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS 3
RD
R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS
PLATFORM
LEVEL
TS59
TS51 AUXILIARY POWER TOGGLE SWITCH
C4B-7 GR/WH
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
TS56 GLOW PLUG TOGGLE SWITCH (OPTION)
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
4
RD RD
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
TS62 TURNTABLE ROTATE TOGGLE SWITCH
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
P-BOX
RD
BREAKER
CIRCUIT
TS60
CB2
TEMP
LED
L43
OIL
WH-23
5
DALE RH-25 25W

PRESSURE
+
+
-
-
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD 6
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
7
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS
RD RD
P1
NC NC
RD
8
FUNCTION
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6 - 28


CE Models Deutz F3L-2011 Models
8
7
6
5
4
3
2
1
6 - 29
Genie Industries
U33
BK-R1
30
OR/BK-41A
85
86
A
BK-33B C32
87A
RD-27B
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 7 TO KEY SW (DIESEL ONLY) RD TS51
RD TS52
BK C7B-1
BRN GND
GR/BK H6
BK/WH C1B-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
87A = NC
B
I.S.M.
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B

C
H6
4 4
BK

Z-45/25 • Z-45/25J
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
D
C3B-10 BL BL-TS60
I.S.M.
BK
CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
E
C3B
C6-18 GR/BK
BK-ALARM

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
Part No. 107846

WH-IS7
C7B-2 WH WH-KS
C6
F
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
RD-CB1
FUNCTIONS
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD

WH/BK-L42-
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
26 OIL TEMPERATURE SWITCH 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models
August 2006
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
32 BRAKE 32
C4B-4
BK-IS3
G
C1B-7 BK BK-33 TS52

C3B
33 START ENGINE 33
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-CR4
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN

H
C1B
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
I
C43DLITE GR
RD-24B
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
J
BRN
DRIVE LIGHT
C5
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
L
WH/RD-ALARM
BL-10B
BRN
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

M

I.S.M.
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV A
N
REV B Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models
LABEL DESCRIPTION
TURNTABLE
1
ROTATE
PLATFORM
OVERLOAD
(CE models)
PLATFORM
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD
TS57
BOOM
LED
L45
TS63
RD RD RD RD
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
RD RD
RD
HM HOUR METER RD RD 2
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
WH-4
AUXILIARY
RD RD
POWER
RD
TS51
RD
UP/DOWN
PRIMARY
BOOM
TS61
RD-27
RD
RD
RD
RD
3
RD
PLATFORM
LEVEL
TS59
C4B-7 GR/WH
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
TS59 PLATFORM LEVEL TOGGLE SWITCH 4
RD RD
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
P-BOX
RD
BREAKER
CIRCUIT
TS60
CB2
TEMP
LED
L43
OIL
WH-23
DALE RH-25 25W

5
PRESSURE
+
+
-
-
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD
6
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
CIRCUIT
7
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS RD RD
P1
NC NC
RD
8
FUNCTION
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6 - 30


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


RD-P2
DESCRIPTION
RD-H1
M
TILT ALARM
Y
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
TS7
L
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
CE OPTION
K
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
C9HRN BK/RD C3P-9
I
C8PBR BK/WH C3P-8

C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
C3P
F.S.
CWLITE RD C2P-11
H
C45GEN GR/WH C2P-7

C9
P26ESTP BK
11
3
1
G
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
C30FWD WH C1P-4
F
BRN C1PBU RD C3P-1

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
August 2006
Part No. 107846

C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C5TRR WH/BK C3P-5
ALC-500
19/18 CONTROL CABLE

U13
E
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
9
JC1-3 OR
JC2-4 RD
Z-45/25 • Z-45/25J
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C7P
JC2-2 BRN
C
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
B
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
RED - LS18
A
BRN
BRN
BRN BRN
6 - 31
1
8

TS47
GENERATOR
1
(OPTION)
JC2
TS15
DRIVE
JC3 PLATFORM CONTROL
HARNESS
GR/WH DRIVE
PRIMARY BOOM UP/DOWN
& TURNTABLE ROTATE 7 JC1 7
ENABLE RD FORWARD/REVERSE
7
(TO CONTROL BOX)
SECONDARY BOOM & STEER

LEFT/RIGHT UP/DOWN LEFT/RIGHT
6 6 6
2
5 5 + 5
RD
BK
GR/WH
L48
4 4 TILT ALARM LED 4
BK
TS48
TS13 DRIVE LIGHTS/
3 PRIMARY BOOM 3 WORK LIGHTS 3
EXTEND/RETRACT (OPTION)
RD
2 2 2 3
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED +
RD
L4 F18
PLATFORM FUSE 10A 4
CR13
C45GEN GR/WH C2P-7

OVERLOAD
GENERATOR OPTION
C8PBR BK/WH C3P-8
JIB BOOM LED
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P-4 DLITE WH
C7PBE BK C3P-7
BL/RD-DE3 J1-16
RELAY
GR/BK H1 (D39)
BL/BK-DE2 J1-7
BL-DE1 J1-6
BK
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
WH-JIB
BL J1-5
BRN
RD
RD
BK
5
BK
C35RPM BK/RD C1P-9
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
P24FS WH
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C19JSV GR/WH
C17PRL GR C4P-5
GR/BK-44 C2P-6
WH-JIB
C27AUX RD C1P-1
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
RD
6
White wire replaced
by CR27 and CR30
on CE models
WH WH
RD
2 2 2
GR
3
NO
4
DRIVE
SPEED
P2
EMERGENCY
NC NC NC 7
TS4 STOP
TS14 TS6 TS2 HIGH/LOW 1 1 1
P3 WH TS8 HIGH/LOW GLOW ENGINE RD
TS1 RPM
HORN TS9 JIB BOOM (2WD/4WD) PLUG START
GR/BK AUXILIARY
RD
PLATFORM (OPTION)
LEVEL PUMP WH-24 RD
TS7
PLATFORM
RD ROTATE RD RD RD RD RD
NOTE:
DASHED LINES INDICATE OPTION WIRES
Part No. 107846 Z-45/25 • Z-45/25J 6 - 32


Electrical Schematic, Z-45/25J REV C

1 C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
P2
C9P-1 BK BK-(FS)
FS1
C7P-1
C2P-5
TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
2
LOW RPM
HIGH RPM
TS1
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
6
GENERATOR
POWER
AUXILIARY
L48
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
C32 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
4
C7B-2
C2B-3
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
5 NO CR2
NO CR2
10 ENG. FAULT
OIL
TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
6 CR4
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3
BRN
NO U32
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
OIL PRESSURE LED
OIL TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
8
C2B & C2P = BLACK
6 - 33 Z-45/25 • Z-45/25J Part No. 107846

6 - 34
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

L1
B
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
Z-45/25 • Z-45/25J
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
PRIMARY BOOM
E
YOUT 5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
C6-1
August 2006
BRN
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
F
7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
G
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
H

LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
TB8 BOOM RETRACT
C17-1 C17-2
J

TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
K

WH
CR13
NC

DOWN
JIB BOOM
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
DOWN JIB BOOM DOWN
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
TS57
RIGHT
PLATFORM C5-25
L
LEFT ROTATE RIGHT

PLATFORM
LEFT ROTATE
TS7
WH
C129DA BK C6-19
H3

CR13

C19JSV GR/WH
M
BRN
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

BK WH
JIB BOOM VALVE
JIB BOOM VALVE
NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK
N

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

1 C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
P2
C9P-1 BK BK-(FS)
FS1
C7P-1
LS18 FUSE 10A (ONLY FOR WORKLIGHTS)
C2P-5
C1P-12
4 TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
2
LOW RPM
HIGH RPM
TS1
L4
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
GENERATOR
POWER
AUXILIARY
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
D39 C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
U33 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
4
C7B-2
C2B-3
H6 L45
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
5 NO CR2
NO CR2
10 ENG. FAULT
OIL
TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
6 CR4
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3 U32
BRN
NO
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
LOAD SENSE MODULE
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
OIL PRESSURE LED
OIL TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
8
C2B & C2P = BLACK
4 CE and platform overload option
C3B & C3P = GREEN
5 Add D40 only if unit has L4 and L48. C4B & C4P = BROWN
6 - 35 Z-45/25 • Z-45/25J Part No. 107846

6 - 36
Electrical Schematic, Z-45/25J, CE Models
C7P-3 BATGND C7B-3

GROUND
A
C41RPM OR/BK
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
B
8
H4

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32

TS15

Z-45/25 • Z-45/25J
LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
C
P26ESTP BK
P24FS WH
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D
9
CR33

TB5
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
E
14
6
CR32
TURNTABLE ROTATE
Part No. 107846
BK
TB1
YOUT PRIMARY BOOM

5 2
SELECT RELAY
86
85
RD
C12-1 C12-2
JC2
XOUT 4 1
August 2006
UP R1PBU RD
J1
TB2

87a 87
PWR 3 11 DOWN
30
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
F

7
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
G

CR37
12
TB10
BRN
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
H

3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
LS1

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
P22LS BK
EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
J
BOOM RETRACT
TB8
C17-1 C17-2
TS9
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
K
TB15
TB44
C21-1 C21-2
WH
CR13
NC

DOWN
JIB BOOM
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
DOWN JIB BOOM DOWN
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
L
TS57
RIGHT
PLATFORM C5-25
LEFT ROTATE RIGHT
PLATFORM
LEFT ROTATE
TS7
WH
C129DA BK C6-19
H3

CR13

M

C19JSV GR/WH
BRN
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
C1B & C1P - GRAY

BK WH
JIB BOOM VALVE
JIB BOOM VALVE
NOTES:
WHEEL.
C41RPM OR/BK
REV C
C28TTA RD/BK
P26ESTP BK
P24FS WH
N
BRN
RD
RD
BK
Electrical Schematic, Z-45/25J, CE Models


8
7
6
5
4
3
2
1
6 - 37
BK-R1
30
OR/BK-41A
85
86
BK-33B C32
87A
RD-27B
A
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 7 TO KEY SW (DIESEL ONLY)
RD TS51
RD TS52
BK C7B-1
BRN GND
GR/BK H6

BK/WH C1B-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
87A = NC
I.S.M.

B
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B

H6
C
4 4
BK

(CE OPTION ONLY)

C6-7 BK
C3B
Z-45/25 • Z-45/25J
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
C3B-10 BL BL-TS60
I.S.M.
BK
D

CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
BK-ALARM
E

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
WH-IS7
Part No. 107846

August 2006
C7B-2 WH WH-KS
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
RD-CB1
FUNCTIONS
F
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD

WH/BK-L42-
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
C4B 26 OIL TEMPERATURE SWITCH 26
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
32 BRAKE 32
C4B-4
BK-IS3
C1B-7 BK BK-33 TS52
C3B
33 START ENGINE 33
G
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-CR4
C2B-2
C1B-3
C1B-11
C1B-10
C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN
C1B
H
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
C43DLITE GR
RD-24B
I
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
BRN
DRIVE LIGHT
C5
J
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
C6-11 BL/BK
C6-5 WH/BK
K
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
BL-10B
BRN
L
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

I.S.M.

M
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV A
N

LABEL DESCRIPTION 1
TURNTABLE
ROTATE
PLATFORM
OVERLOAD
(CE models)
PLATFORM
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD GR/BK
TS57
BOOM
LED
L45
TS63
RD RD RD RD
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
GR
RD RD
2
RD
HM HOUR METER RD RD
GR/BK
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
RD
WH-4
AUXILIARY
RD RD
POWER
RD
TS51
RD
UP/DOWN
GR/BK GR/BK
PRIMARY
BOOM
TS61
RD RD
RD-27
RD
RD
RD
GR
RD
GR GR
R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS 3
RD
PLATFORM
LEVEL
TS59
UP/DOWN
JIB BOOM
TS58
C4B-7 GR/WH
GR/BK-44A
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
4
RD RD
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
P-BOX
RD
BREAKER
CIRCUIT
TS60
CB2
TEMP
LED
L43
OIL
WH-23
5
DALE RH-25 25W

PRESSURE
+
+
-
-
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD 6
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
7
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS
RD RD
P1
NC NC
RD
8
FUNCTION
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6 - 38


8
7
6
5
4
3
2
1
6 - 39
Genie Industries
U33
BK-R1
30
OR/BK-41A
85
86
BK-33B C32
87A
A
RD-27B
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 7 TO KEY SW (DIESEL ONLY)
RD TS51
RD TS52
BK C7B-1
BRN GND
GR/BK H6
BK/WH C1B-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
87A = NC
I.S.M.
B
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B

C
H6
4 4
BK


C6-7 BK
Z-45/25 • Z-45/25J
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
C3B-10 BL BL-TS60
I.S.M.
BK
D

CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
E
BK-ALARM

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
WH-IS7
Part No. 107846

C7B-2 WH WH-KS
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
F
RD-CB1
FUNCTIONS
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD

WH/BK-L42-
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
C4B 26 OIL TEMPERATURE SWITCH 26
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models
August 2006
32 BRAKE 32
C4B-4
BK-IS3
C1B-7 BK BK-33 TS52
G
C3B
33 START ENGINE 33
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-CR4
C2B-2
C1B-3
C1B-11
C1B-10
C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN
C1B
H
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
C43DLITE GR
RD-24B
I
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
BRN
DRIVE LIGHT
J
C5
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
C6-11 BL/BK
C6-5 WH/BK
K
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
BL-10B
BRN
L
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

M
I.S.M.
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV A
N
REV B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models
LABEL DESCRIPTION
TURNTABLE
ROTATE
1
PLATFORM
OVERLOAD
(CE models)
PLATFORM
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD GR/BK
TS57
BOOM
LED
L45
TS63
RD RD RD RD
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
GR
RD RD
RD
HM HOUR METER RD RD
2
GR/BK
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
RD
WH-4
AUXILIARY
RD RD
POWER
RD
TS51
RD
UP/DOWN
GR/BK GR/BK
PRIMARY
BOOM
TS61
RD RD
RD-27
RD
RD
RD
GR
RD
GR GR
RD
R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS 3
PLATFORM
LEVEL
TS59
UP/DOWN
JIB BOOM
TS58
C4B-7 GR/WH
GR/BK-44A
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH 4
RD RD
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
P-BOX
RD
BREAKER
CIRCUIT
TS60
CB2
TEMP
LED
L43
OIL
WH-23
DALE RH-25 25W

PRESSURE
+
+
-
-
5
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD
6
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS
RD RD
P1
NC NC
RD
8
FUNCTION
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6 - 40


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


M
RD-P2
DESCRIPTION
RD-H1
TILT ALARM
Y
C19JSV WH
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
L
OPT.
TS7
CR27
JIB
BRN
C32BRK WH/RD C1P-6

K
C32BRK WH/RD J2-19

CE OPTION
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18JD GR/BK C4P-6
JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
I
C9HRN BK/RD C3P-9

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
H
C3P
F.S.
CWLITE RD C2P-11
JIB
C45GEN GR/WH C2P-7

C9
P26ESTP BK
G
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
F

C30FWD WH C1P-4
BRN C1PBU RD C3P-1
August 2006
Part No. 107846

JIB BK
C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2

C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
E
C5TRR WH/BK C3P-5

ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9

C33STR BK C1P-7
D
C27AUX RD C1P-1
C2P(BK)
J1
C1P
9
JC1-3 OR
Z-45/25 • Z-45/25J
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C
C7P
JC2-2 BRN
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
B
C29MS RD/WH
JIB BK
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
A RED-TILT RED-TILT C2P-5
RED - LS18
BRN
BRN
BRN BRN
6 - 41
1
8

TS47
GENERATOR 1
(OPTION)
JC2
TS15
DRIVE
HARNESS
GR/WH DRIVE
7
(TO CONTROL BOX)

6 6 6
5 5 + 5 2
RD
BK
GR/WH
L48
BK
TS48
TS13 DRIVE LIGHTS/
RD
2 2 2 3
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED +
RD
L4 F18
PLATFORM
CR13
FUSE 10A 4
C45GEN GR/WH C2P-7

OVERLOAD
GENERATOR OPTION
C8PBR BK/WH C3P-8
JIB BOOM LED
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P-4 DLITE WH
C7PBE BK C3P-7
BL/RD-DE3 J1-16
RELAY
GR/BK H1 (D39)
BL/BK-DE2 J1-7
BL-DE1 J1-6
BK
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
WH-JIB
BL J1-5
BRN
RD
RD
BK
5
BK
C35RPM BK/RD C1P-9
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
P24FS WH
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C19JSV GR/WH
C17PRL GR C4P-5
GR/BK-44 C2P-6
WH-JIB
C27AUX RD C1P-1
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
RD
White wire replaced 6
by CR27 and CR30
on CE models
WH WH
RD
2 2 2
GR
3
NO
4
DRIVE P2
SPEED EMERGENCY
NC NC NC
7
TS4 STOP
TS14 TS6 TS2 HIGH/LOW 1 1 1
P3 WH TS8 HIGH/LOW GLOW ENGINE RD
TS1 RPM
HORN TS9 JIB BOOM (2WD/4WD) PLUG START
GR/BK AUXILIARY
RD
PLATFORM (OPTION)
LEVEL PUMP WH-24 RD
TS7
PLATFORM
NOTE:
Part No. 107846 Z-45/25 • Z-45/25J 6 - 42

Platform Control Box Switch Panel Wiring Diagram, Z-45/25J


Perkins 404-22 Models
Electrical Schematic, Z-45/25 REV C


P2
C9P-1 BK BK-(FS)
FS1
C7P-1
C2P-5
TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
LOW RPM
HIGH RPM
TS1
2
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
6
GENERATOR
POWER
AUXILIARY
L48
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
C32 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
C7B-2
4
C2B-3
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
CR2 OIL
NO 10 ENG. FAULT
5 NO CR2 TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
CR4
6
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2 U32
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3
BRN
NO
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
COOLANT TEMPERATURE SWITCH
OIL PRESSURE LED
COOLANT TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
C2B & C2P = BLACK
6-44 Z-45/25 • Z-45/25J Part No. 107846

6-45

C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

L1
CDE3 BL/RD
16
J1
B
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
Z-45/25 • Z-45/25J
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C

C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
9
CR33

TB5
D
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
YOUT PRIMARY BOOM

5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2
PRIMARY BOOM
E
OR PRIMARY BOOM UP
87a 87
PWR 3 11 DOWN
30
August 2006
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
7
F
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
G
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
LS1
4
H
DRIVE LIMIT SWITCH

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
P22LS BK
I

EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
TB8 BOOM RETRACT
C17-1 C17-2
TS9
J
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
WH

RIGHT
K
PLATFORM
LEFT ROTATE
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
RIGHT JIB BOOM DOWN
PLATFORM
LEFT ROTATE
C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
C5-25
L
C129DA BK C6-19
H3
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
M
C1B & C1P - GRAY

NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK
N


8
7
6
5
4
3
2
1
6-48
BK-R1
30
OR/BK-41A
85
86
BK-33B C32
87A
A
RD-27B
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 TO KEY SW (DIESEL ONLY)
BK C7-1
7
RD TS51
RD TS52
BRN GND
GR/BK H6
BK/WH C1-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
87A = NC
I.S.M.
B
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B
H6
C
4 4
BK

(CE OPTION ONLY)

C6-7 BK
Z-45/25 • Z-45/25J
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH

CR37 #86 BL
C6
C3B-10 BL BL-TS60
I.S.M.
BK
D

CR37 #30 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
E
BK-ALARM

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
WH-IS7
Part No. 107846

August 2006
C7B-2 WH WH-KS
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
C6
F
RD-CB1
FUNCTIONS
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD

WH/BK-L42-
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
26 COOLANT TEMPERATURE SWITCH 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
32 BRAKE 32
C4B-4
BK-IS3
C1B-7 BK BK-33 TS52
G
C3B
33 START ENGINE 33
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C1B-10
C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN
C1B
H
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
C43DLITE GR
RD-24B
I
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
BRN
DRIVE LIGHT
J
C5
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
C6-11 BL/BK
C6-5 WH/BK
K
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
BL-10B
BRN
L
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

M
I.S.M.
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV A
N

LABEL DESCRIPTION
TURNTABLE
ROTATE
PLATFORM
OVERLOAD
(CE models)
PLATFORM
CB1 CIRCUIT BREAKER, ENGINE, 15A 1
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD
TS57
BOOM
LED
L45
TS63
RD RD RD RD
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
RD RD
RD
HM HOUR METER RD RD
2
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
WH-4
AUXILIARY
RD RD
POWER
RD
TS51
RD
L43 COOLANT TEMPERATURE LED
UP/DOWN
PRIMARY
BOOM
TS61
RD-27
RD
RD
RD
RD
RD
R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS 3
PLATFORM
LEVEL
TS59
C4B-7 GR/WH
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
RD RD 4
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
P-BOX
RD
BREAKER
CIRCUIT
TS60
COOLANT
CB2
TEMP
LED
L43
WH-23
DALE RH-25 25W

PRESSURE
+
+
-
-
5
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD
6
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS
RD RD
P1
NC NC
RD
FUNCTION
8
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6-49


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


M
RD-P2
DESCRIPTION
RD-H1
TILT ALARM
Y
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
L
OPT.
TS7
CR27
BRN
C32BRK WH/RD C1P-6

K
C32BRK WH/RD J2-19

CE OPTION
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
I
C9HRN BK/RD C3P-9

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
H
C3P
F.S.
CWLITE RD C2P-11
C45GEN GR/WH C2P-7
C9
P26ESTP BK
G
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
F

C30FWD WH C1P-4
BRN C1PBU RD C3P-1
August 2006
Part No. 107846

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
E
C5TRR WH/BK C3P-5

ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9

C34SA BK/WH C1P-8
C33STR BK C1P-7
D
C27AUX RD C1P-1
C2P(BK)
J1
C1P
9
JC1-3 OR
Z-45/25 • Z-45/25J
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C
C7P
JC2-2 BRN
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
B
C29MS RD/WH
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
RED - LS18
BRN
BRN
BRN BRN
6-52
1
8

TS47
GENERATOR 1
(OPTION)
JC2
TS15
DRIVE
HARNESS
GR/WH DRIVE
7
(TO CONTROL BOX)

6 6 6
5 5 + 5 2
RD
BK
GR/WH
L48
BK
TS48
TS13 DRIVE LIGHTS/
RD
2 2 2
3
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED +
RD
L4 F18
PLATFORM FUSE 10A
4
C45GEN GR/WH C2P-7

OVERLOAD
GENERATOR OPTION
C8PBR BK/WH C3P-8
LED
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
BL/RD-DE3 J1-16
GR/BK H1 (D39)
BL/BK-DE2 J1-7
BL-DE1 J1-6
BK
CDLITE GR
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
BL J1-5
RD
RD
BK
5
BK
C35RPM BK/RD C1P-9
RD
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C19JSV GR/WH
C17PRL GR C4P-5
C27AUX RD C1P-1
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
6
WH WH
RD
2 2 2
3
NO
4
DRIVE P2 NC NC NC
SPEED
TS4
EMERGENCY 7
TS6 STOP 1 1 1
TS14 TS2 HIGH/LOW
P3 WH HIGH/LOW GLOW ENGINE RD
TS1 RPM
HORN TS9 (2WD/4WD) PLUG START
AUXILIARY
RD
PLATFORM
LEVEL PUMP WH-24 RD
TS7
PLATFORM
NOTE:
Part No. 107846 Z-45/25 • Z-45/25J 6-53



Electrical Schematic, Z-45/25J REV C


P2
C9P-1 BK BK-(FS)
FS1
C7P-1
C2P-5
TS4
RD
TS2 TS48 TS47
TS6
P22BAT BK
RD
LOW RPM
HIGH RPM
2 TS1
BK
C132PLI BL/WH
RD
START
ENGINE
PLUG
GLOW
WORK LIGHTS
DRIVE LIGHTS
C134PWR GN
6
GENERATOR
POWER
AUXILIARY
L48
P3
H1
SPEED
ENGINE
C2P-11
C2P-12
HORN
5
D40
C7B-1
C28TTA RD/BK
C3P-9
C7P-2
C1P-1
C1P-7
C1P-8
C3P-4
C2P-7
C1P-9
C1P-2
C1B-12
C2B-5
L30 L30
CB2 TB134 BK
P1
3 15A
RD RD
RD
RD
C28TTA RD/BK
C133PLA BL/RD
C46HRN BK/RD
1 3
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
DLITE WH
C45GEN GR/WH
C35RPM BK/RD
C33STR BK
4 5
C2P-9
C2P-10
PLAT
START
ENGINE
HIGH RPM
LOW RPM
PLUG
GLOW
C32 D3
POWER
AUXILIARY
6 7
GND
12 8
ENABLE
FUNCTION
C1B-7
BK
D4
C1B-1
C3B-9
C4B-1
C1B-2
RD
PBOX GND
BRN
C7B-2
4
C2B-3
C1B-9
TB27
C3B-4
C2B-7
GR/BK D2 TB33
RD
C1B-8
TB23
TB41 1 START RELAY
2 TACHOMETER
CB1 3 START INPUT
IGNITION/ L42
4 AUX. ON
15A START
RD TB24 MODULE
6 BATTERY PRES.
7 KEY PWR. TB35
+
C3 8 KEY BYPASS
C5-17
CR1 U1 L43
CR2 OIL
10 ENG. FAULT
5 NO
NO CR2 TEMP.
C7B-4
C35RPM BK/RD
P20BAT RD
C5-3 C21IGN WH TB21
P134 RD
C45GEN GR/WH
C34SA BK/WH
P134TTS WH
P22BAT BK
C46HRN BK/RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C25PSR WH/BK
C26TSR WH/RD
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
P20BAT RD
C107AF WH
FUSE 10A
TB25 CR23
C6-34 P134FB RD
C5-23
CR23
CR4
6
C5-5
NO
C6-27
NO CR4
CR5 TB26
BK/RD
NO
C5-2
ALTERNATOR A C
D1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
PR1 PR2
C6-9
BAT. BAT. PR1 PR2

B1
C5-18
+ -
12V DC PR3
S8 NO NO
+ PR3
RD
RD
STA. W NO
SW2 U32
+ NC
H2 M3
7
BK
PUMP M2
REGULATOR _ SW3
BRN
NO
IND. FB1 L29 L29 Q3
- B
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

ALTERNATOR
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
HOUR METER
FUEL SOLENOID
POWER RELAY
OIL PRESSURE SWITCH
COOLANT TEMPERATURE SWITCH
OIL PRESSURE LED
COOLANT TEMPERATURE LED
WORK LIGHT OPTION
DRIVE LIGHT OPTION
GENERATOR OPTION
HIGH RPM SOLENOID
HIGH IDLE RELAY

AUXILIARY PUMP
GLOW PLUG
NOTE:
C2B & C2P = BLACK
6-56 Z-45/25 • Z-45/25J Part No. 107846

6-57

C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14

C28TTA RD/BK
DRIVE MODE
8
H4

L1
CDE3 BL/RD
16
J1
B
C26-1 C26-2
TB32

TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
Z-45/25 • Z-45/25J
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
C

C1P-11 C1B-11 C6-37
JC3
J1
4 5
17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
9
CR33

TB5
D
10 SELECT RELAY
85
86
RIGHT R5TRR WH/BK

87a 87
C6-5
30
LEFT
C15-1 C15-2
TS62
R4TRL WH
TB6
6
C6-4
20
C14-1 C14-2
7
R4
14
6
CR32
TURNTABLE ROTATE
BK
TB1
YOUT PRIMARY BOOM

5 2
SELECT RELAY
86
85
RD
Part No. 107846
C12-1 C12-2
JC2
XOUT 4 1
UP R1PBU RD
J1
TB2
PRIMARY BOOM
E
OR PRIMARY BOOM UP
87a 87
PWR 3 11 DOWN
30
August 2006
BRN C6-1
R2PBD RD/BK
J2
GND 2 12
R14
TS61
7.5
PRIMARY BOOM DOWN

TB3
1
C6-2 C13-1 C13-2
6
7
F
8
7

6 14
YEL
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
BRN
SELECT RELAY
86
85
1 C18-1 C18-2
UP R10SBU BL
G
P26ESTP BK
87a 87
30
DOWN
C6-10
BRN R11SBD BL/BK
TS60
SECONDARY BOOM DOWN

TB11
1
TB12
C6-11 C19-1 C19-2

P24FS WH
D3
2
P24FS WH
J3
LS3
4
3
LS3 - DRIVE ENABLE
13
14
P26ESTP BK
2
3 LIMIT SWITCH
LS1
4
H
DRIVE LIMIT SWITCH

C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20
BK
21
22
LS2

C40LSS OR
DRIVE LIMIT SWITCH

21
22
LS4
CR27
CR30
OPTION
NC
NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
P22LS BK
I

EXTEND
BOOM
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
TB8 BOOM RETRACT
C17-1 C17-2
TS9
J
DOWN
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
DOWN
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
WH
CR13
NC

K
DOWN
JIB BOOM
TS8
TB18
C23-1 C23-2
C6-18 C18JD GR/BK
TS58
DOWN JIB BOOM DOWN
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP
TB17
C22-1 C22-2
TS57
RIGHT
PLATFORM C5-25
LEFT ROTATE RIGHT
PLATFORM
LEFT ROTATE
TS7
WH
L
C129DA BK C6-19
H3

CR13

C19JSV GR/WH
BRN
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
EXCEPT AS NOTED.
M
C1B & C1P - GRAY

BK WH
JIB BOOM VALVE
JIB BOOM VALVE
NOTES:
WHEEL.
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
REV C
BRN
RD
RD
BK
N


8
7
6
5
4
3
2
1
6-60
BK-R1
30
OR/BK-41A
85
86
BK-33B C32
A
87A
RD-27B
4 4 AUX PWR UNIT
1 3 4 5 6 7 8 12
87
BRN-IS5
5 5 GROUND
RD-CR1 6 BATTERY
6
RD H6
WH-23B
BK 22B
7 TO KEY SW (DIESEL ONLY)
BK C7-1
7
RD TS51
RD TS52
BRN GND
GR/BK H6
BK/WH C1-12
WH-R2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D & 26D
87 = NO
87A = NC
I.S.M.
B
86 = COIL POSITIVE
85 = COIL NEGATIVE

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B
C
H6
4 4
BK

(CE OPTION ONLY)

Z-45/25 • Z-45/25J
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
CR37 #86 BL
C6
C3B-10 BL BL-TS60
D
I.S.M.
BK
CR37 #30 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C7B
C4B-5 GR GR-TS57
C3B
E
C6-18 GR/BK
BK-ALARM

CR23 RD RD-CB2
12V DC TO PLAT
C7B-4 RD RD-CB1
WH-CR2 BRN
C5-3 WH WH-HM
C6-20 BK BK-CR5
C5
C7B
C32-4 BK BK-KSI
Part No. 107846

August 2006
WH-IS7
C7B-2 WH WH-KS
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CR2
F
C6
RD-CB1
FUNCTIONS
24 CB1 POWER 24
C7B-3
I.S.M.
C5-16 WH/RD

WH/BK-L42-
C5-14 WH/RD
WH/RD-L43 (-)
WH/RD-L43-
26 COOLANT TEMPERATURE SWITCH 26
C4B
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C6-27 RD RD-IS4
C36STCC BL
C40LS1 OR
C1B-1 RD RD-TS51
BRN
C1B-6 WH/RD
C4B
32 BRAKE 32
C4B-4
BK-IS3
G
C1B-7 BK BK-33 TS52

C3B
33 START ENGINE 33
C5-22 BK/WH
C3B
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
C2B
C2B
BL/WH-L2 (-)
19/18 CABLES
38 (SPARE) 38

C1B
39 (SPARE) 39
+
C2B-3 OR/BK C3 BRN

H
C1B
C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 (SPARE) 42
BK-ALARM
C3B
BRN
I.S.M.
ENGINE HARNESS
C5-17 WH RD KS1
134 KS POWER 134
C3B-4 WH RD H6
C30FWD WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
C6-34 RD
134A KS POWER 134A
C3B-4
C4B
C43DLITE GR
I
RD-24B
CR2
CR1
RELAY
START
RELAY
POWER
RELAY
FUNCTION
CR4
IGNITION
RELAY
P20DLITE RD
RD-IS6 WH
HIGH RPM
SOLENOID
BK-IS1 BRN
HARNESS
HARNESS
C5-20
C5-21
C5-24
C5-12
CR23
C5-5 BK
J
BRN
DRIVE LIGHT
C5
WH-IS9
OPTION RELAY
WH-21C
BRN-GND
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
F19
C6-38 R43DLITE1 RD
10A FUSE
RD
BRN
BATGND BRN
C6-10 BL
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
C6-9 BK/RD
CR37
BOOM
RELAY
SECONDARY
BK-22B
C6-13 BK
BK-ALARM
WH/RD-ALARM
L
BL-10B
BRN
BRN
BRN
BL/WH-12B
CR5
CR33
CR32
HORN
WH/BK-5B
RELAY
RELAY
BOOM
RELAY
ROTATE
C6
PRIMARY
WH/RD-6B
C4B
TURNTABLE
RD-1B
RD/WH-3B
GROUND BOLT
RD-20C DRIVE LIGHTS

M

I.S.M.
OR/BK-IS2 OR/BK-41A
C7B3 BRN
RD-IS4 RD-27B
BK-IS3 BK-33B
WH-IS7 WH-23B
F.H.
E.H.
PANEL)
BRN BRN
GROUND
HARNESS
CONTROL
(TO SWITCH
REV B
N

N N M M L L K K J J I I H H G G F F E E D D C C B B A A
LABEL DESCRIPTION
TURNTABLE
11
ROTATE
PLATFORM
OVERLOAD
(CE models)
PLATFORM
TS62
ROTATE
RETRACT
PRIMARY
EXTEND/
RD RD GR/BK
TS57
BOOM
LED
L45
TS63
RD RD RD RD
BK-7
CR4 HIGH IDLE RELAY
RD
-
GR/BK-18
C19JSV GR/WH
CR5 HORN RELAY
RD
GR
RD RD
RD
HM HOUR METER RD RD
22
GR/BK
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
RD
WH-4
AUXILIARY
RD RD
POWER
RD
TS51
RD
L43 COOLANT TEMPERATURE LED
UP/DOWN
GR/BK GR/BK
PRIMARY
BOOM
TS61
RD RD
RD-27
RD
RD
RD
GR
RD
GR GR
33
RD
PLATFORM
LEVEL
TS59
UP/DOWN
JIB BOOM
TS58
C4B-7 GR/WH
GR/BK-44A
OR/BK-15A
GR/BK-18A
RD/WH-3A
WH/RD-6A
BK/WH-8A
WH/BK-5A
GR/BK H6
RD/BK-2A
RD C32-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
WH
RD
RD
RD
RD RD 44
RD 134A
WH-23A
BK-22A
BL/WH-12A
WH/BK-25A
BL/BK-11A
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
TS62 TURNTABLE ROTATE TOGGLE SWITCH P-BOX
RD
BREAKER
CIRCUIT
TS60
COOLANT
CB2
TEMP
LED
L43
WH-23
DALE RH-25 25W

55
PRESSURE
+
+
-
-
7.5 ohm 1%
LED
L42
OIL
G-BOX RD RD
RD
RD
RD
RD-20B
RD
RD
SECONDARY BOOM
UP/DOWN SPEED
RESISTOR
R14
RD RD RD
66
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4
ENGINE 15A
BRN
BREAKER
CIRCUIT
77
CB1
WH-21
BK/WH-34A
BRN
RD-20A
CONTROL VARIABLE
ENGINE
FUNCTION SPEED
START
TS52
RESISTER, 20W
RD
RD
STOP SWITCH
RD
EMERGENCY
HOUR METER
RD
1 1
RD
RD
(TO TERMINAL STRIP)
R4
BASE BOX HARNESS RD RD
P1
NC NC
RD
88
FUNCTION
(OPTION)
2 2
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD
14W
6W
Part No. 107846 Z-45/25 • Z-45/25J 6-61


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


M
RD-P2
DESCRIPTION
RD-H1
TILT ALARM
Y
C19JSV WH
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
L
OPT.
TS7
CR27
JIB
BRN
C32BRK WH/RD C1P-6

K
C32BRK WH/RD J2-19

CE OPTION
BRN
LS18
ONLY
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
TS1 WH
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18JD GR/BK C4P-6
JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
I
C9HRN BK/RD C3P-9

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9-1
P25FS RD C9-3
P24FS WH C9-2
CDLITE GR
FOOT SWITCH
CWLITE RD C2P-12
H
C3P
F.S.
CWLITE RD C2P-11
JIB
C45GEN GR/WH C2P-7

C9
P26ESTP BK
G
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPY
C11SBD BL/BK C3P-11
C7P
C40LSS OR C2P-2
C12SBF BL/WH C3P-12
F

C30FWD WH C1P-4
BRN C1PBU RD C3P-1
August 2006
Part No. 107846

C31REV WH/BK C1P-5 JIB BK
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
E
C5TRR WH/BK C3P-5

ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9

C34SA BK/WH C1P-8
C33STR BK C1P-7
D
C27AUX RD C1P-1
C2P(BK)
J1
C1P
9
JC1-3 OR
Z-45/25 • Z-45/25J
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C
C7P
JC2-2 BRN
JC3-5 WH
JC3-3 OR
C28TTA RD/BK C1P-2

JC3-4 BL *
JC3-2 BRN
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
B
C29MS RD/WH
JIB BK
RD/BK-L48 (-)
GR/BK C4P-1
ALARM
TILT
H1
GR/BK-L4
RED - LS18
BRN
BRN
BRN BRN
6-64
1
8

TS47
GENERATOR 1
(OPTION)
JC2
TS15
DRIVE
HARNESS
GR/WH DRIVE
7
(TO CONTROL BOX)

6 6 6
5 5 + 5 2
RD
BK
GR/WH
L48
BK
TS48
TS13 DRIVE LIGHTS/
RD
2 2 2
3
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE
LED +
RD
L4 F18
PLATFORM FUSE 10A
CR13 4
C45GEN GR/WH C2P-7

OVERLOAD
GENERATOR OPTION
C8PBR BK/WH C3P-8
JIB BOOM LED
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
BL/RD-DE3 J1-16
RELAY
GR/BK H1 (D39)
BL/BK-DE2 J1-7
BL-DE1 J1-6
BK
CDLITE GR
BRN J1-14
BRN J1-10
BRN J1-12
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
WH-JIB
BL J1-5
BL J1-5
BRN
RD
RD
BK
5
BK
C35RPM BK/RD C1P-9
RD
C9HRN BK/RD C3P-9
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
P24FS WH
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7
C19JSV GR/WH
C17PRL GR C4P-5

Manual de Servicio Z45 PDF

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Manual de Servicio Z45 PDF

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Service Manual

Serial Number Range

Z-45/25 Deutz models: from 23041 to 34010

Z-45/25J All models: from A34011 to A47000

Part No. 107846

Important Serial Number Information

Compliance Z-45/25 and Z-45/25J Service Manual ............... 219418

Machine Design Life

ii Z-45/25 • Z-45/25J Part No. 107846

Serial Number Legend

Serial number: Z452506-12345

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

Genie Industries Serial label

Redmond, WA 98052 Serial number

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

This page intentionally left blank.

iv Z-45/25 • Z-45/25J Part No. 107846

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 107846 Z-45/25 • Z-45/25J v

Personal Safety Be sure to wear protective eye wear and

vi Z-45/25 • Z-45/25J Part No. 107846

Section 1 Safety Rules

Section 2 Rev Specifications

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

Section 3 Rev Scheduled Maintenance Procedures

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

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 107846 Z-45/25 • Z-45/25J ix

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

x Z-45/25 • Z-45/25J Part No. 107846

Section 4 Rev Repair Procedures, continued

Part No. 107846 Z-45/25 • Z-45/25J xi

Section 4 Rev Repair Procedures, continued

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

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

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

Section 6 Rev Schematics, continued

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

Section 6 Rev Schematics, continued

Part No. 107846 Z-45/25 • Z-45/25J xv

This page intentionally left blank.

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

Overall tire diameter 36.9 in 28 in Wheel width 14 inches

Lug nut torque Tire pressure 38 psi

Tire pressure (air-filled tires) 50 psi 100 psi

For operational specifications, refer to the

Continuous improvement of our products is a

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

Fluid capacities Performance Specifications

Secondary boom up 24 to 28 seconds

Secondary boom down 38 to 42 seconds

Secondary boom down 24 to 28 seconds

Turntable rotate, 359° 62 to 68 seconds

Continuous improvement of our products is a

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

Hydraulic Specifications Drive pump

Hydraulic Oil Specifications Type: bi-directional, variable

Cleanliness level, minimum 15/13 Drive pressure, maximum 3500 psi

Optional fluids Function pump