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Genie Z-45 XC, Service Manual

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Ground Control Box Wiring Diagram-
Z-45/25J Perkins Models (after serial number 16303)

1

2

3

4

5

6

7

8

A

B

C

D

E

F

G

H

I

J

K

L

M

N

First Edition • Second Printing

Section 6 • Schematics

6 - 76

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

AUXILIARY

TS63

PLAT.

BLU/BLK-11

RED-R1

RED-20

LEVEL

BLU-10

BLK/RED-35

BLK-33

BRN-(GRND)
WHT-21

WHT-23

BLK-22
RED-27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59

CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARY

BOOM

TS58

TS62

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1

KS1

ROTATE

ORG/BLK-15

ORG-14

PLATFORM

ROTATE

TURNTABLE

EXTEND

RETRACT

GRN-17

GRN/BLK-18

WHT/RED-6

WHT/BLK-5

WHT-4

BLK/WHT-8

RED/BLK-2

RED/WHT-3

BLK-7

RED-1

WHT/BLK-25

9

BK/RD-R5

BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

C

D

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4
RED/BLK-4

R/W-4

WHT-4
WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1-86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2#30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND

TURNTABLE ROTATE FUNCTION CTRL

PRIMARY BOOM DOWN
PRIMARY BOOM FUNCTION CONTROL

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

PRIMARY BOOM RETRACT

A

B

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM-7

RED-ISM-4

28

RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3
BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT-12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.-6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1
GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN

DRIVE ENABLE RELAY COIL

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT/JIB UP

PLATFORM ROTATE RIGHT/JIB DOWN

DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH

OIL TEMPERATURE SWITCH

GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE

AUXILARY PUMP SELECT

STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED

ALTERNATOR PULSE PICKUP

GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.

BLK-ISM-3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT-12

SECONDARY BOOM FUNCTION CTRL

LED

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED-R4

WHT-40B

BRN-(GRND H.M)

CR4

CR3

BLK/RED-35B

WHT-21

CR2

BLK-R1-E.H.

CR1

BLK-R1

RED-R1

WHT-R2

ORG-4

CR7

PLATFORM LEVEL

CUTOUT

(CE MODELS ONLY)

BRN-(R5)

GRN/WHT-19

JIB

BLK/RED-R5

BLK-22

BLK/RED-9A

RED-R2

WHT-21 (R2)

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RED

WHT/RED-26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM-10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1

BLK/RED-EH-r.male

r.fem-BLK/RED-R4

BLK/RED-EH-r.fem

r.male-BLK/RED-R5

BLK-E.H-r.fem

r.male-BLK-R1

ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8

SPEED LIMITING VARIABLE RESISTOR 10 OHMS

CR2

CR3

CR1

CR4

CR7

CR8

L2

PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)

PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

RPM SOLENOID RELAY

IGNITION / START RELAY

POWER RELAY

HIGH IDLE CUTOUT RELAY

OIL PRESSURE LED

DESCRIPTION

LABEL

TS52

TS57

TS59

TS54

KS1

TS51

TS58

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1

SECONDARY BOOM UP/DOWN SWITCH

CIRCUIT BREAKER, CONTROLS, 15A

PRIMARY BOOM UP/DOWN SWITCH

CIRCUIT BREAKER, ENGINE, 15A

PRIMARY BOOM EXTEND/RETRACT SWITCH

HOUR METER

TURNTABLE ROTATE SWITCH

FUNCTION ENABLE SWITCH

PLATFORM LEVEL SWITCH

PLATFORM ROTATE SWITCH
JIB BOOM UP/DOWN (JIB OPTION ONLY)

KEY SWITCH

EMERGENCY STOP BUTTON

AUXILIARY SWITCH

START ENGINE SWITCH

OIL TEMPERATURE LED

L3

HORN RELAY

CR5

ENGINE HARNESS

EH

HOUR METER

IGNITION/START MODULE

CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR

RELAY

C.H.

S.P.

M.H.

WIRE CONNECTION ABBREVIATION KEY:

ENGINE FAULT

GROUND CONTROL SWITCH PANEL

GROUND CONTROL BOX

BASE TERMINATION BLOCK

CR5

R4

+

BLK/RED-35GEN

BLK/RED-35GEN

BLK/WHT-34

TS56

GLOW PLUG

GLOW PLUG

TS56

Summary of Contents for Z-45 XC

Page 1: ...First Edition Second Printing Part No 52709 Service Manual From Serial number 9998 to 21179...

Page 2: ...ures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting eq...

Page 3: ...njury 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 qualifi...

Page 4: ...avoided may result in property damage Green used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be awa...

Page 5: ...ons Machine Specifications 2 1 Performance Specifications 2 2 Hydraulic Specifications 2 4 Ford LRG 425 EFI Engine Specifications 2 5 Deutz F3L 1011F Engine Specifications 2 7 Perkins 104 22 Engine Sp...

Page 6: ...eaks 4 10 A 9 Check the Tire Pressure 4 10 A 10 Test the Oscillate Axle if equipped 4 11 A 11 Test the Platform and Ground Controls 4 11 A 12 Test the Auxiliary Power Operation 4 12 A 13 Test the Tilt...

Page 7: ...Confirm the Proper Brake Configuration 4 34 B 9 Check the Oil Level in the Drive Hubs 4 34 B 10 Check and Adjust the Engine RPM Ford and Deutz Diesel Models 4 35 B 11 Test the Key Switch 4 37 B 12 Tes...

Page 8: ...Models 4 55 C 2 Replace the Engine Oil and Filter Deutz Diesel Models 4 57 C 3 Check the Engine Valve Clearances Deutz Diesel Models 4 57 C 4 Change or Recondition the Engine Coolant Liquid Cooled Mod...

Page 9: ...ngs 2WD Models 4 78 Section Five Troubleshooting Flow Charts Introduction 5 1 Fault Codes 5 3 1 Engine Will Not Crank Over 5 6 2 Engine Cranks Over But Will Not Start Ford Models 5 8 2A Engine Runs Wh...

Page 10: ...e 5 45 22 Turntable Rotate Right Function Inoperative 5 49 23 All Platform Leveling Functions Inoperative 5 53 24 Platform Level Up Function Inoperative 5 54 25 Platform Level Down Function Inoperativ...

Page 11: ...Ford Models before serial number 13099 6 12 Electrical Schematic Z 45 25 Ford Models from serial number 13098 to 16303 6 14 Ground Control Box Wiring Diagram Z 45 25 Ford Models from serial number 130...

Page 12: ...ic Z 45 25 Deutz Models before serial number 13099 6 34 Ground Control Box Wiring Diagram Z 45 25 Deutz Models before serial number 13099 6 35 Platform Control Box Wiring Diagram Z 45 25 Deutz Models...

Page 13: ...t Option Z 45 25 Deutz Models after serial number 16303 6 54 Electrical Schematic Z 45 25J Deutz Models after serial number 16303 6 56 Ground Control Box Wiring Diagram Z 45 25J Deutz Models after ser...

Page 14: ...iagram Z 45 25 Perkins Models after serial number 16303 6 72 Electrical Schematic Z 45 25J Perkins Models after serial number 16303 6 74 Ground Control Box Wiring Diagram Z 45 25J Perkins Models after...

Page 15: ...nder Z 45 25J Models 7 19 3 3 Jib Boom Platform Rotate Manifold Components Z 45 25J Models 7 21 Primary Boom Components 4 1 Plastic Cable Track 7 22 4 2 Primary Boom 7 27 4 3 Primary Boom Lift Cylinde...

Page 16: ...uges 7 46 Ground Controls 10 1 Control Relays 7 48 10 2 Toggle Switches See 1 4 Toggle Switches 7 49 10 3 Wago Components 7 49 10 4 Engine Fault Codes Ford Models 7 50 Hydraulic Pumps 11 1 Lift Steer...

Page 17: ...ponents 14 1 Rotation Hydraulic Motor 7 80 2WD Steering Axle Components 15 1 Yoke and Hub 7 84 15 2 Steering Cylinders 7 84 15 3 Tie Rod 7 85 4WD Steering Axle Components 16 1 Yoke and Hub 7 86 16 2 S...

Page 18: ...Genie Z 45 25 Genie Z 45 25J Part No 52709 First Edition Second Printing This page intentionally left blank...

Page 19: ...tional dimensions Maximum platform height Standard Base Models 45 ft 8 in 45 ft 6 in 13 9 m 13 8 m Narrow Base Models 45 ft 5 in 45 ft 5 in 13 9 m 13 9 m Maximum horizontal reach 124 ft 6 in 25 ft 3 i...

Page 20: ...71 cm Tire pressure 45 psi Foam filled 2 76 bar Fluid capacities Fuel tank 17 gallons 64 3 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 24 gallons 91 liters Hydraulic system 30 gallons including...

Page 21: ...m up 24 to 27 seconds Primary boom down 32 to 37 seconds Secondary boom up 23 to 27 seconds Secondary boom down 23 to 27 seconds Primary boom extend 10 to 14 seconds Primary boom retract 18 to 22 seco...

Page 22: ...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...

Page 23: ...acity 5 quarts including filter 4 7 liters Oil viscosity requirements Temperature below 60 F 15 5 C 5W 30 10 F to 90 F 23 C to 32 C 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C Temperature abov...

Page 24: ...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...

Page 25: ...ne F3L 1011F Displacement 125 cu in 2 05 liters Number of cylinders 3 Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Horsepower gross intermittent 44 continuous 40 horsepower 3000 rpm 36 Firing order...

Page 26: ...mm Lubrication system Oil pressure 41 psi at 2600 rpm 2 8 bar Oil capacity 8 6 quarts including filter 8 2 liters Oil viscosity requirements below 68 F 20 C synthetic 5W 20 5 F to 104 F 15 C to 40 C...

Page 27: ...ice kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end...

Page 28: ...2 10 Genie Z 45 25 Genie Z 45 25J Part No 52709 Section 2 Specifications First Edition Second Printing This page intentionally left blank...

Page 29: ...m The boom lift cylinder boom extend cylinder platform leveling slave cylinder platform rotator and jib boom cylinder Z 45 25J models incorporate counterbalance valves to prevent movement in the event...

Page 30: ...ional controls which are found in two locations the ground controls located on the engine side of the machine and the platform controls located in the platform All lift and drive functions are availab...

Page 31: ...secured with the turntable rotation lock Key switch in the OFF position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance...

Page 32: ...is procedure Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two years The Scheduled Maintenan...

Page 33: ...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...

Page 34: ...inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual...

Page 35: ...ion 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed Table A Procedures A 2 Inspect the De...

Page 36: ...trical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable rotation motors and drive torque hubs Axle components Boom components and wear pads Platform...

Page 37: ...0 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG Units ship with 10 40 CC SG Deutz Engine F3L 1011F 6 3 quarts Oil...

Page 38: ...Result The fluid level should be at the FULL mark Do not remove the radiator cap A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or f...

Page 39: ...ntaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in o...

Page 40: ...ic cylinders All hydraulic manifolds Primary and jib boom The underside of the turntable The underside of the drive chassis Ground area under the machine A 9 Check the Tire Pressure Bodily injury haza...

Page 41: ...t Up the Directional Valve Linkage A 11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An u...

Page 42: ...eature selecting and operating the ground controls will override the platform controls including the Emergency Stop button Deutz and Perkins Diesel models All functions should stop immediately The eng...

Page 43: ...n alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate Select a level test area The tilt alarm should not be sounding prior to the test 1 Open the eng...

Page 44: ...boom drive limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring 4 Manually activate the primary boom drive limit switch Result The primary boom drive limit sw...

Page 45: ...OCEDURES 13 Start the engine from the platform controls 14 Move the lift drive select switch to the lift position if equipped 15 Press down the foot switch Fully retract the primary boom 16 Move the l...

Page 46: ...e speed maximum raised or extended Drive speed boom 0 6 mph raised or extended 1 0 km h Standard Base Models 40 ft 45 sec 12 2 m 45 sec Drive speed boom 0 36 mph raised or extended 0 58 km h Narrow Ba...

Page 47: ...oom is past the left non steer wheel Result The drive enable indicator light should be on 11 Move the lift drive select switch to the drive position if equipped 12 Press down the foot switch and slowl...

Page 48: ...sult in severe burns 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2...

Page 49: ...rntable 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 TABLE A PROCEDURES 3 Remove the end cap f...

Page 50: ...o Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Locate the fuel system components mounted underneath the engine pivot plate viewed from botto...

Page 51: ...s discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Fuel filters Genie part numbers Fuel pre filter 52179 Fuel pressure regulat...

Page 52: ...e engine pivot plate safety pin A 19 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage After thi...

Page 53: ...e the safety pin if equipped from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine...

Page 54: ...C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade A 21 Inspect the Fuel Filter Water Separator Diesel Models Engine specifications require that this pro...

Page 55: ...6 Clean up any fuel that may have spilled 7 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel leak is dis...

Page 56: ...additional personnel from entering the area and do not operate the machine Repair the leak immediately 6 Swing the engine back to its original position and close the engine pivot plate latch 7 Instal...

Page 57: ...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...

Page 58: ...e components Contact with hot engine components may result in severe burns 1 Remove the safety pin if equipped from the engine pivot plate latch The engine pivot plate latch is located under the engin...

Page 59: ...not require the replenishing of electrolyte Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Table B Procedures B 2 Ins...

Page 60: ...ts original position and close the engine pivot plate latch 12 Install the engine pivot plate safety pin if equipped B 3 Check the Radiator Ford Models Maintaining the radiator in good condition is es...

Page 61: ...th a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operatio...

Page 62: ...hydraulic filter is being bypassed and the filter should be replaced The hydraulic filter condition indicator gauge is mounted to the hydraulic return filter on the engine side bulkhead B 6 Check the...

Page 63: ...cluding lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component dam...

Page 64: ...el valve on the drive pump is closed clockwise The free wheel valve is located on the side of the drive pump a drive pump b free wheel valve c lift pump d screwdriver The free wheel valve should alway...

Page 65: ...aining 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 contin...

Page 66: ...lockwise to decrease the rpm Tighten the low idle lock nut and recheck the rpm a solenoid boot b high idle adjustment nut c yoke lock nut d yoke e low idle adjustment screw f low idle lock nut 5 Move...

Page 67: ...ngine should stop and no functions should operate Deutz and Perkins Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds B 12 Test the Emergency Stop Butto...

Page 68: ...useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform Emergency Stop button to the OFF position 2 Start the engine from the ground contr...

Page 69: ...throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed lo...

Page 70: ...machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift...

Page 71: ...vates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Start the engine from the ground controls t...

Page 72: ...emperature 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform...

Page 73: ...allow the machine to be moved into an unsafe position 1 Start the engine from the platform controls 2 Rotate the turntable to the right until the boom is past the right non steering wheel Result The...

Page 74: ...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 foo...

Page 75: ...ish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot...

Page 76: ...n the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when...

Page 77: ...und when the switch is held down 3 Move the function enable switch to either side and activate the secondary boom toggle switch in the DOWN position hold for a moment and then release it Result The de...

Page 78: ...ge Extremely dirty conditions may require that the filter be replaced more often Burn hazard Beware of hot oil Contact with hot oil may result in severe burns Perform this procedure with the engine of...

Page 79: ...1 Open the engine side turntable cover and locate the fuel filter water separator next to the hydraulic return filter on the bulkhead 2 Disconnect and plug the fuel supply hose from the fuel tank to...

Page 80: ...ft pump 14 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug 15 Clean up any fuel that may have spilled during this procedur...

Page 81: ...Perform this procedure with the engine off 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight...

Page 82: ...fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system B 29 Replace the Spark Plugs Ford Models Engine specifications requires that this procedu...

Page 83: ...to 14 Nm TABLE B PROCEDURES B 30 Replace the Engine Air Filter Element Engine specifications requires that this procedure be performed every 400 hours or annually whichever comes first Perform this p...

Page 84: ...ement 6 Clean the inside of the canister and the gasket with a damp cloth 7 Install the new air filter element and install the mounting fastener 8 Install the end cap onto the canister Install and tig...

Page 85: ...vot 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 pl...

Page 86: ...sult in severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the safety pin if equipped from the engine pivot plate latch The engine pivot plate latch...

Page 87: ...il capacity including filter 6 liters Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have...

Page 88: ...se the drain valve 9 Replace all coolant hoses and clamps 10 Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full 11 Fill the coolant return tank to th...

Page 89: ...latch 16 Install the engine pivot plate safety pin if equipped 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature 18 Turn the engine off Allow th...

Page 90: ...the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Open the engine pivot plate latch and swing the e...

Page 91: ...are not worn below specification but are still within tolerence see Repair Procedure 4 2 How to Shim the Primary Boom 1 Start the engine from the ground controls 2 Raise the end of the primary boom to...

Page 92: ...lift cylinder safety chock is available through Genie part number 33484 2 Turn the engine off 3 Remove the safety pin if equipped from the engine pivot plate latch The engine pivot plate latch is loca...

Page 93: ...uration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury...

Page 94: ...e the jack stands Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage Steer Wheels 4WD Models 7 Chock the non steer wheels to prevent the machine...

Page 95: ...screwdriver The free wheel valve should always remain closed D 4 Grease the Turntable Rotation Bearing and Rotate Gear Yearly application of lubrication to the turntable bearing and rotate gear is es...

Page 96: ...ent damage Drive Hubs 1 Select the drive hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine until one...

Page 97: ...may cause severe burns Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted near the pump 2 Remove the filter housing b...

Page 98: ...eaner 3 Loosen the lock nut on the high idle mixture adjustment screw 4 Load the system by activating the primary boom retract function then move the function enable toggle switch to the high idle rab...

Page 99: ...e 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...

Page 100: ...hydraulic hose at the hydraulic tank Cap the fitting on the tank E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and servic...

Page 101: ...ic tank may become unbalanced and fall if it is not properly supported by the lifting device 14 Remove the suction strainers from the tank and clean them using a mild solvent 15 Rinse out the inside o...

Page 102: ...ns 91 liters Hydraulic system 30 gallons capacity including tank 114 liters Hydraulic fluid Dexron equivalent E 2 Change or Recondition the Engine Coolant Ford Models Replacing or reconditioning the e...

Page 103: ...ty 11 5 quarts 10 9 liters 4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container 5 Slowly remove the radiator cap from the radiator Bodily in...

Page 104: ...3 Change the Fuel Hoses Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsa...

Page 105: ...e injectors TABLE E PROCEDURES Deutz Diesel Models At the fuel pump disconnect the fuel hose to the fuel tank and drain the fuel tank into the container 5 Remove and replace all of the fuel line hoses...

Page 106: ...l personnel from entering the area and do not operate the machine Repair the leak immediately TABLE E PROCEDURES Explosion and fire hazard Electronic Fuel Injection EFI systems operate at a very high...

Page 107: ...Ford number FPP 194 303 Genie part number 52695 E 6 Check the Engine Cylinder Compression Ford Models Complete information to perform this procedure is available in the Ford LRG 425 EFI 2 5 Liter Ind...

Page 108: ...ub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement 6 Remove the dust cap from the hub then remove the cotter pin fr...

Page 109: ...ease seal when removing the hub 17 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into t...

Page 110: ...4 80 Genie Z 45 25 Genie Z 45 25J Part No 52709 First Edition Second Printing Section 4 Scheduled Maintenance Procedures This page intentionally left blank...

Page 111: ...jewelry Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or...

Page 112: ...as a machine in good working condition refer to the flow chart which most closely describes the problem Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem s...

Page 113: ...ctions or shorted wires from the TP sensor to the ECM OR replace the TP sensor 24 Manifold Absolute Pressure MAP sensor high voltage Faulty MAP sensor OR sensor wires shorted to ground or poor termina...

Page 114: ...ections OR HO2 sensor is bad Test for a leaking or malfunctioning fuel injector misfiring cylinder or bad TP sensor Remove HO2 sensor and check condition of sensor for contamination OR check for poor...

Page 115: ...r terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor 54 ECM Fault Illegal Operation The ECM received an illegal instruction signal from one or more of the se...

Page 116: ...NK YZGXZ ZUMMRK Y OZIN ZU KOZNKX YOJK GTJ INKIQ ZNK URZGMK GZ KOZNKX YOJK ZKXSOTGR UT YZGXZ Y OZIN 8KVRGIK YZGXZ ZUMMRK Y OZIN 9 URJ ZNK YZGXZ Y OZIN ZU KOZNKX YOJK GTJ INKIQ URZGMK GZ ZKXSOTGR 8KVGOX...

Page 117: ...OTGR URJ ZNK YZGXZ Y OZIN ZU KOZNKX YOJK GTJ INKIQ URZGMK GZ ZKXSOTGR UT 8 8KVRGIK 8 XKRG_ URJ ZNK YZGXZ Y OZIN ZU KOZNKX YOJK GTJ INKIQ URZGMK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT HRQ OXK LXUS ZKXSOTGR UT...

Page 118: ...K HGZZKX_ SUXK ZNGT 8KSU K YVGXQ VR M GTJ MXU TJ YVGXQ VR M HUJ_ XGTQ KTMOTK GTJ UHYKX K YVGXQ MUUJ YVGXQ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ KGQ UX TU YVGXQ UTZOT KJ UT ZNK TK Z VGMK 9KK 8KVGOX 9...

Page 119: ...ZNK YZGXZ Y OZIN ZU KOZNKX YOJK GTJ INKIQ URZGMK GZ ZNK ROMNZ MXKKT OXK UT ZNK OMTOZOUT IUOR VR M 9KK UXJ 28 9KX OIK 3GT GR LUX ZXU HRKYNUUZOTM ZNK OMTOZOUT Y_YZKS 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KV...

Page 120: ...OXK IOXI OZ LXUS GRZKXTGZUX ZU ZU ZKXSOTGR UT OMTOZOUT YZGXZ SUJ RK ZU NKIQ URZGMK GZ ZKXSOTGR UT OMTOZOUT YZGXZ SUJ RK OYIUTTKIZ XKJ OXK LXUS ZKXSOTGR UT OMTOZOUT YZGXZ SUJ RK GTJ INKIQ URZGMK GZ ZKX...

Page 121: ..._ IUTJOZOUT 58 INKIQ GRZKXTGZUX 58 INKIQ LUX YNUXZ IOXI OZY 58 INKIQ HGZZKX_ IGHRKY 58 XKVRGIK ZNK HGZZKX_ UX SUXK OYGHRK ZNK YZGXZKX H_ XKSU OTM ZNK HRQ OXK GZ ZNK YZGXZKX YURKTUOJ URJ ZNK YZGXZ Y OZ...

Page 122: ...RK 8KVRGIK ZNK OMTOZOUT YZGXZ SUJ RK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ URZGMK GZ ZKXSOTGR GTJ UT OMTOZOUT YZGXZ SUJ RK 8KVGOX UVKT OT VU KX Y VVR_ OXKY ZU ZKXSOTGR GTJ UT OMTOZOUT YZGX...

Page 123: ...KXSOTGR UT OMTOZOUT YZGXZ SUJ RK OYIUTTKIZ XKJ OXK LXUS ZKXSOTGR UT OMTOZOUT YZGXZ SUJ RK GTJ INKIQ URZGMK GZ ZKXSOTGR 8KVRGIK OMTOZOUT YZGXZ SUJ RK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ KYZ G O...

Page 124: ...KR YKRKIZ Y OZIN 9 8KVGOX UVKT OT VU KX Y VVR_ IOXI OZ ZU L KR YKRKIZ Y OZIN 9 NKIQ URZGMK GZ 8KVGOX UVKT OT HR XKJ OXK IOXI OZ LXUS L KR YKRKIZ Y OZIN ZU NKIQ URZGMK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT...

Page 125: ...TUOJ ZU UNSY 8KIUTTKIZ 26 ZGTQ GTJ YZGXZKX ZNKT YKK 3GOTZKTGTIK YKIZOUT LUX 26 GJP YZSKTZY 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ XGTQ KTMOTK LUX YKIUTJY GTJ INKIQ LUX IUTZOT OZ_ ZU MXU TJ GZ ZKX...

Page 126: ...V RRKJ U Z ZU ZNK 54 VUYOZOUT Z XT ZNK QK_ Y OZIN ZU MXU TJ IUTZXURY GTJ ROYZKT LUX ZNK L KR V SV ZU Z XT 54 LUX GVVXU OSGZKR_ YKIUTJY OJ ZNK L KR V SV Z XT UT TU 9KK UXJ 28 YKX OIK SGT GR LUX L KR Y...

Page 127: ...VVR_ IOXI OZ ZU IKTZKX ZKXSOTGR UL 863 Y OZIN 8KVRGIK XVS YKRKIZ ZUMMRK Y OZIN NKIQ URZGMK GZ 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZUMMRK Y OZIN ZU 8KVGOX UVKT OT HXT HR OXK LXUS ZU 3 58 IUTY RZ KT...

Page 128: ...GTJ 9 INKIQ OTJO OJ GRR_ GTJ XKVRGIK JKLKIZO K Y OZIN 8KVRGIK 3 UX IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 9KK 8KVGOX 9KIZOUT U ZU 8KZXOK K G RZ UJKY Y ZNKXK G LG RZ IUJK YZUXKJ OT ZNK 3 SKSUX_ _KY T...

Page 129: ...RY ZU ZXU HRKYNUUZ L KR OTPKIZOUT Y_YZKS YURKTUOJ JUKY TUZ V RR OT NKIQ URZGMK GZ HRQ XKJ OXK UT 863 YKRKIZ Y OZIN 9 GTJ 9 NKIQ URZGMK UT XKJ OXK GZ IKTZKX ZKXSOTGR UL 863 YKRKIZ Y OZIN 8KVGOX UVKT OT...

Page 130: ...J SU KY OT GTJ U Z LXKKR_ YURKTUOJ HOTJY NKIQ ROTQGMK UX XKVRGIK YURKTUOJ SU KY LXKKR_ 8KVRGIK YVKKJ YURKTUOJ 4UZK XKYOYZGTIK GIXUYY YURKTUOJ ZKXSOTGRY YNU RJ HK GVVXU OSGZKR_ UNSY UTZOT KJ LXUS ZNK V...

Page 131: ...RU OJRK Z XZRK Y_SHUR NKIQ URZGMK GZ HRQ XKJ OXK UT XVS YKRKIZ Y OZIN YURGZK ZNK VRGZLUXS GTJ MXU TJ 863 Y OZINKY 9 GTJ 9 INKIQ OTJO OJ GRR_ GTJ XKVRGIK JKLKIZO K Y OZIN NKIQ URZGMK GZ ZNK HRQ XKJ OX...

Page 132: ...SU K ZNK L KR YKRKIZ ZUMMRK Y OZIN 9 ZU ZNK 26 VUYOZOUT 5T K Z GTJ 6KXQOTY SUJKRY NURJ SGT GR L KR YN ZULL RK KX ZU ZNK IRUYKJ VUYOZOUT IRUIQ OYK 8KSU K L TIZOUT V SV LXUS SGOT V SV H Z RKG K GRR NUYK...

Page 133: ...ZOUT OTJO OJ GRR_ UX IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ RKYY ZNGT VYO JP YZ ZNK L TIZOUT SGTOLURJ Y_YZKS XKROKL GR K OZKS GRR ZNK G_ OT IRUIQ OYK IU TZOTM ZNK T SHKX UL Z XTY 3U K ZNK L TIZOUT K...

Page 134: ...UMMRK Y OZIN XU HRKYNUUZ KGIN L TIZOUT OTJO OJ GRR_ TU 6 RR HUZN SKXMKTI_ 9ZUV H ZZUTY U Z ZU ZNK 54 VUYOZOUT NKIQ URZGMK GZ XKJ OXK UT ZNK OTV Z YOJK UL ZNK MXU TJ IUTZXURY IUTZGIZ UL ZNK QK_ Y OZIN...

Page 135: ...OT XKJ OXK IOXI OZ LXUS QK_ Y OZIN ZU 58 8KVRGIK ZNK VRGZLUXS IUTZXURY IUTZGIZ GZ ZNK QK_ Y OZIN NKIQ URZGMK GZ 6 8KVGOX UVKT OT HRQ OXK IOXI OZ LXUS 6 NKIQ URZGMK GZ HRQ OXK UT OTV Z YOJK UL VRGZLUXS...

Page 136: ...X_ HUUS V ZUMMRK Y OZIN 9 GZ ZNK MXU TJ IUTZXURY OT ZNK V JOXKIZOUT NKIQ URZGMK GZ ZU 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU VXOSGX_ HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 22 58 XKVGOX UVKT OT HXU...

Page 137: ...T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ VXOSGX_ HUUS L TIZOUT IUTZXURRKX...

Page 138: ...11 GTJ YZGXZ ZNK KTMOTK 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK VXOSGX_ HUUS V ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK V JOXKIZOUT NKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 8KV...

Page 139: ...NK VXOSGX_ HUUS JU T ZUMMRK Y OZIN 9 GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU VXOSGX_ HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 22 58...

Page 140: ...T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ VXOSGX_ HUUS L TIZOUT IUTZXURRKX...

Page 141: ...TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK VXOSGX_ HUUS JU T ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 JP YZ VXOSGX_ JU T XKROKL...

Page 142: ...NK VXOSGX_ HUUS JU T ZUMMRK Y OZIN 9 GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU VXOSGX_ HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 22 58...

Page 143: ...T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ VXOSGX_ HUUS L TIZOUT IUTZXURRKX...

Page 144: ...NK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK VXOSGX_ HUUS JU T ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 JP YZ 9_YZKS XKROKL GR...

Page 145: ...IUTJGX_ HUUS V ZUMMRK Y OZIN 9 GZ ZNK MXU TJ IUTZXURY OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT HR NZ OXK IOXI OZ LXUS ZU YKIUTJGX_ HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGOX UVK...

Page 146: ...MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ YKIUTJGX_ HUUS L TIZOUT IUTZXURRKX...

Page 147: ...UT KTGHRK ZUMMRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK YKIUTJGX_ HUUS V ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK V JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 JP YZ YKIUTJGX_ HUUS XKROKL...

Page 148: ...UTJGX_ HUUS JU T ZUMMRK Y OZIN 9 GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT HR NZ OXK IOXI OZ LXUS ZU YKIUTJGX_ HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGO...

Page 149: ...XU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ YKIUTJGX_ HUUS L TIZOUT IUTZXU...

Page 150: ...UT KTGHRK ZUMMRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK YKIUTJGX_ HUUS JU T ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 JP YZ YKIUTJGX_ HUUS X...

Page 151: ...MMRK Y OZIN 9 GZ ZNK VRGZLUXS IUTZXURY OT ZNK K ZKTJ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK HRGIQ OXK UT ZNK VXOSGX_ HUUS K ZKTJ XKZXGIZ ZUMMRK Y OZIN 9 8KVGOX UVKT OT XKJ VU KX Y VVR_ IOXI OZ ZU 9 GTJ 9 5...

Page 152: ...XK OU Y VGMK JP YZ Y_YZKS XKROKL GR K YKK 8KVGOX 9KIZOUT OZKS 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR LG RZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSK...

Page 153: ...RK Y OZIN 9 GZ ZNK VRGZLUXS IUTZXURY OT ZNK XKZXGIZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK HRGIQ NZ OXK UT ZNK VXOSGX_ HUUS K ZKTJ XKZXGIZ ZUMMRK Y OZIN 9 8KVGOX UVKT OT XKJ VU KX Y VVR_ IOXI OZ ZU 9 GTJ 9...

Page 154: ...XK OU Y VGMK JP YZ Y_YZKS XKROKL GR K YKK 8KVGOX 9KIZOUT OZKS 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR LG RZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSK...

Page 155: ...ZUMMRK Y OZIN 9 UT MXU TJ VGTKR OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT NZ XKJ OXK IOXI OZ LXUS ZU Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T M...

Page 156: ...U GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZ Y OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRG...

Page 157: ...W OIQ JOYIUTTKIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ YZGXZ ZNK KTMOTK 3U K ZNK L TIZOUT KTGHRK ZUMMRK Y OZIN OT ZNK NOMN XVS VUYOZOUT GTJ NURJ ZNK Z XTZGHRK XUZGZK RKLZ ZUMMRK Y OZIN GZ ZNK MX...

Page 158: ...TOLURJ ZU ZNK Z XTZGHRK XUZGZOUT HXGQK 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ GIZO GZK ZNK Z XTZGHRK XUZGZK RKLZ L TIZOUT RKYYZNGT VYO VYO UX SUXK INGTMK Z XTZGHRK XUZGZK RKLZ GTJ XOMNZ IU...

Page 159: ...ZUMMRK Y OZIN 9 UT MXU TJ VGTKR OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT NZ XKJ OXK IOXI OZ LXUS ZU Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T...

Page 160: ...ZU GR K IUOR OZN QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZ Y OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT V...

Page 161: ...W OIQ JOYIUTTKIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ YZGXZ ZNK KTMOTK 3U K ZNK L TIZOUT KTGHRK ZUMMRK Y OZIN OT ZNK NOMN XVS VUYOZOUT GTJ NURJ ZNK Z XTZGHRK XUZGZK XOMNZ ZUMMRK Y OZIN GZ ZNK MX...

Page 162: ...RJ ZU ZNK Z XTZGHRK XUZGZOUT HXGQK 3U K ZNK L TIZOUT KTGHRK ZUMMRK Y OZIN ZU KOZNKX YOJK GTJ GIZO GZK ZNK Z XTZGHRK XUZGZK XOMNZ L TIZOUT RKYYZNGT VYO VYO UX SUXK INGTMK Z XTZGHRK XUZGZK XOMNZ GTJ RKL...

Page 163: ...VYO ZU HGX VXKYY XK MG MK OTZU SGYZKX I_ROTJKX XUJ KTJ N_JXG ROI NUYK NUYK IUTTKIZKJ ZU VUXZ 62 YOTM G ZKK LOZZOTM IZO GZK VXOSGX_ HUUS V L TIZOUT GTJ INKIQ ZNK VXKYY XK RKYY ZNGT 69 TYZGRR G ZU VYO...

Page 164: ...NKIQ ZNK URZGMK GZ OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ ZNK VRGZLUXS RK KR ZUMMRK Y OZIN 9 OT ZNK V...

Page 165: ...V GTJ JU T IU TZKXHGRGTIK GR KY OZKSY 7 GTJ 8 GTJ GIZO GZK ZNK VRGZLUXS RK KR V L TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK ZNK LG RZ_ IU TZKXHGRGTIK GR K TYZGRR G ZU ZU HGX VXKYY XK MG MK...

Page 166: ...IQ ZNK URZGMK GZ OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZ Y OZIN GTJ ZNK VRGZLUXS RK KR ZUMMRK Y OZIN 9 OT ZNK JU T...

Page 167: ...JU T GTJ V IU TZKXHGRGTIK GR KY OZKSY 7 GTJ 8 GTJ GIZO GZK ZNK VRGZLUXS RK KR JU T L TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK ZNK LG RZ_ IU TZKXHGRGTIK GR K TYZGRR G ZU ZU HGX VXKYY XK MG...

Page 168: ...S XUZGZK ZUMMRK Y OZIN 9 OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK MXT NZ OXK GZ ZNK POH JKRG_ IGVGIOZUX 8KVGOX UVKT OT MXT NZ OXK LXUS 6 ZU POH JKRG_ IGVGIOZUX UTZOT KJ UT ZNK TK Z VGMK 8KVGOX UV...

Page 169: ...N 9 OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ OXK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT XKJ OXK LXUS POH JKRG_ IGVGIOZUX ZU 8 IZO GZK LUUZ Y OZIN GTJ VRGZLUXS XUZGZK ZUMMRK Y OZIN 9 OT ZNK RKLZ JOXK...

Page 170: ...ZOUT OTUVKXGZO K 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY 8KVGOX UX XKVRGIK VRGZLUXS XUZGZUX 58 UXOLOIK OT POH SGTOLURJ OY VR MMKJ 58 POH SGTOLURJ SG_ NG K GT OTZKXTGR LG RZ UTY RZ KTOK T...

Page 171: ...XUZGZK ZUMMRK Y OZIN 9 OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK MXT NZ OXK GZ ZNK POH JKRG_ IGVGIOZUX 8KVGOX UVKT OT MXT NZ OXK LXUS 6 ZU POH JKRG_ IGVGIOZUX UTZOT KJ UT ZNK TK Z VGMK 8KVGOX UV...

Page 172: ...9 OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ OXK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT XKJ OXK LXUS POH JKRG_ IGVGIOZUX ZU 8 IZO GZK LUUZ Y OZIN GTJ VRGZLUXS XUZGZK ZUMMRK Y OZIN 9 OT ZNK XOMNZ JOX...

Page 173: ...T OTUVKXGZO K 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY 8KVGOX UX XKVRGIK VRGZLUXS XUZGZUX 58 UXOLOIK OT POH SGTOLURJ OY VR MMKJ 58 POH SGTOLURJ SG_ NG K GT OTZKXTGR LG RZ UTY RZ KTOK TJ Y...

Page 174: ...X UVKT OT XKJ VU KX OXK IOXI OZ LXUS QK_ Y OZIN ZU 9 58 XKVRGIK ZUMMRK Y OZIN 9 OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK...

Page 175: ...VYO ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK POH HUUS V L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVRGIK LG RZ_ GR K NKIQ LUX SKINGTOIGR...

Page 176: ...8KVGOX UVKT OT XKJ VU KX OXK IOXI OZ LXUS QK_ Y OZIN ZU 9 58 XKVRGIK ZUMMRK Y OZIN 9 OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZ...

Page 177: ...O ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK POH HUUS JU T L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVRGIK LG RZ_ GR K NKIQ LUX SKINGTOIGR...

Page 178: ...YZKKX XUIQKX Y OZIN UT JXO K IUTZXURRKX 6 OT RKLZ JOXKIZOUT GTJ INKIQ URZGMK UT HR OXK UT YZKKX JOXKIZOUTGR GR K IUOR OZKS UT L TIZOUT SGTOLURJ UX SUXK 8KVGOX UVKT OT HR OXK IOXI OZ ZNGZ X TY LXUS ZU...

Page 179: ...X XUIQKX Y OZIN UT JXO K IUTZXURRKX 6 OT XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT HR HRQ OXK UT YZKKX JOXKIZOUTGR GR K IUOR OZKS UT L TIZOUT SGTOLURJ UX SUXK 8KVGOX UVKT OT HR HRQ OXK IOXI OZ ZNGZ X TY LXU...

Page 180: ...ROTQGMK LUX JGSGMK UX OSVXUVKX ROTQGMK GJP YZSKTZ 9KK 8KVGOX YKIZOUT U ZU 9KZ V ZNK OXKIZOUTGR GR K 2OTQGMK HGJ 8K GJP YZ UX XKVRGIK ROTQGMK MUUJ TYZGRR G ZU VYO ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JO...

Page 181: ...VGOX UVKT OT VU KX Y VVR_ IOXI OZ LXUS 6 ZU ZKXSOTGR UT JXO K PU_YZOIQ 6 UX SUXK NKIQ IUTZOT OZ_ UL HXU T MXU TJ OXK LXUS ZKXSOTGR UT 6 ZU MXU TJ IUTZOT OZ_ TU IUTZOT OZ_ 8KVGOX UVKT OT HXU T MXU TJ O...

Page 182: ...J ZKXSOTGRY UT ZNK JXO K PU_YZOIQ IUTZXURRKX 8KVRGIK JXO K PU_YZOIQ IUTZXURRKX 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ TU IUTZOT OZ_ IUTZOT OZ_ NKIQ IUTZOT OZ_ LXUS ZKXSOTGR UT JXO K PU_YZOIQ ZU M...

Page 183: ...OZ K RKGJ LXUS G URZSKZKX ZU ZKXSOTGR UT ZNK PU_YZOIQ GTJ OZN ZNK LUUZ Y OZIN GIZO GZKJ GTJ ZNK JXO K PU_YZOIQ OT ZNK L RR LUX GXJ VUYOZOUT SU K ZNK JXO K KTGHRK ZUMMRK Y OZIN 9 ZU KOZNKX YOJK GTJ NUR...

Page 184: ...MK GIXUYY ZNK NZ GTJ ZNK NZ HRQ OXK ZKXSOTGRY UT ZNK 8K KXYK ZNK URZ SKZKX RKGJY GTJ SU K ZNK JXO K IUTZXURRKX ZU L RR XK KXYK VUYOZOUT GTJ TUZK ZNK URZGMK URZGMK XKGJOTMY JOLLKXKTZ 8KVGOX UX XKVRGIK...

Page 185: ...Z 45 25J 5 75 First Edition Second Printing Section 5 Troubleshooting Flow Charts Chart 35 Traction Function Inoperative Be sure all other functions operate normally T_ Z_VK UL ZXGIZOUT VXUHRKS IUTY R...

Page 186: ...n the boom is fully retracted Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Be sure the free wheel valve is closed on the drive pump OZN ZNK HUUS OT ZNK YZU KJ...

Page 187: ...rimary boom is extended Be sure the wiring to limit switches is intact and show no sign of damage or corrosion ZKTJ ZNK HUUS VGYZ ZNK JXO K ROSOZ Y OZIN GTJ INKIQ IUTZOT OZ_ LXUS MXU TJ ZU ZKXSOTGR UT...

Page 188: ...RK ZUMMRK Y OZIN 9 IZO GZK LUUZ Y OZIN GTJ JXO K IUTZXURRKX OT LUX GXJ JOXKIZOUT GTJ INKIQ URZGMK GZ ZKXSOTGR UT JXO K IUTZXURRKX 6 OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V...

Page 189: ...GZZKX_ IUTJOZOUT NKXK OY VUYYOHR_ TUZ KTU MN HGZZKX_ IGVGIOZ_ ZU UVKXGZK HUZN G V SV GTJ L TIZOUT GR KY SUZUX JUKY TUZ UVKXGZK OZN ZNK QK_ Y OZIN Z XTKJ ZU MXU TJ IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUT...

Page 190: ...5 80 Genie Z 45 25 Genie Z 45 25J Part No 52709 First Edition Second Printing Section 5 Troubleshooting Flow Charts This page intentionally left blank...

Page 191: ...here are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with electrically charged circuits may resul...

Page 192: ...0424 OEM Controls MCH1159AD1386 1 FB Flashing beacon 20189 ECCO Electronic Controls 6400A GEN 1 FS1 Footswitch 13482 Linemaster Switch Corp 632 S 1 H1 Alarm Warble tone 19270 Floyd Bell Inc MW 09 616...

Page 193: ...15R 1 1 R4 after serial number 13098 Resistor 10 25 watt 54516 Dale D25K10R 1 R5 Resistor 10 25 watt 27287 Dale RH25 10R 1 1 TS1 TS51 TS64 Gas LPG Toggle switch DPST 2 position momentary 13480 Microsw...

Page 194: ...First Edition Second Printing Section 6 Schematics 6 4 Genie Z 45 25 Genie Z 45 25J Part No 52709 Electrical Symbols Legend...

Page 195: ...FB Flashing beacon FS Foot switch H Horn or Alarm HM Hour meter KS Keyswitch L LED LS Limit switch P Power switch PR Power relay R Resistor TB Terminal base location TP Terminal platform location TS T...

Page 196: ...First Edition Second Printing Section 6 Schematics 6 6 Genie Z 45 25 Genie Z 45 25J Part No 52709...

Page 197: ...Ford LRG 425 EFI Engine Wire Harness before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 198: ...0CBK W12 107P20 151LB BK20 11T Y20 914T O20 32ADKBL16 915PK LB20 359LGY Y20 32R LB16 209W P20 306T LB20 307BK Y20 658PK LG20 674BR W20 198DG O20 253DG W20 264W LB18 16R LG16 361JR14 32ADKBL16 342LG P1...

Page 199: ...6 915PK LB20 359LG Y20 32R LB16 209W P20 306T LB20 307BK Y20 658PK LG20 674Y BK20 198DG O20 253DG W20 264W LB18 16R LG16 361JR14 32ADKBL16 342LG P16 32R LB16 361ER16 787APK BK16 926ALB O16 37CY16 16BR...

Page 200: ...Section 6 Schematics First Edition Second Printing Ford LRG 425 EFI Engine Wire Harness after serial number 13908...

Page 201: ......

Page 202: ...RELAY START ENGINE TS64 4 STARTER PUMP AUX RELAY PR1 RED 27 C H PR1 NO RED BLK 28 C H CR1 NO CR1 BLK R1 E H 1 RD LG FEH 16A PIN1 BR WT FEH 674 PIN7 BRN BLU FEH 253 PIN24 Y FEH 37B PIN8 Y FEH 37 PIN9 G...

Page 203: ...ONTROL TB2 UP DOWN PRIMARY BOOM 10 R5 PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 15 R4 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB5 RIGHT LEFT TURNTABLE ROTAT...

Page 204: ...Electrical Schematic Z 45 25 Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 205: ...Ground Control Box Wiring Diagram Z 45 25 Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 206: ...BOOM EXTEND PRI BOOM UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD R5 RD WT S P RED S P RD BK S P A IGN FUEL ON KEY BYPASS KEY PWR START INPUT AUX ON BATTERY GROUND WHT 21TO R2 CHECK HOUR ME...

Page 207: ...N BLK 1 GRN WHT 1 GRN 1 ORG RED 1 ORG BLK 1 ORG 1 42 40 41 45 44 43 EXTEND HORN RETRACT SEC BOOM F C JIB VALVE L P BRAKE AUX PWR E D C E D C 2WD 4WD RPM START ENGINE FAULT SPARE SPARE SPARE WHT 24 TO...

Page 208: ...Platform Control Box Wiring Diagram Z 45 25 Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 209: ......

Page 210: ...PIN1 YEL BLK FEH 674 PIN7 TAN BLU FEH 306 PIN24 Y FEH 37B PIN8 Y FEH 37 PIN9 GND BLK WT FEH 570E PIN42 PINK LG FEH 658 PIN6 WT PUR FEH 209 PIN18 TB21 TB25 NO CR2 8 7 6 5 10 9 CR2 TS51 RED 1 RED BLK 1...

Page 211: ...TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB4 RIGHT LEFT TURNTABLE ROTATE RED 1 M H BOOM EX...

Page 212: ...Electrical Schematic Z 45 25 Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 213: ...Ground Control Box Wiring Diagram Z 45 25 Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 214: ...OTATE LEFT TURNTABLE ROTATE RIGHT PRIMARY BOOM FUNTION CONTROL PRIMARY BOOM DOWN TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD...

Page 215: ...SEC BOOM F C JIB VALVE L P GAS BRAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT...

Page 216: ...Platform Control Box Wiring Diagram Z 45 25 Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 217: ......

Page 218: ...C H CR1 NO CR1 BLK R1 E H 1 RD LG FEH 16A PIN1 BR WT FEH 674 PIN7 BRN BLU FEH 253 PIN24 Y FEH 37B PIN8 Y FEH 37 PIN9 GND BLK WT FEH 570E PIN42 PINK LG FEH 658 PIN6 WT PUR FEH 209 PIN18 TB21 TB25 NO CR...

Page 219: ...TURNTABLE ROTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM 10 R5 PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 15 R4 R X TS62 WHT...

Page 220: ...Electrical Schematic Z 45 25J Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 221: ...Ground Control Box Wiring Diagram Z 45 25J Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 222: ...UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD R5 RD WT S P RED S P RD BK S P A IGN FUEL ON KEY BYPASS KEY PWR START INPUT AUX ON BATTERY GROUND WHT 21TO R2 CHECK HOUR METER TS54 R5 BLK RED...

Page 223: ...E AUX PWR E D C E D C 2WD 4WD RPM START ENGINE FAULT SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN OG BK...

Page 224: ...Platform Control Box Wiring Diagram Z 45 25J Ford Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 225: ......

Page 226: ...R FEH 209 PIN18 TB21 TB25 NO CR2 8 7 6 5 10 9 CR2 TS51 RED 1 RED BLK 1 TB27 TB28 RED TS1 WHT AUXILIARY PUMP AUXILIARY PUMP TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H 1 IGN START HM TB38...

Page 227: ...OTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT R...

Page 228: ...Electrical Schematic Z 45 25J Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 229: ...Ground Control Box Wiring Diagram Z 45 25J Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 230: ...TURNTABLE ROTATE RIGHT PRIMARY BOOM FUNTION CONTROL PRIMARY BOOM DOWN TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD R5 RD WT...

Page 231: ...SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 BLU RED 39 OPTION WIRE WHT GRN WHT...

Page 232: ...Platform Control Box Wiring Diagram Z 45 25J Ford Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 233: ......

Page 234: ...1 NO CR1 BLK R1 E H 1 RD LG FEH 16A PIN1 YEL BLK FEH 674 PIN7 TAN BLU FEH 306 PIN24 Y FEH 37B PIN8 Y FEH 37 PIN9 GND BLK WT FEH 570E PIN42 PINK LG FEH 658 PIN6 WT PUR FEH 209 PIN18 TB21 TB25 NO CR2 8...

Page 235: ...GHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H...

Page 236: ...Electrical Schematic Z 45 25 Ford Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 237: ...Ground Control Box Wiring Diagram Z 45 25 Ford Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 238: ...TURNTABLE ROTATE RIGHT PRIMARY BOOM FUNTION CONTROL PRIMARY BOOM DOWN TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD R5 RD WT S...

Page 239: ...E L P GAS BRAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 10...

Page 240: ...Platform Control Box Wiring Diagram Z 45 25 Ford Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 241: ......

Page 242: ...FEH 306 PIN24 Y FEH 37B PIN8 Y FEH 37 PIN9 GND BLK WT FEH 570E PIN42 PINK LG FEH 658 PIN6 WT PUR FEH 209 PIN18 TB21 TB25 NO CR2 8 7 6 5 10 9 CR2 TS51 RED 1 RED BLK 1 TB27 TB28 RED TS1 WHT PUMP PUMP AU...

Page 243: ...LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M...

Page 244: ...Electrical Schematic Z 45 25J Ford Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 245: ...Ground Control Box Wiring Diagram Z 45 25J Ford Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 246: ...TATE RIGHT PRIMARY BOOM FUNTION CONTROL PRIMARY BOOM DOWN TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM UP WHT S P BK WT S P BLK S P WT RD S P WT BLK S P BK RD R5 RD WT S P RED S P R...

Page 247: ...ARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 BLU RED 39 OPTION WIRE WHT GRN WHT 19 CABLE 3 H1 BLK JI...

Page 248: ...Platform Control Box Wiring Diagram Z 45 25J Ford Models after serial number First Edition Second Printing Section 6 Schematics...

Page 249: ......

Page 250: ...NO CR2 8 7 6 5 10 9 CR2 TS51 RED 1 RED BLK 1 TB27 TB28 RED TS1 WHT AUXILIARY PUMP AUXILIARY PUMP TP27 TP28 TS52 BLK 1 2 TB33 3 RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45...

Page 251: ...S62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB5 RED 1 M H BOOM EXTEND TB7 TP5 TP6 WHT RED 3 WHT BLK 3 TS63 BLK WHT 8 M H TB8 WHT 3 TB4 BOARD POWER TS13 TP7 BLK 3 TP8 BLK WHT 3 BLK 7 M H BRAKE RELEASE VALV...

Page 252: ...Electrical Schematic Z 45 25 Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 253: ...Ground Control Box Wiring Diagram Z 45 25 Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 254: ...PLAT ROT R DRV ENA LT IGNITION PWR KEYSWITCH PWR PWR TO PLAT OIL PRESSURE SENDER WATER TEMP SENDER GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BLK SP WHT S P RED S P WHT S P BLK...

Page 255: ...34 37 38 36 GRN BLK 1 GRN WHT 1 GRN 1 ORG RED 1 ORG BLK 1 ORG 1 42 40 41 45 44 43 EXTEND HORN RETRACT SEC BOOM F C JIB VALVE L P BRAKE AUX PWR E D C E D C 2WD 4WD RPM START ENGINE FAULT SPARE SPARE S...

Page 256: ...Platform Control Box Wiring Diagram Z 45 25 Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 257: ......

Page 258: ...LK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 GENERATOR ON OFF TS47 TP45 RED WHT WHT TP25 TP24 RED FS1 RED BLK BLK RED TS54 BLK RED 1 HI...

Page 259: ...PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB4 RIGHT LEFT TURNT...

Page 260: ...Electrical Schematic Z 45 25 Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 261: ...Ground Control Box Wiring Diagram Z 45 25 Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 262: ...RM ROTATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WH...

Page 263: ...1 ORG BLK 1 ORG 1 42 40 41 45 44 43 BOOM EXTEND HORN BOOM RETRACT SEC BOOM F C JIB VALVE BRAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26...

Page 264: ...Platform Control Box Wiring Diagram Z 45 25 Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 265: ......

Page 266: ...BLK 1 TB27 TB28 RED TS1 WHT PUMP PUMP AUXILIARY AUXILIARY TP27 TP28 TS52 BLK 1 2 TB33 3 RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 TS47 TP45 RED WHT WHT TP25 TP...

Page 267: ...RED 6 M H TB5 RED 1 M H BOOM EXTEND TB7 TP5 TP6 WHT RED 3 WHT BLK 3 TS63 BLK WHT 8 M H TB8 WHT 3 TB4 BOARD POWER TS13 TP7 BLK 3 TP8 BLK WHT 3 BLK 7 M H BRAKE RELEASE VALVE RED WHT 1 MOTOR STROKE SECO...

Page 268: ...Electrical Schematic Z 45 25J Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 269: ...Ground Control Box Wiring Diagram Z 45 25J Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 270: ...L PLAT ROT R DRV ENA LT IGNITION PWR KEYSWITCH PWR PWR TO PLAT OIL PRESSURE SENDER WATER TEMP SENDER GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BLK SP WHT S P RED S P WHT S P B...

Page 271: ...EXTEND HORN RETRACT SEC BOOM F C JIB VALVE L P BRAKE AUX PWR E D C E D C 2WD 4WD RPM START ENGINE FAULT SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TIL...

Page 272: ...Platform Control Box Wiring Diagram Z 45 25J Deutz Models before serial number 13099 First Edition Second Printing Section 6 Schematics...

Page 273: ......

Page 274: ...1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 GENERATOR GLOW PLUG GLOW PLUG TS47 TP45 RED WHT WHT TP25 TP24 RED FS1 RED BLK BLK RED TS54 B...

Page 275: ...E ROTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WH...

Page 276: ...Electrical Schematic Z 45 25J Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 277: ...Ground Control Box Wiring Diagram Z 45 25J Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 278: ...P PLATFORM ROTATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU W...

Page 279: ...RAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY...

Page 280: ...Platform Control Box Wiring Diagram Z 45 25J Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 281: ...P SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN O...

Page 282: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25J Deutz Models from serial number 13099 to 16303 First Edition Second Printing Section 6 Schematics...

Page 283: ......

Page 284: ...S51 RED 1 RED BLK 1 TB27 TB28 RED TS1 WHT PUMP PUMP AUAXILIARY AUAXILIARY TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1...

Page 285: ...URNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB4...

Page 286: ...Electrical Schematic Z 45 25 Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 287: ...Ground Control Box Wiring Diagram Z 45 25 Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 288: ...RM ROTATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WH...

Page 289: ...D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 4...

Page 290: ...Platform Control Box Wiring Diagram Z 45 25 Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 291: ...RED 1 ORG BLK 1 ORG 1 42 40 41 45 44 43 BOOM EXTEND HORN BOOM RETRACT SEC BOOM F C JIB VALVE BRAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L B...

Page 292: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25 Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 293: ......

Page 294: ...PUMP AUXILIARY PUMP TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 TS47 TP45 RED WHT WHT TP25 RED FS FS1 BLK RED TS54 BL...

Page 295: ...L PRIMARY BOOM TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M...

Page 296: ...Electrical Schematic Z 45 25J Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 297: ...Ground Control Box Wiring Diagram Z 45 25J Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 298: ...OTATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BL...

Page 299: ...K 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 RED 10 OPTION WIRE WHT GRN WHT 19 CABLE 3 BLK JIB CABLE GRN WHT RED OUTPUT BR...

Page 300: ...Platform Control Box Wiring Diagram Z 45 25J Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 301: ...OW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 RED 10 OPTION W...

Page 302: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25J Deutz Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 303: ......

Page 304: ...Y TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 TS47 TP45 RED WHT WHT TP25 TP24 RED FS1 RED BLK BLK RED TS54 BLK RED 1 H...

Page 305: ...TE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H PWM BP1 A R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M H TB4 RIGHT LEFT TU...

Page 306: ...Electrical Schematic Z 45 25 Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 307: ...Ground Control Box Wiring Diagram Z 45 25 Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 308: ...LATFORM ROTATE RIGHT DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BL...

Page 309: ...G 1 42 40 41 45 44 43 BOOM EXTEND HORN BOOM RETRACT SEC BOOM F C JIB VALVE BRAKE AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC...

Page 310: ...Platform Control Box Wiring Diagram Z 45 25 Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 311: ......

Page 312: ...WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 TS47 TP45 RED WHT WHT TP25 TP24 RED FS1 RED BLK BLK RED TS54 BLK RED 1 HIGH RPM FUNCTION ENABLE TS4 TP35 NOTE JIB VALVES RED CR13 CR14 BRN RED RED W...

Page 313: ...RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6...

Page 314: ...Electrical Schematic Z 45 25J Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 315: ...Ground Control Box Wiring Diagram Z 45 25J Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 316: ...ATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BLK...

Page 317: ...H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 OPTION WIRE WHT GRN WHT 19 CABLE H1 3 BLK JIB CABLE GRN WHT RED OUTP...

Page 318: ...Platform Control Box Wiring Diagram Z 45 25J Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 319: ...4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 OPTI...

Page 320: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25J Perkins Models before serial number 16304 First Edition Second Printing Section 6 Schematics...

Page 321: ......

Page 322: ...2 TS51 RED 1 RED BLK 1 TB27 TB28 RED TS1 WHT AUXILIARY PUMP AUXILIARY PUMP TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1...

Page 323: ...IGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H A PWM BP1 R X TS62 WHT BLK 5 M H TB1 TB6 WHT RED 6 M...

Page 324: ...Electrical Schematic Z 45 25 Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 325: ...Ground Control Box Wiring Diagram Z 45 25 Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 326: ...LATFORM ROTATE RIGHT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S...

Page 327: ...UMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN...

Page 328: ...Platform Control Box Wiring Diagram Z 45 25 Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 329: ...E AUX PUMP SEL E D C E D C 2WD 4WD HIGH LOW RPM START ENGINE SPARE SPARE SPARE SPARE WHT 24 TO H P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY ST...

Page 330: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25 Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 331: ......

Page 332: ...UMP AUXILIARY AUXILIARY TP27 TP28 TS52 BLK 1 2 TB33 3 START ENGINE RED WHT 23 E H IGN START MODULE WHT 21 GRN WHT 45 E H FB BLK 1 TP33 TB45 GRN WHT 1 TS47 TP45 RED WHT WHT TP25 RED FS FS1 BLK RED TS54...

Page 333: ...PRIMARY BOOM TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE PRIMARY BOOM UP FLOW CONTROL TB2 UP DOWN PRIMARY BOOM PWM A X R TP1 TS61 TP2 RED BLK 3 RED 3 TB3 RED BLK 2 M H RED WHT 3 M H...

Page 334: ...Electrical Schematic Z 45 25J Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 335: ...Ground Control Box Wiring Diagram Z 45 25J Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 336: ...HT JIB DOWN DRIVE ENABLE LIGHT IGNITION POWER KEYSWITCH POWER 12 V TO PLATFORM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH GR BK S P OG BK SP ORG SP GRN S P BU BK S P BLU S P BLU WT S P WHT BLK SP WHT...

Page 337: ...BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 OPTION WIRE WHT GRN WHT 19 CABLE 3 H1 BLK JIB CABLE GRN WHT RED OUTPUT BRN...

Page 338: ...Platform Control Box Wiring Diagram Z 45 25J Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 339: ...P L BLK 26 BRN TO GRD NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 250 100 EMERGENCY STOP HORN ORG BLK 41 ORG 40 OPTION WIRE WHT GRN WHT 19 CABLE 3 H1 BLK JIB CABLE GRN WHT RED OUTPUT...

Page 340: ...Platform Control Box Wiring Diagram Lift Drive Select Option Z 45 25J Perkins Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 341: ...Platform Control Box Wiring Diagram Load Sensor Option All Models after serial number 16303 First Edition Second Printing Section 6 Schematics...

Page 342: ...W RPM START ENGINE SPARE SPARE SPARE SPARE NC NC R A X R A X A R X 4 2 3 1 5 6 7 8 TILT ALARM RED BLK 1 EMERGENCY STOP HORN OPTION WIRE WHT CABLE 3 HIGH LOW START DRIVE SEC BOOM DRV ENA HIGH LOW 2WD 4...

Page 343: ...First Edition Second Printing Section 6 Schematics Hydraulic Symbols Legend Part No 52709 Genie Z 45 25 Genie Z 45 25J 6 80...

Page 344: ...First Edition Second Printing Section 6 Schematics 6 81 Genie Z 45 25 Genie Z 45 25J Part No 52709...

Page 345: ...r 5 1 ATMOS 1500 PSI 103 4 bar 3 1 ATMOS 1000 PSI 68 9 bar 360 PSI 24 8 bar 50 PSI 3 4 bar NOTE 1 250 PSI 17 2 bar before serial number 280 PSI 19 3 bar after serial number 12603 12604 3500 PSI 241 3...

Page 346: ...2WD Hydraulic Schematic First Edition Second Printing Section 6 Schematics...

Page 347: ...2 GPM 7 6 L min before serial number 0 8 GPM after serial number 14774 14775 3 02 L min NOTE 2 250 PSI 17 2 bar before serial number 280 PSI 19 3 bar after serial number 12603 12604 RA LB BRAKE 2 SPEE...

Page 348: ...4WD Hydraulic Schematic First Edition Second Printing Section 6 Schematics...

Page 349: ...hocked 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 afte...

Page 350: ...result in death or serious injury Remove all rings watches and other jewelry Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating pr...

Page 351: ...trimpot to achieve an 32 to 37 second cycle time Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not...

Page 352: ...clockwise to decrease the time Boom up down specifications Threshold 2 85V DC Primary boom up hi range 6 5V DC Cycle time 24 to 27 seconds Primary boom down lo range 5 5V DC Cycle time 32 to 37 second...

Page 353: ...Adjust the voltage to 6 5V DC Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Set the lo range Press down the foot switch th...

Page 354: ...time or counterclockwise to decrease the time Secondary boom up down specifications Threshold 2 85V DC Secondary boom up hi range 6 5V DC Cycle time 23 to 27 seconds Secondary boom down lo range 5 5V...

Page 355: ...rimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 6 Set the hi range Press down the foot switch fully retract the boom then move the control handle...

Page 356: ...timum performance How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure See Maintenance Procedure A 22 Check and Adjust the Engine RPM for Perkins...

Page 357: ...9 to 10V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 1V DC to 0 5V DC voltage reading 9 Move the...

Page 358: ...peed boom 0 6 mph raised or extended 1 km h Standard Base Models 40 ft 45 sec 12 2 m 45 sec Drive speed boom 0 36 mph raised or extended 0 58 km h Narrow Base Models 40 ft 79 sec 12 2 m 79 sec 1 3 Foo...

Page 359: ...N C to N O no continuity infinite C to N O continuity zero 1 4 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching req...

Page 360: ...1 to 2 3 4 5 6 no continuity infinite W terminal 2 to 3 continuity zero W terminal 2 to 4 5 6 no continuity infinite W terminal 3 to 4 5 6 no continuity infinite W terminal 4 to 5 6 no continuity inf...

Page 361: ...form control box mounting fasteners Then lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before...

Page 362: ...boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 4 Z 45 25J Models Tag disconnect and plug the hydraulic hos...

Page 363: ...tal position 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 Platform Rotator The platform rotator is a hydraulicall...

Page 364: ...e platform mounting weldment may become unbalanced and fall if it is not properly supported 5 Support the platform rotator with a lifting device Do not apply any lifting pressure Z 45 25J Models 6 Rem...

Page 365: ...b bottom bleed valve c container d clear hose 4 Move the function enable toggle switch to either side and hold the platform rotate switch to the LEFT position until the platform is fully rotated Conti...

Page 366: ...the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow th...

Page 367: ...may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane 3 2 Jib Boom Lift Cylinder Z 45 25J Models How to Remove the Jib Boom Lift Cyli...

Page 368: ...f way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a liftin...

Page 369: ...J Models 1 Orifice 0 030 inch 0 76 mm AU Platform rotate circuit 2 Solenoid valve 2 position 3 way AV Platform rotate jib boom select 8 10 ft lbs 11 14 Nm Plug Torque Specifications Description Hex Si...

Page 370: ...rack to the platform control box Number each cable and its entry location at the platform control box 2 Open the platform control box Primary Boom Components 3 Label and disconnect each wire of the ca...

Page 371: ...ard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 11 Pull the four hy...

Page 372: ...ve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow t...

Page 373: ...hose clamp on the primary boom bellcrank 14 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower cable tracks ar...

Page 374: ...rack mounting fasteners that attach the lower cable track to the primary boom 27 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable...

Page 375: ...g or scraping of the boom Always maintain squareness between the outer and inner boom tubes How to Remove the Primary Boom Bodily injury hazard This procedure requires specific repair skills lifting e...

Page 376: ...h inside of the extension boom 11 Remove the primary boom extension drive speed limit switch mounting fasteners Do not disconnect the wiring 12 Pull the limit switch and the wiring out of the extensio...

Page 377: ...the pivot end of the primary boom Use a soft metal drift to remove the pin PRIMARY BOOM COMPONENTS 4 Remove and label the location of the wear pads from the platform end of the primary boom Pay carefu...

Page 378: ...ift the boom 4 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 5 Tag disconnect and plug the primary boom lift cylinder...

Page 379: ...ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boo...

Page 380: ...eveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion T...

Page 381: ...arrel 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 PRIMARY BOOM COMPONE...

Page 382: ...s and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemb...

Page 383: ...n hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Remove the pin retaining fasteners from both sides of the secondary boom lif...

Page 384: ...ate the 4 cables that enter the platform control box Number each cable and its entry location at the platform control box 24 Open the platform control box 25 Label and disconnect each wire of the cabl...

Page 385: ...er point of the number 2 arm for support Do not lift it 40 Remove the pin retaining fasteners from both compression link pivot pins Do not remove the pins 41 Use a soft metal drift to remove the lower...

Page 386: ...lide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box 55 Remove the number 3 arm from the machine Crushing hazard The number 3...

Page 387: ...n the secondary boom lift cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do...

Page 388: ...e on the support bracket on the cover to ensure proper cover alignment during installation Ground controls side cover Mark the location of the hinge on the cover to ensure proper cover alignment durin...

Page 389: ...ce Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remo...

Page 390: ...crank the engine with the low oil pressure light on How to Remove the Oil Temperature and Oil Pressure Switches Perform this procedure with the engine off 1 Remove the safety pin if equipped from the...

Page 391: ...plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywhe...

Page 392: ...y set The contacts will close at approximately 4 2 psi 0 3 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on the gauge when the engine is...

Page 393: ...Procedures B 10 Check and Adjust the Engine RPM Ford and Deutz Diesel Models 9 3 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and ha...

Page 394: ...orque the pump mounting plate fasteners to 34 ft lbs 46 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged 9 4 Water Temperature and...

Page 395: ...m the desired switch 3 Remove the switch from the engine block and then install the new switch Do not over tighten Burn hazard Contact with hot engine fluids or components may result in severe burns A...

Page 396: ...o be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other...

Page 397: ...n death or serious injury Remove all rings watches and other jewelry Wago tools are available from the Genie Service Parts Department Genie part number 33996 1 Label the wiring from the component to b...

Page 398: ...ld the run test toggle switch to the test position and turn the key switch to the ground controls position Result The check engine light should turn on The check engine light should begin to blink 5 C...

Page 399: ...nd the key switch in the OFF position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes Electrocution ha...

Page 400: ...ent damage hazard The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur If the tank valves are closed remove the key from the key...

Page 401: ...d then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controll...

Page 402: ...ive pump 2 Remove the safety pin if equipped from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3...

Page 403: ...e starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 Ford models Connect the LPG hose to the LPG tank and open t...

Page 404: ...t lbs 14 6 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 regu...

Page 405: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 57 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 406: ...ircuits to tank 10 12 ft lbs 14 16 Nm 16 Check valve P Differential sensing circuit platform level down 11 13 ft lbs 15 18 Nm 17 Counterbalance valve Q Platform level down 35 40 ft lbs 47 54 Nm 18 Cou...

Page 407: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 59 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 408: ...b boom up down and platform rotate left right 25 30 ft lbs 34 41 Nm 30 Solenoid valve 3 position 4 way DD Primary boom up down 25 30 ft lbs 34 41 Nm 31 Differential sensing valve EE Meters flow to fun...

Page 409: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 61 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 410: ...e cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure MANIFOLDS How to Adjust the Primary Boom Down Relief Valve befor...

Page 411: ...ding on the pressure gauge Secondary boom down relief valve specifications Pressure 1800 psi 124 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 5 5 Adjust the...

Page 412: ...artment Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position 3 way MM Turntable rotation brake release 10 13 ft lbs 14 18 Nm 2 Counterbalance valve NN Turntable rotate right...

Page 413: ...ection 7 Repair Procedures 12 4 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...

Page 414: ...vers 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...

Page 415: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 67 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS This page intentionally left blank...

Page 416: ...re circuit 10 12 ft lbs 14 16 Nm 3 Flow divider combiner valve RR Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 4 Orifice 0 070 in 1 78 mm SS Drive circuit 5 Check valve T...

Page 417: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 69 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 418: ...ion and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 4 Turn the engine off Hold the charge pressure relief valve and remove...

Page 419: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 71 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS This page intentionally left blank...

Page 420: ...3 way AG Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 7 Relief va...

Page 421: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 73 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 422: ...r 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...

Page 423: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 75 First Edition Second Printing Section 7 Repair Procedures MANIFOLDS...

Page 424: ...on and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 4 Turn the engine off Hold the charge pressure relief valve and remove t...

Page 425: ...from the machine 13 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump...

Page 426: ...a suitable container See capacity specifications below 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 6 Disconnect and plug the return filter hy...

Page 427: ...Part No 52709 Genie Z 45 25 Genie Z 45 25J 7 79 First Edition Second Printing Section 7 Repair Procedures This page intentionally left blank...

Page 428: ...o allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the turntable rotation motor mounting fasteners then remove the motor from the brake 5 Remove the turntable...

Page 429: ...ION COMPONENTS 3 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold and the brake Cap the fittings on the manifold and the brake Bodily injury hazard Spraying hydra...

Page 430: ...etaining fasteners from the yoke pivot pins Do not remove the pins 7 Support and secure the yoke hub assembly to a lifting jack 2WD Steering Axle Components 15 1 Yoke and Hub How to Remove the Yoke an...

Page 431: ...t torque lubricated 94 ft lbs 127 4 Nm 2WD STEERING AXLE COMPONENTS How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a liftin...

Page 432: ...ghten to 8 ft lbs 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 ft lbs 169 5 Nm 15 2 Stee...

Page 433: ...m the barrel end clevis pin of the steer cylinder then remove the clevis pin Always use a new cotter pin when installing a clevis pin 4 Remove the steering cylinder from the machine 2WD STEERING AXLE...

Page 434: ...nd then center a lifting jack of ample capacity under the steering axle 4 Raise the machine 6 inches 15 cm and place blocks under the chassis for support 4WD Steering Axle Components 16 1 Yoke and Hub...

Page 435: ...fasteners 8 Slide the drive motor shaft out of the drive hub and then remove the drive motor from the machine 9 Remove the pin retaining fasteners from the upper and lower yoke pivot pins Do not remov...

Page 436: ...nut dry 125 ft lbs 169 5 Nm lubricated 94 ft lbs 127 4 Nm Drive hub mounting bolts dry 120 ft lbs 163 Nm lubricated 90 ft lbs 122 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm lubricated 56 ft lb...

Page 437: ...O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Oscillating Axle Comp...

Page 438: ...or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fasteners from cover on the non st...

Page 439: ...enter a lifting jack of ample capacity under the non steering axle Raise the machine approximately 6 inches 15 cm and place blocks under the drive chassis for support 5 Remove the wheel lug nuts then...

Page 440: ...44 1636 611090 Genie China Phone 86 21 62483040 Fax 86 21 62488180 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie France Pho...

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