GENIE z45 25 Parts Sn. 21179to26998 PDF

Service Manual Part No.
77809
Rev C2
Refer to inside cover for additional serial number information August 2005
Introduction March 2005
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
maintenance information for the machine owner
(before serial number 21180) ............................... 52709
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service Z-45/25 and Z-45/25J Service Manual
professionals. After the following serial numbers:
Deutz models: 23040
Basic mechanical, hydraulic and electrical skills
Ford models: 23189
are required to perform most procedures. Perkins models: 23008) ...................................... 107846
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 2003 by Genie Industries
http://www.genieindustries.com 77809 Rev C March 2005

e-mail: [email protected] "Genie" and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005 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. 77809 Genie Z-45/25 and Genie Z-45/25J iii

Section 1 • Safety Rules March 2005
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.
iv Genie Z-45/25 and Genie Z-45/25J Part No. 77809

August 2005
Table of Contents
Introduction
Important Information .................................................................................................. ii
Section 1 Safety Rules

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

A Machine Specifications .......................................................................................... 2 - 1
B Performance Specifications ................................................................................... 2 - 1
B Hydraulic Specifications ........................................................................................ 2 - 2
B Manifold Component Specifications ...................................................................... 2 - 4
A Ford LRG-425 EFI Engine Specifications .............................................................. 2 - 5
A Deutz F3L-1011F Engine Specifications ................................................................ 2 - 7
A Perkins 104-22 Engine Specifications ................................................................... 2 - 8
A Machine Torque Specifications ............................................................................ 2 - 10
B Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 11
A SAE and Metric Fastener Torque Chart .............................................................. 2 - 12
Section 3 Rev Scheduled Maintenance Procedures

Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
E Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................ 3 - 7
A-2 Perform Function Tests ............................................................................... 3 - 7
A-3 Perform Engine Maintenance - Deutz Models .............................................. 3 - 8
A-4 Perform Engine Maintenance - Ford Models ................................................ 3 - 8
A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9
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June 2005
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A-6 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 9
A-7 Test the Oscillate Axle (if equipped) .......................................................... 3 - 10
A-8 Perform 30 Day Service ............................................................................. 3 - 10
A-9 Perform Engine Maintenance - Ford and Perkins Models .......................... 3 - 11
A-10 Replace the Fuel Filters - Ford Models ...................................................... 3 - 11
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 13
A-12 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 15
A-13 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 16
A-14 Perform Engine Maintenance - Ford Models .............................................. 3 - 16
A-15 Perform Engine Maintenance - Perkins Models ......................................... 3 - 17
D Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 18
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3 Test the Key Switch ................................................................................... 3 - 19
B-4 Perform Engine Maintenance - Ford Models .............................................. 3 - 20
B-5 Check the Exhaust System ........................................................................ 3 - 20
B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21
B-7 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 22
B-8 Confirm the Proper Brake Configuration .................................................... 3 - 22
B-9 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23
B-10 Check and Adjust the Engine RPM - Ford and Deutz Models .................... 3 - 23
B-11 Test the Ground Control Override .............................................................. 3 - 24
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June 2005
TABLE OF CONTENTS

B-12 Check the Directional Valve Linkage ......................................................... 3 - 25
B-13 Test the Platform Self-leveling ................................................................... 3 - 25
B-14 Test the Engine Idle Select ........................................................................ 3 - 26
B-15 Test the Fuel Select Operation - Ford Models ........................................... 3 - 26
B-16 Test the Drive Brakes ................................................................................ 3 - 27
B-17 Test the Drive Speed - Stowed Position .................................................... 3 - 28
B-18 Test the Drive Speed - Raised or Extended Position ................................. 3 - 28
B-19 Test the Alarm Package (if equipped) ........................................................ 3 - 29
B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 30
B-21 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 31
B-22 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 33
B-23 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34
B-24 Perform Engine Maintenance - Ford Models .............................................. 3 - 35
B-25 Perform Engine Maintenance - Perkins Models ......................................... 3 - 35
C Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 36
C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 36
C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 37
C-4 Perform Engine Maintenance - Perkins Models ......................................... 3 - 39
C-5 Perform Engine Maintenance - Ford Models .............................................. 3 - 39
Part No. 77809 Z-45/25 • Z-45/25J vii

June 2005
TABLE OF CONTENTS

D Checklist D Procedures
D-1 Check the Boom Wear Pads ..................................................................... 3 - 40
D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 40
D-3 Check the Free-wheel Configuration .......................................................... 3 - 42
D-4 Replace the Drive Hub Oil ......................................................................... 3 - 43
D-5 Check and Adjust the Air/LPG Mixture - Ford Models ................................ 3 - 44
D-6 Perform Engine Maintenance - Deutz Models ............................................ 3 - 45
D-7 Inspect for Turntable Bearing Wear ........................................................... 3 - 45
D-8 Calibrate the Platform Overload System (if equipped) ............................... 3 - 47
D-9 Replace the Hydraulic Filters ..................................................................... 3 - 48
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 50
E-2 Change the Fuel Hoses - Ford Models ...................................................... 3 - 52
E-3 Perform Engine Maintenance - Deutz Models ............................................ 3 - 53
E-4 Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 53
Section 4 Rev Repair Procedures

Introduction ........................................................................................................... 4 - 1
C Platform Controls
1-1 ALC-500 Circuit Board ................................................................................. 4 - 2
1-2 Joysticks ...................................................................................................... 4 - 3
A Platform Components
2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7
2-2 Platform Rotator ........................................................................................... 4 - 8
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March 2005
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

B Jib Boom Components, Z-45/25J
3-1 Jib Boom .................................................................................................... 4 - 10
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11
A Primary Boom Components
4-1 Cable Track ............................................................................................... 4 - 12
4-2 Primary Boom ............................................................................................ 4 - 16
4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 18
4-4 Primary Boom Extension Cylinder ............................................................. 4 - 19
4-5 Platform Leveling Master Cylinder ............................................................. 4 - 20
A Secondary Boom Components
5-1 Secondary Boom ....................................................................................... 4 - 22
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 27
B Engines
6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 28
6-2 RPM Adjustment - Perkins Models ............................................................ 4 - 28
6-3 Flex Plate ................................................................................................... 4 - 28
6-4 Engine Fault Codes - Ford Models ............................................................ 4 - 29
A Hydraulic Pumps
7-1 Lift/Steer Pump .......................................................................................... 4 - 31
7-2 Drive Pump ................................................................................................ 4 - 32
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J ix

March 2005
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

B Manifolds
8-1 Function Manifold Components (before serial number 22050) ................... 4 - 34
8-2 Valve Adjustments - Function Manifold (before serial number 22050) ....... 4 - 38
8-3 Function Manifold Components (after serial number 22049) ...................... 4 - 40
8-4 Valve Adjustments - Function Manifold (after serial number 22049) .......... 4 - 44
8-5 Jib Boom / Platform Rotate Manifold Components
(before serial number 22050) ..................................................................... 4 - 45
8-6 Jib Boom / Platform Rotate Manifold Components
(after serial number 22049) ........................................................................ 4 - 46
8-7 Turntable Rotation Manifold Components .................................................. 4 - 47
8-8 Directional Valve Manifold Components .................................................... 4 - 48
8-9 Drive Manifold Components, 2WD ............................................................. 4 - 50
8-10 Valve Adjustments, 2WD Drive Manifold ................................................... 4 - 52
8-11 Drive Manifold Components, 4WD ............................................................. 4 - 54
8-12 Valve Adjustments, 4WD Drive Manifold ................................................... 4 - 56
. A Turntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 57
B Axle Components
10-1 Hub and Bearings, 2WD Models ................................................................ 4 - 58
10-2 Oscillate Lock-out Cylinders ...................................................................... 4 - 59
Section 5 Rev Fault Codes

Introduction ........................................................................................................... 5 - 1
B Fault Codes - Control System ............................................................................... 5 - 2
B Fault Codes - Ford Models .................................................................................... 5 - 6
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March 2005
TABLE OF CONTENTS
Section 6 Rev Schematics

Introduction ........................................................................................................... 6 - 1
B Electrical Symbols Legend .................................................................................... 6 - 2
B Hydraulic Symbols Legend .................................................................................... 6 - 3
Ford LRG-425 EFI models
A Engine Harness (before serial number 22050) ...................................................... 6 - 5
A Engine Harness (after serial number 22049) ......................................................... 6 - 6
A Electrical Schematic, Z-45/25 (before serial number 22050) ................................. 6 - 7
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................... 6 - 9
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 22050) .............................................................................. 6 - 11
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(after serial number 22049) ................................................................................. 6 - 13
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xi

March 2005
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Ford LRG-425 EFI models, continued
A Electrical Schematic, Z-45/25J (before serial number 22050) ............................. 6 - 19
A Electrical Schematic, Z-45/25J (after serial number 22049) ................................ 6 - 21
A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J
A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J
xii Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005
TABLE OF CONTENTS

Deutz F3L-1011F models
A Electrical Schematic, Z-45/25 (before serial number 22050) ............................... 6 - 31
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................. 6 - 33
A Electrical Schematic, Z-45/25 (after serial number 22049)
CE models ........................................................................................................... 6 - 35
CE Models (after serial number 22049) ............................................................... 6 - 41
A Electrical Schematic, Z-45/25J (after serial number 22049)
CE models ........................................................................................................... 6 - 51
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xiii

March 2005
TABLE OF CONTENTS

Deutz F3L-1011F models, continued
xiv Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005
TABLE OF CONTENTS

Perkins 104-22 models
A Electrical Schematic, Z-45/25 (before serial number 22050) ............................... 6 - 63
A Electrical Schematic, Z-45/25 (after serial number 22049) .................................. 6 - 65
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xv

March 2005
TABLE OF CONTENTS

Perkins 104-22 models, continued
Hydraulic Schematics
A Hydraulic Schematic, 2WD Models (before serial number 22050) ....................... 6 - 87
B Hydraulic Schematic, 2WD Models (after serial number 22049) .......................... 6 - 88
A Hydraulic Schematic, 4WD Models (before serial number 22050) ....................... 6 - 89
B Hydraulic Schematic, 4WD Models (after serial number 22049) .......................... 6 - 90
xvi Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005 Section 2 • Specifications
REV B
Specifications
Machine Specifications Performance Specifications
Tires and wheels Rough terrain Industrial Drive speed, maximum
Wheel lugs, 4WD 9 @ 5/8 -18 Stowed position 4.8 mph

7.7 km/h
Wheel lugs, 2WD 40 ft/5.7 sec
Front 9 @ 5/8 -18 9 @ 5/8 -18 12.2 m/5.7 sec
Rear 9 @ 5/8 -18 9 @ 5/8 -18
Raised or extended position 0.3 mph
Lug nut torque, dry 125 ft-lbs 125 ft-lbs 0.5 km/h
169.5 Nm 169.5 Nm 40 ft/45 sec
12.2 m/45 sec
Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs
127.4 Nm 127.4 Nm Braking distance, maximum
Tire ply rating 14 Tread 8 High range on paved surface 3 to 6 ft

Sidewall 6 0.9 to 1.8 m
Tire contact area 59 sq in 43.5 sq in Boom function speeds, maximum

149.9 sq cm 280 sq cm from platform controls
Overall tire diameter 35.8 in 28 in Jib boom up, Z-45/25J 28 to 32 seconds

90.9 cm 71 cm
Jib boom down, Z-45/25J 16 to 20 seconds
Tire pressure (air filled tires) 45 psi 100 psi
3.1 bar 6.9 bar Primary boom up 24 to 28 seconds
Fluid capacities Primary boom down 24 to 28 seconds
LPG tank 33.5 pounds Secondary boom up 24 to 28 seconds

15.2 kg
Secondary boom down 38 to 42 seconds
Hydraulic tank 24 gallons
91 liters Primary boom extend 14 to 18 seconds
Hydraulic system 30 gallons Primary boom retract 16 to 20 seconds

(including tank) 113.6 liters
Turntable rotate, 359° 62 to 68 seconds
Drive hubs 17 fl oz primary boom retracted
0.5 liters
Platform rotate, 180° 5 to 7 seconds
Z-45/25
For operational specifications, refer to the
Operator's Manual. Platform rotate, 160° 5 to 7 seconds
Z-45/25J
Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2-1

Section 2 • Specifications March 2005
SPECIFICATIONS REV B
Hydraulic Specifications Drive pump
Hydraulic Oil Specifications Type: bi-directional, variable

displacement piston pump
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Multi-viscosity Flow rate @ 2500 rpm 30.3 gpm
Viscosity index 200 (before serial number 22050) 114.7 L/min
Cleanliness level, minimum 15/13 Flow rate @ 2500 rpm 32 gpm

(after serial number 22049) 121 L/min
Water content, maximum 200 ppm
Drive pressure, maximum 3500 psi
Chevron Rykon MV oil is fully compatible and (before serial number 22050) 241.3 bar
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are Drive pressure, maximum 3750 psi
designed to give maximum protection to hydraulic (after serial number 22049) 259 bar
systems, have the ability to perform over a wide Charge pump
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear, Type: gerotor
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Displacement 0.85 cu in
(before serial number 22050) 13.9 cc
Optional fluids
Displacement 0.84 cu in
Biodegradable Petro Canada Premium ECO 46 (after serial number 22049) 13.76 cc
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S Flow rate @ 2500 rpm 9.2 gpm
(before serial number 22050) 34.8 L/min
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822 Flow rate @ 2500 rpm 9.1 gpm
(after serial number 22049) 34.4 L/min
Mineral based Shell Tellus T32
Shell Tellus T46 Charge pressure @ 2500 rpm 250 psi
Chevron Aviation A (before serial number 22050) 17.2 bar
Charge pressure @ 2500 rpm 315 psi

(after serial number 22049) 21.7 bar
Use Chevron Aviation A hydraulic
oil when in ambient temperatures Function pump
consistently below 0°F / -18°C.
Type: gear, pressure balanced
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently Displacement 0.67 cu in
exceed 205°F / 96°C. 11 cc
Genie specifications require Flow rate @ 2500 rpm 7.25 gpm

additional equipment and special 27.4 L/min
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
2-2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809

REV B SPECIFICATIONS
Auxiliary pump Hydraulic filters
Type: gear, fixed displacement High pressure filter Beta 3 ³ 200
Displacement 1.75 gpm High pressure filter 100 psi

2.8 L/min bypass pressure 6.89 bar
Auxiliary pump relief pressure 3200 psi Medium pressure filter Beta 3 ³ 200
220.6 bar
Medium pressure filter 50 psi
Function manifold bypass pressure 3.4 bar
System relief valve pressure 3200 psi Hydraulic return filter 10 micron with
220.6 bar 25 psi / 1.7 bar bypass
Secondary boom down 1800 psi

relief valve pressure 124 bar
Platform level relief valve pressure 3500 psi

(after serial number 22049) 241.3 bar
Steer flow regulator 1.5 gpm

5.7 L/min
Boom extend flow regulator 2 gpm

7.6 L/minSteer
Jib boom / platform rotate flow regulator 0.6 gpm

(before serial number 22050) 2.27 L/min
Jib boom / platform rotate flow regulator 0.4 gpm

(after serial number 22049) 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 0.16 to 2.8 cu in

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

2WD 18.4 to 45.9 cc

SPECIFICATIONS REV A
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
Valve coil resistance specifications

(before serial number 22050)
Proportional solenoid valve, 12V DC 4 to 5Ω

(schematic items A, B and KK)
3 position 4 way directional valve, 10V DC 5 to 7Ω

(schematic items R, AA, CC, EE, FF and HH)
2 position 3 way solenoid valve, 10V DC 5 to 7Ω

(schematic items J, K, AI, AK, AU, AV,
OO and XX)
Valve coil resistance specifications

(after serial number 22049)
Proportional directional solenoid valve, 10V DC 6 to 8Ω

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

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

(schematic items E, G, AD, OO, XX, AI and AK)

REV A SPECIFICATIONS
Ford LRG-425 EFI Engine Oil viscosity requirements
Displacement 153 cu in Below 60°F / 15.5°C 5W-30

2.5 liters -10°F to 90°F / -23°C to 32°C 10W-30
Number of cylinders 4 Above -10°F / -23°C 10W-40 to 10W-50
Bore & stroke 3.78 x 3.4 in Above 20°F / -6.6°C 20W-40 or 20W-50
96.01 x 86.36 mm
Use oils meeting API classification SG (labeled SG/CC
Horsepower or SG/CD) as they offer improved wear protection.
Gross intermittent @ 3600 rpm 97 Units ship with 10W-40 SG/CC.
Continuous @ 3600 rpm 82 Oil pressure switch specifications
Horsepower @ 2500 rpm 70
Torque 8-18 ft-lbs
Firing order 1-3-4-2 11-24 Nm
Low idle 1600 rpm Oil pressure switch point 3-5 psi
High idle 2500 rpm 0.21-0.34 bar
Compression ratio 9.4:1 Starter motor
Compression pressure (approx.) Normal engine cranking speed 200 to 250 rpm
Pressure (psi) of lowest cylinder must be Current draw, normal load 140-200A
at least 75% of highest cylinder
Current draw, maximum load 800A
Valve clearances - 0.035 to 0.055 in
collapsed tappet 0.889 to 1.397 mm Current draw, minimum 60-80A
Lubrication system Maximum circuit voltage drop 0.5V DC
while starting (normal temperature)
Oil pressure 40 to 60 psi
(operating temp. @ 2000 rpm) 2.75 to 4.1 bar Brush length, new 0.66 in
16.8 mm
Oil capacity 5 quarts
(including filter) 4.7 liters Brush length wear limit 0.25 in
6.35 mm
Brush spring tension 64 ounces

18 Newtons
Bolt torque 45 to 84 in-lbs

through brush 5.08 to 9.5 Nm
Brush mounting 15 to 20 ft-lbs

bolt torque 20 to 27 Nm
Maximum commutator 0.005 in

run-out 0.127 mm

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

4.4 bar
Fuel flow rate 0.58 gpm

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

1.07 to 1.18 mm
Spark plug torque 5 to 10 ft-lbs

7 to 14 Nm
Engine coolant
Capacity 111/2 quarts

10.9 liters
Coolant temperature switch
Torque 8-18 ft-lbs

11-24 Nm
Temperature switch point 230° F

112° C
Alternator
Output 95A, 14.5V DC

Deutz F3L 1011F Engine Oil temperature switch specifications
Displacement 125 cu in Torque 8-18 ft-lbs

2.05 liters 11-24 Nm
Number of cylinders 3 Temperature switch point 220° F

104° C
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm Oil pressure switch specifications
Horsepower Torque 8-18 ft-lbs

11-24 Nm
Gross intermittent @ 3000 rpm 44
Continuous @ 3000 rpm 40 Oil pressure switch point 15 psi
Horsepower @ 2500 rpm 36 1 bar
Firing order 1-2-3 Fuel injection system
Low idle 1400 rpm Injection pump make OMAP
High idle 2500 rpm Injection pump pressure 4351 psi

300 bar
Compression ratio 18.5:1
Injector opening pressure 3626 psi
Compression pressure 362 to 435 psi 250 bar
25 to 30 bar
Fuel requirement diesel number 2-D
Governor centrifugal mechanical
Alternator output 60A, 14V DC
Valve clearance, cold
Starter motor
Intake 0.012 in
0.3 mm Current draw, no load 90A
Exhaust 0.020 in Brush length, new 0.72 in

0.5 mm 18.5 mm
Lubrication system Brush length, minimum 0.27 in

7 mm
Oil pressure 26 to 87 psi
1.8 to 6 bar Battery
Oil capacity 6.5 quarts Type 12V DC, Group 34/78

(including filter) 6 liters Quantity 1
Oil viscosity requirements Cold cranking ampere 900A
Below 60°F / 15.5°C 5W-30 Reserve capacity @ 25A rate 200 minutes
(synthetic)
Fan belt deflection 3 /8
to 1/2 inch
-10°F to 90°F / -23°C to 32°C 10W-40 9 to 12 mm
Above -4°F / -34°C 15W-40
Engine oil should have minimum properties of API

classification CC/SG or CD/SG grades.
Units ship with 10W-40 CH-4

Perkins 104-22 Engine Lubrication system

(KR model) Oil pressure @ 2500 rpm 41 psi
2.8 bar
Displacement 135 cu in
2.2 liters Oil capacity 8.6 quarts
(including filter) 8.2 liters
Number of cylinders 4
Oil viscosity requirements
Bore and stroke 3.31 x 3.94 inches
84 x 100 mm Below 68°F / 20°C (synthetic) 5W-20
Horsepower 5°F to 104°F / -15°C to 40°C 10W-30
Gross intermittent @ 2800 rpm 50 Above 14°F / -10°C 15W-40

Net intermittent @ 2800 rpm 46.9
Net continuous @ 2800 rpm 41 Engine oil should have minimum properties of API
Intermittent @ 2500 rpm 44 classification CC/SE. API classification CD/SE or CCMC
D4 can be used, but is not recommended during the
Firing order 1-3-4-2 first 50 hours nor for light load applications.
Units ship with CH-4
Low idle 1600 rpm
Oil pressure sending unit
High idle 2500 rpm
Torque 8-18 ft-lbs
Compression ratio 22:1 11-24 Nm
Compression pressure 300 to 500 psi Oil pressure switch point 4.2 psi
20.7 to 34.5 bar 0.3 bar
Pressure (psi) of lowest cylinder must
be within 50 psi / 3.45 bar of highest cylinder Fuel injection system
Governor centrifugal mechanical Injection pump make Zexel
Valve clearance, cold Injection pressure 2133 psi

147 bar
Intake 0.008 in
0.2 mm Fuel requirement #2 Diesel
Exhaust 0.008 in Alternator output 55A @ 13.8V DC

0.2 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

Perkins Engine 104-22

(KR model), continued
Battery
Type 12V DC, Group 34/78
Quantity 1
Cold cranking ampere 900A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8 in

10 mm
Engine coolant
Capacity 7.7 quarts

7.3 liters
Coolant temperature sending unit
Torque 8-18 ft-lbs

11-24 Nm
Temperature switch point 221° F

105° C

Machine Torque Specifications

Platform rotator
1-8 center bolt 480 ft-lbs

651 Nm
3 /8 -16 bolts 47 ft-lbs
63.7 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 200 ft-lbs

271 Nm
Drive hub mounting bolts, lubricated 150 ft-lbs

203 Nm
Drive motor mounting bolts, dry 75 ft-lbs

102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs

76 Nm
2 - 10 Genie Z-45/25 and Genie Z-45/25J Part No. 77809

August 2005 Section 2 • Specifications
REV B SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
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. 77809 Z-45/25 • Z-45/25J 2 - 11

Section 2 • Specifications June 2005
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 20 100 11.3 80 9 140 15.8 110 12.4 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -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
1 8 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
1 1/8 7 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
1 1/4 7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
1 1/2 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
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 f t -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 - 12 Z-45/25 • Z-45/25J Part No. 77809

March 2005 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
Used to indicate the presence of a
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-steering 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 supply disconnected
from the machine

Section 3 • Scheduled Maintenance Procedures March 2005
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, six months, annual, and two years.
perform this procedure. 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 group(s)
Indicates that new parts will be required
of procedures are required to perform a scheduled
to perform this procedure.
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.

Pre-Delivery 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 A
Section 3 • Scheduled Maintenance Procedures March 2005
This page intentionally left blank.

August 2005 Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report

Model Checklist A - Rev E Y N R Checklist B - Rev D Y N R
A-1 Pre-operation B-1 Battery
Serial number inspection B-2 Electrical wiring
Date A-2 Functions tests B-3 Key switch
A-3 Engine maintenance - B-4 Engine maintenance -
Hour meter Deutz models Ford models
A-4 Engine maintenance - B-5 Exhaust system
Machine owner Ford models
B-6 Oil cooler and fins-
A-5 Engine maintenance - Deutz models
Inspected by (print) Perkins models
B-7 Lug nut torque
Inspector signature A-6 Filter condition indicator
B-8 Brake configuration
A-7 Oscillate axle
B-9 Drive hub oil level
Inspector title Perform after 40 hours:
B-10 Engine RPM - Ford
A-8 30 day service and Deutz models
Inspector company
Perform every 100 hours: B-11 Ground control override
Instructions A-9 Engine maintenance - B-12 Directional valve
· Make copies of both pages to use Ford and Perkins
B-13 Platform leveling
for each inspection. models
B-14 Engine idle select
· Select the appropriate checklist(s) A-10 Fuel filters -
Ford models B-15 Fuel select -
for the type of inspection to be
Ford models
performed. A-11 Fuel filter/separator -
Diesel models B-16 Drive brakes
Daily or 8 hour A-12 Check engine RPM- B-17 Drive speed -
Inspection: A Perkins models stowed position
Quarterly or 250 hour A-13 Rotation bearing B-18 Drive speed -
Inspection: A+B raised position
Perform every 200 hours:
Six Month or 500 hour B-19 Alarm package
A-14 Engine maintenance -
Inspection: A+B+C B-20 Hydraulic oil analysis
Ford models
Annual or 1000 hours A-15 Engine maintenance - B-21 Fuel filter/separator -
Inspection: A+B+C+D Perkins models Perkins models
2 Year or 2000 hour B-22 Replace fuel filter -
Inspection: A+B+C+D+E Perkins models
Perform every 400 hours:
· Place a check in the appropriate box
after each inspection procedure is B-23 Engine maintenance -
completed. Deutz models
· If any inspection receives an “N”, tag B-24 Engine maintenance -
and remove the machine from Ford models
service, repair and re-inspect it. After B-25 Engine maintenance -
repair, place a check in the “R” box. Perkins models
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Part No. 77809 Z-45/25 • Z-45/25J 3-5

Section 3 • Scheduled Maintenance Procedures August 2005
MAINTENANCE INSPECTION REPORT
Model Checklist C - Rev C Y N R Checklist E - Rev B Y N R

C-1 Engine maintenance - E-1 Hydraulic oil
Serial number Deutz models E-2 Fuel hoses -
Date C-2 Grease platform Ford models
overload (if equipped) E-3 Engine maintenance -
Hour meter C-3 Test platform overload Deutz models
(if equipped) E-4 Grease steer axle
Machine owner Perform every 600 hours: wheel bearings,
C-4 Engine maintenance - 2WD models
Inspected by (print) Perkins models
Inspector signature Perform every 800 hours:

C-5 Engine maintenance -
Inspector title Ford models
Inspector company Checklist D - Rev D Y N R

D-1 Boom wear pads
Instructions
· Make copies of both pages to use D-2 Turntable bearing bolts
for each inspection. D-3 Free-wheel
· Select the appropriate checklist(s) configuration
for the type of inspection to be D-4 Drive hub oil
performed. D-5 Air/LPG mixture -
Ford models
Daily or 8 hour
Inspection: A D-6 Engine maintenance -
Deutz models
Quarterly or 250 hour
D-7 Turntable bearing wear
Inspection: A+B
D-8 Calibrate platform
Six Month or 500 hour
overload system
Inspection: A+B+C
(if equipped)
Annual or 1000 hours D-9 Hydraulic filters
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
· Place a check in the appropriate box

after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
3-6 Z-45/25 • Z-45/25J Part No. 77809

REV E
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 Genie Z-45/25 and Genie Z-45/25J
procedures are required. Operator's Manual on your machine.
Complete information to perform this procedure is
available in the Genie Z-45/25 and Genie Z-45/25J
Operator's Manual on your machine.
Part No. 77809 Z-45/25 • Z-45/25J 3-7

CHECKLIST A PROCEDURES REV E
A-3 A-4
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Ford Models
Engine specifications require that Engine specifications require that

this procedure be performed daily this procedure be performed daily
or every 10 hours, whichever or every 8 hours, whichever comes
comes first. first.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Deutz FL 1011F Operation Manual Ford LRG-425 EFI Operator Handbook
(Deutz part number 0297 9683). (Ford part number FPP 194-302).
Deutz FL 1011F Operation Manual Ford LRG-425 EFI Operator Handbook

Genie part number 52883 Genie part number 84792
To access the engine: To access the engine:
1 Remove the safety pin from the engine pivot 1 Remove the safety pin from the engine pivot
plate latch. plate latch.
The engine pivot plate latch is The engine pivot plate latch is
located under the engine turntable located under the engine turntable
pivot plate at the counterweight pivot plate at the counterweight
end of the machine. end of the machine.
2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the engine pivot plate out and away from the
machine. machine.
3-8 Z-45/25 • Z-45/25J Part No. 77809

REV E CHECKLIST A PROCEDURES
A-5 A-6
Perform Engine Maintenance - Check the High Pressure
Perkins Models Hydraulic Filter Condition
Indicator
Maintaining the high pressure hydraulic filter in
good condition is essential to good system
Engine specifications require that performance and safe machine operation. The filter
this procedure be performed daily condition indicator will show when the hydraulic flow
or every 8 hours, whichever comes is bypassing a clogged filter. If the filter is not
first. frequently checked and replaced, impurities will
remain in the hydraulic system and cause
Proper engine maintenance, following the engine
component damage.
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure 1 Open the engine side turntable cover.
to perform the maintenance procedures can lead to
poor engine performance and component damage. 2 Start the engine from the ground controls.
Required maintenance procedures and additional 3 Change the engine idle to high rpm (rabbit
engine information are available in the symbol).
Perkins 100 Series Workshop Manual 4 Visually inspect the filter condition indicator.
(Perkins part number TPD 1377E).
Result: The filter condition indicator should be
operating with the plunger in the green area.
Perkins 100 Series Workshop Manual
Genie part number 72352 Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter should be
To access the engine: replaced. See D-9, Replace the Hydraulic
Filters.
1 Remove the safety pin from the engine pivot
plate latch.
The engine pivot plate latch is
located under the engine turntable
pivot plate at the counterweight
end of the machine.
2 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.
Part No. 77809 Z-45/25 • Z-45/25J 3-9

A-7 A-8
Test the Oscillate Axle Perform 30 Day Service
(if equipped)
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
Proper axle oscillation is essential to safe machine
first 30 days or 40 hours of usage, whichever
operation. If the axle oscillation system is not
comes first. After this interval, refer to the
operating correctly, the stability of the machine is
maintenance checklist for continued scheduled
compromised and it may tip over.
maintenance.
1 Start the engine from the platform controls.
1 Perform the following maintenance procedures:
2 Drive the right steer tire up onto a 6 inch /
15.2 cm block or curb. • A-9 Perform Engine Maintenance -
Ford and Perkins Models
Result: The three remaining tires should stay in
firm contact with the ground and the chassis • A-13 Grease the Turntable Rotation Bearing
should remain level at all times. and Rotate Gear
3 Drive the left steer tire up onto a 6 inch / • B-7 Check the Lug Nut Torque
15.2 cm block or curb. (including tires and wheels)
• B-9 Check the Oil Level in the Drive Hubs
Result: The three remaining tires should stay in
firm contact with the ground and the chassis • C-1 Perform Engine Maintenance -
should remain level at all times. Deutz Models
4 Drive both steer tires up onto a 6 inch / • D-2 Check the Turnable Rotation Bearing
15.2 cm block or curb. Bolts
• D-9 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 8-8, How to Set Up the
Directional Valve Linkage.
3 - 10 Z-45/25 • Z-45/25J Part No. 77809

A-9 A-10
Perform Engine Maintenance - Replace the Fuel
Ford and Perkins Models Filters - Ford Models
Engine specifications require that Engine specifications require that

this procedure be performed every this procedure be performed every
100 hours. Perform this procedure 100 hours.
more often if dusty conditions exist
or the machine is subjected to Replacing the gasoline fuel filters is essential to
extended low idle operation. good engine performance and service life. A dirty or
clogged filter may cause the engine to perform
Proper engine maintenance, following the engine poorly and continued use may cause component
manufacturer's maintenance schedule, is essential damage. Extremely dirty conditions may require
to good engine performance and service life. Failure that the filter be replaced more often.
poor engine performance and component damage. Explosion and fire hazard. Engine
fuels are combustible. Replace the
Required maintenance procedures and additional fuel filter in an open, well-ventilated
engine information are available in the area away from heaters, sparks,
Ford LRG-425 EFI Operator Handbook flames and lighted tobacco.
(Ford part number FPP 194-302) OR the Always have an approved fire
Perkins 100 Series Workshop Manual extinguisher within easy reach.
Perform this procedure with the
engine off.
Ford LRG-425 EFI Operator Handbook
Genie part number 84792 1 Put on protective clothing and eye wear.
Perkins 100 Series Workshop Manual 2 Open the tank side turntable cover and locate
Genie part number 72352 the fuel system components mounted to the
plate under the fuel tank.
To access the engine:

plate latch.
end of the machine.
machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 11

3 Remove the fuel system plate retaining 8 Remove the regulator/filter mounting fasteners
fasteners. Carefully lower the fuel system plate. and remove the regulator/filter from the fuel
system mounting plate.
“From tank”
9 Install the new regulator/filter onto the fuel
system mounting plate. Connect the fuel hoses
to the regulator/filter.
Pre-Filter Fuel Pump
Component damage hazard. Be
sure the correct regulator/filter is
installed or component damage
Fuel pressure
“To engine” may occur.
regulator/filter
Be sure each fuel hose is

“Return to tank” connected to the correct port of the
pressure/regulator.
4 At the pre-filter, disconnect and plug the fuel 10 Install the fuel hose from the fuel tank to the fuel
hose that goes to the fuel tank. pre-filter.
5 Disconnect the fuel hose from the fuel pre-filter 11 Clean up any fuel that may have spilled during
to the fuel pump. Remove the pre-filter. the installation procedure.
6 Install the new fuel pre-filter and connect the fuel 12 Start the machine from the ground controls.
hose between the fuel pump and the pre-filter. Inspect the fuel filters and hoses for leaks.
Be sure the arrow on the pre-filter Explosion and fire hazard. If a fuel
is pointing towards the fuel pump. leak is discovered, keep any
7 Tag and disconnect the fuel hoses from the additional personnel from entering
pressure regulator/filter. the area and do not operate the
machine. Repair the leak
Explosion and fire hazard. immediately.
Electronic Fuel Injection (EFI)
systems operate at a very high
pressure. Fuel may be expelled
under pressure if the hoses are
removed too quickly. Loosen the
fuel lines very slowly to allow the
fuel pressure to dissipate
gradually. Wrap a cloth around fuel
hoses to absorb leaking fuel before
disconnecting them.
3 - 12 Z-45/25 • Z-45/25J Part No. 77809

A-11 4 Loosen the vent plug located on the fuel filter/

water separator head.
Inspect the Fuel Filter/ Water
Separator - Diesel Models
a
Engine specifications require that

this procedure be performed every
100 hours. c
Proper maintenance of the fuel filter/water separator b

is essential for good engine performance. Failure to
perform this procedure can lead to poor engine
performance and component damage.
Explosion and fire hazard. Engine a vent plug

fuels are combustible. Perform this b drain plug
procedure in an open, well- c filter bowl
d separator head
ventilated area away from heaters,
sparks, flames and lighted 5 Loosen the drain plug located at the bottom of
tobacco. Always have an approved the bowl. Allow the water to drain into a suitable
fire extinguisher within easy reach. container until fuel starts to come out.
Perform this procedure with the Immediately tighten the drain plug.
engine off. 6 Tighten the vent plug.
Perkins models: If the fuel filter/water separator is
1 Put on protective clothing and eye wear. completely drained, you must
prime the fuel filter/water separator
2 Open the engine side turntable cover and locate before starting the engine.
the fuel filter/water separator next to the See B-22, Replace The Fuel Filter
hydraulic return filter on the bulkhead. Element - Perkins Models, for
3 Visually inspect the filter bowl for water buildup. instructions on how to prime the
fuel filter/water separator.
Result: If water is present in the filter bowl,
7 Clean up any fuel that may have spilled.
continue with steps 3 through 7.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 13

8 Start the engine from the ground controls and 5 Loosen the drain plug located at the bottom of
check the fuel filter/water separator and vent the filter. Allow the water to drain into a suitable
plug for leaks. container until fuel starts to come out.
Immediately tighten the drain plug.
Explosion and fire hazard. If a fuel
leak is discovered, keep any Do not completely drain the filter.
additional personnel from entering
the area and do not operate the
immediately.
Deutz models:
1 Put on protective clothing and eye wear.
a
plate latch.
b
end of the machine. a fuel filter/water separator
b drain valve
engine pivot plate out and away from the 6 Clean up any fuel that may have spilled.
machine. 7 Start the engine from the ground controls and
4 Locate the fuel filter/water separator next to the check the fuel filter/water separator for leaks.
oil filter. Explosion and fire hazard. If a fuel
leak is discovered, keep any
immediately.
8 Swing the engine back to its original position
and close the engine pivot plate latch.
9 Install the engine pivot plate safety pin.
3 - 14 Z-45/25 • Z-45/25J Part No. 77809

A-12 2 Loosen the low idle lock nut and turn the low idle
adjustment screw clockwise to increase the
Check and Adjust the rpm, or counterclockwise to decrease the rpm.
Engine RPM - Perkins Models Tighten the low idle lock nut and confirm the
rpm.
Engine specifications require that

100 hours.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
This procedure will require two
people.
1 Connect a tachometer to the engine. Start the
engine from the ground controls.
Result: Low idle should be 1600 rpm. a b c d
Skip to step 3 if the low idle rpm is correct. a solenoid boot
b high idle adjustment nut
c yoke
d low idle lock nut and adjustment
screw
3 Move the function enable toggle switch to the

high idle (rabbit symbol) position.
Result: High idle should be 2500 rpm.
If high idle rpm is correct, disregard adjustment
step 4.
4 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Be sure the solenoid fully retracts
when activating high idle.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 15

A-13 A-14
Grease the Turntable Rotation Perform Engine Maintenance -
Bearing and Rotate Gear Ford Models
Genie specifications require that Ford engine specifications require

this procedure be performed every that this procedure be performed
100 hours of operation. Perform every 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
Required maintenance procedures and additional
result in component damage.
engine information are available in the
1 Locate the grease fitting on the front turntable Ford LRG-425 EFI Operator Handbook
cover. (Ford part number FPP 194-302).
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5 Ford LRG-425 EFI Operator Handbook
Genie part number 84792
inches / 10 to 13 cm at a time and repeat this
step until the entire bearing has been greased.
3 Apply grease to each tooth of the drive gear, To access the engine:
located under the turntable.
Grease Specification plate latch.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based) located under the engine turntable
or equivalent
end of the machine.
machine.
3 - 16 Z-45/25 • Z-45/25J Part No. 77809

A-15
Perform Engine Maintenance -
Perkins Models
Perkins engine specifications

require that this procedure be
performed every 200 hours.
to good engine performance and service life. Failure
poor engine performance and component damage.



plate latch.
end of the machine.
machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 17

Section 3 • Scheduled Maintenance Procedures June 2005
Checklist B Procedures REV D
B-1 B-2
Inspect the Battery Inspect the Electrical Wiring
Proper battery condition is essential to good engine Maintaining electrical wiring in good condition is
performance and operational safety. Improper fluid essential to safe operation and good machine
levels or damaged cables and connections can performance. Failure to find and replace burnt,
result in engine component damage and hazardous chafed, corroded or pinched wires could result in
conditions. unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in Electrocution hazard. Contact with
death or serious injury. Remove all hot or live circuits could result in
rings, watches and other jewelry. death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 1 Open the engine side turntable cover.
contacting battery acid. Neutralize
battery acid spills with baking soda
plate latch.
and water.
2 Be sure that the battery cable connections are pivot plate at the counterweight
free of corrosion. end of the machine.
3 Be sure that the battery hold downs and cable 3 Open the engine pivot plate latch and swing the
connections are tight. engine pivot plate out and away from the
machine.
The battery is a maintenance free
battery and does not require the 4 Inspect the following areas for burnt, chafed,
replenishing of electrolyte. corroded and loose wires:
Adding terminal protectors and a · Engine wiring harness
corrosion preventative sealant will · Hydraulic manifold wiring
help eliminate corrosion on the
battery terminals and cables.
3 - 18 Z-45/25 • Z-45/25J Part No. 77809

June 2005 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST B PROCEDURES
5 Open the ground controls side turntable cover. B-3

6 Inspect the following areas for burnt, chafed, Test the Key Switch
corroded and loose wires:
Proper key switch action and response is essential
· Inside of the ground control box to safe machine operation. The machine can be
· Hydraulic manifold wiring operated from the ground or platform controls and
the activation of one or the other is accomplished
7 Start the engine from the ground controls and
with the key switch. Failure of the key switch to
raise the boom above the turntable covers.
activate the appropriate control panel could cause a
8 Inspect the turntable area for burnt, chafed and hazardous operating situation.
pinched cables.
1 Pull out the red Emergency Stop button to the
9 Lower the boom to the stowed position and turn on position at both the ground and platform
the engine off. controls.
10 Inspect the following areas for burnt, chafed, 2 Turn the key switch to ground control, start the
corroded, pinched and loose wires: engine and then turn the key switch to platform
· Cable track on the primary boom control.
· Cables on the primary, and jib booms 3 Check all machine function from the ground
controls.
· Jib boom/Platform rotate manifold
· Inside of the platform control box Result: All machine functions should not
operate.
and close the engine pivot plate latch. 4 Turn the key switch to ground control.
12 Install the engine pivot plate safety pin. 5 Check all machine function from the platform
controls.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no functions
should operate.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 19

CHECKLIST B PROCEDURES REV D
B-4 B-5
Perform Engine Maintenance - Check the Exhaust System
Ford Models Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
Ford engine specifications require operating conditions.
that this procedure be performed
Bodily injury hazard. Do not
every 250 hours.
inspect while the engine is running.
Proper engine maintenance, following the engine Remove the key to secure from
manufacturer's maintenance schedule, is essential operation.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
Required maintenance procedures and additional severe burns.
engine information are available in the Ford models:
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302). 1 Remove the safety pin from the engine pivot
plate latch.
Ford LRG-425 EFI Operator Handbook The engine pivot plate latch is
end of the machine.
1 Remove the safety pin from the engine pivot engine pivot plate out and away from the
plate latch. machine to access the exhaust system.
The engine pivot plate latch is All models:
pivot plate at the counterweight 3 Be sure that all nuts and bolts are tight.
end of the machine. 4 Inspect all welds for cracks.
2 Open the engine pivot plate latch and swing the 5 Inspect for exhaust leaks; i.e., carbon buildup
engine pivot plate out and away from the around seams and joints.
machine.
Ford models:

and close the engine pivot plate latch.
3 - 20 Z-45/25 • Z-45/25J Part No. 77809

B-6 4 Inspect the oil cooler for leaks and physical

damage.
Check the Oil Cooler and a b c
Cooling Fins - Deutz Models
Maintaining the oil cooler in good condition is

essential for good engine performance. Operating a
machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not

inspect while the engine a oil cooler
is running. Remove the key to b cylinder head cooling fins
c fan blower fins
secure from operation.
Burn hazard. Beware of hot engine 5 Clean the oil cooler of debris and foreign
components. Contact with hot material.
engine components may result in Cooling and fan blower fins
severe burns.
6 Inspect the fan blower fins for physical damage.
Oil cooler
7 Clean the fan blower fins of debris and foreign
1 Remove the safety pin from the engine pivot material.
plate latch.
8 Inspect the head cooling passages and fins for
The engine pivot plate latch is physical damage or foreign material, using a
located under the engine turntable flashlight.
end of the machine. 9 Clean the cylinder head cooling passages of
debris and foreign material.
engine pivot plate out and away from the 10 Install the engine side cover.
machine. 11 Swing the engine back to its original position
3 Remove the fasteners from the engine side and close the engine pivot plate latch.
cover, then remove the cover. 12 Install the engine pivot plate safety pin.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 21

B-7 B-8
Check the Lug Nut Torque Confirm the Proper
(including the tires and wheels) Brake Configuration
Maintaining the tires and wheels in good Proper brake configuration is essential to safe
condition is essential to safe operation and good operation and good machine performance.
performance. Tire and/or wheel failure could result Hydrostatic brakes and hydraulically-released,
in a machine tip-over. Component damage may spring-applied individual wheel brakes can appear
also result if problems are not discovered and to operate normally when they are actually not fully
repaired in a timely fashion. operational.
Bodily injury hazard. An over- 1 Check each drive hub disconnect cap to be sure
inflated tire can explode and could it is in the engaged position.
cause death or serious injury.
brake disengaged position
Tip-over hazard. Do not use
temporary flat tire repair products.
The tires on some machines are
foam-filled and do not need air
brake engaged position
added to them.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear. 2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications. d
4 Check the pressure in each air-filled tire. Refer a c

to Section 2, Specifications. b
a drive pump
b free-wheel valve
c lift pump
d screwdriver
The free-wheel valve is located on

the side of the drive pump.
The free-wheel valve should
always remain closed.
3 - 22 Z-45/25 • Z-45/25J Part No. 77809

B-9 B-10
Check the Oil Level Check and Adjust the
in the Drive Hubs Engine RPM - Ford and Deutz
Models
Failure to maintain proper drive hub oil levels may

cause the machine to perform poorly and continued Maintaining the engine rpm at the proper setting for
use may cause component damage. both low and high idle is essential to good engine
1 Drive the machine to rotate the hub until the performance and service life. The machine will not
plugs are located one on top and the other at operate properly if the rpm is incorrect and
90 degrees. continued use may cause component damage.
Ford models:
a
The engine rpm is controlled by the
ECM and can only be adjusted by
re-programming the ECM. If rpm
adjustment or service is required,
please contact Genie Industries
Service Department OR your local
Ford dealer.
Deutz models:
a drive hub plugs This procedure will require two
people.
2 Remove the plug located at 90 degrees and
check the oil level. 1 Remove the safety pin from the engine pivot
plate latch.
Result: The oil level should be even with the
bottom of the side plug hole. The engine pivot plate latch is
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
end of the machine.
side plug hole.
4 Apply pipe thread sealant to the plug(s), and
install the plug(s) in the drive hub.
machine.
5 Repeat this procedure for each drive hub.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 23

3 Connect an rpm gauge to the engine, and then 6 Loosen the yoke lock nut, then turn the high idle
start the engine from the ground controls. adjustment nut and solenoid boot
counterclockwise to increase the rpm or
Result: Low idle should be 1400 rpm.
clockwise to decrease the rpm. Tighten the
Skip to step 5 if the low idle rpm is correct. yoke lock nut and recheck the rpm.
4 Loosen the low idle lock nut, then turn the low Be sure the solenoid fully retracts
idle adjustment screw clockwise to increase the when activating high idle.
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and recheck the
rpm.
B-11
Test the Ground Control
Override
f A properly functioning ground control override is
essential to safe machine operation. The ground
e 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
a b c d
boom to the stowed position.
a solenoid boot
b high idle adjustment nut 1 Push in the platform red Emergency Stop button
c yoke lock nut to the off position.
d yoke
e low idle adjustment screw 2 Start the engine from the ground controls.
f low idle lock nut
3 At the ground controls, operate each boom
5 Move the function enable toggle switch to the function through a partial cycle.
high idle (rabbit symbol) position at the ground
controls. Result: All boom functions should operate.
Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregard adjustment
step 6.
3 - 24 Z-45/25 • Z-45/25J Part No. 77809

B-12 B-13
Check the Directional Valve Test the Platform Self-leveling
Linkage
Automatic platform self-leveling throughout

Perform this test only on models the full cycle of boom raising and lowering is
equipped with a 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 directional valve linkage is not loop hydraulic circuit with the master cylinder
operating correctly, the stability of the machine is located at the base of the boom.
compromised and it may tip over. A platform self-leveling failure creates an unsafe
working condition for platform and
1 Remove the drive chassis cover and the axle ground 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 directional valve inside of the non-
steer axle and inspect the linkage for the 2 Hold the function enable toggle switch to either
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. 77809 Z-45/25 • Z-45/25J 3 - 25

B-14 B-15
Test the Engine Idle Select Test the Fuel Select Operation -
A properly operating engine idle select switch Ford Models
is essential to good engine performance and safe
machine operation. There are two settings.
Foot switch activated low idle (turtle symbol)

The ability to select and switch between
allows the operator to control individual boom
gasoline and LPG fuels as needed is essential to
functions. Drive functions will operate at low idle,
safe machine operation. A fuel selection can be
but at reduced performance.
made when the engine is running or not.
Foot switch activated high idle (rabbit symbol) Switching malfunctions and/or the failure of the
should be used for normal machine operation. This engine to start and run properly in both fuel
selection activates high idle only when the foot modes and through all idle speeds can indicate fuel
switch is pressed down. system problems that could develop into a
hazardous situation.
on position at both the ground and platform Perform this test after checking
controls. the gasoline and LPG fuel levels,
and warming the engine to normal
2 Start the engine from the ground controls then operating temperature.
move the function enable toggle switch to the
high idle (rabbit symbol) position and hold in the 1 At the platform controls, move the fuel select
on position. switch to gasoline and then move the engine
idle control switch to foot switch activated high
Result: The engine should change to high idle. idle (rabbit and foot switch symbol).
3 Release the function enable toggle switch. 2 Start the engine from the platform controls and
Result: The engine should return to low idle. allow it to run at low idle.
4 Turn the key switch to platform controls. 3 Press down the foot switch to allow the engine
to run at high idle.
5 Move the engine idle control switch to foot
switch activated high idle (rabbit symbol). Result: The engine should start promptly and
operate smoothly in low and high idle.
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
6 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
3 - 26 Z-45/25 • Z-45/25J Part No. 77809

4 Release the foot switch and shut the engine off B-16
by pushing in the red Emergency Stop button in
to the off position. Test the Drive Brakes
5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at
low idle. Proper brake action is essential to safe machine
operation. The drive brake function should operate
7 Press down the foot switch to allow the engine
smoothly, free of hesitation, jerking and unusual
to run at high idle.
noise. Hydrostatic brakes and hydraulically-
Result: The engine should start promptly and released individual wheel brakes can appear to
operate smoothly in low and high idle. operate normally when they are actually not fully
operational.
The engine may hesitate
momentarily and then continue Collision hazard. Be sure that the
to run on the selected fuel if the machine is not in free-wheel or
fuel source is switched while partial free-wheel configuration.
the engine is running. Refer to B-8, Confirm the Proper
Brake Configuration.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and
foot switch), then lower the boom into the
stowed position.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
The brakes must be able to hold
the machine on any slope it is able
to climb.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 27

B-17 B-18
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised or Extended Position
Proper drive function movement is essential to safe Proper drive function movement is essential to safe
machine operation. The drive function should machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, Drive performance should also be free of hesitation,
jerking and unusual noise over the entire jerking and unusual noise over the entire
proportionally controlled speed range. proportionally controlled speed range.
Select a test area that is firm, level Select a test area that is firm, level
and free of obstructions. and free of obstructions.
1 Create start and finish lines by marking two lines 1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart. on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls. 2 Start the engine from the platform controls.
3 Move the engine idle control switch to 3 Move the engine idle select switch to foot switch
foot switch activated high idle (rabbit and foot activated high idle (rabbit and foot switch).
switch), then lower the boom into the stowed Press down the foot switch and raise the boom
position. above horizontal.
4 Choose a point on the machine; i.e., contact 4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use patch of a tire, as a visual reference for use
when crossing the start and finish lines. when crossing the start and finish lines.
5 Bring the machine to top drive speed before 5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your reaching the start line. Begin timing when your
reference point on the machine crosses the reference point on the machine crosses the
start line. start line.
6 Continue at full speed and note the time when 6 Continue at full speed and note the time when
the machine reference point crosses the finish the machine reference point crosses the finish
line. Refer to Section 2, Specifications. line.
3 - 28 Z-45/25 • Z-45/25J Part No. 77809

7 Press down the foot switch and lower the boom B-19
to the stowed position.
Test the Alarm Package
8 Extend the boom 1 foot / 30 cm.
(if equipped)
9 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use The alarm package includes:
when crossing the start and finish lines. · Travel alarm
10 Bring the machine to top drive speed before · Descent alarm
reaching the start line. Begin timing when your
· Flashing beacon
reference point on the machine crosses the
start line. Alarms and a beacon are installed to alert operators
and ground personnel of machine proximity and
11 Continue at top speed and note the time when motion. The alarm package is installed on the
the machine reference point crosses the finish turntable covers.
line. Refer to Section 2, Specifications.
The alarms and beacon will
operate with the engine
running or not running.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: The flashing beacon should be on and
flashing.
2 Move the function enable switch to either side
and activate the primary boom toggle switch in
the down position, hold for a moment and then
release it.
Result: The descent alarm should sound when
the switch is held down.
3 Move the function enable switch to either side
and activate the secondary boom toggle switch
in the down position, hold for a moment and
then release it.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 29

4 Z-45/25J: Move the function enable switch to B-20

either side and activate the jib boom toggle
switch in the down position, hold for a moment Perform Hydraulic Oil Analysis
and then release it.
the switch is held down. Replacement or testing of the hydraulic oil is
5 Turn the key switch to platform control. essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
Result: The flashing beacon should be on or hydraulic filters may cause the machine to
and flashing. perform poorly and continued use may cause
6 Press down the foot switch. Move the primary component damage. Extremely dirty conditions
boom control handle to the down position, hold may require oil changes to be performed more
for a moment and then release it. often.
Result: The descent alarm should sound when Before replacing the hydraulic oil,
the control handle is held down. the oil may be tested by an oil
distributor for specific levels of
7 Press down the foot switch. Move the contamination to verify that
secondary boom control handle to the down changing the oil is necessary. If
position, hold for a moment and then release it. the hydraulic oil is not replaced
Result: The descent alarm should sound when at the two year inspection, test
the control handle is held down. the oil quarterly. Replace the oil
when it fails the test.
8 Z-45/25J: Press down the foot switch. Activate See E-1, Test or Replace the
the jib boom toggle switch in the down position, Hydraulic Oil.
hold for a moment and then release it.
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 - 30 Z-45/25 • Z-45/25J Part No. 77809

B-21 3 Loosen the vent plug located on the fuel filter/

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

d
element is essential for good engine performance
and service life. A dirty or clogged filter may cause c
the engine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
a vent plug
Explosion and fire hazard. Engine b main fuel line
fuels are combustible. Perform this c drain plug
procedure in an open, well- d filter bowl
ventilated area away from heaters, e filter element
f separator head
sparks, flames and lighted
tobacco. Always have an approved 4 Place a suitable container under the filter bowl.
fire extinguisher within easy reach. Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel.
engine off. 5 Rotate the filter bowl counterclockwise and
remove it from the element.
1 Open the engine side turntable cover and locate
the fuel filter/water separator on the bulkhead. 6 Rotate the filter element counterclockwise and
remove it from the filter head.
2 Disconnect and plug the fuel supply hose from
the fuel tank to the fuel filter/water separator. 7 Install the bowl onto the new filter element.
8 Apply a thin layer of oil onto the element gasket.
Install the filter/bowl assembly onto the filter
head. Tighten the drain plug and vent plug.
Component damage hazard. The
drain plug and vent plug can be
damaged if they are overtightened.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 31

9 Clean up any diesel fuel that may have spilled 15 Operate the priming lever or priming bulb (if
during the installation procedure. equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
10 Install the fuel supply hose from the fuel tank to
vent plug.
the fuel filter/water separator. Tighten the
clamp. 16 Clean up any fuel that may have spilled during
this procedure.
11 Use a permanent ink marker to write the date
and number of hours from the hour meter on the 17 Operate the starter motor for intervals of 15
filter element housing. seconds until the engine starts.
Bleed the system: It is important to allow the starter
motor to cool for 30 seconds
between each 15 second interval
plate latch.
of operation.
If the engine runs correctly for a
short time and then stops or runs
roughly, check for air in the fuel
end of the machine.
system. If there is air in the fuel
13 Open the engine pivot plate latch and swing the system, there is probably a leak in
engine pivot plate out and away from the the low pressure side of the
machine. system.
14 Loosen the vent plug on top of the fuel injection 17 Swing the engine back to its original position
pump. and close the engine pivot plate latch.
c b
a vent plug
b fuel injection pump
c fuel lift pump
3 - 32 Z-45/25 • Z-45/25J Part No. 77809

B-22 5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
Replace the Fuel Filter Element -
Perkins Models
a
b
Replacing the diesel fuel filter element is essential
for good engine performance and service life. A c
dirty or clogged filter may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may required that the filter be replaced more often.
Explosion and fire hazard. Engine

fuels are combustible. Perform this a fuel line
b filter head
procedure in an open, well- c fuel filter element
sparks, flames and lighted 6 Remove the fuel filter element with a filter
tobacco. Always have an approved wrench.
7 Apply a thin layer of fuel to the O-ring of the new
Perform this procedure with the fuel filter element.
engine off.
8 Install the new fuel filter element and tighten it
1 Remove the safety pin from the engine pivot securely by hand. Clean up any fuel that may
plate latch. have spilled during the installation procedure.
The engine pivot plate latch is 9 Use a permanent ink marker to write the date
located under the engine turntable and number of hours from the hour meter on the
pivot plate at the counterweight oil filter housing.
end of the machine.
machine.
3 Thoroughly clean the outside surfaces of the
fuel filter assembly.
4 Place a suitable container under the fuel filter
element.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 33

Bleed the fuel system: B-23

9 Loosen the vent plug on top of the fuel injection Perform Engine Maintenance -
pump.
Deutz Models
a
Deutz engine specifications require
c b that this procedure be performed
every 400 hours.
a vent plug
b fuel injection pump engine information are available in the
c fuel lift pump Deutz FL 1011F Operation Manual
(Deutz part number 0297 9683).
10 Operate the priming lever or priming bulb (if
equipped) of the fuel lift pump until fuel, free
Deutz FL 1011F Operation Manual
from air, comes from the vent plug. Tighten the
vent plug.
11 Clean up any fuel that may have spilled during
this procedure. To access the engine:
12 Operate the starter motor for intervals of 15 1 Remove the safety pin from the engine pivot
seconds until the engine starts. plate latch.
It is important to allow the starter The engine pivot plate latch is
motor to cool for 30 seconds located under the engine turntable
between each 15 second interval pivot plate at the counterweight
of operation. end of the machine.
If the engine runs correctly for a 2 Open the engine pivot plate latch and swing the
short time and then stops or runs engine pivot plate out and away from the
roughly, check for air in the fuel machine.
system. If there is air in the fuel
system, there is probably a leak in
the low pressure side of the
system.
3 - 34 Z-45/25 • Z-45/25J Part No. 77809

B-24 B-25
Ford Models Perkins Models
Ford engine specifications require Perkins engine specifications

that this procedure be performed require that this procedure be
every 400 hours. performed every 400 hours.
Ford LRG-425 EFI Operator Handbook Perkins 100 Series Workshop Manual
(Ford part number FPP 194-302). (Perkins part number TPD 1377E).
Ford LRG-425 EFI Operator Handbook Perkins 100 Series Workshop Manual
machine. machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 35

Checklist C Procedures REV C
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
Deutz FL 1011F Operation Manual
result in component damage.
(Deutz part number 0297 9683).
1 Locate the grease fittings on each pivot pin of
Deutz FL 1011F Operation Manual the platform overload assembly.
2 Thoroughly pump grease into each grease fitting
using a mulit-purpose grease.

plate latch.
end of the machine.
machine.
3 - 36 Z-45/25 • Z-45/25J Part No. 77809

REV C CHECKLIST C PROCEDURES
C-3 4 Using a suitable lifting device, place an

appropriate test weight equal to that of the
Test the Platform Overload maximum platform capacity in one of the
System (if equipped) locations shown.
Genie specifications require that

500 hours or six months.
Testing the platform overload system regularly is
essential to safe machine operation. Continued use
of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity Result: The platform overload indicator light
could be compromised resulting in the machine should be off at both the ground and platform
tipping over. controls.
Perform this procedure with the 5 Carefully move the test weight to each
machine on a firm, level surface. remaining location.
1 Turn the key switch to platform control. Start the Result: The platform overload indicator light
engine from the platform controls. should be off at both the ground and platform
controls.
2 Level the platform.
6 Add an additional 66 lbs / 30 kg of weight to
3 Determine the maximum platform capacity.
overload the platform.
Refer to the machine serial plate.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at both the ground and platform
controls.
Result: If the alarm does not sound and the
platform overload indicator light does not come
on with the test weights in any of the platform
locations, the platform overload system needs
to be calibrated. See D-8, Calibrate the Platform
Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 37

CHECKLIST C PROCEDURES REV C
7 Carefully move the test weights to each 11 Lift the test weights off the platform floor using a
remaining location in the platform. suitable lifting device.
Result: The alarm should be sounding. Result: The platform overload indicator light and
The platform overload indicator light should be alarm should turn off at both the ground and
flashing at both the ground and platform platform controls.
controls.
Result: If the alarm does not sound and the second delay before the overload
platform overload indicator light does not come indicator light and alarm turn off.
on with the test weights in any of the platform
12 Test all machine functions from the ground
locations, the platform overload system needs
controls.
to be calibrated. See D-8, Calibrate the Platform
Overload System. Result: All ground control functions should
operate normally.
second delay before the overload 13 Turn the key switch to platform control.
alarm sounds. 14 Test all machine functions from the platform
controls.
8 Test all machine functions from the platform
controls. Result: All platform control functions should
operate.
Result: All platform control functions should not
operate. If the platform overload system is
not operating properly, see D-8,
9 Turn the key switch to ground control. Calibrate the Platform Overload
System.
10 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.
3 - 38 Z-45/25 • Z-45/25J Part No. 77809

REV C CHECKLIST C PROCEDURES
C-4 C-5
Perkins Models Ford Models
Perkins engine specifications Ford engine specifications require

require that this procedure be that this procedure be performed
performed every 600 hours. every 800 hours.
Perkins 100 Series Workshop Manual Ford LRG-425 EFI Operator Handbook
(Perkins part number TPD 1377E). (Ford part number FPP 194-302).
Perkins 100 Series Workshop Manual Ford LRG-425 EFI Operator Handbook
machine. machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 39

Checklist D Procedures REV D
D-1 D-2
Check the Boom Check the Turntable Rotation
Wear Pads Bearing Bolts
Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing
is essential to safe machine operation. Wear pads bolts is essential to safe machine operation.
are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe
friction, replaceable wear pad between moving operating condition and component damage.
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in component 1 Raise the secondary boom and place safety
damage and unsafe operating conditions. chocks on the lift cylinders rods. Carefully lower
the boom onto the lift cylinder safety chocks.
1 Start the engine from the ground controls.
Crushing hazard. Keep hands
2 Raise the end of the primary boom to a away from cylinders and all moving
comfortable working height (chest high), then parts when lowering the boom.
extend the boom 1 foot / 30 cm.
The lift cylinder safety chock is
3 Measure each wear pad. Replace the wear pad if available through Genie Service
it is less than 9/16 inch / 14.3 mm. If the wear Parts.
pad is not less than 9/16 inch / 14.3 mm, shim
2 Turn the engine off.
as necessary to obtain zero clearance and zero
drag. 3 Remove the safety pin from the engine pivot
plate latch.
4 Extend and retract the primary boom through the
entire range of motion to check for tight spots The engine pivot plate latch is
that may cause binding or scraping of the boom. located under the engine turntable
Always maintain squareness
end of the machine.
between the outer and inner
boom tubes. 4 Open the engine pivot plate latch and swing the
Wear pad specifications machine.
All wear pads 9/16 inch

14.3 mm
3 - 40 Z-45/25 • Z-45/25J Part No. 77809

REV D CHECKLIST D PROCEDURES
5 Be sure that each turntable mounting bolt is 10 Remove the lower chassis cover mounting
torqued in sequence to 210 ft-lbs / 285 Nm. fasteners from inside of the drive chassis (if
equipped).
11 Remove the lower chassis cover to access the
lower turntable bearing bolts under the drive
chassis.
12 Check to ensure that each lower bearing
mounting bolt under the drive chassis is torqued
in sequence to 210 ft-lbs / 285 Nm.
Bolt torque sequence

10 1 15
13 19
6 7
18 12
3 4 Bolt torque sequence
11 17
8 5 10 1
15
20 14 13 7
16 2 9
6 4
11 12
3 5
7 Raise the secondary boom and remove the
safety chocks. 8 14
16 2 9
8 Lower the boom to the stowed position.
9 Remove drive chassis covers from both the (after serial number 23331)
steer end and the non-steer end of the machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 41

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

Check the Free-wheel Result: Each non-steer wheel should rotate with
minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Proper use of the free-wheel configuration is
essential to safe machine operation. The Collision hazard. Failure to
free-wheel configuration is used primarily for towing. re-engage the drive hubs may
A machine configured to free-wheel without operator cause death or serious injury and
knowledge may cause death or serious injury and property damage.
property damage.
Steer wheels: 4WD models
Collision hazard. Select a work site
7 Chock the non-steer wheels to prevent the
that is firm and level.
machine from rolling.
Component damage hazard. If the
8 Center a lifting jack of ample capacity
machine must be towed, do not
(20,000 lbs / 10,000 kg) under the drive chassis
exceed 2 mph / 3.2 km/h.
between the steer tires.
Non-steer wheels: All models
9 Lift the wheels off the ground and then place
1 Chock the steer wheels to prevent the machine jack stands under the drive chassis for support.
from rolling.
10 Disengage the drive hubs by turning over the
2 Center a lifting jack of ample capacity drive hub disconnect caps on each
(20,000 lbs / 10,000 kg) under the drive chassis steer wheel hub.
between the non-steer tires. disengaged position
3 Lift the wheels off the ground and then place

jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
engaged position
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
3 - 42 Z-45/25 • Z-45/25J Part No. 77809

11 Manually rotate each steer wheel. D-4

Result: Each steer wheel should rotate with Replace the Drive Hub Oil
minimum effort.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine and Replacing the drive hub oil is essential for good
remove the jack stands. machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
Collision hazard. Failure to
cause the machine to perform poorly and continued
re-engage the drive hubs may
use may cause component damage.
cause death or serious injury and
property damage. 1 Select the drive hub to be serviced. Then drive
All Models: the machine until one of the two plugs is at the
lowest point.
13 Be sure the free-wheel valve on the drive pump
2 Remove both plugs and drain the oil.
is closed (clockwise).
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
d
a
c
a b
a drive pump
b free-wheel valve
c lift pump
d screwdriver
a drive hub plugs
The free-wheel valve is located on
4 Fill the hub with oil from the top hole until the oil
the side of the drive pump.
level is even with the bottom of the side hole.
The free-wheel valve should Apply pipe thread sealant to the plugs, and then
always remain closed. install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 43

D-5 5 Adjust the high idle adjustment screw to obtain

an air-to-fuel mixture ratio of 13:1 to 13.2:1,
Check and Adjust the Air/LPG using an exhaust gas analyzer.
Mixture - Ford Models Preliminary setting is 1/4 inch /
6.4 mm of threads showing.
Measure from the top of the lock
nut to the top of the adjustment
Maintaining the proper air-to-fuel mixture during screw.
LPG operation is essential to good engine
If an exhaust gas analyzer is not
performance.
available, adjust to obtain peak or
Explosion and fire hazard. Engine optimum rpm.
fuels are combustible. Perform this 6 Hold the adjustment screw and tighten the
procedure in an open, well- lock nut.
sparks, flames and lighted 7 Return the function enable toggle switch to the
tobacco. Always have an approved center position.
8 Locate the low idle mixture adjustment screw on
The engine should be warmed to the LPG regulator.
normal operating temperature
9 Adjust the low idle mixture adjustment screw to
before performing this procedure.
obtain an air-to-fuel mixture ratio of 13:1 to
1 Move the fuel select toggle switch to LPG fuel 13.2:1.
and start the engine from the ground controls.
Preliminary setting: turn low idle
2 Locate the high idle mixture adjustment adjustment screw clockwise all the
screw on the LPG venturi that attaches to the way in. Turn low idle adjustment
air cleaner air cleaner hose. screw counterclockwise 2 3/4
turns.
3 Loosen the lock nut on the high idle mixture
adjustment screw.
4 Load the system by activating the primary boom
retract function and moving the function enable
toggle switch to the high idle (rabbit symbol)
position.
3 - 44 Z-45/25 • Z-45/25J Part No. 77809

D-6 D-7
Perform Engine Maintenance - Inspect for Turntable Bearing
Deutz Models Wear
Deutz engine specifications require Periodic inspection of turntable bearing wear is

that this procedure be performed essential to safe machine operation, good machine
every 1000 hours. performance and service life. Continued use of a
Proper engine maintenance, following the engine worn turntable bearing could create an unsafe
manufacturer's maintenance schedule, is essential operating condition, resulting in death or serious
to good engine performance and service life. Failure injury and component damage.
to perform the maintenance procedures can lead to Perform this procedure with the
poor engine performance and component damage. machine on a firm, level surface
and the boom in the stowed
position.
Deutz FL 1011F Operation Manual 1 Grease the turntable bearing. See A-13, Grease
(Deutz part number 0297 9683). the Turntable Bearing and Rotate Gear.
2 Torque the turntable bearing bolts to
Deutz FL 1011F Operation Manual specification. See D-2, Check the Turntable
Rotation Bearing Bolts.
3 Start the machine from the ground controls and
To access the engine: raise the primary and secondary booms to full
height. Do not extend the primary boom.
plate latch.
end of the machine.
machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 45

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.
3 - 46 Z-45/25 • Z-45/25J Part No. 77809

D-8 Determine the limit switch trigger point:

Calibrate the Platform Overload 4 Gently move the platform up and down by hand,
System (if equipped) so it bounces approximately 2.5 to 5 cm. Allow
the platform to settle.
Result: The overload indicator light and the
alarm is on. Slowly tighten the load spring
Genie specifications require that adjustment nut by turning it clockwise just until
this procedure be performed every the overload indicator light and alarm turns off.
1000 hours of operation or yearly. The platform will need to be moved
Yearly calibration of the platform overload system up and down and allowed to settle
is essential to safe machine operation. Continued in between adjustments.
use of an improperly calibrated platform overload There may be an approximate 2
system could result in the system failing to sense second delay before the overload
an overloaded platform. The stability of the indicator light turns on and the
machine is compromised and it could tip over. alarm sounds.
Perform this procedure with the Result: The overload indicator light and
machine on a firm, level surface. alarm is off. Slowly loosen the load spring
adjustment nut by turning it counterclockwise
1 Level the platform.
just until the overload indicator light and alarm
2 Determine the maximum platform capacity. turn on.
Refer to the machine serial plate.
3 Using a suitable lifting device, place an second delay before the overload
appropriate test weight equal to that of the indicator light turns on and the
maximum platform capacity at the center of the alarm sounds.
platform floor.
The platform will need to be moved
up and down and allowed to settle
in between adjustments.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 47

Confirm the setting: D-9

5 Turn the key switch to platform control. Start the Replace the Hydraulic Filters
engine from the platform controls.
6 Lift the test weight off the platform floor using a
suitable lifting device.
Genie requires that this procedure
7 Place the test weight back onto the center of the be performed quarterly or every
platform floor using a suitable lifting device. 250 hours, whichever comes first.
Result: The alarm should be off. The platform Perform this procedure more often
overload indicator light should be off at both the if dusty conditions exist.
ground and platform controls. Replacement of the hydraulic filters is essential for
There may be an approximate 2 good machine performance and service life. A dirty
second delay before the overload or clogged filter may cause the machine to perform
indicator light and alarm turn off. poorly and continued use may cause component
damage. Extremely dirty conditions may require
8 Add an additional 10 lb / 4.5 kg test weight to that the filters be replaced more often.
the original test weight to overload the platform.
Bodily injury hazard. Beware of hot
Result: The alarm should be sounding. oil. Contact with hot oil may cause
The platform overload indicator light should be severe burns.
flashing at both the ground and platform
controls. Perform this procedure with the
engine off.
second delay before the overload Hydraulic return filter
1 Open the ground controls side turntable cover
alarm sounds.
and locate the hydraulic return filter housing on
9 Test all machine functions from the platform top of the hydraulic tank.
controls.
2 Remove the cap from the filter housing.
Result: All platform control functions should not
3 Lift the handle on the filter element and rotate
operate.
the element counterclockwise to release the
10 Turn the key switch to ground control. element from the housing.
11 Test all machine functions from the ground 4 Remove the filter element from the filter
controls. housing.
Result: All ground control functions should not
operate.
If the platform overload system is
not operating properly, repeat
steps 1 through 4.
3 - 48 Z-45/25 • Z-45/25J Part No. 77809

5 Install the new filter element into the filter 15 Install the new filter elements into the housings
housing. and tighten them securely.
6 Push the filter element down to be sure the o- The medium and high pressure
ring on the element is fully seated into the filters use the same elements.
housing.
16 Clean up any oil that may have spilled during the
7 Rotate the filter element clockwise to lock it in installation procedure.
place.
8 Install the filter housing cap. and number of hours from the hour meter on the
oil filter housings.
and number of hours from the hour meter on the 18 Start the engine from the ground controls.
oil filter housing.
19 Inspect the filter housings and related
Medium and high pressure filters components to be sure that there are no leaks.
The medium pressure filter is for
the charge pump and the high
pressure filter is for all machine
functions except the drive circuit
and oscillating axle circuit.
the medium and high pressure filters.
The medium pressure filter is
mounted near the pump. The high
pressure filter, with filter condition
indicator, is mounted to the
bulkhead.
11 Place a suitable container under each filter.
12 Remove the filter housings by using a wrench on
the nut provided on the bottom of the housings.
13 Remove the filter elements from the housings.
14 Inspect the housing seals and replace them if
necessary.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 49

Checklist E Procedures REV B
E-1 3 Models with hydraulic tank shut-off valves:

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

essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require oil changes to be open closed
performed more often. Component damage hazard. The
engine must not be started with the
Before replacing the hydraulic oil,
hydraulic tank shut-off valves in
the oil may be tested by an oil
the closed position or component
distributor for specific levels of
damage will occur. If the tank
contamination to verify that
valves are closed, remove the key
changing the oil is necessary. If
from the key switch and tag the
the hydraulic oil is not replaced
machine to inform personnel of the
at the two year inspection, test
condition.
the oil quarterly. Replace the oil
when it fails the test. 3 Place a suitable container underneath the
hydraulic tank.
boom in the stowed position. 4 Remove the drain plug from the hydraulic tank.
1 Ford models: Turn the valve on the LPG tank 5 Completely drain the tank into a suitable
clockwise to the off position (if equipped). Then container. See capacity specifications.
slowly disconnect the hose from the LPG tank.
6 Tag, disconnect and plug the two suction hoses
2 Ford models: Open the clamps from the LPG and supply hose for the auxiliary pump from the
tank straps and remove the LPG tank from the hydraulic tank. Cap the fittings on the tank.
machine (if equipped).
The hoses can be accessed
through the access hole under the
turntable.
7 Disconnect and plug the return filter hydraulic
hose at the return filter. Cap the fitting on the
filter housing.
3 - 50 Z-45/25 • Z-45/25J Part No. 77809

REV B CHECKLIST E PROCEDURES
8 Remove the ground controls side turntable 21 Models with hydraulic tank shut-off valves:
cover. Open the two hydraulic tank valves at the
hydraulic tank.
9 Support the hydraulic tank with an appropriate
lifting device. 22 Fill the tank with the proper hydraulic oil for your
machine until the level is within the top
10 Remove the hydraulic tank mounting fasteners.
2 inches / 5 cm of the sight gauge. Do not
11 Remove the hydraulic tank from the machine. overfill. Refer to Section 2, Specifications.
Crushing hazard. The hydraulic 23 Clean up any oil that may have spilled.
tank could become unbalanced
24 Prime the pump. Refer to Repair Procedure 7-2,
and fall if not properly supported
How to Prime the Pump.
when removed from the machine.
Always use pipe thread sealant
12 Remove the hydraulic return filter housing
when installing the suction hose
mounting fasteners. Remove the hydraulic
fittings and the drain plug.
return filter housing from the hydraulic tank.
13 Remove the suction strainers from the tank and
clean them using a mild solvent.
14 Rinse out the inside of the tank using a mild
solvent.
15 Install the suction strainers using a thread
sealant on the threads.
16 Install the drain plug using a thread sealant on
the threads.
17 Install the hydraulic return filter housing onto the
hydraulic tank.
18 Install the hydraulic tank onto the machine.
19 Install the two suction hoses to the suction
strainers.
20 Install the supply hose for the auxiliary power
unit and the return filter hose.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 51

CHECKLIST E PROCEDURES REV B
E-2 5 Remove and replace all of the fuel line hoses

and clamps according to the following
Change the Fuel Hoses - illustration.
Ford Models
“From tank”
Maintaining the fuel hoses in good condition is Pre-Filter Fuel Pump

essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel hose may cause an unsafe operating Fuel pressure
“To engine”
condition. regulator/filter

“Return to tank”
fuels are combustible. Replace the
fuel hoses in an open, well-
sparks, flames and lighted Explosion and fire hazard.
tobacco. Always have an approved Electronic Fuel Injection (EFI)
fire extinguisher within easy reach. systems operate at a very high
Component damage hazard. Be pressure. Fuel may be expelled
sure the fuel hoses are routed the under pressure if the hoses are
same way the original hoses were. removed too quickly. Loosen the
fuel lines very slowly to allow the
Perform this procedure with the fuel pressure to dissipate
engine off and the key switch in gradually. Wrap a cloth around fuel
the off position. hoses to absorb leaking fuel before
disconnecting them.
6 Clean up any fuel that may have spilled during
2 Open the tank side turntable cover and locate
this procedure.
the fuel system components mounted to the
plate under the fuel tank. 7 Start the engine from the ground controls, then
inspect the fuel filter and hoses for leaks.
3 Remove the fuel system plate retaining
fasteners. Carefully lower the fuel system plate. Explosion and fire hazard. If a fuel
leak is discovered, keep any
4 At the pre-filter, disconnect and drain the fuel
tank into a suitable container. See capacity
specifications.
immediately.
3 - 52 Z-45/25 • Z-45/25J Part No. 77809

REV B CHECKLIST E PROCEDURES
E-3 E-4
Perform Engine Maintenance - Grease the Steer Axle
Deutz Models Wheel Bearings, 2WD Models
Deutz engine specifications require Maintaining the steer axle wheel bearings is
that this procedure be performed essential for safe machine operation and service
every 3000 hours. life. Operating the machine with loose or worn
Proper engine maintenance, following the engine wheel bearings may cause an unsafe operating
manufacturer's maintenance schedule, is essential condition and continued use may result in
to good engine performance and service life. Failure component damage. Extremely wet or dirty
to perform the maintenance procedures can lead to conditions or regular steam cleaning and pressure
poor engine performance and component damage. washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove them.
Deutz FL 1011F Workshop Manual 2 Block the non-steer wheels, then center a lifting
(Deutz part number: 0297 7195). jack under the steer axle.
3 Raise the machine 6 inches / 15 cm and place
Deutz FL 1011F Workshop Manual blocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire and wheel
assembly.
To access the engine: 5 Check for wheel bearing wear by attempting to
1 Remove the safety pin from the engine pivot move the wheel hub side to side, then up and
plate latch. down.
The engine pivot plate latch is Result: There should be no side to side or up
located under the engine turntable and down movement.
pivot plate at the counterweight Skip to step 10 if there is no movement.
end of the machine.
machine.
Part No. 77809 Z-45/25 • Z-45/25J 3 - 53

CHECKLIST E PROCEDURES REV B
6 Remove the dust cap from the hub. Remove the 14 Pack both bearings with clean, fresh grease.
cotter pin from the castle nut.
15 Place the large inner bearing into the rear of the
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to hub.
seat the bearings.
16 Install a new bearing grease seal into the hub by
8 Loosen the castle nut and re-tighten to pressing it evenly into the hub until it is flush.
8 ft-lbs / 11 Nm.
17 Slide the hub onto the yoke spindle.
9 Check for wheel bearing wear by attempting to
Component damage hazard. Do
move the wheel hub side to side, then up and
not apply excessive force or
down.
damage to the lip of the seal may
Result: If there is side to side or up and down occur.
movement, continue to step 11 and replace the
18 Place the outer bearing into the hub.
wheel bearings with new ones.
19 Install the washer and castle nut.
When replacing a wheel bearing,
both the inner and outer bearings, 20 Tighten the slotted nut to 35 ft-lbs / 47 Nm to
including the pressed-in races, seat the bearings.
must be replaced.
21 Loosen the castle nut and re-tighten to
Result: If there is no side to side or up and 8 ft-lbs / 11 Nm.
down movement, continue with step 11 and
grease the wheel bearings. 22 Install a new cotter pin. Bend the cotter pin
to lock it in.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut. Always use a new cotter pin when
installing a castle nut.
11 Remove the castle nut.
23 Install the dust cap, then the tire and wheel
12 Pull the hub off of the spindle. The washer and assembly. Torque the wheel lug nuts to
outer bearing should fall loose from the hub. specification. Refer to Section 2, Specifications.
13 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the rear
bearing.
3 - 54 Z-45/25 • Z-45/25J Part No. 77809

March 2005 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 Genie Z-45/25 death or serious injury.
and Genie Z-45/25J Operator’s Manual on your
machine. Used to indicate the presence of a
Be sure that all necessary tools and parts are which, if not avoided, could result
available and ready for use. in death or serious injury.
Read each procedure completely and adhere With safety alert symbol—used to
to the instructions. Attempting shortcuts may indicate the presence of a
produce hazardous conditions. potentially hazardous situation
which, if not avoided, may cause
Unless otherwise specified, perform each
minor or moderate injury.
repair procedure with the machine in the
following configuration: Without safety alert symbol—used
· Machine parked on a firm, level surface to indicate the presence of a
· Boom in stowed position which, if not avoided, may result in
· Turntable rotated with the boom between property damage.
the non-steer wheels
Used to indicate operation or
· Turntable secured with the turntable maintenance information.
rotation lock
Indicates that a specific result is expected after
· Key switch in the off position with the
performing a series of steps.
key removed
· Wheels chocked Indicates that an incorrect result has occurred
after performing a series of steps.
· All external AC power supply disconnected
from the machine

Section 4 • Repair Procedures March 2005
Platform Controls REV C
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 (non-contact) and require no with electrically charged circuits
adjustment. The operating parameters of the could result in death or serious
joysticks are stored in memory at the ECM circuit injury. Remove all rings, watches
board at the platform controls. If a joystick error and other jewelry.
occurs or if a joystick is replaced, it will need to be When the ALC-500 circuit board is
calibrated before that particular machine function replaced, the joystick controllers
will operate. See 1-2, 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
For further information or assistance, consult the
Genie Industries Service Department. 1 Push in the red Emergency Stop button to the off
position at both the ground and platform controls.
a
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

REV C 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 ramping 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 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Select a joystick to calibrate.
4 Move the joystick full stroke in either direction
and hold for 5 seconds.
5 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.
6 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.

PLATFORM CONTROLS REV C
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
performance. The max-out settings on the joystick specifications and determine whether the
can be changed to compensate for hydraulic pump function time needs to increase or decrease.
wear to maintain peak performance from the Refer to Section 2, Specifications
machine. for function speeds.
Perform this procedure with the 11 While the joystick is activated, adjust the max-
boom in the stowed position. out setting to achieve the proper function cycle
1 Pull out the red Emergency Stop button to the time. Momentarily move the drive enable toggle
on position at both the ground and platform switch in the right direction to increase the
controls. function speed or momentarily move the drive
enable toggle switch in the left direction to
2 Turn the key switch to platform control. Do not decrease the function speed.
start the engine.
Each time the drive enable toggle
3 Push in the platform controls red Emergency switch is momentarily moved, the
Stop button to the off position. function speed will change in 2%
increments.
4 Do not press down the foot switch.
12 Repeat steps 9 through 11 for each joystick
5 Move and hold the drive enable toggle switch in
controlled machine function.
the right position and pull out the red
Emergency Stop button to the on position. 13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
6 When the alarm sounds, release the drive
enable toggle switch. Result: The alarm should sound indicating that
the settings have been saved in memory.
7 Momentarily activate the drive enable toggle
switch in the right direction 4 times. Do not operate any machine
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.

REV C 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.
3 Push in the platform controls red Emergency Result: The alarm should sound indicating that
Stop button to the off position. the settings have been saved in memory.
4 Do not press down the foot switch. Do not operate any machine
waiting time.
Emergency Stop button to the on position.
Ramp rate (factory settings)
enable toggle switch. Primary boom up/down
accelerate 4 seconds
7 Momentarily activate the drive enable toggle decelerate 0.5 second
switch in the right direction 6 times.
Secondary boom up/down
Result: There should be a pause and the alarm accelerate 2 seconds
should sound 6 times indicating that the decelerate 0.5 second
machine is in ramp rate calibration mode.
Turntable rotate
8 Start the engine from the platform controls and accelerate 2 seconds
press down the foot switch. decelerate 0.5 second
9 Start a timer and simultaneously move the Drive

joystick in either direction full stroke. Note how accelerate 3.3 seconds
long it takes the function to reach maximum accelerate (narrow models) 3.8 seconds
speed. This is the ramp rate. 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

PLATFORM CONTROLS REV C
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.
3 Push in the platform controls red Emergency Result: The alarm should sound indicating that
Stop button to the off position. the settings have been saved in memory.
4 Do not press down the foot switch. Do not operate any machine
waiting time.
Emergency Stop button to the on position.
enable toggle switch.
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.

REV A
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 Z-45/25J: Tag, disconnect and plug the hydraulic
entire range of boom motion. It operates in a hoses from the slave cylinder at the union
closed-circuit hydraulic loop with the master located near the jib/rotate manifold and connect
cylinder. The slave cylinder is equipped with them together using a connector. Connect the
counterbalance valves to prevent movement in hoses from the cylinder together using a
the event of a hydraulic line failure. connector.
How to Remove the Platform Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Leveling Slave Cylinder burn skin. Loosen hydraulic
Before cylinder removal is connections very slowly to allow
considered, bleed the slave the oil pressure to dissipate
cylinder to be sure there is no gradually. Do not allow oil to
air in the closed loop. squirt or spray.
When removing a hose assembly Z-45/25: Tag, disconnect and plug the hydraulic
or fitting, the O-ring on the fitting hoses from the slave cylinder and connect the
and/or hose end must be replaced hoses together using a connector. Cap the
and then torqued to specification fittings on the cylinder. Then pull the slave
during installation. cylinder hoses out through the primary
Refer to Section 2, Hydraulic Hose extension boom.
and Fitting Torque Specifications. Bodily injury hazard. Spraying
1 Z-45/25J: Extend the primary boom until the hydraulic oil can penetrate and
slave cylinder barrel-end pivot pin is accessible. burn skin. Loosen hydraulic
connections very slowly to allow
2 Raise the primary boom slightly and place the oil pressure to dissipate
blocks under the platform for support. gradually. Do not allow oil to
squirt or spray.
5 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Do not remove the
pin.

PLATFORM COMPONENTS REV A
6 Z-45/25J: Remove the external snap rings from 2-2

the barrel-end pivot pin.
Platform Rotator
Z-45/25: Remove the pin retaining fastener from
the slave cylinder barrel-end pivot pin. Do not
remove the pin.
How to Bleed the Platform
Rotator
7 Support the slave cylinder with a lifting device.
This procedure will require two
8 Z-45/25J: Support the jib boom bell crank with a
people. Do not start the engine.
Use auxiliary power for this
9 Use a soft metal drift to drive the rod-end pivot procedure.
pin out.
1 Move the function enable toggle switch to either
Crushing hazard. The jib boom bell side and activate the platform rotate toggle
crank could fall when the slave switch to the right then the left through two
cylinder rod-end pivot pin is platform rotation cycles, then hold the switch to
removed if not properly supported. the right position until the platform is fully
rotated to the right.
slave cylinder rod may become 2 Connect a clear hose to the top bleed valve.
damaged if it is allowed to fall if Place the other end of the hose in a container to
not properly supported by the lifting collect any drainage. Secure the container to
device. the boom.
10 Use a soft metal drift and drive the barrel-end 3 Open the top bleed valve on the rotator, but do
pin out. not remove it.
a
11 Carefully pull the cylinder out of the primary
boom.
How to Bleed the Slave Cylinder

Do not start the engine. Use
auxiliary power for this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
d c b
a top bleed valve

b bottom bleed valve
c container
d clear hose

REV A PLATFORM COMPONENTS

side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of the
platform during rotation.
5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of the
platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.

Jib Boom Components, Z-45/25J REV A
3-1 6 Support the barrel end of the cylinder with a

Jib Boom
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
How to Remove the Jib Boom
8 Use a soft metal drift to remove the pin and let
Perform this procedure with the the cylinder hang down.
boom in the stowed position.
9 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 on the fitting the pin, then remove the jib boom from the
and/or hose end must be replaced primary boom bellcrank.
and then torqued to specification
during installation. Crushing hazard. The jib boom
Refer to Section 2, Hydraulic Hose could become unbalanced and fall
and Fitting Torque Specifications. when removed from the machine if
not properly attached to the
1 Remove the platform. overhead crane.
2 Remove the platform mounting weldment 10 Remove the pin retaining fastener from the jib
and the platform rotator. boom lift cylinder rod-end pivot pin. Do not
3 Remove the hose and cable cover from the side remove the pin.
of the jib boom. 11 Slide both of the jib boom leveling arms off of
4 Attach a lifting strap from an overhead crane to the jib boom cylinder rod-end pivot pin.
the jib boom. 12 Attach a lifting strap from an overhead crane to
5 Tag, disconnect and plug the jib boom lift the lug on the rod end of the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the cylinder.
cylinder. 13 Use a soft metal drift to remove the jib boom lift
Bodily injury hazard. Spraying cylinder rod-end pivot pin, then remove the jib
hydraulic oil can penetrate and boom lift cylinder from the primary boom
burn skin. Loosen hydraulic bellcrank.
connections very slowly to allow Crushing hazard. The jib boom lift
the oil pressure to dissipate cylinder could become unbalanced
gradually. Do not allow oil to and fall when removed from the
squirt or spray. machine if not properly attached to
the overhead crane.

REV B JIB BOOM COMPONENTS, Z-45/25J
3-2 4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
Jib Boom Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
How to Remove the Jib Boom opposite leveling arm. Do not remove the pin.
Lift Cylinder 5 Support the jib boom lift cylinder with a lifting
device.
boom in the stowed position. 6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
When removing a hose assembly
soft metal drift to remove the barrel-end pin and
or fitting, the O-ring on the fitting
let the cylinder hang down.
and/or hose end must be replaced
and then torqued to specification 7 Attach a lifting strap from an overhead crane to
during installation. the lug on the rod end of the jib boom lift
Refer to Section 2, Hydraulic Hose cylinder.
and Fitting Torque Specifications.
8 Use a soft metal drift to remove the jib boom lift
1 Raise the jib boom slightly and place blocks cylinder rod-end pin. Remove the cylinder from
under the platform mounting weldment. Then the machine.
lower the jib boom until the platform is resting
Crushing hazard. The jib boom lift
on the blocks just enough to support the
cylinder could become unbalanced
platform.
and fall when removed from the
Do not rest the entire weight of the machine if not properly attached to
boom on the blocks. the overhead crane.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
burn skin. Loosen hydraulic
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 11

Primary Boom Components REV A
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 on the fitting manifold.
and then torqued to specification Bodily injury hazard. Spraying
during installation. hydraulic oil can penetrate and
Refer to Section 2, Hydraulic Hose burn skin. Loosen hydraulic
and Fitting Torque Specifications. connections very slowly to allow
1 Locate the cables from the primary boom cable gradually. Do not allow oil to
track to the platform control box. Number each squirt or spray.
cable and its entry location at the platform
control box. 7 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master cylinder. Cap
2 Disconnect the cables from the platform control the fittings on the cylinder.
box.
3 Pull all of the electrical cables out of the plastic hydraulic oil can penetrate and
cable track. Do not pull out the hydraulic hoses. burn skin. Loosen hydraulic
4 Raise the primary boom to a horizontal position. connections very slowly to allow
squirt or spray.

REV A PRIMARY BOOM COMPONENTS
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.
could become unbalanced and fall
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 and/or hose end must be replaced
cable tracks and secure the upper and lower and then torqued to specification
tracks together. during installation.
Crushing hazard. If the upper and Refer to Section 2, Hydraulic Hose
lower cable tracks are not properly and Fitting Torque Specifications.
secured together, the cable track 1 Locate the cables from the primary boom cable
could become unbalanced and fall track to the platform control box. Number each
when removed from the machine. cable and its entry location at the platform
11 Remove all hose and cable clamps from the control box.
underside of the primary boom. 2 Disconnect the cables from the platform control
12 Attach a strap from an overhead crane to the box.
cable track. 3 Pull all of the electrical cables out of the plastic
13 Remove the mounting fasteners from the upper cable track. Do not pull out the hydraulic hoses.
cable track at the platform end of the extension
boom.
14 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.

PRIMARY BOOM COMPONENTS REV A
4 Tag, disconnect and plug the hydraulic hoses 7 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.
8 Tag, disconnect and plug the hydraulic hoses
5 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.
9 Raise the boom to a horizontal position.
squirt or spray. 10 Remove the hose and cable cover from the side
of the jib boom.
from the jib boom/platform rotate manifold. Cap 11 Remove the hose clamp on the primary boom
the fittings on the manifold. bellcrank.
Bodily injury hazard. Spraying 12 Place blocks between the upper and lower cable
hydraulic oil can penetrate and tracks and secure the upper and lower tracks
burn skin. Loosen hydraulic together.
the oil pressure to dissipate Crushing hazard. If the upper and
gradually. Do not allow oil to lower cable tracks are not properly
squirt or spray. secured together, the cable track
when removed from the machine.

13 Attach a lifting strap from an overhead 5 ton / 24 Remove the cable track mounting fasteners that
5,000 kg capacity crane to the platform end of attach the lower cable track to the primary
the primary boom for support. Do not lift it. boom.
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 lifting device. could become unbalanced and fall
if it is 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 fastener.
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
lower clip.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to the
side.
3 Repeat steps 1 and 2 for each link.

4-2 4 Remove the cable track. See 4-1, How to

Remove the Cable Track.
Primary Boom
5 Raise the primary boom to a horizontal position.
How to Remove the Primary 6 Remove the hose and cable cover from the
Boom upper pivot.
7 Remove the pin retaining fastener from the
Bodily injury hazard. This
master cylinder barrel-end pivot pin. Use a soft
procedure requires specific repair
metal drift to remove the pin. Then lower the
skills, lifting equipment and a
cylinder and let it hang down.
suitable workshop. Attempting this
procedure without these skills and Component damage hazard.
tools could result in death or When lowering the master cylinder
serious injury and significant down, be sure not to damage the
component damage. Dealer master cylinder hoses or fittings.
service is strongly recommended.
8 Locate the primary boom drive speed limit
Perform this procedure with the switch inside of the upper pivot.
boom in the stowed position.
9 Remove the primary boom drive speed limit
When removing a hose assembly switch mounting fasteners. Do not disconnect
or fitting, the O-ring on the fitting the wiring.
and then torqued to specification 10 Locate the primary boom extension drive speed
during installation. limit switch inside of the extension boom.
Refer to Section 2, Hydraulic Hose 11 Remove the primary boom extension drive
and Fitting Torque Specifications. speed limit switch mounting fasteners. Do not
1 Remove the platform. disconnect the wiring.
2 Remove the platform rotator and platform 12 Pull the limit switch and the wiring out of the
mounting weldment. extension tube and move it out of the way.
3 Z-45/25: Remove the platform leveling slave 13 Tag, disconnect and plug the primary boom
cylinder. See 2-1, How to Remove the Platform extension cylinder hydraulic hoses. Cap the
Leveling Slave Cylinder. 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
squirt or spray.

14 Remove the hose clamp at the pivot end of the How to Disassemble the Primary
boom.
Boom
15 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
16 Attach a similar lifting device to the primary if the outer or inner boom tube
boom lift cylinder. must be replaced. The extension
17 Place support blocks under the primary boom lift cylinder can be removed without
cylinder. completely disassembling the
boom. See 4-4, How to Remove
18 Remove the pin retaining fastener 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.
19 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
20 Remove the pin retaining fastener from the drift to remove the pin.
primary boom pivot pin.
4 Remove and label the location of the wear pads
21 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.

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
during installation.
Refer to Section 2, Hydraulic Hose
1 Raise the primary boom until the primary boom
is horizontal.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above
the turntable covers.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support. Do not lift the boom.

4 Support the rod end and the barrel end of the 4-4
primary boom lift cylinder with a second
overhead crane or similar lifting device. Primary Boom Extension
5 Tag, disconnect and plug the primary boom lift
Cylinder
cylinder. The primary boom extension cylinder extends and
retracts the primary boom extension tube.The
Bodily injury hazard. Spraying primary boom extension cylinder is equipped with
hydraulic oil can penetrate and counterbalance valves to prevent movement in the
burn skin. Loosen hydraulic event of a hydraulic line failure.
the oil pressure to dissipate How to Remove the Primary
squirt or spray.
Boom Extension Cylinder
Bodily injury hazard. This
primary boom lift cylinder rod-end pivot pin. Use
skills, lifting equipment and a
a soft metal drift to remove the pin.
suitable workshop. Attempting this
The primary boom will fall if not procedure without these skills and
properly supported when the tools could result in death or
primary boom rod-end pivot pin is serious injury and significant
removed. component damage. Dealer
7 Place a support block across both turntable
covers under the primary boom lift cylinder. When removing a hose assembly
8 Lower the lift cylinder onto the block. Protect the
cylinder rod from damage.
Crushing hazard. The primary during installation.
boom lift cylinder could fall if not Refer to Section 2, Hydraulic Hose
properly supported. and Fitting Torque Specifications.
9 Remove the primary boom lift cylinder barrel-end 1 Raise the primary boom to a horizontal position.
pivot pin retaining fasteners. Do not remove the
2 Extend the primary boom until the primary boom
pin.
extension cylinder rod-end pivot pin is
10 Use a slide hammer to remove the barrel-end accessible in the primary boom extension tube.
pivot pin. Carefully remove the primary boom lift
3 Remove the hose and cable guard from the
cylinder from the machine.
upper pivot.
Crushing hazard. The lift cylinder
if not properly supported and
secured to the lifting device.

4 Tag, disconnect and plug the primary boom 4-5

extension cylinder hydraulic hoses. Cap the
fittings on the cylinder. Platform Leveling
Master Cylinder
burn skin. Loosen hydraulic The master cylinder acts as a pump for the slave
connections very slowly to allow cylinder. It’s part of the closed circuit hydraulic loop
the oil pressure to dissipate that keeps the platform level through the entire
gradually. Do not allow oil to range of boom motion. The master cylinder is
squirt or spray. located at the base of the primary boom.
5 At the platform end, remove the external snap How to Remove the Platform
rings from the extension cylinder rod-end pivot
pin. Use a soft metal drift to remove the pin.
Leveling Master Cylinder
6 Remove the barrel-end pivot pin retaining
fasteners.
7 Place a rod through the barrel-end pivot pin and and then torqued to specification
twist to remove the pin. during installation.
8 Support and slide the extension cylinder out of
the upper pivot.
1 Raise the secondary boom until both the rod-end
Crushing hazard. The extension
and barrel-end pivot pins on the master cylinder
cylinder could fall when removed
are accessible.
from the extension boom if not
properly supported. 2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the cylinder.
careful not to damage the Bodily injury hazard. Spraying
counterbalance valves on the hydraulic oil can penetrate and
primary boom extension cylinder burn skin. Loosen hydraulic
when removing the cylinder from connections very slowly to allow
the primary boom. the oil pressure to dissipate
Component damage hazard. Hoses
squirt or spray.
and cables can be damaged if the
primary boom extension cylinder is 3 Attach overhead crane or similar lifting device to
dragged across them. the master cylinder.
Note the length of the cylinder after
removal. The cylinder must be at
the same length for installation.


master cylinder barrel-end pivot pin. Do not
remove the pin.
5 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
6 Remove the pin retaining fastener from the rod-
end pivot pin.
7 Place a rod through the rod-end pivot pin and
twist to remove the pin.
8 Remove the master cylinder from the machine.
Crushing hazard. The master
cylinder could become unbalanced
and fall if not properly attached to
the overhead crane.

Secondary Boom Components REV A
a b c
h d
5-1
Secondary Boom
f
How to Disassemble the
Secondary Boom
Secondary Boom components
Bodily injury hazard. The
procedures in this section require a upper secondary boom
specific repair skills, lifting (number 1 arm)
b upper tension link
equipment and a suitable (number 2 arm)
workshop. Attempting this c lower tension link
procedure without these skills and (number 3 arm)
tools could result in death or d mid-pivot
e compression link
serious injury and significant f secondary boom lift cylinder (2)
component damage. Dealer g lower secondary boom
service is required. (number 4 arm)
h turntable pivot
Follow the disassembly steps to the point required i boom rest
to complete the repair. Then re-assemble the j upper pivot
secondary boom by following the disassembly
steps in reverse order.

REV A SECONDARY BOOM COMPONENTS
When removing a hose assembly 8 Use a slide hammer to remove the pin. Remove
or fitting, the O-ring on the fitting the primary boom lift cylinder from the machine.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the overhead crane.
1 Remove the platform.
on both of the secondary boom lift cylinders.
2 Z-45/25J: Remove the jib boom. Cap the fittings on the cylinders.
See 3-1, How to Remove the Jib Boom.
3 Remove the primary boom. See 3-2, How to hydraulic oil can penetrate and
Remove the Primary Boom. burn skin. Loosen hydraulic
4 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder.
gradually. Do not allow oil to squirt
5 Attach a lifting strap from an overhead crane to or spray.
to the lug on the rod end of the primary boom lift
10 Remove the pin retaining fasteners from both
cylinder. Then raise the primary boom lift
sides of the secondary boom lift cylinder rod-
cylinder with the crane, to a vertical position.
end pivot pin and barrel-end pivot pin. Do not
6 Tag, disconnect and plug the hydraulic hoses at remove the pins.
the primary boom lift cylinder. Cap the fittings
11 Attach a strap from an overhead crane to the lug
on the cylinder.
on the rod end of one of the secondary boom lift
Bodily injury hazard. Spraying cylinders for support. Do not apply any lifting
hydraulic oil can penetrate and pressure.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
or spray.
13 Use a soft metal drift to drive the rod-end pivot
pin half way out.
primary boom lift cylinder barrel-end pivot pin.
14 Remove the secondary boom lift cylinder from
the machine.

SECONDARY BOOM COMPONENTS REV A
15 Repeat steps 11 through 14 for the other 21 Using the overhead crane attached to upper
secondary boom lift cylinder. pivot, raise the secondary boom assembly
approximately 30 inches / 76 cm.
Crushing hazard. The secondary
boom lift cylinder could become 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
unbalanced and fall when removed between the number 2 arm and the boom rest.
from the machine if not properly Then lower the secondary boom assembly onto
attached to the overhead crane. the block.
Component damage hazard. When Crushing hazard. The secondary
removing a secondary boom lift boom assembly could fall if not
cylinder from the machine, be properly supported by the
careful not to damage the 4 x 4 x 11 inch / 10 x 10 x
counterbalance valve at the barrel 28 cm block.
end of the cylinder.
23 Pull all of the cables and hoses out through the
16 Attach a lifting strap from an overhead crane to upper pivot.
the upper pivot for support. Do not lift it.
17 Attach a lifting strap from a second overhead Cables and hoses can be
crane to the number 1 arm at the mid-point damaged if they are kinked or
between the upper pivot and mid-pivot. pinched.
18 Remove the pin retaining fasteners from the 24 Remove the hose and cable covers from the top
number 1 arm pivot pins at the mid-pivot and of the number 2 arm.
the upper pivot. Do not remove the pins.
25 Pull all of the hoses and cables out of the upper
19 Use a soft metal drift to drive both pins out. pivot and out through the mid-pivot. Lay the
hoses and cables on the ground.
20 Remove the number 1 arm from the machine.
Crushing hazard. The number 1
Cables and hoses can be
arm could become unbalanced and
damaged if they are kinked or
fall when removed from the
pinched.
machine if not properly attached to
the overhead crane. 26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use a
Crushing hazard. The upper pivot
soft metal drift to remove the pin.
could fall when the number 1 arm
is removed from the machine if not
properly supported by the overhead
crane.

27 Remove the upper pivot from the machine. 36 Remove the pin retaining fasteners from both
compression link pivot pins. Do not remove the
Crushing hazard. The upper pivot
pins.
when removed from the machine if 37 Use a soft metal drift to remove the lower
not properly attached to the compression link pivot pin at the number 3 arm.
overhead crane.
38 Support the compression link with an appropriate
28 Attach the lifting strap from an overhead crane lifting device.
to the number 2 arm at the upper pivot end.
39 Use a soft metal drift to remove the upper
29 Raise the number 2 arm slightly and remove the compression link pivot pin from the number 2
4 x 4 x 11 inch / 10 x 10 x 28 cm block. arm. Remove the compression link from the
machine.
30 Lower the number 2 arm onto the boom rest pad.
31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
arm could fall when the
block between the number 3 arm and the
compression link is disconnected
number 4 arm at the mid-pivot end.
from the number 2 arm if not
32 Attach a lifting strap from the overhead crane to properly supported by the overhead
the mid-pivot for support. Do not lift it. crane.
33 Remove the pin retaining fasteners from the Crushing hazard. The compression
number 2, 3 and 4 arm pivot pins at the link may fall if not properly
mid-pivot. Do not remove the pins. supported when removed from the
secondary boom assembly.
34 Use a soft metal drift to drive each pin out. Then
remove the mid-pivot from the secondary boom 40 Remove the number 2 arm from the machine.
assembly.
Crushing hazard. The mid-pivot arm could become unbalanced and
could become unbalanced and fall fall when removed from the
when removed from the secondary secondary boom assembly if not
boom assembly if not properly properly supported by the overhead
supported by the overhead crane. crane.
35 Attach the lifting strap from an overhead crane 41 Remove the upper and lower hose and cable
to the center point of the number 2 arm for covers from the number 3 arm.
support. Do not lift it.

SECONDARY BOOM COMPONENTS REV A
42 Pull all of the cables and hoses from the number 50 Use a slide hammer to remove the number 3
3 arm and lay them over the turntable arm pivot pin from the turntable pivot through
counterweight. the access hole behind the ground control box.
Component damage hazard. 51 Remove the number 3 arm from the machine.
Cables and hoses can be
damaged if they are kinked or
arm could become unbalanced and
pinched.
fall when removed from the
43 Open the ground controls side turntable cover. machine if not properly supported
by the overhead crane.
44 Remove the fuel tank.
52 Remove the secondary boom drive speed limit
switch mounting fasteners from the number 4
fuels are combustible. Perform this
arm at the mid-pivot end. Do not disconnect the
procedure in an open, well-
wiring.
sparks, flames and lighted 53 Remove the pin retaining fasteners from the
tobacco. Always have an approved number 4 arm at the turntable pivot. Do not
fire extinguisher within easy reach. remove the pin.
45 Remove the retaining fastener from the ground 54 Attach a lifting strap from the overhead crane to
control box and function manifold pivot plate. the center point of the number 4 arm. Do not
lift it.
46 Lower the ground control box and function
manifold pivot plate to access the number 3 arm 55 Use a slide hammer to remove the number 4
pivot pin. arm from the turntable pivot through the ground
controls side bulkhead.
47 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for 56 Remove the number 4 arm from the machine.
support. Do not lift it.
48 Remove the mounting fasteners from the cover arm could become unbalanced and
located in the boom storage area to access the fall when removed from the
number 3 and number 4 arm pivot pin retaining machine if not properly supported
fasteners at the turntable pivot. by the overhead crane.
number 3 arm at the turntable pivot. Do not
remove the pin.

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.
7 Use a soft metal drift to drive the rod-end pivot
When removing a hose assembly pin half way out.
and/or hose end must be replaced 8 Remove the secondary boom lift cylinder from
and then torqued to specification the machine.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when removed
1 Lower the secondary boom to the stowed from the machine if not properly
position. attached to the overhead crane.
2 Raise the primary boom so that it is above the Component damage hazard. When
secondary boom lift cylinder rod-end pivot pin. removing a secondary boom lift
cylinder from the machine, be
careful not to damage the
counterbalance valve at the barrel
end of the cylinder.

Engines REV A
6-1 How to Remove the Flex Plate

RPM Adjustment - Ford and 1 Disconnect the wiring plug at the electronic
Deutz Models displacement controller (EDC), located on
the drive pump.
Refer to Maintenance Procedure B-9, Check and 2 Support the drive pump with an appropriate
Adjust the Engine RPM- Ford and Deutz Models. lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
3 Carefully pull the pump away from the engine
6-2 and secure it from moving.
RPM Adjustment - Perkins 4 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine
Models flywheel.
Refer to Maintenance Procedure A-13, Check and How to Install the Flex Plate
Adjust the Engine RPM- Perkins Models.
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump. Torque
the flex plate mounting bolts to 34 ft-lbs /
6-3 46 Nm.
Flex Plate 2 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
The flex plate acts as a coupler between the engine appropriate gap between coupler and pump end
and the pump. It is bolted to the engine flywheel plate for your engine.
and has a splined center to drive the pump.
Pump coupler gap specification
a b c d e
Deutz models 7/16
inch
11 mm
Ford and Perkins models 1/16inch

1.5 mm
f
3 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
a pump
b pump shaft
to 45 ft-lbs / 61 Nm.
c pump coupler
4 Install the pump and torque the pump mounting
d flex plate with raised spline
e engine flywheel plate fasteners to 34 ft-lbs / 46 Nm.
f 7/16 inch / 11 mm gap - Deutz Models
1/16 inch / 1.5 mm gap - Perkins Models Component damage hazard. Do
1/16 inch / 1.5 mm gap - Ford Models not force the drive pump during
installation or the flex plate teeth
may become damaged.

REV B ENGINES
6-4 5 Continue to hold the run/test toggle switch in the

test position and count the blinks.
Engine Fault Codes -
If any fault codes are present, the
Ford Models ECM will blink a three digit code.
It will blink the first digit of a three
How to Retrieve Engine Fault digit code, pause, blink the second
Codes digit, pause, and then blink the
third digit. For example: the check
When an engine malfunction is detected by the engine light blinks 5 consecutive
Electronic Control Module (ECM), a fault code is times, blinks 3 times and then 1
recorded and the check engine light will turn on at time. That would indicate code
the ground controls. Use the following procedure to 531.
retrieve the engine fault code to determine the
Before the fault codes are
engine malfunction.
displayed, the check engine light
Perform this procedure with the will blink a code 123 three times.
key switch in the off position. After the fault codes, the check
engine light will blink a code 123
1 Open the ground controls side turntable cover. three times again indicating the
2 Locate the run/test toggle switch located on the end of the stored codes.
left side of the ground control box. 6 Refer to the Fault Code Section for definition of
3 Pull out the red Emergency Stop button to the engine fault codes.
on position at the ground controls. Once a fault code has been
4 Hold the run/test toggle switch to the test retrieved and the repair has been
position and turn the key switch to the ground completed, the ECM memory must
controls position. be reset to clear the fault code
from the ECM. See How to Clear
Result: The check engine light should turn on. Engine Fault Codes.
The check engine light should begin to blink.
The check engine light will blink a
"123" code three times before
blinking a fault code if one is
present.

ENGINES REV A
How to Clear Engine Fault

Codes from the ECM
engine off and the key switch in
the off position.
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Connect the negative battery cable to the
battery.

REV A
Hydraulic Pumps
7-1 Models without hydraulic tank shut-off
valves: Remove the drain plug from the
Lift/Steer Pump hydraulic tank and completely drain the tank
into a suitable container. See capacity
How to Remove the specifications.
Lift/Steer Pump 2 Tag, disconnect and plug the lift/steer pump
hydraulic hoses. Cap the fittings on the pump.
or fitting, the O-ring on the fitting Bodily injury hazard. Spraying
and/or hose end must be replaced hydraulic oil can penetrate and
and then torqued to specification burn skin. Loosen hydraulic
during installation. connections very slowly to allow
Refer to Section 2, Hydraulic Hose the oil pressure to dissipate
and Fitting Torque Specifications. gradually. Do not allow oil to
squirt or spray.
1 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the 3 Remove the pump mounting bolts. Carefully
hydraulic tank through the access hole remove the pump.
underneath the turntable. Close the valves.
Models with hydraulic tank shut-off valves:

sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:

open closed
sure to fill the hydraulic tank to
Component damage hazard. The specification and prime the pump
engine must not be started with the after installing the pump.
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.

HYDRAULIC PUMPS REV A
7-2 2 Models with hydraulic tank shut-off valves:

Locate the two hydraulic tank valves at the
Drive Pump hydraulic tank through the access hole
underneath the turntable. Close the valves.
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local open closed
authorized service center.
How to Remove the Drive Pump engine must not be started with the
Component damage hazard. The the closed position or component
work area and surfaces where this damage will occur. If the tank
procedure will be performed must valves are closed, remove the key
be clean and free of debris that from the key switch and tag the
could get into the hydraulic system machine to inform personnel of the
and cause severe component condition.
damage. Dealer service is
recommended. Models without hydraulic tank shut-off
valves: Remove the drain plug from the
When removing a hose assembly hydraulic tank and completely drain the tank
or fitting, the O-ring on the fitting into a suitable container. See capacity
and/or hose end must be replaced specifications.
during installation. 3 Tag and disconnect and plug the hydraulic
Refer to Section 2, Hydraulic Hose hoses from the drive and lift/steer pumps. Cap
and Fitting Torque Specifications. the fittings on the pumps.
1 Disconnect the electrical connection at the Bodily injury hazard. Spraying
electronic displacement controller (EDC) located hydraulic oil can penetrate and
on the drive pump. burn skin. Loosen hydraulic
squirt or spray.

REV A HYDRAULIC PUMPS
4 Support the pump with a lifting device and 4 Ford models: Close the valve on the LPG tank
remove the two drive pump mounting fasteners. then disconnect the hose from the tank. Then
move the fuel select switch to the LPG position.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate. Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
6 Remove the drive pump from the machine.
pump.
Deutz models: Hold the manual fuel shutoff
hydraulic pump may become
valve clockwise to the closed position.
unbalanced and fall if it is not
properly supported.
a
Models with hydraulic tank shut-off valves:

sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:

sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
a manual fuel shutoff valve
5 Have another person crank the engine with the

How to Prime the Pump starter motor for 15 seconds, wait 15 seconds,
1 Connect a 0 to 600 psi / 0 to 41 bar pressure then crank the engine an additional 15 seconds
gauge to the test port on the drive pump. or until the pressure reaches 320 psi / 22 bar.
2 Remove the safety pin (if equipped) from the 6 Ford models: Connect the LPG hose to the
engine pivot plate latch. LPG tank and open the valve on the tank.
The engine pivot plate latch is Perkins models: Connect the engine wiring
located under the engine turntable harness to the fuel solenoid.
7 Start the engine from the ground controls and
end of the machine.
check for hydraulic leaks.
machine.

Manifolds REV B
8-1
Function Manifold Components (before serial number 22050)
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 solenoid valve .............. A ........... Turntable rotate left/right .................. 10-12 ft-lbs / 14-16 Nm
2 Proportional solenoid valve .............. B ........... Secondary boom up/down ............... 10-12 ft-lbs / 14-16 Nm
3 Flow regulator valve .......................... C ........... Secondary boom up/down
(prevents overflowing
the proportional valve) ..................... 10-12 ft-lbs / 14-16 Nm
4 Check valve ....................................... D ........... Differential sensing circuit,
secondary boom up/down ................ 11-13 ft-lbs / 15-18 Nm
5 Relief valve, 1800 psi / 124 bar ........ E ........... Secondary boom down .................... 25-30 ft-lbs / 34-41 Nm
6 Priority flow regulator valve,
1.5 gpm / 5.7 L/min ............................ F ........... Steer left/right circuit ......................... 10-12 ft-lbs / 14-16 Nm
7 Flow regulator valve .......................... G ........... Turntable rotate left/right
8 Relief valve, 3200 psi / 220.6 bar ..... H ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
9 Flow regulator valve .......................... I ............ Primary boom up/down
10 Solenoid valve, 2 position 3 way ...... J ............ Primary boom retract ........................ 25-30 ft-lbs / 34-41 Nm
11 Solenoid valve, 2 position 3 way ...... K ........... Primary boom extend ....................... 25-30 ft-lbs / 34-41 Nm
12 Flow regulator valve,
2 gpm / 7.6 L/min ............................... L ........... Primary boom extend/
retract circuit ..................................... 10-12 ft-lbs / 14-16 Nm
13 Flow regulator valve, adjustable ....... M .......... Platform level circuit ......................... 10-12 ft-lbs / 14-16 Nm
0.1 gpm / 0.38 L/min .......................... N ........... Bleeds off check valves in
differential sensing circuits to tank ... 10-12 ft-lbs / 14-16 Nm
15 Check valve ....................................... O ........... Differential sensing circuit,
platform level down .......................... 11-13 ft-lbs / 15-18 Nm
16 Counterbalance valve ....................... P ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
17 Counterbalance valve ....................... Q ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
This list continues. Please turn the page

REV B MANIFOLDS
1 2 3 4 5 6 7 8 9 10
J 11
E H
K
I
F
D L
C 12
A M
13
N
14
B O
15
37 KK
JJ
36
P
16
II
Q
35
17
HH
GG
34
FF
33 V
X T
U S
32 EE R
Y W
31 DD
CC
30
29
AA
28
BB
Z
27
26 25 24 23 22 21 20 19 18

MANIFOLDS REV B
Function Manifold Components

(before serial number 22050), continued
Index Schematic
18 Solenoid valve, 3 position 4 way ...... R ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm
19 Check valve ....................................... S ........... Differential sensing circuit,
platform level up ............................... 11-13 ft-lbs / 15-18 Nm
20 Check valve ....................................... T ........... Differential sensing circuit,
jib boom up/platform rotate left ......... 11-13 ft-lbs / 15-18 Nm
21 Check valve ....................................... U ........... Differential sensing circuit,
jib boom down/
platform rotate right ........................... 11-13 ft-lbs / 15-18 Nm
22 Check valve ....................................... V ........... Differential sensing circuit,
primary boom extend ........................ 11-13 ft-lbs / 15-18 Nm
23 Check valve ....................................... W .......... Differential sensing circuit,
primary boom retract ........................ 11-13 ft-lbs / 15-18 Nm
24 Check valve ....................................... X ........... Differential sensing circuit,
primary boom up/down ..................... 11-13 ft-lbs / 15-18 Nm
25 Check valve ....................................... Y ........... Differential sensing circuit,
turntable rotate left/right .................... 11-13 ft-lbs / 15-18 Nm
26 Diagnostic nipple .............................. Z ........... Testing
27 Solenoid valve, 3 position 4 way ...... AA ......... Jib boom up/down and
platform rotate left/right ..................... 25-30 ft-lbs / 34-41 Nm
0.6 gpm / 2.3 L/min ............................ BB ......... Jib boom up/down and
platform rotate left/right ..................... 25-30 ft-lbs / 34-41 Nm
29 Solenoid valve, 3 position 4 way ...... CC ........ Primary boom up/down .................... 25-30 ft-lbs / 34-41 Nm
30 Differential sensing valve .................. DD ........ Meters flow to functions .................... 10-12 ft-lbs / 14-16 Nm
31 Solenoid valve, 3 position 4 way ...... EE ......... Turntable rotate left/right .................. 25-30 ft-lbs / 34-41 Nm
32 Solenoid valve, 3 position 4 way ...... FF ......... Steer left/right .................................... 25-30 ft-lbs / 34-41 Nm
33 Orifice, 0.039 in / 0.99 mm ................ GG ........ Secondary boom circuit
34 Solenoid valve, 3 position 4 way ...... HH ........ Secondary boom up/down ............... 25-30 ft-lbs / 34-41 Nm
35 Check valve ....................................... II ............ Secondary boom circuit .................... 10-12 ft-lbs / 14-16 Nm
36 Diagnostic nipple .............................. JJ .......... Testing
37 Proportional solenoid valve .............. KK ......... Primary boom up/down .................... 10-12 ft-lbs / 14-16 Nm

REV B MANIFOLDS
1 2 3 4 5 6 7 8 9 10
J 11
E H
K
I
F
D L
C 12
A M
13
N
14
B O
15
37 KK
JJ
36
P
16
II
Q
35
17
HH
GG
34
FF
33 V
X T
U S
32 EE R
Y W
31 DD
CC
30
29
AA
28
BB
Z
27
26 25 24 23 22 21 20 19 18

MANIFOLDS REV B
8-2 How to Adjust the Secondary

Valve Adjustments - Boom Down Relief Valve
Function Manifold Perform this procedure with the
(before serial number 22050) boom in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
How to Adjust the System gauge to the test port (item JJ) on the function
Relief Valve manifold.
boom in the stowed position. 3 Hold the function enable switch to the high rpm
position and activate and hold the secondary
boom down switch with the secondary boom
gauge to the test port (item JJ) on the function
fully lowered.
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 E).
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 H).
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.

REV B MANIFOLDS

MANIFOLDS REV B
8-3
Function Manifold Components (after serial number 22049)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
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
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.

REV B 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

MANIFOLDS REV B
Function Manifold Components (after serial number 22049)

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

REV B 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

MANIFOLDS REV B
8-4 How to Adjust the Secondary

Valve Adjustments - Boom Down Relief Valve
Function Manifold Perform this procedure with the
(after serial number 22049) 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 AC).
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 P).
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.

REV B MANIFOLDS
8-5
Jib Boom / Platform Rotate Manifold Components
Index Schematic
1 Solenoid valve, 2 position 3 way ..... AU ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
2 Solenoid valve, 2 position 3 way ..... AV ......... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
1 2
AU AV

MANIFOLDS REV B
8-6
Jib Boom / Platform Rotate Manifold Components
Index Schematic
1 Solenoid valve, 2 position 3 way ..... AD ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
AD

REV B 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
1 Shuttle valve, 2 position 3 way ....... LL ........... Turntable rotation brake release ..... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve .................... MM .......... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve .................... NN ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
1 2 3
MM
NN
LL

MANIFOLDS REV B
8-8
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

REV B MANIFOLDS
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.

MANIFOLDS REV B
8-9
Drive Manifold Components, 2WD
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Solenoid valve, 2 position 3 way ...... OO ........ 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 ...... XX ......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm

REV B MANIFOLDS
1 2 3
QQ
OO
10
PP
RR
4
XX
SS
TT
9
WW
UU
VV
8 7

MANIFOLDS REV B
8-10
Valve Adjustments, 2WD
Drive 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).
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.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
(item VV) located on the drive manifold.
remove the cap (item PP).
(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.

REV B MANIFOLDS

MANIFOLDS REV B
8-11
Drive Manifold Components, 4WD
The drive manifold is mounted inside the drive chassis at the non-steer end.
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
3 Bi-directional flow control valve,
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
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
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 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
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
18 Check valve ....................................... AS ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
19 Check valve ....................................... AT ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

REV B
1 2 3 4 5 6 7 8 9
AG
AF
AD AJ 10
AI
AC AE
AH AK
AB
19
AT
18
AS
17 AL
11
AN
AM
12
AR AO
13
14
AP 15
AQ
16

MANIFOLDS REV B
8-12
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port on the drive pump.
remove the cap (item AH).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
(rabbit symbol) position. Note the reading on the
pressure gauge.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
(item AF) located on the drive manifold.
remove the cap (item AH).
(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.

REV A
Turntable Rotation Components
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 Open the engine pivot plate latch and swing the
or fitting, the O-ring on the fitting engine pivot plate out and away from the
and/or hose end must be replaced machine to access the turntable rotation motor.
from the turntable rotation motor manifold. Cap
the fittings on the manifold.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine
off.
2 Secure the turntable from rotating with the the oil pressure to dissipate
turntable rotation lock pin. gradually. Do not allow oil to squirt
or spray.
Crushing hazard. The machine
could tip over when the turntable 6 Attach a lifting strap from and overhead crane or
rotation assembly is removed if the other suitable lifting device to the turntable
turntable rotation lock is not in the rotator assembly.
locked position.
7 Remove the turntable rotation assembly
mounting fasteners.
8 Carefully remove the turntable rotation assembly
from the machine.
Crushing hazard. The turntable
rotation assembly could become
Unlocked position unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
Locked position

Axle Components REV B
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-steering 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.

REV A AXLE COMPONENTS
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.
or spray.

REV A

March 2005 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.
Observe and Obey:
Be sure that all necessary tools and test
Troubleshooting and repair procedures shall be equipment are available and ready for use.
completed by a person trained and qualified on
Read each appropiate fault code thoroughly.
the repair of this machine.
Attempting shortcuts may produce hazardous
Immediately tag and remove from service a conditions.
Be aware of the following hazards and follow
Repair any machine damage or malfunction generally accepted safe workshop practices.
before operating the machine.
Crushing hazard. When testing
Unless otherwise specified, perform each or replacing any hydraulic
repair procedure with the machine in the component, always support
following configuration: the structure and secure it
from movement.
· Machine parked on a firm, level surface
· Boom in stowed position Electrocution hazard. Contact
with electrically charged circuits
· Turntable rotated with the boom between
could result in death or serious
the non-steering wheels
injury. Remove all rings, watches
· Turntable secured with the turntable and other jewelry.
rotation lock
· Key switch in the off position with the hydraulic oil can penetrate and
key removed burn skin. Loosen hydraulic
· Wheels chocked connections very slowly to allow
· All external AC power supply disconnected the oil pressure to dissipate
from the machine gradually. Do not allow oil to
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 • Fault Codes March 2005
FAULT CODES REV B
Fault Codes - 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.

REV B 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

FAULT CODES REV B

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.

REV B 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.

FAULT CODES REV B
Fault codes - Ford Models

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 Repair Procedure 6-4, How to Retrieve

Engine Fault Codes. Use the Fault Code Chart on
the following pages to aid in identifying the fault.

REV B FAULT CODES
Code Problem Cause Solution

Heated Oxygen Sensor wiring
Repair wiring and/or
and/or connections open or
Closed Loop Multiplier connections OR replace
111 High (LPG)
shorted OR sensor is faulty
sensor OR repair vacuum
OR there are vacuum leaks or
and exhaust leaks.
exhaust leaks.
Heated Oxygen Sensor wiring Repair wiring and/or
HO2S Open/Inactive
112 and/or connections open or connections OR replace
(Bank 1)
shorted OR sensor is faulty. sensor.

HO2S Open/Inactive
113 and/or connections open or connections OR replace
(Bank 2)
shorted OR sensor is faulty. sensor.

connections OR replace
shorted OR sensor is faulty
sensor OR repair any
Closed Loop Multiplier OR there are vacuum leaks or
121 vacuum and exhaust leaks
High (Gasoline) exhaust leaks OR fuel
OR test the fuel pressure OR
pressure is low OR the fuel
clean or replace the fuel
injectors need cleaning or
injectors.
replacing.
MAP, IAT or ECT sensors not
in correct position OR wiring
and/or connections for
sensors open or shorted OR
Adjust or replace sensors
Closed Loop Multiplier sensor is faulty OR one or
122 OR clean or repair fuel
Low (Gasoline) more fuel injectors are stuck
injectors.
open OR there is electro-
magnetic interference from a
faulty crankshaft and/or
camshaft po
Closed Loop Multiplier shorted OR sensor is faulty
124 sensor OR replace fuel OR
Low (LPG) OR fuel quality is poor OR
test and repair the fuel
fuel system components may
system components.
be faulty.

FAULT CODES REV B

and/or connections open or Repair heated oxygen sensor
shorted OR sensor is faulty wiring and/or connections
OR there are vacuum or OR replace sensor OR repair
Adaptive Lean Fault -
141 High Limit (Gasoline)
exhaust leaks OR one or vacuum and exhaust leaks
more fuel injectors faulty or OR test the fuel pressure OR
stuck closed OR fuel quality clean or replace the fuel
is poor OR fuel pressure is injectors.
too low.
MAP, IAT or ECT sensors not
in correct position OR wiring
and/or connections for
sensors open or shorted OR
Adjust or replace sensors
Adaptive Rich Fault - sensor is faulty OR one or
142 OR clean or repair fuel
Low Limit (Gasoline) more fuel injectors are stuck
injectors.
closed OR there is electro-
magnetic interference from a
faulty crankshaft and/or
camshaft
and/or connections open or connections OR replace
shorted OR sensor is faulty sensor OR repair any
Adaptive Learn High
143 OR there are vacuum leaks or vacuum and exhaust leaks
(LPG)
exhaust leaks OR fuel quality OR replace fuel OR test and
is poor OR fuel system repair the fuel system
components may be faulty. components.
Engine wire harness may

have an intermittent short to Repair short in engine wire
Adaptive Learn Low
144 (LPG)
5V DC or 12V DC OR fuel harness OR test and repair
system components may be the fuel system components.
faulty.
Battery is faulty OR alternator
Replace battery OR repair
is not charging OR battery
161 System Voltage Low alternator OR repair battery
supply wiring to ECM is open
supply wiring to ECM.
or shorted.
Alternator is overcharging the
Repair or replace the
162 System Voltage High battery when engine RPM is
alternator.
greater than 1500 rpm.

REV B FAULT CODES

IAT sensor wiring and/or
connections are open or
211 IAT High Voltage shorted OR sensor is faulty
sensor OR direct warmer air
OR engine intake 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
sensor OR direct cooler air
OR engine intake air
into air intake.
temperature is too hot.
Air intake temperature is
greater than 200° F with the Check air intake system for
IAT Higher Than engine greater than 1000 rpm damage and proper routing of
213 Expected (1) OR air intake system as air intake components OR
leaks OR IAT sensor is replace the IAT sensor.
faulty.
Air intake temperature is
greater than 210° F with the Check air intake system for
IAT Higher Than engine greater than 1000 rpm damage and proper routing of
214 Expected (2) OR air intake system as air intake components OR
leaks OR IAT sensor is replace the IAT sensor.
faulty.
Replace oil pressure sensor
Faulty oil pressure sensor
OR repair sensor wiring
OR sensor wiring and/or
215 Oil Pressure Low
connections open or shorted
and/or connections OR fill
engine oil level to
OR engine oil level too low.
specification.
Engine cooling system is
Repair engine cooling
malfunctioning OR sensor
CHT/ECT High system problems OR repair
221 Voltage
wires and/or connections
open or shorted wiring to
open or shorted OR sensor is
sensor OR replace sensor.
faulty.
malfunctioning and
system problems OR repair
overheating the engine OR
CHT/ECT Low open or shorted wiring to
222 Voltage
sensor wires and/or
sensor OR replace sensor
OR fill engine coolant level to
OR sensor is faulty OR
specification.
coolant level is low.

FAULT CODES REV B

Coolant temperature at the
cylinder head is 240° F.
malfunctioning and
CHT Higher Than open or shorted wiring to
223 Expected (1)
sensor wires and/or
specification.
Coolant temperature at the
cylinder head is 250° F.
malfunctioning and
CHT Higher Than open or shorted wiring to
224 Expected (2)
sensor wires and/or
specification.
Open or shorted wiring and/or Repair wiring and/or
231 MAP High Pressure connections to MAP sensor connections to sensor OR
OR sensor is faulty. replace MAP sensor.
Open or shorted wiring and/or Repair wiring and/or
232 MAP Low Voltage connections to MAP sensor connections to sensor OR
OR sensor is faulty. replace MAP sensor.
MAP sensor is faulty OR Replace MAP sensor OR
234 BP High Pressure
ECM is faulty. replace the ECM.
MAP sensor is faulty OR Replace MAP sensor OR
235 BP Low Pressure
ECM is faulty. replace the ECM.
Crankshaft position sensor
Be sure system ground
wiring and/or connections
connections are in place and
open or shorted OR there is a
242 Crank Sync Noise secure OR repair wiring
poor system ground
and/or connections to sensor
connection OR sensor is
OR replace sensor.
faulty.
Crankshaft position sensor
Be sure system ground
wiring and/or connections
connections are in place and
Never Crank Synced open or shorted OR there is a
243 secure OR repair wiring
At Start poor system ground
and/or connections to sensor
connection OR sensor is
OR replace sensor.
faulty.

REV B FAULT CODES
Camshaft position sensor Be sure system ground

wiring and/or connections open connections are in place and
244 Camshaft Sensor Loss or shorted OR there is a poor secure OR repair wiring
system ground connection OR and/or connections to sensor
sensor is faulty. OR replace sensor.
Camshaft position sensor Be sure system ground

Camshaft Sensor
245 Noise
or shorted OR there is a poor secure OR repair wiring
system ground connection OR and/or connections to sensor
sensor is faulty. OR replace sensor.
Knock sensor wiring and/or Repair wiring and/or
253 Knock Sensor Open connections open or shorted connections to knock sensor
OR sensor is faulty. OR replace knock sensor.
Check for excessive engine
Knock sensor wiring and/or
vibration OR repair wiring
Excessive Knock connections open or shorted
254 Signal OR there is excessive engine
and/or connections to knock
sensor OR replace knock
vibration OR sensor is faulty.
sensor.
Open wiring and/or Repair wiring and/or
connections to fuel injector #1 connections to fuel injector #1
311 Injector Driver #1 Open
OR fuel injector #1 is faulty OR OR replace fuel injector #1
ECM is faulty. OR replace the ECM.
Wiring and/or connections to Repair wiring and/or
Injector Driver #1 fuel injector #1 shorted OR fuel connections to fuel injector #1
312 Shorted injector #1 is faulty OR ECM is OR replace fuel injector #1
faulty. OR replace the ECM.

FAULT CODES REV B

Open wiring and/or
Fuel Pump Loop Open Repair wiring and/or
connections to fuel pump OR
351 or High Side Short To
fuel pump power shorted to
connections to fuel pump OR
Ground replace fuel pump.
ground OR fuel pump is faulty.
Fuel Pump High Side
352 Shorted To Power
fuel pump shorted to power connections to fuel pump OR
OR fuel pump is faulty. replace fuel pump.
411 Coil Driver #1 Open connections to ignition coil #1 connections to ignition coil #1
OR ignition coil #1 is faulty. OR replace ignition coil #1.

412 Coil Driver #1 Shorted ignition coil #1 shorted OR connections to ignition coil #1
ignition coil #1 is faulty. OR replace ignition coil #1.

REV B FAULT CODES

413 Coil Driver #2 Open connections to ignition coil #2 connections to ignition coil #1
OR ignition coil #2 is faulty. OR replace ignition coil #1.

414 Coil Driver #2 Shorted ignition coil #2 shorted OR connections to ignition coil #2
ignition coil #2 is faulty. OR replace ignition coil #2.
If this fault appears on your
machine, contact Genie
511 FPP1 High Voltage Not used.
Industries Service
Department.
512 FPP1 Low Voltage Not used.
Industries Service
Department.
FPP1 Higher than IVS machine, contact Genie
513 Limit
Not used.
Industries Service
Department.
FPP1 Lower than IVS machine, contact Genie
514 Limit
Not used.
Industries Service
Department.
521 FPP2 High Voltage Not used.
Industries Service
Department.
522 FPP2 Low Voltage Not used.
Industries Service
Department.

FAULT CODES REV B
The #1 throttle position sensor Be sure system ground

TPS1 (Signal Voltage) or shorted OR there is a poor secure OR repair wiring
531 High system ground connection OR and/or connections to sensor
throttle position sensor #1 is OR replace throttle position
faulty. sensor #1.

532 Low system ground connection OR and/or connections to sensor
faulty. sensor #1.

533 High system ground connection OR and/or connections to sensor
faulty. sensor #2.

534 Low system ground connection OR and/or connections to sensor
faulty. sensor #2.
The throttle position sensor
Be sure engine harness wiring
wiring and/or connections for
and connections are in place
either TPS1 or TPS2 open or
TPS1 Higher than and secure OR repair wiring
535 TPS2
shorted OR there is a poor
and/or connections to one or
system ground connection OR
both TPS sensors OR replace
one or both throttle position
one or both TPS sensors.
sensors are faulty.

REV B FAULT CODES

The throttle position sensor
Be sure engine harness wiring
wiring and/or connections for
and connections are in place
either TPS1 or TPS2 open or
TPS1 Lower than and secure OR repair wiring
536 TPS2
shorted OR there is a poor
and/or connections to one or
system ground connection OR
both TPS sensors OR replace
one or both throttle position
one or both TPS sensors.
sensors are faulty.
Governor actuator is stuck Repair wiring and/or
Throttle Unable to closed OR wiring and/or connections to governor
537 Open connections open or shorted actuator OR replace the
OR governor actuator is faulty. governor actuator.
Governor actuator is stuck Repair wiring and/or

Throttle Unable to open OR wiring and/or connections to governor
538 Close connections open or shorted actuator OR replace the
OR governor actuator is faulty. governor actuator.
Engine harness wiring and/or
connections open or shorted Repair wiring and/or
Governor Interlock
545 Failure
OR there is a poor system connections in engine harness
ground connection OR ECM is OR replace the ECM.
faulty.
ECM needs to be re- Re-program ECM OR repair
programmed OR throttle is binding throttle operation OR
Max Governor Speed
551 Override
sticking open OR there are air repair any air leaks between
leaks between the throttle body the throttle body and cylinder
and cylinder head. head.
552 Fuel Rev Limit sticking open OR there are air repair any air leaks between
553 Spark Rev Limit sticking open OR there are air repair any air leaks between

FAULT CODES REV B
Locate and repair any engine

Loose wire connections to harness wiring damage or
611 COP Failure
ECM OR ECM is faulty. shorts to ECM to be sure they
are secure OR replace ECM.

612 Invalid Interrupt

613 A/D Loss

614 RTI 1 Loss

Flash Checksum Loose wire connections to harness wiring damage or
615 Invalid ECM OR ECM is faulty. shorts to ECM to be sure they

616 RAM Failure
harness wiring damage or
connections open or shorted to
External 5V DC Ref shorts OR locate and
631 Lower than Expected
ground OR there is a faulty
troubleshoot or repair faulty
engine sensor OR ECM is
engine sensor OR replace
faulty.
ECM.

REV B FAULT CODES

harness wiring damage or
connections open or shorted to
External 5V DC Ref shorts OR locate and
632 Higher than Expected
ground OR there is a faulty
troubleshoot or repair faulty
engine sensor OR ECM is
engine sensor OR replace
faulty.
ECM.
655 RTI 2 Loss

656 RTI 3 Loss

REV B

March 2005 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
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 gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
Genie Z-45/25 and Genie Z-45/25J General Repair Process
Operator's Manual on your machine.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics March 2005
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

Circuits crossing OPS1
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
Fuse
PULL IN
HOLD
15A with amperage CR4

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

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)
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


REV A Ford LRG-425 EFI Engine Wire Harness

N M L K J I H G F E D C B A
1
6 361 R 16 361 R 16 361 R 16 361 R 16 361 R 16
J1 INJ +
7 555 T 16
INJ 1 555 T 16 FORD WIRING HARNESS WIRE COLOR CODE
(BLACK) INJ 3
8 557 BR-Y 16 557 BR-Y 16
9 558 BR-LB 16 558 BR-LB 16
INJ 4
INJ 2
10 556 W 16 556 W 16 CODE COLOR CODE COLOR CODE COLOR
11
INJ 5
12 BL BLUE GY GREY P
INJ 6
31
PURPLE
AUX OUT 2
21 18 O-Y 18
EGR BK BLACK LB LIGHT BLUE R RED
19 198 DG-O 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2
AUX ANA PD1
20 358 LG-BK 18
MAP 151 LB-BK 18
FPP 1
15 BR BROWN LG LIGHT GREEN T TAN
27 743 GY 18
IAT 354 LG-R 18
28
ECT DB DARK BLUE N NATURAL W WHITE
AUX ANA PU1
IVS
17
18
307 BK-Y 18
150 DG-W 18
DG O Y
2
FPP 2
16 114 LB-Y 18 DARK GREEN ORANGE YELLOW
22 352 BR-LG 18
EGR PWM
23 360 BR-PK 18 354 LG-R 18 GN GREEN PK PINK
EGR RECIRC
1 570 BK-W 16 359 GY-R 18
POWER GROUND
2 570 BK-W 16
POWER GROUND
13 359 GY-R 18
ANA_RTN
14 351 BR-W 18
5 VOLT REF
3 16 R-LG 18
VSW TWR MANIFOLD
EGO 1
24 74 GY-LB 18 351 BR-W 18
C ENGINE
EGO 2
25 ABSOLUTE COOLANT 570 BK-W 16 39 R-W 18
26 358 LG-BK 18 PRESSURE
EGO 3
29
B TEMPERATURE
KNK +
30 TWIST 10 TURNS/FOOT MIN FULL LENGTH 359 GY-R 18 SENSOR SENSOR FORD 42 PIN
KNK - A (MAP) WATER TEMP. CONNECTOR
CRANK -
33 350 GY 18 (ECT) 39 R-W 18
32 349 DB 18 SWITCH (NO) 16 WATER TEMP
CRANK +
CAM -
35
34
452 GY-R 18
282 DB-O 18
TWIST 10 TURNS/FOOT MIN FULL LENGTH
307 BK-Y 18
3
CAM + 25 IVS
4 361 R 16 151 LB-BK 14 FPP1
VBAT
5 361 R 16 361 R 14 570 BK-W 16
VBAT F1
570 BK-W 16 570 BK-W 12 570 BK-W 12 * 34 GROUND
570 BK-W 16
30A
16 R-LG 18
F2 16 R-LG 18 16 R-LG 18
282 DB-O 18 * 1 VSW
HEATED 5A
452 GY-R 18
OXYGEN F3
349 DB 18 361 R 14 361 R 14 361 R 12
SENSOR * 9 VBATT
(HO2S) 20A
350 GY 18
361A R 16 359 GY-R 18

361 R 14
18 O-Y 18
4
CAMSHAFT 38 EGR ANA IN
570 BK-W 16 198 DG-O 18
32 ANA AUX PD1
POSITION
74 GY-LB 18 150 DG-W 18
SENSOR 37 ANA AUX PU1
(CMP) CRANKSHAFT INTAKE AIR 114 LB-Y 18
12 FPP2
359 GY-R 18 352 BR-LG 18
TEMPERATURE 40 EGR PWM
POSITION SENSOR 360 BR-PK 18 41 EGR REC
SENSOR 359 GY-R 18 359 GY-R 18 33 ANA RTN
(IAT) 351 BR-W 18 351 BR-W 18
IGNITION (CKP) 31 VREF
SYSTEM TWR
242 DG 18
A TWR SHD
355 GY-W 18 A A 355 GY-W 18 6
850 Y-BK 18 1 COIL 1 1 2 3 357 Y-W 18 357 Y-W 18
4 570 BK-W 16 361A R 16 B B 5
SPK PWR GROUND 361A R 16 B 151 LB-BK 18 151 LB-BK 18
1 850 Y-BK 18 2 VBAT C C 4
COIL 1 851 Y-R 18 317 GY-O 18
J2 COIL 2
2
3
851 Y-R 18 3 COIL 2
FUEL LOCKOFF 351 BR-W 18
D
E
D
E
317 GY-O 18
351 BR-W 18
1
3
5
(GREY) COIL COIL 4
3
13 SOLENOID 359 GY-R 18
F F
359 GY-R 18
2
24
COIL 5
25 THROTTLE ACTUATOR/
COIL 6 342 LG-P 18 253 DG-W 18
22
STARTER LOCKOUT POSITION SENSOR
FUEL LOCKOFF
23 242 DG 18 D-89
9 926A LB-O 18
FUEL PUMP
32 15 R-Y 18 OIL
RELAY CONTROL
30 355 GY-W 18 PRESSURE
TPS1
31 357 Y-W 18
TPS2
28 151 LB-BK 18
DBW +
29 317 GY-O 18
DBW - 511 LG-R 18
6 511 LG-R 18
BRAKE SWITCH 253 DG-W 18 4 BRAKE
7 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 2 TACH
TACH
FUEL PUMP MON

MIL
27
10
658 PK-LG 18
238 DG-Y 18
658 PK-LG 18
* 6 MIL 6
5 71 O-LG 18 71 O-LG 18
AUX OUT 1 72 Y-BK 18 39 AUX OUT1
14 72 Y-BK 18
FUEL SELECT * 7 FUEL SELECT
15 148 Y-R 18 148 Y-R 18
AUX ANA PU2 306 T-LB 18 10 AUX ANA PU2
16 306 T-LB 18
GOV SELECT 1 * 24 GOV SELECT 1
17 307 BK-Y 18 307 BK-Y 18
11 169 LG-BK 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18 349A DB 18
GASEOUS TRIM 30 OVERSPEED
33 349A DB 18 662 DG-P 18
OVERSPEED 28 CAN +
18 662 DG-P 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 459 O-LG 18
CAN + 29 CAN -
19 459 O-LG 18 642 DG-O 18
CAN - 20 RS 485+
20 642 DG-O 18 461 O 18
RS 485 + 21 RS 485-
21 461 O 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 669 DG-W 18
RS 485 - 11 RS 232+
34 669 DG-W 18 458 O-BK 18
RS 232 TX * 3 RS 232-
35
RS 232 RX
359 GY-R 18 D
TWR
32A R-LB 16
32A R-LB 16
32 R-LB 16
15 STARTER SWITCH
13 STARTER CONTROL
7
RTN 87A 32 R-LB 16
458 O-BK 18
30 787A PK-BK 16
351 BR-W 18 C * 5 FUEL PUMP
5V 87
669 DG-W 18 B 16 R-LG 18
TX 86
458 O-BK 18 A STARTER
RX NOTE: * SHOWS USED WIRES
342 LG-P 18 85
RELAY 238 DG-Y 18
DIAGNOSTIC
CONNECTOR
361 R 14 30
TRIM VALVE 787 PK-BK 16 F4 787A PK-BK 16
TWR 87
77 DB-Y 18 16 R-LG 18 15A
A 86
FUEL 8
361A R 16 PUMP
B 926A LB-O 18 85 RELAY
361 R 14 30
361 R 16
F5
361A R 16
87
16 R-LG 18 86 15A
NOTES: POWER
1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE RELAY
15 R-Y 18 85
EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE
2. INTERNAL SPLICES ARE NOT SHOWN

Ford LRG-425 EFI Engine Wire Harness

REV A Ford LRG-425 EFI Engine Wire Harness

J1 BLACK
INJ +
6
7
361 R 16
555 T 16
361 R 16
555 T 16
361 R 16 361 R 16 361 R 16 FORD WIRING HARNESS WIRE COLOR CODE 1
INJ 1
8 557 BR-Y 16 557 BR-Y 16 CODE COLOR CODE COLOR CODE COLOR
INJ 3
9 558 BR-LB 16 558 BR-LB 16
INJ 4
10 556 W 16 556 W 16
INJ 2
11 BL BLUE GY GREY P PURPLE
INJ 5
12
INJ 6
AUX OUT 2
31 BK BLACK LB LIGHT BLUE R RED
21 18 O-Y 18
EGR
19 198 DG-O 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2 BR LG T TAN
AUX ANA PD1 BROWN LIGHT GREEN
20 358 LG-BK 18
MAP 151 LB-BK 18
15
FPP 1
27 743 GY 18 DB DARK BLUE N NATURAL W WHITE
IAT 354 LG-R 18
28
ECT
IVS
17 307 BK-Y 18 DG DARK GREEN O ORANGE Y YELLOW
18 150 DG-W 18
AUX ANA PU1
FPP 2
EGR PWM
16
22
114 LB-Y 18
352 BR-LG 18
GN GREEN PK PINK 2
23 360 BR-PK 18 354 LG-R 18
EGR RECIRC
1 570 BK-W 16 359 GY-R 18
POWER GROUND
2 570 BK-W 16
POWER GROUND
13 359 GY-R 18
ANA_RTN
5 VOLT REF
14 351 BR-W 18 ENGINE COOLANT
3 16 R-LG 18 TEMPERATURE
VSW
24 74 GY-LB 18 351 BR-W 18
TWR MANIFOLD
EGO 1
25
C
ABSOLUTE SENSOR 570 BK-W 16 39 R-W 18
EGO 2 (ECT)
26 358 LG-BK 18 PRESSURE
EGO 3 B
29
KNK +
30 TWIST 10 TURNS/FOOT MIN FULL LENGTH 359 GY-R 18 SENSOR
KNK - A (MAP) WATER TEMP. FORD 42 PIN CONNECTOR
33 350 GY 18
CRANK - 39 R-W 18
CRANK +
32 349 DB 18 SWITCH (NO) 16 WATER TEMP
35 452 GY-R 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH
CAM -
CAM +
VBAT
34
4
282 DB-O 18
361 R 16
307 BK-Y 18
151 LB-BK
25 IVS
14 FPP1
3
5 361 R 16 361 R 14 570 BK-W 16
VBAT F1
570 BK-W 16 570 BK-W 12 570 BK-W 12 * 34 GROUND
570 BK-W 16
30A
16 R-LG 18
F2 16 R-LG 18 16 R-LG 18
282 DB-O 18 * 1 VSW
5A
HEATED 452 GY-R 18
OXYGEN 361 R 14 F3 361 R 14 361 R 12
349 DB 18 * 9 VBATT
SENSOR
(HO2S) 350 GY 18 20A
361 R 14
359 GY-R 18
361A R 16
570 BK-W 16 CAMSHAFT
18 O-Y 18
198 DG-O 18
38 EGR ANA IN
32 ANA AUX PD1
4
POSITION INTAKE AIR
74 GY-LB 18 TEMPERATURE 150 DG-W 18
359 GY-R 18
SENSOR 37 ANA AUX PU1
114 LB-Y 18
(CMP) CRANKSHAFT SENSOR 12 FPP2
352 BR-LG 18
POSITION (IAT) 360 BR-PK 18
40 EGR PWM
41 EGR REC
SENSOR 359 GY-R 18 359 GY-R 18 33 ANA RTN
351 BR-W 18 351 BR-W 18
IGNITION (CKP) 31 VREF
SYSTEM TWR
242 DG 18
A TWR SHD
355 GY-W 18 A A 355 GY-W 18 6
850 Y-BK 18 1 COIL 1 1 2 3 357 Y-W 18 357 Y-W 18
4 570 BK-W 16 361A R 16 B B 5
SPK PWR GROUND 361A R 16 B 151 LB-BK 18 151 LB-BK 18
1 850 Y-BK 18 2 VBAT C C 4
COIL 1 851 Y-R 18 317 GY-O 18
2 851 Y-R 18 3 COIL 2 D D 317 GY-O 18 1
COIL 2 FUEL LOCKOFF SOLENOID 351 BR-W 18 351 BR-W 18
3
J2 GREY COIL 3 E E 3
COIL 4
13
24
359 GY-R 18
F F
359 GY-R 18
2 5
COIL 5
25 THROTTLE ACTUATOR/
COIL 6 342 LG-P 18 253 DG-W 18
22
STARTER LOCKOUT
23 242 DG 18
POSITION SENSOR D-89
FUEL LOCKOFF
9 926A LB-O 18
FUEL PUMP OIL
32 15 R-Y 18
RELAY CONTROL
TPS1
30 355 GY-W 18 PRESSURE
31 357 Y-W 18
TPS2
28 151 LB-BK 18
DBW +
29 317 GY-O 18
DBW - 511 LG-R 18
6 511 LG-R 18
BRAKE SWITCH 253 DG-W 18 4 BRAKE
7 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 2 TACH
TACH
27 658 PK-LG 18 658 PK-LG 18
MIL * 6 MIL
10 238 DG-Y 18
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
5
14
71 O-LG 18
72 Y-BK 18
71 O-LG 18
72 Y-BK 18
39 AUX OUT1
* 7 FUEL SELECT
6
15 148 Y-R 18 148 Y-R 18
AUX ANA PU2 306 T-LB 18 10 AUX ANA PU2
16 306 T-LB 18
17 307 BK-Y 18 307 BK-Y 18
11 169 LG-BK 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18 349A DB 18
GASEOUS TRIM 30 OVERSPEED
33 349A DB 18 662 DG-P 18
OVERSPEED 28 CAN +
18 662 DG-P 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 459 O-LG 18
CAN + 29 CAN -
19 459 O-LG 18 642 DG-O 18
CAN - 20 RS 485+
20 642 DG-O 18 461 O 18
RS 485 + 21 RS 485-
21 461 O 18 TWIST 10 TURNS/FOOT MIN FULL LENGTH 669 DG-W 18
RS 485 - 11 RS 232+
34 669 DG-W 18 458 O-BK 18
RS 232 TX * 3 RS 232-
35
RS 232 RX 32A R-LB 16 15 STARTER SWITCH
458 O-BK 18
359 GY-R 18 D
TWR
RTN
32A R-LB 16
87a 3 32 R-LB 16
32 R-LB 16 13 STARTER CONTROL
7
351 BR-W 18 C 787A PK-BK 16 * 5 FUEL PUMP
5V 1 30 4
87
669 DG-W 18 B 16 R-LG 18
TX
2 86 85
5 STARTER
458 O-BK 18 A
RX RELAY
238 DG-Y 18 NOTE: * SHOWS USED WIRES
342 LG-P 18
DIAGNOSTIC
CONNECTOR 87a 3
361 R 14 F4
TRIM VALVE 1 30 4 787 PK-BK 16 787A PK-BK 16
87
TWR
77 DB-Y 18 16 R-LG 18 15A
A FUEL PUMP
2 86 85
5 RELAY
B
361A R 16
926A LB-O 18
8
87a 3
361 R 14 F5
1 30 4 361 R 16 361A R 16
NOTES: 87
1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE 16 R-LG 18 15A
(EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE) 2 86 85
5
POWER RELAY
15 R-Y 18
2. INTERNAL SPLICES ARE NOT SHOWN

Ford LRG-425 EFI Engine Wire Harness

N
REV A
RD
RD
BRN
C22LS RD
P24FS WH
P26ESTP BK
C41RPM OR/BK
C28TTA RD/BK
C1P-9 C35ESPD BK/RD C1B-9

FOOT SW. HIGH
FOOT SW. LOW C2P-4 C128LRPM OR/RD C2B-4 C128LRPM OR/RD C5-9
TS4
TB42
TS54
ENGINE
SPEED
TB35
LOW RPM
M
FUNCTION ENA.
BL/RD
HIGH RPM
TS47
OFF
GENERATOR GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH OPTION
WH
RD
L
TS48
C2P-5 C43DLITE GR C2B-5

DRIVE LIGHT
L29
LIGHTS
WORK LIGHT C4B-12 RD DRIVE LIGHT
CR23
OPTION
PBOX
L29
GND
L30
RD
RD
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
WORK LIGHTS
OPTION
K
C2P-11 C2P-9
FB1
L30
C23ALRM RD C6-34 FLASHING BEACONS

OPTION
TS3
C2P-1 C39LP BL/RD C2B-1 C5-10

LP
TB39
FUEL
GAS C21HM WH
HM
TS53
HOUR METER
J
L2
LP CHECK ENGINE LED

FUEL C108ESL BK/RD
GAS
TB38
ENGINE
CHECK
C35ESPD BK/RD
IGNITION/
MODULE
START
U1
RUN/TEST SWITCH
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
7 KEY POWER
10 ENG. FAULT
TS2
C1P-7 C33STR BK C1B-7

6 BATTERY
5 GROUND
I
4 AUX. ON
TEST
ENGINE
START
TS64
TS52
C5-13
C5-8
C5-9
ENGINE
START WH
TB33
POWER RELAY
H
C127TSW
C108ESL
OR/RD FEH(306) PIN24

CR2
BK/RD FEH(658) PIN6
FORD 42 PIN QUICK DISCONNECT

TB25
TB21
GR FEH(458) PIN3
C5-11 RD/LG FEH(16A) PIN1
ENGINE HARNESS #2
C39LP BL/RD BL/RD FEH(72) PIN7
C5-18 BK/RD FEH(307A) PIN23
C28TTA RD/BK
C5-1 RD FEH(361) PIN9

G
(GND) BRN FEH(570) PIN34

BL/WH FEH(787) PIN5
C5-3
M4
BL/WH
PUMP
BK
FUEL
FUEL PUMP
P26ESTP BK
IGNITION/START RELAY
P24FS WH
P25FS RD
CR1
F
M3
TB24
R33STR BK C5-5
March 2005
Part No. 77809

C9P-2
C9P-3
STARTER
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1
PUMP C6-27 C27AUX RD

AUXILIARY POWER RELAY
WH-(FS)
RD-(FS)
AUXILIARY
PR1
E
PUMP C1P-1 C27AUX RD C1P-1
PUMP
AUX
AUXILIARY PUMP
FS1
C28TTA RD/BK
M2
BK-(FS)
Ford LRG-425 EFI Models (before serial number 22050)
WH C1P-2 C28TTA RD/BK C1P-2 C5-24 C28TTA RD/BK WH

TILT ALARM
H1
C7P-2 P23BAT WH C7B-2 C5-23 P23TTSR WH RD BK BRN

LEVEL SENSOR
C9P-1 BK
TB23
D
S8
HORN
P3
P2
BK C3P-9 C46HRN BK/RD C3B-9 C46HRN BK/RD

HORN RELAY
Genie Z-45/25 and Genie Z-45/25J

CR5
TB22
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK/RD C6-9
HORN
H2
GRND
PLAT
KS1
C
RD
Electrical Schematic, Z-45/25
P1
R16
C21IGN WH
500
TB41
RD
C41RPM OR/BK C2B-3 C5-2 C41RPM OR/BK
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
D1
FLD.
Section 6 • Schematics
CB2
CB1
15A
15A
GND.
BAT.
FUSE
LINK
A
TB20
-
P20BAT RD C7B-4
12V DC
B2
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
C31REV WH/BK
TS14
C1P-5 C1B-5 C5-20 C31REV WH/BK RD BK BRN

C28TTA RD/BK
16 DRIVE EDC REVERSE

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

B
TRAVEL ALARM OPTION

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15
CDE1 BL C1P-6 C32BRK WH/RD C1B-6 C6-32 C32BRK WH/RD

7 19 BRAKE RELEASE VALVE
LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
CDE2 BL/BK C1P-3 C29MS RD/WH C1B-3 C6-29 C29MS RD/WH
20 MOTOR STROKE
P26ESTP BK
ROCKER
SWITCH
OPTION
P24FS WH
STEER
C
7
BL
RKOUT 6
DRIVE & STEER
WH C25-1 C25-2
YOUT 5 4
BL C1P-11 C37STC BL/BK C1B-11 C6-37 C37STC BL/BK
JC3
J1
XOUT 4 5 17 STEER RIGHT

OR
PWR 3 13
BRN C36STCC BL C36STCC BL
C1P-10 C1B-10 C6-36
GND 2 14 18 STEER LEFT
1 C24-1 C24-2
C3P-6 C6TRF WH/RD C3B-6
11
C4TRL WH
D
C3P-4 C3B-4
9
C5TRR WH/BK C15-1 C15-2
TB5
C3P-5 C3B-5
10
C6-5 C5TRR WH/BK TURNTABLE ROTATE RIGHT
RIGHT
TURNTABLE ROTATE
LEFT C6-4 C4TRL WH
TURNTABLE ROTATE LEFT
TS62
R4
10
C14-1 C14-2
TB4
C31-1 C31-2
PRIMARY BOOM UP/DOWN &
7 C6-6 C6TRF WH/RD TURNTABLE ROTATE

FLOW CONTROL
TURNTABLE ROTATE
6
TB6
C12-1 C12-2
TB1
BK
E
YOUT 5 2
RD C6-1 C1PBU RD
PRIMARY BOOM UP
JC2
XOUT 4 1
UP
Part No. 77809
TB2
Y22
J1
OR PRIMARY BOOM
PWR 3 11 C6-2 C2PBD RD/BK
BRN DOWN
PRIMARY BOOM DOWN
TS61
GND 2 12
J2
March 2005
C13-1 C13-2
TB3
1
C29-1 C29-2
C6-3 C3PBF RD/WH PRIMARY BOOM
FLOW CONTROL
C3P-1 C1PBU RD C3B-1
6
C3P-2 C2PBD RD/BK C3B-2
7
F
C3P-3 C3PBF RD/WH C3B-3

8
7
C3P-12 C12SBF BL/WH C3B-12
SECONDARY BOOM
6 14
YEL
OUT 5 3
C3P-11 C11SBD BL/BK C3B-11
UP/DOWN
13
JC1
4
J1
OR
PWR 3 9 C3P-10 C10SBU BL C3B-10
BRN 12
TB10
C18-1 C18-2
GND 2 10
G
C6-10 C10SBU BL
1 SECONDARY BOOM UP
P26ESTP BK
UP
BOOM SECONDARY
DOWN C6-11 C11SBD BL/BK
SECONDARY BOOM DOWN
U13 JOYSTICK CONTROL CARD
BRN
TS60
TB11
1 C19-1 C19-2
TB12
C30-1 C30-2
P24FS WH C6-12 C12SBF BL/WH SECONDARY BOOM
2
FLOW CONTROL
P24FS WH
LS3
J3
4
C4P-4 C16PDRE OR/RD C4B-4 C6-16 BK-6 WH-6 C6-13 LS3-DRIVE ENABLE
3
P26ESTP BK LIMIT SWITCH
13
14
3
H
C2P-2 LS1-PRIMARY BOOM EXTEND

LS1
4
C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20 DRIVE LIMIT SWITCH
BK
21
22
LS2
C40LSS OR
C11-4 WH-7 BK-7 C11-3 LS2-PRIMARY BOOM UP

DRIVE LIMIT SWITCH
21
22
LS4
CR30
OPTION
LS4-SECONDARY BOOM UP
CR27
NC
C2B-2 C6-40 OR C10-3 BK-4 WH-4 C10-4 BK C10-1 BK-5

NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
C22LS RD
C3P-7 C7PBE BK C3B-7
EXTEND
BOOM
RETRACT C3P-8 C8PBR BK/WH C3B-8
TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
RETRACT C6-8 C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
J
C4P-2 C14PLU OR C4B-2

TS9
UP
PLATFROM LEVEL
DOWN C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLATFROM LEVEL
DOWN C6-15 C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
WH
C4P-6 C18PRR GR/BK C4B-6

K
RIGHT PLATFORM
LEFT ROTATE C17PRL GR C4B-5
TS7
TB18
C4P-5 C23-1 C23-2
C6-18 C18JD GR/BK
TS57
PLATFORM ROTATE RIGHT
RIGHT
PLATFORM ROTATE
LEFT C6-17 C17 JU GR
PLATFORM ROTATE LEFT
C22-1 C22-2
TB17
C5-25
L
C44DA BK C6-19
DESCENT ALARM OPTION
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
BRN
RD
RD
RD
REV A
N

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

FOOT SWITCH HIGH
FOOT SWITCH LOW C128LRPM OR/RD C2B-4 C128LRPM OR/RD C5-9
TS4
C2P-4
TB42
ENGINE
SPEED
TS54
TB35
LOW RPM FUNCTION

M
ENABLE
BL/RD
HIGH RPM
TS47
OFF
GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH
GENERATOR OPTION
WH
RD
L
CR23
FUSE 10A (ONLY ON WORKLIGHTS)
TS48

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
WORK LIGHTS OPTION

NO
K
PBOX GND
C2P-11 C2P-9
FB1
C23ALRM RD C6-34 FLASHING BEACONS OPTION

L30

TS3
LP
FUEL
TB39
GAS C21HM WH
HM
HOUR METER
TS53
J
_
L2
LP
FUEL C108ESL BK/RD CHECK ENGINE LED
GAS
TB38
ENGINE
CHECK
C35ESPD BK/RD
IGNITION/
MODULE
START
U1
RUN/TEST SWITCH
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
10 ENG. FAULT
C1P-7 C33STR BK C1B-7 TEST

7 KEY PWR.
TS2
6 BATTERY
5 GROUND
I
4 AUX. ON
ENGINE ENGINE
START
TS64
START
TS52
C5-13
C5-8
C5-9
ENGINE
START WH
TB33
POWER RELAY
CR2
C127TSW
H
C108ESL

BK/RD FEH(658) PIN6

TB25
TB21
GR FEH(458) PIN3
ENGINE HARNESS #2
CR2
NO

C28TTA RD/BK

G

BL/WH FEH(787) PIN5
C5-3
PUMP M4
CR1
BL/WH BK
FUEL
FUEL PUMP
P26ESTP BK
P24FS WH
P25FS RD
F
M3
TB24
R33STR BK C5-5
March 2005
Part No. 77809

CR1
NO
C9P-2
C9P-3
STARTER
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1
PUMP C6-27 C27AUX RD AUXILIARY POWER RELAY

WH-(FS)
RD-(FS)
AUXILIARY
PR1
E
PUMP
AUX
C28TTA RD/BK AUXILIARY PUMP
PR1
NO
L4
FS1
M2
BK-(FS)

TILT ALARM
Ford LRG-425 EFI Models (after serial number 22049)
RD C2P-5 C134PWR BL/RD C2B-5 C5-23 P23TTSR WH RD BK BRN

LEVEL SENSOR
C9P-1 BK
TB134
HORN
C4B & C4P - BROWN

D
C3B & C3P - GREEN

C2B & C2P - BLACK
S8
P3
C1B & C1P - GRAY

BK C3P-9 C46HRN BK/RD C3B-9
P2
C46HRN BK/RD HORN RELAY

H1
C7P-2 P23BAT WH C7B-2
CR5

TB23
HORN
CR5
TB22
H2
NO
boom in the stowed position and the keyswitch off.

C
1) All switches and contacts are shown with the

GRND
PLAT
KS1
R16
RD
C21IGN WH
P1
500
TB41
RD
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
CB2
15A
CB1
15A
FLD.
GND.
D1
BAT.
FUSE
LINK
A
TB20
NOTE:
+
-
P20BAT RD C7B-4
12V DC
B1
6-9
1
8
1
8
6 - 10
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
B

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3
J1
4 5 17 STEER RIGHT
OR
PWR 3 13
C1P-10 C1B-10 C6-36
1 C24-1 C24-2
11
9
D
CR33
C5TRR WH/BK TURNTABLE ROTATE

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

TURNTABLE ROTATE TURNTABLE ROTATE RIGHT
87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
10
TB6

C6-4 C14-1 C14-2
PRIMARY BOOM UP/DOWN
7
AND TURNTABLE ROTATE
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

E
UP C1PBU RD
TB2
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
C6-1
Part No. 77809
BRN
C2PBD RD/BK
TS61
GND 2 12
J2
TB3
1
C6-2 C13-1 C13-2 PRIMARY BOOM DOWN
March 2005

6
7
F
8
7
SECONDARY BOOM
6 14
YEL
UP/DOWN
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10 SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
BOOM SECONDARY
SECONDARY BOOM UP
87a 87
DOWN
G
30
C6-10
BRN C11SBD BL/BK

TS60
TB11
1
TB12
C6-11 C19-1 C19-2 SECONDARY BOOM DOWN

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
H
BK
21
22
LS2
C40LSS OR

DRIVE LIMIT SWITCH
21
22
LS4
OPTION
CR30
CR27
DRIVE
NO

NC
LIFT/
DRIVE LIMIT SWITCH

CE
21
22
C22LS BK
EXTEND
BOOM
I

TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
BOOM RETRACT
TB8
C17-1 C17-2
TS9
UP PLATFROM
DOWN LEVEL C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
J
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLATFROM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
WH

RIGHT PLATFORM
TS7
TB18
C4P-5 C23-1 C23-2
PLATFORM ROTATE RIGHT AND
K
C6-18 C18JD GR/BK

TS57
JIB BOOM DOWN
RIGHT
PLAT ROTATE
LEFT C6-17 C17 JU GR PLATFORM ROTATE LEFT AND
JIB BOOM UP
C22-1 C22-2
TB17
C5-25
C44DA BK C6-19
H3
L
ROTATED PAST EITHER NON-STEER

WITH BOOM IN STOWED POSITION
1. ALL LIMIT SWITCHES SHOWN
3 ROCKER STEER OPTION ONLY.

2 SWITCH SHOWN WITH BOOM
C41RPM OR/BK
C28TTA RD/BK
M
P26ESTP BK
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
BK
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
C1B & C1P - GRAY
NOTES:
WHEEL.
REV A
N

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

8
7
6
5
4
3
2
1
6 - 11
Genie Industries
BK-R1 TO REMOVE: 1 START RELAY
1
OR/BK-41A Push gently 2 TACHOMETER
A
2
BK-33B and lift 3 START INPUT
3
RD-27B 4 AUX PWR UNIT
4
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
WH-TS64 7 TO KEY SW (DIESEL ONLY)

7
8 8 JUMP TO 7 (GAS ONLY)
WH-R2 9 IGN OR FUEL ON
9 1 3 4 7 10 9 2
WH-25D & 26D 10 TEMP OR PRESS FAULT
10
B
I.S.M.
12/24V DC IGNITON/START MODULE P/N 56057
TERMINAL BASE (TB)

D C B A
C6-1 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
C6-2 RD/BK BK
C3B
C3B-2 RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C3B-3 RD/WH
C
NOTE:
C6-3 RD/WH RD/WH-TS61
3 PRIMARY BOOM FLOW CONTROL 3
C6-4 WH
C3B-4 WH WH-TS62
4 TURNTABLE ROTATE LEFT 4
C6-5 WH/BK
C3B-5 WH/BK WH/BK-TS62
OPTION WIRES
BK
5 TURNTABLE ROTATE RIGHT 5

C6-6 WH/RD

C3B-6 WH/RD WH/RD-TS62
6 TURNTABLE ROTATE FLOW CONTROL 6
C6-7 BK
C3B
C3B-7 BK BK-TS63
7 PRIMARY BOOM EXTEND 7
C6-8 BK/WH
DASHED LINES INDICATE

C3B-8 BK/WH BK/WH-TS63
D
8 PRIMARY BOOM RETRACT 8

C6-10 BL
C3B-10 BL BL-TS60
10 SECONDARY BOOM UP 10
C6-11 BL/BK BK
I.S.M.
C3B-11 BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6-12 BL/WH
C3B-12 BL/WH BL/WH-TS60

12 SECONDARY BOOM FLOW CONTROL 12
C6-14 OR
C4B-2 OR OR-TS59
14 PLATFORM LEVEL UP 14
C6-15 OR/BK
C4B
C4B-3 OR/BK OR/BK-TS59
E
15 PLATFORM LEVEL DOWN 15

C6-17 GR
C4B-5 GR GR-TS57
C3B
17 PLATFORM ROTATE LEFT 17
C6-18 GR/BK
C7B
C4B-6 GR/BK GR/BK-TS57
18 PLATFORM ROTATE RIGHT 18
BK-ALARM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
12V DC TO
20 +12V DC VOLT POWER 20
PLATFORM
WH-TS64 BRN
C5-3 WH WH-HM
Part No. 77809

March 2005
21 IGNITION POWER 21
C6-20 RD
C5
C7B
C7B-1 BK BK-R5
22 +12V DC VOLT TO PLATFORM 22
F
C5-23 WH WH-TS64
C7B-2 WH WH-KS
23 KEY SWITCH POWER 23
C6-34 RD FB
C6
C6
RD-R2
C4B
C6-16
C6-40
C6-37
C6-36
C6-29
I.S.M.
C7B-3
C5-1 RD RD-CB1
24 CB1 POWER 24
FUNCTIONS
WH-IS10 WH/BK-L2-
25 (UNUSED) 25
WH/RD-L3-
26 (UNUSED) 26
C40LS1 OR
C6-27 RD RD-IS4
G
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C1B-1 RD RD-TS51
BRN
27 AUXILIARY PUMP 27
C1B-6 WH/RD
C6-32 WH/RD WH/RD-ALARM
32 BRAKE 32
BK-TS64 BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 ENGINE START 33
C3B

34 (UNUSED) 34
C2B-2 C5-18 BK/RD
C1B-3
C1B-11
C1B-10
C1B-9 BK/RD BK/RD-TS54

C5
35 HIGH RPM 35
H
C2B
C5-13 BL/WH BL/WH-L2-

38 CHECK ENGINE LED 38
C5-10 BL/RD
19/18 CABLES
C2B-1 BL/RD BL/RD-TS53
39 LIQUID PROPANE FUEL 39
C1B
C2B-3 OR/BK
C5-2 OR/BK OR/BK-IS2
41 ALTERNATOR PULSE PICKUP 41
C4B C3B C2B 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
44 JIB DOWN DESCENT ALARM 44
I
C3B
C4B
BRN
I.S.M.
RD-24B
C30FWD WH
P20DLITE RD
C43DLITE GR
C125TSW WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
CR1
CR2
START
ENGINE HARNESS
RELAY
RELAY
IGNITION
POWER
FUNCTION HARNESS
RD-IS6
C5-20
C5-21
C5-24
C5-12
BK-IS1
J
C5
BRN
C5-8
C5-11
ENGINE
C5-5 BK
WH-IS9
C3B
C4B
BRN
BK-33B
GROUND CONTROL HARNESS
C21IGN2 WH
C5-3 WH
C127TSW GR
WH-21C
GR
BATGND BRN
WH-23B C23TSW WH
K
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
WH-21C C6-9 BK/RD
C3B-9 BK/RD
WH-IS7
CR23
RELAY
BK-22B
OPTION
C6-13 BK
DRIVE LIGHT
BRN
TS64
BRN
SWITCH
BK-ALARM
L
RUN/TEST
GROUND
BRN-TS
F19
10A
WH/RD-ALARM
CR5
FUSE
HORN
BRN
RELAY
BRN RD
C2B-5 GR
CONTROL HARNESS
RD-20C DRIVE LIGHTS
C6-33 WH/RD-ALARM WH/RD-32A

C5-19 BK-ALARM BK-ALARM
C4B
OR/BK-IS2 OR/BK-41A
M
GROUND BOLT
RD-IS4 RD-27B
GROUND
BK-IS3 BK-33B
HARNESS
CONTROL
C4B-7 GR/WH C19JSV GR/WH TS57

PANEL)
C7B3 BRN
F.H.
E.H.
BRN
BRN
BRN
(TO SWITCH
I.S.M.
BRN BRN
REV A
N
N
REV A
M
L
K
STACKED CONTACTS
KEY SWITCH
P1 3 3
STOP
J
SWITCH NO NO
2
1
NC
RD
4 4
KS1 TS51
2
1
NC
RD RD AUXILIARY POWER
RD
RD-27A RD-27
RD
RD
RD
RD
KS1
3 3
RD RD RD
RD RD
I
NO NO
RD
RD
RD
RD
RD
4 4 BK-22
RD
WH-23A
WH-21
WH-23
H
RD
L2 TS53
BRN + CHECK FUEL
ENGINE SELECT
-
RD
LED
BRN
BL/RD-39A
WH-CR2
BL/WH-38
HOUR METER
G
GROUND CONTROL BOX HARNESS

(TO TERMINAL STRIP)
RD
RD
RD
RD
RD RD RD RD TS63
RD/BK-2A PRIMARY BOOM
F
EXTEND/RETRACT
R4 RD/WH-3A RD RD
FUNCTION SPEED RD RD
CONTROL VARIABLE
TS61
RESISTER
RD PRIMARY
RD
RD
BOOM
BK-7
RD-1A
March 2005
UP/DOWN
RD
RD
RD
RD RD RD BK-7A
BK/WH-8
BK/WH-8A
Part No. 77809
E
RD
RD
RD
RD
RD RD RD RD
WH/BK-5A WH/BK-5
TS60
RD
RD
SECONDARY WH-4A WH-4

WH/RD-6A WH/RD-6
RD
BOOM UP/DOWN
D
BL/WH-12A
RD
RD
RD
RD RD
BL/BK-11A
TS52 RD TS62
ENGINE BL-10A TURNTABLE
RD
RD
RD
START ROTATE
RD
BK-33A
RD
RD
RD RD RD RD RD
RD RD RD
C
RD
RD
CB1
B
CIRCUIT
RD
C4B-7 GR/WH C19JSV GR/WH

RD
RD
RD
BREAKER
ENGINE, 15A RD RD GR-17A GR-17
RD
OR/BK-15A
RD-24A RD-20B RD TS57
OR-14A PLATFORM
RD-20A CB2 ROTATE
TS54 TS59
BK/RD-35A CIRCUIT BREAKER PLATFORM RD RD
FUNCTION
CONTROLS, 15A LEVEL
ENABLE
A
GR/BK-18A GR/BK-18
OR/RD-42A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
6 - 12
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 13
30
85
86
Genie Industries
87A
1
OR/BK-41A
87
2 Push gently 2 TACHOMETER
A
3
4
BRN-IS5 5 GROUND
5
87 = NO
87A = NC
RD-CR1 6 BATTERY
6

7
9 1 3 4 7 10 9 2
86 = COIL POSITIVE
85 = COIL NEGATIVE
10
30 = COMMON (12V DC IN)

B
I.S.M.
12/24 Volt IGNITON/START MODULE P/N 56057
D C TERMINAL BASE (TB) B A

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
BK
C3B
C3B-3 RD/WH
CR32 #30 RD/WH RD/WH-TS61
3 PRIMARY BOOM FUNCTION CONTROL 3
C
4 4
CR33 #86 WH/BK
BK

C3B-6 WH/RD
CR33 #30 WH/RD WH/RD-TS62
6 TURNTABLE ROTATE FUNCTION CTRL 6
C6-7 BK

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

12 SECONDARY BOOM FUNCTION CTRL 12
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C4B-5 GR GR-TS57
E
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
20 +12 VOLT POWER 20
WH-TS64 BRN
C5-3 WH WH-HM
C6-20 BK
C5
C7B
Part No. 77809

March 2005
C7B-1 BK BK-R5
22 +12 VOLT TO PLATFORM 22
WH-TS64
C7B-2 WH WH-KS
23 KEYSWITCH POWER 23
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
C5-1 RD RD-CB1
24 CB1 POWER 24
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
25 (UNUSED) 25
WH/RD-L3-
26 (UNUSED) 26
C4B
C40LS1 OR
C6-27 RD RD-IS4
C36STCC BL
C1B-1 RD RD-TS51
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
BRN
C1B-6 WH/RD
32 BRAKE 32
G
BK-TS64 BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
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

C5-10 BL/RD
19/18 CABLES
C1B
C2B-3 OR/BK
H

C4B C3B C2B C1B

C5-9 OR/RD
C1B-2
C2B-7
C1B-5
C1B-4

42 LOW RPM 42
C2B-6 GR/BK
44 44
C3B
BRN
I.S.M.
C125TSW WH
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
C45 GEN GR/WH

ENGINE HARNESS
I
C2B-5 GR
C43DLITE
RD-24B
CR1
CR2
START
RELAY
RELAY
POWER
IGNITION
RD-IS6
P20DLITE RD
CR23
BK-IS1
DRIVE LIGHT
OPTION RELAY
BRN
C5-20
C5-21
C5-24
C5-12
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-3 WH
C5-11
ENGINE
BK-33B
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
C5-8 C127TSW
F19
GR
10A FUSE
C21IGN2 WH
RD
WH-23B C23TSW WH
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
WH-21C C6-2 RD/BK
C3B-9 BK/RD
CR37
BOOM
CR33
RELAY
RELAY
WH-IS7 C6-9 BK/RD

CR32
ROTATE
BOOM
RELAY
BRN
PRIMARY
SECONDARY
TURNTABLE
87
87
87
CR5
TS64
HORN
RELAY
SWITCH
BK-22B
87A
87A
87A
C6-13 BK
L
BK-ALARM
RUN/TEST
85
85
85
86
86
86
BRN-TS
WH/RD-ALARM
30
30
30
BRN
BRN
BRN
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B GROUND CONTROL
C7B3 BRN
HARNESS
BK-IS3 BK-33B (TO SWITCH PANEL)
NOTE: DASHED LINES INDICATE OPTION WIRES
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

EXTEND/RETRACT
TURNTABLE
LABEL DESCRIPTION
PRIMARY BOOM
PLATFORM
ROTATE
CB1 CIRCUIT BREAKER, ENGINE, 15A
ROTATE
TS62
CB2 CIRCUIT BREAKER, CONTROLS, 15A RD RD
TS57
CR1 IGNITION / START RELAY
CR2 INGITION POWER RELAY
TS63
BK/WH-8 RD
CR5 HORN RELAY RD RD RD
HM HOUR METER BK-7
KS1 KEY SWITCH
RD
GR/BK-18
C19JSV GR/WH
L2
P1
CHECK ENGINE LED
RED EMERGENCY STOP BUTTON
2
RD
RD
RD RD
RD
R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS
RD RD
TS51 AUXILIARY POWER TOGGLE SWITCH
WH/RD-6
GR-17
WH/BK-5
TS52 ENGINE START TOGGLE SWITCH
RD
WH-4
AUXILIARY
RD RD
SWITCH
TS53 FUEL SELECT TOGGLE SWITCH
RD
TS51
TS54 FUNCTION ENABLE TOGGLE SWITCH
RD RD RD RD RD
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS59 PLATFORM LEVEL TOGGLE SWITCH
UP/DOWN
PRIMARY
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
BOOM
RD-27
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
RD
RD
RD
3
RD
TS61
TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
RD
TS64 RUN/TEST TOGGLE SWITCH
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
RD/BK-2A
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
UP/DOWN BL/WH-12A
BL/BK-11A
RD
BL-10A
ENGINE
CHECK
KS1
RD
LED
SECONDARY
RD
L2
CONTROLS 15A
BREAKER
5
CIRCUIT
BOOM
CB2
TS60
WH-23
+
-
RD RD
RD
RD
RD RD
RD RD
RD
RD-20B
RD
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
BK/RD-35A
RD
RD
RD
7
ENGINE 15A
BRN
BREAKER
CIRCUIT
ENGINE
START
CB1
TS52
WH-21
BRN
RD-20A
CONTROL VARIABLE
FUNCTION SPEED
RD
RESISTER
STOP SWITCH
RD
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
ENABLE
RD
TS54
RD
RD RD RD


Platform Control Box Wiring Diagram, Z-45/25

N
REV A
NOTE: DASHED LINES INDICATE OPTION WIRING

PLATFORM CONTROL HARNESS
12V DC PLATFORM POWER CONNECTOR
CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD POWER CONNECTOR
CONTROL BOARD INPUT CONNECTOR
(TO SWITCH PANEL)
CONTROL RELAY (CE OPTION)

FOOT SWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
ALC-500 CONTROL BOARD

M
DESCRIPTION
TILT ALARM
CE LIFT/DRIVE OPTION
ITEM
CR27
CR30
C1P-
C4P
C7P
U13
R24FS WH C9P-2
H1
C9
J1
J2
J3
CR27
L
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
K
OPT.
BRN
C40LSS OR C2P-2
CR30
C40LSS OR J2-4
P24FS WH C9P-2
J
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 C2P-5
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P
F.S.
H
C45GEN GR/WH C2P-7

SWITCH
FOOT
C128LS OR/RD C2P-4

C9
C39LP BL/RD C2P-1

P26ESTP BK
WH/RD C1P-6
11
G
C6TRF WH/RD C3P-6
12V DC BATTERY
J3
C10SBU BL C3P-10
C16DRE OR/RD C4P-4
C11SBD BL/BK C3P-11
C7P
P24FS WH C40LSS OR C2P-2
C12SBF BL/WH C3P-12
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
F
BRN C1PBU RD C3P-1

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
March 2005
Part No. 77809

C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C4TRL WH C3P-4
C32BRK WH/RD C1P-6 C4P(BR)
C5TRR WH/BK C3P-5
ALC-500
U13
19/18 CONTROL CABLE

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
* WIRE CONNECTS TO JC3-6
C1P
9
JC1-3 OR

JC2-4 RD
FOR STEER ROCKER
Platform Box Wiring Diagram, Z-45/25
JC1-2 BRN
JC2-5 BK
SWITCH OPTION. C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
DRE A BL/WH C28TTA RD/BK C1P-2
DRE B BL/BK
C13LED BL/RD
C28TTA RD/BK C1P-2

C29MS RD/WH
B
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
RED/BLK-28
ALALRM
TILT
H1
A RED-TILT RED-TILT
BRN
BRN
BRN BRN
6 - 15
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25

1
PLATFORM
CONTROL
HARNESS
(TO CONTROL BOX)
2
TS47
GENERATOR
(OPTION) JC3
JC2 TS15 GR/WH DRIVE
JC1 BK FORWARD/REVERSE
& TURNTABLE ROTATE
7 SECONDARY BOOM 7 DRIVE
ENABLE
RD
& STEER 7
UP/DOWN LEFT/RIGHT
LEFT/RIGHT
6 6 6 3
5 5 5
RD
BK
GR/WH
4 4 4
TS48
TS13
3 PRIMARY BOOM 3 DRIVE LIGHTS/
WORK LIGHTS
3
EXTEND/ RETRACT (OPTION) 4
2 2 2 NOTE:
DASHED LINES
INDICATE OPTION
1 1 + 1 WIRING
BL J1-5 (ROCKER SWITCH OPTION ONLY)

BK
L1
BK
RD
5
F18
FUSE 10A
C45GEN GR/WH C2P-7

C8PBR BK/WH C3P-8
GENERATOR OPTION
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
CDLITE GR C2P-5
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
BRN J1-12
BRN J1-10
OR J1-11
RD
BK
BRN J1-14
OR J1-13
BL J1-5
WH J1-4
YEL J1-3
BK J1-2
RD J1-1
OR J1-9
6
RD
BK
PDLITE RD
C39LP BL/RD C2P-1
BK
RD-TILT
P23BAT WH C7P-2
P26BAT BK C9P-1
P26BAT BK-LOAD
P22BAT BK C7P-1
P25FS RD C9-3
RD
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C128LS OR/RD C2P-4
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

7
BK BK
WH WH
8
3
2
NO
NC
1
4
DRIVE P2
SPEED EMERGENCY
NC
1
STOP
TS14 TS4 TS3
2
TS2
RD
P3 TS9 WH TS7 TS1 HIGH/LOW ENGINE HIGH/LOW FUEL
HORN PLATFORM (2WD/4WD) START RPM SELECT
RD
PLATFORM AUXILIARY
LEVEL ROTATE
PUMP
WH-24
RD RD

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


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS

LOAD SENSE LIMIT SWITCH

RD-P2
DESCRIPTION
RD-H1
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
M
TILT ALARM
Y
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
R24FS WH C9P-2
L
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
K
OPT.
BRN
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
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
CWLITE RD C2P-11
C3P
F.S.
C45GEN GR/WH C2P-7

H
C128LS OR/RD C2P-4

C9
C39LP BL/RD C2P-1

P26ESTP BK
11
3
1
G
C6TRF WH/RD C3P-6
12V DC BATTERY
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPLY
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
March 2005
Part No. 77809

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
C29MS RD/WH C1P-3

E
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
Platform Box Wiring Diagram, Z-45/25
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
C28TTA RD/BK C1P-2

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
RED/BLK-28
ALARM
TILT
H1
RED-TILT RED-TILT C2P-5
RED LS18
A
BRN
BRN
BRN BRN
6 - 17
1
8

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 2
& TURNTABLE ROTATE SECONDARY BOOM & STEER LEFT/RIGHT
LEFT/RIGHT UP/DOWN TS15
6 6 DRIVE
ENABLE 6
5 5 + 5
RD
BK
GR/WH
L48
4 TS13 4 TILT ALARM LED 4 3
BK
PRIMARY TS48
BOOM
3 EXTEND/ 3 DRIVE LIGHTS/
WORK LIGHTS
3
RETRACT (OPTION)
RD
2 2 2
1 1 + 1

L1 BK 4
DRIVE
BK
RD
ENABLE
LED
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
BL/BK-DE2 J1-7
5
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
RD
RD
BK
BK
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
RD
C33STR BK C1P-7
C35HS 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
6
BK BK 7
WH WH TS3
FUEL
SELECT 2 2 2
3
NO
4
DRIVE P2
SPEED EMERGENCY NC NC NC
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 8
RD
LEVEL WH-24
RD RD RD RD RD RD


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

FOOT SW. HIGH
FOOT SW. LOW C2P-4 C128LRPM OR/RD C2B-4 C128LRPM OR/RD C5-9
TS4
TB42
TS54
ENGINE
SPEED
M
TB35
LOW RPM
FUNCTION ENA.
BL/RD
HIGH RPM
TS47
OFF
GENERATOR GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH OPTION
WH
RD
L
TS48

DRIVE LIGHT
L29
LIGHTS
WORK LIGHT C4B-12 RD DRIVE LIGHT
CR23
OPTION
PBOX
L29
GND
L30
RD
RD
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
WORK LIGHTS
K
OPTION
C2P-11 C2P-9
FB1
L30

OPTION
TS3

LP
TB39
FUEL
GAS C21HM WH
HM
TS53
J
HOUR METER
L2
LP CHECK ENGINE LED

FUEL C108ESL BK/RD
GAS
TB38
ENGINE
CHECK
C35ESPD BK/RD
IGNITION/
MODULE
START
U1
RUN/TEST SWITCH
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
7 KEY POWER
10 ENG. FAULT
I
TS2
C1P-7 C33STR BK C1B-7

6 BATTERY
5 GROUND
4 AUX. ON
TEST
ENGINE
START
TS64
TS52
C5-13
C5-8
C5-9
ENGINE
START WH
TB33
POWER RELAY
H
C127TSW
C108ESL

CR2
BK/RD FEH(658) PIN6

TB25
TB21
GR FEH(458) PIN3
ENGINE HARNESS #2
C28TTA RD/BK

G

BL/WH FEH(787) PIN5
C5-3
M4
BL/WH
PUMP
BK
FUEL
FUEL PUMP
P26ESTP BK
P24FS WH
P25FS RD
F
CR1
M3
TB24
R33STR BK C5-5
March 2005
Part No. 77809

C9P-2
C9P-3
STARTER
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1
PUMP C6-27 C27AUX RD

WH-(FS)
RD-(FS)
AUXILIARY
E
PR1
PUMP
AUX
AUXILIARY PUMP
FS1
C28TTA RD/BK
M2
BK-(FS)

TILT ALARM
H1
C7P-2 P23BAT WH C7B-2 C5-23 P23TTSR WH RD BK BRN

LEVEL SENSOR
C9P-1 BK
D
TB23
S8
HORN
P3
P2
BK C3P-9 C46HRN BK/RD C3B-9 C46HRN BK/RD

HORN RELAY

CR5
TB22

HORN
H2
GRND
PLAT
KS1
C
Electrical Schematic, Z-45/25J
RD
P1
R16
C21IGN WH
500
TB41
RD
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
D1
FLD.
CB2
CB1
15A
15A
GND.
BAT.
FUSE
A
LINK
TB20
-
P20BAT RD C7B-4
12V DC
B2
6 - 19
1
8
1
8
6 - 20
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
TS14
C1P-5 C31REV WH/BK C1B-5 C5-20 C31REV WH/BK RD BK BRN

C28TTA RD/BK

DRIVE MODE
H4
8
C6-33 C32TA WH/RD
TRAVEL ALARM OPTION
L1
B
CDE3 BL/RD
J1
16
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
ROCKER
SWITCH
OPTION
P24FS WH
STEER
7
BL
C
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3

J1
4 5 17 STEER RIGHT
OR
PWR 3 13
BRN C1P-10 C36STCC BL C1B-10 C6-36 C36STCC BL
1 C24-1 C24-2
11
C3P-4 C4TRL WH C3B-4
9
D

TB5
C3P-5 C3B-5
10
C6-5 C5TRR WH/BK
RIGHT TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
TS62
LEFT C6-4 C4TRL WH

R4

10
C14-1 C14-2
TB4
C31-1 C31-2

FLOW CONTROL
TURNTABLE ROTATE
6
TB6
C12-1 C12-2
TB1
YOUT 5 BK
2
C6-1 C1PBU RD
E
RD
JC2
XOUT 4 1
UP PRIMARY BOOM UP
J1
TB2
Y22
PWR 3
OR PRIMARY BOOM
11
Part No. 77809
DOWN C6-2 C2PBD RD/BK

TS61
BRN
J2
GND 2 12 PRIMARY BOOM DOWN

C13-1 C13-2
March 2005
TB3
1
C29-1 C29-2
FLOW CONTROL
6
7
F

8
7
14
SECONDARY BOOM
6
YEL
OUT 5 3
UP/DOWN
13
JC1
4
J1
OR
12
TB10
BRN C18-1 C18-2

GND 2 10
C6-10 C10SBU BL
1 SECONDARY UP
G
P26ESTP BK
UP
BOOM SECONDARY
TS60
JOYSTICK CONTROL CARD
SECONDARY DOWN
BRN
TB11
1 C19-1 C19-2
TB12
C30-1 C30-2
2
FLOW CONTROL
P24FS WH
LS3
J3
4
C4P-4 C16PDRE OR/RD C4B-4 C6-16 BK-6 WH-6 C6-13
3
P26ESTP BK LS3-DRIVE ENABLE
13
14
3
LIMIT SWITCH
LS1

H
4
U13
BK
LS2
21
22
C40LSS OR

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

CE
21
22
C22LS RD
I

EXTEND
BOOM
RETRACT C8PBR BK/WH C3B-8
TS13
C3P-8 C16-1 C16-2

TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
BOOM RETRACT
TB8
C17-1 C17-2
TS9

J
UP
PLATFROM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLAT LEVEL UP
UP
PLATFROM LEVEL
PLAT LEVEL DOWN
TB15
TB44
C21-1 C21-2
GR/BK-44 C2P-6 JDALARM GR/BK C2B-6
CR13
TS8
NC
C4P-6 C18JD GR/BK C4B-6

DOWN
K
JIB BOOM
UP C4P-5 C17JU GR C4B-5
TB18
C23-1 C23-2
TS58
C6-18 C18JD GR/BK JIB BOOM DOWN /
DOWN PLATFORM ROTATE RIGHT
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP /
C22-1 C22-2 PLATFORM ROTATE RIGHT
TB17
RIGHT PLATFORM
C5-25
LEFT ROTATE RIGHT PLATFORM
TS7
LEFT ROTATE
TS57
WH
L
C44DA BK C6-19
H3
C4P-7 C19JSV GR/WH C4B-7
CR13
C19JSV GR/WH
BRN
M
JIB VALVES JIB VALVES

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

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

FOOT SWITCH HIGH
FOOT SWITCH LOW C128LRPM OR/RD C2B-4 C128LRPM OR/RD C5-9
TS4
C2P-4
TB42
ENGINE
SPEED
TS54
TB35
LOW RPM FUNCTION

M
ENABLE
BL/RD
HIGH RPM
TS47
OFF
GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH
GENERATOR OPTION
WH
RD
L
CR23
FUSE 10A (ONLY ON WORKLIGHTS)
TS48

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
WORK LIGHTS OPTION

NO
K
PBOX GND
C2P-11 C2P-9
FB1
C23ALRM RD C6-34 FLASHING BEACONS OPTION

L30

TS3
LP
FUEL
TB39
GAS C21HM WH
HM
HOUR METER
TS53
J
_
L2
LP
FUEL C108ESL BK/RD CHECK ENGINE LED
GAS
TB38
ENGINE
CHECK
C35ESPD BK/RD
IGNITION/
MODULE
START
U1
RUN/TEST SWITCH
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
3 START INPUT
8 KEY BYPASS
10 ENG. FAULT
C1P-7 C33STR BK C1B-7 TEST

7 KEY PWR.
TS2
6 BATTERY
5 GROUND
I
4 AUX. ON
ENGINE ENGINE
START
TS64
START
TS52
C5-13
C5-8
C5-9
ENGINE
START WH
TB33
POWER RELAY
CR2
C127TSW
H
C108ESL

BK/RD FEH(658) PIN6

TB25
TB21
GR FEH(458) PIN3
ENGINE HARNESS #2
CR2
NO

C28TTA RD/BK

G

BL/WH FEH(787) PIN5
C5-3
PUMP M4
CR1
BL/WH BK
FUEL
FUEL PUMP
P26ESTP BK
P24FS WH
P25FS RD
F
M3
TB24
R33STR BK C5-5
March 2005
Part No. 77809

CR1
NO
C9P-2
C9P-3
STARTER
STARTER MOTOR
TS51
TB27
AUXILIARY
TS1
PUMP C6-27 C27AUX RD AUXILIARY POWER RELAY

WH-(FS)
RD-(FS)
AUXILIARY
PR1
E
PUMP
AUX
C28TTA RD/BK AUXILIARY PUMP
PR1
NO
L4
FS1
M2
BK-(FS)

TILT ALARM
RD C2P-5 C134PWR BL/RD C2B-5 C5-23 P23TTSR WH RD BK BRN

LEVEL SENSOR
C9P-1 BK
TB134
HORN
C4B & C4P - BROWN

D
C3B & C3P - GREEN

C2B & C2P - BLACK
S8
P3
C1B & C1P - GRAY

BK C3P-9 C46HRN BK/RD C3B-9
P2
C46HRN BK/RD HORN RELAY

H1
C7P-2 P23BAT WH C7B-2
CR5

TB23
HORN
CR5
TB22
H2
NO
boom in the stowed position and the keyswitch off.

C
1) All switches and contacts are shown with the

GRND
PLAT
KS1
R16
RD
C21IGN WH
P1
500
TB41
RD
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
CB2
15A
CB1
15A
FLD.
GND.
D1
BAT.
FUSE
LINK
A
TB20
NOTE:
+
-
P20BAT RD C7B-4
12V DC
B1
6 - 21
1
8
1
8
6 - 22
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
B

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT DRIVE
RIGHT ENABLE C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3
J1
4 5 17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
9
D
CR33

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
20
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

E
UP C1PBU RD
TB2
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
C6-1
Part No. 77809
BRN
C2PBD RD/BK
TS61
GND 12
J2
2
TB3
1
March 2005

6
7
F
8
7
SECONDARY BOOM
6 14
YEL
OUT 5 3
UP/DOWN

13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10
SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
SECONDARY BOOM
SECONDARY BOOM UP
87a 87
DOWN
30
G
C6-10
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
H
21
22
LS2
C40LSS OR

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

LIFT/
21
22
CE
C22LS BK
EXTEND
BOOM
I

TS13
C16-1 C16-2
TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
BOOM RETRACT
TB8
C17-1 C17-2
TS9
C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
J
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLATFROM LEVEL
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
CR13
NC

DOWN JIB
UP BOOM C4P-5 C17JU GR C4B-5
TS8
TB18
C23-1 C23-2
K
TS58
C6-18 C18JD GR/BK
JIB BOOM DOWN
DOWN
JIB BOOM
UP C6-17 C17 JU GR
PLATFORM ROTATE LEFT AND
C22-1 C22-2 JIB BOOM UP
TB17
TS57
RIGHT PLATFORM
C5-25
LEFT ROTATE RIGHT
PLAT ROTATE
LEFT
TS7
WH
C44DA BK C6-19
H3
L
CR13
C19JSV GR/WH

VALVE

JIB

BRN

BK WH
JIB BOOM VALVE
C41RPM OR/BK
C28TTA RD/BK
M
P26ESTP BK
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
removed after
BK
serial number
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
One valve
C1B & C1P - GRAY

22565
NOTES:
WHEEL.
REV A
N

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

8
7
6
5
4
3
2
1
6 - 23
Genie Industries
1
A
2
3
4
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6

7
9 1 3 4 7 10 9 2
10
B
I.S.M.
12/24V DC IGNITON/START MODULE P/N 56057
TERMINAL BASE (TB)

D C B A
C6-1 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
C6-2 RD/BK BK
C3B
C3B-3 RD/WH
C
NOTE:
C6-4 WH
C3B-4 WH WH-TS62
C6-5 WH/BK
OPTION WIRES
BK

C6-6 WH/RD

C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
DASHED LINES INDICATE

D

C6-10 BL
C3B-10 BL BL-TS60
C6-11 BL/BK BK
I.S.M.
C6-12 BL/WH

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
E

C6-17 GR
C4B-5 GR GR-TS57
C3B
17 PLATFORM ROTATE LEFT/JIB UP 17
C6-18 GR/BK
C7B
18 PLATFORM ROTATE RIGHT/JIB DOWN 18
BK-ALARM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
12V DC TO
20 +12V DC VOLT POWER 20
PLATFORM
WH-TS64 BRN
C5-3 WH WH-HM
Part No. 77809

March 2005
C6-20 RD
C5
C7B
C7B-1 BK BK-R5
22 +12V DC VOLT TO PLATFORM 22
F
C5-23 WH WH-TS64
C7B-2 WH WH-KS
C6-34 RD FB
C6
C6
RD-R2
C4B
C6-16
C6-40
C6-37
C6-36
C6-29
I.S.M.
C7B-3
C5-1 RD RD-CB1
24 CB1 POWER 24
FUNCTIONS
WH-IS10 WH/BK-L2-
25 (UNUSED) 25
WH/RD-L3-
26 (UNUSED) 26
C40LS1 OR
C6-27 RD RD-IS4
G
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
BRN C1B-1 RD RD-TS51
C1B-6 WH/RD
32 BRAKE 32
BK-TS64 BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 ENGINE START 33
C3B

34 (UNUSED) 34
C5-18 BK/RD
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
H
C2B

C5-10 BL/RD
19/18 CABLES
C1B
C2B-3 OR/BK
C4B C3B C2B C1B
C5-9 OR/RD
C1B-2
C2B-7
C1B-5
C1B-4

42 LOW RPM 42
BK-ALARM
I
C3B
C4B
BRN
I.S.M.
RD-24B
C30FWD WH
P20DLITE RD
C43DLITE GR
C125TSW WH
C28TTA RD/BK
C31REV WH/BK
C45 GEN GR/WH
CR1
CR2
START
ENGINE HARNESS
RELAY
RELAY
IGNITION
POWER
FUNCTION HARNESS
RD-IS6
C5-20
C5-21
C5-24
C5-12
BK-IS1
J
C5
BRN
C5-8
C5-11
ENGINE
C5-5 BK
WH-IS9
C3B
C4B
BRN
BK-33B
C21IGN2 WH
C5-3 WH
C127TSW GR
WH-21C
GR
BATGND BRN
WH-23B C23TSW WH
K
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
WH-21C C6-9 BK/RD
C3B-9 BK/RD
WH-IS7
CR23
RELAY
BK-22B
OPTION
C6-13 BK
DRIVE LIGHT
BRN
TS64
BRN
SWITCH
BK-ALARM
L
RUN/TEST
GROUND
BRN-TS
F19
10A
WH/RD-ALARM
CR5
FUSE
HORN
BRN
RELAY
BRN RD
C2B-5 GR
CONTROL HARNESS
RD-20C DRIVE LIGHTS

C4B
OR/BK-IS2 OR/BK-41A
M
GROUND BOLT
RD-IS4 RD-27B
GROUND
BK-IS3 BK-33B
HARNESS
CONTROL

PANEL)
C7B3 BRN
F.H.
E.H.
BRN
BRN
BRN
(TO SWITCH
I.S.M.
BRN BRN
REV A
N
N
REV A
M
L
K
STACKED CONTACTS
KEY SWITCH
P1 3 3
STOP
SWITCH NO NO
J
2
1
NC
RD 4 4
KS1 TS51
2
1
NC
RD RD AUXILIARY POWER
RD
RD-27A RD-27
RD
RD
RD
RD
KS1
3 3
RD RD RD
RD RD
NO NO
I
RD
RD
RD
RD
RD
4 4 BK-22
RD
WH-23A
WH-21
WH-23
H
RD
L2 TS53
BRN + CHECK FUEL
ENGINE SELECT
-
RD
LED
BRN
BL/RD-39A
WH-CR2
BL/WH-38
HOUR METER
G
GROUND CONTROL BOX HARNESS

(TO TERMINAL STRIP)
RD
RD
RD
RD
RD RD RD RD TS63
RD/BK-2A PRIMARY BOOM
EXTEND/RETRACT
F
R4 RD/WH-3A RD RD
FUNCTION SPEED RD RD
CONTROL VARIABLE
TS61
RESISTER
RD PRIMARY
RD
RD
BOOM
BK-7
RD-1A
UP/DOWN
RD
RD
RD
RD RD RD BK-7A
BK/WH-8
March 2005
BK/WH-8A
Part No. 77809
E
RD
RD
RD
RD
RD RD RD RD
WH/BK-5A WH/BK-5
TS60
RD
RD
SECONDARY WH-4A WH-4

WH/RD-6A WH/RD-6
RD
BOOM UP/DOWN
BL/WH-12A
D
TS58
RD
RD
RD
RD RD JIB BOOM
BL/BK-11A
TS52 RD TS62
GR/BK-44A
ENGINE BL-10A TURNTABLE
RD
RD
RD
START ROTATE
RD
GR/BK
RD
BK-33A
RD
GR
RD
RD RD RD RD RD
RD RD RD
C
RD
GR
RD
GR/BK
RD
GR/BK
CB1 RD
CIRCUIT
B
RD

RD
RD
RD
BREAKER
ENGINE, 15A RD RD GR-17A GR-17
RD
GR/BK
OR/BK-15A TS57
RD-24A RD-20B RD PLATFORM
ROTATE
OR-14A GR
RD-20A CB2
TS54 TS59
BK/RD-35A CIRCUIT BREAKER PLATFORM RD RD
FUNCTION
CONTROLS, 15A LEVEL
ENABLE
GR/BK-18A GR/BK-18
A
OR/RD-42A
6 - 24
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 25
30
85
86
Genie Industries
87A
1
OR/BK-41A
87
A
3
4
BRN-IS5 5 GROUND
5
87 = NO
87A = NC
RD-CR1 6 BATTERY
6

7
9 1 3 4 7 10 9 2
86 = COIL POSITIVE
85 = COIL NEGATIVE
10

B
I.S.M.

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
BK
C3B
C3B-3 RD/WH
C
4 4
CR33 #86 WH/BK
BK

C3B-6 WH/RD
CR33 #30 WH/RD WH/RD-TS62
C6-7 BK

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

C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
C4B-5 GR GR-TS57
E
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
WH-TS64 BRN
C5-3 WH WH-HM
C6-20 BK
C5
C7B
Part No. 77809

March 2005
C7B-1 BK BK-R5
WH-TS64
C7B-2 WH WH-KS
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
C5-1 RD RD-CB1
24 CB1 POWER 24
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
25 (UNUSED) 25
WH/RD-L3-
26 (UNUSED) 26
C4B
C40LS1 OR
C6-27 RD RD-IS4
C36STCC BL
C1B-1 RD RD-TS51
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
BRN
C1B-6 WH/RD
32 BRAKE 32
G
BK-TS64 BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 START ENGINE 33
C3B

34 (UNUSED) 34
C5-18 BK/RD
C2B-2
C1B-3
C1B-11
C5
35 HIGH RPM 35
C2B

C5-10 BL/RD
19/18 CABLES
C1B
C2B-3 OR/BK
H

C4B C3B C2B C1B

C5-9 OR/RD
C1B-2
C2B-7
C1B-5
C1B-4

42 LOW RPM 42
BK-ALARM
C3B
BRN
I.S.M.
C125TSW WH
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
C45 GEN GR/WH

ENGINE HARNESS
I
C2B-5 GR
C43DLITE
RD-24B
CR1
CR2
START
RELAY
RELAY
POWER
IGNITION
RD-IS6
P20DLITE RD
CR23
BK-IS1
DRIVE LIGHT
OPTION RELAY
BRN
C5-20
C5-21
C5-24
C5-12
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-3 WH
C5-11
ENGINE
BK-33B
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
C5-8 C127TSW
F19
GR
10A FUSE
C21IGN2 WH
RD
WH-23B C23TSW WH
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
WH-21C C6-2 RD/BK
C3B-9 BK/RD
CR37
BOOM
CR33
RELAY
RELAY
WH-IS7 C6-9 BK/RD

CR32
ROTATE
BOOM
RELAY
BRN
PRIMARY
SECONDARY
TURNTABLE
87
87
87
CR5
TS64
HORN
RELAY
SWITCH
BK-22B
87A
87A
87A
C6-13 BK
L
BK-ALARM
RUN/TEST
85
85
85
86
86
86
BRN-TS
WH/RD-ALARM
30
30
30
BRN
BRN
BRN
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B GROUND CONTROL
C7B3 BRN
HARNESS
BK-IS3 BK-33B (TO SWITCH PANEL)
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

EXTEND/RETRACT
TURNTABLE
LABEL DESCRIPTION
PRIMARY BOOM
PLATFORM
ROTATE
ROTATE
TS62
CB2 CIRCUIT BREAKER, CONTROLS, 15A RD RD GR/BK
TS57
CR1 IGNITION / START RELAY
CR2 INGITION POWER RELAY
TS63
BK/WH-8 RD
CR5 HORN RELAY RD RD RD
HM HOUR METER BK-7
KS1 KEY SWITCH
RD
GR/BK-18
C19JSV GR/WH
L2
P1
CHECK ENGINE LED
RED EMERGENCY STOP BUTTON
2
RD
RD
RD RD
GR
RD
RD RD
GR/BK
WH/RD-6
GR-17
WH/BK-5
RD
RD
WH-4
AUXILIARY
RD RD
SWITCH
TS53 FUEL SELECT TOGGLE SWITCH
RD
TS51
RD RD RD RD RD
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
UP/DOWN
GR/BK GR/BK
PRIMARY
RD RD
BOOM
RD-27
RD
RD
RD
3
GR
RD
TS61
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH GR GR
RD
PLATFORM
LEVEL
TS64 RUN/TEST TOGGLE SWITCH
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
RD/BK-2A
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
UP/DOWN BL/WH-12A
BL/BK-11A
RD
BL-10A
ENGINE
CHECK
KS1
RD
LED
SECONDARY
RD
L2
CONTROLS 15A
BREAKER
5
CIRCUIT
BOOM
CB2
TS60
WH-23
+
-
RD RD
RD
RD
RD RD
RD RD
RD
RD-20B
RD
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
BK/RD-35A
RD
RD
RD
7
ENGINE 15A
BRN
BREAKER
CIRCUIT
ENGINE
START
CB1
TS52
WH-21
BRN
RD-20A
CONTROL VARIABLE
FUNCTION SPEED
RD
RESISTER
STOP SWITCH
RD
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
ENABLE
RD
TS54
RD
RD RD RD


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

N
REV A
(TO SWITCH PANEL)
NOTE: DASHED LINES INDICATE OPTION WIRING

PLATFORM
CONTROL
HARNESS
M
WHT
C19JSV BLK
R24FS WH C9P-2
CR27
L
JIB
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
K
OPT.
BRN
C40LSS OR C2P-2
CR30
C40LSS OR J2-4
P24FS WH C9P-2
J
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
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 C2P-5
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P
F.S.
JIB
H
C45GEN GR/WH C2P-7

SWITCH
FOOT
C44JDALARM GR/BK C2P-6

C128LS OR/RD C2P-4
C9
C39LP BL/RD C2P-1

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

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
JIB
March 2005
Part No. 77809

C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C4TRL WH C3P-4
C5TRR WH/BK C3P-5
ALC-500
U13
19/18 CONTROL CABLE

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
* WIRE CONNECTS TO JC3-6
C1P
9
JC1-3 OR

JC2-4 RD
FOR STEER ROCKER
JC1-2 BRN
JC2-5 BK
SWITCH OPTION. C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
DRE B BL/BK
C13LED BL/RD
C28TTA RD/BK C1P-2

C29MS RD/WH
B
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
RED/BLK-28
ALALRM
TILT
H1
JIB
A RED-TILT RED-TILT
BRN
BRN
BRN BRN
6 - 27
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J

1
PLATFORM
CONTROL
HARNESS
(TO CONTROL BOX)
2
TS47
GENERATOR
(OPTION) JC3
JC2 TS15 GR/WH DRIVE
JC1 BK FORWARD/REVERSE
& TURNTABLE ROTATE
7 SECONDARY BOOM 7 DRIVE
ENABLE
RD
& STEER 7
UP/DOWN LEFT/RIGHT
LEFT/RIGHT
6 6 6 3
5 5 5
RD
BK
GR/WH
4 4 4
TS48
TS13
WORK LIGHTS
3
EXTEND/ RETRACT (OPTION) 4
2 2 2 NOTE:
DASHED LINES
CR13 INDICATE OPTION
1 1 + 1 WIRING

BK
L1
BK
RD
F18 5
FUSE 10A
C45GEN GR/WH C2P-7

C8PBR BK/WH C3P-8
GENERATOR OPTION
CWLITE RD C2P-12
CWLITE RD C2P-11
C7PBE BK C3P-7
CDLITE GR C2P-5
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
BRN J1-12
BRN J1-10
OR J1-11
RD
BK
BRN J1-14
OR J1-13
BL J1-5
WH J1-4
YEL J1-3
BK J1-2
RD J1-1
OR J1-9
WH-JIB
BRN
RD
BK
PDLITE RD
C39LP BL/RD C2P-1
BK
RD-TILT
P23BAT WH C7P-2
P26BAT BK C9P-1
P26BAT BK-LOAD
P22BAT BK C7P-1
P25FS RD C9-3
RD
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C128LS OR/RD C2P-4
GR/BK-44 C2P-6
WH-JIB
C19JSV GR/WH
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

P24FS WH
BK BK
WH WH
TS8
GR JIB
3
2
NO
NC
1
4
BOOM DRIVE P2 8
SPEED EMERGENCY
NC
1
STOP
TS14 TS4 TS3
2
TS2
RD
P3 TS9 WH
TS1 HIGH/LOW ENGINE HIGH/LOW FUEL
HORN GR/BK (2WD/4WD) START RPM SELECT
TS7
RD
PLATFORM AUXILIARY
LEVEL PLATFORM PUMP
ROTATE WH-24
RD RD

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


N
REV A

PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


RD-P2
DESCRIPTION
RD-H1
M
TILT ALARM
Y
C19JSV WH
C1P - C4P
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
R24FS WH C9P-2
OPT.
L
CR27
JIB
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
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
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
CWLITE RD C2P-11
C3P
F.S.
JIB
C45GEN GR/WH C2P-7

H

C128LS OR/RD C2P-4
C9
C39LP BL/RD C2P-1

P26ESTP BK
11
3
1
G
C6TRF WH/RD C3P-6
12V DC BATTERY
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 JIB BK
C2P
C3P
C4P
C7P
March 2005
Part No. 77809

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
C29MS RD/WH C1P-3

E
J2
C3P(GR)
C35HS BK/RD C1P-9
C33STR BK C1P-7
C2P(BK)
C27AUX RD C1P-1
D
J1
C1P
9
JC1-3 OR

JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
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
JIB BK
B
RED/BLK-28
ALARM
TILT
H1
RED LS18
A
BRN
BRN
BRN BRN
6 - 29
1
8

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 2
& TURNTABLE ROTATE SECONDARY BOOM & STEER LEFT/RIGHT
LEFT/RIGHT UP/DOWN TS15
6 6 DRIVE
ENABLE 6
5 5 + 5
RD
BK
GR/WH
L48
4 TS13 4 TILT ALARM LED 4 3
BK
PRIMARY TS48
BOOM
3 EXTEND/ 3 DRIVE LIGHTS/
WORK LIGHTS
3
RETRACT (OPTION)
RD
2 CR13
2 2
JIB BOOM
1 RELAY
1 + 1
L1 BK 4
DRIVE
BK
RD
ENABLE
LED
RD
F18
FUSE 10A
C45GEN GR/WH C2P-7

BK
C8PBR BK/WH C3P-8
GENERATOR OPTION
CWLITE RD C2P-11
CWLITE RD C2P-12
BL/RD-DE3 J1-16
C7PBE BK C3P-7
CDLITE GR
BL/BK-DE2 J1-7

BL-DE1 J1-6
RD/BK H1
WH-JIB
BRN
BK
RD
RD
BK
BRN J1-14
BRN J1-12
BRN J1-10
YEL J1-3
WH J1-4
OR J1-13
OR J1-11
OR J1-9
RD J1-1
BK J1-2
BL J1-5
RD
BK
6
WH-JIB
RD LS18
BK C7P-1
P24FS WH
PDLITE RD
BK J3-3
BK C9P-1
WH C7P-2
C19JSV GR/WH
P25FS RD C9-3
P24FS WH C9-2
C27AUX RD C1P-1
C33STR BK C1P-7
C17PRL GR C4P-5
C14PLU OR C4P-2
GR/BK-44 C2P-6
C29MS RD/WH J1-8
C39LP BL/RD C2P-1

C9HRN BK/RD C3P-9
C35HS BK/RD C1P-9

C19JSV GR/WH C4P-7
C128LS OR/RD C2P-4

C15PLD OR/BK C4P-3
C18PRR GR/BK C4P-6
BK BK 7
WH WH TS3
FUEL
SELECT 2 2 2
GR
3
NO
4
DRIVE P2
SPEED EMERGENCY NC NC NC
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 8
RD
LEVEL WH-24
RD RD RD RD RD RD


N
REV A
BRN
RD
RD
RD
P24FS WH
C41RPM OR/BK
P26ESTP BK
C28TTA RD/BK
C1P-9 C35HS BK/RD C1B-9

FOOTSW. HIGH
TS4
ENGINE
SPEED
CR4
TS54
LOW RPM
M
FUNCTION ENABLE
HIGH RPM C35HS BK/RD BRN
HIGH IDLE RELAY
BK/RD
BK/RD C5-18
HIGH RPM SOLENOID
Q3
TS47
GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C45GEN GR/WH C5-12
L
GENERATOR
OPTION
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A
WORK LIGHT C6-39 RD DRIVE LIGHT

OPTION
L29
RD
RD
L30
FUSE 10A
K
C6-38 RD
C2P-12 C2P-10
WORK LIGHTS
OPTION
PBOX GND
C2P-11 C2P-9
FB1

L30
OPTION
PR3
J
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22

ON
GLOW PLUG
U32
TS56
GLOW PLUG OPTION

ON
GLOW PLUG
C26TSR WH/RD OIL TEMPERATURE LED
I
PRESS
L42
TEMP.
L43
OIL
OIL
C25PSR WH/BK OIL PRESSURE LED

IGNITION/
MODULE
START
U1
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
3 START INPUT
8 KEY BYPASS
7 KEY POWER
10 ENG. FAULT
TS2
6 BATTERY
C33STR BK
5 GROUND
C1P-7 C1B-7 C5-14 OIL TEMPERATURE

4 AUX. ON
ENGINE SWITCH
TS52
H
TB25
START
ENGINE C5-16 OIL PRESSURE
START SWITCH
SW2
NC
BK
TB33
CR2
POWER RELAY
TB21
G
C28TTA RD/BK
C21IGN2 WH C5-11
FUEL SOLENOID
C21IGN WH
HM
HOUR METER
CR1
_
P26ESTP BK
F
P24FS WH
P25FS RD
M3
TB24
March 2005
Part No. 77809

R33STR BK C5-5
PR2
STARTER
STARTER MOTOR
C9P-3
C9P-2
TS51
TS1
TB27
AUXILIARY
AUXILIARY POWER RD-27-E.H.
C28TTA RD/BK
POWER RD C6-27 AUXILIARY POWER

E
C1P-1 C27AUX RD RELAY
M2
PR1
WH-(FS)
RD-(FS)
PUMP
AUX
AUXILIARY PUMP
FS1
B
RD C1P-2 C28TTA RD/BK C5-24 C28TTA RD/BK WH
TILT ALARM
H1
BK-(FS)
Deutz F3L-1011F Models (before serial number 22050)
C7P-2 P23BAT WH C5-23 C23TTSR WH RD BK BRN

LEVEL SENSOR
C
A
S8
D
TB23
C9P-1 BK
CR5
HORN
P3

P2
BK C3P-9 C46HRN BK/RD C3B-9 C46HRN BK/RD HORN RELAY

TB22
C7P-1 P22BAT BK C7B-1 P22BAT BK C5-12
HORN
H2
C5-3
C
KS1
PLAT
GRD
C21IGN WH
P20BAT RD
C41RPM OR/BK
RD
P1
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
EXCT.
C21IGN WH
STA.
BAT.
IND.
RD
-
RD
ALTERNATOR
REGULATOR
CB2
CB1
15A
15A
BAT.
+
A
D1
TB20
-
RD C7B-4 P20BAT RD
12 V
DC
B2
6 - 31
1
8
6 - 32
C7P-3 BATGND C7B-3

GROUND
A
C41RPM OR/BK
C2P-3
U4
5
C31REV WH/BK
TS14

DRIVE EDC REVERSE
C28TTA RD/BK
16
DRIVE MODE
8
H4
B
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION

L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
ROCKER
SWITCH
OPTION
P24FS WH
STEER
C
7
BL
RKOUT 6
DRIVE & STEER
WH C25-1 C25-2
YOUT 5 4
JC3
J1
XOUT 4 5 17 STEER RIGHT

OR
PWR 3 13
C1P-10 C1B-10 C6-36
1 C24-1 C24-2
11
D

9
TB5
C3P-5 C3B-5
10
C6-5 C5TRR WH/BK TURNTABLE ROTATE RIGHT
RIGHT
TURNTABLE ROTATE
LEFT C6-4 C4TRL WH
TS62
R4
10
C14-1 C14-2
TB4
C31-1 C31-2

FLOW CONTROL
TURNTABLE ROTATE
6
TB6
C12-1 C12-2
E
TB1
BK
YOUT 5 2
RD C6-1 C1PBU RD
PRIMARY BOOM UP
JC2
XOUT 4
Part No. 77809
1
UP
TB2
Y22
J1
OR PRIMARY BOOM
BRN DOWN
PRIMARY BOOM DOWN
March 2005
TS61
GND 2 12
J2
C13-1 C13-2
TB3
1
C29-1 C29-2
FLOW CONTROL
6
F
7
8
7
SECONDARY BOOM
6 14
YEL
OUT 5 3
UP/DOWN
13
JC1
4
J1
OR
BRN 12
TB10
C18-1 C18-2
GND 2 10
G
C6-10 C10SBU BL
1 SECONDARY BOOM UP
P26ESTP BK
UP
BOOM SECONDARY
SECONDARY BOOM DOWN
BRN
TS60
TB11
1 C19-1 C19-2
TB12
C30-1 C30-2
2
FLOW CONTROL
P24FS WH
LS3
J3
4
3
13
14
3
H

LS1
4
BK
21
22
LS2
C40LSS OR

DRIVE LIMIT SWITCH
21
22
LS4
CR30
OPTION
CR27
NC

NO
DRIVE
LIFT/
DRIVE LIMIT SWITCH

21
22
CE
I
C22LS RD
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
UP
PLATFROM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLATFROM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
WH
K

RIGHT PLATFORM
TS7
TB18
C4P-5 C23-1 C23-2
C6-18 C18JD GR/BK
TS57
RIGHT
PLATFORM ROTATE
LEFT C6-17 C17 JU GR
PLATFORM ROTATE LEFT
C22-1 C22-2
TB17
C5-25
L
C44DA BK C6-19
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
BRN
RD
RD
RD
REV A
N

Electrical Schematic, Z-45/25 REV A

Deutz F3L-1011F Models (after serial number 22049)
A B C D E F G H I J K L M N
C28TTA RD/BK C28TTA RD/BK

1
C41RPM OR/BK C41RPM OR/BK
P26ESTP BK P26ESTP BK
P2
C9P-1 BK BK-(FS) RD-(FS) C9P-3 P25FS RD
WH-(FS) C9P-2 P24FS WH P24FS WH
FS1
BK/RD
C7P-1
FUSE 10A (ONLY FOR WORKLIGHTS)
C2P-5
TS4
2 TS2
TS6
TS48 TS47
C1P-12
RD
P22BAT BK
TS1 ENGINE
FOOT SWITCH HIGH

RD
6
BK
ON
RD
SPEED
START
ENGINE
C134PWR BL/RD
ON
DRIVE LIGHT
WORK LIGHT
C132PLI BL/WH
PUMP
AUXILARY
GENERATOR
L48
P3
H1
GLOW PLUG
HORN
C2P-11
C2P-12
D40 5
C28TTA RD/BK
C7B-1
LIGHTS
C3P-9
C4P-1
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
C2P-5
C2P-7
C1P-9
C1B-12
C2B-5
3 CB2
15A
TB134 L30 L30
BK
P1
RD RD
RD
RD
C133PLA
C46HRN BK/RD
C28TTA RD/BK
TB22 1 3
TS51
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
C43DLITE GR
C45GEN GR/WH
C35HS BK/RD
C33STR BK
KS1 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
START
D3
ENGINE
C32
PUMP
ON
LOW RPM
HIGH RPM
AUXILIARY
GRD
6 7
PLUG
GLOW
12 8
4 D4
C1B-7
BK
C1B-1
PBOX GND
ENABLE
C3B-9
C4B-1
C1B-2
RD
FUNCTION
C7B-2
C2B-3
C1B-9
TB27
TB33
C2B-5
C2B-7
D2
RD
TB23
C1B-8
TB41 1 START RELAY
CB1 2 TACHOMETER
15A 3 START INPUT
4 AUX. ON U1 L42
TB20 TB24 5 GROUND IGNITION/ OIL TB34
RD
6 BATTERY START PRES.
+ 7 KEY PWR. MODULE
5 C3 CR1
8 KEY BYPASS
L43
C5-24
3MF CR1 9 IGN./FUEL ON

CR2 10 ENG. FAULT OIL
NO CR2 TEMP.
NO
C7B-4
P20BAT RD
C35HS BK/RD
C21IGN WH C5-3 TB21
C23 ALARM RD
C45GEN GR/WH
C34SA BK/WH
C25PSR WH/BK
C26TSR WH/RD
C6-34
P22BAT BK
C46HRN BK/RD
C23TTSR WH
C28TTA RD/BK
C27AUX RD
R33STR BK
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
FUSE
P20BAT RD
C21IGN WH
10A
6 TB25
CR23
CR23
CR4
NO
C5-5
CR5 TB26 NO CR4

NO
BK/RD
ALTERNATOR A B
C5-2
D1 FB1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
BAT. BAT. PR1 PR2
C6-9
B1 + - PR1 PR2
C5-18
12V DC S8 NO NO PR3
NO PR3
RD
RD
+
STA.
7 STARTER M3 +
SW2
NC
H2 AUX
M2 HM
BK
PUMP
REGULATOR _ SW3 U32
BRN
- IND. C NO L29 L29 Q3
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR
FLASHING BEACONS OPTION

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

AUXILIARY PUMP
GLOW PLUG OPTION

NOTE:
8
1. All switches and contacts are shown with the boom
in the stowed position and the keyswitch off.
4 CE and Platform Overload Option C1B & C1P = GRAY
5 Add D40 only if unit has L4 and L48. C2B & C2P = BLACK
C3B & C3P = GREEN
6 ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN


6 - 34
1
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
B
L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
BL
C
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3
J1
4 5 17 STEER RIGHT
OR
PWR 3 13
C1P-10 C1B-10 C6-36
1 C24-1 C24-2
11
9
CR33
D

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
10
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

UP C1PBU RD
E
TB2
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
BRN
C6-1
C2PBD RD/BK
Part No. 77809
TS61
GND 2 12
J2
TB3
1
March 2005

6
7
8
F
7
SECONDARY BOOM
6 14
YEL
UP/DOWN
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10 SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
BOOM SECONDARY
SECONDARY BOOM UP
87a 87
DOWN
30
C6-10
G
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
21
22
H
LS2
C40LSS OR

DRIVE LIMIT SWITCH
21
22
LS4
OPTION
CR30
CR27
DRIVE
NO

NC
LIFT/
DRIVE LIMIT SWITCH

CE
21
22
C22LS BK
EXTEND
BOOM
I

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

RIGHT PLATFORM
TS7
TB18
C4P-5 C23-1 C23-2
C6-18 C18JD GR/BK PLATFORM ROTATE RIGHT AND
TS57
K
JIB BOOM DOWN

RIGHT
PLAT ROTATE
JIB BOOM UP
C22-1 C22-2
TB17
C5-25
C44DA BK C6-19
H3
L


C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
M
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
BK
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
C1B & C1P - GRAY
NOTES:
WHEEL.
REV A
N

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


1
P2
FS1
BK/RD
C7P-1
4
C2P-5
C1P-12
TS4
2 TS2
TS6
TS48 TS47
RD
P22BAT BK
LS18 L4 TS1 ENGINE
FOOT SWITCH HIGH

RD
BK
ON
RD
SPEED
START
ENGINE
C134PWR BL/RD
ON
DRIVE LIGHT
WORK LIGHT
C132PLI BL/WH
PUMP
AUXILARY
GENERATOR
P3
H1
GLOW PLUG
HORN
C2P-11
C2P-12
D40 5
C28TTA RD/BK
C7B-1
D39
LIGHTS
C3P-9
C4P-1
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
C2P-5
C2P-7
C1P-9
C1B-12
C2B-5
3 CB2
15A
TB134 L30 L30
BK
P1
RD RD
RD
RD
C133PLA
C46HRN BK/RD
C28TTA RD/BK
TB22 1 3
TS51
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
C43DLITE GR
C45GEN GR/WH
C35HS BK/RD
C33STR BK
KS1 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
U32
START
D3
ENGINE
PUMP
ON
LOW RPM
HIGH RPM
AUXILIARY
GRD PLAT.
6 OVER 7
LOAD
PLUG
GLOW
12 8
4 D4
C1B-7
BK
C1B-1
PBOX GND
ENABLE
C3B-9
C4B-1
C1B-2
RD
FUNCTION
C7B-2
C2B-3
H6 L45
C1B-9
TB27
TB33
C2B-5
C2B-7
D2
RD
TB23
C1B-8
TB41 1 START RELAY
CB1 2 TACHOMETER
15A 3 START INPUT
4 AUX. ON U1 L42
RD
+ 7 KEY PWR. MODULE
5 C3 CR1
8 KEY BYPASS
L43
C5-24

NO CR2 TEMP.
NO
C7B-4
P20BAT RD
C35HS BK/RD
C21IGN WH C5-3 TB21
C23 ALARM RD
C45GEN GR/WH
C34SA BK/WH
C25PSR WH/BK
C26TSR WH/RD
C6-34
P22BAT BK
C46HRN BK/RD
C23TTSR WH
C28TTA RD/BK
C27AUX RD
R33STR BK
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
FUSE
P20BAT RD
C21IGN WH
10A
6 TB25
CR23
CR23
CR4
NO
C5-5
CR5 TB26 NO CR4

NO
BK/RD
ALTERNATOR A B
C5-2
D1 FB1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
BAT. BAT. PR1 PR2
C6-9
B1 + - PR1 PR2
C5-18
12V DC S8 NO NO PR3
NO PR3
RD
RD
+
STA.
7 STARTER M3 +
SW2
NC
H2 AUX
M2 HM
BK
PUMP
REGULATOR _ SW3 U32
BRN
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

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

AUXILIARY PUMP
GLOW PLUG OPTION

8 NOTE:
in the stowed position and the keyswitch off. C1B & C1P = GRAY
4 CE and Platform Overload Option C2B & C2P = BLACK
5 Add D40 only if unit has L4 and L48. C3B & C3P = GREEN
C4B & C4P = BROWN

Electrical Schematic, Z-45/25, CE Models

6 - 36
1
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
B
L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
BL
C
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3
J1
4 5 17 STEER RIGHT
OR
PWR 3 13
C1P-10 C1B-10 C6-36
1 C24-1 C24-2
11
9
CR33
D

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
10
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

UP C1PBU RD
E
TB2
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
BRN
C6-1
C2PBD RD/BK
Part No. 77809
TS61
GND 2 12
J2
TB3
1
March 2005

6
7
8
F
7
SECONDARY BOOM
6 14
YEL
UP/DOWN
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10 SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
BOOM SECONDARY
SECONDARY BOOM UP
87a 87
DOWN
30
C6-10
G
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
21
22
H
LS2
C40LSS OR

DRIVE LIMIT SWITCH
21
22
LS4
OPTION
CR30
CR27
DRIVE
NO

NC
LIFT/
DRIVE LIMIT SWITCH

CE
21
22
C22LS BK
EXTEND
BOOM
I

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

RIGHT PLATFORM
TS7
TB18
C4P-5 C23-1 C23-2
TS57
K
JIB BOOM DOWN

RIGHT
PLAT ROTATE
JIB BOOM UP
C22-1 C22-2
TB17
C5-25
C44DA BK C6-19
H3
L


C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
M
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
BK
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
C1B & C1P - GRAY
NOTES:
WHEEL.
REV A
N
Electrical Schematic, Z-45/25, CE Models


8
7
6
5
4
3
2
1
6 - 37
Genie Industries
1
A
2
3
4
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
WH-23B 7 TO KEY SW (DIESEL ONLY)

7
NOTE:
9 1 3 4 7 10 9 2
10
B
I.S.M.
TERMINAL BASE (TB)

D C B A
C6-1 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
C6-2 RD/BK BK
C3B
C3B-3 RD/WH
C

C6-4 WH
C3B-4 WH WH-TS62
C6-5 WH/BK
BK
DASHED LINES INDICATE OPTION WIRING

C6-6 WH/RD

C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
D

C6-10 BL
C3B-10 BL BL-TS60
C6-11 BL/BK BK
I.S.M.
C6-12 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
E

C6-17 GR
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
C7B
BK-ALARM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
12V DC TO
PLATFORM

WH-R2 BRN
C5-3 WH WH-HM
Part No. 77809

March 2005
C6-20 RD
C5
C7B
C7B-1 BK BK-R5
F
C5-23 WH WH-IS7
C7B-2 WH WH-KS
C6-34 RD FB
C6
C6
RD-R2
C4B
C6-16
C6-40
C6-37
C6-36
C6-29
I.S.M.
C7B-3
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
FUNCTIONS
WH-IS10 WH/BK-L2-
25 OIL PRESSURE SWITCH 25
C5-14 WH/RD
WH/RD-L3-
26 OIL TEMPERATURE SWITCH 26
C40LS1 OR
C6-27 RD RD-IS4
G
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C1B-1 RD RD-TS51
BRN 27 AUXILIARY PUMP 27
C1B-6 WH/RD
32 BRAKE 32
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 ENGINE START 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
H
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
C2B-3 OR/BK
C4B C3B C2B C1B
OR/RD-CR3
C1B-2
C2B-7
C1B-5
C1B-4

42 LOW RPM 42
BK-ALARM
44 JIB BOOM DOWN DESCENT ALARM 44
I
C3B
C4B
BRN
I.S.M.
RD-24B
C30FWD WH
P20DLITE RD
C43DLITE GR
C28TTA RD/BK
C31REV WH/BK
CR1
C45 GEN GR/WH

RELAY HARNESS
IGNITION
WH
ENGINE HARNESS
CR2
RELAY
POWER
START RELAY
FUNCTION HARNESS
RD-IS6
CR4
RELAY
HIGH RPM
SOLENOID
C5-20
C5-21
C5-24
C5-12
BK-IS1
J
C5
WH
ENGINE
C5-5 BK BRN BRN

WH-IS9
C3B
C4B
BRN
C5-18 BK/RD
C5-11 WH
BK/RD-35C
WH-21C
BRN
BATGND BRN
K
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
C6-9 BK/RD
C3B-9 BK/RD
BK-22B
CR23
RELAY
C6-13 BK
BRN
OPTION
BRN
DRIVE LIGHT
BRN
BK-ALARM
L
F19
WH/RD-ALARM
10A FUSE
CR5
HORN
RELAY
BRN
BRN RD
C2B-5 GR
RD-20C DRIVE LIGHTS
GROUNDCONTROL HARNESS

C4B
OR/BK-IS2 OR/BK-41A
WH-IS7 WH-23B
M
GROUND BOLT
RD-IS4 RD-27B
BK-IS3 BK-33B
GROUND
HARNESS
CONTROL

PANEL)
(TO SWITCH
C7B3 BRN
F.H.
E.H.
BRN
BRN
BRN
I.S.M.
BRN BRN
REV A
N
N
REV A
M
L
K
STACKED CONTACTS
J
P1 3 3
STOP
SWITCH NO NO TS51
AUXILIARY
2
1
NC
POWER
RD
4 4
KS1
2
1
NC
KEY SWITCH RD
RD
RD-27A RD-27
RD
RD
RD
KS1
I
3 3
RD
RD
NO NO
RD
RD
RD
RD

4 4 BK-22
RD
WH-23A
WH-21
H
WH-23
BRN +
WH-23
L2
-
RD
OIL
PRESSURE
WH-CR4
LED WH/BK-25
HOUR METER
G
BASE BOX HARNESS

(TO TERMINAL STRIP)
WH-23
RD
RD RD RD
F
RD/BK-2A TS63
RD PRIMARY BOOM
R4 RD/WH-3A RD EXTEND/RETRACT
FUNCTION SPEED + OIL TEMP RD
CONTROL VARIABLE L3
- LED
RESISTER TS61
RD PRIMARY
RD
RD
BOOM
BK-7
RD-1A
March 2005
RD
BK-7A UP/DOWN
RD
BK/WH-8
Part No. 77809
BK/WH-8A
WH/RD-26A
E
RD
RD
RD
RD
RD RD
WH/BK-5A WH/BK-5
WH-4A WH-4
BK/WH-34A WH/RD-6A WH/RD-6
RD
D
RD BL/WH-12A
RD
RD
RD RD TS62
BL/BK-11A TURNTABLE
TS52 RD ROTATE
ENGINE BL-10A
START
RD
TS56 BK-33A TS60

RD
GLOW PLUG SECONDARY RD

(OPTION) BOOM UP/DOWN RD RD
RD
C
RD

RD

B
RD
RD
RD
CB1 RD GR-17A GR-17

CIRCUIT BREAKER
RD
ENGINE, 15A OR/BK-15A

RD-24A RD-20B RD TS57
PLATFORM
OR-14A
ROTATE
TS54 RD-20A CB2 TS59
FUNCTION BK/RD-35A CIRCUIT BREAKER PLATFORM RD
ENABLE CONTROLS, 15A LEVEL
GR/BK-18A GR/BK-18
A
6 - 38
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 39
30
Genie Industries 4 5 6 7
85
86
BK-R1
87A
1 TO REMOVE: 1 START RELAY
A
OR/BK-41A
87
BK-33B C32
3 and lift 3 START INPUT
4 1 3 4 5 6 7 8 12
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
7
RD H6
87 = NO
BK 22B
BK C7-1
87A = NC
RD TS51
RD TS52
BRN GND
GR/BK H6

9 1 3 4 7 10 9 2
BK/WH C1-12
10
B
86 = COIL POSITIVE
85 = COIL NEGATIVE
I.S.M.

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C23-1 BK
C3B
RD 134B C3B-3 RD/WH
C

H6
4 4
GR/BK C23-8 CR33 #86 WH/BK
BK

GR/BK L45 C3B-6 WH/RD
GR/BK C4B-1 CR33 #30 WH/RD WH/RD-TS62

(CE option only)
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
CR37 #86 BL
D
C3B-10 BL BL-TS60
BK
I.S.M.
CR37 #30 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
E
C4B-5 GR GR-TS57
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
WH-R2 BRN
C5-3 WH WH-HM
C6-20 BK
C5
Part No. 77809

March 2005
C7B
C7B-1 BK BK-R5
WH-IS7
C7B-2 WH WH-KS
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
C40LS1 OR
C4B C6-27 RD RD-IS4
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C1B-1 RD RD-TS51
C16DRE OR/RD
BRN
C1B-6 WH/RD
32 BRAKE 32
G
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 START ENGINE 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C5
35 HIGH RPM 35
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
+
C2B-3 OR/BK C3 BRN

H

C4B C3B C2B C1B

C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 LOW RPM 42
C2B-6 GR/BK
44 44
C3B
BRN
I.S.M.
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD RD H6
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
ENGINE HARNESS
C45 GEN GR/WH

I
C2B-5 GR
C43DLITE
RD-24B
IGNITION POWER HIGH RPM DRIVE LIGHT
START RELAY RELAY SOLENOID RELAY OPTION RELAY
RELAY
RD-IS6 WH
CR4
P20DLITE RD
30
30
30
30
86
86
86
86
BK-IS1
85
85
85
85
87A
87A
87A
87A
87
87
87
HARNESS
CR23
BRN
C5-20
C5-21
C5-24
C5-12
87 CR1
CR2
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
F19
10A FUSE
RD
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
CR37
CR33
BOOM
C6-9 BK/RD
RELAY
CR32
RELAY
BOOM
BRN
ROTATE
PRIMARY
TURNTABLE
87
RELAY 87
87
87
SECONDARY
BK-22B
C6-13 BK
87A
87A
87A
87A
L
BK-ALARM
86
85
85
85
85
86
86
86
CR5
WH/RD-ALARM
HORN
RELAY
30
30
30
30
BRN
BRN
BRN CR37
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B
C7B3 BRN
BK-IS3 BK-33B
(TO SWITCH PANEL)
HARNESS
CONTROL
GROUND

WH-IS7 WH-23B
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

1
LABEL DESCRIPTION
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 2
RD
RD
RD
RD
HM HOUR METER RD RD
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
WH-4
AUXILIARY
RD RD
POWER
L42 OIL PRESSURE LED
TS51
L43 OIL TEMPERATURE LED RD RD RD RD RD
L45 PLATFORM OVERLOAD
UP/DOWN
PRIMARY
BOOM
P1 RED EMERGENCY STOP BUTTON
TS61
RD-27
RD
RD
RD
3
GR
RD
RD
PLATFORM
LEVEL
TS59
C4B-7 GR/WH
TS56 GLOW PLUG TOGGLE SWITCH (OPTION)
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 C23-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
TS59 PLATFORM LEVEL TOGGLE SWITCH 4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
BL/WH-12A
BL/BK-11A
WH/BK-25
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
RD
BREAKER
CIRCUIT
TS60
5
CB2
TEMP
LED
L43
OIL
WH-23
PRESSURE
+
+
-
-
LED
L42
OIL
RD RD
RD
RD
RD RD
RD
RD
RD-20B
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4 7
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
ENGINE
CONTROL VARIABLE
START
TS52
FUNCTION SPEED
RD
RD
RESISTER
STOP SWITCH
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
(OPTION)
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD


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

8
7
6
5
4
3
2
1
6 - 41
30
Genie Industries
85
86
U33
BK-R1
87A
MODULE
A
OR/BK-41A
PLATFORM
OVERLOAD
87
BK-33B C32
4 1 3 4 5 6 7 8 12
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
7
RD H6
87 = NO
BK 22B
BK C7-1
87A = NC
RD TS51
RD TS52
BRN GND
GR/BK H6

9 1 3 4 7 10 9 2
BK/WH C1-12
10
B
86 = COIL POSITIVE
85 = COIL NEGATIVE
I.S.M.

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C23-1 BK
C3B
RD 134B C3B-3 RD/WH
C

H6
4 4
BK


C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
CR37 #86 BL
D
C3B-10 BL BL-TS60
BK
I.S.M.
CR37 #30 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
E
C4B-5 GR GR-TS57
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
WH-R2 BRN
C5-3 WH WH-HM
C6-20 BK
C5
Part No. 77809

C7B
C7B-1 BK BK-R5
WH-IS7
C7B-2 WH WH-KS
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
C40LS1 OR
C4B C6-27 RD RD-IS4
C36STCC BL
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models
March 2005
C37STC BL/BK
C29MS RD/WH
C1B-1 RD RD-TS51
C16DRE OR/RD
BRN
C1B-6 WH/RD
32 BRAKE 32
G
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 START ENGINE 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C5
35 HIGH RPM 35
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
+
C2B-3 OR/BK C3 BRN

H

C4B C3B C2B C1B

C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 LOW RPM 42
C2B-6 GR/BK
44 44
C3B
BRN
I.S.M.
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD RD H6
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
ENGINE HARNESS
C45 GEN GR/WH

I
C2B-5 GR
C43DLITE
RD-24B
RELAY
RD-IS6 WH
CR4
P20DLITE RD
30
30
30
30
86
86
86
86
BK-IS1
85
85
85
85
87A
87A
87A
87A
87
87
87
HARNESS
CR23
BRN
C5-20
C5-21
C5-24
C5-12
87 CR1
CR2
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
F19
10A FUSE
RD
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
CR37
CR33
BOOM
C6-9 BK/RD
RELAY
CR32
RELAY
BOOM
BRN
ROTATE
PRIMARY
TURNTABLE
87
RELAY 87
87
87
SECONDARY
BK-22B
C6-13 BK
87A
87A
87A
87A
L
BK-ALARM
86
85
85
85
85
86
86
86
CR5
WH/RD-ALARM
HORN
RELAY
30
30
30
30
BRN
BRN
BRN CR37
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B
C7B3 BRN
BK-IS3 BK-33B
(TO SWITCH PANEL)
HARNESS
CONTROL
GROUND

WH-IS7 WH-23B
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models
1
LABEL DESCRIPTION
TURNTABLE
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 2
RD
RD
RD
RD
HM HOUR METER RD RD
WH/RD-6
GR-17
WH/BK-5
KS1 KEY SWITCH
RD
WH-4
AUXILIARY
RD RD
POWER
TS51
L43 OIL TEMPERATURE LED RD RD RD RD RD
L45 PLATFORM OVERLOAD
UP/DOWN
PRIMARY
BOOM
TS61
RD-27
RD
RD
RD
3
GR
RD
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 C23-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
TS59 PLATFORM LEVEL TOGGLE SWITCH 4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
BL/WH-12A
BL/BK-11A
WH/BK-25
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
WH-23 WH-23
SECONDARY
CONTROLS 15A
RD
BREAKER
CIRCUIT
TS60
5
CB2
TEMP
LED
L43
OIL
WH-23
PRESSURE
+
+
-
-
LED
L42
OIL
RD RD
RD
RD
RD RD
RD
RD
RD-20B
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4 7
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
ENGINE
CONTROL VARIABLE
START
TS52
FUNCTION SPEED
RD
RD
RESISTER
STOP SWITCH
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
(OPTION)
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD

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


N
REV A
PLATFORM CONTROL HARNESS

(TO SWITCH PANEL)
M
R24FS WH C9P-2
L
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
K
OPT.
BRN
C40LSS OR C2P-2
CR30
C40LSS OR J2-4
P24FS WH C9P-2
J
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 C2P-5
FOOT SWITCH
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P
F.S.
H
C45GEN GR/WH C2P-7

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

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
March 2005
Part No. 77809

C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C4TRL WH C3P-4
C5TRR WH/BK C3P-5
ALC-500
U13
E
19/18 CONTROL CABLE

C29MS RD/WH C1P-3
J2
C3P(GR)
C35HS BK/RD C1P-9
C34SA BK/WH C1P-8

C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
JC3-6 FOR STEER ROCKER
9
JC1-3 OR

JC2-4 RD
WIRE CONNECTS TO
JC1-2 BRN
C1P(GY)
SWITCH OPTION.
JC2-5 BK
JC2-3 OR
JC1-5 YEL
* NOTE:
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
DRE B BL/BK
C13LED BL/RD
C28TTA RD/BK C1P-2

C29MS RD/WH
B
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
RED/BLK-28
ALARM
TILT
H1
A RED-TILT RED-TILT
BRN
BRN
BRN BRN
6 - 43
1
8

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

6 6 TS47 6
GENERATOR
(OPTION)
5 5 5 2
BK
4 4 4
TS48
TS13
WORK LIGHTS 3
EXTEND/RETRACT (OPTION)
2 2 2 3
1 1 + 1

BK
L1
BK
RD
F18 4
FUSE 10A
C45GEN GR/WH C2P-7
GENERATOR OPTION
C8PBR BK/WH C3P-8
CWLITE RD C2P-12
CWLITE RD C2P-11
CDLITE GR C2P-5
C7PBE BK C3P-7
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
BRN J1-10
BRN J1-12
BRN J1-14
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
RD
RD
BK
5
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
C34SA BK/WH C1P-8
P25FS RD C9-3
RD
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
PDLITE RD
BK
RD-TILT
P23BAT WH C7P-2
P26BAT BK C9P-1
P26BAT BK-LOAD
P22BAT BK C7P-1
6
WH WH
RD
7
3
2
NO
NC
1
4
TS4
NC
1
TS2
2
TS7 TS14 TS6 HIGH/LOW
RD
P3 TS9 WH PLATFORM TS1 HIGH/LOW GLOW PLUG START RPM P2
HORN ROTATE (2WD/4WD) (OPTION) EMERGENCY
PLATFORM AUXILIARY
RD
LEVEL POWER STOP

WH-24
RD RD RD 8



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
OPTION
J1
J2
J3
R24FS WH C9P-2
Y
CE Models: CR27 and CR30 replaces white wire between TS1 and TS7
L
CR27
RD LS CABLE
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
(CE ONLY)
K
LS18
BRN
BK LS CABLE C1P-12
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
P23SWBAT WH C7P-2
P22BAT BK C7P-1
BOOM
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
C133PLA GR/BK C4P-1
1
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
CWLITE RD C2P-11
C3P
F.S.
H
C45GEN GR/WH C2P-7

C9
P26ESTP BK
11
G
C6TRF WH/RD C3P-6
12V DC BATTERY
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPLY
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
March 2005
Part No. 77809

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

U13
19/18 CONTROL CABLE

E
C29MS RD/WH C1P-3

J2
C3P(GR)
C35HS BK/RD C1P-9
C34SA BK/WH C1P-8

C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
9
JC1-3 OR

JC2-4 RD
JC1-2 BRN
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
C28TTA RD/BK C1P-2

WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
B
RED/BLK-28
ALALRM
GR/BK C4P-1
TILT
H1
GR/BK-L4
RED LS18
A
BRN
BRN
BRN BRN
6 - 45
1
8

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

LEFT/RIGHT UP/DOWN LEFT/RIGHT 2
6 6 6
5 5 + 5
RD
BK
GR/WH
L48
4 4 TILT ALARM LED 4

BK
TS48
TS13
WORK LIGHTS 3 3
RD
2 2 2
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE 4
LED +
RD
L4 F18
PLATFORM FUSE 10A
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
BK
BL-DE1 J1-6
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
RD
RD
BK BK
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
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
C35HS BK/RD C1P-9
P24FS WH C9-2
PDLITE RD
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
6
White wire replaced

by CR27 and CR30
on CE models
WH WH
RD
7
2 2 2
3
NO
4
DRIVE P2 NC NC NC
SPEED EMERGENCY
TS4 STOP
TS14 TS6 TS2 HIGH/LOW 1 1 1
P3 WH HIGH/LOW GLOW ENGINE RD
TS1 RPM
HORN TS9 (2WD/4WD) PLUG START
AUXILIARY
RD
PLATFORM TS7 (OPTION)

LEVEL PLATFORM PUMP WH-24 RD
ROTATE 8
RD RD RD RD RD RD
NOTE:
DASHED LINES INDICATE OPTION WIRES


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

FOOTSW. HIGH
TS4
ENGINE
SPEED
CR4
TS54
LOW RPM
M
FUNCTION ENABLE
HIGH IDLE RELAY
BK/RD
BK/RD C5-18
HIGH RPM SOLENOID
Q3
TS47
GENERATOR
ON C2P-7 C45GEN GR/WH C2B-7 C45GEN GR/WH C5-12
L
GENERATOR
OPTION
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A

OPTION
L29
RD
RD
L30
FUSE 10A
K
C6-38 RD
C2P-12 C2P-10
WORK LIGHTS
OPTION
PBOX GND
C2P-11 C2P-9
FB1

L30
OPTION
PR3
J
TB34
TS6

ON
GLOW PLUG
U32
TS56
GLOW PLUG OPTION

ON
GLOW PLUG
I
PRESS
L42
TEMP.
L43
OIL
OIL

IGNITION/
MODULE
START
U1
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
3 START INPUT
8 KEY BYPASS
7 KEY POWER
10 ENG. FAULT
TS2
6 BATTERY
C33STR BK
5 GROUND

4 AUX. ON
ENGINE SWITCH
TS52
H
TB25
START
START SWITCH
SW2
NC
BK
TB33
CR2
POWER RELAY
TB21
G
C28TTA RD/BK
C21IGN2 WH C5-11
FUEL SOLENOID
C21IGN WH
HM
HOUR METER
CR1
_
P26ESTP BK
F
P24FS WH
P25FS RD
M3
TB24
March 2005
Part No. 77809

R33STR BK C5-5
PR2
STARTER
STARTER MOTOR
C9P-3
C9P-2
TS51
TS1
TB27
AUXILIARY
C28TTA RD/BK
POWER RD C6-27 AUXILIARY POWER

E
M2
PR1
WH-(FS)
RD-(FS)
PUMP
AUX
AUXILIARY PUMP
FS1
B
TILT ALARM
H1
BK-(FS)

LEVEL SENSOR
C
A
S8
D
TB23
C9P-1 BK
CR5
HORN
P3

P2

TB22
HORN
H2
C5-3
C
KS1
PLAT
GRD
C21IGN WH
P20BAT RD
C41RPM OR/BK
RD
P1
TB41
B
EXCT.
C21IGN WH
STA.
BAT.
IND.
RD
-
RD
ALTERNATOR
REGULATOR
CB2
CB1
15A
15A
BAT.
+
A
D1
TB20
-
RD C7B-4 P20BAT RD
12 V
DC
B2
6 - 47
1
8
6 - 48
C7P-3 BATGND C7B-3

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

C28TTA RD/BK

DRIVE MODE
H4
8
B
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION

L1
CDE3 BL/RD
J1
16
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
ROCKER
SWITCH
OPTION
P24FS WH
STEER
C
7
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3

J1
4 5 17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
D

9
TB5
C3P-5 C3B-5
10
C6-5 C5TRR WH/BK
RIGHT TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
TS62
LEFT C6-4 C4TRL WH

R4

10
C14-1 C14-2
TB4
C31-1 C31-2

FLOW CONTROL
TURNTABLE ROTATE
6
TB6
C12-1 C12-2
E
TB1
YOUT 5 BK
2
RD C6-1 C1PBU RD
JC2
XOUT 4
Part No. 77809
1
UP PRIMARY BOOM UP
J1
TB2
Y22
PWR 3
OR PRIMARY BOOM
11 DOWN C6-2 C2PBD RD/BK
TS61
March 2005
BRN
J2
GND 2 12 PRIMARY BOOM DOWN

C13-1 C13-2
TB3
1
C29-1 C29-2
FLOW CONTROL
6
F
7
8
7
14
SECONDARY BOOM
6
YEL
OUT 5 3
UP/DOWN
13
JC1
4
J1
OR
12
TB10
BRN C18-1 C18-2

GND 2 10
G
C6-10 C10SBU BL
1 SECONDARY UP
P26ESTP BK
UP
BOOM SECONDARY
TS60
SECONDARY DOWN
BRN
TB11
1 C19-1 C19-2
TB12
C30-1 C30-2
2
FLOW CONTROL
P24FS WH
LS3
J3
4
C4P-4 C16PDRE OR/RD C4B-4 C6-16 BK-6 WH-6 C6-13
3
P26ESTP BK LS3-DRIVE ENABLE
13
14
3
H
LIMIT SWITCH
LS1

4
U13
BK
LS2
21
22
C40LSS OR

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

CE
21
22
I
C22LS RD
EXTEND
BOOM
TS13
C3P-8 C16-1 C16-2

TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
BOOM
TB8 BOOM RETRACT
C17-1 C17-2
J
TS9

UP
PLATFROM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLAT LEVEL UP
UP
PLATFROM LEVEL
PLAT LEVEL DOWN
TB15
TB44
C21-1 C21-2
CR13
K
TS8
NC

DOWN
JIB BOOM
UP C4P-5 C17JU GR C4B-5
TB18
C23-1 C23-2
TS58
C6-18 C18JD GR/BK JIB BOOM DOWN /
DOWN PLATFORM ROTATE RIGHT
JIB BOOM
UP C6-17 C17 JU GR
JIB BOOM UP /
C22-1 C22-2 PLATFORM ROTATE RIGHT
TB17
RIGHT PLATFORM
C5-25
LEFT ROTATE RIGHT PLATFORM
TS7
L
LEFT ROTATE
TS57
WH
C44DA BK C6-19
H3
CR13
C19JSV GR/WH
M
BRN
JIB VALVES JIB VALVES

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

Electrical Schematic, Z-45/25J REV A


1
P2
FS1
BK/RD
C7P-1
C2P-5
TS4
2 TS2
TS6
TS48 TS47
C1P-12
RD
P22BAT BK
TS1 ENGINE
FOOT SWITCH HIGH

RD
6
BK
ON
RD
SPEED
START
ENGINE
C134PWR BL/RD
ON
DRIVE LIGHT
WORK LIGHT
C132PLI BL/WH
PUMP
AUXILARY
GENERATOR
L48
P3
H1
GLOW PLUG
HORN
C2P-11
C2P-12
D40 5
C28TTA RD/BK
C7B-1
LIGHTS
C3P-9
C4P-1
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
C2P-5
C2P-7
C1P-9
C1B-12
C2B-5
3 CB2
15A
TB134 L30 L30
BK
P1
RD RD
RD
RD
C133PLA
C46HRN BK/RD
C28TTA RD/BK
TB22 1 3
TS51
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
C43DLITE GR
C45GEN GR/WH
C35HS BK/RD
C33STR BK
KS1 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
START
D3
ENGINE
C32
PUMP
ON
LOW RPM
HIGH RPM
AUXILIARY
GRD
6 7
PLUG
GLOW
12 8
4 D4
C1B-7
BK
C1B-1
PBOX GND
ENABLE
C3B-9
C4B-1
C1B-2
RD
FUNCTION
C7B-2
C2B-3
C1B-9
TB27
TB33
C2B-5
C2B-7
D2
RD
TB23
C1B-8
TB41 1 START RELAY
CB1 2 TACHOMETER
15A 3 START INPUT
4 AUX. ON U1 L42
RD
+ 7 KEY PWR. MODULE
5 C3 CR1
8 KEY BYPASS
L43
C5-24

NO CR2 TEMP.
NO
C7B-4
P20BAT RD
C35HS BK/RD
C21IGN WH C5-3 TB21
C23 ALARM RD
C45GEN GR/WH
C34SA BK/WH
C25PSR WH/BK
C26TSR WH/RD
C6-34
P22BAT BK
C46HRN BK/RD
C23TTSR WH
C28TTA RD/BK
C27AUX RD
R33STR BK
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
FUSE
P20BAT RD
C21IGN WH
10A
6 TB25
CR23
CR23
CR4
NO
C5-5
CR5 TB26 NO CR4

NO
BK/RD
ALTERNATOR A B
C5-2
D1 FB1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
BAT. BAT. PR1 PR2
C6-9
B1 + - PR1 PR2
C5-18
12V DC S8 NO NO PR3
NO PR3
RD
RD
+
STA.
7 STARTER M3 +
SW2
NC
H2 AUX
M2 HM
BK
PUMP
REGULATOR _ SW3 U32
BRN
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

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

AUXILIARY PUMP
GLOW PLUG OPTION

NOTE:
8
C3B & C3P = GREEN

6 - 50
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
L1
B
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

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

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
20
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

UP C1PBU RD
TB2
E
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
BRN C6-1
C2PBD RD/BK
TS61
Part No. 77809
GND 12
J2
2
TB3
1
March 2005

6
7
8
F
7
SECONDARY BOOM
6 14
YEL
OUT 5 3
UP/DOWN

13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10
SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
SECONDARY BOOM
SECONDARY BOOM UP
87a 87
DOWN
30
C6-10
G
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
21
22
H
LS2
C40LSS OR

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

LIFT/
21
22
CE
C22LS BK
EXTEND
BOOM
I

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

DOWN JIB
TS8
TB18
C23-1 C23-2
TS58
C6-18 C18JD GR/BK
K
JIB BOOM DOWN

DOWN
JIB BOOM
UP C6-17 C17 JU GR
TB17
TS57
RIGHT PLATFORM
C5-25
LEFT ROTATE RIGHT
PLAT ROTATE
LEFT
TS7
WH
C44DA BK C6-19
H3
L
CR13
C19JSV GR/WH

VALVE

JIB

BRN

BK WH
JIB BOOM VALVE
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
M
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
removed after
BK
serial number
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
One valve
C1B & C1P - GRAY

22565
NOTES:
WHEEL.
REV A
N

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


1
P2
FS1
BK/RD
C7P-1
4
C2P-5
C1P-12
TS4
2 TS2
TS6
TS48 TS47
RD
P22BAT BK
LS18 L4 TS1 ENGINE
FOOT SWITCH HIGH

RD
BK
ON
RD
SPEED
START
ENGINE
C134PWR BL/RD
ON
DRIVE LIGHT
WORK LIGHT
C132PLI BL/WH
PUMP
AUXILARY
GENERATOR
P3
H1
GLOW PLUG
HORN
C2P-11
C2P-12
D40 5
C28TTA RD/BK
C7B-1
D39
LIGHTS
C3P-9
C4P-1
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
C2P-5
C2P-7
C1P-9
C1B-12
C2B-5
3 CB2
15A
TB134 L30 L30
BK
P1
RD RD
RD
RD
C133PLA
C46HRN BK/RD
C28TTA RD/BK
TB22 1 3
TS51
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
C43DLITE GR
C45GEN GR/WH
C35HS BK/RD
C33STR BK
KS1 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
U32
START
D3
ENGINE
PUMP
ON
LOW RPM
HIGH RPM
AUXILIARY
GRD PLAT.
6 OVER 7
LOAD
PLUG
GLOW
12 8
4 D4
C1B-7
BK
C1B-1
PBOX GND
ENABLE
C3B-9
C4B-1
C1B-2
RD
FUNCTION
C7B-2
C2B-3
H6 L45
C1B-9
TB27
TB33
C2B-5
C2B-7
D2
RD
TB23
C1B-8
TB41 1 START RELAY
CB1 2 TACHOMETER
15A 3 START INPUT
4 AUX. ON U1 L42
RD
+ 7 KEY PWR. MODULE
5 C3 CR1
8 KEY BYPASS
L43
C5-24

NO CR2 TEMP.
NO
C7B-4
P20BAT RD
C35HS BK/RD
C21IGN WH C5-3 TB21
C23 ALARM RD
C45GEN GR/WH
C34SA BK/WH
C25PSR WH/BK
C26TSR WH/RD
C6-34
P22BAT BK
C46HRN BK/RD
C23TTSR WH
C28TTA RD/BK
C27AUX RD
R33STR BK
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
FUSE
P20BAT RD
C21IGN WH
10A
6 TB25
CR23
CR23
CR4
NO
C5-5
CR5 TB26 NO CR4

NO
BK/RD
ALTERNATOR A B
C5-2
D1 FB1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
BAT. BAT. PR1 PR2
C6-9
B1 + - PR1 PR2
C5-18
12V DC S8 NO NO PR3
NO PR3
RD
RD
+
STA.
7 STARTER M3 +
SW2
NC
H2 AUX
M2 HM
BK
PUMP
REGULATOR _ SW3 U32
BRN
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

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

AUXILIARY PUMP
GLOW PLUG OPTION

8 NOTE:
in the stowed position and the keyswitch off. C1B & C1P = GRAY
4 CE and Platform Overload Option C2B & C2P = BLACK
5 Add D40 only if unit has L4 and L48. C3B & C3P = GREEN
C4B & C4P = BROWN

6 - 52
Electrical Schematic, Z-45/25J, CE Models
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
L1
B
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

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

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
20
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

UP C1PBU RD
TB2
E
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
BRN C6-1
C2PBD RD/BK
TS61
Part No. 77809
GND 12
J2
2
TB3
1
March 2005

6
7
8
F
7
SECONDARY BOOM
6 14
YEL
OUT 5 3
UP/DOWN

13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10
SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
SECONDARY BOOM
SECONDARY BOOM UP
87a 87
DOWN
30
C6-10
G
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
21
22
H
LS2
C40LSS OR

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

LIFT/
21
22
CE
C22LS BK
EXTEND
BOOM
I

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

DOWN JIB
TS8
TB18
C23-1 C23-2
TS58
C6-18 C18JD GR/BK
K
JIB BOOM DOWN

DOWN
JIB BOOM
UP C6-17 C17 JU GR
TB17
TS57
RIGHT PLATFORM
C5-25
LEFT ROTATE RIGHT
PLAT ROTATE
LEFT
TS7
WH
C44DA BK C6-19
H3
L
CR13
C19JSV GR/WH

VALVE

JIB

BRN

BK WH
JIB BOOM VALVE
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
M
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
removed after
BK
serial number
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
One valve
C1B & C1P - GRAY

22565
NOTES:
WHEEL.
REV A
N
Electrical Schematic, Z-45/25J, CE Models


8
7
6
5
4
3
2
1
6 - 53
Genie Industries
1
A
2
3
4
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6

7
NOTE:
9 1 3 4 7 10 9 2
10
B
I.S.M.
TERMINAL BASE (TB)

D C B A
C6-1 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
C6-2 RD/BK BK
C3B
C3B-3 RD/WH
C

C6-4 WH
C3B-4 WH WH-TS62
C6-5 WH/BK
BK

C6-6 WH/RD

C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
D

C6-10 BL
C3B-10 BL BL-TS60
C6-11 BL/BK BK
I.S.M.
C6-12 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
14 PLATFORM LEVEL UP/JIB UP 14
C6-15 OR/BK
C4B
E
15 PLATFORM LEVEL DOWN/JIB DOWN 15

C6-17 GR
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
C7B
BK-ALARM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
12V DC TO
PLATFORM
WH-R2 BRN
C5-3 WH WH-HM
Part No. 77809

March 2005
C6-20 RD
C5
C7B
C7B-1 BK BK-R5
F
C5-23 WH WH-IS7
C7B-2 WH WH-KS
C6-34 RD FB
C6
C6
RD-R2
C4B
C6-16
C6-40
C6-37
C6-36
C6-29
I.S.M.
C7B-3
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
C40LS1 OR
C6-27 RD RD-IS4
G
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
C1B-1 RD RD-TS51
BRN 27 AUXILIARY PUMP 27
C1B-6 WH/RD
32 BRAKE 32
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 ENGINE START 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C1B-10

C5
35 HIGH RPM 35
H
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
C2B-3 OR/BK
C4B C3B C2B C1B
OR/RD-CR3
C1B-2
C2B-7
C1B-5
C1B-4

42 LOW RPM 42
BK-ALARM
44 JIB BOOM DOWN DESCENT ALARM 44
I
C3B
C4B
BRN
I.S.M.
RD-24B
C30FWD WH
P20DLITE RD
C43DLITE GR
C28TTA RD/BK
C31REV WH/BK
CR1
C45 GEN GR/WH

RELAY HARNESS
IGNITION
WH
ENGINE HARNESS
CR2
RELAY
POWER
START RELAY
FUNCTION HARNESS
RD-IS6
CR4
RELAY
HIGH RPM
SOLENOID
C5-20
C5-21
C5-24
C5-12
BK-IS1
J
C5
WH
ENGINE
C5-5 BK BRN BRN

WH-IS9
C3B
C4B
BRN
C5-18 BK/RD
C5-11 WH
BK/RD-35C
WH-21C
BRN
BATGND BRN
K
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
C6-9 BK/RD
C3B-9 BK/RD
BK-22B
CR23
RELAY
C6-13 BK
BRN
OPTION
BRN
DRIVE LIGHT
BRN
BK-ALARM
L
F19
WH/RD-ALARM
10A FUSE
CR5
HORN
RELAY
BRN
BRN RD
C2B-5 GR
RD-20C DRIVE LIGHTS
GROUNDCONTROL HARNESS

C4B
OR/BK-IS2 OR/BK-41A
WH-IS7 WH-23B
M
GROUND BOLT
RD-IS4 RD-27B
BK-IS3 BK-33B
GROUND
HARNESS
CONTROL

PANEL)
(TO SWITCH
C7B3 BRN
F.H.
E.H.
BRN
BRN
BRN
I.S.M.
BRN BRN
REV A
N
N
REV A
M
L
K
J
STACKED CONTACTS
P1 3 3
STOP
SWITCH NO NO TS51
AUXILIARY
2
1
NC
POWER
RD
4 4
KS1
2
1
NC
KEY SWITCH RD
RD
RD-27A RD-27
RD
RD
RD
I
KS1
3 3
RD
RD
NO NO
RD
RD
RD
RD

4 4 BK-22
RD
WH-23A
H
WH-21
WH-23
BRN +
WH-23
L2
-
RD
OIL
PRESSURE
WH-CR4
LED WH/BK-25
HOUR METER
G
BASE BOX HARNESS

(TO TERMINAL STRIP)
WH-23
RD
F
RD RD RD
RD/BK-2A TS63
RD PRIMARY BOOM
R4 RD/WH-3A RD EXTEND/RETRACT
FUNCTION SPEED + OIL TEMP RD
CONTROL VARIABLE L3
- LED
RESISTER TS61
March 2005
RD PRIMARY
RD
RD
BOOM
BK-7
RD-1A
Part No. 77809
RD
BK-7A UP/DOWN
RD
BK/WH-8
BK/WH-8A
E
WH/RD-26A
RD
RD
RD
RD
RD RD
WH/BK-5A WH/BK-5
WH-4A WH-4
D
BK/WH-34A WH/RD-6A WH/RD-6

RD
RD BL/WH-12A TS58
RD
RD
RD RD JIB UP/DOWN TS62

BL/BK-11A TURNTABLE
TS52 RD ROTATE
GR/BK-44A
ENGINE BL-10A
RD
GR/BK
START
RD
TS56 BK-33A TS60

GR
RD
GLOW PLUG SECONDARY TS58 RD

(OPTION) BOOM UP/DOWN RD RD
RD
C
RD
GR/BK
B
RD
RD

RD
RD
RD
RD GR-17A GR-17
GR/BK
CB1
CIRCUIT BREAKER
RD
ENGINE, 15A OR/BK-15A TS57

RD-24A RD-20B RD PLATFORM
OR-14A GR ROTATE
TS54 RD-20A CB2 TS59
FUNCTION BK/RD-35A CIRCUIT BREAKER PLATFORM RD
ENABLE CONTROLS, 15A LEVEL
A
GR/BK-18A GR/BK-18
6 - 54
8
7
6
5
4
3
2
1


8
7
6
5
4
3
2
1
6 - 55
30
Genie Industries 4 5 6 7
85
86
BK-R1
87A
A
OR/BK-41A
87
BK-33B C23
4 1 3 4 5 6 7 8 12
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
7
RD H6
87 = NO
BK 22B
BK C7-1
87A = NC
RD TS51
RD TS52
BRN GND
GR/BK H6

9 1 3 4 7 10 9 2
BK/WH C1-12
10
B
86 = COIL POSITIVE
85 = COIL NEGATIVE
I.S.M.

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C23-1 BK
C3B
RD 134B C3B-3 RD/WH
C

H6
4 4
BK


(CE option only)
C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
CR37 #86 BL
D
C3B-10 BL BL-TS60
BK
I.S.M.
CR37 #30 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
E
C4B-5 GR GR-TS57
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
WH-R2 BRN
C5-3 WH WH-HM
C6-20 BK
C5
Part No. 77809

March 2005
C7B
C7B-1 BK BK-R5
WH-IS7
C7B-2 WH WH-KS
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
C4B 26 OIL TEMPERATURE SWITCH 26
C6-27 RD RD-IS4
C37STC BL/BK
C1B-1 RD RD-TS51
C29MS RD/WH
C16DRE OR/RD
C36STCC BL
C40LS1 OR
BRN
C1B-6 WH/RD
32 BRAKE 32
G
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 START ENGINE 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C5
35 HIGH RPM 35
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
+
C2B-3 OR/BK C3 BRN

H

C4B C3B C2B C1B

C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 LOW RPM 42
BK-ALARM
C3B
BRN
I.S.M.
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD RD H6
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
ENGINE HARNESS
C45 GEN GR/WH

I
C2B-5 GR
C43DLITE
RD-24B
RELAY
RD-IS6 WH
CR4
P20DLITE RD
30
30
30
30
86
86
86
86
BK-IS1
85
85
85
85
87A
87A
87A
87A
87
87
87
HARNESS
CR23
BRN
C5-20
C5-21
C5-24
C5-12
87 CR1
CR2
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
F19
10A FUSE
RD
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
CR37
CR33
BOOM
C6-9 BK/RD
RELAY
CR32
RELAY
BOOM
BRN
ROTATE
PRIMARY
TURNTABLE
87
RELAY 87
87
87
SECONDARY
BK-22B
C6-13 BK
87A
87A
87A
87A
L
BK-ALARM
86
85
85
85
85
86
86
86
CR5
WH/RD-ALARM
HORN
RELAY
30
30
30
30
BRN
BRN
BRN CR37
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B
C7B3 BRN
BK-IS3 BK-33B
(TO SWITCH PANEL)
HARNESS
CONTROL
GROUND

WH-IS7 WH-23B
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

1
LABEL DESCRIPTION
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 2
RD
RD
RD RD
GR
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 RD RD RD RD
L43 OIL TEMPERATURE LED
L45 PLATFORM OVERLOAD GR/BK GR/BK
UP/DOWN
PRIMARY
BOOM
TS61
RD RD
RD-27
RD
RD
RD
3
GR
RD
GR GR
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 C23-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH 4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
BL/WH-12A
BL/BK-11A
WH/BK-25
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH WH-23 WH-23
SECONDARY
CONTROLS 15A
RD
BREAKER
CIRCUIT
TS60
5
CB2
TEMP
LED
L43
OIL
WH-23
PRESSURE
+
+
-
-
LED
L42
OIL
RD RD
RD
RD
RD RD
RD
RD
RD-20B
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4 7
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
ENGINE
CONTROL VARIABLE
START
TS52
FUNCTION SPEED
RD
RD
RESISTER
STOP SWITCH
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
(OPTION)
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD


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

8
7
6
5
4
3
2
1
6 - 57
30
Genie Industries
85
86
U32
BK-R1
87A
MODULE
A
OR/BK-41A
PLATFORM
OVERLOAD
87
BK-33B C23
4 1 3 4 5 6 7 8 12
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6
7
RD H6
87 = NO
BK 22B
BK C7-1
87A = NC
RD TS51
RD TS52
BRN GND
GR/BK H6

9 1 3 4 7 10 9 2
BK/WH C1-12
10
B
86 = COIL POSITIVE
85 = COIL NEGATIVE
I.S.M.

CR32 #86 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
RD C32-1 BK
C3B
RD 134B C3B-3 RD/WH
C

H6
4 4
BK


C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
CR37 #86 BL
D
C3B-10 BL BL-TS60
BK
I.S.M.
CR37 #30 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
C6-17 GR
E
C4B-5 GR GR-TS57
C7B
C3B
C6-18 GR/BK
12V DC TO
BK-ALARM
PLATFORM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
WH-R2 BRN
C5-3 WH WH-HM
C6-20 BK
C5
Part No. 77809

C7B
C7B-1 BK BK-R5
WH-IS7
C7B-2 WH WH-KS
F
C6
RD-R2
C6
C6-16
C6-40
C6-37
C6-36
C6-29
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
C7B-3
I.S.M.
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
C4B 26 OIL TEMPERATURE SWITCH 26
C6-27 RD RD-IS4
C37STC BL/BK
C1B-1 RD RD-TS51
C29MS RD/WH
C16DRE OR/RD
C36STCC BL
C40LS1 OR
BRN
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models
March 2005
C1B-6 WH/RD
32 BRAKE 32
G
BK-IS3
C4B-4
C1B-7 BK BK-33 TS52
33 START ENGINE 33
C3B
C5-22 BK/WH
34 GLOW PLUG 34
BK/RD-R4
C2B-2
C1B-3
C1B-11
C5
35 HIGH RPM 35
C2B
BL/WH-L2-
38 (SPARE) 38
19/18 CABLES
39 (SPARE) 39
C1B
+
C2B-3 OR/BK C3 BRN

H

C4B C3B C2B C1B

C1B-2
C2B-7
C1B-5
C1B-4
C2B-4 OR/RD
42 LOW RPM 42
BK-ALARM
C3B
BRN
I.S.M.
C5-23 WH RD KS1
134 KS POWER 134
C2-5 RD RD H6
C6-34 RD
C30FWD WH
134A KS POWER 134A

C28TTA RD/BK
C31REV WH/BK
C4B
ENGINE HARNESS
C45 GEN GR/WH

I
C2B-5 GR
C43DLITE
RD-24B
RELAY
RD-IS6 WH
CR4
P20DLITE RD
30
30
30
30
86
86
86
86
BK-IS1
85
85
85
85
87A
87A
87A
87A
87
87
87
HARNESS
CR23
BRN
C5-20
C5-21
C5-24
C5-12
87 CR1
CR2
C5-5 BK BRN
J
WH-IS9
C5
BRN
WH-21C
C5-11 WH
BK/RD-35C
ENGINE
C5-18 BK/RD
C3B
C4B
C6-39 R43DLITE2 RD
C6-38 R43DLITE1 RD
F19
10A FUSE
RD
C6-10 BL
BATGND BRN
K
C6-11 BL/BK
C6-5 WH/BK
C6-4 WH
C6-1 RD
C6-2 RD/BK
C3B-9 BK/RD
CR37
CR33
BOOM
C6-9 BK/RD
RELAY
CR32
RELAY
BOOM
BRN
ROTATE
PRIMARY
TURNTABLE
87
RELAY 87
87
87
SECONDARY
BK-22B
C6-13 BK
87A
87A
87A
87A
L
BK-ALARM
86
85
85
85
85
86
86
86
CR5
WH/RD-ALARM
HORN
RELAY
30
30
30
30
BRN
BRN
BRN CR37
FUNCTION HARNESS
RD/WH 3D
RD 1C
C4B
WH/RD 6D
WH/BK 5C
BL/WH 12C
BL
BL 10C
RD-20C DRIVE LIGHTS
M
GROUND BOLT

I.S.M.
OR/BK-IS2 OR/BK-41A
RD-IS4 RD-27B
C7B3 BRN
BK-IS3 BK-33B
(TO SWITCH PANEL)
HARNESS
CONTROL
GROUND

WH-IS7 WH-23B
F.H.
E.H.
BRN BRN
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models
1
LABEL DESCRIPTION
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 2
RD
RD
RD RD
GR
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 RD RD RD RD
L43 OIL TEMPERATURE LED
L45 PLATFORM OVERLOAD GR/BK GR/BK
UP/DOWN
PRIMARY
BOOM
TS61
RD RD
RD-27
RD
RD
RD
3
GR
RD
GR GR
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 C23-6
GR-17A
OR-14A
RD-27A
WH-4A
RD-1A
BK-7A
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH 4
WH
RD
RD
RD
RD RD
RD 134A
BK-22A
WH-23A
BL/WH-12A
BL/BK-11A
WH/BK-25
RD
WH/RD-26A
BL-10A
KS1
RD
BOOM UP/DOWN
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH WH-23 WH-23
SECONDARY
CONTROLS 15A
RD
BREAKER
CIRCUIT
TS60
5
CB2
TEMP
LED
L43
OIL
WH-23
PRESSURE
+
+
-
-
LED
L42
OIL
RD RD
RD
RD
RD RD
RD
RD
RD-20B
RD
RD
6
RD RD RD
RD
RD
RD-24A
BK-33A
RD C23-7
BK/RD-35A
RD
RD
RD
WH-CR4 7
ENGINE 15A
BRN
BREAKER
CIRCUIT
CB1
WH-21
BK/WH-34A
BRN
RD-20A
ENGINE
CONTROL VARIABLE
START
TS52
FUNCTION SPEED
RD
RD
RESISTER
STOP SWITCH
RD
EMERGENCY
HOUR METER
1 1
RD
RD
RD
(TO TERMINAL STRIP)
8
BASE BOX HARNESS

RD RD
R4
P1
NC NC
RD
FUNCTION
2 2
(OPTION)
ENABLE
RD
GLOW
PLUG
TS56
TS54
RD
RD RD RD

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


N
REV A
CONTROL HARNESS
(TO SWITCH PANEL)
PLATFORM
M
WHT
C19JSV BLK
R24FS WH C9P-2
L
CR27
JIB
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
K
OPT.
BRN
C40LSS OR C2P-2
CR30
C40LSS OR J2-4
P24FS WH C9P-2
J
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
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 C2P-5
FOOT SWITCH
CWLITE RD C2P-12
CWLITE RD C2P-11
C3P
F.S.
JIB
H
C45GEN GR/WH C2P-7

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

C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
JIB
March 2005
Part No. 77809

C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BK C1P-10
C4TRL WH C3P-4
C5TRR WH/BK C3P-5
ALC-500
U13
E
19/18 CONTROL CABLE

C29MS RD/WH C1P-3
J2
C3P(GR)
C35HS BK/RD C1P-9

C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
JC3-6 FOR STEER ROCKER
9
JC1-3 OR

JC2-4 RD
WIRE CONNECTS TO
JC1-2 BRN
C1P(GY)
SWITCH OPTION.
JC2-5 BK
JC2-3 OR
JC1-5 YEL
* NOTE:
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
DRE B BL/BK
C13LED BL/RD
C28TTA RD/BK C1P-2

C29MS RD/WH
B
WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
RED/BLK-28
ALARM
TILT
H1
JIB
A RED-TILT RED-TILT
BRN
BRN
BRN BRN
6 - 59
1
8

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

6 6 TS47 6
GENERATOR
(OPTION) 2
5 5 5
BK
4 4 4
TS48
TS13
WORK LIGHTS 3
2 2 2 3
CR13
1 1 + 1

BK
L1
BK
RD
F18 4
FUSE 10A
C45GEN GR/WH C2P-7
GENERATOR OPTION
C8PBR BK/WH C3P-8
CWLITE RD C2P-12
CWLITE RD C2P-11
CDLITE GR C2P-5
C7PBE BK C3P-7
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
BRN J1-10
BRN J1-12
BRN J1-14
OR J1-13
YEL J1-3
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
BL J1-5
5
WH-JIB
RD
RD
BRN
BK
C19JSV GR/WH
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
C34SA BK/WH C1P-8
P25FS RD C9-3
RD
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
PDLITE RD
BK
RD-TILT
P23BAT WH C7P-2
P26BAT BK C9P-1
P26BAT BK-LOAD
P22BAT BK C7P-1
GR/BK-44 C2P-6
WH-JIB
P24FS WH
WH WH
RD
GR
7
3
2
NO
NC
1
4
TS4
NC
1
TS2
2
TS7 TS14 TS6 HIGH/LOW
RD
P3 TS9 WH PLATFORM TS8 TS1 HIGH/LOW GLOW PLUG START RPM P2
HORN ROTATE (2WD/4WD) (OPTION) EMERGENCY
PLATFORM GR/BK JIB AUXILIARY
RD
LEVEL BOOM POWER STOP

WH-24
RD RD RD 8



N
REV A
PLATFORM CONTROL
(TO SWITCH PANEL)

HARNESS


RD-P2
RD-H1
DESCRIPTION
M
TILT ALARM
Y
C19JSV WH
OPTION
R24FS WH C9P-2
Y
C1P - C4P
L
ITEM
CR27
CR27
CR30
LS18
C7P
U13
JIB
H1
C9
J1
J2
J3
RD LS CABLE
CE Models: CR27 and CR30 replaces white wire between TS1 and TS7
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
CE ONLY
K
LS18
BRN
BK LS CABLE C1P-12
C40LSS OR C2P-2
C40LSS OR J2-4
CR30
P24FS WH C9P-2
J
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
BOOM
C18JD GR/BK C4P-6

JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C133PLA GR/BK C4P-1
C9HRN BK/RD C3P-9
I
C8PBR BK/WH C3P-8

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

C9
P26ESTP BK
11
3
1
G
C6TRF WH/RD C3P-6
12V DC BATTERY
J3
C10SBU BL C3P-10
P24FS WH
C16DRE OR/RD C4P-4
SUPPLY
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 JIB BK
C2P
C3P
C4P
C7P
March 2005
Part No. 77809

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

U13
19/18 CONTROL CABLE

E
C29MS RD/WH C1P-3

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

C34SA BK/WH C1P-8
C33STR BK C1P-7
C2P(BK)
C27AUX RD C1P-1
D
J1
C1P
9
JC1-3 OR
JC2-4 RD

JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
C7P
C
JC3-5 WH
JC3-3 OR
JC3-4 BL *
JC3-2 BRN
C28TTA RD/BK C1P-2

WLITE BRN C2P-10

WLITE BRN C2P-9
BATGRN C7P-3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
JIB BK
B
RED/BLK-28
ALARM
GR/BK C4P-1
TILT
H1
GR/BK-L4
RED LS18
A
BRN
BRN
BRN BRN
6 - 61
1
8

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

LEFT/RIGHT LEFT/RIGHT
UP/DOWN 2
6 6 6
5 5 + 5
RD
BK
GR/WH
L48
4 4 TILT ALARM LED 4

BK
TS48
TS13
WORK LIGHTS 3 3
RD
2 2 2
1 1 + 1
L1 BK
BK
RD
DRIVE
ENABLE 4
LED +
RD
L4 F18
PLATFORM FUSE 10A
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
RELAY
C7PBE BK C3P-7
BL/RD-DE3 J1-16
GR/BK H1 (D39)
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
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
5
BK J1-2
RD J1-1
WH-JIB
BL J1-5
BRN
RD
RD
BK
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
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9
P24FS WH C9-2
PDLITE RD
BK C9P-1
WH C7P-2
BK J3-3
BK C7P-1
RD LS18
6
White wire replaced

by CR27 and CR30
on CE models
WH WH
RD 7
2 2 2
GR
3
NO
4
DRIVE P2 NC NC NC
SPEED EMERGENCY
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 8
RD ROTATE RD RD RD RD RD
NOTE:
DASHED LINES INDICATE OPTION WIRES


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

FOOTSW. HIGH
TS4
ENGINE
SPEED
CR4
TS54
LOW RPM
M
FUNCTION ENABLE
HIGH IDLE RELAY
BK/RD
BK/RD C5-18
HIGH RPM SOLENOID
Q3
TS47
GENERATOR
ON
L
C2P-7 C45GEN GR/WH C2B-7 C45GEN GR/WH C5-12 GENERATOR

OPTION
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A

OPTION
L29
RD
RD
L30
K
FUSE 10A
C6-38 RD
C2P-12 C2P-10
WORK LIGHTS
OPTION
PBOX GND
C2P-11 C2P-9
FB1

L30
OPTION
J
PR3
TB34
TS6

ON
GLOW PLUG
TS56
ON
GLOW PLUG GLOW PLUGS
U32

I
PRESS
L42
TEMP.
L43
OIL
OIL

IGNITION/
MODULE
START
U1
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
3 START INPUT
8 KEY BYPASS
7 KEY POWER
10 ENG. FAULT
TS2
6 BATTERY
C33STR BK
5 GROUND

4 AUX. ON
ENGINE SWITCH
H
TS52
TB25
START
START SWITCH
SW2
NC
BK
TB33
CR2
POWER RELAY
TB21
G
C28TTA RD/BK
C21IGN2 WH C5-11
FUEL SOLENOID
C21IGN WH
HM
HOUR METER
CR1
_
P26ESTP BK
F
P24FS WH
P25FS RD
M3
TB24
March 2005
Part No. 77809

R33STR BK C5-5
PR2
STARTER
STARTER MOTOR
C9P-3
C9P-2
TS51
TS1
TB27
AUXILIARY
C28TTA RD/BK
RD C6-27 AUXILIARY POWER

E
POWER
M2
PR1
WH-(FS)
RD-(FS)
PUMP
AUX
AUXILIARY PUMP
FS1
B
TILT ALARM
H1
BK-(FS)

LEVEL SENSOR
Perkins 104-22 Models (before serial number 22050)
C
A
D
S8
TB23
C9P-1 BK
CR5
HORN

P3
P2

TB22
HORN
H2
C
C5-3
KS1
PLAT
GRD
C21IGN WH
P20BAT RD
C41RPM OR/BK
RD
C3 3MF
P1
+
TB41
B
W
EXCT.
C21IGN WH
STA.
BAT.
IND.
RD
-
RD
ALTERNATOR
REGULATOR
CB2
CB1
15A
15A
BAT.
+
A
D1
TB20
-
RD C7B-4 P20BAT RD
12 V
DC
B2
6 - 63
1
8

6 - 64
1
C7P-3 BATGND C7B-3

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

C28TTA RD/BK

DRIVE MODE
H4
8
C6-33 C32TA WH/RD
TRAVEL ALARM OPTION
L1
B
CDE3 BL/RD
J1
16
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
ROCKER
SWITCH
OPTION
P24FS WH
STEER
7
C
BL
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3

J1
4 5 17 STEER RIGHT
OR
PWR 3 13
1 C24-1 C24-2
11
9
D

TB5
C3P-5 C3B-5
10
C6-5 C5TRR WH/BK
TURNTABLE ROTATE RIGHT
RIGHT
TURNTABLE ROTATE
TS62
LEFT C6-4 C4TRL WH

R4
10
C14-1 C14-2
TB4
C31-1 C31-2

FLOW CONTROL
TURNTABLE ROTATE
6
TB6
C12-1 C12-2
TB1
YOUT 5 BK
2
E
RD C6-1 C1PBU RD
PRIMARY BOOM UP
JC2
XOUT 4 1
UP
J1
TB2
Y22
OR PRIMARY BOOM
Part No. 77809

DOWN
TS61
BRN PRIMARY BOOM DOWN

J2
GND 2 12
C13-1 C13-2
March 2005
TB3
1
C29-1 C29-2
FLOW CONTROL
6
7
F

8
7
14
SECONDARY BOOM
6
YEL
OUT 5 3
UP/DOWN
13
JC1
4
J1
OR
12
TB10
BRN C18-1 C18-2

GND 2 10
C6-10 C10SBU BL
SECONDARY BOOM UP
G
1
P26ESTP BK
UP
SECONDARY BOOM
TS60
SECONDARY BOOM DOWN

BRN
TB11
1 C19-1 C19-2
TB12
C30-1 C30-2
2
FLOW CONTROL
P24FS WH
LS3
J3
4
3
13
14
3
H
LS1
C2P-2
4
LS1-PRIMARY BOOM EXTEND
U13
C11-1 BK-6 WH-6 C11-2 WH-5 C10-2 RD C6-20

DRIVE LIMIT SWITCH
BK
LS2
21
22
C40LSS OR

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

CE
21
22
C22LS RD
I

EXTEND
PRIMARY BOOM
TS13
C3P-8 C16-1 C16-2

TB7
TS63
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
PRIMARY BOOM
BOOM RETRACT
TB8
C17-1 C17-2
TS9

J
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
WH
TS7

K
RIGHT PLATFORM
TB18
C4P-5 C23-1 C23-2
TS57
C6-18 C18JD GR/BK
RIGHT PLATFORM
LEFT ROTATE C6-17 C17 JU GR
C22-1 C22-2
TB17
C5-25
L
C44DA BK C6-19
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
BRN
RD
RD
RD
REV A
N

Electrical Schematic, Z-45/25 REV A

Perkins 104-22 Models (after serial number 22049)

1
P2
FS1
BK/RD
C7P-1
C2P-5
C1P-12
TS4
2 TS2
TS6
TS48 TS47
RD
P22BAT BK
TS1 ENGINE
FOOT SWITCH HIGH

RD
6
BK
ON
RD
SPEED
START
ENGINE
C134PWR BL/RD
ON
DRIVE LIGHT
WORK LIGHT
C132PLI BL/WH
PUMP
AUXILARY
GENERATOR
L48
P3
H1
GLOW PLUG
HORN
C2P-11
C2P-12
D40 5
C28TTA RD/BK
C7B-1
LIGHTS
C3P-9
C4P-1
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
C2P-5
C2P-7
C1P-9
C1B-12
C2B-5
3 CB2
15A
TB134 L30 L30
BK
P1
RD RD
RD
RD
C133PLA
C46HRN BK/RD
C28TTA RD/BK
TB22 1 3
TS51
C41RPM OR/BK
P23BAT WH
C27AUX RD
C34SA BK/WH
C43DLITE GR
C45GEN GR/WH
C35HS BK/RD
C33STR BK
KS1 TS52 TS56 TS54
4 5
C2P-9
C2P-10
PLAT
START
D3
ENGINE
PUMP
C32
ON
LOW RPM
HIGH RPM
AUXILIARY
GRD
6 7
PLUG
GLOW
12 8
4 D4
C1B-7
BK
C1B-1
PBOX GND
ENABLE
C3B-9
C4B-1
C1B-2
RD
FUNCTION
C7B-2
C2B-3
C1B-9
TB27
TB33
C2B-5
C2B-7
D2
RD
TB23
C1B-8
TB41 1 START RELAY
CB1 2 TACHOMETER
15A 3 START INPUT
4 AUX. ON U1 L42
RD
+ 7 KEY PWR. MODULE
5 C3 3MF CR1
8 KEY BYPASS
L43
C5-24
CR1 9 IGN./FUEL ON
CR2 10 ENG. FAULT WATER
NO CR2
NO TEMP.
C7B-4
P20BAT RD
C35HS BK/RD
C21IGN WH C5-3 TB21
C23 ALARM RD
C45GEN GR/WH
C34SA BK/WH
C25PSR WH/BK
C26TSR WH/RD
C6-34
P22BAT BK
C46HRN BK/RD
C23TTSR WH
C28TTA RD/BK
C27AUX RD
R33STR BK
C41RPM OR/BK
C21IGN WH
C21IGN2 WH
FUSE
P20BAT RD
C21IGN WH
10A
6 TB25
CR23
CR23
CR4
NO
C5-5
CR5 TB26 NO CR4

NO
BK/RD
ALTERNATOR A B
C5-2
D1 FB1
RD
WH
C6-38
C6-39
EXCT.
C5-22
C5-12
C5-11
C5-16
C5-14
BAT. BAT. PR1 PR2
C6-9
B1 + - PR1 PR2
C5-18
12V DC S8 NO NO PR3
NO PR3
RD
RD
+
STA.
7 STARTER M3 +
SW2
NC
U32
H2 AUX
M2 HM
BK
PUMP
REGULATOR _ SW3
BRN
BRN
BRN
SUPRESSION DIODE
STARTER MOTOR

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

AUXILIARY PUMP
GLOW PLUGS
NOTE:
8
C3B & C3P = GREEN


6 - 66
1
C7P-3 BATGND C7B-3

GROUND
C41RPM OR/BK
A
C2P-3
U4
5
C31REV WH/BK
TS14

C28TTA RD/BK

DRIVE MODE
8
H4
C6-33 C32TA WH/RD

TRAVEL ALARM OPTION
B
L1
CDE3 BL/RD
16
J1
C26-1 C26-2
TB32
TS15

LEFT
DRIVE ENABLE
RIGHT C28-1 C28-2
6
20 MOTOR STROKE
P26ESTP BK
P24FS WH
7
BL
C
RKOUT 6
DRIVE & STEERING
WH C25-1 C25-2
YOUT 5 4
JC3
J1
4 5 17 STEER RIGHT
OR
PWR 3 13
C1P-10 C1B-10 C6-36
1 C24-1 C24-2
11
9
CR33
D

TB5
C3P-5 C3B-5
10
SELECT RELAY
86
85
RIGHT C5TRR WH/BK

87a 87
LEFT
30
C6-5 C15-1 C15-2

TS62
C4TRL WH
R4
20
TB6

C6-4 C14-1 C14-2
7
CR32
6
TB1
BK PRIMARY BOOM
YOUT 5 2
SELECT RELAY
86
85
RD
JC2
XOUT 4 1 C12-1 C12-2

UP C1PBU RD
E
TB2
J1
PWR 3
OR PRIMARY BOOM
11 PRIMARY BOOM UP
87a 87
DOWN
30
BRN
C6-1
C2PBD RD/BK
Part No. 77809
TS61
GND 2 12
J2
TB3
1
March 2005

6
7
8
F
7
SECONDARY BOOM
6 14
YEL
UP/DOWN
OUT 5 3
13
JC1
4
J1
OR
CR37
12
TB10
GND 2
BRN
10 SECONDARY BOOM
SELECT RELAY
86
85
1 C18-1 C18-2
P26ESTP BK
UP C10SBU BL
BOOM SECONDARY
SECONDARY BOOM UP
87a 87
DOWN
30
C6-10
G
BRN C11SBD BL/BK

TS60
TB11
1
TB12

P24FS WH
2
P24FS WH
LS3
J3
4
3
13
14
3
2
C2P-2
LS1
4
DRIVE LIMIT SWITCH
BK
21
22
H
LS2
C40LSS OR

DRIVE LIMIT SWITCH
21
22
LS4
OPTION
CR30
CR27
DRIVE
NO

NC
LIFT/
DRIVE LIMIT SWITCH

CE
21
22
C22LS BK
EXTEND
BOOM
I

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

RIGHT PLATFORM
TS7
TB18
C4P-5 C23-1 C23-2
TS57
K
JIB BOOM DOWN

RIGHT
PLAT ROTATE
JIB BOOM UP
C22-1 C22-2
TB17
C5-25
C44DA BK C6-19
H3
L


C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
M
P24FS WH
EXCEPT AS NOTED.
BRN
RD
RD
BK
C4B & C4P - BROWN

C3B & C3P - GREEN
C2B & C2P - BLACK
C1B & C1P - GRAY
NOTES:
WHEEL.
REV A
N


8
7
6
5
4
3
2
1
6 - 67
Genie Industries
1
A
2
3
4
BRN-IS5 5 GROUND
5
RD-CR1 6 BATTERY
6

7
NOTE:
9 1 3 4 7 10 9 2
10
B
I.S.M.
TERMINAL BASE (TB)

D C B A
C6-1 RD
C3B-1 RD RD-TS61
1 PRIMARY BOOM UP 1
C6-2 RD/BK BK
C3B
C3B-3 RD/WH
C

C6-4 WH
C3B-4 WH WH-TS62
C6-5 WH/BK
BK

C6-6 WH/RD

C6-7 BK
C3B
C3B-7 BK BK-TS63
C6-8 BK/WH
D

C6-10 BL
C3B-10 BL BL-TS60
C6-11 BL/BK BK
I.S.M.
C6-12 BL/WH
C6-14 OR
C4B-2 OR OR-TS59
C6-15 OR/BK
C4B
E

C6-17 GR
C4B-5 GR GR-TS57
C3B
C6-18 GR/BK
C7B
BK-ALARM
CR23 RD RD-CB2
C7B-4 RD RD-CB1
12V DC TO
PLATFORM

WH-R2 BRN
C5-3 WH WH-HM
Part No. 77809

March 2005
C6-20 RD
C5
C7B
C7B-1 BK BK-R5
F
C5-23 WH WH-IS7
C7B-2 WH WH-KS
C6-34 RD FB
C6
C6
RD-R2
C4B
C6-16
C6-40
C6-37
C6-36
C6-29
I.S.M.
C7B-3
RD-CB1
24 CB1 POWER 24
C5-16 WH/RD
FUNCTIONS
WH-IS10 WH/BK-L2-
C5-14 WH/RD
WH/RD-L3-
26 COOLANT TEMPERATURE SWITCH 26
C40LS1 OR
C6-27 RD RD-IS4
G
C36STCC BL
C37STC BL/BK
C29MS RD/WH
C16DRE OR/RD
BRN C1B-1 RD RD-TS51
C1B-6 WH/RD
32 BRAKE 32
BK-IS3
C4B-4
C1B

GENIE z45 25 Parts Sn. 21179to26998 PDF

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What is the purpose of this manual?

What is the purpose of this manual?

What safety precautions should be followed when performing maintenance?

What safety precautions should be followed when performing maintenance?

Service Manual Part No.

Important Serial Number Information

Contact Us: Copyright © 2003 by Genie Industries

http://www.genieindustries.com 77809 Rev C March 2005

Printed on recycled paper

ii Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J iii

Personal Safety Be sure to wear protective eye wear and

iv Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 77809 Z-45/25 • Z-45/25J v

Section 3 Rev Scheduled Maintenance Procedures, continued

vi Z-45/25 • Z-45/25J Part No. 77809

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 77809 Z-45/25 • Z-45/25J vii

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

viii Z-45/25 • Z-45/25J Part No. 77809

Section 4 Rev Repair Procedures, continued

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J ix

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

x Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Section 6 Rev Schematics

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xi

Section 6 Rev Schematics, continued

xii Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Section 6 Rev Schematics, continued

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xiii

Section 6 Rev Schematics, continued

xiv Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Section 6 Rev Schematics, continued

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J xv

Section 6 Rev Schematics, continued

xvi Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Wheel lugs, 4WD 9 @ 5/8 -18 Stowed position 4.8 mph

Tire ply rating 14 Tread 8 High range on paved surface 3 to 6 ft

Tire contact area 59 sq in 43.5 sq in Boom function speeds, maximum

Overall tire diameter 35.8 in 28 in Jib boom up, Z-45/25J 28 to 32 seconds

Fluid capacities Primary boom down 24 to 28 seconds

LPG tank 33.5 pounds Secondary boom up 24 to 28 seconds

Hydraulic system 30 gallons Primary boom retract 16 to 20 seconds

Continuous improvement of our products is a

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2-1

Hydraulic Specifications Drive pump

Hydraulic Oil Specifications Type: bi-directional, variable

Cleanliness level, minimum 15/13 Flow rate @ 2500 rpm 32 gpm

Charge pressure @ 2500 rpm 315 psi

Genie specifications require Flow rate @ 2500 rpm 7.25 gpm

2-2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809

Auxiliary pump Hydraulic filters