77809 cover.cdr:coreldraw - manuals.gogenielift.commanuals.gogenielift.com/parts and service...

Service Manual

Z-45/25Z-45/25JIC Power

Part No. 77809

Rev C2

August 2005

Serial Number Range

Deutz models: from 21180 to 23040Ford models: from 21180 to 23189Perkins models: from 21180 to 23008

Z-45/25 • Z-45/25J Part No. 77809

March 2005

ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-45/25 andGenie Z-45/25J Operator's Manual beforeattempting any maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specifications aresubject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genieindustries.come-mail: [email protected]

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Z-45/25 and Z-45/25J Service Manual ................. 52709From serial number 9998 to 21179

Z-45/25 and Z-45/25J Service Manual ................. 77809Deutz models: from 21180 to 23040Ford models: from 21180 to 23189Perkins models: from 21180 to 23008

Z-45/25 and Z-45/25J Service Manual ...............107846Deutz models: from 23041 to 34010Ford models: from 23190 to 34010Perkins models: from 23009 to 34010All models: from A34011 to A47000All models: from B101

Z-45/25 and Z-45/25J Service Manual ...............219418From serial number 13A-47001

Copyright © 2003 by Genie Industries

77809 Rev C March 2005

"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J

March 2005

iii

Safety Rules

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-45/25 andGenie Z-45/25J Operator's Manual will result indeath or serious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005

SAFETY RULES

iv

Section 1 • Safety Rules

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Used to indicate operation ormaintenance information.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammableand combustible materials like battery

gases and engine fuels. Always have an approvedfire extinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.

Part No. 77809 Z-45/25 • Z-45/25J

August 2005

Table of Contents

v

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

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vi

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

Part No. 77809 Z-45/25 • Z-45/25J

June 2005

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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

Z-45/25 • Z-45/25J Part No. 77809

June 2005


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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TABLE OF CONTENTS


March 2005

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

ix

TABLE OF CONTENTS


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(before serial number 22050) .............................................................................. 6 - 12

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25(after serial number 22049) ................................................................................. 6 - 13

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25(after serial number 22049) ................................................................................. 6 - 14

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25(before serial number 22050) .............................................................................. 6 - 15

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25(before serial number 22050) .............................................................................. 6 - 16

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25(after serial number 22049) ................................................................................. 6 - 17

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25(after serial number 22049) ................................................................................. 6 - 18

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xii

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(before serial number 22050) .............................................................................. 6 - 23

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J(before serial number 22050) .............................................................................. 6 - 24

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J(after serial number 22049) ................................................................................. 6 - 25

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J(after serial number 22049) ................................................................................. 6 - 26

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J(before serial number 22050) .............................................................................. 6 - 27

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J(before serial number 22050) .............................................................................. 6 - 28

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J(after serial number 22049) ................................................................................. 6 - 29

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J(after serial number 22049) ................................................................................. 6 - 30


March 2005


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





A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25CE Models (after serial number 22049) ............................................................... 6 - 41

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25CE Models (after serial number 22049) ............................................................... 6 - 42







A Electrical Schematic, Z-45/25J (after serial number 22049)CE models ........................................................................................................... 6 - 51

TABLE OF CONTENTS

xiii


March 2005


Deutz F3L-1011F models, continued





A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JCE Models (after serial number 22049) ............................................................... 6 - 57

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25JCE Models (after serial number 22049) ............................................................... 6 - 58





TABLE OF CONTENTS

xiv


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















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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

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 1

Section 2 • SpecificationsMarch 2005

REV B Specifications

Machine Specifications

Tires and wheels Rough terrain Industrial

Wheel lugs, 4WD 9 @ 5/8 -18

Wheel lugs, 2WDFront 9 @ 5/8 -18 9 @ 5/8 -18Rear 9 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque, dry 125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs127.4 Nm 127.4 Nm

Tire ply rating 14 Tread 8Sidewall 6

Tire contact area 59 sq in 43.5 sq in149.9 sq cm 280 sq cm

Overall tire diameter 35.8 in 28 in90.9 cm 71 cm

Tire pressure (air filled tires) 45 psi 100 psi3.1 bar 6.9 bar

Fluid capacities

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 24 gallons91 liters

Hydraulic system 30 gallons(including tank) 113.6 liters

Drive hubs 17 fl oz0.5 liters

For operational specifications, refer to theOperator's Manual.

Performance Specifications

Drive speed, maximum

Stowed position 4.8 mph7.7 km/h

40 ft/5.7 sec12.2 m/5.7 sec

Raised or extended position 0.3 mph0.5 km/h

40 ft/45 sec12.2 m/45 sec

Braking distance, maximum

High range on paved surface 3 to 6 ft0.9 to 1.8 m

Boom function speeds, maximumfrom platform controls

Jib boom up, Z-45/25J 28 to 32 seconds

Jib boom down, Z-45/25J 16 to 20 seconds

Primary boom up 24 to 28 seconds

Primary boom down 24 to 28 seconds

Secondary boom up 24 to 28 seconds

Secondary boom down 38 to 42 seconds

Primary boom extend 14 to 18 seconds

Primary boom retract 16 to 20 seconds

Turntable rotate, 359° 62 to 68 secondsprimary boom retracted

Platform rotate, 180° 5 to 7 secondsZ-45/25

Platform rotate, 160° 5 to 7 secondsZ-45/25J

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

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

Section 2 • Specifications March 2005

REV BSPECIFICATIONS

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentISO viscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexrating of 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 0°F / -18°C.

Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

Drive pump

Type: bi-directional, variabledisplacement piston pump

Flow rate @ 2500 rpm 30.3 gpm(before serial number 22050) 114.7 L/min

Flow rate @ 2500 rpm 32 gpm(after serial number 22049) 121 L/min

Drive pressure, maximum 3500 psi(before serial number 22050) 241.3 bar

Drive pressure, maximum 3750 psi(after serial number 22049) 259 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in(before serial number 22050) 13.9 cc

Displacement 0.84 cu in(after serial number 22049) 13.76 cc

Flow rate @ 2500 rpm 9.2 gpm(before serial number 22050) 34.8 L/min

Flow rate @ 2500 rpm 9.1 gpm(after serial number 22049) 34.4 L/min

Charge pressure @ 2500 rpm 250 psi(before serial number 22050) 17.2 bar

Charge pressure @ 2500 rpm 315 psi(after serial number 22049) 21.7 bar

Function pump

Type: gear, pressure balanced

Displacement 0.67 cu in11 cc

Flow rate @ 2500 rpm 7.25 gpm27.4 L/min



REV B

Auxiliary pump

Type: gear, fixed displacement

Displacement 1.75 gpm2.8 L/min

Auxiliary pump relief pressure 3200 psi220.6 bar

Function manifold

System relief valve pressure 3200 psi220.6 bar

Secondary boom down 1800 psirelief valve pressure 124 bar

Platform level relief valve pressure 3500 psi(after serial number 22049) 241.3 bar

Steer flow regulator 1.5 gpm5.7 L/min

Boom extend flow regulator 2 gpm7.6 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 psi17.2 bar

Steer end drive motors (4WD models)

Displacement 1.53 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.16 to 2.8 cu in4WD (2 speed motor) 2.62 to 45.9 cc

Displacement per revolution, variable 1.1 to 2.8 cu in2WD 18.4 to 45.9 cc

Hydraulic filters

High pressure filter Beta 3 200

High pressure filter 100 psibypass pressure 6.89 bar

Medium pressure filter Beta 3 200

Medium pressure filter 50 psibypass pressure 3.4 bar

Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass

SPECIFICATIONS



REV A

Manifold ComponentSpecifications

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)

SPECIFICATIONS



REV A SPECIFICATIONS

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

Horsepower

Gross intermittent @ 3600 rpm 97Continuous @ 3600 rpm 82Horsepower @ 2500 rpm 70

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm

High idle 2500 rpm

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 incollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 5 quarts(including filter) 4.7 liters

Oil viscosity requirements

Below 60°F / 15.5°C 5W-30

-10°F to 90°F / -23°C to 32°C 10W-30

Above -10°F / -23°C 10W-40 to 10W-50

Above 20°F / -6.6°C 20W-40 or 20W-50

Use oils meeting API classification SG (labeled SG/CCor SG/CD) as they offer improved wear protection.Units ship with 10W-40 SG/CC.

Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 3-5 psi0.21-0.34 bar

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, minimum 60-80A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Brush length, new 0.66 in16.8 mm

Brush length wear limit 0.25 in6.35 mm

Brush spring tension 64 ounces18 Newtons

Bolt torque 45 to 84 in-lbsthrough brush 5.08 to 9.5 Nm

Brush mounting 15 to 20 ft-lbsbolt torque 20 to 27 Nm

Maximum commutator 0.005 inrun-out 0.127 mm



REV ASPECIFICATIONS

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 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min

Ignition System

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 in1.07 to 1.18 mm

Spark plug torque 5 to 10 ft-lbs7 to 14 Nm

Engine coolant

Capacity 111/2 quarts10.9 liters

Coolant temperature switch


Temperature switch point 230° F112° C

Alternator

Output 95A, 14.5V DC



REV A SPECIFICATIONS

Oil temperature switch specifications


Temperature switch point 220° F104° C

Oil pressure switch specifications


Oil pressure switch point 15 psi1 bar

Fuel injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement diesel number 2-D

Alternator output 60A, 14V DC

Starter motor

Current draw, no load 90A

Brush length, new 0.72 in18.5 mm

Brush length, minimum 0.27 in7 mm

Battery


Quantity 1



Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz F3L 1011F Engine



Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower

Gross intermittent @ 3000 rpm 44Continuous @ 3000 rpm 40Horsepower @ 2500 rpm 36

Firing order 1 - 2 - 3

Low idle 1400 rpm

High idle 2500 rpm

Compression ratio 18.5:1

Compression pressure 362 to 435 psi25 to 30 bar

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6 bar

Oil capacity 6.5 quarts(including filter) 6 liters


Below 60°F / 15.5°C 5W-30(synthetic)

-10°F to 90°F / -23°C to 32°C 10W-40

Above -4°F / -34°C 15W-40

Engine oil should have minimum properties of APIclassification CC/SG or CD/SG grades.Units ship with 10W-40 CH-4



REV A

Perkins 104-22 Engine(KR model)



Bore and stroke 3.31 x 3.94 inches84 x 100 mm

Horsepower

Gross intermittent @ 2800 rpm 50Net intermittent @ 2800 rpm 46.9Net continuous @ 2800 rpm 41Intermittent @ 2500 rpm 44

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm

High idle 2500 rpm

Compression ratio 22:1

Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi) of lowest cylinder mustbe within 50 psi / 3.45 bar of highest cylinder

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.008 in0.2 mm

Exhaust 0.008 in0.2 mm

Lubrication system

Oil pressure @ 2500 rpm 41 psi2.8 bar

Oil capacity 8.6 quarts(including filter) 8.2 liters


Below 68°F / 20°C (synthetic) 5W-20

5°F to 104°F / -15°C to 40°C 10W-30

Above 14°F / -10°C 15W-40

Engine oil should have minimum properties of APIclassification CC/SE. API classification CD/SE or CCMCD4 can be used, but is not recommended during thefirst 50 hours nor for light load applications.Units ship with CH-4

Oil pressure sending unit


Oil pressure switch point 4.2 psi0.3 bar

Fuel injection system

Injection pump make Zexel

Injection pressure 2133 psi147 bar

Fuel requirement #2 Diesel

Alternator output 55A @ 13.8V DC

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm

SPECIFICATIONS



REV A

Perkins Engine 104-22(KR model), continued

Battery


Quantity 1



Fan belt deflection 3/8 in10 mm

Engine coolant

Capacity 7.7 quarts7.3 liters

Coolant temperature sending unit


Temperature switch point 221° F 105° C

SPECIFICATIONS



REV A

Machine Torque Specifications

Platform rotator

1-8 center bolt 480 ft-lbs651 Nm

3/8 -16 bolts 47 ft-lbs63.7 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 200 ft-lbs271 Nm

Drive hub mounting bolts, lubricated 150 ft-lbs203 Nm

Drive motor mounting bolts, dry 75 ft-lbs102 Nm

Drive motor mounting bolts, lubricated 56 ft-lbs76 Nm

SPECIFICATIONS

Part No. 77809 Z-45/25 • Z-45/25J 2 - 11

Section 2 • SpecificationsAugust 2005

REV B SPECIFICATIONS

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

2 - 12 Z-45/25 • Z-45/25J Part No. 77809

Section 2 • Specifications June 2005

REV A

SIZE THREAD

in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m20 100 11.3 80 9 140 15.8 110 12.4 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide Bolts

Grade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

Size

(mm)in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 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

f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m8 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 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

10.9 12.98.84.6

SPECIFICATIONS


March 2005 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steering wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetyinformation and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.


March 2005Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

to use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine which group(s)of procedures are required to perform a scheduledinspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev A

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

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

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removed fromservice.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listed inthe responsibilities manual.


March 2005Section 3 • Scheduled Maintenance Procedures

This page intentionally left blank.

Part No. 77809 Z-45/25 • Z-45/25J 3 - 5

August 2005 Section 3 • Scheduled Maintenance Procedures

Checklist A - Rev E Y N R

A-1 Pre-operationinspection

A-2 Functions tests

A-3 Engine maintenance -Deutz models

A-4 Engine maintenance -Ford models

A-5 Engine maintenance -Perkins models

A-6 Filter condition indicator

A-7 Oscillate axle

Perform after 40 hours:

A-8 30 day service

Perform every 100 hours:

A-9 Engine maintenance -Ford and Perkinsmodels

A-10 Fuel filters -Ford models

A-11 Fuel filter/separator -Diesel models

A-12 Check engine RPM-Perkins models

A-13 Rotation bearing


A-14 Engine maintenance -Ford models

A-15 Engine maintenance -Perkins models

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist B - Rev D Y N R

B-1 Battery

B-2 Electrical wiring

B-3 Key switch

B-4 Engine maintenance -Ford models

B-5 Exhaust system

B-6 Oil cooler and fins-Deutz models

B-7 Lug nut torque

B-8 Brake configuration

B-9 Drive hub oil level

B-10 Engine RPM - Fordand Deutz models

B-11 Ground control override

B-12 Directional valve

B-13 Platform leveling

B-14 Engine idle select

B-15 Fuel select -Ford models

B-16 Drive brakes

B-17 Drive speed -stowed position

B-18 Drive speed -raised position

B-19 Alarm package

B-20 Hydraulic oil analysis

B-21 Fuel filter/separator -Perkins models

B-22 Replace fuel filter -Perkins models


B-23 Engine maintenance -Deutz models

B-24 Engine maintenance -Ford models

B-25 Engine maintenance -Perkins models

Maintenance Inspection Report

3 - 6 Z-45/25 • Z-45/25J Part No. 77809

August 2005Section 3 • Scheduled Maintenance Procedures

Checklist C - Rev C Y N R

C-1 Engine maintenance -Deutz models

C-2 Grease platformoverload (if equipped)

C-3 Test platform overload(if equipped)


C-4 Engine maintenance -Perkins models


C-5 Engine maintenance -Ford models

Checklist D - Rev D Y N R

D-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Free-wheelconfiguration

D-4 Drive hub oil

D-5 Air/LPG mixture -Ford models

D-6 Engine maintenance -Deutz models

D-7 Turntable bearing wear

D-8 Calibrate platformoverload system(if equipped)

D-9 Hydraulic filters

MAINTENANCE INSPECTION REPORT

Checklist E - Rev B Y N R

E-1 Hydraulic oil

E-2 Fuel hoses -Ford models

E-3 Engine maintenance -Deutz models

E-4 Grease steer axlewheel bearings,2WD models

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Part No. 77809 Z-45/25 • Z-45/25J 3 - 7


REV E

A-1Perform Pre-operationInspectionCompleting a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Genie Z-45/25 and Genie Z-45/25JOperator's Manual on your machine.

Checklist A Procedures

A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the Genie Z-45/25 and Genie Z-45/25JOperator's Manual on your machine.

3 - 8 Z-45/25 • Z-45/25J Part No. 77809


REV ECHECKLIST A PROCEDURES

A-3Perform Engine Maintenance -Deutz Models

Engine specifications require thatthis procedure be performed dailyor every 10 hours, whichevercomes first.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in theDeutz FL 1011F Operation Manual(Deutz part number 0297 9683).

Deutz FL 1011F Operation ManualGenie part number 52883

To access the engine:

1 Remove the safety pin from the engine pivotplate latch.

The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.

2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.

A-4Perform Engine Maintenance -Ford Models

Engine specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.


Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator HandbookGenie part number 84792





Part No. 77809 Z-45/25 • Z-45/25J 3 - 9


REV E CHECKLIST A PROCEDURES

A-5Perform Engine Maintenance -Perkins Models

Engine specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.


Required maintenance procedures and additionalengine information are available in thePerkins 100 Series Workshop Manual(Perkins part number TPD 1377E).

Perkins 100 Series Workshop ManualGenie part number 72352





A-6Check the High PressureHydraulic Filter ConditionIndicatorMaintaining the high pressure hydraulic filter ingood condition is essential to good systemperformance and safe machine operation. The filtercondition indicator will show when the hydraulic flowis bypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Open the engine side turntable cover.

2 Start the engine from the ground controls.

3 Change the engine idle to high rpm (rabbitsymbol).

4 Visually inspect the filter condition indicator.

Result: The filter condition indicator should beoperating with the plunger in the green area.

Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-9, Replace the HydraulicFilters.

3 - 10 Z-45/25 • Z-45/25J Part No. 77809


REV E

A-7Test the Oscillate Axle(if equipped)

Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a 6 inch /15.2 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a 6 inch /15.2 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a 6 inch /15.2 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

If the chassis does not remainlevel during test, refer to RepairProcedure 8-8, How to Set Up theDirectional Valve Linkage.

A-8Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance checklist for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-9 Perform Engine Maintenance -Ford and Perkins Models

• A-13 Grease the Turntable Rotation Bearingand Rotate Gear

• B-7 Check the Lug Nut Torque(including tires and wheels)

• B-9 Check the Oil Level in the Drive Hubs

• C-1 Perform Engine Maintenance -Deutz Models

• D-2 Check the Turnable Rotation BearingBolts

• D-9 Replace the Hydraulic Filters

CHECKLIST A PROCEDURES

Part No. 77809 Z-45/25 • Z-45/25J 3 - 11


REV E

A-9Perform Engine Maintenance -Ford and Perkins Models

Engine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditions existor the machine is subjected toextended low idle operation.


Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR thePerkins 100 Series Workshop Manual(Perkins part number TPD 1377E).







A-10Replace the FuelFilters - Ford Models

Engine specifications require thatthis procedure be performed every100 hours.

Replacing the gasoline fuel filters is essential togood engine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilatedarea away from heaters, sparks,flames and lighted tobacco.Always have an approved fireextinguisher within easy reach.

Perform this procedure with theengine off.

1 Put on protective clothing and eye wear.

2 Open the tank side turntable cover and locatethe fuel system components mounted to theplate under the fuel tank.


3 - 12 Z-45/25 • Z-45/25J Part No. 77809



3 Remove the fuel system plate retainingfasteners. Carefully lower the fuel system plate.

4 At the pre-filter, disconnect and plug the fuelhose that goes to the fuel tank.

5 Disconnect the fuel hose from the fuel pre-filterto the fuel pump. Remove the pre-filter.

6 Install the new fuel pre-filter and connect the fuelhose between the fuel pump and the pre-filter.

Be sure the arrow on the pre-filteris pointing towards the fuel pump.

7 Tag and disconnect the fuel hoses from thepressure regulator/filter.

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel lines very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth around fuelhoses to absorb leaking fuel beforedisconnecting them.

8 Remove the regulator/filter mounting fastenersand remove the regulator/filter from the fuelsystem mounting plate.

9 Install the new regulator/filter onto the fuelsystem mounting plate. Connect the fuel hosesto the regulator/filter.

Component damage hazard. Besure the correct regulator/filter isinstalled or component damagemay occur.

Be sure each fuel hose isconnected to the correct port of thepressure/regulator.

10 Install the fuel hose from the fuel tank to the fuelpre-filter.

11 Clean up any fuel that may have spilled duringthe installation procedure.

12 Start the machine from the ground controls.Inspect the fuel filters and hoses for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

Fuel Pump

Fuel pressureregulator/filter

Pre-Filter

“To engine”

“From tank”

“Return to tank”

Part No. 77809 Z-45/25 • Z-45/25J 3 - 13


REV E CHECKLIST A PROCEDURES

A-11Inspect the Fuel Filter/ WaterSeparator - Diesel Models


Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.


Perkins models:


2 Open the engine side turntable cover and locatethe fuel filter/water separator next to thehydraulic return filter on the bulkhead.

3 Visually inspect the filter bowl for water buildup.

Result: If water is present in the filter bowl,continue with steps 3 through 7.

4 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

5 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

6 Tighten the vent plug.

If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/water separatorbefore starting the engine.See B-22, Replace The Fuel FilterElement - Perkins Models, forinstructions on how to prime thefuel filter/water separator.

7 Clean up any fuel that may have spilled.

b

d

a

c

3 - 14 Z-45/25 • Z-45/25J Part No. 77809



8 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.


Deutz models:





4 Locate the fuel filter/water separator next to theoil filter.

5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Do not completely drain the filter.

a fuel filter/water separatorb drain valve

6 Clean up any fuel that may have spilled.

7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.


8 Swing the engine back to its original positionand close the engine pivot plate latch.

9 Install the engine pivot plate safety pin.

a

b

Part No. 77809 Z-45/25 • Z-45/25J 3 - 15


REV E

A-12Check and Adjust theEngine RPM - Perkins Models


Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

This procedure will require twopeople.

1 Connect a tachometer to the engine. Start theengine from the ground controls.

Result: Low idle should be 1600 rpm.

Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut and turn the low idleadjustment screw clockwise to increase therpm, or counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

a solenoid bootb high idle adjustment nutc yoked low idle lock nut and adjustment

screw

3 Move the function enable toggle switch to thehigh idle (rabbit symbol) position.

Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregard adjustmentstep 4.

4 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.


a b c d

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REV E

A-13Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require thatthis procedure be performed every100 hours of operation. Performthis procedure more often if dustyconditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Locate the grease fitting on the front turntablecover.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.

3 Apply grease to each tooth of the drive gear,located under the turntable.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent


A-14Perform Engine Maintenance -Ford Models

Ford engine specifications requirethat this procedure be performedevery 200 hours.








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REV E

A-15Perform Engine Maintenance -Perkins Models

Perkins engine specificationsrequire that this procedure beperformed every 200 hours.









3 - 18 Z-45/25 • Z-45/25J Part No. 77809

June 2005Section 3 • Scheduled Maintenance Procedures

REV D

B-1Inspect the Battery

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.


2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

The battery is a maintenance freebattery and does not require thereplenishing of electrolyte.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

Checklist B Procedures

B-2Inspect the Electrical Wiring

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Open the engine side turntable cover.




4 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine wiring harness

· Hydraulic manifold wiring

Part No. 77809 Z-45/25 • Z-45/25J 3 - 19

June 2005 Section 3 • Scheduled Maintenance Procedures

REV D

5 Open the ground controls side turntable cover.

6 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Inside of the ground control box

· Hydraulic manifold wiring

7 Start the engine from the ground controls andraise the boom above the turntable covers.

8 Inspect the turntable area for burnt, chafed andpinched cables.

9 Lower the boom to the stowed position and turnthe engine off.

10 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the primary boom

· Cables on the primary, and jib booms

· Jib boom/Platform rotate manifold

· Inside of the platform control box



B-3Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could cause ahazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and no functionsshould operate.

CHECKLIST B PROCEDURES

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REV D

B-4Perform Engine Maintenance -Ford Models









B-5Check the Exhaust SystemMaintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Ford models:



2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine to access the exhaust system.

All models:

3 Be sure that all nuts and bolts are tight.

4 Inspect all welds for cracks.

5 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

Ford models:




Part No. 77809 Z-45/25 • Z-45/25J 3 - 21


REV D

B-6Check the Oil Cooler andCooling Fins - Deutz Models

Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Oil cooler




3 Remove the fasteners from the engine sidecover, then remove the cover.

4 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

5 Clean the oil cooler of debris and foreignmaterial.

Cooling and fan blower fins

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

9 Clean the cylinder head cooling passages ofdebris and foreign material.

10 Install the engine side cover.




cba

3 - 22 Z-45/25 • Z-45/25J Part No. 77809


REV D

B-7Check the Lug Nut Torque(including the tires and wheels)

Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

The tires on some machines arefoam-filled and do not need airadded to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

4 Check the pressure in each air-filled tire. Referto Section 2, Specifications.

B-8Confirm the ProperBrake Configuration

Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to be sureit is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve is located onthe side of the drive pump.

The free-wheel valve shouldalways remain closed.


a

b

c

d

brake disengaged position

brake engaged position

Part No. 77809 Z-45/25 • Z-45/25J 3 - 23


REV D

B-9Check the Oil Levelin the Drive Hubs

Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90 degrees.

a drive hub plugs

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Apply pipe thread sealant to the plug(s), andinstall the plug(s) in the drive hub.

5 Repeat this procedure for each drive hub.

B-10Check and Adjust theEngine RPM - Ford and DeutzModels

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Ford models:

The engine rpm is controlled by theECM and can only be adjusted byre-programming the ECM. If rpmadjustment or service is required,please contact Genie IndustriesService Department OR your localFord dealer.

Deutz models:

This procedure will require twopeople.





a

3 - 24 Z-45/25 • Z-45/25J Part No. 77809


REV D

3 Connect an rpm gauge to the engine, and thenstart the engine from the ground controls.

Result: Low idle should be 1400 rpm.

Skip to step 5 if the low idle rpm is correct.

4 Loosen the low idle lock nut, then turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and recheck therpm.

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut

5 Move the function enable toggle switch to thehigh idle (rabbit symbol) position at the groundcontrols.

Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregard adjustmentstep 6.

6 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.

B-11Test the Ground ControlOverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton on the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the platform red Emergency Stop buttonto the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.


f

e

c dba

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


REV D

B-12Check the Directional ValveLinkage

Perform this test only on modelsequipped with a oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Remove the drive chassis cover and the axlecovers from the non-steer end of the drivechassis.

2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve

B-13Test the Platform Self-leveling

Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform andground personnel.

1 Start the engine from the ground controls andlower the boom into the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.


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REV D

B-14Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.

Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions. Drive functions will operate at low idle,but at reduced performance.

Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.


2 Start the engine from the ground controls thenmove the function enable toggle switch to thehigh idle (rabbit symbol) position and hold in theon position.

Result: The engine should change to high idle.

3 Release the function enable toggle switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 Move the engine idle control switch to footswitch activated high idle (rabbit symbol).

Result: The engine should not change tohigh idle.

6 Press down the foot switch.

Result: The engine should change to high idle.

6 Move the engine idle control switch to footswitch activated low idle (turtle symbol).

Result: The engine should change to low idle.

B-15Test the Fuel Select Operation -Ford Models

The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicate fuelsystem problems that could develop into ahazardous situation.

Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.

1 At the platform controls, move the fuel selectswitch to gasoline and then move the engineidle control switch to foot switch activated highidle (rabbit and foot switch symbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.


Part No. 77809 Z-45/25 • Z-45/25J 3 - 27


REV D

4 Release the foot switch and shut the engine offby pushing in the red Emergency Stop button into the off position.

5 Move the fuel select switch to LPG.

6 Restart the engine and allow it to run atlow idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.

B-16Test the Drive Brakes

Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-8, Confirm the ProperBrake Configuration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch), then lower the boom into thestowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

The brakes must be able to holdthe machine on any slope it is ableto climb.


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REV D

B-17Test the Drive Speed -Stowed Position

Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch), then lower the boom into the stowedposition.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

B-18Test the Drive Speed -Raised or Extended Position

Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switch).Press down the foot switch and raise the boomabove horizontal.



6 Continue at full speed and note the time whenthe machine reference point crosses the finishline.


Part No. 77809 Z-45/25 • Z-45/25J 3 - 29


REV D

7 Press down the foot switch and lower the boomto the stowed position.

8 Extend the boom 1 foot / 30 cm.



11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

B-19Test the Alarm Package(if equipped)The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable covers.

The alarms and beacon willoperate with the enginerunning or not running.

1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: The flashing beacon should be on andflashing.

2 Move the function enable switch to either sideand activate the primary boom toggle switch inthe down position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe switch is held down.

3 Move the function enable switch to either sideand activate the secondary boom toggle switchin the down position, hold for a moment andthen release it.



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REV D

4 Z-45/25J: Move the function enable switch toeither side and activate the jib boom toggleswitch in the down position, hold for a momentand then release it.


5 Turn the key switch to platform control.

Result: The flashing beacon should be onand flashing.

6 Press down the foot switch. Move the primaryboom control handle to the down position, holdfor a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

7 Press down the foot switch. Move thesecondary boom control handle to the downposition, hold for a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

8 Z-45/25J: Press down the foot switch. Activatethe jib boom toggle switch in the down position,hold for a moment and then release it.


9 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center in eitherdirection.

B-20Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.See E-1, Test or Replace theHydraulic Oil.


Part No. 77809 Z-45/25 • Z-45/25J 3 - 31


REV D

B-21Replace the Fuel Filter/ WaterSeparator Element -Perkins Models

Replacing the diesel fuel filter/water separatorelement is essential for good engine performanceand service life. A dirty or clogged filter may causethe engine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.



1 Open the engine side turntable cover and locatethe fuel filter/water separator on the bulkhead.

2 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separator.

3 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb main fuel linec drain plugd filter bowle filter elementf separator head

4 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.

5 Rotate the filter bowl counterclockwise andremove it from the element.

6 Rotate the filter element counterclockwise andremove it from the filter head.

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 filterhead. Tighten the drain plug and vent plug.

Component damage hazard. Thedrain plug and vent plug can bedamaged if they are overtightened.


d

c

f

e b

a

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REV D

a

bc

9 Clean up any diesel fuel that may have spilledduring the installation procedure.

10 Install the fuel supply hose from the fuel tank tothe fuel filter/water separator. Tighten theclamp.

11 Use a permanent ink marker to write the dateand number of hours from the hour meter on thefilter element housing.

Bleed the system:




14 Loosen the vent plug on top of the fuel injectionpump.

a vent plugb fuel injection pumpc fuel lift pump

15 Operate the priming lever or priming bulb (ifequipped) of the fuel lift pump until fuel, freefrom air, comes from the vent plug. Tighten thevent plug.

16 Clean up any fuel that may have spilled duringthis procedure.

17 Operate the starter motor for intervals of 15seconds until the engine starts.

It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.




Part No. 77809 Z-45/25 • Z-45/25J 3 - 33


REV D

B-22Replace the Fuel Filter Element -Perkins Models

Replacing the diesel fuel filter element is essentialfor good engine performance and service life. Adirty or clogged filter may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay required that the filter be replaced more often.






3 Thoroughly clean the outside surfaces of thefuel filter assembly.

4 Place a suitable container under the fuel filterelement.

5 Disconnect and plug the fuel line from the fuelpump to the fuel filter element.

a fuel lineb filter headc fuel filter element

6 Remove the fuel filter element with a filterwrench.

7 Apply a thin layer of fuel to the O-ring of the newfuel filter element.

8 Install the new fuel filter element and tighten itsecurely by hand. Clean up any fuel that mayhave spilled during the installation procedure.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.


b

a

c

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REV D

Bleed the fuel system:

9 Loosen the vent plug on top of the fuel injectionpump.

a vent plugb fuel injection pumpc fuel lift pump

10 Operate the priming lever or priming bulb (ifequipped) of the fuel lift pump until fuel, freefrom air, comes from the vent plug. Tighten thevent plug.


12 Operate the starter motor for intervals of 15seconds until the engine starts.

It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.

B-23Perform Engine Maintenance -Deutz Models

Deutz engine specifications requirethat this procedure be performedevery 400 hours.









a

bc

Part No. 77809 Z-45/25 • Z-45/25J 3 - 35


REV D

B-24Perform Engine Maintenance -Ford Models









B-25Perform Engine Maintenance -Perkins Models










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REV C

C-1Perform Engine Maintenance -Deutz Models









Checklist C Procedures

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each grease fittingusing a mulit-purpose grease.

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REV C

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Perform this procedure with themachine on a firm, level surface.

1 Turn the key switch to platform control. Start theengine from the platform controls.

2 Level the platform.

3 Determine the maximum platform capacity.Refer to the machine serial plate.

4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

5 Carefully move the test weight to eachremaining location.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

6 Add an additional 66 lbs / 30 kg of weight tooverload the platform.

Result: The alarm should be sounding.The platform overload indicator light should beflashing at both the ground and platformcontrols.

Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-8, Calibrate the PlatformOverload System.

There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.

CHECKLIST C PROCEDURES

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7 Carefully move the test weights to eachremaining location in the platform.


Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-8, Calibrate the PlatformOverload System.


8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

Machine functions should stilloperate with auxiliary power at theground controls.

11 Lift the test weights off the platform floor using asuitable lifting device.

Result: The platform overload indicator light andalarm should turn off at both the ground andplatform controls.

There may be an approximate 2second delay before the overloadindicator light and alarm turn off.


Result: All ground control functions shouldoperate normally.

13 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, see D-8,Calibrate the Platform OverloadSystem.


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REV C

C-4Perform Engine Maintenance -Perkins Models









C-5Perform Engine Maintenance -Ford Models










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REV DChecklist D Procedures

D-1Check the BoomWear Pads

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result in componentdamage and unsafe operating conditions.


2 Raise the end of the primary boom to acomfortable working height (chest high), thenextend the boom 1 foot / 30 cm.

3 Measure each wear pad. Replace the wear pad ifit is less than 9/16 inch / 14.3 mm. If the wearpad is not less than 9/16 inch / 14.3 mm, shimas necessary to obtain zero clearance and zerodrag.

4 Extend and retract the primary boom through theentire range of motion to check for tight spotsthat may cause binding or scraping of the boom.

Always maintain squarenessbetween the outer and innerboom tubes.

Wear pad specifications

All wear pads 9/16 inch14.3 mm

D-2Check the Turntable RotationBearing Bolts

Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place safetychocks on the lift cylinders rods. Carefully lowerthe boom onto the lift cylinder safety chocks.

Crushing hazard. Keep handsaway from cylinders and all movingparts when lowering the boom.

The lift cylinder safety chock isavailable through Genie ServiceParts.

2 Turn the engine off.




Part No. 77809 Z-45/25 • Z-45/25J 3 - 41


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5 Be sure that each turntable mounting bolt istorqued in sequence to 210 ft-lbs / 285 Nm.

Bolt torque sequence(before serial number 23332)

Bolt torque sequence(after serial number 23331)


7 Raise the secondary boom and remove thesafety chocks.

8 Lower the boom to the stowed position.

9 Remove drive chassis covers from both thesteer end and the non-steer end of the machine.

10 Remove the lower chassis cover mountingfasteners from inside of the drive chassis (ifequipped).

11 Remove the lower chassis cover to access thelower turntable bearing bolts under the drivechassis.

12 Check to ensure that each lower bearingmounting bolt under the drive chassis is torquedin sequence to 210 ft-lbs / 285 Nm.

Bolt torque sequence(before serial number 23332)

Bolt torque sequence(after serial number 23331)

CHECKLIST D PROCEDURES

191510

136

18

3

11

8

2016 2 9

145

17

4

12

7

1

115

7

12

4

5

14

9216

8

3

11

6

1310

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disengaged position

engaged position

disengaged position

engaged position

D-3Check the Free-wheelConfiguration

Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

Steer wheels: 4WD models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.


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11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

All Models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve is located onthe side of the drive pump.

The free-wheel valve shouldalways remain closed.

D-4Replace the Drive Hub Oil

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.

1 Select the drive hub to be serviced. Then drivethe machine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs, and theninstall the plugs.

5 Repeat steps 1 through 4 for all the other drivehubs.


a b

c

da

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D-5Check and Adjust the Air/LPGMixture - Ford Models

Maintaining the proper air-to-fuel mixture duringLPG operation is essential to good engineperformance.


The engine should be warmed tonormal operating temperaturebefore performing this procedure.

1 Move the fuel select toggle switch to LPG fueland start the engine from the ground controls.

2 Locate the high idle mixture adjustmentscrew on the LPG venturi that attaches to theair cleaner air cleaner hose.

3 Loosen the lock nut on the high idle mixtureadjustment screw.

4 Load the system by activating the primary boomretract function and moving the function enabletoggle switch to the high idle (rabbit symbol)position.

5 Adjust the high idle adjustment screw to obtainan air-to-fuel mixture ratio of 13:1 to 13.2:1,using an exhaust gas analyzer.

Preliminary setting is 1/4 inch /6.4 mm of threads showing.Measure from the top of the locknut to the top of the adjustmentscrew.

If an exhaust gas analyzer is notavailable, adjust to obtain peak oroptimum rpm.

6 Hold the adjustment screw and tighten thelock nut.

7 Return the function enable toggle switch to thecenter position.

8 Locate the low idle mixture adjustment screw onthe LPG regulator.

9 Adjust the low idle mixture adjustment screw toobtain an air-to-fuel mixture ratio of 13:1 to13.2:1.

Preliminary setting: turn low idleadjustment screw clockwise all theway in. Turn low idle adjustmentscrew counterclockwise 2 3/4turns.


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D-6Perform Engine Maintenance -Deutz Models










D-7Inspect for Turntable BearingWear

Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Perform this procedure with themachine on a firm, level surfaceand the boom in the stowedposition.

1 Grease the turntable bearing. See A-13, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-2, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the primary and secondary booms to fullheight. Do not extend the primary boom.

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4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.

To obtain an accuratemeasurement, place the dialindicator no more than 1 inch /2.5 cm from the turntable rotationbearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.


7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the the dial indicator to be surethe needle returns to the "zero" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the primary and secondary booms to thestowed position and turn the machine off.

12 Remove the dial indicator from the machine.

a

b

c

d

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D-8Calibrate the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every1000 hours of operation or yearly.

Yearly calibration of the platform overload systemis essential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Perform this procedure with themachine on a firm, level surface.

1 Level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity at the center of theplatform floor.

Determine the limit switch trigger point:

4 Gently move the platform up and down by hand,so it bounces approximately 2.5 to 5 cm. Allowthe platform to settle.

Result: The overload indicator light and thealarm is on. Slowly tighten the load springadjustment nut by turning it clockwise just untilthe overload indicator light and alarm turns off.

The platform will need to be movedup and down and allowed to settlein between adjustments.


Result: The overload indicator light andalarm is off. Slowly loosen the load springadjustment nut by turning it counterclockwisejust until the overload indicator light and alarmturn on.


The platform will need to be movedup and down and allowed to settlein between adjustments.


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REV D

Confirm the setting:

5 Turn the key switch to platform control. Start theengine from the platform controls.

6 Lift the test weight off the platform floor using asuitable lifting device.

7 Place the test weight back onto the center of theplatform floor using a suitable lifting device.

Result: The alarm should be off. The platformoverload indicator light should be off at both theground and platform controls.

There may be an approximate 2second delay before the overloadindicator light and alarm turn off.

8 Add an additional 10 lb / 4.5 kg test weight tothe original test weight to overload the platform.




Result: All platform control functions should notoperate.



Result: All ground control functions should notoperate.

If the platform overload system isnot operating properly, repeatsteps 1 through 4.


D-9Replace the Hydraulic Filters

Genie requires that this procedurebe performed quarterly or every250 hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the cap from the filter housing.

3 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

4 Remove the filter element from the filterhousing.

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5 Install the new filter element into the filterhousing.

6 Push the filter element down to be sure the o-ring on the element is fully seated into thehousing.

7 Rotate the filter element clockwise to lock it inplace.

8 Install the filter housing cap.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.

Medium and high pressure filters

The medium pressure filter is forthe charge pump and the highpressure filter is for all machinefunctions except the drive circuitand oscillating axle circuit.

10 Open the engine side turntable cover and locatethe medium and high pressure filters.

The medium pressure filter ismounted near the pump. The highpressure filter, with filter conditionindicator, is mounted to thebulkhead.

11 Place a suitable container under each filter.

12 Remove the filter housings by using a wrench onthe nut provided on the bottom of the housings.

13 Remove the filter elements from the housings.

14 Inspect the housing seals and replace them ifnecessary.

15 Install the new filter elements into the housingsand tighten them securely.

The medium and high pressurefilters use the same elements.

16 Clean up any oil that may have spilled during theinstallation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.


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3 Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Place a suitable container underneath thehydraulic tank.

4 Remove the drain plug from the hydraulic tank.

5 Completely drain the tank into a suitablecontainer. See capacity specifications.

6 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

The hoses can be accessedthrough the access hole under theturntable.

7 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.

E-1Test or Replace the HydraulicOil

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.

Perform this procedure with theboom in the stowed position.

1 Ford models: Turn the valve on the LPG tankclockwise to the off position (if equipped). Thenslowly disconnect the hose from the LPG tank.

2 Ford models: Open the clamps from the LPGtank straps and remove the LPG tank from themachine (if equipped).

Checklist E Procedures

open closed

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8 Remove the ground controls side turntablecover.

9 Support the hydraulic tank with an appropriatelifting device.

10 Remove the hydraulic tank mounting fasteners.

11 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

12 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

13 Remove the suction strainers from the tank andclean them using a mild solvent.

14 Rinse out the inside of the tank using a mildsolvent.

15 Install the suction strainers using a threadsealant on the threads.

16 Install the drain plug using a thread sealant onthe threads.

17 Install the hydraulic return filter housing onto thehydraulic tank.

18 Install the hydraulic tank onto the machine.

19 Install the two suction hoses to the suctionstrainers.

20 Install the supply hose for the auxiliary powerunit and the return filter hose.

21 Models with hydraulic tank shut-off valves:Open the two hydraulic tank valves at thehydraulic tank.

22 Fill the tank with the proper hydraulic oil for yourmachine until the level is within the top2 inches / 5 cm of the sight gauge. Do notoverfill. Refer to Section 2, Specifications.

23 Clean up any oil that may have spilled.

24 Prime the pump. Refer to Repair Procedure 7-2,How to Prime the Pump.

Always use pipe thread sealantwhen installing the suction hosefittings and the drain plug.

CHECKLIST E PROCEDURES

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E-2Change the Fuel Hoses -Ford Models

Maintaining the fuel hoses in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel hose may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel hoses in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

Component damage hazard. Besure the fuel hoses are routed thesame way the original hoses were.

Perform this procedure with theengine off and the key switch inthe off position.


2 Open the tank side turntable cover and locatethe fuel system components mounted to theplate under the fuel tank.

3 Remove the fuel system plate retainingfasteners. Carefully lower the fuel system plate.

4 At the pre-filter, disconnect and drain the fueltank into a suitable container. See capacityspecifications.

5 Remove and replace all of the fuel line hosesand clamps according to the followingillustration.

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel lines very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth around fuelhoses to absorb leaking fuel beforedisconnecting them.


7 Start the engine from the ground controls, theninspect the fuel filter and hoses for leaks.



Fuel Pump

Fuel pressureregulator/filter

Pre-Filter

“To engine”

“From tank”

“Return to tank”

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REV B

E-4Grease the Steer AxleWheel Bearings, 2WD Models

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels, then center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

E-3Perform Engine Maintenance -Deutz Models



Required maintenance procedures and additionalengine information are available in theDeutz FL 1011F Workshop Manual(Deutz part number: 0297 7195).

Deutz FL 1011F Workshop ManualGenie part number 52229






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14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of thehub.

16 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the slotted nut to 35 ft-lbs / 47 Nm toseat the bearings.

21 Loosen the castle nut and re-tighten to8 ft-lbs / 11 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in.

Always use a new cotter pin wheninstalling a castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearings.

8 Loosen the castle nut and re-tighten to8 ft-lbs / 11 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

Result: If there is no side to side or up anddown movement, continue with step 11 andgrease the wheel bearings.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove the rearbearing.



March 2005 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie Z-45/25and Genie Z-45/25J Operator’s Manual on yourmachine.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:



· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· Wheels chocked


About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. To re-assemble,perform the disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.


March 2005Section 4 • Repair Procedures

REV C

The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology (non-contact) and require noadjustment. The operating parameters of thejoysticks are stored in memory at the ECM circuitboard at the platform controls. If a joystick erroroccurs or if a joystick is replaced, it will need to becalibrated before that particular machine functionwill operate. See 1-2, How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

For further information or assistance, consult theGenie Industries Service Department.

a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down

joystick controllerd primary boom up/down and

turntable rotate left/rightjoystick controller

1-1ALC-500 Circuit Board

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

When the ALC-500 circuit board isreplaced, the joystick controllerswill need to be calibrated. See 1-2,How to Calibrate a Joystick.

How to Remove the ALC-500Circuit Board1 Push in the red Emergency Stop button to the off

position at both the ground and platform controls.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted to theinside of the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Platform Controls

bcd

a



REV C

1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

The joystick must be calibratedbefore the threshold, max-out orramping can be set.



2 Turn the key switch to platform control. Do notstart the engine.

3 Select a joystick to calibrate.

4 Move the joystick full stroke in either directionand hold for 5 seconds.

5 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds andreturn the joystick to the neutral position.

Result: The alarm should sound indicatingsuccessful joystick calibration.

6 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

No machine fuction should operatewhile performing the joystickcalibration procedure.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit board fromthe platform control box.

PLATFORM CONTROLS



REV CPLATFORM CONTROLS

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time withspecifications and determine whether thefunction time needs to increase or decrease.

Refer to Section 2, Specificationsfor function speeds.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.

Each time the drive enable toggleswitch is momentarily moved, thefunction speed will change in 2%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

13 Return the joystick to the neutral position andwait for approximately 10 seconds.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Do not operate any machinefunction during the 10 secondwaiting time.



REV C PLATFORM CONTROLS

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.









Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.


9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Each time the drive enable toggleswitch is momentarily moved, thetime will change in 10%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.




Ramp rate (factory settings)

Primary boom up/downaccelerate 4 secondsdecelerate 0.5 second

Secondary boom up/downaccelerate 2 secondsdecelerate 0.5 second

Turntable rotateaccelerate 2 secondsdecelerate 0.5 second

Driveaccelerate 3.3 secondsaccelerate (narrow models) 3.8 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 2 seconds



REV CPLATFORM CONTROLS

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.









Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.


9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick controlled machine function (boom up/down, boom extend/retract and turntable rotate).






REV APlatform Components

2-1Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave Cylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

1 Z-45/25J: Extend the primary boom until theslave cylinder barrel-end pivot pin is accessible.

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

4 Z-45/25J: Tag, disconnect and plug the hydraulichoses from the slave cylinder at the unionlocated near the jib/rotate manifold and connectthem together using a connector. Connect thehoses from the cylinder together using aconnector.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Z-45/25: Tag, disconnect and plug the hydraulichoses from the slave cylinder and connect thehoses together using a connector. Cap thefittings on the cylinder. Then pull the slavecylinder hoses out through the primaryextension boom.


5 Remove the pin retaining fastener from the slavecylinder rod-end pivot pin. Do not remove thepin.



REV APLATFORM COMPONENTS

6 Z-45/25J: Remove the external snap rings fromthe barrel-end pivot pin.

Z-45/25: Remove the pin retaining fastener fromthe slave cylinder barrel-end pivot pin. Do notremove the pin.

7 Support the slave cylinder with a lifting device.

8 Z-45/25J: Support the jib boom bell crank with asuitable lifting device.

9 Use a soft metal drift to drive the rod-end pivotpin out.

Crushing hazard. The jib boom bellcrank could fall when the slavecylinder rod-end pivot pin isremoved if not properly supported.

Component damage hazard. Theslave cylinder rod may becomedamaged if it is allowed to fall ifnot properly supported by the liftingdevice.

10 Use a soft metal drift and drive the barrel-endpin out.

11 Carefully pull the cylinder out of the primaryboom.

How to Bleed the Slave CylinderDo not start the engine. Useauxiliary power for this procedure.

1 Raise the primary boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.

2-2Platform Rotator

How to Bleed the PlatformRotator

This procedure will require twopeople. Do not start the engine.Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a container tocollect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a top bleed valveb bottom bleed valvec containerd clear hose

a

d c b



REV A PLATFORM COMPONENTS

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear of theplatform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear of theplatform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.



REV A

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.


1 Remove the platform.

2 Remove the platform mounting weldmentand the platform rotator.

3 Remove the hose and cable cover from the sideof the jib boom.

4 Attach a lifting strap from an overhead crane tothe jib boom.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Support the barrel end of the cylinder with asuitable lifting device.

7 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pin and letthe cylinder hang down.

9 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from theprimary boom bellcrank.

Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

10 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

11 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin.

12 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

13 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the primary boombellcrank.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

Jib Boom Components, Z-45/25J



REV B JIB BOOM COMPONENTS, Z-45/25J

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a liftingdevice.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin andlet the cylinder hang down.

7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.



REV A

4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Remove the Cable Track,Z-45/25


1 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

2 Disconnect the cables from the platform controlbox.

3 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.


Primary Boom Components

5 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.


6 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.


7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.




REV A PRIMARY BOOM COMPONENTS

8 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder and connectthem together using a connector. Cap thefittings on the cylinder.


9 Pull the four hydraulic hoses toward the platformto clear the rod end of the primary boom liftcylinder.

10 Place blocks in between the upper and lowercable tracks and secure the upper and lowertracks together.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

11 Remove all hose and cable clamps from theunderside of the primary boom.

12 Attach a strap from an overhead crane to thecable track.

13 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

14 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

15 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

How to Remove the Cable Track,Z-45/25J


1 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

2 Disconnect the cables from the platform controlbox.

3 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.



REV A

4 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.


5 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder at the unionand connect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.


6 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold. Capthe fittings on the manifold.


7 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.


8 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.


9 Raise the boom to a horizontal position.

10 Remove the hose and cable cover from the sideof the jib boom.

11 Remove the hose clamp on the primary boombellcrank.

12 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

PRIMARY BOOM COMPONENTS



REV A

a

b

13 Attach a lifting strap from an overhead 5 ton /5,000 kg capacity crane to the platform end ofthe primary boom for support. Do not lift it.

14 Remove all hose and cable clamps from theunderside of the primary boom.

15 Support the rod end of the primary boom liftcylinder with a lifting device.

16 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Donot remove the pin.

17 Raise the primary boom slightly with theoverhead crane to relieve the pressure on theprimary boom lift cylinder rod-end pivot pin.

18 Use a soft metal drift to remove the primaryboom lift cylinder rod-end pivot pin.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the lifting device.

19 Lower the rod end of the primary boom liftcylinder approximately 12 inches / 30 cm.

20 Pull all of the hoses and cables out and awayfrom the mounting ears for the rod end of theprimary boom lift cylinder.

21 Raise the rod end of the primary boom liftcylinder back into position and install the rod-end pivot pin. Install the pin retaining fastener.

22 Attach a strap from an overhead crane to thecable track.

23 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

24 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

25 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif it is not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

How to Repair the Primary BoomCable Track

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

A 7 link repair section of cabletrack is available throughthe Genie Industries Service PartsDepartment.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 To remove a single link, open the lower clipand then use a screw driver to pry the link to theside.

3 Repeat steps 1 and 2 for each link.




REV APRIMARY BOOM COMPONENTS

4-2Primary Boom

How to Remove the PrimaryBoom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.




2 Remove the platform rotator and platformmounting weldment.

3 Z-45/25: Remove the platform leveling slavecylinder. See 2-1, How to Remove the PlatformLeveling Slave Cylinder.

Z-45/25J: Remove the jib boom.See 3-1, How to Remove the Jib Boom.

4 Remove the cable track. See 4-1, How toRemove the Cable Track.


6 Remove the hose and cable cover from theupper pivot.

7 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal drift to remove the pin. Then lower thecylinder and let it hang down.

Component damage hazard.When lowering the master cylinderdown, be sure not to damage themaster cylinder hoses or fittings.

8 Locate the primary boom drive speed limitswitch inside of the upper pivot.

9 Remove the primary boom drive speed limitswitch mounting fasteners. Do not disconnectthe wiring.

10 Locate the primary boom extension drive speedlimit switch inside of the extension boom.

11 Remove the primary boom extension drivespeed limit switch mounting fasteners. Do notdisconnect the wiring.

12 Pull the limit switch and the wiring out of theextension tube and move it out of the way.

13 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.




REV A PRIMARY BOOM COMPONENTS

14 Remove the hose clamp at the pivot end of theboom.

15 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the primary boom.

16 Attach a similar lifting device to the primaryboom lift cylinder.

17 Place support blocks under the primary boom liftcylinder.

18 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The boom liftcylinder and primary boom will fallif not properly supported.

19 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.

20 Remove the pin retaining fastener from theprimary boom pivot pin.

21 Remove the primary boom pivot pin with a softmetal drift, then carefully remove the primaryboom from the machine and place it on astructure capable of supporting it.

Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

How to Disassemble the PrimaryBoom

Complete disassembly of theboom is only necessaryif the outer or inner boom tubemust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Primary Boom ExtensionCylinder.

1 Remove the primary boom. See How to Removethe Primary Boom.

2 Place blocks under the barrel end of the primaryboom extension cylinder for support.

3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom. Use a soft metaldrift to remove the pin.

4 Remove and label the location of the wear padsfrom the platform end of the primary boom.

Pay careful attention to thelocation and amount of shims usedwith each wear pad.

5 Support and slide the extension tube andextension cylinder assembly out of the boomtube.

Crushing hazard. The primaryboom extension tube couldbecome unbalanced and fall whenremoved from the primary boomtube if not properly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.



REV APRIMARY BOOM COMPONENTS

6 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the extension tube. Use a softmetal drift to remove the pin.

7 Support and slide the extension cylinder out ofthe base end of the extension tube. Place theextension cylinder on blocks for support.

Crushing hazard. The extensioncylinder could become unbalancedand fall when removed fromprimary boom extension tube if notproperly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

4-3Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers theprimary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder



1 Raise the primary boom until the primary boomis horizontal.

2 Raise the secondary boom until the primaryboom lift cylinder barrel-end pivot pin is abovethe turntable covers.

3 Attach a 5 ton / 5000 kg overhead crane to theprimary boom for support. Do not lift the boom.



REV A

4 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.

5 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

The primary boom will fall if notproperly supported when theprimary boom rod-end pivot pin isremoved.

7 Place a support block across both turntablecovers under the primary boom lift cylinder.

8 Lower the lift cylinder onto the block. Protect thecylinder rod from damage.

Crushing hazard. The primaryboom lift cylinder could fall if notproperly supported.

9 Remove the primary boom lift cylinder barrel-endpivot pin retaining fasteners. Do not remove thepin.

10 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported andsecured to the lifting device.


4-4Primary Boom ExtensionCylinder

The primary boom extension cylinder extends andretracts the primary boom extension tube.Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder




2 Extend the primary boom until the primary boomextension cylinder rod-end pivot pin isaccessible in the primary boom extension tube.

3 Remove the hose and cable guard from theupper pivot.



REV A

4 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


5 At the platform end, remove the external snaprings from the extension cylinder rod-end pivotpin. Use a soft metal drift to remove the pin.

6 Remove the barrel-end pivot pin retainingfasteners.

7 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

8 Support and slide the extension cylinder out ofthe upper pivot.

Crushing hazard. The extensioncylinder could fall when removedfrom the extension boom if notproperly supported.

Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe primary boom.

Component damage hazard. Hosesand cables can be damaged if theprimary boom extension cylinder isdragged across them.

Note the length of the cylinder afterremoval. The cylinder must be atthe same length for installation.

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulic loopthat keeps the platform level through the entirerange of boom motion. The master cylinder islocated at the base of the primary boom.

How to Remove the PlatformLeveling Master Cylinder


1 Raise the secondary boom until both the rod-endand barrel-end pivot pins on the master cylinderare accessible.

2 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on the cylinder.


3 Attach overhead crane or similar lifting device tothe master cylinder.




REV A

4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin. Do notremove the pin.

5 Place a rod through the barrel-end pivot pin andtwist 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 andtwist to remove the pin.

8 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly attached tothe overhead crane.




REV ASecondary Boom Components

j

a b c

d

e

i

g

f

h

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.

Secondary Boom components

a upper secondary boom(number 1 arm)

b upper tension link(number 2 arm)

c lower tension link(number 3 arm)

d mid-pivote compression linkf secondary boom lift cylinder (2)g lower secondary boom

(number 4 arm)h turntable pivoti boom restj upper pivot



REV A SECONDARY BOOM COMPONENTS



2 Z-45/25J: Remove the jib boom.See 3-1, How to Remove the Jib Boom.

3 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

4 Remove the master cylinder. See 4-5, How toRemove the Master Cylinder.

5 Attach a lifting strap from an overhead crane toto the lug on the rod end of the primary boom liftcylinder. Then raise the primary boom liftcylinder with the crane, to a vertical position.

6 Tag, disconnect and plug the hydraulic hoses atthe primary boom lift cylinder. Cap the fittingson the cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

7 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.

8 Use a slide hammer to remove the pin. Removethe primary boom lift cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the overhead crane.

9 Tag, disconnect and plug the hydraulic hoseson both of the secondary boom lift cylinders.Cap the fittings on the cylinders.


10 Remove the pin retaining fasteners from bothsides of the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do notremove the pins.

11 Attach a strap from an overhead crane to the lugon the rod end of one of the secondary boom liftcylinders for support. Do not apply any liftingpressure.

12 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

13 Use a soft metal drift to drive the rod-end pivotpin half way out.

14 Remove the secondary boom lift cylinder fromthe machine.



REV ASECONDARY BOOM COMPONENTS

15 Repeat steps 11 through 14 for the othersecondary boom lift cylinder.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.

16 Attach a lifting strap from an overhead crane tothe upper pivot for support. Do not lift it.

17 Attach a lifting strap from a second overheadcrane to the number 1 arm at the mid-pointbetween the upper pivot and mid-pivot.

18 Remove the pin retaining fasteners from thenumber 1 arm pivot pins at the mid-pivot andthe upper pivot. Do not remove the pins.

19 Use a soft metal drift to drive both pins out.

20 Remove the number 1 arm from the machine.

Crushing hazard. The number 1arm could become unbalanced andfall when removed from themachine if not properly attached tothe overhead crane.

Crushing hazard. The upper pivotcould fall when the number 1 armis removed from the machine if notproperly supported by the overheadcrane.

21 Using the overhead crane attached to upperpivot, raise the secondary boom assemblyapproximately 30 inches / 76 cm.

22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm blockbetween the number 2 arm and the boom rest.Then lower the secondary boom assembly ontothe block.

Crushing hazard. The secondaryboom assembly could fall if notproperly supported by the4 x 4 x 11 inch / 10 x 10 x28 cm block.

23 Pull all of the cables and hoses out through theupper pivot.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

24 Remove the hose and cable covers from the topof the number 2 arm.

25 Pull all of the hoses and cables out of the upperpivot and out through the mid-pivot. Lay thehoses and cables on the ground.


26 Remove the pin retaining fastener from thenumber 2 arm pivot pin at the upper pivot. Use asoft metal drift to remove the pin.



REV A

27 Remove the upper pivot from the machine.

Crushing hazard. The upper pivotcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

28 Attach the lifting strap from an overhead craneto the number 2 arm at the upper pivot end.

29 Raise the number 2 arm slightly and remove the4 x 4 x 11 inch / 10 x 10 x 28 cm block.

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 cmblock between the number 3 arm and thenumber 4 arm at the mid-pivot end.

32 Attach a lifting strap from the overhead crane tothe mid-pivot for support. Do not lift it.

33 Remove the pin retaining fasteners from thenumber 2, 3 and 4 arm pivot pins at themid-pivot. Do not remove the pins.

34 Use a soft metal drift to drive each pin out. Thenremove the mid-pivot from the secondary boomassembly.

Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the secondaryboom assembly if not properlysupported by the overhead crane.

35 Attach the lifting strap from an overhead craneto the center point of the number 2 arm forsupport. Do not lift it.

36 Remove the pin retaining fasteners from bothcompression link pivot pins. Do not remove thepins.

37 Use a soft metal drift to remove the lowercompression link pivot pin at the number 3 arm.

38 Support the compression link with an appropriatelifting device.

39 Use a soft metal drift to remove the uppercompression link pivot pin from the number 2arm. Remove the compression link from themachine.

Crushing hazard. The number 2arm could fall when thecompression link is disconnectedfrom the number 2 arm if notproperly supported by the overheadcrane.

Crushing hazard. The compressionlink may fall if not properlysupported when removed from thesecondary boom assembly.


Crushing hazard. The number 2arm could become unbalanced andfall when removed from thesecondary boom assembly if notproperly supported by the overheadcrane.

41 Remove the upper and lower hose and cablecovers from the number 3 arm.

SECONDARY BOOM COMPONENTS



REV A

50 Use a slide hammer to remove the number 3arm pivot pin from the turntable pivot throughthe access hole behind the ground control box.


Crushing hazard. The number 3arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.

52 Remove the secondary boom drive speed limitswitch mounting fasteners from the number 4arm at the mid-pivot end. Do not disconnect thewiring.

53 Remove the pin retaining fasteners from thenumber 4 arm at the turntable pivot. Do notremove the pin.

54 Attach a lifting strap from the overhead crane tothe center point of the number 4 arm. Do notlift it.

55 Use a slide hammer to remove the number 4arm from the turntable pivot through the groundcontrols side bulkhead.


Crushing hazard. The number 4arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.

42 Pull all of the cables and hoses from the number3 arm and lay them over the turntablecounterweight.



44 Remove the fuel tank.


45 Remove the retaining fastener from the groundcontrol box and function manifold pivot plate.

46 Lower the ground control box and functionmanifold pivot plate to access the number 3 armpivot pin.

47 Attach the lifting strap from the overhead craneto the centerpoint of the number 3 arm forsupport. Do not lift it.

48 Remove the mounting fasteners from the coverlocated in the boom storage area to access thenumber 3 and number 4 arm pivot pin retainingfasteners at the turntable pivot.

49 Remove the pin retaining fasteners from thenumber 3 arm at the turntable pivot. Do notremove the pin.




REV A

3 Tag, disconnect and plug the hydraulic hoseson the secondary boom lift cylinder.


4 Remove the pin retaining fasteners from thesecondary boom lift cylinder rod-end pivot pinand barrel-end pivot pin. Do not remove thepins.

5 Attach a strap from an overhead crane to the lugon the rod end of the secondary boom liftcylinder for support. Do not apply any liftingpressure.

6 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

7 Use a soft metal drift to drive the rod-end pivotpin half way out.

8 Remove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.


5-2Secondary Boom Lift Cylinders

There are two secondary boom lift cylindersincorporated in the structure of the secondary boomassembly. These cylinders operate in parallel andrequire hydraulic pressure to extend and retract.Each secondary boom lift cylinder is equipped witha counterbalance valve to prevent movement in theevent of a hydraulic line failure.

How to Remove a SecondaryBoom Lift Cylinder



1 Lower the secondary boom to the stowedposition.

2 Raise the primary boom so that it is above thesecondary boom lift cylinder rod-end pivot pin.



REV A

6-1RPM Adjustment - Ford andDeutz Models

Refer to Maintenance Procedure B-9, Check andAdjust the Engine RPM- Ford and Deutz Models.

6-2RPM Adjustment - PerkinsModels

Refer to Maintenance Procedure A-13, Check andAdjust the Engine RPM- Perkins Models.

6-3Flex Plate

The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 7/16 inch / 11 mm gap - Deutz Models

1/16 inch / 1.5 mm gap - Perkins Models1/16 inch / 1.5 mm gap - Ford Models

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

displacement controller (EDC), located onthe drive pump.

2 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

3 Carefully pull the pump away from the engineand secure it from moving.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump. Torquethe flex plate mounting bolts to 34 ft-lbs /46 Nm.

2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

Pump coupler gap specification

Deutz models 7/16 inch11 mm

Ford and Perkins models 1/16 inch1.5 mm

3 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 45 ft-lbs / 61 Nm.

4 Install the pump and torque the pump mountingplate fasteners to 34 ft-lbs / 46 Nm.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

Engines

a b c d e

f



REV B ENGINES

6-4Engine Fault Codes -Ford Models

How to Retrieve Engine FaultCodesWhen an engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn on atthe ground controls. Use the following procedure toretrieve the engine fault code to determine theengine malfunction.

Perform this procedure with thekey switch in the off position.


2 Locate the run/test toggle switch located on theleft side of the ground control box.

3 Pull out the red Emergency Stop button to theon position at the ground controls.

4 Hold the run/test toggle switch to the testposition and turn the key switch to the groundcontrols position.

Result: The check engine light should turn on.The check engine light should begin to blink.

The check engine light will blink a"123" code three times beforeblinking a fault code if one ispresent.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

If any fault codes are present, theECM will blink a three digit code.It will blink the first digit of a threedigit code, pause, blink the seconddigit, pause, and then blink thethird digit. For example: the checkengine light blinks 5 consecutivetimes, blinks 3 times and then 1time. That would indicate code531.

Before the fault codes aredisplayed, the check engine lightwill blink a code 123 three times.After the fault codes, the checkengine light will blink a code 123three times again indicating theend of the stored codes.

6 Refer to the Fault Code Section for definition ofengine fault codes.

Once a fault code has beenretrieved and the repair has beencompleted, the ECM memory mustbe reset to clear the fault codefrom the ECM. See How to ClearEngine Fault Codes.



REV AENGINES

How to Clear Engine FaultCodes from the ECM

Perform this procedure with theengine off and the key switch inthe off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.



REV AHydraulic Pumps

7-1Lift/Steer Pump

How to Remove theLift/Steer Pump




Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

2 Tag, disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

open closed



REV AHYDRAULIC PUMPS

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the electrical connection at theelectronic displacement controller (EDC) locatedon the drive pump.



Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


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REV A

a

4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if it is notproperly supported.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

How to Prime the Pump1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the test port on the drive pump.

2 Remove the safety pin (if equipped) from theengine pivot plate latch.



HYDRAULIC PUMPS

4 Ford models: Close the valve on the LPG tankthen disconnect the hose from the tank. Thenmove the fuel select switch to the LPG position.

Perkins models: Disconnect the engine wiringharness from the fuel solenoid at the injectorpump.

Deutz models: Hold the manual fuel shutoffvalve clockwise to the closed position.

a manual fuel shutoff valve

5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

6 Ford models: Connect the LPG hose to theLPG tank and open the valve on the tank.

Perkins models: Connect the engine wiringharness to the fuel solenoid.

7 Start the engine from the ground controls andcheck for hydraulic leaks.



REV BManifolds

8-1Function Manifold Components (before serial number 22050)

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index SchematicNo. 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 overflowingthe 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(prevents overflowingthe proportional valve) ..................... 10-12 ft-lbs / 14-16 Nm

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(prevents overflowingthe proportional valve) ..................... 10-12 ft-lbs / 14-16 Nm

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

14 Flow regulator valve,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

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REV B

Function Manifold Components(before serial number 22050), continued


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 andplatform rotate left/right ..................... 25-30 ft-lbs / 34-41 Nm

28 Flow regulator valve,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

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REV B MANIFOLDS

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REV BMANIFOLDS

8-2Valve Adjustments -Function Manifold(before serial number 22050)

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port (item JJ) on the functionmanifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item H).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

7 Repeat steps 2 through 5 and recheck reliefvalve pressure.

8 Remove the pressure gauge.

How to Adjust the SecondaryBoom Down Relief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port (item JJ) on the functionmanifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item E).







REV B MANIFOLDS




REV B

8-3Function Manifold Components (after serial number 22049)

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.


1 Proportional directionalsolenoid 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

3 Proportional directionalsolenoid valve, 3 position 4 way ....... C ........... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm

4 Proportional directionalsolenoid 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 andjib 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 andjib boom up (Z-45/25J) ..................... 12-14 ft-lbs / 16-19 Nm

11 Check valve ....................................... K ........... Differential sensing circuit,platform rotate left andjib boom down (Z-45/25J) ................ 12-14 ft-lbs / 16-19 Nm

12 Differential sensing valve .................. L ........... Meters flow to functions ............................... 25 ft-lbs / 34 Nm

13 Check valve ....................................... M .......... Differential sensing circuit,secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm

14 Check valve ....................................... N ........... Differential sensing circuit,secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm

15 Priority flow regulator valve,1.5 gpm / 5.7 L/min ............................ O ........... Steer circuit .................................................. 25 ft-lbs / 34 Nm

16 Relief valve, 3200 psi / 220.6 bar ..... P ........... System relief ................................................ 20 ft-lbs / 27 Nm

17 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... Q ........... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm

18 Shuttle valve ...................................... R ........... Primary boom circuit ..................................4-5 ft-lbs / 5-7 Nm

19 Flow regulator valve,2 gpm / 7.6 L/min ............................... S ........... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm

20 Flow regulator valve,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.

MANIFOLDS



REV B

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REV B

Function Manifold Components (after serial number 22049)


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

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REV B

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REV BMANIFOLDS

8-4Valve Adjustments -Function Manifold(after serial number 22049)

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item P).





How to Adjust the SecondaryBoom Down Relief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AC).







REV B

8-5Jib Boom / Platform Rotate Manifold Components(before serial number 22050)


1 Solenoid valve, 2 position 3 way ..... AU ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm2 Solenoid valve, 2 position 3 way ..... AV ......... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm

AU AV

1 2

MANIFOLDS



REV B

8-6Jib Boom / Platform Rotate Manifold Components(after serial number 22049)


1 Solenoid valve, 2 position 3 way ..... AD ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm

MANIFOLDS

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REV B

8-7Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.


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

MANIFOLDS

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REV B

8-8Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end.

IndexNo. Description Function Torque

1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm

2 Spool valve ...................................................... Directional control

MANIFOLDS

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REV B

How to Set Up the DirectionalValve Linkage

Adjustment of the directional valvelinkage is only necessary when thelinkage or valve has beenreplaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor iscompletely level.

Tip-over hazard. Failure to performthis procedure on a level floorcould compromise the stability ofthe machine resulting in themachine tipping over.

3 Check the tire pressure in all four tires and addair 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 drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

6 To level the drive chassis, start the engine andloosen the lock nuts on both sides of theurethane cushions.

7 Push up or pull down on the threaded rod untilthe machine is completely level.

MANIFOLDS

8 Verify that the ground and drive chassis arecompletely level.

9 Tighten the nuts on both sides of the urethanecushions until they are snug. Tighten thelocknuts.

10 Check to be sure the drive chassis iscompletely level.

11 Measure the distance between the drive chassisand the non-steer axle on both sides (from theinside of the drive chassis).

If the distance is not equal and theadjustment to the linkage wascompleted with the ground anddrive chassis level, repeat steps 6through 10 OR consult GenieIndustries Service Department.



REV B

8-9Drive Manifold Components, 2WD

The drive manifold is mounted inside the drive chassis at the non-steer end.


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 motorsin 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 thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor 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

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REV B

8-10Valve Adjustments, 2WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure


2 Hold the charge pressure relief valve andremove the cap (item PP).

3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.

4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.


6 Remove the pressure gauge from the drivepump. Connect the gauge to the test port(item VV) located on the drive manifold.

7 Hold the charge pressure relief valve andremove the cap (item PP).

8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.

9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.

10 Turn the engine off and remove the pressuregauge.

MANIFOLDS



REV B MANIFOLDS




REV B

8-11Drive Manifold Components, 4WD

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Flow divider/combiner valve .............. AB ......... Controls flow to non-steer enddrive motors in forwardand 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 thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor 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 flowdivider/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 enddrive motors in forwardand 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

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REV BMANIFOLDS

8-12Valve Adjustments, 4WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure


2 Hold the charge pressure relief valve andremove the cap (item AH).

3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.

4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.


6 Remove the pressure gauge from the drivepump. Connect the gauge to the test port(item AF) located on the drive manifold.

7 Hold the charge pressure relief valve andremove the cap (item AH).

8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.

9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.

10 Turn the engine off and remove the pressuregauge.



REV A



4 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine to access the turntable rotation motor.

5 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.


6 Attach a lifting strap from and overhead crane orother suitable lifting device to the turntablerotator assembly.

7 Remove the turntable rotation assemblymounting fasteners.

8 Carefully remove the turntable rotation assemblyfrom the machine.

Crushing hazard. The turntablerotation assembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.

Turntable Rotation Components

9-1Turntable Rotation Assembly

How to Remove the TurntableRotation Assembly


1 Raise the secondary boom until the upper pivotis above the turntable covers. Turn the machineoff.

2 Secure the turntable from rotating with theturntable rotation lock pin.

Crushing hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.

Unlocked position

Locked position



REV B

How to Install the Hub andBearings, 2WD Models

When replacing a wheel bearing,both the inner and outer bearingsincluding the pressed-in racesmust be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearing.

8 Fully loosen the castle nut, then re-tighten to8 ft-lbs / 11 Nm.

9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.


10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

Axle Components

10-1Hub and Bearings, 2WD Models

How to Remove theHub and Bearings, 2WD Models1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steering wheels and place a liftingjack of ample capacity under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the chassis for support.

Crushing hazard. The machinemay fall if not properly supported.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Remove the dust cap, cotter pin andcastle nut.


6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub.

8 Remove the rear bearing.



REV A

10-2Oscillating AxleLock-out Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are not adjustable.

How to Remove an OscillatingAxle Cylinder

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


2 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

3 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

4 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

Crushing hazard. The oscillatecylinder may become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

5 Remove the oscillate cylinder from the machine.

AXLE COMPONENTS



REV A



March 2005 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-45/25 and Genie Z-45/25J Operator’sManual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:



· Turntable rotated with the boom between the non-steering wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· Wheels chocked



March 2005Section 5 • Fault Codes

REV BFAULT CODES

Fault Codes - Control System

How to Retrieve Control SystemFault Codes

At least one fault code is presentwhen the alarm at the platformcontrols produces two short beepsevery 30 seconds for 10 minutes.

Perform this procedure with theengine off, the key switch turned toplatform controls and the redEmergency Stop button pulled outto the on position at both theground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the red LED is flashing thecode, the yellow LED will be onsolid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the yellow LED is flashingthe code, the red LED will be onsolid.

5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.



REV B

Error Source Error TypeID Name ID Name

Condition Solution11121516

Value at 5VValue too highValue too lowValue at 0V

Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.

Power upcontroller withproblem corrected.

17 Not calibratedJoystick speed anddirection frozen atzero and neutral.

Calibrate joystick.

21 Boom 1 Joystick(primary boom up/down)

18 Just calibrated Initiate 1-second beepof alarm.

Self-clearing.(transient)

22 Boom 1 directionalvalves

21 Fault



1215

Value too highValue too low



17 Not calibrated Calibrate valvethresholds.

23 Boom 1 flowcontrol valve

18 Just calibrated

Normal functionexcept threshold forone or both directionsis zero.


11121516





Calibrate joystick.

31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)

18 Just calibrated Initiate 1 second beepof alarm.


32 Boom 2 directionalvalves

21 Fault



Continued on next page

FAULT CODES



REV B


Condition Solution

1215




17 Not calibratedCalibrate valvethresholds.

33 Boom 2 flowcontrol valve

18 Just calibrated



11121516





Calibrate joystick.

41 Turntable rotatejoystick



42 Turntable rotatedirectional valves

21 Fault



1215




17 Not calibrated Calibrate valvethresholds.

43 Turntable rotateflow control valve

18 Just calibrated



44 Drive enableoverride switches 21 Fault

Enable overridedirection is frozen atneutral.


FAULT CODES



REV B


Condition Solution11121516





Calibrate joystick

51 Drive joystick



1215




17 Not calibrated Calibrate valvethresholds

53 Drive flow valve(EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drivemotor Valve 21 Fault

Motor speed frozen inthe low state. Alarmsounds indicatingfault.


11121516





Calibrate Joystick

61 Steer joystick



62 Steer directionalvalves

21 Fault



FAULT CODES



REV B

Fault codes - Ford Models

The ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Refer to Repair Procedure 6-4, How to RetrieveEngine Fault Codes. Use the Fault Code Chart onthe following pages to aid in identifying the fault.

FAULT CODES



REV B FAULT CODES

Code Problem Cause Solution

111Closed Loop Multiplier High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112HO2S Open/Inactive (Bank 1)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

113HO2S Open/Inactive (Bank 2)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

121Closed Loop Multiplier High (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

122Closed Loop Multiplier Low (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft po

Adjust or replace sensors OR clean or repair fuel injectors.

124Closed Loop Multiplier Low (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR replace fuel OR test and repair the fuel system components.




REV BFAULT CODES


141Adaptive Lean Fault - High Limit (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low.

Repair heated oxygen sensor wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

142Adaptive Rich Fault - Low Limit (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft

Adjust or replace sensors OR clean or repair fuel injectors.

143Adaptive Learn High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components.

144Adaptive Learn Low (LPG)

Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty.

Repair short in engine wire harness OR test and repair the fuel system components.

161 System Voltage Low

Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repair battery supply wiring to ECM.

162 System Voltage HighAlternator is overcharging the battery when engine RPM is greater than 1500 rpm.

Repair or replace the alternator.



REV B FAULT CODES


211 IAT High Voltage

IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold.

Repair wiring and/or connections OR replace sensor OR direct warmer air into air intake.

212 IAT Low Voltage

IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot.

Repair wiring and/or connections OR replace sensor OR direct cooler air into air intake.

213IAT Higher Than Expected (1)

Air intake temperature is greater than 200° F with the engine greater than 1000 rpm OR air intake system as leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

214IAT Higher Than Expected (2)

Air intake temperature is greater than 210° F with the engine greater than 1000 rpm OR air intake system as leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

215 Oil Pressure Low

Faulty oil pressure sensor OR sensor wiring and/or connections open or shorted OR engine oil level too low.

Replace oil pressure sensor OR repair sensor wiring and/or connections OR fill engine oil level to specification.

221CHT/ECT High Voltage

Engine cooling system is malfunctioning OR sensor wires and/or connections open or shorted OR sensor is faulty.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor.

222CHT/ECT Low Voltage

Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification.




REV B


223CHT Higher Than Expected (1)

Coolant temperature at the cylinder head is 240° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


224CHT Higher Than Expected (2)

Coolant temperature at the cylinder head is 250° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


231 MAP High PressureOpen or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

232 MAP Low VoltageOpen or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

234 BP High PressureMAP sensor is faulty OR ECM is faulty.

Replace MAP sensor OR replace the ECM.

235 BP Low PressureMAP sensor is faulty OR ECM is faulty.

Replace MAP sensor OR replace the ECM.

242 Crank Sync Noise

Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor.

243Never Crank Synced At Start

Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


FAULT CODES



REV B



FAULT CODES

244 Camshaft Sensor Loss

Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


245 Camshaft Sensor Noise

Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


253 Knock Sensor OpenKnock sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections to knock sensor OR replace knock sensor.

254Excessive Knock Signal

Knock sensor wiring and/or connections open or shorted OR there is excessive engine vibration OR sensor is faulty.

Check for excessive engine vibration OR repair wiring and/or connections to knock sensor OR replace knock sensor.

311 Injector Driver #1 Open

Open wiring and/or connections to fuel injector #1 OR fuel injector #1 is faulty OR ECM is faulty.

Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM.

312 Injector Driver #1 Shorted

Wiring and/or connections to fuel injector #1 shorted OR fuel injector #1 is faulty OR ECM is faulty.







REV B


FAULT CODES
















351Fuel Pump Loop Open or High Side Short To Ground

Open wiring and/or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

352Fuel Pump High Side Shorted To Power

Wiring and/or connections to fuel pump shorted to power OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

411 Coil Driver #1 OpenOpen wiring and/or connections to ignition coil #1 OR ignition coil #1 is faulty.

Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1.

412 Coil Driver #1 ShortedWiring and/or connections to ignition coil #1 shorted OR ignition coil #1 is faulty.




REV B


FAULT CODES

413 Coil Driver #2 OpenOpen wiring and/or connections to ignition coil #2 OR ignition coil #2 is faulty.


414 Coil Driver #2 ShortedWiring and/or connections to ignition coil #2 shorted OR ignition coil #2 is faulty.


511 FPP1 High Voltage Not used.

If this fault appears on your machine, contact Genie Industries Service Department.

512 FPP1 Low Voltage Not used.


513 FPP1 Higher than IVS Limit

Not used.


514 FPP1 Lower than IVS Limit

Not used.


521 FPP2 High Voltage Not used.


522 FPP2 Low Voltage Not used.





REV B


FAULT CODES

531TPS1 (Signal Voltage) High

The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #1.

532TPS1 (Signal Voltage) Low



533TPS2 (Signal Voltage) High



534TPS2 (Signal Voltage) Low



535TPS1 Higher than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.



REV B


FAULT CODES

536TPS1 Lower than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

537Throttle Unable to Open

Governor actuator is stuck closed OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

538Throttle Unable to Close

Governor actuator is stuck open OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

545Governor Interlock Failure

Engine harness wiring and/or connections open or shorted OR there is a poor system ground connection OR ECM is faulty.

Repair wiring and/or connections in engine harness OR replace the ECM.

551Max Governor Speed Override

ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.

Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head.

552 Fuel Rev Limit



553 Spark Rev Limit






REV B


FAULT CODES

611 COP FailureLoose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM.

612 Invalid InterruptLoose wire connections to ECM OR ECM is faulty.


613 A/D LossLoose wire connections to ECM OR ECM is faulty.


614 RTI 1 LossLoose wire connections to ECM OR ECM is faulty.


615Flash Checksum Invalid

Loose wire connections to ECM OR ECM is faulty.


616 RAM FailureLoose wire connections to ECM OR ECM is faulty.


631 External 5V DC Ref Lower than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.



REV B


FAULT CODES

632 External 5V DC Ref Higher than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.







REV B


Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-45/25 and Genie Z-45/25JOperator's Manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


Section 6 • SchematicsMarch 2005

March 2005Section 6 • Schematics


Electrical Symbols Legend

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch(before serial number 22051)

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B

Key switch(after serial number 22050)

KS1

REV A

March 2005 Section 6 • Schematics

Hydraulic Symbols Legend


Pumpfixed displacement

Motorbi-directional

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

Solenoid operated3 position, 4 way,

proportional directional valve

REV A

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A


Ford LRG-425 EFI Engine Wire Harness(before serial number 22050)


REV A

DIAGNOSTICCONNECTOR

A

E

F

B

C

D

SHD

B

ATWR

FUELPUMPRELAY

87

30

85

86

POWERRELAY

87

30

85

86

STARTERRELAY

87

30

85

86

A

B

TWR

RTND

5VC

TXB

RXA

TWR

B

A

CTWR

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

F2

F4

15A

F5

15A

F1

20A

F3

CAM +34

CAM -35

KNK -30

CRANK +32

CRANK -33

OVERSPEED33

AUX OUT 15

COIL 413

COIL 33

COIL 22

COIL 11

SPK PWR GROUND4

5 VOLT REF14

KNK +29

VBAT5

VBAT4

VSW3

EGR RECIRC23

EGR PWM22

POWER GROUND2

POWER GROUND1

EGR21

MAP20

IAT27

FPP 216

FPP 115

INJ 511

INJ +6

INJ 17

INJ 612

ECT28

IVS17

EGO 225

EGO 124

EGO 326

ANA_RTN13

AUX ANA PU118

AUX ANA PD119

AUX OUT 231

35RS 232 TX

34RS 485 -

21RS 485 +

20CAN -

19CAN +

18

ROAD SPEED -12

ROAD SPEED +11

GOV SELECT 217

GOV SELECT 116

FUEL PUMP MON10

TACH8

OIL PRESSURE7

BRAKE SWITCH6

TPS231

TPS130

FUEL LOCKOFF23

STARTER LOCKOUT22

FUEL SELECT14

AUX ANA PU215

MIL27

GASEOUS TRIM26

DBW -29

DBW +28

COIL 524

COIL 625

RELAY CONTROL32

FUEL PUMP9

INJ 38

INJ 49

INJ 210

J1(BLACK)

J2(GREY)

OILPRESSURE

D

C

B

F

E

ATWR

COIL 2

VBAT

COIL 111 2

2

3

3

2

3

1

4

56

851 Y-R 18850 Y-BK 18

851 Y-R 18

850 Y-BK 18

359 GY-R 18

351 BR-W 18317 GY-O 18

151 LB-BK 18

357 Y-W 18355 GY-W 18

FUEL LOCKOFFSOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

452 GY-R 18

452 GY-R 18

361A R 16

172 LB-R 18172 LB-R 18169 LG-BK 18169 LG-BK 18

148 Y-R 18148 Y-R 18

317 GY-O 18

317 GY-O 18

15 R-Y 18

15 R-Y 18

361 R 16 361 R 16361 R 16361 R 16361 R 16

39 R-W 18

39 R-W 18

32A R-LB 1632 R-LB 16

32 R-LB 16

32A R-LB 16

361A R 16

787A PK-BK 16

787A PK-BK 16787 PK-BK 16

361A R 16361 R 16

458 O-BK 18669 DG-W 18

461 O 18642 DG-O 18

459 O-LG 18662 DG-P 18

458 O-BK 18

669 DG-W 18

458 O-BK 18

669 DG-W 18

461 O 18642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

349A DB 1877 DB-Y 18

307 BK-Y 18307 BK-Y 18

306 T-LB 18306 T-LB 18

72 Y-BK 1872 Y-BK 1871 O-LG 1871 O-LG 18

361 R 14

361 R 14

361 R 14

361 R 12361 R 14361 R 14

361 R 14361 R 16361 R 16

16 R-LG 1816 R-LG 18 16 R-LG 18

16 R-LG 18

16 R-LG 18

16 R-LG 18

16 R-LG 18

151 LB-BK307 BK-Y 18

307 BK-Y 18

238 DG-Y 18

238 DG-Y 18

658 PK-LG 18658 PK-LG 1811 T-Y 1811 T-Y 18

253 DG-W 18

253 DG-W 18

253 DG-W 18

511 LG-R 18511 LG-R 18

151 LB-BK 18

151 LB-BK 18

357 Y-W 18

357 Y-W 18

355 GY-W 18

355 GY-W 18

926A LB-O 18

342 LG-P 18

926A LB-O 18

242 DG 18

342 LG-P 18

282 DB-O 18

282 DB-O 18

349 DB 18

349 DB 18

350 GY 18

350 GY 18

74 GY-LB 18

74 GY-LB 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

354 LG-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 16

360 BR-PK 18

360 BR-PK 18

352 BR-LG 18

352 BR-LG 18

114 LB-Y 18

114 LB-Y 18

150 DG-W 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

354 LG-R 18

151 LB-BK 18

198 DG-O 1818 O-Y 18

TWIST 10 TURNS/FOOT MIN FULL LENGTH



* 1 VSW



16 WATER TEMP

* 34 GROUND

25 IVS14 FPP1

87A13 STARTER CONTROL

15 STARTER SWITCH

* 5 FUEL PUMP

* 9 VBATT

33 ANA RTN31 VREF

38 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM41 EGR REC

4 BRAKE

26 OIL PRES2 TACH

* 6 MIL

39 AUX OUT1

* 7 FUEL SELECT

10 AUX ANA PU2

* 24 GOV SELECT 1

* 23 GOV SELECT 2

35 ROADSPEED +

36 ROADSPEED -

30 OVERSPEED

28 CAN +

29 CAN -

20 RS 485+

21 RS 485-

11 RS 232+

* 3 RS 232-

555 T 16 555 T 16

556 W 16556 W 16

557 BR-Y 16 557 BR-Y 16

558 BR-LB 16 558 BR-LB 16

358 LG-BK 18

358 LG-BK 18

743 GY 18

FORD 42 PINCONNECTOR

D-89

30A

5A

FORD WIRING HARNESS WIRE COLOR CODE

YELLOWYORANGEODARK GREENDG

GN GREEN PK PINK

BLACKBK

DB

BR

DARK BLUE

BROWN

BL

CODE

BLUE

COLOR

LIGHT BLUELB

LIGHT GREEN

N

LG

NATURAL

GY

CODE

GREY

COLOR

REDR

W

T

WHITE

TAN

P

CODE

PURPLE

COLOR

NOTE: * SHOWS USED WIRES

ENGINECOOLANT

TEMPERATURESENSOR

(ECT)

CRANKSHAFTPOSITIONSENSOR

(CKP)

CAMSHAFTPOSITIONSENSOR

(CMP) INTAKE AIRTEMPERATURE

SENSOR(IAT)

MANIFOLDABSOLUTEPRESSURESENSOR

(MAP)

NOTES:1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE

EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE2. INTERNAL SPLICES ARE NOT SHOWN

WATER TEMP.SWITCH (NO)

THROTTLE ACTUATOR/POSITION SENSOR

RS 232 RX

HEATEDOXYGENSENSOR(HO2S)

IGNITIONSYSTEM


Ford LRG-425 EFI Engine Wire Harness(before serial number 22050)

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2

3

4

5

6

7

8



Ford LRG-425 EFI Engine Wire Harness(after serial number 22049)


REV A

FORD WIRING HARNESS WIRE COLOR CODE

YELLOWYORANGEODARK GREENDG

GN GREEN PK PINK

BLACKBK

DB

BR

DARK BLUE

BROWN

BL

CODE

BLUE

COLOR

LIGHT BLUELB

LIGHT GREEN

N

LG

NATURAL

GY

CODE

GREY

COLOR

REDR

W

T

WHITE

TAN

P

CODE

PURPLE

COLOR

DIAGNOSTICCONNECTOR

A

E

F

B

C

D

SHD

B

ATWR

FUEL PUMPRELAY

POWER RELAY

STARTERRELAY

A

B

TWR

RTND

5VC

TXB

RXA

TWR

B

A

CTWR

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

F2

F4

15A

F5

15A

F1

20A

F3

CAM +34

CAM -35

KNK -30

CRANK +32

CRANK -33

OVERSPEED33

AUX OUT 15

COIL 413

COIL 33

COIL 22

COIL 11

SPK PWR GROUND4

5 VOLT REF14

KNK +29

VBAT5

VBAT4

VSW3

EGR RECIRC23

EGR PWM22

POWER GROUND2

POWER GROUND1

EGR21

MAP20

IAT27

FPP 216

FPP 115

INJ 511

INJ +6

INJ 17

INJ 612

ECT28

IVS17

EGO 225

EGO 124

EGO 326

ANA_RTN13

AUX ANA PU118

AUX ANA PD119

AUX OUT 231

35RS 232 TX

34RS 485 -

21RS 485 +

20CAN -

19CAN +

18

ROAD SPEED -12

ROAD SPEED +11

GOV SELECT 217

GOV SELECT 116

FUEL PUMP MON10

TACH8

OIL PRESSURE7

BRAKE SWITCH6

TPS231

TPS130

FUEL LOCKOFF23

STARTER LOCKOUT22

FUEL SELECT14

AUX ANA PU215

MIL27

GASEOUS TRIM26

DBW -29

DBW +28

COIL 524

COIL 625

RELAY CONTROL32

FUEL PUMP9

INJ 38

INJ 49

INJ 210

J1 BLACK

J2 GREY

OILPRESSURE

D

C

B

F

E

ATWR

COIL 2

VBAT

COIL 111 2

2

3

3

2

3

1

4

5

6

851 Y-R 18850 Y-BK 18

851 Y-R 18

850 Y-BK 18

359 GY-R 18

351 BR-W 18317 GY-O 18

151 LB-BK 18

357 Y-W 18355 GY-W 18

FUEL LOCKOFF SOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

452 GY-R 18

452 GY-R 18

361A R 16

172 LB-R 18172 LB-R 18169 LG-BK 18169 LG-BK 18

148 Y-R 18148 Y-R 18

317 GY-O 18

317 GY-O 18

15 R-Y 18

15 R-Y 18

361 R 16 361 R 16361 R 16361 R 16361 R 16

39 R-W 18

39 R-W 18

32A R-LB 1632 R-LB 16

32 R-LB 16

32A R-LB 16

361A R 16

787A PK-BK 16

787A PK-BK 16787 PK-BK 16

361A R 16361 R 16

458 O-BK 18669 DG-W 18

461 O 18642 DG-O 18

459 O-LG 18662 DG-P 18

458 O-BK 18

669 DG-W 18

458 O-BK 18

669 DG-W 18

461 O 18642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

349A DB 1877 DB-Y 18

307 BK-Y 18307 BK-Y 18

306 T-LB 18306 T-LB 18

72 Y-BK 1872 Y-BK 1871 O-LG 1871 O-LG 18

361 R 14

361 R 14

361 R 14

361 R 12361 R 14361 R 14

361 R 14361 R 16361 R 16

16 R-LG 1816 R-LG 18 16 R-LG 18

16 R-LG 18

16 R-LG 18

16 R-LG 18

16 R-LG 18

151 LB-BK307 BK-Y 18

307 BK-Y 18

238 DG-Y 18

238 DG-Y 18

658 PK-LG 18658 PK-LG 1811 T-Y 1811 T-Y 18

253 DG-W 18

253 DG-W 18

253 DG-W 18

511 LG-R 18511 LG-R 18

151 LB-BK 18

151 LB-BK 18

357 Y-W 18

357 Y-W 18

355 GY-W 18

355 GY-W 18

926A LB-O 18

342 LG-P 18

926A LB-O 18

242 DG 18

342 LG-P 18

282 DB-O 18

282 DB-O 18

349 DB 18

349 DB 18

350 GY 18

350 GY 18

74 GY-LB 18

74 GY-LB 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

351 BR-W 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

354 LG-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 16

360 BR-PK 18

360 BR-PK 18

352 BR-LG 18

352 BR-LG 18

114 LB-Y 18

114 LB-Y 18

150 DG-W 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

354 LG-R 18

151 LB-BK 18

198 DG-O 1818 O-Y 18




* 1 VSW



16 WATER TEMP

* 34 GROUND

25 IVS14 FPP1

13 STARTER CONTROL

15 STARTER SWITCH

* 5 FUEL PUMP

* 9 VBATT

33 ANA RTN31 VREF

38 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM41 EGR REC

4 BRAKE

26 OIL PRES2 TACH

* 6 MIL

39 AUX OUT1

* 7 FUEL SELECT

10 AUX ANA PU2

* 24 GOV SELECT 1

* 23 GOV SELECT 2

35 ROADSPEED +

36 ROADSPEED -

30 OVERSPEED

28 CAN +

29 CAN -

20 RS 485+

21 RS 485-

11 RS 232+

* 3 RS 232-

555 T 16 555 T 16

556 W 16556 W 16

557 BR-Y 16 557 BR-Y 16

558 BR-LB 16 558 BR-LB 16

358 LG-BK 18

358 LG-BK 18

743 GY 18

FORD 42 PIN CONNECTOR

D-89

30A

5A

NOTE: * SHOWS USED WIRES

ENGINE COOLANTTEMPERATURE

SENSOR(ECT)

CRANKSHAFTPOSITIONSENSOR

(CKP)

CAMSHAFTPOSITIONSENSOR(CMP)

INTAKE AIRTEMPERATURE

SENSOR(IAT)

MANIFOLDABSOLUTEPRESSURESENSOR

(MAP)

NOTES:1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE

(EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE)

2. INTERNAL SPLICES ARE NOT SHOWN

WATER TEMP.SWITCH (NO)

POSITION SENSORTHROTTLE ACTUATOR/

RS 232 RX

HEATEDOXYGENSENSOR(HO2S)

IGNITIONSYSTEM

5

87a

87

1

2 86

30 4

85

3

5

87a

87

1

2 86

30 4

85

3

5

87a

87

1

2 86

30 4

85

3


Ford LRG-425 EFI Engine Wire Harness(after serial number 22049)


Electrical Schematic, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


REV A

FO

OT

SW

.H

IGH

FO

OT

SW

.L

OW

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

.

LP

FU

EL

GA

S

LP

FU

EL

GA

S

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C1

B-7

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

P2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.

D1ALTERNATOR

LINK

FUSE

50

0

R4

6H

RN

BK

/RD

C2

1IG

NW

H

C4

1R

PM

OR

/BK

RD

CR5

C4

6H

RN

BK

/RD

CB1

RD

CB2

15A

TB41TB23

KS1

PLAT

GRND

P1RD

P3HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

FORD 42 PIN QUICK DISCONNECTENGINE HARNESS #2

TB35

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER

IGN./FUEL ONENG. FAULT

KEY BYPASS

START INPUT

START RELAY

TS64

4

PR1

C2

7A

UX

RD

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

RD

/LG

FE

H(1

6A

)P

IN1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

RD

FE

H(3

61

)P

IN9

BK

/RD

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN3

TB21

TB25

8765

109

CR2

TS51

TB27

TS1

WH

TS52

1

2

TB33

3 C2

3A

LR

MR

D

IGNITION/START

MODULE

C5-13

L2T

ES

T

C1

08

ES

LB

K/R

D

C2

1H

MW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)FS1

(GN

D)

BR

NF

EH

(57

0)

PIN

34

TS3

CH

EC

KE

NG

INE

LE

D

12V DC

TIL

TA

LA

RM

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

)P

IN5

FUELPUMP

AUXPUMP

BL

/WH

BK

FU

EL

PU

MP

P2RD

WH

C2

P-4

C1

P-9

C3

5E

SP

DB

K/R

D

TS54

ENGINESPEED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

RD

RD

BRN

C1

28

LR

PM

OR

/RD

C4

5G

EN

GR

/WH

C2

P-7

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1

C28TTA RD/BK C28TTA RD/BK

C5-9

C1

28

LR

PM

OR

/RD

C35ESPD BK/RD

C1

B-9

C2

B-4

C5

-9

C5

-12

C2

B-7

C2

B-1

C5

-10

C6

-34

C5-8

C7

B-4

C2

B-3

C5

-2

C2

8T

TA

RD

/BK

C5

-5

C6

-9

C5

-23

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-11

C3

9L

PB

L/R

D

C7

B-1

C5

-1

TB38

B2

R16

M3M2

S8M4

U1

C5

-18

FUSE 10A

TS48

WO

RK

LIG

HT

ON

DR

IVE

LIG

HT

OF

F

LIG

HT

S

GE

NE

RA

TO

R

L30

C2

P-1

2

C2

P-1

1

C2

P-5

RD

RD

L30

L29

RD

C4

B-1

2

C2

B-5

C4

3D

LIT

EG

R

C2

P-1

0

PBOXGND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-1

1

CR23

C127TSW

C108ESL

TB24

BL/RD

WH CHECK

ENGINE

STARTER

HM

WH-(FS)

H2

H1


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RD

C1

B-1

0

TB1

C3

B-1

2

C3

B-1

0

C3

B-11

BK

-4

WH

-6TB8TB15TB17

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

PL

AT

FO

RM

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

SE

CO

ND

AR

YB

OO

MU

P

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

LS2

22

21

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32

PRIMARY BOOM UP/DOWN &TURNTABLE ROTATE

P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

BO

OMC

4P

-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

LS1

21

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4

U13 JOYSTICK CONTROL CARD

CR30NO

CELIFT/DRIVEOPTION

4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR YE

L

11 2

12

J2

6

1

J1

RD

ORB

RN

BK

1

P26ESTP BK

SECONDARY BOOMUP/DOWN

OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

10

C3

7S

TC

BL

/BK

C2

9M

SR

D/W

H

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

C3

B-4

C3

B-6

C3

B-5

C1

B-11

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

K

TS62 C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4

C3

P-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WHB

RN

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEER

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

L1

TS15

C28TTA RD/BK

STEERROCKERSWITCHOPTION


Electrical Schematic, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8



REV A

P2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.LINK

FUSE

50

0

R4

6H

RN

BK

/RD

C2

1IG

NW

H

C4

1R

PM

OR

/BK

RD

CR5NO

CR5

C4

6H

RN

BK

/RD

CB115A

RD

CB215A

TB41TB23

KS1

PLAT

GRND

P1RD

P3HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

TS64

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

RD

/LG

FE

H(1

6A

)P

IN1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

RD

FE

H(3

61

)P

IN9

BK

/RD

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN3

TB21

TB25

CR2NO

8765

109

CR2

TS51

TB27

TS1

WH

TS52

1

2

TB33

3 C2

3A

LR

MR

D

U1IGNITION/

STARTMODULE

HM

C5-13

L2

TE

ST

C1

08

ES

LB

K/R

D

C2

1H

MW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)FS1

NOTE:1) All switches and contacts are shown with theboom in the stowed position and the keyswitch off.

(GN

D)

BR

NF

EH

(57

0)

PIN

34

TS3

CH

EC

KE

NG

INE

LE

D

B1DC12V

CHECKENGINE

TIL

TA

LA

RM

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

)P

IN5

FUELPUMP

BL

/WH

BK

FU

EL

PU

MP

P2RD

WHWH-(FS)

H2

H1

C2

P-4

C1

P-9

C3

5E

SP

DB

K/R

D

TS54

ENGINESPEED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

BRN

C1

28

LR

PM

OR

/RD

C4

5G

EN

GR

/WH

C2

P-7

GE

NE

RA

TO

RO

N

OF

F

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1


C5-9

FO

OT

SW

ITC

HH

IGH

FO

OT

SW

ITC

HL

OW

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

28

LR

PM

OR

/RD

C35ESPD BK/RD

C1

B-9

C2

B-4

C5

-9

C5

-12

LP

FU

EL

GA

S

LP

FU

EL

GA

S

C2

B-7

C2

B-1

C5

-10

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C1

B-7

C6

-34

C5-8

C7

B-4

C2

B-3

C5

-2

C2

8T

TA

RD

/BK

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

C5

-5

C6

-9

C5

-23

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-11

C3

9L

PB

L/R

D

C7

B-1

C5

-1

TB38

D1ALTERNATOR

R16

M3

M2

S8M4

C5

-18

FUSE 10A (ONLY ON WORKLIGHTS)

TS48

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

SL30

C2

P-1

2

C2

P-1

1

C2

P-5

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C2

B-5

C4

3D

LIT

EG

R

C2

P-1

0

PBOX GND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23NO

C1B & C1P - GRAYC2B & C2P - BLACKC3B & C3P - GREENC4B & C4P - BROWN

C127TSW

C108ESL

TB24

BL/RD

WH

C1

34

PW

RB

L/R

DC

2B

-5R

DC

2P

-5

L4

TB134

FUSE 10A


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RE

TR

AC

T

EX

TE

ND

BO

OM

J3 J1 J1

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C4

P-5

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

10

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT

PRIMARY BOOM UP/DOWNAND TURNTABLE ROTATE

JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WHB

RN

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

3

NOTES:1. ALL LIMIT SWITCHES SHOWNWITH BOOM IN STOWED POSITIONEXCEPT AS NOTED.

SWITCH SHOWN WITH BOOMROTATED PAST EITHER NON-STEERWHEEL.

ROCKER STEER OPTION ONLY.

2


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

DC

VO

LT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

BK

-TS

64

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

/RD

C2

B-3

OR

/BK

C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B

GROUND CONTROL HARNESS

(TO SWITCHPANEL)

CONTROL HARNESS

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GROUND

GROUNDCONTROLHARNESS

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT1

34

71

09

2

12

/24

VD

CIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN

I.S.M. I.S.M. I.S.M. I.S.M.

C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLTNOTE:DASHED LINES INDICATEOPTION WIRES

RD

-IS

6

RD

-IS

4

FUNCTIONS ENGINE19/18 CABLES

C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-(U

NU

SE

D)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

-

(UN

US

ED

)

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

C3

B-9

BK

/RD

C3B

+1

2V

DC

VO

LT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

BRN

CR1

STARTRELAY

IGNITION

CR2

RELAYPOWER

C16DRE OR/RDC6-16 C4B-4

C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B

C36STCC BLC6-36 C1B-10

C37STC BL/BKC6-37 C1B-11

C30FWD WHC1B-4 C5-21

C31REV WH/BKC1B-5 C5-20

C28TTA RD/BK C5-24C1B-2C29MS RD/WHC6-29 C1B-3

C40LS1 ORC6-40 C2B-2

C1

B-8

BK

/WH

BRN

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

WH

-21

C

WH

-23

B

WH

-IS

7

BRN-TS

GR

TS64RUN/TESTSWITCH

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-3 WH

BK

-R5

OR

/RD

-TS

54

BRN

CR23DRIVE LIGHT

OPTIONRELAY

C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-TS

64

C5-8 C127TSW GR

C2

3T

SW

WH

C125TSW WH

WH

-IS

10

C2

B-4

OR

/RD

F1910A

FUSE

C45 GEN GR/WH C5-12C2B-7

RD

-R2

RD

-CB

1

RD

-CB

2

C5

-1R

D

CR

23

RD

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-TS

64

C5-11 C21IGN2 WH

KE

YS

WIT

CH

PO

WE

R2

32

3

GR

/BK

-TS

58

BK

-AL

AR

M

I.S.M.

BRN

BK-33B

WH

-TS

64

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

KE

YS

WIT

CH

KS

1

GR

OU

ND

CO

NT

RO

LB

OX

HA

RN

ES

S(T

OT

ER

MIN

AL

ST

RIP

)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RD

RDRD

RD

BRN

WH-CR2

WH

-21

BR

N

RD

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

RD

-27

RD

-27

A

RD

RD

RD

RD

KS

1

TS

59

LE

VE

LP

LA

TF

OR

M

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S,

15

A

CB

1

BR

EA

KE

RE

NG

INE

,1

5A

CIR

CU

IT

TS

54

EN

AB

LE

FU

NC

TIO

N

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

RO

TA

TE

TU

RN

TA

BL

E

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

BO

OM

UP

/DO

WN

PR

IMA

RY

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

RD

RD

RD

RD

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

RD

RD

BL

/RD

-39

A

TS

53

FU

EL

SE

LE

CT

BL

/WH

-38

L2

EN

GIN

EL

ED

CH

EC

K

-+

RD

-24

A

OR

/RD

-42

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

BK

-TS

64

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

/RD

C2

B-3

OR

/BK

C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GR

OU

ND

CO

NT

RO

LH

AR

NE

SS

(TO

SW

ITC

HP

AN

EL

)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

BR

NB

RN

GROUND BOLT

NOTE: DASHED LINES INDICATE OPTION WIRES

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-(U

NU

SE

D)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

-

(UN

US

ED

)

CR2POWERRELAY

CR1IGNITION

STARTRELAY

BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

WH

-21

C

WH

-23

B

WH

-IS

7

BRN-TS

GR

TS64RUN/TESTSWITCH

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-3 WH

BK

-R5

OR

/RD

-TS

54

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-TS

64

C5-8 C127TSW

C2

3T

SW

WH

C125TSW WH

WH

-IS

10

C2

B-4

OR

/RD


RD

-R2

RD

-CB

1

RD

-CB

2

C5

-1R

D

CR

23

RD

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-TS

64

C5-11 C21IGN2 WH

I.S.M.

BRN

BK-33B

WH

-TS

64

BK

-33

BB

K-I

S3

BK

-IS

3

CR23DRIVE LIGHT

OPTION RELAY

F1910A FUSE

C6-13 BK

BK-22B

RD

CR32PRIMARY

BOOMRELAY

CR33TURNTABLE

ROTATERELAY

CR37SECONDARY

BOOMRELAY

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A

30 = COMMON (12V DC IN)87A = NC87 = NO85 = COIL NEGATIVE86 = COIL POSITIVE

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

85

87

86

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

NT

S6

2T

UR

NTA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YS

WIT

CH

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L2

CH

EC

KE

NG

INE

LE

D

RD

RD

RD

RD


1

2

NC

1

2

NC

P1 RED EMERGENCY STOP BUTTON

KS1 KEY SWITCH

TS51 AUXILIARY POWER TOGGLE SWITCH

TS52 ENGINE START TOGGLE SWITCH

TS53 FUEL SELECT TOGGLE SWITCH

TS54 FUNCTION ENABLE TOGGLE SWITCH

TS57 PLATFORM ROTATE TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH

TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH

TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH

TS62 TURNTABLE ROTATE TOGGLE SWITCH

LABEL DESCRIPTION

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

CB1 CIRCUIT BREAKER, ENGINE, 15A

CB2 CIRCUIT BREAKER, CONTROLS, 15A

HM HOUR METER

R4 SPEED LIMITING VARIABLE RESISTOR 10 OHMS

L2 CHECK ENGINE LED

CR1 IGNITION / START RELAY

CR2 INGITION POWER RELAY

CR5 HORN RELAY

TS64 RUN/TEST TOGGLE SWITCH

-+

RD

-24

A

BK-22A

WH

-23

A

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)


Platform Box Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

H1

ALALRMTILT

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P

PLATFORM CONTROL HARNESS(TO SWITCH PANEL)

12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOTSWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* WIRE CONNECTS TO JC3-6

FOR STEER ROCKERSWITCH OPTION.

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4

CE LIFT/DRIVE OPTION

NOTE: DASHED LINES INDICATE OPTION WIRING

R2

4F

SW

HC

9P

-2

H1

J3

J2

J1

U13

C1P-

C7P

ALC-500 CONTROL BOARD

CONTROL BOARD POWER CONNECTOR

CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD INPUT CONNECTOR

TILT ALARM

12V DC PLATFORM POWER CONNECTOR

48 PIN CONNECTOR BLOCK

DESCRIPTIONITEM

FOOT SWITCH CONNECTORC9

C4P

CR27 CONTROL RELAY (CE OPTION)


CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4

RPMHIGH/LOW

TS2ENGINESTART

TS15DRIVE

ENABLE

L1

TS14

(2WD/4WD)HIGH/LOW

SPEED

DRIVE

TS1AUXILIARY

PUMP

TS13BOOM

EXTEND/ RETRACTPRIMARY

TS7

ROTATEPLATFORM

TS9

LEVELPLATFORM

P3HORN

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD

BK

TS3FUEL

SELECT

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH

NOTE:DASHED LINESINDICATE OPTIONWIRING

TS47

(OPTION)GENERATOR

RD

-TILT

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

C1

28

LS

OR

/RD

C2

P-4

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO

PLATFORMCONTROLHARNESS

(TO CONTROL BOX)

BL

J1

-5

+

TS48

WORK LIGHTS(OPTION)

DRIVE LIGHTS/

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

RC

2P

-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2

PRIMARY BOOM UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC3DRIVE

FORWARD/REVERSE& STEER

LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)


Platform Box Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

TILTALARM

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P

PLATFORM CONTROLHARNESS

(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPLY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM




LS18 LOAD SENSE LIMIT SWITCH

RD

-P2

RD

-H1

RE

DL

S1

8

OPT.

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4

HIGH/LOWRPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED

TS14HIGH/LOW(2WD/4WD)

TS13PRIMARY

BOOMEXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY PUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

BK

C9

P-1

WH

C7

P-2

RD

WH

RD RD

WH-24

RD

BK

RD RD

TS3FUEL

SELECT

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH


C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC2PRIMARY BOOM

UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

C1

28

LS

OR

/RD

C2

P-4

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+

TS48DRIVE LIGHTS/WORK LIGHTS

(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

BK

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford LRG-425 EFI Models (after serial number 22049)


Electrical Schematic, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

FO

OT

SW

.H

IGH

FO

OT

SW

.L

OW

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

.

LP

FU

EL

GA

S

LP

FU

EL

GA

S

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C1

B-7

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

P2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.

D1ALTERNATOR

LINK

FUSE

50

0

R4

6H

RN

BK

/RD

C2

1IG

NW

H

C4

1R

PM

OR

/BK

RD

CR5

C4

6H

RN

BK

/RD

CB1

RD

CB2

15A

TB41TB23

KS1

PLAT

GRND

P1RD

P3HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y


TB35

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

TS64

4

PR1

C2

7A

UX

RD

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

RD

/LG

FE

H(1

6A

)P

IN1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

RD

FE

H(3

61

)P

IN9

BK

/RD

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN3

TB21

TB25

8765

109

CR2

TS51

TB27

TS1

WH

TS52

1

2

TB33

3 C2

3A

LR

MR

D

IGNITION/START

MODULE

C5-13

L2T

ES

T

C1

08

ES

LB

K/R

D

C2

1H

MW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)FS1

(GN

D)

BR

NF

EH

(57

0)

PIN

34

TS3

CH

EC

KE

NG

INE

LE

D

12V DC

TIL

TA

LA

RM

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

)P

IN5

FUELPUMP

AUXPUMP

BL

/WH

BK

FU

EL

PU

MP

P2RD

WHC

2P

-4

C1

P-9

C3

5E

SP

DB

K/R

D

TS54

ENGINESPEED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

RD

RD

BRN

C1

28

LR

PM

OR

/RD

C4

5G

EN

GR

/WH

C2

P-7

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1


C5-9

C1

28

LR

PM

OR

/RD

C35ESPD BK/RD

C1

B-9

C2

B-4

C5

-9

C5

-12

C2

B-7

C2

B-1

C5

-10

C6

-34

C5-8

C7

B-4

C2

B-3

C5

-2

C2

8T

TA

RD

/BK

C5

-5

C6

-9

C5

-23

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-11

C3

9L

PB

L/R

D

C7

B-1

C5

-1

TB38

B2

R16

M3M2

S8M4

U1

C5

-18

FUSE 10A

TS48

WO

RK

LIG

HT

ON

DR

IVE

LIG

HT

OF

F

LIG

HT

S

GE

NE

RA

TO

R

L30

C2

P-1

2

C2

P-11

C2

P-5

RD

RD

L30

L29

RD

C4

B-1

2

C2

B-5

C4

3D

LIT

EG

R

C2

P-1

0

PBOXGND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23

C127TSW

C108ESL

TB24

BL/RD

WH CHECK

ENGINE

STARTER

HM

WH-(FS)

H2

H1


1

2

3

4

5

6

7

8




REV A

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RD

C1

B-1

0

TB1

C3

B-1

2

C3

B-1

0

C3

B-11

BK

-4

WH

-6TB8TB15TB17

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

M

SE

CO

ND

AR

YD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LS

3-D

RIV

EE

NA

BL

E

PL

AT

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

DO

WN

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

JIB

BO

OM

UP

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

FL

OW

CO

NT

RO

L

SE

CO

ND

AR

YU

P

LIM

ITS

WIT

CH

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13

LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32


P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

BO

OMC

4P

-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

LS121

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4

U13 JOYSTICK CONTROL CARDCELIFT/DRIVEOPTION

4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR

YE

L

11 2

12

J2

6

1

J1

RD

OR

BR

N

BK

1

P26ESTP BK


OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

10

C3

7S

TC

BL

/BK

C2

9M

SR

D/W

H

C3

B-4

C3

B-6

C3

B-5

C1

B-11

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

K

TS62 C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4

C3

P-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WH

BR

N

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEERING

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

LS2

22

21

JIB

VA

LV

ES

C1

8JD

GR

/BK

C1

7JU

GR

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

TS58

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

B-7

TS57

C2

B-6

TB44

C19JSV GR/WH

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

P-7

JIB

VA

LV

ES

CR13TS7

UP

DO

WN

JIB

BO

OM

C2

P-6

GR

/BK

-44

TS8

BRN

WH

NCCR13

L1

TS15

C28TTA RD/BK

DO

WN

UP

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

CR30NO


Electrical Schematic, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.LINK

FUSE

50

0

R4

6H

RN

BK

/RD

C2

1IG

NW

H

C4

1R

PM

OR

/BK

RD

CR5NO

CR5

C4

6H

RN

BK

/RD

CB115A

RD

CB215A

TB41TB23

KS1

PLAT

GRND

P1RD

P3HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

TS64

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

RD

/LG

FE

H(1

6A

)P

IN1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

RD

FE

H(3

61

)P

IN9

BK

/RD

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN3

TB21

TB25

CR2NO

8765

109

CR2

TS51

TB27

TS1

WH

TS52

1

2

TB33

3 C2

3A

LR

MR

D

U1IGNITION/

STARTMODULE

HM

C5-13

L2

TE

ST

C1

08

ES

LB

K/R

D

C2

1H

MW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)FS1

NOTE:1) All switches and contacts are shown with theboom in the stowed position and the keyswitch off.

(GN

D)

BR

NF

EH

(57

0)

PIN

34

TS3

CH

EC

KE

NG

INE

LE

D

B1DC12V

CHECKENGINE

TIL

TA

LA

RM

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

)P

IN5

FUELPUMP

BL

/WH

BK

FU

EL

PU

MP

P2RD

WHWH-(FS)

H2

H1

C2

P-4

C1

P-9

C3

5E

SP

DB

K/R

D

TS54

ENGINESPEED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

BRN

C1

28

LR

PM

OR

/RD

C4

5G

EN

GR

/WH

C2

P-7

GE

NE

RA

TO

RO

N

OF

F

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1


C5-9

FO

OT

SW

ITC

HH

IGH

FO

OT

SW

ITC

HL

OW

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

28

LR

PM

OR

/RD

C35ESPD BK/RD

C1

B-9

C2

B-4

C5

-9

C5

-12

LP

FU

EL

GA

S

LP

FU

EL

GA

S

C2

B-7

C2

B-1

C5

-10

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C1

B-7

C6

-34

C5-8

C7

B-4

C2

B-3

C5

-2

C2

8T

TA

RD

/BK

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

C5

-5

C6

-9

C5

-23

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-11

C3

9L

PB

L/R

D

C7

B-1

C5

-1

TB38

D1ALTERNATOR

R16

M3

M2

S8M4

C5

-18

FUSE 10A (ONLY ON WORKLIGHTS)

TS48

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

SL30

C2

P-1

2

C2

P-1

1

C2

P-5

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C2

B-5

C4

3D

LIT

EG

R

C2

P-1

0

PBOX GND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23NO


C127TSW

C108ESL

TB24

BL/RD

WH

C1

34

PW

RB

L/R

DC

2B

-5R

DC

2P

-5

L4

TB134

FUSE 10A


1

2

3

4

5

6

7

8




REV A

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

3




2


C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LV

E

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

JIBVALVE

One valveremoved afterserial number22565

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

JIB

BO

OM

GR

/BK

-44

J3 J1 J1

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

RO

TA

TE

LE

FT

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

UP

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

20

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7 TS8

BRN

TS9

CR13NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

WH

BK

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

DC

VO

LT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

BK

-TS

64

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

/RD

C2

B-3

OR

/BK

C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


(TO SWITCHPANEL)

CONTROL HARNESS

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GROUND


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT1

34

71

09

2

12

/24

VD

CIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLTNOTE:DASHED LINES INDICATEOPTION WIRES

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-(U

NU

SE

D)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

-

(UN

US

ED

)

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

C3

B-9

BK

/RD

C3B

+1

2V

DC

VO

LT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

BRN

CR1

STARTRELAY

IGNITION

CR2

RELAYPOWER


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B






C40LS1 ORC6-40 C2B-2C

1B

-8B

K/W

H

BRN

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

WH

-21

C

WH

-23

B

WH

-IS

7

BRN-TS

GR

TS64RUN/TESTSWITCH

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-3 WH

BK

-R5

OR

/RD

-TS

54

BRN

CR23DRIVE LIGHT

OPTIONRELAY

C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-TS

64

C5-8 C127TSW GR

C2

3T

SW

WH

C125TSW WHW

H-I

S1

0

C2

B-4

OR

/RD

F1910A

FUSE


RD

-R2

RD

-CB

1

RD

-CB

2

C5

-1R

D

CR

23

RD

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-TS

64

C5-11 C21IGN2 WH

KE

YS

WIT

CH

PO

WE

R2

32

3

GR

/BK

-TS

58

BK

-AL

AR

M

I.S.M.

BRN

BK-33B

WH

-TS

64

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

KE

YS

WIT

CH

KS

1

GR

OU

ND

CO

NT

RO

LB

OX

HA

RN

ES

S(T

OT

ER

MIN

AL

ST

RIP

)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RD

RDRD

RD

BRN

WH-CR2W

H-2

1

BR

N

RD

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

RD

-27

RD

-27

A

RD

RD

RD

RD

KS

1

TS

59

LE

VE

LP

LA

TF

OR

M

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S,

15

A

CB

1

BR

EA

KE

RE

NG

INE

,1

5A

CIR

CU

IT

TS

54

EN

AB

LE

FU

NC

TIO

N

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

RO

TA

TE

TU

RN

TA

BL

E

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

BO

OM

UP

/DO

WN

PR

IMA

RY

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

RD

RD

RD

RD

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

RD

RD

BL

/RD

-39

A

TS

53

FU

EL

SE

LE

CT

BL

/WH

-38

L2

EN

GIN

EL

ED

CH

EC

K

-+

RD

-24

A

OR

/RD

-42

A

GR

GRGR

GR/BK

RD

GR/BK

RD

GR/BK

RD

GR

/BK

TS

58

JIB

BO

OM

GR

/BK

-44

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

BK

-TS

64

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

/RD

C2

B-3

OR

/BK

C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GR

OU

ND

CO

NT

RO

LH

AR

NE

SS

(TO

SW

ITC

HP

AN

EL

)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-(U

NU

SE

D)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

-

(UN

US

ED

)

CR2POWERRELAY

CR1IGNITION

STARTRELAY

BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

WH

-21

C

WH

-23

B

WH

-IS

7

BRN-TS

GR

TS64RUN/TESTSWITCH

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-3 WH

BK

-R5

OR

/RD

-TS

54

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-TS

64

C5-8 C127TSW

C2

3T

SW

WH

C125TSW WH

WH

-IS

10

C2

B-4

OR

/RD


RD

-R2

RD

-CB

1

RD

-CB

2

C5

-1R

D

CR

23

RD

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-TS

64

C5-11 C21IGN2 WH

I.S.M.

BRN

BK-33B

WH

-TS

64

BK

-33

BB

K-I

S3

BK

-IS

3

CR23DRIVE LIGHT

OPTION RELAY

F1910A FUSE

C6-13 BK

BK-22B

RD

CR32PRIMARY

BOOMRELAY

CR33TURNTABLE

ROTATERELAY

CR37SECONDARY

BOOMRELAY

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

85

87

86

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

JIB

DO

WN

DE

SC

EN

TA

LA

RM

GR

/BK

-TS

58

BK

-AL

AR

M

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YS

WIT

CH

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L2

CH

EC

KE

NG

INE

LE

D

GR

/BK

-44

A

RD

RD

RD

RD


1

2

NC

1

2

NC


KS1 KEY SWITCH



TS53 FUEL SELECT TOGGLE SWITCH



TS58 JIB BOOM UP/DOWN TOGGLE SWITCH





LABEL DESCRIPTION




HM HOUR METER


L2 CHECK ENGINE LED


CR2 INGITION POWER RELAY

CR5 HORN RELAY

TS64 RUN/TEST TOGGLE SWITCH

-+

RD

-24

A

BK-22A

WH

-23

A

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

H1

ALALRMTILT

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOTSWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* WIRE CONNECTS TO JC3-6

FOR STEER ROCKERSWITCH OPTION.

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


NOTE: DASHED LINES INDICATE OPTION WIRING

R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

BL

K

WH

T

C1

9JS

V

JIBJIB JIB JIB

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4

RPMHIGH/LOW

TS2ENGINESTART

TS15DRIVE

ENABLE

L1

TS14

(2WD/4WD)HIGH/LOW

SPEED

DRIVE

TS1AUXILIARY

PUMP

TS13BOOM

EXTEND/ RETRACTPRIMARY

TS7

ROTATEPLATFORM

TS9

LEVELPLATFORM

P3HORN

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD

BK

TS3FUEL

SELECT

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH

NOTE:DASHED LINESINDICATE OPTIONWIRING

TS47

(OPTION)GENERATOR

RD

-TIL

T

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

C1

28

LS

OR

/RD

C2

P-4

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+

TS48

WORK LIGHTS(OPTION)

DRIVE LIGHTS/

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

RC

2P

-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC3DRIVE


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

TS8JIB

BOOM

GR/BK

GR

GR

/BK

-44

C2

P-6

CR13

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

TILTALARM

WH

C1

9JS

V

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

DL

S1

8

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4

HIGH/LOWRPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY

BOOMEXTEND/RETRACT

CR13JIB BOOM

RELAY

TS8JIB

BOOM

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY PUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD

BK

RD RD

TS3FUEL

SELECT

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH

GR

/BK

-44

C2

P-6


C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC2PRIMARY BOOM

UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

C1

28

LS

OR

/RD

C2

P-4

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

BK

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord LRG-425 EFI Models (after serial number 22049)


Electrical Schematic, Z-45/25Deutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2

3B

AT

WH

C2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

RD

RD

CB215A

CB115A

TB41

C4

6H

RN

BK

/RD

TB23

KS1PLAT

GRD

P1

RD

P3HORN

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

RD

-27

-E.H

.

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

TB21

TB25

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

3A

LR

MR

D

IGNITION/START

MODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

GE

NE

RA

TO

R

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

RD

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

12 VDC

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L43OIL

TEMP.

L42

PRESSOIL

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

OP

TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C7

P-2

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK

C28TTA RD/BKC28TTA RD/BK

C28TTA RD/BK

C41RPM OR/BK

FO

OT

SW

.H

IGH

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C5

-12

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C6

-27

C7

B-4

C5

-24

C5

-23

C2

B-7

B2

D1

M2M3

PR2

Q3

S8

U1

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29

FUSE 10A

C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-1

1

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

BK/RD

P20BAT RD

A B

C


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RD

C1

B-1

0

TB1

C3

B-1

2

C3

B-1

0

C3

B-11

BK

-4

WH

-6TB8TB15TB17

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

PL

AT

FO

RM

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

SE

CO

ND

AR

YB

OO

MU

P

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

LS2

22

21

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32


P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

BO

OMC

4P

-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

LS1

21

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4


CR30NO

CELIFT/DRIVEOPTION

4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR YE

L

11 2

12

J2

6

1

J1

RD

ORB

RN

BK

1

P26ESTP BK


OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

10

C3

7S

TC

BL

/BK

C2

9M

SR

D/W

H

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

C3

B-4

C3

B-6

C3

B-5

C1

B-11

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

K

TS62 C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4

C3

P-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WHB

RN

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEER

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

L1

TS15

C28TTA RD/BK


Electrical Schematic, Z-45/25Deutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42OILPRES.

L43OILTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4NO CR4

PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

OP

TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29

FUSE 10A (ONLY FOR WORKLIGHTS)

C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

C1B & C1P = GRAYC2B & C2P = BLACKC3B & C3P = GREENC4B & C4P = BROWN

FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

C32

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

D

C2

B-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

NOTE:

1. All switches and contacts are shown with the boomin the stowed position and the keyswitch off.

4

5 Add D40 only if unit has L4 and L48.

CE and Platform Overload Option

ANSI/CSA (Domestic machine) add L48.6

6

5


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RE

TR

AC

T

EX

TE

ND

BO

OM

J3 J1 J1

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C4

P-5

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

10

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WHB

RN

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

3




2


Electrical Schematic, Z-45/25, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42OILPRES.

L43OILTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4NO CR4

PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

OP

TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29


C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1


FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

U32PLAT.OVERLOAD

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D39

D40

1 3

H6 L45

LS18

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

D

C2

B-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

L4

NOTE:


4



5

4


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RE

TR

AC

T

EX

TE

ND

BO

OM

J3 J1 J1

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C4

P-5

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

10

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WHB

RN

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

3




2


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


(TO SWITCHPANEL)

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GROUNDCONTROL HARNESS


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

BK

/RD

-R4

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

BO

OM

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

NOTE:DASHED LINES INDICATE OPTION WIRING

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

OIL

PR

ES

SU

RE

SW

ITC

H

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

BRN

C3

B-9

BK

/RD

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

CR4

SOLENOIDRELAY

HIGH RPM

C5-18 BK/RD

BR

N

WH

BR

N

WH

CR1

START RELAYIGNITION

CR2

RELAYPOWER

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B






C40LS1 ORC6-40 C2B-2G

LO

WP

LU

GC

1B

-8B

K/W

H

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

OR

/RD

-TS

54

OR

/RD

-CR

3

BRN

CR23DRIVE LIGHTOPTIONRELAY

C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

BRN

BRN

F1910A FUSE

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

KE

YS

WIT

CH

PO

WE

R2

32

3

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A


HO

UR

ME

TE

R

KS

1K

EY

SW

ITC

H

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RD

RDRD

WH

-21

BR

N

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RDG

R-1

7G

R-1

7A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RD

RD

RDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RD

RD

RDRD RD

RDRD RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

-27

RD

-27

A

RD

RD

RD

KS

1

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2B

RE

AK

ER

CO

NT

RO

LS

,1

5A

CIR

CU

IT

CB

1B

RE

AK

ER

EN

GIN

E,1

5A

CIR

CU

IT

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

FU

NC

TIO

NS

PE

ED

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

L2

OIL

PR

ES

SU

RE

LE

D

BK

/WH

-34

A

RD

RD

RDTS

56

GL

OW

PL

UG

(OP

TIO

N)

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

-+

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

LE

D

OIL

TE

MP

L3

RD

-24

A

-+

WH-CR4

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C3

2

13

44

55

66

77

81

2

RD

H6

RD

C2

3-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

H6(CE option only)

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH




TS56 GLOW PLUG TOGGLE SWITCH (OPTION)






LABEL DESCRIPTION




HM HOUR METER


L42 OIL PRESSURE LED


CR2 IG ITION POWER RELAYN

CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 OIL TEMPERATURE LED

HIGH IDLE RELAY

L45 PLATFORM OVERLOAD

HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

U33PLATFORMOVERLOAD

MODULE

C3

2

13

45

67

81

2

RD

H6

H6

RD

C2

3-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH










LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-1011F Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


H1TILT

ALARM12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-1

1

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* NOTE:

WIRE CONNECTS TOJC3-6 FOR STEER ROCKERSWITCH OPTION.

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4

CE LIFT/DRIVE OPTION R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

START

TS15DRIVE ENABLE

L1


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY

POWER

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

C2

9M

SR

D/W

HJ1

-8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

(OPTION)

WHWH

RD


RD

-TIL

T

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC2PRIMARY BOOM UP/DOWN

& TURNTABLE ROTATELEFT/RIGHT

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18

FUSE 10A

CD

LIT

EG

RC

2P

-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

TILTALALRM

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1


C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIBBOOM

LS18(CE ONLY) OPTION

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-1

1

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

RD LS CABLE

Y

Y

BK

LS

CA

BL

EC

1P

-12

GR

/BK

-L4

GR

/BK

C4

P-1

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

-P2

RD

-H1

C1

33

PL

AG

R/B

KC

4P

-1

RE

DL

S1

8

1

CE Models: CR27 and CR30 replaces white wire between TS1 and TS71

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

RD RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

(OPTION)

C3

4S

AB

K/W

HC

1P

-8

WHWH

RD

NOTE:DASHED LINES INDICATE OPTION WIRES

C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)B

LJ1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

White wire replacedby CR27 and CR30on CE models

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-1011F Models (after serial number 22049)


Electrical Schematic, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2

3B

AT

WH

C2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

RD

RD

CB215A

CB115A

TB41

C4

6H

RN

BK

/RD

TB23

KS1PLAT

GRD

P1

RD

P3HORN

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

RD

-27

-E.H

.

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

TB21

TB25

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

3A

LR

MR

D

IGNITION/START

MODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

GE

NE

RA

TO

R

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

RD

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

12 VDC

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L43OIL

TEMP.

L42

PRESSOIL

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

OP

TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C7

P-2

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BKF

OO

TS

W.

HIG

H

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C5

-12

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C6

-27

C7

B-4

C5

-24

C5

-23

C2

B-7

B2

D1

M2M3

PR2

Q3

S8

U1

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29

FUSE 10A

C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

BK/RD

P20BAT RD

A B

C


1

2

3

4

5

6

7

8




REV A

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RD

C1

B-1

0

TB1

C3

B-1

2

C3

B-1

0

C3

B-1

1

BK

-4

WH

-6TB8TB15TB17

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

M

SE

CO

ND

AR

YD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LS

3-D

RIV

EE

NA

BL

E

PL

AT

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

DO

WN

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

JIB

BO

OM

UP

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

FL

OW

CO

NT

RO

L

SE

CO

ND

AR

YU

P

LIM

ITS

WIT

CH

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13

LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32


P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

BO

OMC

4P

-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

LS121

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4


4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR

YE

L

11 2

12

J2

6

1

J1

RD

OR

BR

N

BK

1

P26ESTP BK


OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

C3

7S

TC

BL

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C2

9M

SR

D/W

H

C3

B-4

C3

B-6

C3

B-5

C1

B-1

1

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

K

TS62 C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4

C3

P-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WH

BR

N

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEERING

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

LS2

22

21

JIB

VA

LV

ES

C1

8JD

GR

/BK

C1

7JU

GR

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

TS58

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

B-7

TS57

C2

B-6

TB44

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RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

P-7

JIB

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LV

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CR13TS7

UP

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WN

JIB

BO

OM

C2

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TS8

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DO

WN

UP

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

10

CR30NO


Electrical Schematic, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

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SR

WH

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L42OILPRES.

L43OILTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

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TS6

PR3

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PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

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TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

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+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29


C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1


FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

C32

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

D

C2

B-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

NOTE:


4




6

5


1

2

3

4

5

6

7

8




REV A

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

3




2


C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LV

E

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

JIBVALVE


RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

JIB

BO

OM

GR

/BK

-44

J3 J1 J1

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

RO

TA

TE

LE

FT

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

UP

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

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C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

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C6

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22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

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21

OR BK

-6

C6

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C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

20

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7 TS8

BRN

TS9

CR13NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

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J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

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C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

WH

BK

Electrical Schematic, Z-45/25J, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42OILPRES.

L43OILTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4NO CR4

PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

OP

TIO

N

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29


C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1


FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

U32PLAT.OVERLOAD

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D39

D40

1 3

H6 L45

LS18

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

D

C2

B-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

L4

NOTE:


4



5

4


1

2

3

4

5

6

7

8




REV A

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

3




2


C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LV

E

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

JIBVALVE


RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

JIB

BO

OM

GR

/BK

-44

J3 J1 J1

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

RO

TA

TE

LE

FT

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

UP

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

20

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7 TS8

BRN

TS9

CR13NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

WH

BK

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N/J

IBD

OW

N

PL

AT

FO

RM

LE

VE

LU

P/J

IBU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


(TO SWITCHPANEL)

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41



1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

BK

/RD

-R4

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

BO

OM

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

OIL

PR

ES

SU

RE

SW

ITC

H

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

BRN

C3

B-9

BK

/RD

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

CR4

SOLENOIDRELAY

HIGH RPM

C5-18 BK/RD

BR

N

WH

BR

N

WH

CR1

START RELAYIGNITION

CR2

RELAYPOWER

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B







LO

WP

LU

GC

1B

-8B

K/W

H

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

OR

/RD

-TS

54

OR

/RD

-CR

3

BRN


C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

BRN

BRN

F1910A FUSE

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

KE

YS

WIT

CH

PO

WE

R2

32

3

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

KS

1K

EY

SW

ITC

H

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RD

RDRD

WH

-21

BR

N

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RD

RD

RDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RD

RD

RDRD RD

RDRD RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

-27

RD

-27

A

RD

RD

RD

KS

1

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2B

RE

AK

ER

CO

NT

RO

LS

,1

5A

CIR

CU

IT

CB

1B

RE

AK

ER

EN

GIN

E,

15

AC

IRC

UIT

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

FU

NC

TIO

NS

PE

ED

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

L2

OIL

PR

ES

SU

RE

LE

D

BK

/WH

-34

A

RD

RD

RD


TS

56

GL

OW

PL

UG

(OP

TIO

N)

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

-+

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

LE

D

OIL

TE

MP

L3

RD

-24

A

-+

WH-CR4

GR

GR

GR/BK

RD

GR/BK

RD

GR

/BK

TS

58

JIB

UP

/DO

WN

TS

58

GR

/BK

-44

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C2

3

13

44

55

66

77

81

2

RD

H6

H6(CE option only)

RD

C2

3-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH











LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-1011F Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

U32PLATFORMOVERLOAD

MODULE

C2

3

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH











LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-1011F Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

BL

K

WH

T

C1

9JS

V

JIBJIB JIB JIB

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P

PLATFORMCONTROL HARNESS(TO SWITCH PANEL)

H1TILT

ALARM12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* NOTE:


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

START

TS15DRIVE ENABLE

L1


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY

POWER

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

C2

9M

SR

D/W

HJ1

-8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

(OPTION)

WHWH

RD


RD

-TIL

T

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN



P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18

FUSE 10A

CD

LIT

EG

RC

2P

-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

TS8JIB

BOOM

GR/BK

GR

GR

/BK

-44

C2

P-6

CR13

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





TILTALARM

WH

C1

9JS

V

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1


C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIBBOOM

LS18CE ONLY

OPTION

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-1

1

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


R2

4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

RD LS CABLE

Y

Y

BK

LS

CA

BL

EC

1P

-12

GR

/BK

-L4

GR

/BK

C4

P-1

RD

-P2

RD

-H1

C1

33

PL

AG

R/B

KC

4P

-1

RE

DL

S1

8

1

CE Models: CR27 and CR30 replaces white wire between TS1 and TS71

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

(OPTION)

C3

4S

AB

K/W

HC

1P

-8

WHWH

White wire replacedby CR27 and CR30on CE models

GR

/BK

-44

C2

P-6

RD


C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-1011F Models (after serial number 22049)


Electrical Schematic, Z-45/25Perkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2

3B

AT

WH

C2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

RD

RD

CB215A

CB115A

TB41

C4

6H

RN

BK

/RD

TB23

KS1PLAT

GRD

P1

RD

P3HORN

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

RD

-27

-E.H

.

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

TB21

TB25

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

3A

LR

MR

D

IGNITION/START

MODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

GE

NE

RA

TO

R

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

RD

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

12 VDC

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L43OIL

TEMP.

L42

PRESSOIL

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C7

P-2

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BKF

OO

TS

W.H

IGH

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C5

-12

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C6

-27

C7

B-4

C5

-24

C5

-23

C2

B-7

B2

D1

M2M3

PR2

Q3

S8

U1

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29

FUSE 10A

C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

BK/RD

P20BAT RD

A B

C

W

C3 3MF+

GL

OW

PL

UG

S


1

2

3

4

5

6

7

8




REV A

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RD

C1

B-1

0

TB1

C3

B-1

2

C3

B-1

0

C3

B-1

1

BK

-4

WH

-6TB8TB15TB17

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

PL

AT

FO

RM

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

SE

CO

ND

AR

YB

OO

MU

P

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13

LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32


P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

PR

IMA

RY

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

PR

IMA

RY

BO

OM

C4

P-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

LS121

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4


4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR

YE

L

11 2

12

J2

6

1

J1

RD

OR

BR

N

BK

1

P26ESTP BK


OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

C3

7S

TC

BL

/BK

C2

9M

SR

D/W

H

C3

B-4

C3

B-6

C3

B-5

C1

B-1

1

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

K

TS62 C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4

C3

P-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WH

BR

N

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEERING

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

LS2

22

21

TS57

RIG

HT

RIG

HT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

RO

TA

TE

LE

FT

LE

FT

TS7

L1

TS15

C28TTA RD/BK

DO

WN

UP

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

10

CR30NO


WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

Electrical Schematic, Z-45/25Perkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

CO

OL

AN

TT

EM

PE

RA

TU

RE

LE

D

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42OILPRES.

L43WATERTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4NO CR4

PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

S

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C3 3MF+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29


C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1


FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

C32

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

DC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

NOTE:


4




6

5


1

2

3

4

5

6

7

8




REV A

TS7

TS57

WH

C1

7P

RL

GR

C1

8P

RR

GR

/BK

LE

FT

RIG

HT

PL

AT

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RE

TR

AC

T

EX

TE

ND

BO

OM

J3 J1 J1

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FR

OM

LE

VE

L

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C4

P-5

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

20

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WHB

RN

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

3




2


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

CO

OL

AN

TT

EM

PE

RA

TU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


(TO SWITCHPANEL)

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41



1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

BK

/RD

-R4

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

BO

OM

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

OIL

PR

ES

SU

RE

SW

ITC

H

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

BRN

C3

B-9

BK

/RD

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

CR4

SOLENOIDRELAY

HIGH RPM

C5-18 BK/RD

BR

N

WH

BR

N

WH

CR1

START RELAYIGNITION

CR2

RELAYPOWER

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B







LO

WP

LU

GC

1B

-8B

K/W

H

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

OR

/RD

-TS

54

OR

/RD

-CR

3

BRN


C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

BRN

BRN

F1910A FUSE

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

KE

YS

WIT

CH

PO

WE

R2

32

3

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

KS

1K

EY

SW

ITC

H

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RD

RDRD

WH

-21

BR

N

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RD

RD

RDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RD

RD

RDRD RD

RDRD RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

-27

RD

-27

A

RD

RD

RD

KS

1

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2B

RE

AK

ER

CO

NT

RO

LS

,1

5A

CIR

CU

IT

CB

1B

RE

AK

ER

EN

GIN

E,1

5A

CIR

CU

IT

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

FU

NC

TIO

NS

PE

ED

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

L2

OIL

PR

ES

SU

RE

LE

D

BK

/WH

-34

A

RD

RD

RD


TS

56

GL

OW

PL

UG

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

-+

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

L3

CO

OL

AN

TT

EM

PL

ED

RD

-24

A

-+

WH-CR4

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C3

2

13

44

55

66

77

81

2

RD

H6

RD

C2

3-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

H6(CE option only)

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH




TS56 GLOW PLUG TOGGLE SWITCH






LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 COOLANT TEMPERATURE LED

HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3C

OO

LA

NT

TE

MP

LE

DR

4F

UN

CT

ION

SP

EE

DC

ON

TR

OL

VA

RIA

BL

ER

ES

IST

ER

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

ON

LY

)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


H1TILT

ALARM12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* NOTE:


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

START

TS15DRIVE ENABLE

L1


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY

POWER

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

C2

9M

SR

D/W

HJ1

-8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

WHWH

RD


RD

-TIL

T

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN



P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18

FUSE 10A

CD

LIT

EG

RC

2P

-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

TILTALALRM

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1


C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIBBOOM

OPTION

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2


U13ALC-500

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BR

N

Y

GR

/BK

-L4

GR

/BK

C4

P-1

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM


RD

-P2

RD

-H1

C1

33

PL

AG

R/B

KC

4P

-1

RE

DL

S1

8

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

RD RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

C3

4S

AB

K/W

HC

1P

-8

WHWH

RD


C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

BK

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 104-22 Models (after serial number 22049)


Electrical Schematic, Z-45/25JPerkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2

3B

AT

WH

C2

3T

TS

RW

H

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

RD

RD

CB215A

CB115A

TB41

C4

6H

RN

BK

/RD

TB23

KS1PLAT

GRD

P1

RD

P3HORN

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

RD

-27

-E.H

.

C2

8T

TA

RD

/BK

CR1

R3

3S

TR

BK

TB21

TB25

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

3A

LR

MR

D

IGNITION/START

MODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

GE

NE

RA

TO

R

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

RD

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

12 VDC

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L43OIL

TEMP.

L42

PRESSOIL

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C7

P-2

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BKF

OO

TS

W.

HIG

H

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C5

-12

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C6

-27

C7

B-4

C5

-24

C5

-23

C2

B-7

B2

D1

M2M3

PR2

Q3

S8

U1

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29

FUSE 10A

C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

BK/RD

P20BAT RD

A B

C

W

C3 3MF+

GL

OW

PL

UG

S


1

2

3

4

5

6

7

8




REV A

P24FS WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

RDC

1B

-10

TB1

C3

B-1

2

C3

B-1

0

C3

B-1

1

BK

-4

WH

-6TB8TB15TB17

BO

OM

RE

TR

AC

T

C6

TR

FW

H/R

D

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

PL

AT

FO

RM

LE

VE

LD

OW

N

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

DO

WN

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

JIB

BO

OM

UP

/P

LA

TF

OR

MR

OTA

TE

RIG

HT

C7

PB

EB

K

C8

PB

RB

K/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

7JU

GR

C1

8JD

GR

/BK

C5

-25

C2

2-1

C6

-19

H3

C2

2-2

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

0-1

C2

0-2

C2

1-1

C2

3-1

C2

3-2

C2

1-2

C1

7-1

C1

6-1

C1

7-2

C1

6-2

C4

4D

AB

K

C6

-18

C6

-17

C6

-15

C6

-14

C6

-8

C6

-7

TB14

TB18 TB7

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C11

SB

DB

L/B

K

C1

0-1

WH

-6

C1

2S

BF

BL

/WH

SE

CO

ND

AR

YB

OO

MU

P

C11

-3 C6

-20

BK

-5

RD

C3

0-1C

6-1

3 C3

0-2

C1

9-2

C1

9-1

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

C1

8-2

C1

8-1

C1

2-1

C2

9-1

C1

3-1

C2

9-2

C1

3-2

C1

2-2

Y22

TB10

C6

-10

BK C1

0-2

BK

-7

C1

0-4

WH

-5

14

13

LS3

BK

-6

C6

-12

C6

-11

WH

-4

LS4

22

21

C11

-2

WH

-7

TB12

C6

-16

TB11

C6

-3

C6

-1

C6

-2

TB3

TB2

TB6

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

C3

1R

EV

WH

/BK

C3

0F

WD

WH

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

8-1

C2

8-2

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C1

4-1

C3

1-1

C1

5-1

C1

4-2

C3

1-2

C1

5-2

C2

5-1

C2

4-1

C2

5-2

C2

4-2

BR

N

BR

N

GR

OU

ND

RD

C2

6-1

C2

6-2

BK

H4 BK

RD

U4

C6

-5

C6

-4

C6

-6

C6

-37

C6

-36

C6

-29

TB5

TB4

C6

-32

C5

-20

C6

-33

C5

-21

TB32


P2

4F

SW

H

CR27

P2

4F

SW

H

P2

6E

ST

PB

K

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

DO

WN

UP

UP

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

C4

B-6

C4

B-5

C4

B-2

C4

B-3

C3

B-8

TS59

C1

4P

LU

OR

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

TS63

RE

TR

AC

T

EX

TE

ND

BO

OMC

4P

-6

C4

P-5

C3

P-8

TS9 TS13

C11

-1

C6

-40

C11

-4

DO

WN

UP

BO

OM

SE

CO

ND

AR

Y

LS121

C1

0-3

C3

B-7

22

OR BK

-6

C4

B-4

C2

B-2

C7

PB

EB

K

C2

2L

SR

D

BK

C1

6P

DR

EO

R/R

D

TS60 C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

B-3

C3

B-2

C3

B-1

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

TS61

C2

P-2

C40LSS OR

C3

P-7

C4

P-4


4

NC

23 4

3

J3

1B

RN

13

12

14

C3

P-1

2

C3

P-1

0

C3

P-11

C3

P-2

C3

P-3

C3

P-1

3

10 9

J1

8 7

BR

N

OR

YE

L

11 2

12

J2

6

1

J1

RD

OR

BR

N

BK

1

P26ESTP BK


OU

T

PW

R

GN

D

42 3 5 6 7

JC1

GN

D21

YO

UT

PW

R

XO

UT

43 65

JC2

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

CD

E1

BL

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

C3

7S

TC

BL

/BK

C2

9M

SR

D/W

H

C3

B-4

C3

B-6

C3

B-5

C1

B-1

1

C1

B-3

C6

TR

FW

H/R

D

C4

TR

LW

H

C5

TR

RW

H/B

KTS62 C

36

ST

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

0F

WD

WH

BA

TG

ND

20

17

11

18

10

R4C

3P

-6

C3

P-4

C3

P-5

C1

P-1

0

C1

P-11

C1

P-3

9

45

13

14

J1

6

WH

BR

N

OR

BL

BL

16

15

19

C4

1R

PM

OR

/BK

C1

P-6

C1

P-5

C2

P-3

C1

P-4

C7

P-3

8

167

J1

15

5

7

DRIVE & STEERING

YO

UT

PW

R

GN

D

31 2 54

RK

OU

T6 7

JC3

P24FS WH

P26ESTP BK

TS14

LS2

22

21

JIB

VA

LV

ES

C1

8JD

GR

/BK

C1

7JU

GR

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

TS58

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

B-7

TS57

C2

B-6

TB44

C19JSV GR/WH

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

C4

P-7

JIB

VA

LV

ES

CR13TS7

UP

DO

WNJIB

BO

OM

C2

P-6

GR

/BK

-44

TS8

BRN

WH

NCCR13

L1

TS15

C28TTA RD/BK

DO

WN

UP

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

10

CR30NO


Electrical Schematic, Z-45/25JPerkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

C1

33

PL

AC

23

TT

SR

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

-

RD

P2

0B

AT

RD

TB20

C2

1IG

NW

H

C4

1R

PM

OR

/BK

CR5NO

C4

6H

RN

BK

/RD

CB115A

RD

RD

CB215A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GRD

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BKP2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

PR1

C2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

R3

3S

TR

BK

TB21

TB25

NO

CR2

8765

109

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1RD

TS52

BK

1

2

TB33

3

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

CO

OL

AN

TT

EM

PE

RA

TU

RE

LE

D

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42OILPRES.

L43WATERTEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

CR4NO CR4

PR3NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

GL

OW

PL

UG

S

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2HM

+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C4

P-1

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

GE

NE

RA

TO

R

C1

P-9

C3

5H

SB

K/R

D

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

ENGINESPEED

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

C1

B-9

C5

-18

ON

GL

OW

PL

UG

C1

B-8

ON

GL

OW

PL

UG

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

C5

-12

AU

XIL

IAR

YP

UM

P

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11

C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-24

C2

B-7

B112V DC

D1

C3 3MF+

M2

M3

PR2PR2NO

Q3

S8

U1IGNITION/

STARTMODULE

U32

C3

5H

SB

K/R

D

BK

/RD

C6

-34

C2

B-3

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30 L30

L29L29


C2

P-5

C2

B-5

C4

3D

LIT

EG

R

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

CR23NO

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

SO

PT

ION

C6

-38

C6

-39

TS48

RD

RD

C7

B-1


FUSE10A

BK/RD

P20BAT RD

A B

C

FO

OT

SW

ITC

HH

IGH

ON

SU

PR

ES

SIO

ND

IOD

E

C32

4

6

12 8

7

5

AU

XIL

AR

YP

UM

PC

1B

-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C1

P-1

2

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RB

L/R

DC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

C23 ALARM RD

NOTE:


4




6

5


1

2

3

4

5

6

7

8




REV A

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

AN

DJIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

AN

DJIB

BO

OM

UP

3




2


C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LV

E

H3

C2

2-2

C5

-25

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C4

4D

AB

K

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5

C6

-13

LS

4-S

EC

ON

DA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

DD

RIV

EL

IMIT

SW

ITC

H

LS

2-P

RIM

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

3-D

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6RD

C11

-3B

K-7

C1

0-2

14

C11

SB

DB

L/B

K

C1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

C4

TR

LW

H

C5

TR

RW

H/B

K

C2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

C1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1 H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

JIBVALVE


RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

JIB

BO

OM

GR

/BK

-44

J3 J1 J1

JD

AL

AR

MG

R/B

K

C1

9JS

VG

R/W

H

UP

DO

WN

JIB

BO

OM

RIG

HT

PL

AT

RO

TA

TE

LE

FT

C1

5P

LD

OR

/BK

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

UP

PL

AT

FR

OM

LE

VE

L

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

C2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

DO

WN

UP

PR

IMA

RY

BO

OM

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40

C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

20

R4

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7 TS8

BRN

TS9

CR13NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N

OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

211 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1C

37

ST

CB

L/B

K

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

TC

CB

L

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14 5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

3

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3TS15

15

TS14

WH

BK

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LD

OW

N/J

IBD

OW

N

PL

AT

FO

RM

LE

VE

LU

P/J

IBU

P

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

EN

GIN

ES

TA

RT

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

C6

-1R

D

C3

B-1

RD

C6

-2R

D/B

K

C3

B-2

RD

/BK

C3

B-3

RD

/WH

C6

-4W

H

C3

B-4

WH

C6

-5W

H/B

K

C3

B-5

WH

/BK

C6

-6W

H/R

D

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

C6

-10

BL

C3

B-1

0B

L

C6

-11

BL

/BK

C3

B-1

1B

L/B

K

C6

-12

BL

/WH

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

-TS

62

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

C3

B-6

WH

/RD

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


(TO SWITCHPANEL)

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41



1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

C6

-3R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

BK

/RD

-R4

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

C6

-34

RD

FB

BK

BK

WH/RD-ALARM

JIB

BO

OM

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

WH

/RD

-L3

-C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

OIL

PR

ES

SU

RE

SW

ITC

H

CR5HORNRELAY

BR

N

WH-21C

RD

-24

B

C6-13 BK

C6

-9B

K/R

D

BRN

BRNBRN

BR

N

BRN

C3

B-9

BK

/RD

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C5

-23

WH

BK-22B

C7B-3

CR4

SOLENOIDRELAY

HIGH RPM

C5-18 BK/RD

BR

N

WH

BR

N

WH

CR1

START RELAYIGNITION

CR2

RELAYPOWER

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE GR

C4B C4BC4B







LO

WP

LU

GC

1B

-8B

K/W

H

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

RD

BR

N

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

OR

/RD

-TS

54

OR

/RD

-CR

3

BRN


C6

-38

R4

3D

LIT

E1

RD

C6

-39

R4

3D

LIT

E2

RD

BRN

BR

NR

D

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

BRN

BRN

F1910A FUSE

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

KE

YS

WIT

CH

PO

WE

R2

32

3

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

HO

UR

ME

TE

R

KS

1K

EY

SW

ITC

H

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RD

RDRD

WH

-21

BR

N

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RD

RD

RD

RDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RD

RD

RDRD RD

RDRD RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23

WH

-23

A

RD

BK

-22

RD

RD

-27

RD

-27

A

RD

RD

RD

KS

1

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2B

RE

AK

ER

CO

NT

RO

LS

,1

5A

CIR

CU

IT

CB

1B

RE

AK

ER

EN

GIN

E,1

5A

CIR

CU

IT

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

EN

GIN

ES

TA

RT

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R

FU

NC

TIO

NS

PE

ED

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

STA

CK

ED

CO

NTA

CT

S

L2

OIL

PR

ES

SU

RE

LE

D

BK

/WH

-34

A

RD

RD

RD


TS

56

GL

OW

PL

UG

3 4NO

3 4NO

3

4NO

3 4NO

1

2

NC

1

2

NC

-+

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

L3

CO

OL

AN

TT

EM

PL

ED

RD

-24

A

-+

WH-CR4

GR

GR

GR/BK

RD

GR/BK

RD

GR

/BK

TS

58

JIB

UP

/DO

WN

TS

58

GR

/BK

-44

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011

15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C7

B-1

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11

15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


(TO SWITCH PANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY

)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

M

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TOPLATFORM

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L3

-

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

-

BK

/RD

-R4

CR2

CR1B

RN

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

HIG

HR

PM

SO

LE

NO

IDR

EL

AY

C5-18 BK/RD

WH

IGN

ITIO

NS

TA

RT

RE

LA

YP

OW

ER

RE

LA

Y

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C43DLITE

C4B C4BC4B







GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L2

-

C5-11 WH

BK

-R5

CR4

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C2

B-5

GR

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD


RD

-R2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-R2

WH

-IS

7

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

BK

-33

BB

K-I

S3

BK

-IS

3

CR23

F1910A FUSE

C6-13 BK

BK-22B

RD

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

CR

37

BRN

BRN

BR

N

RD

/WH

3D

RD

1C

C6

-2R

D/B

K

C6

-1R

D

30

85

87

86

87A


C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

6D

WH

/BK

5C

BL

/WH

12

C

BL

10

C

30

30

30

30

30

30

85

85

85

85

85

85

87

8787

87

87

87

86

86

86

86

86

86

87A

87A

87A

87A

87A

87A

30

85

87

86

87A

30

85

87

86

87A

BLBRN

BR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-2

3W

H

C2

-5R

D

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C3

2

13

44

55

66

77

81

2

RD

H6

H6(CE option only)

RD

C2

3-1

RD

13

4B

GR

/BK

C2

3-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

CR32

RELAY

PRIMARYBOOM

CR33

RELAY

TURNTABLEROTATE

CR37SECONDARY

RELAYBOOM

C6

-9B

K/R

D

BR

NC

3

+

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A


KS1 KEY SWITCH


TS52 ENGINE START TOGGLE SWITCHTS54 FUNCTION ENABLE TOGGLE SWITCH

TS56 GLOW PLUG TOGGLE SWITCH







LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 COOLANT TEMPERATURE LED

HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

RDRDRDRDRD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3C

OO

LA

NT

TE

MP

LE

DR

4F

UN

CT

ION

SP

EE

DC

ON

TR

OL

VA

RIA

BL

ER

ES

IST

ER

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C2

3-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

ON

LY

)

-+

KS

1

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

BL

K

WH

T

C1

9JS

V

JIBJIB JIB JIB

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

RE

D/B

LK

-28

RE

D-T

ILTR

ED

-TILT

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P

PLATFORMCONTROL HARNESS(TO SWITCH PANEL)

H1TILT

ALARM12V DC BATTERY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB OPT.

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-1

1

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

C1

P-2

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

* NOTE:


U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

WH/RD C1P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


4F

SW

HC

9P

-2

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

RC

2P

-5

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

START

TS15DRIVE ENABLE

L1


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY

POWER

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

P2

3B

AT

WH

C7

P-2

P2

6B

AT

BK

C9

P-1

P2

6B

AT

BK

-LO

AD

P2

2B

AT

BK

C7

P-1

RD

RD

WH

RD

WH-24

RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

C2

9M

SR

D/W

HJ1

-8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

WHWH

RD


RD

-TILT

C3

5H

SB

K/R

DC

1P

-9

12 NC

1

2

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN



P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18

FUSE 10AC

DL

ITE

GR

C2

P-5

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

TS8JIB

BOOM

GR/BK

GR

GR

/BK

-44

C2

P-6

CR13

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (before serial number 22050)


Platform Control Box Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)


Platform Control Box Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM


TILTALARM

WH

C1

9JS

V

RE

D/B

LK

-28

RE

D-T

ILT

RE

D-T

ILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1


C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIBBOOM

OPTION

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-1

1

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

4S

AB

K/W

HC

1P

-8

C4P

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2


U13ALC-500

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BR

N

Y

GR

/BK

-L4

GR

/BK

C4

P-1

RD

-P2

RD

-H1

C1

33

PL

AG

R/B

KC

4P

-1

RE

DL

S1

8

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)

1

2

3

4

5

6

7

8




REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

C3

4S

AB

K/W

HC

1P

-8

WHWH

GR

/BK

-44

C2

P-6

RD


C3

5H

SB

K/R

DC

1P

-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5(R

OC

KE

RS

WIT

CH

OP

TIO

NO

NLY

)

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 104-22 Models (after serial number 22049)


1

2

3

4

5

6

7

8


Hydraulic Schematic, 2WD Models(before serial number 22050)



REV A

E

M

CHARGEFILTER

DRIVE PUMP

FUNCTIONPUMP7 gpm26.5 L/min

TANK AUXILIARYPOWER UNIT

SLAVECYLINDER

SECONDARYBOOM

PRIMARYBOOM

PRIMARY BOOMEXTENSION

TURNTABLE ROTATE

MASTERCYLINDER

FUNCTION MANIFOLD

REARLEFT

REARRIGHT

GENERATORSELECT

OPTIONALMOTOR/GEN.

DRIVE MANIFOLD

X

X

X

STEER CYLINDERS

LA

LB

RB

0.070 in1.778 mm

50%

50%

0.030 in0.76 mm

250 psi17.2 bar

TEST

PB

RA PA

315 psi21.7 bar

50 psi3.4 bar

3500 psi241 bar

3:13500 psi241 bar

V2

0.030 in0.76 mm

TEST

1.5 gpm5.7 L/min

PR1 PR2 PL1 PL2

3200 psi221 bar

0.6 gpm2.3 L/min

0.1 gpm0.38 L/min

SW1 SW2 S1 S2 P1

1800 psi124 bar

2 gpm7.6 L/min

P2 EXTEN. RET.

TEST 2

2SPD

BRK

AUX

1.5:13800 psi262 bar

3:13300 psi227.5 bar

3200 psi220.6 bar

25 psi1.72 bar

V1

4.25:13626 psi250 bar

1:1ATMOS.3500 psi241 bar

3:11000 psi69 bar

3:13800 psi262 bar

OSCILLATEDIRECTIONAL VALVE

5:1ATMOS1000 psi69 bar

T2

T

OPTIONAL

OPTIONALOSCILLATECYLINDERS

0.039 in1 mm

V2

J1J2

V1

R1R2

JIB BOOMMANIFOLD

JIB BOOM0.6 gpm / 2.27 L/min

PLATFORM ROTATE0.25 gpm / 0.95 L/min

ST1 ST2

T


0.025 in0.64 mm

5:13500 psi241 bar

HIGHPRESSUREFILTER

100 psi6.9 bar

PRESS.

T1

A

Y

Z

M

N

O

P Q

R

S

G

B

I

X

J

K

L W

V

D

C

E

F

T

AA

BB

FF

JJ

OO

PP

XX

QQ

UU

VV

WW

RR

SS

TT

EE

LL

MM NN

GG

HH

II

DD

CC

KK

U

H

AU AV

1

2

3

4

5

6

7

8


Hydraulic Schematic, 2WD Models(after serial number 22049)



REV B

X

LA

LB

RB

50%

50%

PB

RA PA

2SPD

BRK

T2

TT1

REARRIGHT

REARLEFT

DRIVE MANIFOLD

0.030 inch0.76 mm

0.070 inch1.78 mm

250 psi17.2 bar

E

M

CHARGEFILTER

DRIVE PUMP

FUNCTION PUMP7 gpm / 26.5 L/min


FUNCTION MANIFOLD

GENERATOR SELECT

OPTIONALMOTOR/GEN

STEER CYLINDERS


MASTER CYLINDER


SLAVE CYLINDER

SECONDARY BOOMCYLINDERS

TURNTABLE ROTATE


PRIMARY BOOM

3:13800 psi262 bar

4.5:1ATMOS.3500 psi241 bar

4.25:13625 psi250 bar

V2

0.030 inch0.76 mm

V1

315 psi21.7 bar

50 psi3.4 bar

100 psi6.9 bar

3500 psi241 bar

1.5:13800 psi262 bar

3:13300 psi228 bar

EXTEN RETRACT

5:1ATMOS

1000 psi / 69 bar

ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2 S1 S2 P1 P2

AUX

T

TP2

25 psi1.7 bar

3200 psi220.6 bar

OSCILLATECYLINDERS(OPTION)

3:13500 psi241 bar

TP1

0.025 inch0.64 mm

3:11000 psi69 bar


HIGHPRESSURE

FILTER

PRESS

T1/GEN

1.5 gpm5.7 L/min

0.4 gpm1.5 L/min

3200 psi220.6 bar (set at 7 gpm /26.5 L/min at TP1)

2500 psi / 172 bar(set at 0.6 gpm /

2.27 L/min at TP2)

0.037 inch0.9 mm

2100 psi144.8 bar(set at 2.5 gpm /9.5 L/min at TP2)

J1 J2 PR1PR2

V2 V1

OPTIONAL OSCILLATEDIRECTIONAL VALVE

JIB BOOM MANIFOLD(after serial number 22565)

V2

J1J2

V1

R1R2

JIB BOOM MANIFOLD(before serial number 22566)

AU AV

A

MN

F

O

P

JK

D

R

Q

E

Z

G

S

C

AA

AC

AB

LL

MMNN

AD

OO

WW

XX

QQ

UU

RR

SS

TT

PP

H

Y

W X

U

V

T

L

I

B

Orifice removedafter serial number 22449

1

2

3

4

5

6

7

8





REV A

E

M

CHARGEFILTER

DRIVE PUMP


TANK

FUNCTION MANIFOLD

REARLEFT

REARRIGHT

FRONTLEFT

FRONTRIGHT

GENERATOR SELECT

OPTIONALMOTOR/GEN.

DRIVE MANIFOLD

X

X


STEER CYLINDERS

RB

X


JIB BOOMMANIFOLD

MASTERCYLINDER


SLAVECYLINDER

SECONDARYBOOM

TURNTABLE ROTATE


PRIMARY BOOM


3:13800 psi262 bar


4.25:13626 psi250 bar

V2

0.030 in0.762 mm

V1

315 psi21.7 bar

50 psi3.4 bar

B

A

RFB

RFA

LFB

LFA

TEST

T2

T

TANK

67% 33%

0.052 in1.32 mm

250 psi17.2 bar

0.030 in0.76 mm

50%

50%

RA

LB

LA

BRK

2SPD

50%

50%

3500 psi241 bar

1.5:13800 psi262 bar

J2 J1 R2 R1

V2 V1

3:13300 psi227.5 bar

2 gpm7.6 L/min

EXTEN. RETRACT

5:1ATMOS1000 psi69 bar


TEST

AUX

T

3200 psi221 bar

0.6 gpm2.3 L/min

0.1 gpm0.38 L/min

TEST 2

1.5 gpm5.7 L/min

25 psi1.72 bar

3200 psi220.6 bar

2 gpm7.6 L/min

1 gpm3.8 L/min

0.039 in1 mm

OPTIONALOSCILLATECYLINDERS

3:13500 psi241 bar

T1

1800 psi124 bar

0.025 in0.64 mm

3:11000 psi69 bar

5:13500 psi241 bar

100 psi6.9 bar

HIGHPRESSUREFILTER

PRESS.

0.025 in0.64 mm

AUXILIARYPOWER UNIT

A

Y

Z

M

N

O

P Q

R

S

G

B

I

X

J

K

L WVD

C

E

F

T

AA

BB

FF

AU AV

JJ

AB

AS

AT

AG

AE

AN

AF

AH

AI

AL

AM

AK

AJ

AC AD

AO

AQ

AR

AP

EE

LL

MM NN

GG

HH

II

DD

CC

KK

U

H

1

2

3

4

5

6

7

8





REV B

E

M

CHARGEFILTER

DRIVE PUMP



FUNCTION MANIFOLD

GENERATOR SELECT

OPTIONALMOTOR/GEN

STEER CYLINDERS


MASTER CYLINDER


SLAVE CYLINDER

SECONDARY BOOMCYLINDERS

TURNTABLE ROTATE


PRIMARY BOOM

3:13800 psi262 bar

4.5:1ATMOS.3500 psi241 bar

4.25:13625 psi250 bar

V2

0.030 inch0.76 mm

BA

V1

315 psi21.7 bar

50 psi3.4 bar

100 psi6.9 bar

3500 psi241 bar

1.5:13800 psi262 bar

3:13300 psi228 bar

Orifice removedafter serial number 22449

EXTEN RETRACT

5:1ATMOS

1000 psi / 69 bar


AUX

T

TP2

25 psi1.7 bar

3200 psi220.6 bar

OSCILLATECYLINDERS(OPTION)

3:13500 psi241 bar

TP1

0.025 inch0.64 mm

3:11000 psi69 bar


HIGHPRESSURE

FILTER

PRESS

T1/GEN

1.5 gpm5.7 L/min

0.4 gpm1.5 L/min

3200 psi220.6 bar (set at 7 gpm /26.5 L/min at TP1)

2500 psi / 172 bar(set at 0.6 gpm /

2.27 L/min at TP2)

0.037 inch0.9 mm

2100 psi144.8 bar(set at 2.5 gpm /9.5 L/min at TP2)

0.025 inch0.64 mm

1 gpm3.8 L/min

2 gpm7.6 L/min

50%

50%

2SPD

BRK

LA

LB

RA

50%

50%

0.030 inch0.76 mm

250 psi17.2 bar

0.052 inch1.3 mm

33%67%

TANK

T

T2

TEST

LFA

LFB

RFA

RFB

A

BRB

X

DRIVE MANIFOLD

FRONTRIGHT

FRONTLEFT

REARRIGHT

REARLEFT

J1 J2 PR2 PR1

V2 V1

R


JIB BOOM MANIFOLD(after serial number 22565)

V2

J1J2

V1

R1R2

JIB BOOM MANIFOLD(before serial number 22566)

AU AV

AQ

AO

AT

AB

AC

AE

AN

AS

AP

AL

AM

AIAK

AJ

AH

AD

AR

AG

A

MN

F

O

P

JK

D

R

Q

E

Z

G

S

C

AA

AC

AB

AD

H

Y

W X

U

V

T

L

I

B

LL

MMNN

Dis

trib

ute

d B

y:

California Proposition 65

WARNINGWARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

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Fax +86 21 53852569

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Fax +65 67 533 544

Genie JapanPhone +81 3 3453 6082

Fax +81 3 3453 6083

Genie KoreaPhone +82 25 587 267

Fax +82 25 583 910

Genie BrasilPhone +55 11 41 665 755

Fax +55 11 41 665 754

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 575100

Fax +46 31 579020

Genie FrancePhone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Genie IbericaPhone +34 93 579 5042

Fax +34 93 579 5059

Genie GermanyPhone +49 (0)4202 88520

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Fax +52 55 5666 3241

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