Service Genie Z45-25

Service ManualFirst Edition Second Printing Part No. 52709 Introduction First Edition • Second Printing Important Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 & Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure. This service manual covers the Genie Z-45/25 & Genie Z-45/25J 2WD and 4WD models introduced in 1998. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at a Genie dealer service center. Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and other manuals. Please write to the technical publications team in care of Genie Industries, PO Box 97030, Redmond WA 98073-9730 U.S.A. If you have any questions, please call Genie Industries. Contact us: http://www.genielift.com e-mail: [email protected] ® Copyright © 1998 by Genie Industries First Edition: Second Printing, September 2000 "Genie" and "Z" are Registered Trademarks of Genie Industries in the USA and many other countries. These machines comply with ANSI/SIA 92.5-1992. Printed on recycled paper Printed in U.S.A. ii Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie Z-45/25 & Genie Z-45/25J Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J iii Section 1 • Safety Rules First Edition • Second Printing SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Green—used to indicate operation or maintenance information. Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure that your workshop or work area is properly ventilated and well lit. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe . iv Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Table of Contents Introduction Important Information ...................................................................................................... ii Section One Safety Rules General Safety Rules ..................................................................................................... iii Section Two Specifications Machine Specifications ............................................................................................. 2 - 1 Performance Specifications ...................................................................................... 2 - 2 Hydraulic Specifications ............................................................................................ 2 - 4 Ford LRG-425 EFI Engine Specifications ................................................................. 2 - 5 Deutz F3L 1011F Engine Specifications ................................................................... 2 - 7 Perkins 104-22 Engine Specifications ....................................................................... 2 - 8 Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 9 Section Three Theory of Operation Power Source ........................................................................................................... 3 - 1 Hydraulic System ...................................................................................................... 3 - 1 Electrical System ...................................................................................................... 3 - 1 Limit Switches ........................................................................................................... 3 - 2 Machine Controls ...................................................................................................... 3 - 2 Part No. 52709 Genie Z-45/25 & Genie Z-45/25J v First Edition • Second Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures Introduction ............................................................................................................... 4 - 1 Maintenance Inspection Report ................................................................................ 4 - 3 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 Inspect the Operator's and Safety Manuals .................................................... 4 - 5 Inspect the Decals and Placards ..................................................................... 4 - 5 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6 Check the Engine Oil Level ............................................................................. 4 - 7 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8 Check for Fuel Leaks ...................................................................................... 4 - 8 Check the Hydraulic Oil Level ......................................................................... 4 - 9 Check for Hydraulic Leaks ............................................................................ 4 - 10 Check the Tire Pressure ............................................................................... 4 - 10 A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11 A-11 Test the Platform and Ground Controls ......................................................... 4 - 11 A-12 Test the Auxiliary Power Operation ............................................................... 4 - 12 A-13 Test the Tilt Sensor ....................................................................................... 4 - 13 A-14 Test the Limit Switches ................................................................................. 4 - 14 A-15 Check the Engine Belt - Perkins Diesel Models ............................................ 4 - 18 A-16 Inspect the Engine Air Filter Element ............................................................ 4 - 19 A-17 Replace the Fuel Filters - Ford Models ......................................................... 4 - 20 A-18 Inspect the Radiator - Perkins Models .......................................................... 4 - 21 A-19 Perform 30 Day Service ................................................................................ 4 - 22 A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models ............ 4 - 23 A-21 Inspect the Fuel Filter/Water Separator - Diesel Models ............................... 4 - 24 A-22 Check and Adjust the Engine RPM - Perkins Diesel Models ......................... 4 - 26 A-23 Check the Engine Belt - Ford Models ............................................................ 4 - 28 vi Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures, continued B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 Check the Battery ......................................................................................... 4 - 29 Inspect the Electrical Wiring .......................................................................... 4 - 29 Check the Radiator - Ford Models ................................................................ 4 - 30 Check the Exhaust System ........................................................................... 4 - 31 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33 Confirm the Proper Brake Configuration ....................................................... 4 - 34 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34 B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models ............ 4 - 35 B-11 Test the Key Switch ...................................................................................... 4 - 37 B-12 Test the Emergency Stop Buttons ................................................................. 4 - 37 B-13 Test the Ground Control Override ................................................................. 4 - 38 B-14 Check the Directional Valve Linkage ............................................................. 4 - 38 B-15 Test the Platform Self-leveling ...................................................................... 4 - 39 B-16 Test the Horn ................................................................................................ 4 - 40 B-17 Test the Foot Switch ..................................................................................... 4 - 40 B-18 Test the Engine Idle Select ........................................................................... 4 - 41 B-19 Test the Fuel Select Operation - Ford Models ............................................... 4 - 42 B-20 Test the Drive Enable System ....................................................................... 4 - 43 B-21 Test the Drive Brakes ................................................................................... 4 - 44 B-22 Test the Drive Speed - Stowed Position ........................................................ 4 - 45 B-23 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46 Part No. 52709 Genie Z-45/25 & Genie Z-45/25J vii First Edition • Second Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures, continued B-24 Test the Alarm Package - Optional Equipment .............................................. 4 - 47 B-25 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48 B-26 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 48 B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 49 B-28 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 51 B-29 Replace the Spark Plugs - Ford Models ........................................................ 4 - 52 B-30 Replace the Engine Air Filter Element ........................................................... 4 - 53 C-1 C-2 C-3 C-4 C-5 C-6 D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 59 Replace the PCV Valve - Ford Models .......................................................... 4 - 60 Check the Boom Wear Pads ......................................................................... 4 - 61 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62 Check the Free-wheel Configuration ............................................................. 4 - 63 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 65 Replace the Drive Hub Oil ............................................................................. 4 - 66 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69 viii Genie Z-45/25 & Genie Z-45/25J Part No. 52709 ........ Drive Functions Operational .................. 4 ........................................18 Engine High Idle Inoperative . Engine Starts and Runs ...................................6 Engine Cranks Over But Will Not Start . 5 ...........Ford Models ..........Diesel Models ...........................................................77 Check the Engine Cylinder Compression ............... 4 .........17 Engine Low Idle Inoperative .......................19 Engine Low Idle Inoperative ............ 5 . 5 .....................................Deutz Diesel Models ..................................Diesel Models ......23 Part No. 4 ...... 5 ......... 5 ........ But Will Start On LPG .......3 1 2 2A 3 4 5 6 7 8 9 10 11 Engine Will Not Crank Over .. 5 ..........................Ford Models .... 4 ................ continued E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 Test or Replace the Hydraulic Oil ...... 5 ........ 5 ........ 5 ..........77 Replace the Timing Belt ....................................1 Fault Codes ....................................21 All Functions Inoperative.....Ford Models ..............................10 Engine Cranks Over But Will Not Start ..............8 Engine Runs While Cranking Then Dies ..Ford Models ..70 Change or Recondition the Engine Coolant ........... 5 .22 All Lift and Steer Functions Inoperative. 5 .. 5 ...........77 Grease the Steer Axle Wheel Bearings..... 2WD Models .....................................14 Engine Will Not Start On Gasoline.......................Diesel Models . 4 ..................74 Check the Toothed Belt .....First Edition • Second Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures........................................ 4 .... 52709 Genie Z-45/25 & Genie Z-45/25J ix ...........Ford Models ..................77 Check the Fuel Injection Pumps and Injectors ........Ford Models ........72 Change the Fuel Hoses ...........77 Check the Engine Valve Clearance .............................Deutz Diesel Models .........11 Engine Will Not Start On LPG............................................... 4 ..Ford Models ........78 Section Five Troubleshooting Flow Charts Introduction ................ 4 ...............................Ford Models ...16 Engine High Idle Inoperative ......... But Will Start On Gasoline ..Ford Models ..................................................................................................................................................... 4 ... 5 ................... 5 ................. 71 Drive Forward Or Reverse Function Inoperative ... 5 ...41 Primary Boom Retract Function Inoperative ............................49 All Platform Leveling Functions Inoperative ....First Edition • Second Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts. 5 ...............................................................................56 Platform Rotate Left Function Inoperative ...................................64 Jib Boom Down Function Inoperative......69 Oscillate Function Inoperative ...............74 Traction Function Inoperative . 5 ................................................................ Z-45/25J Models .......... 5 .......................................... 5 ....... 5 .................... 5 ......... 5 .78 Auxiliary Functions Inoperative .................. Platform Controls Operate Normally ............................................................... 5 .....................68 Steer Right Function Inoperative .................................................................................70 All Drive Functions Inoperative...............................35 Secondary Boom Down Function Inoperative ..............32 Secondary Boom Up Function Inoperative ........................................... 5 .. 5 ..................53 Platform Level Up Function Inoperative ....................... 5 .................... 5 .......... 5 ..................24 Platform Controls Inoperative........ Ground Controls Operate Normally ....43 Turntable Rotate Left Function Inoperative ..............................................................75 Machine Will Not Drive At Full Speed ..... 5 ........38 Primary Boom Extend Function Inoperative ..................................................76 Machine Drives At Full Speed With Platform Raised or Extended ......26 Primary Boom Down Function Inoperative (before serial number 13099) .........25 Primary Boom Up Function Inoperative ................................. 5 .....79 x Genie Z-45/25 & Genie Z-45/25J Part No...... 5 ..............................61 Jib Boom Up Function Inoperative......... 5 .........77 Drive Enable System Is Malfunctioning .......................................... 5 ............................. 5 ........................................ 5 ... 52709 ...................... 5 ..... 5 ........58 Platform Rotate Right Function Inoperative ....................................................... 5 ....... Z-45/25J Models ................45 Turntable Rotate Right Function Inoperative .. All Other Functions Operate Normally . continued 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Ground Controls Inoperative...................................................29 Primary Boom Down Function Inoperative (after serial number 13098) ... 5 ....54 Platform Level Down Function Inoperative ..66 Steer Left Function Inoperative ................................................. 5 .............. 5 ...... 5 .... ..20 Electrical Schematic................15 Platform Control Box Wiring Diagram...................................................... 6 ........ 6 ...................... 6 .....16 Electrical Schematic........5 Ford LRG-425 EFI Engine Harness (before serial number 13099) ....................................................................................................................... Z-45/25J Ford Models (before serial number 13099) ....................................................................................................................................... Z-45/25 Ford Models (from serial number 13098 to 16303) ...........................................22 Ground Control Box Wiring Diagram.... 6 ........ 6 .....................................23 Part No............. 6 ..................... Z-45/25 Ford Models (before serial number 13099) ........... Z-45/25 Ford Models (from serial number 13098 to 16303) ....7 Ford LRG-425 EFI Engine Harness (after serial number 13098) ..Z-45/25 Ford Models (before serial number 13099) .................................................... 52709 Genie Z-45/25 & Genie Z-45/25J xi .... 6 ........................ 6 ..8 Electrical Schematic ............................................................ 6 .................. 6 ............................... Z-45/25 Ford Models (from serial number 13098 to 16303) .......................... Z-45/25J Ford Models (from serial number 13098 to 16303) ...... 6 ...2 Electrical Symbols Legend ..10 Ground Control Box Wiring Diagram......... 6 ......................First Edition • Second Printing TABLE OF CONTENTS Section Six Schematics Introduction ... Z-45/25J Ford Models (before serial number 13099) ............. 6 ......... Z-45/25J Ford Models (from serial number 13098 to 16303) .11 Platform Control Box Wiring Diagram................................................18 Ground Control Box Wiring Diagram................ 6 .........4 Abbreviation Legend .................................... 6 ......................................................................................................... 6 .......19 Platform Control Box Wiring Diagram....................14 Ground Control Box Wiring Diagram... 6 ..............1 Electrical Components ...................... Z-45/25J Ford Models (before serial number 13099) ................................................................................................. Z-45/25 Ford Models (before serial number 13099) ...12 Electrical Schematic...................... ........................................... 6 ......27 Platform Control Box Wiring Diagram................................................................36 Electrical Schematic............................................................ Z-45/25 Ford Models (after serial number 16303) ..................46 Ground Control Box Wiring Diagram............. Z-45/25J Ford Models (after serial number 16303) .......38 Ground Control Box Wiring Diagram....26 Ground Control Box Wiring Diagram.. 6 ....................... Z-45/25 Deutz Models (from serial number 13098 to 16303) ..................... Z-45/25J Deutz Models (before serial number 13099) ......... Z-45/25 Ford Models (after serial number 16303) ........... Z-45/25J Deutz Models (from serial number 13098 to 16303) .............. 6 ......28 Electrical Schematic.... Z-45/25J Deutz Models (before serial number 13099) ................32 Electrical Schematic...35 Platform Control Box Wiring Diagram.......................... Z-45/25J Deutz Models (from serial number 13098 to 16303) ..................................43 Platform Control Box Wiring Diagram.............................................34 Ground Control Box Wiring Diagram..... 6 ......... 6 ........................ 6 ................... Z-45/25 Deutz Models (from serial number 13098 to 16303) .......................47 xii Genie Z-45/25 & Genie Z-45/25J Part No....... 6 ...............................................39 Platform Control Box Wiring Diagram..................... 52709 ............. Z-45/25 Deutz Models (before serial number 13099) .................................. 6 ................................... 6 . 6 .......... Z-45/25J Ford Models (from serial number 13098 to 16303) ............................................. 6 .........................30 Ground Control Box Wiring Diagram... Z-45/25 Deutz Models (before serial number 13099) ..................................44 Electrical Schematic....... 6 .......31 Platform Control Box Wiring Diagram........................................ Z-45/25J Ford Models (after serial number 16303) ......42 Ground Control Box Wiring Diagram.................... Z-45/25J Deutz Models (before serial number 13099) .. Z-45/25 Deutz Models (from serial number 13098 to 16303) ..... Z-45/25 Ford Models (after serial number 16303) ................... Z-45/25J Ford Models (after serial number 16303) ....................................................... 6 ........First Edition • Second Printing TABLE OF CONTENTS Section Six Schematics............. 6 ........................ continued Platform Control Box Wiring Diagram.............. 6 .. Z-45/25 Deutz Models (before serial number 13099) .......24 Electrical Schematic..........40 Electrical Schematic......... 6 ...................................................... 6 ................ 6 ......... ......... 6 ....... 6 ... 6 ..57 Platform Control Box Wiring Diagram....54 Electrical Schematic..... Z-45/25 Perkins Models (before serial number 16304) ...... 52709 Genie Z-45/25 & Genie Z-45/25J xiii ................. 6 ............ Z-45/25J Deutz Models (after serial number 16303) .........................Lift Drive Select Option.......... continued Platform Control Box Wiring Diagram........................... 6 .......... Z-45/25 Deutz Models (after serial number 16303) .... 6 .61 Ground Control Box Wiring Diagram......................................... 6 ......... Z-45/25 Perkins Models (before serial number 16304) ..............................................First Edition • Second Printing TABLE OF CONTENTS Section Six Schematics......................... Z-45/25 Deutz Models (after serial number 16303) .......................................... Z-45/25J Deutz Models (from serial number 13098 to 16303) ............................48 Platform Control Box Wiring Diagram ......52 Platform Control Box Wiring Diagram......65 Ground Control Box Wiring Diagram.................................... 6 .......62 Platform Control Box Wiring Diagram............. Z-45/25 Deutz Models (after serial number 16303) .......................59 Electrical Schematic................ Z-45/25J Perkins Models (before serial number 16304) ...................................56 Ground Control Box Wiring Diagram..............................................53 Platform Control Box Wiring Diagram ................... Z-45/25J Deutz Models (after serial number 16303) ............................49 Electrical Schematic... 6 ............................. Z-45/25J Perkins Models (before serial number 16304) ....................................................................... Z-45/25 Perkins Models (before serial number 16304) ........ 6 ............66 Part No................................... 6 ..... 6 .............. 6 ...Lift Drive Select Option............................51 Ground Control Box Wiring Diagram................. 6 ......... Z-45/25J Deutz Models (from serial number 13098 to 16303) .... Z-45/25J Deutz Models (after serial number 16303) ...............58 Platform Control Box Wiring Diagram ....Lift Drive Select Option............... Z-45/25J Deutz Models (after serial number 16303) ........... Z-45/25 Deutz Models (after serial number 16303) ....................63 Electrical Schematic............... 6 ... .............................. 7 ...................... 6 ....Lift/Drive Select Option... Z-45/25J Perkins Models (after serial number 16303) ................................ 52709 .............2 Horsepower Limiter Board ............... 6 ..... continued Platform Control Box Wiring Diagram................................................................................................................................74 Ground Control Box Wiring Diagram... 6 ............... 7 ... 6 .... Z-45/25J Perkins Models (after serial number 16303)) ... 6 .........................First Edition • Second Printing TABLE OF CONTENTS Section Six Schematics......8 xiv Genie Z-45/25 & Genie Z-45/25J Part No................ Z-45/25J Perkins Models (before serial number 16304) .................... 6 ................................................ Z-45/25J Perkins Models (after serial number 16303) ......... 6 ............................ 6 .................... Z-45/25J Perkins Models (after serial number 16303) .............75 Platform Control Box Wiring Diagram................................Load Sensor Option........................................ 6 .................................... 6 .........................................80 2WD Hydraulic Schematic ...................................................76 Platform Control Box Wiring Diagram ..........82 4WD Hydraulic Schematic ........... 6 .......... Z-45/25J Perkins Models (before serial number 16304) ...... Z-45/25 Perkins Models (after serial number 16303) .....................................67 Platform Control Box Wiring Diagram ........................................................... Z-45/25 Perkins Models (after serial number 16303) ................... Z-45/25 Perkins Models (after serial number 16303) ............................................ 7 ....79 Hydraulic Symbols Legend ......................... 6 ...........................68 Electrical Schematic............................................... 6 ...........71 Platform Control Box Wiring Diagram.... All Models ...78 Platform Control Box Wiring Diagram............1 Platform Controls 1-1 1-2 Joystick Controllers .....83 Section Seven Repair Procedures Introduction ......................................................72 Electrical Schematic.Lift/Drive Select Option...........70 Ground Control Box Wiring Diagram...................... ..........34 Secondary Boom Lift Cylinders .......... Z-45/25J Models . 7 ........................11 Platform Components 2-1 2-2 2-3 Platform ..........................................................31 Platform Leveling Master Cylinder ..........42 Part No............................. 52709 Genie Z-45/25 & Genie Z-45/25J xv .............................................. 7 ............................................... 7 ..............................32 Secondary Boom Components 5-1 5-2 Secondary Boom ........... Z-45/25J Models 3-1 3-2 3-3 Jib Boom................................................................ 7 ........ 7 ...................... 7 ............................................. 7 ................ 7 ............................... Z-45/25J Models .21 Primary Boom Components 4-1 4-2 4-3 4-4 4-5 Plastic Cable Track ........................ Z-45/25J Models ...........40 Deutz Engine F3L 1011F 7-1 7-2 7-3 RPM Adjustment ......First Edition • Second Printing TABLE OF CONTENTS Section Seven Repair Procedures...................................................................................... 7 .........41 Oil Temperature and Oil Pressure Gauges ............................................... 7 .... 7 .. continued 1-3 1-4 Foot Switch ..................................15 Jib Boom Components...............................10 Toggle Switches .........30 Primary Boom Extension Cylinder .... 7 ...........................14 Platform Rotator ......... 7 ............................................ 7 .. 7 ..........19 Jib Boom / Platform Rotate Manifold Components..............................13 Platform Leveling Slave Cylinder ...........................................................................................18 Jib Boom Lift Cylinder.............................................................................27 Primary Boom Lift Cylinder ........ 7 ........39 Turntable Covers 6-1 Turntable Covers ............................................................................................................................................................................................................................................................................ 7 ................. 7 .................................41 Flex Plate ..............................22 Primary Boom ............................................. 7 ..................................................................... .................................... 7 .............First Edition • Second Printing TABLE OF CONTENTS Section Seven Repair Procedures.........45 RPM Adjustment ............................................................................................. 7 ......... 7 ...... 7 .49 10-3 Wago® Components .....................Function Manifold ........... 7 ..................................... 7 ................................. 7 ............................................................ 52709 ....................................... 7 ....................... 7 ........ 2WD Drive Manifold ............................................. 7 ........45 Flex Plate .......................................... 7 .................................................................44 Ford LRG-425 EFI Engine 9-1 9-2 9-3 9-4 Timing Adjustment .........................43 Coolant Temperature and Oil Pressure Gauages . 7 .68 12-6 Valve Adjustments.......................65 12-5 2WD Drive Manifold Components ......... 7 ............................................................... 7 .46 Ground Controls 10-1 Control Relays .....................................................70 12-7 4WD Drive Manifold Components ..................................72 xvi Genie Z-45/25 & Genie Z-45/25J Part No.............................43 Flex Plate ........................................................................................................................................................ 7 ......... 7 ...........................................53 Manifolds 12-1 Function Manifold Components .......48 10-2 Toggle Switches....... Toggle Switches ...................49 10-4 Engine Fault Codes ............63 12-4 Directional Valve Manifold Components .........52 11-2 Drive Pump .............45 Water Temperature and Oil Pressure Gauges ............................ 7 ..................................................... 7 ....................................................Ford Models ....................................................................... continued Perkins 104-22 Engine 8-1 8-2 8-3 RPM Adjustment ..................................... 7 ................................ 7 .................................. See 1-4.......50 Hydraulic Pumps 11-1 Lift/Steer Pump ...............................................................62 12-3 Turntable Rotation Manifold Components ...............................56 12-2 Valve Adjustments ................. ............................ 7 ..........84 15-3 Tie Rod ...............88 16-3 Tie Rod....................... 52709 Genie Z-45/25 & Genie Z-45/25J xvii ....80 Turntable Rotation Components 14-1 Rotation Hydraulic Motor ................91 Part No.............. 7 ... 4WD Drive Manifold ....86 16-2 Steering Cylinders.................................. 7 ............................90 18-2 Drive Hub ............................................................................................ 7 ............... 7 .................................................84 15-2 Steering Cylinders ................... 7 ................................................... See 15-2................................80 2WD Steering Axle Components 15-1 Yoke and Hub .... 7 ...........................88 Oscillating Axle Components 17-1 Oscillating Axle Lock-out Cylinders ...First Edition • Second Printing TABLE OF CONTENTS Section Seven Repair Procedures....................85 4WD Steering Axle Components 16-1 Yoke and Hub .......................................................................................................................................77 13-2 Hydraulic Tank ............................................... Steering Cylinders .................... 7 .......... 7 ......................... See 15-3............................................................. Tie Rod ................................................76 ..... 7 ............................ Fuel and Hydraulic Tanks 13-1 Fuel Tank ................................................................. 7 ................................................................ continued 12-8 Valve Adjustments.................................. 7 ............................................ 7 .....................................89 Non-steering Axle Components 18-1 Drive Motor . 52709 . Genie Z-45/25 & Genie Z-45/25J Part No.First Edition • Second Printing This page intentionally left blank. 05 m 14. outside Standard Base Models 11 ft 6 in 3.8 m 45 ft 5 in 13.8 m 7 ft 4 in 2.1 m 6 ft 7 in 2.4 m 5 ft 1.4 m 5 ft 1.05 m 14.4 cm 7 in 17.5 m Narrow Base Models 11 ft 3.8 m 6 ft 10 in 2. 52709 Genie Z-45/25 & Genie Z-45/25J 2-1 .100 lbs 7756 kg 10 in 25.9 m 45 ft 5 in 13.First Edition • Second Printing Section 2 • Specifications Specifications Machine Specifications Stowed dimensions Length Width Standard Base Models Narrow Base Models Height Standard Base Models Narrow Base Models Weight Standard Base Models Narrow Base Models Ground clearance Standard Base Models Narrow Base Models Operational dimensions Maximum platform height Standard Base Models Narrow Base Models Maximum horizontal reach Maximum turntable tailswing Wheelbase 1 Z-45/25 (non jib) Z-45/25J (jib) 22 ft 3 in 6.5 m Z-45/25J (jib) 4 ft 6 in 1.7 m 0 in 0 cm 6 ft 8 in 2m ft 6 in m 0 in 0 cm 6 ft 8 in 2m Outreach specification with platform rotated 90 degrees.5 45 ft 6 in 13.700 lbs 6668 kg 17.100 lbs 7756 kg 10 in 25.35 m Turntable rotation Platform rotation Maximum capacity 6 foot platform Maximum allowable side force (ANSI and CSA) Platform dimensions Length Width 359° 180° 500 lbs 227 kg 150 lbs 68 kg 72 in 183 cm 30 in 76 cm 45 ft 8 in 13.7 cm Minimum turning radius.1 m 6 ft 7 in 2.9 m 124 17.2 m 5 ft 9 in 1.2 m 5 ft 9 in 1.000 lbs 6350 kg 17. Part No.8 m 6 ft 10 in 2.5 m 11 ft 3.5 m 11 ft 6 in 3.35 m 359° 160° 500 lbs 227 kg 150 lbs 68 kg Z-45/25 (non jib) 18 ft 5.5 m 7 ft 4 in 2.7 cm Minimum turning radius.9 m 25 ft 3 in 7.4 cm 7 in 17. inside Standard Base Models Narrow Base Models 4 ft 6 in 1. 36 mph 0.76 bar Drive speed. boom raised or extended.3 liters 33. Standard Base Models Drive speed.5 inches 9@ 5 /8 Industrial 14.9 sq cm 35. boom raised or extended.5 inches 7 inches Performance Specifications Drive speeds.7 sec 0.2 kg 24 gallons 91 liters 30 gallons 113.6 liters 17 fl oz 0. Product specifications are subject to change without notice.5 pounds 15. 2-2 Genie Z-45/25 & Genie Z-45/25J Part No. Narrow Base Models Gradeability Boom Stowed Position 17 gallons 64.5 sq in 280 sq cm 28 in 71 cm Foam filled 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.51 liters Continuous improvement of our products is a Genie policy.5 Nm 9-14.Section 2 • Specifications First Edition • Second Printing SPECIFICATIONS Tires and wheels Wheel diameter Wheel width Wheel lugs. 52709 . stowed All models 4.8 in 90.2 m/45 sec 0. 2WD Front Rear Lug nut torque Tire size Tire ply rating Tire contact area Overall tire diameter Tire pressure Fluid capacities Fuel tank LPG tank Hydraulic tank Hydraulic system (including tank) Drive torque hubs Rough terrain 17. 4WD Wheel lugs.5 inches 10.7 km/h 40 ft/5.5 NHS 14 59 sq in 149.6 mph 1 km/h 40 ft/45 sec 12.5 LT Tread 8 Sidewall 6 43.2 m/79 sec 2WD 30% 4WD 45% -18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.9 cm 45 psi 2. maximum Drive speed.2 m/5.8 mph 7.7 sec 12.5 Nm 14-17.58 km/h 40 ft/79 sec 12. 180° Z-45/25 Models Platform rotate .160° Z-45/25J Models Platform level up Platform level down 38 to 42 seconds 24 to 27 seconds 24 to 27 seconds 32 to 37 seconds 23 to 27 seconds 23 to 27 seconds 10 to 14 seconds 18 to 22 seconds 73 to 78 seconds 10 to 14 seconds 9 to 13 seconds 35 to 39 seconds 26 to 32 seconds Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 2-3 . maximum from platform controls Jib boom up Jib boom down Primary boom up Primary boom down Secondary boom up Secondary boom down Primary boom extend Primary boom retract Turntable rotate .First Edition • Second Printing Section 2 • Specifications SPECIFICATIONS Boom function speeds.359° primary boom retracted Platform rotate . 9 cc 1.7 liters/min 2-4 Genie Z-45/25 & Genie Z-45/25J Part No.5 gpm 5.1 to 2.3 bar 290 psi 250 psi 20 bar 17 bar 3 micron 50 psi 3. variable 2WD Function pump Type: pressure balanced gear Displacement .16 to 2.2 bar 4WD models 1.8 liters per minute 3200 psi 220. 52709 .75 gallons per minute 2.62 to 45.9 cc 250 psi 17.Section 2 • Specifications First Edition • Second Printing SPECIFICATIONS Hydraulic Specifications Hydraulic fluid Drive pump Type: bi-directional variable displacement piston pump Displacement @ 2500 rpm 0 to 30.1 gallons per minute 0 to 7. variable 4WD (2 speed motor) Displacement per revolution.67 cu in 11 cc 0 to 2.static Displacement @ 2500 rpm Hydraulic tank circuit return line filter 0.53 cu in 25 cc 3500 psi 241.6 bar 3200 psi 220.8 cu in 18.4 to 45.7 bar) bypass 0.7 liters per minute Maximum drive pressure Charge pressure neutral position drive position Medium pressure filter Medium pressure filter bypass pressure Drive manifold Brake relief pressure Steer end drive motors Displacement per revolution Non-steer end drive motors Displacement per revolution.95 liters per minute 6 micron with 25 psi (1.4 bar Dexron equivalent Function manifold Function relief valve pressure Primary boom down relief valve pressure Secondary boom down relief valve pressure Steer flow regulator Auxiliary pump Type: fixed displacement gear pump Displacement Auxiliary pump relief pressure 1.6 bar 2300 psi 158.3 gallons per minute 0 to 114.6 bar 1800 psi 124 bar 1.8 cu in 2. 36 mm Starter motor Normal engine cranking speed Current draw.78 x 3. Units ship with 10W-40 SG/CC.127 mm Use oils meeting API classification SG (labeled SG/CC or SG/CD) as they offer improved wear protection. new Brush length wear limit Brush spring tension Bolt torque through brush Brush mounting bolt torque Maximum commutator run-out 200 to 250 rpm 140-200A 800A 60-80A 0.397 mm 97 82 70 1-3-4-2 1600 rpm 2500 rpm 9.005 in 0.25 in 6.08 to 9.66 in 16. @ 2000 rpm) Oil capacity (including filter) Oil viscosity requirements Temperature below 60°F / 15.First Edition • Second Printing Section 2 • Specifications SPECIFICATIONS Ford Engine LRG-425 EFI Displacement Number of cylinders Bore & stroke Horsepower gross intermittent continuous horsepower @ 2500 rpm Firing order Low idle High idle Compression ratio Compression pressure (approx.5V DC 0.889 to 1.5 liters 4 3. normal load Current draw.8 mm 0.01 x 86.6°C 5W-30 10W-30 10W-40 to 10W-50 20W-40 or 20W-50 40 to 60 psi 2.) Pressure (psi) of lowest cylinder must be at least 75% of highest cylinder Valve clearances collapsed tappet Lubrication system Oil pressure (operating temp. Part No.75 to 4.5°C -10°F to 90°F / -23°C to 32°C Temperature above -10°F / -23°C Temperature above 20°F / -6. minimum Maximum circuit voltage drop while starting (normal temperature) Brush length. 52709 Genie Z-45/25 & Genie Z-45/25J 2-5 .35 mm 64 ounces 18 Newtons 45 to 84 in-lbs 5.5 Nm 15 to 20 ft-lbs 20 to 27 Nm 0.7 liters 0.4:1 153 cu in 2.4 in 96. maximum load Current draw.035 to 0.1 bar 5 quarts 4.055 in 0. 58 gpm 2. 14.042 to 0.4 bar 0. static Fuel flow rate Ignition System Spark plug type Spark plug gap Engine coolant Capacity Alternator Output 95A.046 in 1.18 L/min 12V.18 mm 64 psi 4.07 to 1.9 liters Motorcraft AWSF-52C 0.Section 2 • Specifications First Edition • Second Printing SPECIFICATIONS Battery Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Electronic fuel pump Fuel pressure. 52709 .5V 111/2 quarts 10. Group 34/78 1 900A 200 minutes 2-6 Genie Z-45/25 & Genie Z-45/25J Part No. 5 mm 44 40 36 1-2-3 1400 rpm 2500 rpm 18.3 mm 0. no load Brush length.13 inches 91 x 105 mm Injection system Injection pump make Injection pump pressure Injector opening pressure Fuel requirement Alternator output Starter motor Current draw.5:1 362 to 435 psi 25 to 30 bar centrifugal mechanical 125 cu in 2.012 in 0.72 in 18.05 liters 3 3. Part No.58 x 4.5 mm 0. Group 34/78 1 900A 200 minutes 3 /8 OMAP 4351 psi 300 bar 3626 psi 250 bar diesel number 2-D 55A.8 to 6 bar 6. Units ship with 10W-40 SG/CC. cold Intake Exhaust Lubrication system Oil pressure Oil capacity (including filter) Oil viscosity requirements Temperature below 60°F / 15. minimum Battery Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Fan belt deflection 12V.27 in 7 mm to 1/2 inch 9 to 12 mm Engine oil should have properties of API classification CC/SG or CD/SG grades. 14V 90A 0.5°C (synthetic) -10°F to 90°F / -23°C to 32°C Temperature above -4°F / -34°C 5W-30 10W-40 15W-40 26 to 87 psi 1.First Edition • Second Printing Section 2 • Specifications SPECIFICATIONS Deutz Engine F3L 1011F Displacement Number of cylinders Bore and stroke Horsepower gross intermittent continuous horsepower @ 3000 rpm Firing order Low idle High idle Compression ratio Compression pressure Governor Valve clearance. new Brush length.020 in 0.5 quarts 6 liters 0. 52709 Genie Z-45/25 & Genie Z-45/25J 2-7 . Section 2 • Specifications First Edition • Second Printing SPECIFICATIONS Perkins Engine 104-22 (KR model) Displacement Number of cylinders Bore and stroke Horsepower 135 cu in 2.31 x 3. Injection system gross intermittent continuous horsepower @ 2800 rpm Firing order Low idle High idle Compression ratio Compression pressure 50 46.7 to 34.2 mm 0. but is not recommended during the first 50 hours nor for light load applications.2 mm Type Quantity Cold cranking ampere Reserve capacity @ 25A rate 12V.5 bar Pressure (psi) of lowest cylinder must be 50 psi (3. cold Intake Exhaust Lubrication system Oil pressure (at 2600 rpm) Oil capacity (including filter) 0.2 liters 4 3.7480 in 19 mm 0.8 bar 8.94 inches 84 x 100 mm Oil viscosity requirements below 68°F / 20°C (synthetic) 5°F to 104°F / -15°C to 40°C above 14°F / -10°C 5W-20 10W-30 15W-40 Engine oil should have properties of API classification CC/SE. 52709 .8V 300 to 500 psi 20.9 41 1-3-4-2 1600 rpm 2500 rpm 22:1 Injection pump make Injection pressure Fuel requirement Alternator output Starter motor Current draw.7 mm Governor Valve clearance. minimum Battery Zexel 2133 psi 147 bar #2 Diesel 55A @ 13. Group 34/78 1 900A 200 minutes 3/8 in 10 mm 41 psi 2.5 in 12. no load Brush length.6 quarts 8.2 liters Fan belt deflection 2-8 Genie Z-45/25 & Genie Z-45/25J Part No.008 in 0.008 in 0. API classification CD/SE or CCMC D4 can be used.45 bar) of highest cylinder centrifugal mechanical 90A 0. new Brush length. 5 284.7 Torque Procedure 1 Replace the O-ring.5 282 427.7 190 223.3 93.9 21.2 47.First Edition • Second Printing Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. .1 Seal-Lok® .hose end SAE Dash Size ft. They are standard SAE size O-rings.6 142..4 36.7 31.2 352. The O-ring must be replaced anytime the seal has been broken. They are available in the O-ring field service kit (Genie part number 49612).. lbs. lbs.5 54. The O-rings used in the Parker Seal Lok® fittings and hose ends are custom-size O-rings. -4 Aluminum 11 Steel 16 -6 Aluminum 23 Steel 35 -8 Aluminum 40 Steel 60 -10 Aluminum 69 Steel 105 -12 Aluminum 93 Steel 140 -16 Aluminum 139 Steel 210 -20 Aluminum 172 Steel 260 -24 Aluminum 208 Steel 315 Nm 14.2 81.6 54. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table above.tube fitting SAE Dash Installing Size into.4 122 162. Machines that utilize Parker Seal-Lok® O-ring face seal fittings and hose ends require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port . 2 Lubricate the O-ring before installation. 52709 Genie Z-45/25 & Genie Z-45/25J 2-9 3 Be sure that the face seal O-ring is seated and retained properly. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.1 190 188. Part No.7 233. 6 Operate all machine functions and inspect the hoses and fittings and related components to be sure that there are no leaks. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight.4 126. ft. -4 18 -6 27 -8 40 -10 63 -12 90 -16 120 -20 140 -24 165 Nm 24.2 85. Section 2 • Specifications First Edition • Second Printing This page intentionally left blank. 52709 .10 Genie Z-45/25 & Genie Z-45/25J Part No. 2 . First Edition • Second Printing Section 3 • Theory of Operation Theory of Operation Power Source The Genie Z-45/25 and Genie Z-45/25J are powered by either a gasoline/LPG engine or one of two diesel engines. rated at 7 gpm (26. Electrical System Boom/Steer functions are accomplished by moving a toggle switch or a controller. The EDC regulates drive pump displacement in direct relation to the drive controller position. 52709 Genie Z-45/25 & Genie Z-45/25J 3-1 . variable output piston pump rated at 0 to 30. reducing pump output. Hydraulic System All machine functions are performed by the hydraulic system.5 L/min). which sends voltage to the appropriate directional control valve. and a Perkins 104-22 KR engine rated at 41 horsepower @ 2800 rpm. The hydraulic system can be divided into two groups: Boom/Steer functions and Drive functions. When activated. Drive forward or reverse is accomplished by pressing down the foot switch in the platform and moving the drive controller (joystick) in the appropriate direction. Two internal 3200 psi (220. Drive functions are powered by a bi-directional. the drive controller completes a circuit to the electronic displacement controller (EDC). where the directional and flow control valves are located.3 gpm (0 to 114.3 bar). The amount of hydraulic fluid volume is determined by a proportional valve or flow regulator valve. set at 3500 psi (241. Part No. which destrokes the pump. The gasoline/LPG option uses a Ford LRG-425 EFI engine rated at 70 horsepower @ 2500 rpm. A flow regulator valve is a mechanical valve and delivers a predetermined amount of hydraulic fluid.6 bar) relief valves are used to prevent over-pressurization of the closed loop drive system. These directional valves determine which direction the hydraulic fluid will travel. The diesel options include a Deutz F3L 1011F engine rated at 36 horsepower @ 3000 rpm. platform rotator and jib boom cylinder (Z-45/25J models) incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure. platform leveling slave cylinder. this pump supplies hydraulic fluid under pressure to the function manifold. Boom/Steer functions are powered by a singlesection gear pump. To protect from overpressurization of the Boom/Steer system. The boom lift cylinder. A proportional valve receives a variable voltage signal and delivers more hydraulic fluid as the voltage increases. When the engine is running. This is done by sensing engine RPM (via an AC tap on the alternator) and limiting the amount of current supplied to the drive controller/EDC. boom extend cylinder.7 L/min) @ 2500 rpm. A horsepower limiter printed circuit board (located in the platform control box) is provided to maintain engine RPM as drive system loads become greater. the pump is provided with a pressure relief valve. A thumb rocker switch on the top of the drive controller is used for steering. The drive controller (joystick) regulates the drive pump displacement through the EDC in direct relation to the drive controller position. located in the platform.Section 3 • Theory of Operation First Edition • Second Printing THEORY OF OPERATION Limit switches There are two types of limit switches which are found in various locations on the machine: drive speed limit switches and a drive enable limit switch. located on the engine side of the machine. Ground controls are activated by holding the function enable toggle switch to either side. use compressed air to remove debris. The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated beyond the non-steer wheels. This will determine which boom function will operate and its direction of travel. Only boom functions are available at the ground controls.6 m) OR when the primary boom is extended more than 18 inches (45.7 cm). Instead.6 miles per hour (1 km/h) when the primary boom is raised more than 2 feet (0. 52709 . and the platform controls. 3-2 Genie Z-45/25 & Genie Z-45/25J Part No. Platform controls use toggle switches and boom function controllers (joysticks) to operate the boom functions. Washing electronic components is not suggested. Machine Controls The Genie Z-45/25 and Genie Z-45/25J machines are equipped with operational controls which are found in two locations: the ground controls. All lift and drive functions are available at the platform controls. The function of a drive speed limit switch is to limit the raised or extended drive speed to 0. then moving a boom function toggle switch in the direction indicated on the control panel decal. First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety information and step-by-step instructions. Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: · Machine parked on a flat, level surface · Boom in stowed position · 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 Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Green—used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4-1 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below. Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two years. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection Daily or every 8 hours Table or Checklist A A+B A+B+C A+B+C+D A+B+C+D+E Indicates that tools will be required to perform this procedure. Indicates that new parts will be required to perform this procedure. Quarterly or every 250 hours Six months or every 500 hours Annual or every 1000 hours Indicates that a cold engine will be required to perform this procedure. Two years or every 2000 hours Indicates that a warm engine will be required to perform this procedure. Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. Indicates that dealer service is required to perform this procedure. 4-2 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions · Make copies of both pages to use for each inspection. · Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: Checklist A A-1 Manuals A-2 Decals and placards A-3 Damage and loose or missing parts A-4 Engine oil level A-5 Engine coolantLiquid Cooled Models A-6 Fuel leaks A-7 Hydraulic oil level A-8 Hydraulic leaks A-9 Tire pressure A-10 Oscillate axle A-11 Platform and ground controls A-12 Auxiliary power A-13 Tilt sensor A-14 Limit switches A-15 Check the engine beltPerkins Models A-16 Air filter A-17 Fuel filter- Ford Models A-18 Inspect the radiatorPerkins Models A-19 Perform 30 day service Perform every 100 hours: A-20 Replace oil filterFord and Perkins Models A-21 Inspect fuel filter/water separator-Diesel Models A-22 Check engine RPMPerkins Engine Models Perform every 200 hours: A-23 Check the engine beltFord Models Y N R Checklist B Y N R B-1 Check the battery B-2 Inspect electrical wiring B-3 Check the radiatorFord Models B-4 Exhaust system B-5 Hydraulic return filter condition indicator B-6 Check oil cooler and finsDeutz Models B-7 Tires and wheels B-8 Brake configuration B-9 Drive hub oil level B-10 Engine RPMFord and Deutz Models B-11 Key switch B-12 Emergency Stop B-13 Ground control override B-14 Directional valve B-15 Platform leveling B-16 Horn B-17 Foot switch B-18 Engine idle select B-19 Fuel select-Ford Models B-20 Drive enable system B-21 Drive brakes B-22 Drive speed-stowed B-23 Drive speed-raised B-24 Alarm package B-25 Hydraulic oil analysis Perform every 250 hours: B-26 Replace hydraulic tank return filter Perform every 400 hours: B-27 Replace fuel filter/water separator elementPerkins models B-28 Replace the fuel filter element - Perkins Models B-29 Replace spark plugsFord Models B-30 Replace engine air filter A A+B Six Month or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E · Place a check in the appropriate box after each inspection procedure is completed. · If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4-3 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing MAINTENANCE INSPECTION REPORT Instructions · Make copies of both pages to use for each inspection. · Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: A A+B Checklist C C-1 Engine beltDeutz Models C-2 Replace engine oil and filter-Deutz Models C-3 Valves-Deutz Models C-4 Check the coolantLiquid Cooled Models C-5 Check the valve clearance-Perkins Models C-6 PCV valve-Ford Models Y N R Six Month or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E · Place a check in the appropriate box after each inspection procedure is completed. · If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Checklist D Y N R D-1 Boom wear pads D-2 Turntable bearing bolts D-3 Free-wheel configuration D-4 Grease rotation bearing D-5 Drive hub oil D-6 Drive loop hydraulic filter D-7 Check Air/LPG mixtureFord Models D-8 Replace the diesel fuel filter/water separatorDeutz Models Checklist E Y N R E-1 Hydraulic oil E-2 Engine coolantFord Models E-3 Fuel hoses E-4 Check the toothed beltDeutz Models E-5 Check the engine valve clearance-Ford Models E-6 Check cylinder compression-Ford Models E-7 Check the fuel injection pump-Deutz Models E-8 Replace timing belt Ford Models E-9 Grease the steer axle wheel bearings, 2WD Models 4-4 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Table A Procedures A-1 Inspect the Operator's and Safety Manuals Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. 1 Check to be sure that the storage container is present and in good condition. 2 Check to make sure that the operator's, responsibilities and safety manuals are present and complete in the storage container in the platform. 3 Examine the pages of each manual to be sure that they are legible and in good condition. 4 Always return the manuals to the storage container after use. Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed. A-2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Refer to the Decals section in the Genie Z45/25 & Genie Z45/25J Operator's Manual and use the decal list and illustrations to determine that all decals and placards are in place. 2 Inspect all decals for legibility and damage. Replace any damaged or illegible decal immediately. Contact your authorized Genie distributor or Genie Industries if replacement decals are needed. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4-5 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-3 Inspect for Damage and Loose or Missing Parts Check entire machine for: · Cracks in welds or structural components · Dents or damage to machine · Battery and connections · Compartment covers and latches Daily machine condition inspections are essential to safe machine operation and good machine performance. Failure to locate and repair damage, and discover loose or missing parts may result in an unsafe operating condition. 1 Inspect the entire machine for damage and improperly installed or missing parts including: · Electrical components, wiring and electrical cables · Hydraulic hoses, fittings, cylinders and manifolds · Fuel and hydraulic tanks · Drive and turntable rotation motors and drive torque hubs · Axle components · Boom components and wear pads · Platform entry mid-rail or gate · Tires and wheels · Engine and related components · Limit switches · Alarms, horn and beacon (if equipped) · Nuts, bolts and other fasteners Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened. After you complete each inspection, be sure that all compartment covers are in place and secured. 4-6 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES A-4 Check the Engine Oil Level Deutz Engine F3L 1011F Oil capacity (including filter) Oil viscosity requirements below 60°F / 15.5°C (synthetic) 6.3 quarts 6 liters 5W-30 10W-40 15W-40 Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level can damage engine components. Check the oil level with the engine off. 1 Check the oil dipstick. Add oil as needed. Result: The oil level should be in the "safe" zone. Ford LRG-425 EFI Engine Oil capacity (including filter) Oil viscosity requirements below 60°F / 15.5°C -10° to 90°F / -23° to 32°C above -10°F / -23°C above 25°F / -4°C Use oils meeting API classification SH or SG. Units ship with 10-40 CC/SG. 5W-30 5W-30 5W-30 10W-30 4.5 quarts 4.3 liters -10°F to 90°F / -23°C to 32°C above -4°F / -34°C Engine oil should have properties of API classification CC/SE, CD/SE, SF/CC or SF/CD grades. Units ship with 10-40 CC/SG. Perkins Engine 104-22 Oil capacity (including filter) Oil viscosity requirements below 60°F / 15.5°C -10° to 90°F / -23° to 32°C above -10°F / -23°C above 25°F / -4°C 5W-20 10W-30 15W-40 20W-50 8.6 quarts 8.2 liters Engine oil should have properties of API classification CC/SE, CD/SE, SF/CC or SF/CD grades. Units ship with 10-40 CC/SG. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4-7 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-5 Check the Engine Coolant Level Liquid Cooled Models A-6 Check for Fuel Leaks Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant level will affect the engine's cooling capability and damage engine components. Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. 1 Check the fluid level in the coolant recovery tank. Add fluid as needed. Result: The fluid level should be at the FULL mark. Do not remove the radiator cap. Failure to detect and correct fuel leaks will result in an unsafe condition. An explosion or fuel fire may cause death or serious injury. Explosion and fire hazard. Engine fuels are combustible. Inspect the machine in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. 1 Open the shutoff valve on the liquid petroleum gas (LPG) tank by turning it counterclockwise (if equipped). 2 Perform a visual inspection around the following areas. Ford Models: · LPG tank, hoses and fittings, solenoid shutoff valve, LPG regulator and throttle body. An LPG detector may be necessary to locate LPG leaks. · Fuel tank, manual shutoff valve, fuel pump, fuel filters, fuel rail and fuel injectors, hoses and fittings and throttle body. 4-8 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES Deutz and Perkins Models: · Fuel tank. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems. keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. fuel pump. fuel filter. If a fuel leak is discovered. 52709 Genie Z-45/25 & Genie Z-45/25J 4-9 . fuel injection pumps and fuel injectors. 2 Add oil as needed. then visually inspect the sight gauge located on the side of the hydraulic oil tank. Improper hydraulic oil levels can damage hydraulic components. shutoff valve. A-7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation.8 liters 113.6 liters Part No. 1 Be sure that the boom is in the stowed position. Explosion and fire hazard. Result: The hydraulic oil level should be within the top 2 inches (5 cm) of the sight gauge. Hydraulic oil specifications Hydraulic oil type Tank capacity Hydraulic system (including tank) 24 gallons 30 gallons Dexron equivalent 90. hoses and fittings. This procedure does not need to be performed on machines equipped with foam-filled tire. Tip-over hazard. To safeguard maximum stability. Undiscovered leaks can develop into hazardous situations.1 bar) Narrow base models Industrial tire Foam Filled Only 14-17. An overinflated tire can explode and could result in death or serious injury.5 NHS 45 psi (3. achieve optimum machine handling and minimize tire wear. hoses. pumps. it is essential to maintain proper pressure in all air-filled tires. dripping or residue on or around the following areas: · Hydraulic tank— fittings. 1 Check each tire with an air pressure gauge and add air as needed. 52709 . auxiliary power unit. fittings. and turntable surface · Engine compartment—hydraulic filters. Tire specifications 2WD Models 4WD Models Standard base models Rough terrain tire 14-17.1 bar) N/A 4 .5 NHS 45 psi (3. filter and turntable surface · All hydraulic cylinders · All hydraulic manifolds · Primary and jib boom · The underside of the turntable · The underside of the drive chassis · Ground area under the machine Bodily injury hazard. hoses. filters. impair machine functions and damage machine components.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-8 Check for Hydraulic Leaks A-9 Check the Tire Pressure Detecting hydraulic fluid leaks is essential to operational safety and good machine performance. 1 Inspect for hydraulic oil puddles.10 Genie Z-45/25 & Genie Z-45/25J Part No. Do not use temporary flat tire repair products. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. see Repair Procedure 12-4. Attempt to activate each boom and platform function toggle switch. Machines equipped with Platform Level Control Disable Function: The platform level function will not operate when the boom is raised or extended past the drive speed limit switches.2 cm) block or curb. 4 Drive both steer tires up onto a 6 inch (15. 2 Drive the right steer tire up onto a 6 inch (15. jerking and unusual noise.2 cm) block or curb. the stability of the machine is compromised and it may tip over. Each function should activate.11 . 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch. 3 Drive the left steer tire up onto a 6 inch (15. Part No. 3 Do not hold the function enable switch to either side. 2 Start the engine from the ground controls. An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine. Descent alarm (if equipped) should sound while the boom is lowering. Result: All boom and platform functions should not operate. Result: All boom and platform functions should operate through a full cycle. operate smoothly and be free of hesitation. Result: The non-steer tires should stay in firm contact with the ground. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. 1 Start the engine from the platform controls.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES A-10 Test the Oscillate Axle (if equipped) Proper axle oscillation is essential to safe machine operation.2 cm) block or curb. How to Set Up the Directional Valve Linkage A-11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation. If the chassis does not remain level during test. If the axle oscillation system is not operating correctly. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. Deutz and Perkins Diesel models: All functions should stop immediately. including the Emergency Stop button. 5 Pull out the Emergency Stop button to the ON position at the platform controls. Result: All machine functions should operate through a full cycle. The engine will shut off after 2 to 3 seconds. 6 Start the engine from the platform controls.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES 5 Push in the Emergency Stop button to the OFF position. selecting and operating the ground controls will override the platform controls. the engine should stop. and excessive use will result in battery drain and component damage. Deutz and Perkins Diesel models: All functions should stop immediately. 8 Attempt to activate each machine function. An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss. A-12 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation. test each function through a partial cycle. 6 Press down the foot switch. The engine will shut off after 2 to 3 seconds. 10 Push in the Emergency Stop button to the OFF position at the platform controls. selecting auxiliary power will stop the engine immediately. To conserve battery power. Result: All machine functions should not operate. Result: No function should operate. As a safety feature. 3 Simultaneously hold the auxiliary power switch ON and activate each boom function toggle switch.12 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. Auxiliary power is designed for short term use only. Machines equipped with Platform Level Control Disable Function: The platform level function will not operate when the boom is raised or extended past the drive speed limit switches. Result: All boom functions should operate. 4 . When operating the machine on engine power. 4 Turn the key switch to platform control. the engine should stop. 9 Press down on the foot switch and activate each machine function. Result: No function should operate. 52709 . 7 Do not press down on the foot switch. 2 Lift the red auxiliary power switch cover. If you can't hear the alarm at the ground controls. 4 Press down on one side of the tilt sensor. A-13 Test the Tilt Sensor The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Select a level test area. should sound. The alarm should be heard at the ground controls. Drive functions should not operate with auxiliary power. Result: The alarm. Part No. replace the alarm in the platform. The tilt alarm should not be sounding prior to the test.13 . 2 Turn the key switch to platform controls and pull out the red Emergency Stop buttons out to the ON position at both the ground and platform controls. 3 Locate the tilt sensor to the right of the hydraulic pump. 1 Open the engine side turntable cover.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 7 Lift the red auxiliary power switch cover. To conserve battery power. 8 Simultaneously hold the auxiliary power switch ON and activate each function control handle or toggle switch. test each function through a partial cycle. Result: All boom and steer functions should operate. Tip-over hazard. located in the platform. 1 Remove the hose and cable cover from the rear of the upper mid-pivot. Result: The primary boom drive limit switch arm should move freely and spring return to center. a primary boom drive limit switch (LS2) 4 . a a a secondary boom drive limit switch (LS3) 6 Visually inspect secondary boom drive limit switch for the following: · Broken or missing roller or arm · Missing fasteners · Loose wiring 7 Manually activate the secondary boom drive limit switch. A distinct click should be felt and heard.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-14 Test the Limit Switches 5 Locate the secondary boom drive limit switch located at the platform end of the lower secondary boom. The drive limit switches are used to restrict drive speed when the boom is raised or extended. An improperly functioning drive limit switch will allow the machine to operate at an unsafe drive speed. 2 Locate the primary boom drive limit switch located on the inside of the upper mid-pivot. Result: The secondary boom drive limit switch arm should move freely and spring return to center. Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation. 3 Visually inspect primary boom drive limit switch for the following: · Broken or missing roller or arm · Missing fasteners · Loose wiring 4 Manually activate the primary boom drive limit switch. A distinct click should be felt and heard.14 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 . Fully retract the primary boom.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 8 Locate the primary boom extend drive limit switch located at the pivot end of the primary boom. Part No. 12 Manually activate the boom extend drive limit switch. 17 Press down the foot switch and slowly move the drive control handle off center. 18 Move the lift/drive select switch to the lift position (if equipped). 23 Press down the foot switch and lower the primary boom to the stowed position. 21 Press down the foot switch and slowly move the drive control handle off center. a primary boom extend drive limit switch (LS1) 9 Visually inspect the boom extend drive limit switch located at the pivot end of the primary boom. then raise the secondary boom approximately 2 feet (61 cm). 16 Move the lift/drive select switch to the drive position (if equipped). 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Result: The machine should move at a reduced drive speed. 20 Move the lift/drive select switch to the drive position (if equipped). Result: The machine should move at normal drive speeds.15 . 15 Press down the foot switch. 11 Turn the engine off. 19 Press down the foot switch and raise the primary boom approximately 2 feet (61 cm). A distinct click should be felt and heard. Inspect for the following: · Broken or missing arm · Missing fasteners · Loose wiring 10 Start the engine from the ground controls and extend the primary boom approximately 2 feet (61 cm). Result: The boom extend drive limit switch arm should move freely and spring return to center. a 13 Start the engine from the platform controls. 14 Move the lift/drive select switch to the lift position (if equipped). 22 Move the lift/drive select switch to the lift position (if equipped). 2 m/45 sec 0. boom raised or extended. Turn the engine off. 52709 .6 m).16 Genie Z-45/25 & Genie Z-45/25J Part No. 26 Move the lift/drive select switch to the lift position (if equipped). maximum. raised or extended Drive speed. The drive enable limit switch stops the drive function when the boom is rotated past a non-steer tire and alerts the operator that the machine may drive in the opposite direction that the drive and steer control handle is moved. then extend the primary boom approximately 2 feet (0. Result: The machine should move at a reduced drive speed. Result: The machine should move at a reduced drive speed. boom raised or extended.6 mph 1. Standard Base Models 0. 29 Press down the foot switch and slowly move the drive control handle off center.36 mph 0. 1 Start the engine from the ground controls and rotate the boom between the steer and non-steer tires. Narrow Base Models c a b c b turntable drive enable limit switch (LS4) turntable rotation bearing 4 . 25 Press down the foot switch and slowly move the drive control handle off center. Drive speed.2 m/79 sec Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine operation and workplace safety. 28 Move the lift/drive select switch to the drive position (if equipped).58 km/h 40 ft/79 sec 12. 27 Press down the foot switch and lower the secondary boom to the stowed position.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES 24 Move the lift/drive select switch to the drive position (if equipped).0 km/h 40 ft/45 sec 12. 2 Visually inspect the drive enable limit switch for the following: · Broken or missing roller or arm · Missing fasteners · Loose wiring a Drive speed. Result: Drive function should operate. Result: Drive function should operate. 4 Start the engine from the platform controls. 10 Press down the foot switch and rotate the turntable to the left until the boom is past the left non-steer wheel. Result: The drive enable indicator light should be on. 19 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. Result: Drive function should not operate. Result: The drive enable indicator light should be on. Result: The drive enable indicator light should be on. 11 Move the lift/drive select switch to the drive position (if equipped). 15 Press down the foot switch and rotate the turntable to the right until the boom is past the right non-steer wheel. Result: The drive enable indicator light should be on. 14 Move the lift/drive select switch to the lift position (if equipped).17 . 18 Press down the foot switch and slowly move the drive control handle off center. A distinct click should be felt and heard. 7 Move the lift/drive select switch to the drive position (if equipped). Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 6 Press down the foot switch. Result: Drive function should not operate. 5 Move the lift/drive select switch to the lift position (if equipped). 17 Move the lift/drive select switch to the drive position (if equipped). 13 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. 9 Move the lift/drive select switch to the lift position (if equipped). Result: The drive function should operate. Result: The drive enable limit switch roller should move freely and spring return to center. 12 Press down the foot switch and slowly move the drive control handle off center.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 3 Manually activate the drive enable limit switch. 16 Rotate the turntable to the left until the boom is past the left non-steer wheel. Then rotate the turntable until the primary boom is in between the non-steer tires. Result: The drive enable indicator light should be off. 8 Press down the foot switch and slowly move the drive control handle off center. 7 Install the engine pivot plate safety pin. Contact with hot engine components may result in severe burns. Bodily injury hazard. Beware of hot engine components.Genie part number 65537 4 . 52709 . 1 Remove the safety pin from the engine pivot plate latch. Remove the key to secure from operation. The machine will not operate properly with a loose or defective belt and continued use may cause component damage.18 Genie Z-45/25 & Genie Z-45/25J Part No.5 mm to 12 mm Engine belt . Belt deflection 3/8 in to 1/2 in 9. 6 Swing the engine back to its original position and close the engine pivot plate latch. 8 Replace the air baffle and install the air baffle retaining fasteners. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Burn hazard. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-15 Check the Engine Belt Perkins Models Maintaining the engine belt is essential to good engine performance and service life. 5 Check the engine belt for proper tension. Do not inspect while the engine is running. 3 Inspect the engine belt for: · Cracking · Glazing · Separation · Breaks 4 Replace belt if any damage is found. Remove the filter element.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES A-16 Clean the Engine Air Filter Element 3 Remove the end cap from the air cleaner canister. 9 Install the engine pivot plate safety pin (if equipped). blow out from inside out using low pressure dry compressed air. 4 Remove the air filter retaining fastener. Install and tighten the retaining ring. 7 Install the end cap onto the canister. If needed. Part No. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 8 Swing the engine back to its original position and close the engine pivot plate latch. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . All Models: 1 Remove the safety pin (if equipped) from the engine pivot plate latch. or tap out dust taking care not to damage the element. 6 Inspect the filter element. Maintaining the engine air filter in good condition is essential to good engine performance and service life. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.19 . 5 Clean the inside of the canister and the gasket with a damp cloth. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. Engine fuels are combustible. disconnect and plug the fuel hose that goes to the fuel tank. Always have an approved fire extinguisher within easy reach. Extremely dirty conditions may require that the filter be replaced more often. flames and lighted tobacco. a b c Replacing the gasoline fuel filter is essential to good engine performance and service life.Ford Models 1 Locate the fuel system components mounted underneath the engine pivot plate (viewed from bottom of engine pivot plate). A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. e d a b c d e hose from fuel pump to regulator/filter hose from fuel pre-filter to fuel pump hose from fuel tank to fuel pre-filter hose from regulator/filter to engine hose from regulator/filter to tank 2 At the pre-filter.20 Genie Z-45/25 & Genie Z-45/25J Part No.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-17 Replace the Fuel Filters . 3 Disconnect the fuel hose from the fuel pre-filter to the fuel pump. 52709 . 4 Install the new fuel pre-filter (Genie part number 52179) and connect the fuel hoses to the filter. 4 . 5 Clean up any fuel that may have spilled during the installation procedure. Perform this procedure with the engine off. sparks. then remove the pre-filter. wellventilated area away from heaters. Explosion and fire hazard. Replace the fuel filter in an open. dirt or debris) will affect the performance of the cooling system. restricting air flow through the radiator (i. 8 Install the new regulator/filter (Genie part number 58967) onto the engine pivot plate and install the hoses to the regulator/filter. Be sure the correct regulator/filter is installed or component damage may occur. Remove the key to secure from operation. keep any additional personnel from entering the area and do not operate the machine. If a fuel leak is discovered. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them. 7 Remove the regulator/filter mounting fasteners. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .. Then remove the regulator/filter from the engine pivot plate.e. Explosion and fire hazard. Electronic Fuel Injection (EFI) systems operate at a very high pressure. 1 Remove the safety pin from the engine pivot plate latch. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems. 9 Start the machine from the ground controls. Fuel may be expelled under pressure if the hoses are removed too quickly. Explosion and fire hazard. Burn hazard. Operating a machine with a damaged or leaking radiator may result in engine damage. Fuel filters . Do not inspect while the engine is running. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Also. Part No. Component damage hazard.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 6 Disconnect the hoses from the pressure regulator/filter. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.Genie part numbers Fuel pre-filter Fuel pressure regulator/filter 52179 58967 A-18 Inspect the Radiator Perkins Models Maintaining the radiator in good condition is essential for good engine performance. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually.21 . Repair the leak immediately. Bodily injury hazard. then inspect the fuel filters and hoses for leaks. 4 Clean the radiator fins of debris and foreign materials............................... B-24 • Check the Turnable Rotation Bearing Bolts ............................ 5 Inspect all radiator hoses and connections........................... refer to the maintenance tables for continued scheduled maintenance.. 52709 ........... B-5 • Replace the Hydraulic Tank Return Filter ............. D-2 4 . A-19 Deutz Diesel Models .... After this interval...22 Genie Z-45/25 & Genie Z-45/25J Part No........ C-2 • Inspect the Tires and Wheels (including lug nut torque) ..... A-19 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage...... 6 Swing the engine back to its original position and close the engine pivot plate latch........Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES 3 Inspect the radiator for leaks and physical damage.... 1 Perform the following maintenance procedures: • Replace the Engine Oil and Filter Ford/Perkins Models ......................................... 7 Install the engine pivot plate safety pin.............. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation. 4 Pull the oil drain hose out from underneath the engine. 7 Place a container under the oil filter. 3 Remove the oil filler cap located on the valve cover. Periodic replacement of the engine oil and filter is essential to good engine performance. 9 Apply a thin layer of oil to the new oil filter gasket. Contact with hot engine oil and/or engine parts may result in severe burns. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 8 Use an oil filter wrench and remove the filter.Ford and Perkins Models 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Burn hazard. 5 Open the valve on the oil pan and allow all of the oil from the engine to drain into a suitable container.Genie part numbers Ford LRG-425 EFI Engine Perkins 104-22 Engine Ford and Perkins engine specifications require that this procedure be performed every 100 hours. Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components. Oil filters .First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES A-20 Replace the Engine Oil and Filter . Perform this procedure after warming the engine to normal operating temperature. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.23 . Then install the filter and tighten it securely by hand. 11 Fill the engine with new oil per specifications and install the filler cap. 6 Close the valve on the oil pan. 28656 65540 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter. 12 Start the engine from the ground controls. Part No. Beware of hot engine parts and oil. See capacity specifications. See capacity specifications. A daily check of machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 100 hour interval. then turn the engine off. Allow the engine to run for 30 seconds. 2 Inspect the filter bowl for water buildup. flames and lighted tobacco. 14 Swing the engine back to its original position and close the engine pivot plate latch.2 liters 5W-30 5W-30 5W-30 10W-30 4.3 liters A-21 Inspect the Fuel Filter/ Water Separator . Ford LRG-425 EFI Engine Oil capacity (including filter) Oil viscosity requirements below 60°F / 15. 52709 . Engine fuels are combustible. 16 Check the engine oil level dipstick. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Units ship with 10-40 CC/SG Perkins 104-22 Engine Oil capacity (including filter) Oil viscosity requirements below 60°F / 15. Engine oil should have properties of API classification CF4 grade. 4 .24 Genie Z-45/25 & Genie Z-45/25J Part No. wellventilated area away from heaters. Explosion and fire hazard.6 quarts 8.5 quarts 4. Perform this procedure in an open. Perform this procedure with the engine off. Add oil if needed.5°C -10° to 90°F / -23° to 32°C above -10°F / -23°C above 25°F / -4°C Use oils meeting API classification SH or SG. sparks. Perkins Models: 1 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. Failure to perform this procedure can lead to poor engine performance and component damage. Always have an approved fire extinguisher within easy reach. Result: If water is present in the filter bowl continue with steps 3 through 7 for Perkins models only.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES 13 Check the oil filter and the oil pan hose for leaks. 15 Install the engine pivot plate safety pin (if equipped).Diesel Models Engine specifications require that this procedure be performed every 100 hours.5°C -10°F to 90°F / -23°C to 32°C above -4°F / -34°C 15W-40 10W-30 15W-40 8. Fuel a b c d filter/water separator vent plug drain plug filter bowl separator head The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 5 Tighten the vent plug. Immediately tighten the drain plug. Refer to B-27 in this section. Allow the water to drain into a suitable container until fuel starts to come out. a d Explosion and fire hazard. you must prime the fuel filter/water separator before starting the engine. for instructions on how to prime the fuel filter/water separator. Repair the leak immediately. If a fuel leak is discovered. Immediately tighten the drain plug. keep any additional personnel from entering the area and do not operate the machine. Replace The Fuel Filter Element . 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.Perkins Diesel Models. Allow the water to drain into a suitable container until fuel starts to come out. 4 Loosen the drain plug located at the bottom of the bowl. Deutz Models: c b 1 Open the engine side turntable cover and locate the fuel filter/water separator. 4 Loosen the drain plug located at the bottom of the filter.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 3 Loosen the vent plug located on the fuel filter/ water separator head. 6 Clean up any fuel that may have spilled. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . If the fuel filter/water separator is completely drained.25 . 7 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. a b a b fuel filter/water separator drain plug Part No. 7 Install the engine pivot plate safety pin (if equipped). you must prime the fuel filter/water separator before starting the engine. Replace The Diesel Fuel Filter/Water Separator Deutz Diesel Models. for instructions on how to prime the fuel filter/water separator. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage.Perkins Diesel Models Perkins specifications require that this procedure be performed every 100 hours. Result: Low idle should be 1600 rpm. Start the engine from the ground controls. 5 Start the engine from the ground controls and check the fuel filter/water separator for leaks.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES 4 Clean up any fuel that may have spilled. If the fuel filter is completely drained. Repair the leak immediately. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. 4 . If a fuel leak is discovered. Refer to D-8 in this section. 52709 . A-22 Check and Adjust the Engine RPM . keep any additional personnel from entering the area and do not operate the machine. 6 Swing the engine back to its original position and close the engine pivot plate latch.26 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Connect a tachometer to the engine. This procedure will require two people. Explosion and fire hazard. Result: High idle should be 2500 rpm. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm.27 . Tighten the yoke lock nut and recheck the rpm.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES Skip to step 3 if the low idle rpm is correct. 4 Loosen the yoke lock nut. disregard adjustment step 4. then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. or counterclockwise to decrease the rpm. Part No. Be sure the solenoid fully retracts when activating high idle. Tighten the low idle lock nut and confirm the rpm. Perkins Diesel models Low idle High idle 1600 rpm 2500 rpm a b a b c d c d solenoid boot high idle adjustment nut yoke low idle lock nut and adjustment screw 3 Move the function enable toggle switch to the high idle (rabbit symbol) position. If high idle rpm is correct. Do not inspect while the engine is running.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE A PROCEDURES A-23 Check the Engine Belt Ford Models 3 Inspect the engine belt for: · Cracking · Glazing · Separation · Breaks 4 Replace belt if any damage is found. Maintaining the engine belt is essential to good engine performance and service life. Engine belt . Remove the key to secure from operation.28 Genie Z-45/25 & Genie Z-45/25J Part No. Engine specifications require that this procedure be performed every 200 hours. Burn hazard. 52709 . 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Bodily injury hazard. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 5 Swing the engine back to its original position and close the engine pivot plate latch.Genie part number Ford Models 52580 4 . Contact with hot engine components may result in severe burns. No adjustment is required. Beware of hot engine components. Ford LRG-425 EFI engines are equipped with a serpentine belt and incorporate a self adjusting belt tensioner. The machine will not operate properly with a loose or defective belt and continued use may cause component damage. 6 Install the engine pivot plate safety pin (if equipped). corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Avoid spilling or contacting battery acid. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Batteries contain acid. 2 Be sure that the battery cable connections are free of corrosion. Remove all rings. watches and other jewelry. Bodily injury hazard. 1 Open the engine side turntable cover. Failure to find and replace burnt.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Table B Procedures B-1 Check the Battery B-2 Inspect the Electrical Wiring Proper battery condition is essential to good engine performance and operational safety. Contact with hot or live circuits could result in death or serious injury. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. corroded and loose wires: · Engine wiring harness · Hydraulic manifold wiring Part No. 3 Be sure that the battery hold downs and cable connections are tight. Electrocution hazard. Electrocution hazard. 1 Put on protective clothing and eye wear.29 . Remove all rings. The battery is a maintenance free battery and does not require the replenishing of electrolyte. Contact with hot or live circuits could result in death or serious injury. 4 Inspect the following areas for burnt. chafed. Neutralize battery acid spills with baking soda and water. chafed. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. watches and other jewelry. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. chafed. chafed. Remove the key to secure from operation. and jib booms · Jib boom/Platform rotate manifold · Inside of the platform control box 11 Swing the engine back to its original position and close the engine pivot plate latch. chafed and pinched cables.e. corroded. Operating a machine with a damaged or leaking radiator may result in engine damage. B-3 Check the Radiator Ford Models Maintaining the radiator in good condition is essential for good engine performance.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES 5 Open the ground controls side turntable cover.30 Genie Z-45/25 & Genie Z-45/25J Part No. Burn hazard. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. corroded and loose wires: · Inside of the ground control box · Hydraulic manifold wiring 7 Start the engine from the ground controls and raise the boom above the turntable covers. Beware of hot engine parts and coolant. 6 Inspect the following areas for burnt.. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. 12 Install the engine pivot plate safety pin (if equipped). dirt or debris) will affect the performance of the cooling system. 9 Lower the boom to the stowed position and turn the engine off. Bodily injury hazard. Do not inspect while the engine is running. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems. Contact with hot engine parts and/or coolant may result in severe burns. 10 Inspect the following areas for burnt. 4 . pinched and loose wires: · Cable track on the primary boom · Cables on the primary. restricting air flow through the radiator (i. 8 Inspect the turntable area for burnt. 52709 . Also. 7 Install the engine pivot plate safety pin (if equipped).31 . 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine to access the exhaust system. 1 Ford models: Remove the safety pin (if equipped) from the engine pivot plate latch. 5 Inspect all radiator hoses and connections. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. Beware of hot engine components.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 6 Swing the engine back to its original position and close the engine pivot plate latch. i. Remove the key to secure from operation. Burn hazard. 4 Clean the radiator fins of debris and foreign materials. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Contact with hot engine components may result in severe burns. Do not inspect while the engine is running. 6 Ford models: Swing the engine back to its original position and close the engine pivot plate latch. 3 All models: Be sure that all nuts and bolts are tight. Bodily injury hazard. 7 Install the engine pivot plate safety pin (if equipped).e. Part No. carbon buildup around seams and joints. 4 Inspect all welds for cracks. 3 Inspect the radiator for leaks and physical damage. 8 Replace the air baffle and install the air baffle retaining fasteners. 5 Inspect for exhaust leaks. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . B-4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life.. Deutz Diesel Models Maintaining the oil cooler in good condition is essential for good engine performance. Oil Cooler 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Result: The needle on the gauge should be operating in the green area. 4 . 4 Inspect the filter condition indicator gauge. Burn hazard. Bodily injury hazard. then remove the cover. Remove the key to secure from operation. Beware of hot engine components. 52709 . The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. this indicates that the hydraulic filter is being bypassed and the filter should be replaced. The hydraulic filter condition indicator gauge is mounted to the hydraulic return filter on the engine side bulkhead. Contact with hot engine components may result in severe burns. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. If the filter is not frequently checked and replaced. Do not inspect while the engine is running.32 Genie Z-45/25 & Genie Z-45/25J Part No. 2 Start the engine from the platform controls. 1 Open the engine side turntable cover. If the needle is in the red area. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. impurities will remain in the hydraulic system and cause component damage. restricting air flow through the oil cooler will affect the performance of the cooling system. Also. 3 Move the engine RPM toggle switch to the maintained high idle position (rabbit symbol).Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-5 Check the Hydraulic Return Filter Condition Indicator Maintaining the hydraulic return filter in good condition is essential to good system performance and safe machine operation. 3 Remove the fasteners from the engine side cover. B-6 Check the Oil Cooler and Cooling Fins . Operating a machine with a damaged oil cooler may result in engine damage. dry Lug nut torque. cracks. Component damage may also result if problems are not discovered and repaired in a timely fashion. Tip-over hazard. Part No.5 Nm 94 ft-lbs 127. 11 Swing the engine back to its original position and close the engine pivot plate latch. Tire specifications Tire size Inflation pressure Tire ply rating (minimum) Wheel lugs. a b c oil cooler cylinder head cooling fins fan blower fins Bodily injury hazard. a b c B-7 Inspect the Tires and Wheels (including lug nut torque) Maintaining the tires and wheels in good condition is essential to safe operation and good performance. using a flashlight. 4WD Wheel lugs.5 LT Foam Filled 12 8 @ 5/8 -18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169. 3 Check each lug nut for proper torque. punctures and unusual wear.5 Nm 94 ft-lbs 127. Do not use temporary flat tire repair products. Cooling and Fan Blower Fins 6 Inspect the fan blower fins for physical damage.4 Nm 5 Clean the oil cooler of debris and foreign material.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 4 Inspect the oil cooler for leaks and physical damage. 7 Clean the fan blower fins of debris and foreign material. lubricated Industrial 9-14. 9 Clean the cylinder head cooling passages of debris and foreign material. 12 Install the engine pivot plate safety pin (if equipped).1 bar) 14 9 @ 5/8 -18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169. Tire and/or wheel failure could result in a machine tip-over.4 Nm Rough terrain 14-17. 8 Inspect the head cooling passages and fins for physical damage or foreign material. An overinflated tire can explode and could cause death or serious injury. 4 Check the pressure in each air-filled tire. bends and cracked welds. 2 Check each wheel for damage. 2WD Front Rear Lug nut torque.5 NHS 45 psi (3. 1 Check all tire treads and sidewalls for cuts. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .33 . 10 Install the engine side cover. 34 Genie Z-45/25 & Genie Z-45/25J Part No. 2 Remove the plug located at 90 degrees and check the oil level. Drive Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees. brake disengage position Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. 1 Check each drive hub disconnect cap to be sure it is in the engaged position. Result: The oil level should be even with the bottom of the plug hole. The free-wheel valve is located on the side of the drive pump. spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. brake engage position 2 Be sure the free-wheel valve on the drive pump is closed (clockwise).Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-8 Confirm the Proper Brake Configuration B-9 Check the Oil Level in the Drive Hubs Proper brake configuration is essential to safe operation and good machine performance. 4 . d a c b a b c d drive pump free-wheel valve lift pump screwdriver The free-wheel valve should always remain closed. 52709 . Hydrostatic brakes and hydraulically-released. Drive hub oil Capacity 17 fl oz 0. 1 Remove the safety pin (if equipped) from the engine pivot plate latch.35 . please contact Genie Industries Service Department OR your local Ford dealer.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 3 If necessary. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. 5 Repeat this procedure for each drive hub.Ford and Deutz Models Type: SAE 90 multipurpose hypoid gear oil . 4 Apply pipe thread sealant to the plug. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Part No.5 liters B-10 Check and Adjust the Engine RPM . and then install it in the drive hub. Ford Models: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. Ford Models Low idle High idle 1600 rpm 2500 rpm Deutz Diesel Models: This procedure will require two people. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .API service classification GL5 Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. If rpm adjustment or service is required. Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Be sure the solenoid fully retracts when activating high idle. 6 Loosen the yoke lock nut. then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. If high idle rpm is correct. disregard adjustment step 6. 4 . Result: Low idle should be 1400 rpm. then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the low idle lock nut and recheck the rpm. Deutz Diesel Models Low idle High idle 1400 rpm 2500 rpm f e a a b c d e f b c d solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 5 Move the function enable toggle switch to the high idle (rabbit symbol) position at the ground controls. 3 Connect an rpm gauge to the engine. 52709 .36 Genie Z-45/25 & Genie Z-45/25J Part No. and then start the engine from the ground controls. Result: High idle should be 2500 rpm. 4 Loosen the low idle lock nut. Skip to step 5 if the low idle rpm is correct. The engine will shut off after 2 to 3 seconds. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . As a safety feature. 2 Push down the Emergency Stop button to the OFF position. 2 Turn the key switch to ground control. Result: The engine should stop and no functions should operate. 4 Push down the Emergency Stop button to the OFF position. The ground Emergency Stop button will stop all machine operation. Deutz and Perkins Diesel models: All functions should stop immediately. Result: The machine functions should not operate. 6 Turn the key switch to the OFF position. An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions. selecting and operating the ground controls will override the platform controls. 5 Check any machine function from the platform controls. Deutz and Perkins Diesel models: All functions should stop immediately.37 . Result: The machine functions should not operate. Part No. The engine will shut off after 2 to 3 seconds. including the platform Emergency Stop button. Result: The engine should shut off and no machine functions should operate. B-12 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation. 3 Check any machine function from the ground controls. start the engine and then turn the key switch to platform control. resulting in a hazardous situation for ground and platform personnel. 1 Start the engine from the ground controls.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-11 Test the Key Switch Proper key switch action and response is essential to safe machine operation. 3 Start the engine from the platform controls. 4 Turn the key switch to ground control. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation. even if the key switch is switched to platform control. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Result: The engine should shut off and no machine functions should operate. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls. 52709 . Result: All boom functions should operate. If the directional valve linkage is not operating correctly. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the ON or OFF position. 1 Remove the drive chassis cover and the axle covers from the non-steer end of the drive chassis.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-13 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation. 4 . operate each boom function through a partial cycle. the stability of the machine is compromised and it may tip over. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position.38 Genie Z-45/25 & Genie Z-45/25J Part No. Proper axle oscillation is essential to safe machine operation. 3 At the ground controls. 1 Push in the platform Emergency Stop button to the OFF position. B-14 Check the Directional Valve Linkage Perform this test only on models equipped with a oscillating axle. 2 Start the engine from the ground controls. The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom. a b c d directional valve clevis pin with cotter pin (hidden) yoke lock nut Result: The platform should remain level at all times to within ±5 degrees. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 1 Start the engine from the ground controls and lower the boom into the stowed position. b c d 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 3 Raise and lower the primary boom through a full cycle. Part No.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 2 Locate the directional valve inside of the nonsteer axle and inspect the linkage for the following: · Lock nut is tight against yoke · Yoke clevis pins are installed · Cotter pins are installed through clevis pins · Linkage is properly attached to directional valve B-15 Test the Platform Self-leveling a Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation.39 . Check the machine functions. 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 4 Do not press down the foot switch. The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol. If necessary. 52709 . 2 Push down the horn button at the platform controls. Result: The engine should not start. The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel. Result: The horn should sound. An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions. 3 Do not press down the foot switch and attempt to start the engine.40 Genie Z-45/25 & Genie Z-45/25J Part No. the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn. The engine should not start if the foot switch is pressed down. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. and promptly stop when the foot switch is released. 2 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side. 4 . Result: The machine functions should operate. 5 Press down the foot switch and operate the machine functions. B-17 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation. Result: The engine should start. Machine functions should activate and operate smoothly as long as the foot switch is pressed down. Result: The machine functions should not operate.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-16 Test the Horn A functional horn is essential to safe machine operation. An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel. 6 Move the engine idle control switch to low idle (turtle symbol). Part No. 8 Press down the foot switch. Result: The engine should return to low idle. 4 Turn the key switch to platform controls. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 7 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). Do not press down the footswitch. This setting maintains a consistent high idle and is usually selected only when the generator option is being used. Foot switch activated high idle (rabbit and foot switch symbols) should be used for normal machine operation. Result: The engine should change to high idle. Result: The engine should change to high idle.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-18 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol) allows the operator to control individual boom functions only. Result: The engine should change to low idle.41 . High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions simultaneously. 3 Release the function enable toggle switch. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls. This selection activates high idle only when the foot switch is pressed down. Result: The engine should not change to high idle. Result: The engine should change to high idle. 5 At the platform controls. 2 Start the engine from the ground controls then move the function enable toggle switch to the high idle (rabbit symbol) position and hold in the ON position. move the engine idle control switch to high idle (rabbit symbol). Drive functions do not operate at low idle. 6 Restart the engine and allow it to run at low idle. 52709 . 5 Move the fuel select switch to LPG.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-19 Test the Fuel Select Operation Ford Models The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation. Switching malfunctions and/or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation. Perform this test after checking the gasoline and LPG fuel levels. Result: The engine should start promptly and operate smoothly in low and high idle. 7 Press down the foot switch to allow the engine to run at high idle. 3 Press down the foot switch to allow the engine to run at high idle. 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 4 Release the foot switch and shut the engine off by pushing the Emergency Stop button in to the OFF position. The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running. 4 . Result: The engine should start promptly and operate smoothly in low and high idle. A fuel selection can be made when the engine is running or not. and warming the engine to normal operating temperature.42 Genie Z-45/25 & Genie Z-45/25J Part No. 2 Start the engine from the platform controls and allow it to run at low idle. Part No. When the boom is past the non-steering wheels. 5 Rotate the turntable to the left until the boom is past the left non-steering wheel. 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center. 2 Rotate the turntable to the right until the boom is past the right non-steering wheel. 1 Start the engine from the platform controls. Always use the color-coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel. 6 Repeat steps 3 and 4.43 . 3 Slowly move the drive control handle off center. Result: The drive enable indicator light should come on. Collsion hazard. An improperly functioning drive enable system may allow the machine to be moved into an unsafe position.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-20 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation. drive movement is stopped and the indicator light turns on. Result: The drive function should operate. The drive enable switch must be to either side to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Result: The drive enable indicator light should turn on. Result: The drive function should not operate. contact patch of a tire. Select a test area that is firm.44 Genie Z-45/25 & Genie Z-45/25J Part No. free of hesitation.8 m The brakes must be able to hold the machine on any slope it is able to climb. level and free of obstructions. Collision hazard. then lower the boom into the stowed position.e. 2 Start the engine from the platform controls. 4WD 3 to 6 ft 0. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Release the drive joystick when your reference point on the machine crosses the test line.. 1 Mark a test line on the ground for reference. Braking: paved surface Stopping distance Proper brake action is essential to safe machine operation. i. 4 Choose a point on the machine. The drive brake function should operate smoothly. 4 . jerking and unusual noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to operate normally when they are actually not fully operational. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch). Refer to B-8 in this section. Confirm the Proper Brake Configuration.9 to 1.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-21 Test the Drive Brakes 5 Bring the machine to top drive speed before reaching the test line. 6 Measure the distance between the test line and your machine reference point. as a visual reference for use when crossing the test line. 52709 . Proper drive function movement is essential to safe machine operation. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch).2 m / 5. then lower the boom into the stowed position.2 m) apart. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-22 Test the Drive Speed Stowed Position 5 Bring the machine to top drive speed before reaching the start line. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .7 sec 12. i. 4 Choose a point on the machine. jerking and unusual noise over the entire proportionally controlled speed range. contact patch of a tire. as a visual reference for use when crossing the start and finish lines.. Drive performance should also be free of hesitation.45 . 2 Start the engine from the platform controls. Drive speed. Begin timing when your reference point on the machine crosses the start line.e. The drive function should respond quickly and smoothly to operator control. 6 Continue at full speed and note the time when the machine reference point crosses the finish line.7 sec Part No. level and free of obstructions. maximum stowed position All models 40 ft / 5. Select a test area that is firm. . 15 Continue at top speed and note the time when the machine reference point crosses the finish line. Standard Base Models 0. 9 Move the lift/drive select switch to the lift position (if equipped).2 m) apart. The drive function should respond quickly and smoothly to operator control. 14 Bring the machine to top drive speed before reaching the start line. 6 Choose a point on the machine.2 m/79 sec Proper drive function movement is essential to safe machine operation. 2 Start the engine from the platform controls. Select a test area that is firm. Begin timing when your reference point on the machine crosses the start line. i. 10 Press down the foot switch and lower the boom to the stowed position.2 m/45 sec 0. Drive speed. 52709 .46 Genie Z-45/25 & Genie Z-45/25J Part No. 3 Move the lift/drive select switch to the lift position (if equipped).Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-23 Test the Drive Speed Raised or Extended Position 8 Continue at full speed and note the time when the machine reference point crosses the finish line. boom raised or extended. i. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.58 km/h 40 ft/79 sec 12. contact patch of a tire. 12 Move the lift/drive select switch to the drive position (if equipped). boom raised or extended. as a visual reference for use when crossing the start and finish lines. contact patch of a tire. as a visual reference for use when crossing the start and finish lines. Narrow Base Models 4 . jerking and unusual noise over the entire proportionally controlled speed range. 13 Choose a point on the machine. Drive speed.. 4 Move the engine idle select switch to foot switch activated high idle (rabbit and foot switch).36 mph 0. Drive performance should also be free of hesitation.e.e. 5 Move the lift/drive select switch to the drive position (if equipped).6 mph 1 km/h 40 ft/45 sec 12. 7 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. Press down the foot switch and raise the boom above horizontal. 11 Extend the boom 1 foot (30 cm). level and free of obstructions. Move the drive control handle off center. 6 Press down the foot switch. hold for a moment and then release it. 2 Move the function enable switch to either side and activate the primary boom toggle switch in the DOWN position. Move the secondary boom control handle to the DOWN position. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Result: The descent alarm should sound when the switch is held down. Move the primary boom control handle to the DOWN position. 4 Turn the key switch to platform control. The alarms and beacon will operate with the engine running or not running. hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. Result: The descent alarm should sound when the switch is held down. Move the drive control handle off center in the opposite direction. hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 7 Press down the foot switch. Part No. Result: The travel alarm should sound when the drive control handle is moved off center in either direction. hold for a moment and then release it. The alarm package is installed on the turntable covers. hold for a moment and then release it.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-24 Test the Alarm Package Optional Equipment The alarm package includes: · Travel alarm · Descent alarm · Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion.47 . 3 Move the function enable switch to either side and activate the secondary boom toggle switch in the DOWN position. hold for a moment and then release it. Result: The flashing beacon should be ON and flashing. Result: The flashing beacon should be ON and flashing. 5 Press down the foot switch. Perform this procedure with the engine off. Perform this procedure more often if dusty conditions exist. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. 4 . Contact with hot oil may result in severe burns.48 Genie Z-45/25 & Genie Z-45/25J Part No. 5 Start the engine from the ground controls. Genie requires that this procedure be performed quarterly or every 250 hours. 6 Inspect the filter and related components to be sure that there are no leaks.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES B-25 Perform Hydraulic Oil Analysis B-26 Replace the Hydraulic Tank Return Filter See E-1. 52709 . whichever comes first. 3 Apply a thin layer of oil to the new oil filter gasket. Burn hazard. Replacement of the hydraulic tank filter is essential for good machine performance and service life. Beware of hot oil. Extremely dirty conditions may require that the filter be replaced more often. 2 Remove the filter with an oil filter wrench. Test or Replace the Hydraulic Oil. 1 Open the engine side turntable cover and locate the hydraulic return filter on the bulkhead. 4 Install the new filter (Genie part number 65540) and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. 7 Install the bowl onto the new filter element (Genie part number 22942). Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Always have an approved fire extinguisher within easy reach. Install the filter/bowl assembly onto the filter head. Extremely dirty conditions may require that the filter be replaced more often. Engine fuels are combustible. wellventilated area away from heaters. Loosen the drain plug located at the bottom of the bowl.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-27 Replace the Fuel Filter/ Water Separator Element Perkins Diesel Models 3 Loosen the vent plug located on the fuel filter/ water separator head. Perform this procedure with the engine off. Explosion and fire hazard. 8 Apply a thin layer of oil onto the element gasket.49 . Perform this procedure in an open. 2 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter/water separator. Tighten the drain plug. 6 Rotate the filter element counterclockwise and remove it from the filter head. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. 10 Tighten the vent plug. sparks. 5 Rotate the filter bowl counterclockwise and remove it from the element. Completely drain the fuel. 1 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. d c Fuel a b c d e f filter/water separator vent plug main fuel line drain plug filter bowl filter element separator head 4 Place a suitable container under the filter bowl. a f e b Replacing the diesel fuel filter/water separator element is essential for good engine performance and service life. flames and lighted tobacco. 4 . check for air in the fuel system. 16 Operate the starter motor for intervals of 15 seconds until the engine starts. If the engine runs correctly for a short time and then stops or runs roughly. Bleed the system: 13 Loosen the vent plug on top of the fuel injection pump. free from air. a c b a b c vent plug fuel injection pump fuel lift pump 14 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel. there is probably a leak in the low pressure side of the system. Tighten the clamp.50 Genie Z-45/25 & Genie Z-45/25J Part No. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. 15 Clean up any fuel that may have spilled during this procedure.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES 11 Clean up any diesel fuel that may have spilled during the installation procedure. 52709 . If there is air in the fuel system. 12 Install the fuel supply hose from the fuel tank to the fuel filter/water separator. comes from the vent plug. 3 Thoroughly clean the outside surfaces of the fuel filter assembly. Extremely dirty conditions may required that the filter be replaced more often. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. a b c a b c fuel line filter head fuel filter element Part No. Engine fuels are combustible. Perform this procedure in an open. 8 Install the new fuel filter element (Genie part number 65542) and tighten it securely by hand. Clean up any fuel that may have spilled during the installation procedure. 6 Remove the fuel filter element with a filter wrench. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. sparks. Replacing the diesel fuel filter element is essential for good engine performance and service life. Explosion and fire hazard. wellventilated area away from heaters. 4 Place a suitable container under the fuel filter element. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .51 . flames and lighted tobacco. 1 Remove the safety pin from the engine pivot plate latch. 7 Apply a thin layer of fuel to the new fuel filter element o-ring. 5 Disconnect and plug the fuel line from the fuel pump to the fuel filter element.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-28 Replace the Fuel Filter Element Perkins Diesel Models 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Do not pull on the plug wire. 11 Clean up any fuel that may have spilled during this procedure. then disconnect the plug wires from the spark plugs by grasping the handle on the spark plug boot. Periodic replacement of the spark plugs is essential to good engine performance and service life. comes from the vent plug.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES Bleed the system: 9 Loosen the vent plug on top of the fuel injection pump. 12 Operate the starter motor for intervals of 15 seconds until the engine starts. Worn. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 52709 . free from air. loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage. 4 . check for air in the fuel system. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. 3 Label. B-29 Replace the Spark Plugs Ford Models a c b Engine specifications requires that this procedure be performed every 400 hours. a b c vent plug fuel injection pump fuel lift pump Perform this procedure with the engine off. If there is air in the fuel system.52 Genie Z-45/25 & Genie Z-45/25J Part No. If the engine runs correctly for a short time and then stops or runs roughly. 10 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel. there is probably a leak in the low pressure side of the system. Part No. Perform this procedure with the engine off. 10 Install the engine pivot plate safety pin (if equipped). 9 Swing the engine back to its original position and close the engine pivot plate latch. 5 Remove all the spark plugs from the engine. Be sure that each spark plug wire is attached to the correct spark plug.18 mm B-30 Replace the Engine Air Filter Element Engine specifications requires that this procedure be performed every 400 hours or annually. 7 Install the new spark plugs and torque to specifications. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . All Models: Spark plug torque 5 to 10 ft-lbs 7 to 14 Nm 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Spark plug specifications Spark plug type Spark plug gap Motorcraft AWSF-52C 0. 8 Connect the wires.53 . 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. whichever comes first.042 to 0. 3 Open the engine side cover and remove the retaining ring from the end cap of the air filter canister. Perform this procedure more often if dusty conditions exist.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 4 Blow out any debris around spark plugs. Failure to perform this procedure can lead to poor engine performance and component damage. Maintaining the engine air filter in good condition is essential to good engine performance and service life.07 to 1. 6 Adjust the gap on each new spark plug. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.046 inch 1. Install and tighten the retaining ring. 6 Clean the inside of the canister and the gasket with a damp cloth. 10 Install the engine pivot plate safety pin (if equipped). 8 Install the end cap onto the canister. 9 Swing the engine back to its original position and close the engine pivot plate latch. 52709 .54 Genie Z-45/25 & Genie Z-45/25J Part No. Remove the filter element. 7 Install the new air filter element and install the mounting fastener. Air filters . 5 Remove the air filter retaining fastener.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE B PROCEDURES 4 Remove the end cap from the air cleaner canister.Genie part numbers All Models 27916 4 . 1 Remove the safety pin (if equipped) from the engine pivot plate latch . 10 Swing the engine back to its original position and close the engine pivot plate latch. Maintaining the engine belt is essential to good engine performance and service life. 7 Check the engine belt for proper tension. The machine will not operate properly with a loose or defective belt and continued use may cause component damage. 11 Install the engine pivot plate safety pin (if equipped). Burn hazard. Contact with hot engine components may result in severe burns. · Breaks 6 Replace belt if any damage is found. Deutz Diesel engine 8 Install the front engine access cover. 9 Replace the air baffle and install the air baffle retaining fasteners. Do not inspect while the engine is running. 5 Inspect the engine belt for: · Cracking · Glazing · Separation Engine specifications require that this procedure be performed every 500 hours.5 mm to 12 mm 32698 Engine belt . Belt deflection 3 /8 inch to 1/2 inch 9. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.Genie part number Part No. Adjust as necessary.55 . 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Beware of hot engine components. Remove the air baffle. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Table C Procedures C-1 Check the Engine Belt Deutz Diesel Models 4 Remove the front engine access cover mounting fasteners. Remove the key to secure from operation. 3 Remove the air baffle retaining fasteners. Bodily injury hazard. Burn hazard. Periodic replacement of the engine oil and filter is essential to good engine performance. a c b a b c engine oil level dipstick fuel filter/water separator oil filter 9 Apply a thin layer of oil to the new oil filter gasket (Genie part number 49924). 5 Remove the plug from the drain hose and allow all of the oil from the engine to drain into a suitable container. Engine specifications require that this procedure be performed every 500 hours. 3 Remove the oil filler cap located above the dipstick.Deutz Diesel Models 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 6 Install the plug on the oil drain hose. 8 Use an oil filter wrench and remove the oil filter. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 7 Place a pan under the oil filter. Beware of hot engine parts and oil. Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components. Contact with hot engine oil and/or engine parts may result in severe burns. Perform this procedure after warming the engine to normal operating temperature. 4 .56 Genie Z-45/25 & Genie Z-45/25J Part No. See capacity specifications.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE C PROCEDURES C-2 Replace the Engine Oil and Filter . Perform this procedure more often if dusty conditions exist or if the machine is operated in hot climates. A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter. 4 Pull the end of the oil drain hose out from under the engine. Install the filter and tighten it securely by hand. 52709 . 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 13 Check the oil filter and oil drain hose for leaks. Deutz part number 0297 7343 (Genie part number 52883). Complete information to perform this procedure is available in the Deutz F3L 1011F Operation Manual.3 quarts 6 liters C-3 Check the Engine Valve Clearances Deutz Diesel Models Engine specifications require that this procedure be performed initially at 500 hours. Deutz Engine F3L 1011F Oil capacity (including filter) Oil viscosity requirements Temperature below 60°F / 15.5°C (synthetic) -10°F to 90°F / -23°C to 32°C Temperature above -4°F / -34°C 5W-30 10W-40 15W-40 6. Add oil if needed. CD/SE. 12 Start the engine from the ground controls.57 . Allow the engine to run for 30 seconds then turn the engine off. CC/SF or CD/SF grades.Genie part number 49924 Part No. at 1000 hours and every 1000 hours thereafter.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE C PROCEDURES 11 Fill the engine with new oil per specifications and install the oil filler cap. Units shipped with 10-40 CC/SG Oil filter . Engine oil should have properties of API classification CC/SE. 14 Check the engine oil level dipstick. Beware of hot engine parts and coolant. Engine specifications require that this procedure be performed every 500 hours or 6 months. Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage. Allow any pressure to dissipate gradually before removing the radiator cap. Bodily injury hazard. 4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container. 10 Fill the radiator with the proper coolant mixture (coolant and water) for your climate until it is full. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. Perform this procedure with the engine off and cooled. whichever comes first. 11 Fill the coolant return tank to the NORMAL range. 4 . The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 9 Replace all coolant hoses and clamps.58 Genie Z-45/25 & Genie Z-45/25J Part No. close the drain valve. 6 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container. 8 Open the drain valve on the engine block and allow the coolant to drain into a suitable container. 52709 . Contact with hot engine parts and/or coolant may result in severe burns. Replacing or reconditioning the engine coolant is essential to good engine performance and service life. 3 Put on protective clothing and eye wear. Burn hazard. 7 After all the coolant has drained. After the fluid is drained.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE C PROCEDURES C-4 Change or Recondition the Engine Coolant Liquid Cooled Models 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. close the drain valve and connect the coolant return hose to the radiator. 5 Slowly remove the radiator cap from the radiator. Extremely dirty conditions may require coolant to be changed more frequently. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Add coolant if needed. 18 Turn the engine off.9 liters 6 liters Part No. Turn the engine off and inspect for leaks.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE C PROCEDURES 12 Clean up any coolant that may have spilled during this procedure. 16 Install the engine pivot plate safety pin (if equipped). 11. 14 Check the coolant level in the coolant return tank. 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature. 19 Check the coolant level in the coolant return tank. Complete information to perform this procedure is available in the Perkins Workshop Manual. Coolant capacity Ford Gasoline/LPG Engine Perkins 104-22 Engine C-5 Check the Engine Valve Clearances Perkins Diesel Models Engine specifications require that this procedure be performed every 600 hours. Add coolant if needed. Perkins part number TPD 1378 (Genie part number 72352).59 . 15 Swing the engine back to its original position and close the engine pivot plate latch. Allow the engine to cool.5 quarts 6.3 quarts 10. 13 Start the engine from the ground controls and let it run for 30 seconds. tubes and fittings. Engine specifications require that this procedure be performed every 800 hours.Genie part number 33957 4 .60 Genie Z-45/25 & Genie Z-45/25J Part No. a b a b PCV valve PCV valve hose 5 Remove the PCV valve from the engine. Discard the valve.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE C PROCEDURES C-6 Replace the PCV Valve Ford Models 4 Locate the PCV valve on the engine under the intake manifold. Replacement of the PCV valve is essential to good engine performance. PCV Valve . 2 Remove the safety pin (if equipped) from the engine pivot plate latch. Perform this procedure with the engine off. 1 Open the engine side turntable cover. 7 Install the new PCV valve and connect the hose. 9 Install the engine pivot plate safety pin (if equipped). Detach the hose from the PCV valve. 52709 . A malfunctioning PCV valve can impair crankcase ventilation and may cause engine damage. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 8 Swing the engine back to its original position and close the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 6 Thoroughly clean the inside and outside of the hose. 3 Measure each wear pad. then extend the boom 1 foot (30 cm). How to Shim the Primary Boom.3 mm Part No. shim as necessary to obtain zero clearance and zero drag.61 . If the wear pads are not worn below specification but are still within tolerence. 1 Start the engine from the ground controls. Replace the wear pad if it is less than 9/16 inch. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . Wear pads are placed on boom tube surfaces to provide a low friction. Always maintain squareness between the outer and inner boom tubes. Wear pad specifications All wear pads 9/16 inch 14. see Repair Procedure 4-2. If the wear pad is not less than 9/16 inch. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures Table D Procedures D-1 Check the Boom Wear Pads 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom. replaceable wear pad between moving parts. 2 Raise the end of the primary boom to a comfortable working height (chest high). Maintaining the boom wear pads in good condition is essential to safe machine operation. Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE D PROCEDURES D-2 Check the Turntable Rotation Bearing Bolts 5 Be sure that each turntable mounting bolt is torqued in sequence to 210 ft-lbs (285 Nm). Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the secondary boom and place safety chocks on the lift cylinders rods. Carefully lower the boom onto the lift cylinders safety chocks. Crushing hazard. Keep hands away from cylinders and all moving parts when lowering the boom. The lift cylinder safety chock is available through (Genie part number 33484). 2 Turn the engine off. 3 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 4 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Bolt torque sequence 6 Start the engine form the ground controls. 7 Rais the secondary boom and remove the safety chocks. 8 Lower the boom to the stowed position. 9 Remove drive chassis covers from both the steer end and the non-steer end of the machine. 10 Remove the lower chassis cover mounting fasteners from inside of the drive chassis. 4 - 62 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE D PROCEDURES 11 Remove the lower chassis cover to access the lower turntable bearing bolts under the drive chassis. 12 Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to 210 ft-lbs (285 Nm). D-3 Check the Free-wheel Configuration Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage. Collision hazard. Select a work site that is firm and level. Component damage hazard. If the machine must be towed, do not exceed 2 mph (3.2 km/h). Bolt torque sequence Non-Steer Wheels: All Models 1 Chock the steer wheels to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (20,000 lbs/10,000 kg) under the drive chassis between the non-steer tires. 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 - 63 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE D PROCEDURES 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub. disengage position Steer Wheels: 4WD Models 7 Chock the non-steer wheels to prevent the machine from rolling. 8 Center a lifting jack of ample capacity (20,000 lbs/10,000 kg) under the drive chassis between the steer tires. engage position 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub. disengage position 5 Manually rotate each non-steering wheel. Result: Each non-steering wheel should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the jack stands. Collision hazard. Failure to re-engage the drive hubs may cause death or serious injury and property damage. engage position 11 Manually rotate each steer wheel. Result: Each steer wheel should rotate with minimum effort. 4 - 64 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE D PROCEDURES 12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Raise the machine and remove the jack stands. Collision hazard. Failure to re-engage the drive hubs may cause death or serious injury and property damage. All Models: 13 Be sure the free-wheel valve on the drive pump is closed (clockwise). The free-wheel valve is located on the side of the drive pump. D-4 Grease the Turntable Rotation Bearing and Rotate Gear Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Locate the grease fitting on the front turntable cover. d c a b a b c d drive pump free-wheel valve lift pump screwdriver a b c The free-wheel valve should always remain closed. a b c turntable bearing grease fitting front turntable cover power to platform plug 2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches (10 to 13 cm) at a time and repeat this step until the entire bearing has been greased. 3 Apply grease to each tooth of the drive gear, located under the turntable. Grease type Multipurpose grease Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 - 65 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE D PROCEDURES D-5 Replace the Drive Hub Oil 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole. Apply pipe thread sealant to the plugs, and then install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs. Oil capacity per hub 17 fl oz 0.5 liters Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. Drive Hubs: 1 Select the drive hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil. 3 Drive the machine until one plug is at the top and the other is at 90 degrees. Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 4 - 66 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE D PROCEDURES D-6 Replace the Drive Loop Hydraulic Filter 3 Remove the filter element from the housing. 4 Inspect the housing seal and replace it if necessary. 5 Install the new filter (Genie part number 20880) and tighten the housing onto the filter securly head by hand. Clean up any oil that may have spilled during the installation procedure. 6 Start the engine from the ground controls. 7 Inspect the filter assembly to be sure that there are no leaks. 8 Clean up any oil that may have spilled during the installation procedure. Replacing the drive loop hydraulic filter is essential to good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted near the pump. 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 - 67 Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE D PROCEDURES D-7 Check and Adjust the Air/LPG Mixture - Ford Models 4 Load the system by activating the primary boom retract function, then move the function enable toggle switch to the high idle (rabbit symbol) position. 5 Adjust the high idle adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1, using an exhaust gas analyzer. Maintaining the proper air-to-fuel mixture during LPG operation is essential to good engine performance. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. The engine should be warmed to normal operating temperature before performing this procedure. 1 Move the fuel select toggle switch to LPG fuel and start the engine from the ground controls. 2 Locate the high idle mixture adjustment screw on the throttle body elbow that attaches to the air cleaner. 3 Loosen the lock nut on the high idle mixture adjustment screw. Preliminary setting is 1/4 inch (6.4mm) of threads showing. Measure from top of lock nut to top of adjustment screw. If an exhaust gas analyzer is not available, adjust to obtain peak or optimum rpm. 6 Hold the adjustment screw and tighten the lock nut. 7 Return the function enable toggle switch to the center position. 8 Locate the low idle mixture adjustment screw on the LPG regulator. 9 Adjust the low idle mixture adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1. Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw counterclockwise 2 3/4 turns. 4 - 68 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE D PROCEDURES D-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 At the fuel pump, disconnect and plug the fuel hose that goes to the fuel tank. 4 Remove the fuel filter with a filter wrench. Replacing the diesel fuel filter/water separator is essential to good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Replace the fuel filter in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. a b a b oil filter fuel filter/water separator Prime the Fuel Pump: 5 Fill the new filter (Genie part number 65541) with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filter gasket. 6 Install the new filter and tighten it securely by hand. Clean up any diesel fuel that might have spilled during the procedure. 7 Connect the fuel hose from the tank to the fuel pump. 8 Start the engine from the ground controls, then inspect the fuel filter for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 4 - 69 disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. 6 Completely drain the tank into a suitable container. 1 Ford models: Turn the valve on the LPG tank clockwise to the OFF position. Replace the oil when it fails the test. 5 Remove the drain plug from the hydraulic tank. If the hydraulic oil is not replaced at the two year inspection. The machine uses Dexron equivalent hydraulic oil. 7 Tag. 2 Ford models: Open the clamps from the LPG tank straps and remove the LPG tank from the machine. See capacity specifications. Then slowly disconnect the hose from the LPG tank. Before replacing the hydraulic oil. 4 Place a suitable container underneath the hydraulic tank. 4 .Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing Table E Procedures E-1 Test or Replace the Hydraulic Oil 3 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. 52709 . the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. Close the valves. Extremely dirty conditions may require oil changes to be performed more often.70 Genie Z-45/25 & Genie Z-45/25J Part No. open closed Component damage hazard. test the oil quarterly. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. 8 Disconnect and plug the return filter hydraulic hose at the hydraulic tank. Perform this procedure with the boom in the stowed position. Cap the fitting on the tank. remove the key from the key switch and tag the machine to inform personnel of the condition. If the tank valves are closed. 19 Install the two suction hoses to the suction strainers. The hydraulic tank may become unbalanced and fall if it is not properly supported by the lifting device. Do not overfill. 17 Install the drain plug using a thread sealant on the threads. 12 Remove the hydraulic tank mounting fasteners. 18 Install the hydraulic tank onto the machine. 21 Fill the tank with hydraulic oil until the level is within the top 2 inches (5 cm) of the sight gauge. Cap the fitting on the hydraulic tank. 10 Remove the ground controls side turntable cover. 16 Install the suction strainers using a thread sealant on the threads. 14 Remove the suction strainers from the tank and clean them using a mild solvent. 20 Install the supply hose for the auxiliary power unit and the return filter hose. Crushing hazard.71 . See Repair Procedure 6-1. 11 Support the hydraulic tank with an appropriate lifting device. Part No. 13 Remove the hydraulic tank from the machine. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE E PROCEDURES 9 Disconnect and plug the supply hose for the auxiliary power unit through the access hole underneath the turntable. How to Remove a Turntable Cover. 22 Clean up any oil that may have spilled and open the hydraulic tank valves. 15 Rinse out the inside of the tank using a mild solvent. Hydraulic system Hydraulic tank capacity 24 gallons 91 liters 30 gallons 114 liters Dexron equivalent E-2 Change or Recondition the Engine Coolant Ford Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. If the tank valves are closed. 1 Put on protective clothing and eye wear. Burn hazard. Beware of hot engine parts and coolant. Be sure that the hydraulic tank shutoff valves are in the OPEN position before priming the pump.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE E PROCEDURES 23 Prime the pump. See Repair Procedure 11-2. Perform this procedure with the engine off and cooled. How to Prime the Pump. Extremely dirty conditions may require coolant to be changed more frequently. Contact with hot engine parts and/or coolant may result in severe burns. Always use pipe thread sealant when installing the suction hose fittings and the drain plug. Use only Dexron equivalent hydraulic fluid. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. 52709 . remove the key from the key switch and tag the machine to inform personnel of the condition. Component damage hazard.72 Genie Z-45/25 & Genie Z-45/25J Part No. Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. Hydraulic system capacity (including tank) Hydraulic fluid 4 . close the drain valve. 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature. 6 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container. 8 Open the drain valve on the engine block and allow the coolant to drain into a container. 18 Turn the engine off. 11 Fill the radiator and then fill the coolant return tank to the NORMAL range.73 . Connect the coolant return hose to the radiator. Add water if needed. After the fluid is drained. 9 Replace all coolant hoses and clamps. close the drain valve. run it for 30 seconds. and then turn it off. 15 Start the engine from the ground controls. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 7 After all the coolant has drained. 12 Clean up any coolant spilled during this procedure. 5 Slowly remove the radiator cap from the radiator. 16 Inspect for leaks and then check the fluid level in the coolant return tank. 14 Install the engine pivot plate safety pin (if equipped). Coolant capacity 11.5 quarts 10. 10 Pour the proper coolant mixture (anti-freeze and water) for your climate into the radiator until it is full. Bodily injury hazard. 19 Allow engine to cool and check the fluid level in the coolant retrun tank. Allow any pressure to dissipate gradually before removing the radiator cap. 13 Swing the engine back to its original position and close the engine pivot plate latch.9 liters Part No.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE E PROCEDURES 4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container. Add water if needed. 52709 . Replace the fuel hoses in an open. cracked or leaking fuel hose may cause an unsafe operating condition. Failure to detect a worn. sparks. disconnect the fuel hose to the fuel tank and drain the fuel tank into the container. Explosion and fire hazard. Engine fuels are combustible. flames and lighted tobacco. 4 Ford Models: At the pre-filter. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance.74 Genie Z-45/25 & Genie Z-45/25J Part No. a b c e d a b c d e hose from fuel pump to regulator/filter hose from fuel pre-filter to fuel pump hose from fuel tank to fuel pre-filter hose from regulator/filter to engine hose from regulator/filter to tank 4 . Be sure the fuel hoses are routed the same way the original hoses were. Component damage hazard. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off and the key switch in the OFF position. 3 Place a suitable container underneath the engine pivot plate.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE E PROCEDURES E-3 Change the Fuel Hoses 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. wellventilated area away from heaters. disconnect the fuel hose to the fuel tank and drain the fuel tank into the container. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them.75 . Fuel Injection systems operate at a very high pressure.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE E PROCEDURES Deutz Diesel Models: At the fuel pump. Fuel may be expelled under pressure if the hoses are removed too quickly. a b b b b b b b f e d c Deutz Diesel models a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors Part No. 5 Remove and replace all of the fuel line hoses and clamps according to the following illustrations: Explosion and fire hazard. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . keep any additional personnel from entering the area and do not operate the machine. If a fuel leak is discovered.76 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 . Explosion and fire hazard. 9 Start the engine from the ground controls. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them. Fuel may be expelled under pressure if the hoses are removed too quickly. 6 Clean up any fuel that may have spilled during this procedure. 8 Install the engine pivot plate safety pin (if equipped). a b c e d Ford models a high pressure hose from fuel pump to regulator/filter b hose from fuel pre-filter to fuel pump c hose from fuel tank to fuel pre-filter d high pressure hose from regulator/ filter to engine e hose from regulator/filter to tank 4 . Repair the leak immediately.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE E PROCEDURES Explosion and fire hazard. 7 Swing the engine back to its original position and close the engine pivot plate latch. then inspect the fuel filter and hoses for leaks. Electronic Fuel Injection (EFI) systems operate at a very high pressure. E-6 Check the Engine Cylinder Compression .5 Liter Industrial Engine Service Manual Ford number: FPP-194-303. 52709 Genie Z-45/25 & Genie Z-45/25J 4 .Ford Models E-8 Replace the Timing Belt Ford Models Complete information to perform this procedure is available in the Ford LRG-425 EFI 2. Complete information to perform this procedure is available in the Ford LRG-425 EFI 2. (Genie part number 52695).77 . Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz part number: 0297 7195. Part No. (Genie part number 52695). (Genie part number 52229). (Genie part number 52695).Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Operation Manual Deutz part number: 0297 4706 EN. E-5 Check the Engine Valve Clearance .First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE E PROCEDURES E-4 Check the Toothed Belt Deutz Diesel Models E-7 Check the Fuel Injection Pump and Injectors .5 Liter Industrial Engine Service Manual Ford part number: FPP-194-303.Ford Models Complete information to perform this procedure is available in the Ford LRG-425 EFI 2.5 Liter Industrial Engine Service Manual Ford number: FPP-194-303. (Genie part number 29790). The washer and outer bearing should fall loose from the hub. 12 Pull the hub off of the spindle. Result: If there is side to side or up and down movement. then remove the tire and wheel assembly. 11 Remove the castle nut. Result: There should be no side to side or up and down movement. 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. 1 Loosen the wheel lug nuts. 4 . including the pressed-in races. Maintaining the steer axle wheel bearings is essential for safe machine operation and service life.78 Genie Z-45/25 & Genie Z-45/25J Part No. then up and down. 7 Tighten the castle nut to 35 ft-lbs (47 Nm) to seat the bearings. continue with step 11 and grease the wheel bearings. 3 Raise the machine 6 inches (15 cm) and place blocks under the drive chassis for support. Do not remove them. then re-tighten to 8 ft-lbs (11 Nm). 10 Remove the dust cap from the hub. both the inner and outer bearings. 6 Remove the dust cap from the hub. then remove the cotter pin from the castle nut. Remove the rear bearing. 9 Check for wheel bearing wear by attempting to move the wheel hub side to side.Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing TABLE E PROCEDURES E-9 Grease the Steer Axle Wheel Bearings. then center a lifting jack under the steer axle. then remove the cotter pin from the castle nut. 4 Remove the lug nuts. continue to step 11 and replace the wheel bearings with new ones. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side. must be replaced. 2WD Models Skip to step 10 if there is no movement. 52709 . Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often. When replacing a wheel bearing. then up and down. 2 Block the non-steering wheels. Result: If there is no side to side or up and down movement. 8 Loosen the castle nut. fresh grease. Always replace the bearing grease seal when removing the hub. 23 Install the dust cap. 18 Place the outer bearing into the hub. 21 Loosen the castle nut. 52709 Genie Z-45/25 & Genie Z-45/25J 4 . 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush. Do not apply excessive force or damage to the lip of the seal may occur. Torque the wheel lug nuts to 125 ft-lbs (169.5 Nm).79 . then re-tighten to 8 ft-lbs (11 Nm). Component damage hazard. 20 Tighten the slotted nut to 35 ft-lbs (47 Nm) to seat the bearings. then the tire and wheel assembly. Part No. 22 Install a new cotter pin. 19 Install the washer and castle nut. 15 Place the large inner bearing into the rear of the hub.First Edition • Second Printing Section 4 • Scheduled Maintenance Procedures TABLE E PROCEDURES 14 Pack both bearings with clean. Bend the cotter pin to lock it in. 17 Slide the hub onto the yoke spindle. 80 Genie Z-45/25 & Genie Z-45/25J Part No. 4 .Section 4 • Scheduled Maintenance Procedures First Edition • Second Printing This page intentionally left blank. 52709 . Bodily injury hazard. perform each repair procedure with the machine in the following configuration: · Machine parked on a flat level surface · Boom in stowed position · 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 Be sure that all necessary tools and test equipment are available and ready for use. watches and other jewelry. Two persons will be required to safely perform some troubleshooting procedures. Crushing hazard. Read each appropiate flow chart thoroughly. When testing or replacing any hydraulic component. always support the structure and secure it from movement. Perform all troubleshooting on a firm level surface. Immediately tag and remove from service a damaged or malfunctioning machine.First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting: Read. Contact with electrically charged circuits may result in death or serious injury. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Be aware of the following hazards and follow generally accepted safe workshop practices. Repair any machine damage or malfunction before operating the machine. understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 and Genie Z-45/25J Operator’s Manual. Spraying hydraulic oil can penetrate and burn skin. Electrocution hazard. Unless otherwise specified. Attempting shortcuts may produce hazardous conditions. Do not allow oil to squirt or spray. 52709 Genie Z-45/25 & Genie Z-45/25J 5-1 . Part No. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Remove all rings. 52709 . pressure gauges. When a sensor fails or returns signals that are outside of set parameters. the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. ohmmeter. Use the Fault Code Chart on the following pages to aid in identifying the fault. To use this section. selecting the appropriate flow chart may be troublesome. See Repair Section. General Repair Process Malfunction discovered Identify symptoms Troubleshoot problem still exists Return to service problem solved Inspect and test Perform repair Fault codes The ECM constantly monitors the engine by the use of sensors on the engine. The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6. When a function will not operate with the same speed or power as a machine in good working condition. the flow charts in this section will help a service professional pinpoint the cause of the problem. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing.Section 5 • Troubleshooting Flow Charts First Edition • Second Printing TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered. 5-2 Genie Z-45/25 & Genie Z-45/25J Part No. refer to the flow chart which most closely describes the problem. How to Retrieve Engine Fault Codes. fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. Schematics. Since various degrees of a particular function loss may occur. basic hand tools and certain pieces of test equipment are required—voltmeter. 12 Throttle Position (TP) sensor low voltage. 14 21 22 Throttle Position (TP) sensor high voltage. Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor. Manifold Absolute Pressure (MAP) sensor low voltage. Check for obstructions in the throttle body that could cause binding of the throttle assembly OR replace ECM. Voltage to fuel pump is greater than or equal to 2V DC below ignition voltage. Check for poor terminal Faulty TP sensor OR sensor connections or shorted wires wires shorted shorted to ground from the TP sensor to the ECM or poor terminal connection. Test the fuel pump relay. Part No. OR replace the TP sensor. Check for water in the fuel. misfiring cylinder or pugged fuel filter OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor. The ECM senses a signal from the TP sensor that is greater than 4. 24 Manifold Absolute Pressure (MAP) sensor high voltage. plugged fuel filter OR the HO2 sensor wiring is shorted to ground OR there is a poor terminal connection OR the HO2 sensor is bad. Obstruction in throttle body OR faulty ECM. Check for poor terminal connections OR wires shorted to ground OR replace MAP sensor.First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Fault Codes Fault Code 11 Problem -- Cause -- Solution Normal operation. misfiring cylinder. see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the fuel pump. 32 Heated Oxygen (HO2) sensor low voltage. Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor. Engine speed exceeded 4000 RPM. Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is bad 33 Engine Coolant Temperature (ECT) sensor high voltage. Faulty MAP sensor OR sensor wires shorted to ground or poor terminal connection. 52709 Genie Z-45/25 & Genie Z-45/25J 5-3 . Water in the fuel. Check for poor terminal Faulty MAP sensor OR sensor connections or shorted wires wires shorted to ground or poor from the MAP sensor to the terminal connection.9V DC OR the TP sensor wiring is shorted to ground OR there is a poor terminal connection OR the TP sensor is bad. ECM to ground OR replace MAP sensor. 31 Fuel pump low voltage. Check engine oil level OR check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch. 5-4 Genie Z-45/25 & Genie Z-45/25J Part No. Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor. sensor. 35 Intake Air Temperature (IAT) sensor high voltage. 52709 . Test the fuel pump relay.93V DC for at least 3 seconds. 45 Intake Air Temperature (IAT) sensor low voltage. The IAT sensor shares the same ground wire as the ECT and MAP sensors. Test for a leaking or A leaking or malfunctioning fuel malfunctioning fuel injector. misfiring cylinder. wires shorted to ground or not enough engine oil. 42 Heated Oxygen (HO2) sensor high voltage. Remove HO2 sensor and from fuel OR use of improper check condition of sensor for thread sealant on sensor contamination OR check for poor threads OR sensor wires terminal connections or shorted shorted to ground or poor wires from the HO2 sensor to the 2 terminal connections OR HO ECM to ground OR replace HO2 sensor is bad. Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor.Section 5 • Troubleshooting Flow Charts First Edition • Second Printing FAULT CODES Fault Code Problem Cause IAT sensor signal is greater than or equal to 4. 41 Fuel pump high voltage. 51 Low oil pressure. ECM detects a excessively low signal voltage from the IAT sensor. Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON. faulty misfiring cylinder or bad TP TP sensor or contamination sensor. Bad oil pressure switch. injector. ECM detects a excessively low signal voltage from the ECT sensor. see the Repair Section OR check for poor terminal connections from the fuel pump relay to fuel pump OR replace the ECM. 43 Engine Coolant Temperature (ECT) sensor low voltage. Solution Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor. Battery supply voltage to the ECM is 18V DC or more. Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM. The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection. The CMP and CKP sensors work together. if one is bad. The ECM uses the missing pulses. The ECM received an illegal instruction signal from one or more of the sensors and has gone into a default program and then return to normal operation. Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM. 55 ECM . the other one won’t work correctly Crankshaft Position (CKP) and causes the ECM to detect sensor senses extra or a fault. the other one won’t work correctly and causes the ECM to detect a fault. If this does not happen. Under normal operation the ECM will store numbers into memory. signal pulses from the CKP and CMP sensors to initiate sequential fuel injection. it will reset itself and set fault code 56.First Edition • Second Printing Section 5 • Troubleshooting Flow Charts FAULT CODES Fault Code Problem Cause Solution 52 The CKP and CMP sensors work together.Illegal Interuption. Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor. 53 Camshaft Position (CMP) sensor senses unknown pattern. if one is bad.Illegal Operation. Replace the ECM.Computer Operating Properly (COP) failure Replace the ECM. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5-5 . 56 ECM . 62 System voltage high. Replace the ECM. 61 System voltage low. The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation. 54 ECM Fault . Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor. Battery supply voltage to the ECM is 8V DC or less. URJÆZNKÆYZGXZÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆINKIQ \URZGMKÆGZÆZKXSOTGR :( < .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 1 Engine Will Not Crank Over Be sure the key switch is in the appropriate position. Be sure the battery is fully charged.URJÆZNKÆYZGXZÆZUMMRK Y]OZINÆZUÆKOZNKXÆYOJKÆGTJ INKIQÆZNKÆ\URZGMKÆGZ KOZNKXÆYOJKÆZKXSOTGRÆUT YZGXZÆY]OZIN < . 52709 . Be sure the circuit breakers are not tripped. Be sure that both Emergency Stop buttons are pulled out to the ON position.URJÆZNKÆYZGXZÆY]OZINÆZU < KOZNKXÆYOJKÆGTJÆINKIQ \URZGMKÆGZÆZKXSOTGRÆÉÆUT OMTOZOUTYZGXZÆSUJ[RK < )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆZNK OMTOZOUTYZGXZÆSUJ[RK < < < :XGIKÆIOXI[OZÆHGIQ ZNXU[MNÆZNKÆQK_ÆY]OZIN KSKXMKTI_ÆYZUVÆH[ZZUT GTJÆ)(ÆXKVGOXÆUVKT 8KVRGIKÆYZGXZÆZUMMRK Y]OZINÆ:9Æ 8KVGOXÆUVKTÆOTÆHRQÆ]OXK IOXI[OZÆLXUSÆYZGXZÆZUMMRK Y]OZINÆ:9ÆZUÆ:( 8KVGOXÆUVKTÆOTÆHRQÆ]OXK IOXI[OZÆLXUSÆ:(ÆZU ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK 8KVGOXÆUVKTÆOTÆXKJ VU]KXÆY[VVR_Æ]OXKÆIOXI[OZ LXUSÆ)(ÆZUÆ)8ÆZUÆ)8 ZNKTÆZUÆZKXSOTGRÆÉÆZUÆUT OMTOZOUTYZGXZÆSUJ[RK < )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5-6 Genie Z-45/25 & Genie Z-45/25J Part No. )NKIQÆHGZZKX_Æ\URZGMK <ÆUXÆSUXK RKYYÆZNGT )NKIQÆHGZZKX_ÆIUTJOZOUT < 58ÆINKIQÆGRZKXTGZUX 58ÆINKIQÆHGZZKX_ÆIGHRKY 58ÆXKVRGIKÆZNKÆHGZZKX_ =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR < GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUT )NKIQÆZNKÆ\URZGMKÆGZÆZNK IKTZKXÆZKXSOTGRÆUTÆZNK YZGXZÆZUMMRKÆY]OZINÆ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irst Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 1 )UTZOT[KJ LXUS ZNK VXK\OU[Y VGMK .URJ ZNK YZGXZ Y]OZIN ZU KOZNKX YOJK GTJ INKIQ \URZGMK GZ ZNK HRGIQ ]OXK UT ZNK YZGXZKX YURKTUOJ < )NKIQ \URZGMK GZ YZGXZKX IGHRK < < 8KVGOX UVKT OT HRQ ]OXK IOXI[OZ LXUS )8 ZU YZGXZKX YURKTUOJ < 8KVGOX UVKT OT HGZZKX_ IGHRK ZU YZGXZKX 8KVGOX UX XKVRGIK YZGXZKX UX YZGXZKX YURKTUOJ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5-7 .URJ ZNK YZGXZ Y]OZIN ZU KOZNKX YOJK GTJ INKIQ \URZGMK GZ ZKXSOTGR  UT )8 < < 8KVGOX UVKT OT HRQ ]OXK LXUS ZKXSOTGR  UT OMTOZOUTYZGXZ SUJ[RK ZU )8 )NKIQ \URZGMK GZ ZKXSOTGR  UT )8 < . Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 2 Engine Cranks Over But Will Not Start Ford Models Be sure to check the engine oil level and fill as needed. 52709 .Æ*OJÆZNKÆL[KRÆV[SV Z[XTÆUT% _KY 8KSU\KÆÉÆYVGXQÆVR[M MUUJ GTJÆMXU[TJÆYVGXQÆVR[M YVGXQ HUJ_Æ)XGTQÆKTMOTKÆGTJ UHYKX\KÆYVGXQ RKYY ZNGT < )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ )NKIQÆHGZZKX_ÆIUTJOZOUT 58ÆINKIQÆGRZKXTGZUXÆ58 INKIQÆLUXÆYNUXZÆIOXI[OZY 58ÆINKIQÆHGZZKX_ÆIGHRKY 58ÆXKVRGIKÆZNKÆHGZZKX_ 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY TU :KYZÆZNKÆL[KRÆV[SV XKRG_Æ9KKÆ8KVGOX 9KIZOUTÆ58ÆXKVRGIKÆZNK L[KRÆV[SV )UTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ ]KGQÆUXÆTU YVGXQ )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5-8 Genie Z-45/25 & Genie Z-45/25J Part No.G[RZ _KY )UJKYÆ/YÆZNKXKÆGÆLG[RZ IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUTÆNURJ YZGXZÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆINKIQÆHGZZKX_ \URZGMKÆ]NORKÆKTMOTKÆOY IXGTQOTM SUXKÆZNGT < =OZNÆZNKÆQK_ÆY]OZINÆOT ZNKÆ5.. 9KKÆ8KVGOXÆ9KIZOUT . Be sure that the radiator overflow tank is at the FULL mark.ÆVUYOZOUTÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆZ[XTÆZNKÆQK_ Y]OZINÆZUÆMXU[TJ IUTZXURYÆGTJÆROYZKTÆLUX ZNKÆL[KRÆV[SVÆZUÆZ[XTÆ54 LUXÆGVVXU^OSGZKR_Æ YKIUTJYÆGTJÆZNKTÆYN[Z 5.. Be sure to check fuel levels and the engine coolant level.U]ÆZUÆ8KZXOK\KÆ. Perform following tests in gasoline mode only. UXJÆ28-Æ+./ 9KX\OIKÆ3GT[GRÆLUX ZXU[HRKYNUUZOTMÆZNK OMTOZOUTÆY_YZKSÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5-9 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 2 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK *OYGHRKÆYZGXZKXÆH_ XKSU\OTMÆHRQÆ]OXKÆGZÆZNK YZGXZKXÆYURKTUOJÆNURJÆZNK < YZGXZÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆINKIQÆ\URZGMK GZÆZNKÆROMNZÆMXKKTÆ]OXKÆUT ZNKÆOMTOZOUTÆIUORÆVR[M RKYYÆZNGT < 8KVGOXÆUVKTÆOTÆROMNZ MXKKTÆ]OXKÆLXUSÆZNK +)3ÆZUÆOMTOZOUTÆIUORÆ58 INKIQÆLUXÆRUUYKÆUXÆHGJ IUTTKIZOUTYÆLXUSÆZNK +)3ÆZUÆZNKÆOMTOZOUTÆIUOR 58ÆXKVRGIKÆZNKÆOMTOZOUT IUORÆ58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 9KKÆ. 9KKÆ8KVGOXÆ9KIZOUT . 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 2A Engine Runs While Cranking Then Dies Be sure that all vacuum hoses are connected and show no signs of damage.URJ YZGXZÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆINKIQÆ\URZGMK GZÆZKXSOTGRÆÉÆUT OMTOZOUTYZGXZÆSUJ[RK ÆZUÆ< )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK < 8KVRGIKÆOMTOZOUTYZGXZ SUJ[RKÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ < )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ )XGTQÆKTMOTKÆGTJÆINKIQ < \URZGMKÆGZÆUXMHRQÆÉ ]OXKÆUTÆGRZKXTGZUX ÆZUÆ< 8KVGOXÆUVKTÆOTÆUXMHRQ ÉÆ]OXKÆIOXI[OZÆLXUS GRZKXTGZUXÆZUÆ:(ÆZU ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK *OYIUTTKIZÆXKJÆ]OXK < LXUSÆZKXSOTGRÆÉÆUT OMTOZOUTYZGXZÆSUJ[RKÆGTJ INKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉ < :KYZÆG[^OROGX_ÆVU]KX ZUMMRKÆY]OZINKYÆ:9ÆGTJ :9Æ9KKÆ8KVGOX 9KIZOUT 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY )NKIQÆGRZKXTGZUXÆ]OXOTM 58ÆXKVGOXÆUXÆXKVRGIK GRZKXTGZUXÆ58ÆIUTZGIZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVRGIKÆOMTOZOUTYZGXZ SUJ[RKÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 5 .10 Genie Z-45/25 & Genie Z-45/25J Part No.U]ÆZUÆ8KZXOK\KÆ.G[RZ _KY )UJKYÆ/YÆZNKXKÆGÆLG[RZ IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR < GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUTÆ. First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 3 Engine Cranks Over But Will Not Start Diesel Models Be sure to check the engine oil level and fill as needed. Be sure to check fuel level.URJÆZNKÆYZGXZÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆINKIQ ZNKÆ\URZGMKÆGZÆVUYOZO\K ZKXSOTGRÆUTÆL[KRÆYN[ZULL YURKTUOJ < .URJ ZNKÆYZGXZÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆINKIQÆHGZZKX_ \URZGMKÆ]NORKÆKTMOTKÆOY IXGTQOTM <ÆUXÆSUXK *OYGHRKÆZNKÆYZGXZKXÆH_ XKSU\OTMÆZNKÆHRQÆ]OXKÆGZ < ZNKÆYZGXZKXÆYURKTUOJ . Be sure that the battery is fully charged. 52709 Genie Z-45/25 & Genie Z-45/25J 5 .URJÆYZGXZÆY]OZINÆGTJ < INKIQÆ\URZGMKÆGZÆ]NZ ÉÆ]OXKÆUTÆZKXSOTGRÆÉ ULÆ)8 < )NKIQÆ\URZGMKÆGZÆXKJ ]OXKÆUTÆZKXSOTGRÆÉÆUL )8 < )NKIQÆHGZZKX_ÆIUTJOZOUT 58ÆINKIQÆGRZKXTGZUXÆ58 INKIQÆLUXÆYNUXZÆIOXI[OZY 58ÆINKIQÆHGZZKX_ÆIGHRKY 58ÆXKVRGIKÆZNKÆHGZZKX_ :[XTÆZNKÆSGINOTKÆULL GTJÆOYURGZKÆZNKÆL[KR YURKTUOJÆ)NKIQÆZNK XKYOYZGTIKÆULÆZNK YURKTUOJ ÆUNSY 9KKÆ*K[Z`ÆUXÆ6KXQOTY YKX\OIKÆSGT[GRYÆLUX ZXU[HRKYNUUZOTMÆL[KR Y_YZKS 8KVGOXÆUVKTÆOTÆ]NZÆÉ ]OXKÆLXUSÆ)8ÆÆZUÆL[KR YURKTUOJ ÆUX OTLOTOZK UNSY 8KVRGIKÆZNKÆL[KR YURKTUOJ 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆHGZZKX_ÆZU )(ÆZUÆ)8ÆZUÆ)8 < )UTZOT[KJÆUTÆZNKÆTK^Z VGMK Part No. RKYY =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR ZNGT < GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUTÆ.11 . 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing CHART 3 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK .URJÆZNKÆYZGXZÆY]OZINÆZU < KOZNKXÆYOJKÆGTJÆINKIQ \URZGMKÆGZÆZKXSOTGRÆÉÆUT ZNKÆOMTOZOUTYZGXZÆSUJ[RK < )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆGTJÆÉÆUT OMTOZOUTYZGXZÆSUJ[RK < < 8KVGOXÆUVKTÆOTÆHRQÆ]OXK LXUSÆZKXSOTGRÆÉÆUT )8ÆZUÆZKXSOTGRÆÉÆUT ZNKÆOMTOZOUTYZGXZÆSUJ[RK 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_Æ]OXKYÆZUÆZKXSOTGR ÉÆGTJÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆZU ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK < )NKIQÆIUTZOT[OZ_ÆLXUS TU MXU[TJÆZUÆHXU]TÆ]OXKÆGZ IUTZOT[OZ_ ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK IUTZOT[OZ_ 8KVRGIKÆZNKÆOMTOZOUT YZGXZÆSUJ[RKÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ TU IUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆZU )8 )NKIQÆIUTZOT[OZ_ÆLXUS MXU[TJÆZUÆZKXSOTGRÆÉ UTÆ)8 MUUJ )XGTQÆKTMOTKÆGTJÆINKIQ < \URZGMKÆGZÆZKXSOTGRÆÉÆUT OMTOZOUTYZGXZÆSUJ[RK )XGTQÆKTMOTKÆGTJÆINKIQ < \URZGMKÆGZÆUXMHRQÆÉ ]OXKÆUTÆGRZKXTGZUX ÆZUÆ< 8KVGOXÆUVKTÆOTÆUXMHRQ ÉÆ]OXKÆIOXI[OZÆLXUS GRZKXTGZUXÆZUÆ:(ÆZU ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK 8KVGOXÆUXÆXKVRGIK GRZKXTGZUXÆ58ÆIUTZGIZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ ÆZUÆ< )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5 .URJÆZNKÆYZGXZÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆINKIQ \URZGMKÆGZÆZKXSOTGRÆÉ ULÆ)8 < .12 Genie Z-45/25 & Genie Z-45/25J Part No. First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 3 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK =NORKÆIXGTQOTMÆKTMOTK LUXÆÆYKIUTJYÆINKIQ IUTZOT[OZ_ÆZUÆMXU[TJÆUT _KY ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RKÆ/Y IUTZOT[OZ_ÆSGOTZGOTKJ% *OYIUTTKIZÆ]NZÆÉÆ]OXK LXUSÆUORÆVXKYY[XKÆYKTJKX GTJÆINKIQÆIUTZOT[OZ_ÆZU _KY MXU[TJÆUTÆYOMTGRÆVUYZÆUL YKTJKXÆ]NORKÆIXGTQOTM ZNKÆKTMOTKÆ/YÆIUTZOT[OZ_ SGOTZGOTKJ% TU *OYIUTTKIZÆ]NZÆÉÆ]OXK LXUSÆKTMOTKÆZKSVKXGZ[XK YKTJKXÆGTJÆINKIQ IUTZOT[OZ_ÆZUÆMXU[TJÆUT _KY YOMTGRÆVUYZÆULÆYKTJKX ]NORKÆIXGTQOTMÆZNK KTMOTKÆ/YÆIUTZOT[OZ_ SGOTZGOTKJ% TU 8KVGOXÆYNUXZÆZUÆMXU[TJ OTÆ]NZÆÉÆ]OXKÆLXUS YKTJOTMÆ[TOZYÆZUÆ:(ÆZU ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK )NKIQÆUORÆRK\KRÆ58 XKVRGIKÆUORÆVXKYY[XK YKTJOTMÆ[TOZÆ58ÆXKLKXÆZU *K[Z`ÆUXÆ6KXQOTYÆYKX\OIK SGT[GRYÆLUX ZXU[HRKYNUUZOTMÆRU]ÆUOR VXKYY[XK )NKIQÆUORÆRK\KRÆ58 XKVRGIKÆKTMOTK ZKSVKXGZ[XKÆYKTJOTM [TOZÆ58ÆXKLKXÆZUÆ*K[Z`ÆUX 6KXQOTYÆYKX\OIKÆSGT[GRY LUXÆZXU[HRKYNUUZOTMÆG U\KXNKGZKJÆKTMOTK TU )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆOMTOZOUT YZGXZÆSUJ[RK < 8KVRGIKÆOMTOZOUTYZGXZ SUJ[RKÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ < *OYIUTTKIZÆXKJÆ]OXK < LXUSÆZKXSOTGRÆÉÆUT OMTOZOUTYZGXZÆSUJ[RKÆGTJ INKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉ < :KYZÆG[^OROGX_ÆVU]KX ZUMMRKÆY]OZINKYÆ:9ÆGTJ :9Æ9KKÆ8KVGOX 9KIZOUT 8KVRGIKÆOMTOZOUTYZGXZ SUJ[RKÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 - 13 Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 4 Engine Will Not Start On LPG, But Will Start On Gasoline Ford Models Be sure fuel select switch is switched to LPG. Be sure the valve on the LPG tank is fully opened. Be sure to check LPG fuel level. =OZNÆZNKÆQK_ÆY]OZIN < Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUT )NKIQÆ\URZGMKÆGZÆ26YOJKÆHR[XKJÆ]OXKÆULÆL[KR YKRKIZÆY]OZINÆ:9 < Æ)NKIQÆ\URZGMKÆGZÆ:( < )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆ)8 < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆ+)3ÆZU ZKXSOTGRÆÉÆUTÆ)8Æ58 XKVRGIKÆ+)3 < 8KVGOXÆUVKTÆOTÆHR[XKJ ]OXKÆIOXI[OZÆLXUSÆL[KR YKRKIZÆY]OZINÆZUÆ:( )NKIQÆZNKÆ\URZGMKÆGZÆZNK < IKTZKXÆZKXSOTGRÆULÆZNK L[KRÆYKRKIZÆY]OZINÆ:9 < 8KVRGIKÆL[KRÆYKRKIZ Y]OZINÆ:9 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_ÆIOXI[OZÆZUÆL[KR YKRKIZÆY]OZINÆ:9 9KKÆ8KVGOXÆ9KIZOUT .U]ÆZUÆ8KZXOK\KÆ,G[RZ )UJKYÆ/YÆZNKXKÆGÆLG[RZ _KY IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY :[XTÆULLÆZNKÆ\GR\KÆUTÆZNK 26-ÆZGTQÆZNKT JOYIUTTKIZÆ26-ÆY[VVR_ ROTKÆLXUSÆ26-ÆZGTQÆGTJ HRKKJÆVXKYY[XKÆLXUS ROTK < )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5 - 14 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 4 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK )XGTQÆKTMOTKÆLUXÆ YKIUTJYÆGTJÆINKIQÆLUX IUTZOT[OZ_ÆZUÆMXU[TJÆGZ ZKXSOTGRÆÉÆUTÆ)8 IUTZOT[OZ_ )XGTQÆKTMOTKÆLUXÆ YKIUTJYÆGTJÆINKIQÆLUX IUTZOT[OZ_ÆZUÆMXU[TJÆGZ ZKXSOTGRÆÉÆUTÆ)8 IUTZOT[OZ_ )NKIQÆXKYOYZGTIKÆUL 26-ÆYURKTUOJ TU 8KVGOXÆUVKTÆOTÆJQÆMXT IUTZOT[OZ_ ]OXKÆLXUSÆ+)3ÆZU ZKXSOTGRÆÉÆUTÆ)8Æ58 XKVRGIKÆ+)3 TU IUTZOT[OZ_ 8KVRGIKÆ26-ÆXKRG_Æ)8 ÆUX OTLOTOZK UNSY 8KVRGIKÆ26-ÆYURKTUOJ ÆZUÆÆUNSY 8KIUTTKIZÆ26-ÆZGTQ GTJÆYZGXZKXÆZNKTÆYKK 3GOTZKTGTIKÆYKIZOUTÆLUX 26-ÆGJP[YZSKTZYÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 - 15 Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 5 Engine Will Not Start On Gasoline, But Will Start On LPG Ford Models Be sure fuel select switch is switched to gasoline. Be sure to check gasoline fuel level. 9KKÆ8KVGOXÆ9KIZOUT .U]ÆZUÆ8KZXOK\KÆ,G[RZ _KY )UJKYÆ/YÆZNKXKÆGÆLG[RZ IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU < =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUT )NKIQÆ\URZGMKÆGZÆ26YOJKÆHR[XKJÆ]OXKÆULÆL[KR YKRKIZÆY]OZINÆ:9 < .URJÆZNKÆYZGXZÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆINKIQ < \URZGMKÆGIXUYYÆZNKÆ]OXKY UTÆZNKÆL[KRÆV[SVÆ]OZNU[Z JOYIUTTKIZOTMÆZNKÆ]OXKY < =OZNÆZNKÆQK_ÆY]OZINÆOT ZNKÆ5,,ÆVUYOZOUTÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV TU H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆZ[XTÆZNKÆQK_ Y]OZINÆZUÆMXU[TJ IUTZXURYÆGTJÆROYZKTÆLUX ZNKÆL[KRÆV[SVÆZUÆZ[XTÆ54 LUXÆGVVXU^OSGZKR_Æ YKIUTJYÆ*OJÆZNKÆL[KR V[SVÆZ[XTÆUT% _KY 9KKÆ,UXJÆ28-Æ+,/ YKX\OIKÆSGT[GRÆLUXÆL[KR Y_YZKSÆZXU[HRKYNUUZOTM 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 8KVRGIKÆL[KRÆYKRKIZ Y]OZIN 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY 8KVRGIKÆZNKÆL[KRÆV[SV XKRG_ÆÈ(ÈÆULÆZNKÆKTMOTK NGXTKYYÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVGOXÆUVKTÆOTÆL[KR V[SVÆ]OXKYÆLXUSÆL[KR V[SVÆXKRG_ÆÈ(ÈÆULÆZNK KTMOTKÆNGXTKYYÆ58 XKVRGIKÆZNKÆL[KRÆV[SV 5 - 16 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 6 Engine High Idle Inoperative Ford Models 9KKÆ8KVGOXÆ9KIZOUT .U]ÆZUÆ8KZXOK\KÆ,G[RZ )UJKYÆ/YÆZNKXKÆGÆLG[RZ _KY IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY 9ZGXZÆZNKÆKTMOTKÆZNKT < SU\KÆGTJÆNURJÆZNKÆ863 ZUMMRKÆY]OZINÆÆZUÆZNK NOMNÆOJRKÆXGHHOZÆY_SHUR VUYOZOUTÆLUXÆLURRU]OTM ZKYZYÆ)NKIQÆ\URZGMKÆGZ HRQXKJÆ]OXKÆUTÆ863 YKRKIZÆY]OZINÆ:9ÆGTJ :9 < )NKIQÆ\URZGMKÆGZÆ:( < 8KVGOXÆUVKTÆOTÆHXTHR[ ]OXKÆLXUSÆ:(ÆZUÆ+)3 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ < )NKIQÆ\URZGMKÆGZÆIKTZKX ZKXSOTGRÆUTÆ863ÆYKRKIZ Y]OZINÆ:9ÆGTJÆ:9 < 8KVRGIKÆXVSÆYKRKIZ ZUMMRKÆY]OZIN < 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_ÆIOXI[OZÆZUÆIKTZKX ZKXSOTGRÆULÆ863ÆY]OZIN 8KVGOXÆUVKTÆOTÆHRQXKJ ]OXKÆIOXI[OZÆLXUSÆZUMMRK Y]OZINÆZUÆ:( Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 - 17 Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 7 Engine Low Idle Inoperative Ford Models 9KKÆ8KVGOXÆ9KIZOUT .U]ÆZUÆ8KZXOK\KÆ,G[RZ )UJKYÆ/YÆZNKXKÆGÆLG[RZ _KY IUJKÆYZUXKJÆOTÆZNKÆ+)3 SKSUX_% TU )NKIQÆLUXÆVUUXÆZKXSOTGR IUTTKIZOUTYÆ58ÆINKIQ LUXÆYNUXZKJÆUXÆJGSGMKJ ]OXKYÆZNGZÆMUÆLXUSÆZNK +)3ÆZUÆZNKÆYKTYUXÆZNGZ OYÆIG[YOTMÆZNKÆLG[RZÆ58 XKVRGIKÆZNKÆYKTYUXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 8KLKXÆZUÆZNKÆLG[RZÆIUJK INGXZÆOTÆZNOYÆYKIZOUTÆLUXÆG JKYIXOVZOUTÆULÆZNKÆLG[RZ GTJÆXKIUSSKTJKJ XKVGOXY 9ZGXZÆKTMOTKÆGTJÆY]OZIN XVSÆYKRKIZÆY]OZINÆZUÆRU] OJRKÆZ[XZRKÆY_SHUR )NKIQÆ\URZGMKÆGZÆ:( < 8KVRGIKÆ+)3ÆUXÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ < /YURGZKÆZNKÆMXU[TJÆGTJ VRGZLUXSÆ863ÆZUMMRK Y]OZINKYÆ:9ÆGTJÆ:9 INKIQÆOTJO\OJ[GRR_ÆGTJ XKVRGIKÆJKLKIZO\KÆY]OZIN 5 - 18 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 8 Engine High Idle Inoperative Diesel Models Be sure mechanical linkage is not binding or defective. Be sure 2-speed solenoid grounding wires are free of corrosion and have full continuity to ground. 9ZGXZÆZNKÆKTMOTKÆZNKT Y]OZINÆXVSÆYKRKIZÆY]OZIN ZUÆNOMNÆOJRKÆXGHHOZ Y_SHURÆGTJÆINKIQÆOLÆ YVKKJÆYURKTUOJÆV[RRYÆOT YURKTUOJ JUKY TUZÆV[RRÆOT )NKIQÆ\URZGMKÆGZÆHRQXKJ ]OXKÆUTÆ863ÆYKRKIZ Y]OZINÆ:9ÆGTJÆ:9 )NKIQÆNOMNÆOJRK YURKTUOJ GJP[YZSKTZÆYKK V[RRYÆOT 3GOTZKTGTIKÆYKIZOUT 58ÆYKKÆ*K[Z`ÆUX 6KXQOTYÆ]UXQYNUV SGT[GRYÆZUÆZXU[HRKYNUUZ L[KRÆOTPKIZOUTÆY_YZKS < )NKIQÆ\URZGMKÆUTÆXKJ ]OXKÆGZÆIKTZKXÆZKXSOTGRÆUL < 863ÆYKRKIZÆÆY]OZIN < 8KVGOXÆUVKTÆOTÆIOXI[OZ Y[VVR_OTMÆ<ÆZUÆIKTZKX ZKXSOTGRÆULÆY]OZIN < 8KVRGIKÆZUMMRKÆY]OZIN )NKIQÆ\URZGMKÆGZÆ:( < )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆ)8 < )NKIQÆ\URZGMKÆZU ZKXSOTGRÆÉÆUTÆ)8 < < 8KVGOXÆUVKTÆOTÆHRQXKJ ]OXKÆIOXI[OZÆLXUSÆZUMMRK Y]OZINÆZUÆ:( < 8KVGOXÆUVKTÆOTÆHRQXKJ ]OXKÆIOXI[OZÆLXUSÆ:(ÆZU ZKXSOTGRÆÉÆUTÆ)8 8KVGOXÆUVKTÆOTÆ]NZÆ]OXK IOXI[OZÆLXUSÆZKXSOTGRÆÉ UTÆ)8ÆZUÆZKXSOTGRÆÉ UTÆ)8 < TU )NKIQÆIUTZOT[OZ_ÆLXUS 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆZUÆHXU]TÆ]OXKÆGZ IUTZOT[OZ_ MXU[TJÆ]OXKÆIOXI[OZÆZU ZKXSOTGRÆÉÆUTÆ)8 ZKXSOTGRÆÉÆUTÆ)8 IUTZOT[OZ_ )NKIQÆ\URZGMKÆZU ZKXSOTGRÆÉÆUTÆ)8 < )UTZOT[KJÆUTÆZNKÆTK^Z VGMK < 8KVRGIKÆ)8ÆXKRG_ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 - 19 Section 5 • Troubleshooting Flow Charts First Edition • Second Printing CHART 8 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK )NKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆ)8 < )NKIQÆIUTZOT[OZ_ÆLXUS MXU[TJÆZUÆHXU]TÆ]OXKÆGZ ZKXSOTGRÆÉÆUTÆ)8 MUUJ )NKIQÆ\URZGMKÆZU ZKXSOTGRÆÉÆUTÆ)8 < )NKIQÆ\URZGMKÆGZÆZNK HRQXKJÆ]OXKÆUTÆZNK YVKKJÆYURKTUOJ < )NKIQÆOLÆYVKKJ YURKTUOJÆSU\KYÆOTÆGTJ U[ZÆLXKKR_ SU\KYÆLXKKR_ 8KVRGIKÆYVKKJ YURKTUOJÆ4UZK XKYOYZGTIKÆGIXUYY YURKTUOJÆZKXSOTGRY YNU[RJÆHKÆGVVXU^OSGZKR_ ÆUNSY < 8KVGOXÆUVKTÆOTÆHRQXKJ ]OXKÆIOXI[OZÆLXUS )8ÆZUÆ)8 HGJ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆZU ZKXSOTGRÆÉÆUTÆ)8 < 8KVGOXÆUVKTÆOTÆ]NZÆ]OXK IOXI[OZÆLXUSÆ)8ÆZUÆ)8 ZUÆ)8 8KVRGIKÆ)8ÆXKRG_ 58ÆXKVGOXÆUVKTÆOT HRQXKJÆ]OXKÆIOXI[OZÆLXUS ZKXSOTGRÆÉÆUTÆ)8ÆZU YVKKJÆYURKTUOJ < YURKTUOJ HOTJY )NKIQÆROTQGMKÆUX XKVRGIKÆYURKTUOJ 5 - 20 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 9 Engine Low Idle Inoperative Diesel Models Check if mechanical linkage from 2-speed solenoid to fuel injection system is binding or defective. 52709 Genie Z-45/25 & Genie Z-45/25J 5 .21 . 'ZÆZNKÆVRGZLUXSÆIUTZXURY YZGXZÆZNKÆKTMOTKÆGTJ SU\KÆZNKÆ863ÆYKRKIZ Y]OZINÆ:9ÆZU SGOTZGOTKJÆRU]ÆOJRK Z[XZRKÆY_SHURÆ)NKIQ \URZGMKÆGZÆHRQXKJÆ]OXK UTÆXVSÆYKRKIZÆY]OZIN < )NKIQÆ\URZGMKÆGZÆZNK HRQXKJÆ]OXKÆUTÆZNK YVKKJÆYURKTUOJ < )NKIQÆOLÆYVKKJ YURKTUOJÆSU\KYÆOTÆGTJ U[ZÆLXKKR_ SU\KYÆLXKKR_ )NKIQÆGJP[YZSKTZÆUL ROTQGMKÆGTJÆL[KRÆOTPKIZOUT Y_YZKSÆRU]ÆOJRKÆ9KK 3GOTZKTGTIKÆYKIZOUT UQ 9KKÆ*K[Z`ÆUXÆ6KXQOTY ]UXQYNUVÆSGT[GRÆZU ZXU[HRKYNUUZÆL[KR OTPKIZOUTÆY_YZKSÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ < 8KVRGIKÆ)8ÆXKRG_ < /YURGZKÆZNKÆVRGZLUXSÆGTJ MXU[TJÆ863ÆY]OZINKY :9ÆGTJÆ:9ÆINKIQ OTJO\OJ[GRR_ÆGTJÆXKVRGIK JKLKIZO\KÆY]OZIN YURKTUOJ HOTJY )NKIQÆROTQGMKÆUX XKVRGIKÆYURKTUOJ Part No. ORRÆ]OZNÆ*K^XUT KW[O\GRKTZÆN_JXG[ROI LR[OJ TU UVKT 5VKTÆ\GR\KYÆGTJÆYZGXZ ZNKÆKTMOTKÆ)NKIQÆGRR SGINOTKÆL[TIZOUTYÆLUX IUXXKIZÆUVKXGZOUT 5TÆ.URJÆYZGXZ Y]OZINÆGTJÆIXGTQÆKTMOTK U\KXÆ]NORKÆUHYKX\OTM YVROTKÆJXO\KÆGZÆXKGXÆUL SGOTÆV[SV YVROTKÆJUKY TUZÆZ[XT +TMOTKÆZUÆV[SVÆLRK^ VRGZKÆIU[VROTMÆOYÆLG[RZ_ 58ÆSGOTÆV[SVÆOYÆLG[RZ_ )UTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ :XU[HRKYNUUZ OTUVKXGZO\KÆHUUS L[TIZOUTYÆGTJ OTUVKXGZO\KÆJXO\K L[TIZOUTYÆYKVGXGZKR_ 5 . 52709 . Engine Starts and Runs )NKIQÆN_JXG[ROI LR[OJÆRK\KR UQ )NKIQÆV[SVÆY[IZOUTÆROTK IRUYKJ YN[ZULLÆ\GR\KYÆ/TÆZNK UVKTÆVUYOZOUTÆZNKÆ\GR\K NGTJRKYÆYNU[RJÆHK VGXGRRKRÆ]OZNÆNUYK *UÆZNKÆV[SVYÆLKKR K^IKYYO\KR_ÆNUZ% _KY /LÆKTMOTKÆNGYÆHKKTÆX[T ]OZNÆ\GR\KYÆIRUYKJÆOZ SG_ÆNG\KÆJGSGMKJÆUTK UXÆHUZNÆV[SVYÆ6RKGYK IUTZGIZÆZNKÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ RU] .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 10 All Functions Inoperative.22 Genie Z-45/25 & Genie Z-45/25J Part No.UXJÆSUJKRYÆIRUYK YVROTK ZNKÆ\GR\KÆUTÆZNKÆ26ZGTQÆGTJÆSU\KÆZNKÆL[KR Z[XTY YKRKIZÆZUMMRKÆY]OZIN :9ÆZUÆZNKÆ26VUYOZOUTÆ5TÆ*K[Z`ÆGTJ 6KXQOTYÆÆSUJKRYÆNURJ SGT[GRÆL[KRÆYN[ZULLÆRK\KX ZUÆZNKÆIRUYKJÆVUYOZOUT IRUIQ]OYK 8KSU\KÆL[TIZOUTÆV[SV LXUSÆSGOTÆV[SVÆH[Z RKG\KÆGRRÆNUYKY IUTTKIZKJÆ. 23 .Æ58ÆSGTOLURJ NGYÆGTÆOTZKXTGRÆLG[RZ )UTY[RZÆZNKÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ HGJ 8KVRGIKÆZNKÆL[TIZOUT V[SV Part No. Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground. Drive Functions Operational Be sure the hydraulic suction line shutoff valve for the lift/steer pump is in the OPEN position. 52709 Genie Z-45/25 & Genie Z-45/25J 5 .Æ58 SGTOLURJÆNGYÆGTÆOTZKXTGR YZKKXOTM OTUVKXGZO\K LG[RZÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ )NKIQÆYZKKXÆL[TIZOUTY )NKIQÆZNKÆL[TIZOUT V[SVÆYKKÆ8KVGOX YKIZOUT UQ 8KVRGIKÆZNKÆXKROKLÆ\GR\K OZKSÆ.First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 11 All Lift and Steer Functions Inoperative. /TYZGRRÆGÆÆZUÆÆ69/ ÆHGXÆVXKYY[XKÆZU ZNKÆZKYZÆVUXZÆOZKSÆ//ÆUT ZNKÆL[TIZOUTÆSGTOLURJ 9ZGXZÆKTMOTKÆSU\KÆZNK L[TIZOUTÆKTGHRKÆZUMMRK Y]OZINÆZUÆZNKÆNOMNÆ863 YOJKÆGTJÆNURJÆZNKÆHUUS XKZXGIZÆL[TIZOUTÆZUMMRK Y]OZINÆGTJÆINKIQÆZNK N_JXG[ROIÆVXKYY[XK  VYO :XU[HRKYNUUZÆKGIN L[TIZOUTÆOTJO\OJ[GRR_ÆUX IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ RKYYÆZNGT ÆVYO 'JP[YZÆZNKÆL[TIZOUT SGTOLURJÆY_YZKSÆXKROKL \GR\KÆOZKSÆ.ÆGRRÆZNK ]G_ÆOTÆIRUIQ]OYK IU[TZOTMÆZNKÆT[SHKXÆUL Z[XTYÆ3U\KÆZNKÆL[TIZOUT KTGHRKÆY]OZINÆZUÆZNK NOMNÆ863ÆYOJKÆGTJÆNURJ ZNKÆHUUSÆXKZXGIZÆZUMMRK Y]OZINÆGTJÆXKINKIQÆZNK VXKYY[XK  VYOÆUX SUXK 3U\KÆZNKÆL[TIZOUT KTGHRKÆY]OZINÆZUÆZNK NOMNÆ863ÆYOJKÆGTJÆNURJ ZNKÆHUUSÆXKZXGIZÆY]OZIN GTJÆXKGJP[YZÆZNKÆXKROKL VXKYY[XKÆZUÆÆVYO ÆHGX RKYYÆZNGT ÆVYO YZKKXOTM UVKXGZKY 8KVGOXÆUXÆXKVRGIK JOLLKXKTZOGRÆYKTYOTMÆ\GR\K OZKSÆ++Æ58ÆXKVGOXÆUX XKVRGIKÆLRU]ÆXKM[RGZUX \GR\KÆOZKSÆ. *UKYÆZNKÆKTMOTKÆYZGXZ LXUSÆZNKÆMXU[TJ IUTZXURY% _KY 9ZGXZÆZNKÆKTMOTKÆLXUS ZNKÆMXU[TJÆIUTZXURY 3U\KÆZNKÆL[TIZOUT KTGHRKÆZUMMRKÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆINKIQ ZNKÆ\URZGMKÆUTÆZNK IKTZKXÆZKXSOTGRÆULÆZNK VRGZLUXSÆXUZGZKÆZUMMRK Y]OZINÆ:9 < :XU[HRKYNUUZÆKGIN L[TIZOUTÆOTJO\OJ[GRR_ < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆQK_ÆY]OZINÆZU L[TIZOUTÆKTGHRKÆZUMMRK Y]OZINÆZUÆKGINÆL[TIZOUT ZUMMRKÆY]OZIN TU 6[RRÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆ)NKIQ \URZGMKÆGZÆXKJÆ]OXKÆUT ZNKÆOTV[ZÆYOJKÆULÆZNK MXU[TJÆIUTZXURYÆIUTZGIZ ULÆZNKÆQK_ÆY]OZINÆ19 ZNKÆXKJÆ]OXKÆINKIQKJ YNU[RJÆUXOMOTGZKÆLXUS ZNKÆ+SKXMKTI_Æ9ZUV H[ZZUT < < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆZNK +SKXMKTI_Æ9ZUVÆH[ZZUT ZUÆZNKÆQK_ÆY]OZIN =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR < GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUT )NKIQÆ\URZGMKÆGZÆXKJ ]OXKÆGZÆZNKÆU[ZV[ZÆYOJKÆUL ZNKÆÆMXU[TJÆIUTZXURY IUTZGIZÆUTÆZNKÆQK_ Y]OZIN < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆQK_ÆY]OZINÆZU L[TIZOUTÆKTGHRKÆZUMMRK Y]OZINÆZUÆKGINÆL[TIZOUT ZUMMRKÆY]OZIN )NKIQÆOLÆQK_ÆY]OZIN OTZKXTGRÆIGSÆOYÆGIZO\GZOTM _KY MXU[TJÆIUTZGIZ TU 8KVRGIKÆQK_ÆY]OZIN 19 8KVRGIKÆQK_ÆY]OZIN IUTZGIZÆLUXÆMXU[TJ IUTZXURY 5 .24 Genie Z-45/25 & Genie Z-45/25J Part No.Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 12 Ground Controls Inoperative. Platform Controls Operate Normally Be sure all other functions operate normally. including the platform controls. 52709 . 52709 < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK ]OZNÆJOUJKÆLXUS +SKXMKTI_Æ9ZUVÆH[ZZUT ZUÆ:6 Genie Z-45/25 & Genie Z-45/25J 5 . Ground Controls Operate Normally Be sure all cables from ground control box through the cable track are in good condition with no kinks or abrasions. *UKYÆKTMOTKÆYZGXZÆLXUS ZNKÆVRGZLUXSÆIUTZXURY% _KY 9ZGXZÆKTMOTKÆLXUSÆZNK VRGZLUXSÆIUTZXURYÆZNKT VXKYYÆJU]TÆZNKÆLUUZ Y]OZINÆGTJÆINKIQ \URZGMKÆGZÆ:6 < < :KYZÆUXÆXKVRGIKÆLUUZ Y]OZINÆYKKÆ8KVGOX 9KIZOUTÆ58ÆXKVGOXÆUVKT OTÆ]NZÆ]OXKÆIOXI[OZÆLXUS LUUZÆY]OZINÆZUÆ:6 TU 8KVGOXÆUVKTÆOTÆ]NZÆ]OXK IOXI[OZÆLXUSÆ:6ÆZU L[TIZOUTÆZUMMRKÆY]OZINKY GTJÆL[TIZOUTÆIUTZXURRKXY < 8KVGOXÆUVKTÆOTÆXKJÆ]OXK IOXI[OZÆLXUSÆQK_ÆY]OZINÆZU :(Æ58Æ8KVRGIKÆZNK VRGZLUXSÆIUTZXURYÆIUTZGIZ GZÆZNKÆQK_ÆY]OZIN 8KVGOXÆUVKTÆOTÆHRQ ]OXKÆIOXI[OZÆÆLXUSÆ:( :6 8KVGOXÆUVKTÆOTÆHRQÆ]OXK LXUSÆ:6ÆZU +SKXMKTI_Æ9ZUVÆH[ZZUT 6 )NKIQÆOLÆ+SKXMKTI_ 9ZUVÆH[ZZUTÆOTZKXTGRÆIGS _KY OYÆGIZO\GZOTMÆZNKÆIUTZGIZ TU 8KVRGIKÆZNKÆVRGZLUXS +SKXMKTI_Æ9ZUVÆH[ZZUT 8KVRGIKÆIUTZGIZÆUT +SKXMKTI_Æ9ZUVÆH[ZZUT 6 )NKIQÆ\URZGMKÆGZÆ:( < )NKIQÆ\URZGMKÆGZÆ:6 < )NKIQÆ\URZGMKÆGZÆHRQ ]OXKÆUTÆOTV[ZÆYOJKÆUL VRGZLUXSÆ+SKXMKTI_ 9ZUVÆH[ZZUTÆIUTZGIZÆ6 < < < =OZNÆZNKÆQK_ÆY]OZIN < Z[XTKJÆZUÆVRGZLUXS IUTZXURÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆ)NKIQÆZNK \URZGMKÆUTÆZNKÆU[ZV[Z YOJKÆULÆZNKÆVRGZLUXS +SKXMKTI_Æ9ZUVÆH[ZZUT IUTZGIZ < )NKIQÆ\URZGMKÆGZÆ:6 < 8KVGOXÆUVKTÆOTÆHRQÆ]OXK IOXI[OZÆLXUSÆVRGZLUXS +SKXMKTI_Æ9ZUVÆH[ZZUT ZUÆ:6ÆZUÆLUUZÆY]OZIN 58ÆXKVRGIKÆLUUZÆY]OZIN 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ Part No.First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 13 Platform Controls Inoperative.25 . =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJ IUTZXURYÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY < V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆSU\KÆZNK L[TIZOUTÆKTGHRKÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆNURJÆZNK VXOSGX_ÆHUUSÆ[VÆZUMMRK Y]OZINÆ:9ÆGZÆZNK MXU[TJÆIUTZXURYÆOTÆZNK [VÆJOXKIZOUTÆGTJÆINKIQ \URZGMKÆUTÆXKJ]NZÆ]OXK UTÆVXOSGX_ÆHUUSÆ[V JU]TÆVXUVUXZOUTGRÆ\GR\K IUORÆOZKSÆ22 3U\KÆZNKÆL[TIZOUT KTGHRKÆY]OZINÆZUÆKOZNKX ÆZU YOJKÆGTJÆNURJÆZNK VXOSGX_ÆHUUSÆ[VÆZUMMRK < Y]OZINÆ:9ÆGZÆZNK MXU[TJÆIUTZXURYÆOTÆZNK [VÆJOXKIZOUTÆ)NKIQ \URZGMKÆGZÆ:( ÆZU < =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆVRGZLUXS IUTZXURYÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆGIZO\GZKÆLUUZ Y]OZINÆGTJÆVXOSGX_ HUUSÆL[TIZOUTÆIUTZXURRKX (6ÆUTÆVRGZLUXS IUTZXURÆVGTKRÆOTÆ[V JOXKIZOUTÆ)NKIQÆ\URZGMK GZÆ:6 < 'IZO\GZKÆLUUZÆY]OZINÆGTJ < INKIQÆ\URZGMKÆGZÆÈÈ ZKXSOTGRÆUTÆ(6 <ÆUXÆSUXK 8KGJP[YZÆIUTZXURRKXÆYKK 8KVGOXÆ9KIZOUTÆ58 XKVRGIKÆIUTZXURRKXÆ(6 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ < 8KVGOXÆUVKTÆOTÆXKJ]NZ ]OXKÆIOXI[OZÆLXUSÆ:(ÆZU VXOSGX_ÆHUUSÆ[VJU]T VXUVUXZOUTGRÆ\GR\KÆIUOR OZKSÆ22Æ58ÆXKVGOX UVKTÆOTÆHXU]TÆMXU[TJ ]OXKÆIOXI[OZÆZUÆ\GR\KÆIUOR 8KVGOXÆUVKTÆOTÆXKJ]NZ ]OXKÆLXUSÆ:6ÆZUÆ:( 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_ÆIOXI[OZÆLXUSÆ:6 ZUÆ(6Æ58ÆXKVGOXÆUVKT OTÆHXU]TÆMXU[TJÆ]OXK IOXI[OZÆLXUSÆMXU[TJÆZU (6 <ÆUXÆSUXK )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5 . 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 14 Primary Boom Up Function Inoperative Be sure all other functions operate normally.26 Genie Z-45/25 & Genie Z-45/25J Part No. First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 14 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK =OZNÆQK_ÆY]OZINÆZ[XTKJ ZUÆMXU[TJÆIUTZXURYÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV < H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆSU\KÆZNK L[TIZOUTÆKTGHRKÆZUMMRK Y]OZINÆZUÆKOZNKXÆYOJKÆGTJ NURJÆZNKÆVXOSGX_ÆHUUS [VÆZUMMRKÆY]OZINÆ:9 GZÆZNKÆMXU[TJÆIUTZXURYÆOT ZNKÆ[VÆJOXKIZOUTÆ)NKIQ \URZGMKÆUTÆXKJÆÉÆ]OXK UTÆVXOSGX_ÆHUUSÆ[V JU]TÆJOXKIZOUTGRÆ\GR\K IUORÆOZKSÆ** 3U\KÆZNKÆL[TIZOUT KTGHRKÆZUMMRKÆY]OZINÆZU <ÆUX KOZNKXÆYOJKÆGTJÆNURJÆZNK SUXK VXOSGX_ÆHUUSÆ[VÆZUMMRK Y]OZINÆ:9ÆGZÆZNK MXU[TJÆIUTZXURYÆOTÆZNK [VÆJOXKIZOUTÆ)NKIQ \URZGMKÆGZÆ:( < =OZNÆQK_ÆY]OZINÆZ[XTKJ ZUÆVRGZLUXSÆIUTZXURYÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK <ÆUX 54ÆVUYOZOUTÆGIZO\GZKÆZNK SUXK LUUZÆY]OZINÆGTJÆVXOSGX_ HUUSÆL[TIZOUTÆIUTZXURRKX (6ÆUTÆVRGZLUXS IUTZXURÆVGTKRÆOTÆ[V JOXKIZOUTÆ)NKIQÆ\URZGMK :( <ÆUX 'IZO\GZKÆLUUZÆY]OZINÆGTJ SUXK VXOSGX_ÆHUUSÆL[TIZOUT IUTZXURRKXÆ(6ÆUT VRGZLUXSÆIUTZXURÆVGTKRÆOT [VÆJOXKIZOUTÆ)NKIQ \URZGMKÆ:6 < 8KVGOXÆUVKTÆOTÆXKJÆÉ ]OXKÆIOXI[OZÆLXUSÆ:(ÆZU VXOSGX_ÆHUUSÆ[V L[TIZOUTÆJOXKIZOUTGRÆ\GR\K IUORÆOZKSÆ**Æ58ÆXKVGOX UVKTÆOTÆHXU]TÆMXU[TJ ]OXKÆIOXI[OZÆZUÆ\GR\KÆIUOR :XU[HRKYNUUZÆZNK VXOSGX_ÆHUUSÆ[V L[TIZOUTÆZUMMRKÆY]OZIN :9ÆUTÆMXU[TJ IUTZXURÆVGTKRÆ58ÆXKVGOX UVKTÆOTÆXKJÆÉÆ]OXK IOXI[OZÆLXUSÆ:9ÆZUÆ:( 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVGOXÆUVKTÆOTÆXKJÆ]OXK LXUSÆ:6ÆZUÆ:( <ÆUXÆSUXK < 'IZO\GZKÆLUUZÆY]OZINÆGTJ < INKIQÆ\URZGMKÆGZÆÈÈ ZKXSOTGRÆUTÆ(6 <ÆUXÆSUXK 8KGJP[YZÆIUTZXURRKXÆYKK 8KVGOXÆ9KIZOUTÆ58 XKVRGIKÆIUTZXURRKXÆ(6 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_ÆIOXI[OZÆLXUSÆ:6 ZUÆ(6Æ58ÆXKVGOXÆUVKT OTÆHXU]TÆMXU[TJÆ]OXK IOXI[OZÆLXUSÆMXU[TJÆZU (6 )UTZOT[KJÆUTÆZNKÆTK^Z VGMK Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 .27 . Section 5 • Troubleshooting Flow Charts First Edition • Second Printing CHART 14 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK ÆUX *OYIUTTKIZÆ]OXKYÆZU OTLOTOZK VXOSGX_ÆHUUSÆ[V UNSY JOXKIZOUTGRÆ\GR\KÆIUOR OZKSÆ**ÆGTJÆZKYZÆZNK XKYOYZGTIKÆULÆZNKÆ\GR\K IUORÆ9KKÆ8KVGOXÆ9KIZOUT ÆZUÆÆUNSY /TYZGRRÆGÆÆZUÆÆ69/ ÆHGXÆVXKYY[XK  MG[MKÆGZÆZNKÆW[OIQ 69/ÆUX JOYIUTTKIZÆIU[VROTMÆUT SUXK ZNKÆL[TIZOUTÆSGTOLURJ OZKSÆ11ÆGTJÆYZGXZÆZNK KTMOTKÆ3U\KÆZNK L[TIZOUTÆKTGHRKÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆNURJÆZNK VXOSGX_ÆHUUSÆ[VÆZUMMRK Y]OZINÆGZÆZNKÆMXU[TJ IUTZXURYÆOTÆZNKÆ[V JOXKIZOUTÆ)NKIQÆZNK VXKYY[XK RKYYÆZNGT Æ69/ 8KVRGIKÆVXOSGX_ÆHUUS [VÆJOXKIZOUTGRÆ\GR\KÆIUOR OZKSÆ** )NKIQÆLUXÆSKINGTOIGR XKYZXOIZOUTYÆQKKVOTM VXOSGX_ÆHUUSÆLXUS SU\OTMÆ58ÆXKVGOX I_ROTJKXÆUXÆI_ROTJKX IU[TZKXHGRGTIKÆ\GR\K 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ L[TIZOUT +^INGTMKÆLRU]ÆXKM[RGZUX UVKXGZKY 8KVRGIKÆLG[RZ_ÆLRU] \GR\KÆOZKSÆ/Æ]OZNÆGÆROQK XKM[RGZUXÆ\GR\K \GR\KÆOZKSÆ-Æ)NKIQ VXOSGX_ÆHUUSÆ[V L[TIZOUT L[TIZOUT OTUVKXGZO\K 8KVGOXÆI_ROTJKXÆUX 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8KVGOXÆUVKTÆOTÆMXTHRQ ]OXKÆLXUSÆ:(ÆZU VRGZLUXSÆXUZGZKÆPOHÆHUUS JOXKIZOUTGRÆ\GR\KÆIUOR OZKSÆ** L[TIZOUT 8KVGOXÆUVKTÆOTÆHXU]T UVKXGZKY MXU[TJÆ]OXKÆIOXI[OZÆZU \GR\KÆIUORY Part No.63 . 64 Genie Z-45/25 & Genie Z-45/25J .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 28 Jib Boom Up Function Inoperative. =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ < 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUTÆSU\K ZNKÆL[TIZOUTÆKTGHRK ZUMMRKÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆGIZO\GZKÆZNKÆPOH HUUSÆZUMMRKÆY]OZIN :9ÆOTÆZNKÆ[VÆJOXKIZOUT GTJÆINKIQÆ\URZGMKÆGZÆZNK MXTÆ]OXKÆUTÆZNKÆPOHÆHUUS [VÆJOXKIZOUTGRÆ\GR\K OZKSÆ(( < =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆVRGZLUXS < IUTZXURÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆGIZO\GZKÆZNK LUUZÆY]OZINÆGTJÆZNKÆPOH HUUSÆZUMMRKÆY]OZINÆ:9 OTÆZNKÆ[VÆJOXKIZOUTÆGTJ INKIQÆ\URZGMKÆGZÆ:( 3U\KÆZNKÆL[TIZOUT KTGHRKÆZUMMRKÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆGIZO\GZK < ZNKÆPOHÆHUUSÆZUMMRK Y]OZINÆ:9ÆOTÆZNKÆ[V JOXKIZOUTÆGTJÆINKIQ \URZGMKÆGZÆ:( < 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all other functions operate normally. 52709 5 . 52709 Genie Z-45/25 & Genie Z-45/25J 5 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 28 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK 'IZO\GZKÆLUUZÆY]OZINÆGTJ POHÆHUUSÆZUMMRKÆY]OZIN :9ÆOTÆZNKÆ[VÆJOXKIZOUT GTJÆINKIQÆ\URZGMKÆUT ZNKÆXKJÆGTJÆHRGIQÆ]OXKY GZÆZNKÆPOHVRGZLUXSÆXUZGZK YKRKIZÆ\GR\KYÆOZKSÆ'< < < 8KVRGIKÆ)8 /TYZGRRÆGÆÆZUÆÆVYOÆ +^INGTMKÆPOHÆHUUS L[TIZOUT ZUÆÆHGXÆVXKYY[XK VRGZLUXSÆXUZGZKÆYKRKIZ UVKXGZKY 8KVRGIKÆLG[RZ_Æ\GR\K ÆVYO \GR\KYÆOZKSÆ'< MG[MKÆGZÆZNKÆW[OIQ JOYIUTTKIZÆIU[VROTMÆUT 'IZO\GZKÆLUUZÆY]OZINÆGTJ ZNKÆL[TIZOUTÆSGTOLURJ POHÆHUUSÆ[VÆL[TIZOUT GTJÆGIZO\GZKÆZNKÆPOH HUUSÆ[VÆL[TIZOUT L[TIZOUT OTUVKXGZO\K )NKIQÆLUXÆSKINGTOIGR XKYZXOIZOUTYÆQKKVOTMÆPOH HUUSÆ[VÆL[TIZOUTÆLXUS UVKXGZOTMÆ58ÆXKVGOXÆUX XKVRGIKÆPOHÆHUUS I_ROTJKXÆ58ÆXKVRGIK IU[TZKXHGRGTIKÆ\GR\K 58ÆÈÆUXOLOIKÆSG_ HKÆVR[MMKJÆ58ÆPOH HUUSVRGZLUXSÆXUZGZK YKRKIZÆSGTOLURJÆNGYÆGT OTZKXTGRÆLG[RZÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ RKYYÆZNGT ÆVYO L[TIZOUT 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Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 29 Jib Boom Down Function Inoperative. Z-45/25J Models Be sure all other functions operate normally. 52709 5 .66 Genie Z-45/25 & Genie Z-45/25J . =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ < 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUTÆSU\K ZNKÆL[TIZOUTÆKTGHRK ZUMMRKÆY]OZINÆZUÆKOZNKX YOJKÆGTJÆGIZO\GZKÆZNKÆPOH HUUSÆZUMMRKÆY]OZIN :9ÆOTÆZNKÆJU]T JOXKIZOUTÆGTJÆINKIQ \URZGMKÆGZÆZNKÆMXTHRQ ]OXKÆUTÆZNKÆPOHÆHUUS JU]TÆJOXKIZOUTGRÆ\GR\K OZKSÆ(( < =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆVRGZLUXS < IUTZXURÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆGIZO\GZKÆZNK LUUZÆY]OZINÆGTJÆZNKÆPOH HUUSÆZUMMRKÆY]OZINÆ:9 OTÆZNKÆJU]TÆJOXKIZOUT GTJÆINKIQÆ\URZGMKÆGZ :( 3U\KÆZNKÆL[TIZOUT KTGHRKÆZUMMRKÆY]OZINÆZU KOZNKXÆYOJKÆGTJÆGIZO\GZK < ZNKÆPOHÆHUUSÆZUMMRK Y]OZINÆ:9ÆOTÆZNKÆJU]T JOXKIZOUTÆGTJÆINKIQ \URZGMKÆGZÆ:( < 8KVGOXÆUVKTÆOTÆXKJ VU]KXÆ]OXKÆIOXI[OZÆLXUS QK_ÆY]OZINÆZUÆ:9Æ58 XKVRGIKÆZUMMRKÆY]OZIN :9 'IZO\GZKÆZNKÆLUUZÆY]OZIN < GTJÆZNKÆPOHÆHUUSÆZUMMRK Y]OZINÆ:9ÆOTÆZNKÆJU]T JOXKIZOUTÆGTJÆINKIQ \URZGMKÆGZÆ:6 < =OZNÆZNKÆQK_ÆY]OZIN 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\URZGMKÆGZÆZNKÆIUTZXURRKX ZKXSOTGRÆ]OZNÆZNKÆHR[ ]OXKÆGZZGINKJ < 8KVGOXÆUXÆXKVRGIKÆYZKKX SOIXUY]OZINÆUTÆJXO\K IUTZXURRKXÆ)UTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVGOXÆUVKTÆOTÆHR[ÆÉ ]OXKÆIOXI[OZÆZNGZÆX[TY LXUSÆ:(ÆZUÆYZKKXÆRKLZ JOXKIZOUTGRÆ\GR\KÆIUORÆUT L[TIZOUTÆSGTOLURJ 8KVRGIKÆYZKKXÆRKLZ JOXKIZOUTGRÆ\GR\KÆIUOR OZKSÆ--Æ58ÆXKVGOX UVKTÆOTÆHXU]TÆMXU[TJ ]OXKÆZUÆYZKKXÆRKLZÆ\GR\K IUOR )NKIQÆLUXÆSKINGTOIGR XKYZXOIZOUTYÆQKKVOTM YZKKXÆRKLZÆL[TIZOUTÆLXUS UVKXGZOTMÆ58ÆXKVGOXÆUX XKVRGIKÆYZKKXÆI_ROTJKX 58ÆXKVRGIKÆLRU] XKM[RGZUXÆ\GR\KÆOZKSÆ.68 Genie Z-45/25 & Genie Z-45/25J Part No. 58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 5 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 30 Steer Left Function Inoperative Be sure all other functions operate normally. 69 . 52709 Genie Z-45/25 & Genie Z-45/25J 5 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 31 Steer Right Function Inoperative Be sure all other functions operate normally. =OZNÆQK_ÆY]OZINÆZ[XTKJ ZUÆVRGZLUXSÆIUTZXURÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆGIZO\GZKÆLUUZ < Y]OZINÆGTJÆYZKKXÆXUIQKX Y]OZINÆUTÆJXO\K IUTZXURRKXÆ*6ÆOTÆXOMNZ JOXKIZOUTÆGTJÆINKIQ \URZGMKÆUTÆ:( <ÆUXÆSUXK 'IZO\GZKÆLUUZÆY]OZINÆGTJ YZKKXÆXUIQKXÆY]OZINÆUT < JXO\KÆIUTZXURRKXÆ*6ÆOT XOMNZÆJOXKIZOUTÆGTJÆINKIQ \URZGMKÆUTÆHR[HRQÆÉ ]OXKÆUTÆYZKKXÆJOXKIZOUTGR \GR\KÆIUORÆOZKSÆ--ÆUT L[TIZOUTÆSGTOLURJ <ÆUXÆSUXK ÆUX *OYIUTTKIZÆ]OXKYÆZU OTLOTOZK YZKKXÆXOMNZÆJOXKIZOUTGR \GR\KÆIUORÆOZKSÆ--ÆUT UNSY L[TIZOUTÆSGTOLURJÆGTJ ZKYZÆZNKÆXKYOYZGTIKÆULÆZNK \GR\KÆIUOR ÆZUÆÆUNSY /TYZGRRÆGÆÆZUÆÆ69/ ÆZUÆÆHGXÆVXKYY[XK MG[MKÆGZÆZNKÆW[OIQ JOYIUTTKIZÆIU[VROTMÆUT ZNKÆHUUSÆL[TIZOUT SGTOLURJÆGTJÆGIZO\GZK ZNKÆYZKKXÆXOMNZÆL[TIZOUT RKYYÆZNGT Æ69/ 8KVGOXÆUXÆXKVRGIKÆYZKKX I_ROTJKXÆ58ÆYZKKX SGTOLURJÆIU[RJÆNG\KÆGT OTZKXTGRÆLG[RZÆ)UTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ  69/ 'IZO\GZKÆLUUZÆY]OZINÆGTJ <ÆUX YZKKXÆXUIQKXÆY]OZINÆUT SUXK JXO\KÆIUTZXURRKXÆ*6ÆOT XOMNZÆJOXKIZOUTÆGTJÆINKIQ \URZGMKÆGZÆZNKÆIUTZXURRKX 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Printing Chart 32 Oscillate Function Inoperative Be sure all other function operate normally. HGJ 8KSU\KÆZNKÆINGYYOY IU\KXÆGTJÆZNKÆG^RK IU\KXYÆLXUSÆZNKÆTUT YZKKXÆKTJÆULÆZNK SGINOTKÆ)NKIQÆZNK ROTQGMKÆLUXÆJGSGMKÆUX OSVXUVKXÆROTQGMK GJP[YZSKTZÆ9KKÆ8KVGOX YKIZOUTÆÆ.U]ÆZUÆ'JP[YZÆZNK ZNKÆJXO\KÆSGTOLURJÆ9ZGXZ 5YIORRGZKÆ9KW[KTIOTM ZNKÆKTMOTKÆGTJÆINKIQ <GR\KÆ6XKYY[XKÆ58 ZNKÆVXKYY[XK IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ ÆVYO )UTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 5 . First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 33 All Drive Functions Inoperative. Be sure the hydraulic tank shut off valves are in the OPEN position. RKYY =OZNÆZNKÆQK_ÆY]OZIN ZNGT Z[XTKJÆZUÆVRGZLUXS < IUTZXURÆGTJÆHUZN +SKXMKTI_Æ9ZUVÆH[ZZUTY V[RRKJÆU[ZÆZUÆZNKÆ54 VUYOZOUTÆGIZO\GZKÆZNK LUUZÆY]OZINÆGTJÆINKIQ ZNKÆ\URZGMKÆGZÆZKXSOTGR ÉÆUTÆZNKÆJXO\KÆPU_YZOIQ *6 <ÆUXÆSUXK 'IZO\GZKÆZNKÆLUUZÆY]OZIN RKYY GTJÆINKIQÆZNKÆ\URZGMKÆGZ ZNGT < ZKXSOTGRÆÉÆUTÆZNK NUXYKVU]KXÆROSOZKX IOXI[OZÆHUGXJ )NKIQÆIUTZOT[OZ_ÆUL 8KVGOXÆUVKTÆOTÆVU]KX HXU]TÆMXU[TJÆ]OXKÆLXUS IUTZOT[OZ_ Y[VVR_ÆIOXI[OZÆLXUSÆ:6 ZKXSOTGRÆÉÆUTÆ*6ÆZU ZUÆZKXSOTGRÆÉÆUTÆJXO\K MXU[TJ PU_YZOIQÆ*6 TUÆIUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆLXUS MXU[TJÆZUÆ*6 )NKIQÆIUTZOT[OZ_ÆUL 8KVGOXÆUVKTÆOTÆVU]KX HXU]TÆMXU[TJÆ]OXKÆLXUS IUTZOT[OZ_ Y[VVR_ÆIOXI[OZÆLXUSÆ:6 ZKXSOTGRÆÉÆUTÆZNK ZUÆZKXSOTGRÆÉÆUTÆZNK NUXYKVU]KXÆROSOZKX NUXYKVU]KXÆROSOZKX IOXI[OZÆHUGXJÆZUÆMXU[TJ IOXI[OZÆHUGXJ TUÆIUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆLXUS MXU[TJÆZUÆZKXSOTGRÆÉÆUT ZNKÆNUXYKVU]KXÆROSOZKX IOXI[OZÆHUGXJ <ÆUXÆSUXK 9ZGXZÆZNKÆKTMOTKÆZNKT GIZO\GZKÆZNKÆLUUZÆY]OZIN GTJÆNURJÆZNKÆJXO\K PU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆGTJ INKIQÆZNKÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆZNK NUXYKVU]KXÆROSOZKX HUGXJ < 'IZO\GZKÆZNKÆLUUZÆY]OZIN ÆZUÆ< GTJÆINKIQÆZNKÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆZNK NUXYKVU]KXÆROSOZKX HUGXJ < 'IZO\GZKÆZNKÆLUUZÆY]OZIN GTJÆINKIQÆZNKÆ\URZGMK UTÆZNKÆUXMHRQÆÉ]OXK UTÆZNKÆGRZKXGZUX < 8KVGOXÆUXÆXKVRGIK GRZKXTGZUX ÆZUÆ< 8KVRGIKÆNUXYKVU]KX ROSOZKXÆHUGXJ 8KVGOXÆUVKTÆOTÆUXMHRQ ÉÆ]OXKÆLXUSÆGRZKXTGZUX ZUÆ:(ÆZUÆ:6ÆZU ZKXSOTGRÆÉÆUT NUXYKVU]KXÆROSOZKX HUGXJ ÆZUÆ< )UTZOT[KJÆUTÆZNKÆTK^Z VGMK Part No. Be sure machine is not in the free wheel configuration.71 . All Other Functions Operate Normally Be sure the rpm toggle switch is in the footswitch activated high idle position. 52709 Genie Z-45/25 & Genie Z-45/25J 5 . 52709 .72 Genie Z-45/25 & Genie Z-45/25J Part No.Section 5 • Troubleshooting Flow Charts First Edition • Second Printing CHART 33 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK 'IZO\GZKÆZNKÆLUUZÆY]OZIN GTJÆNURJÆZNKÆJXO\K PU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆGTJ INKIQÆZNKÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆZNKÆJXO\K PU_YZOIQÆIUTZXURRKX ÆZUÆ< < 8KVGOXÆUVKTÆOTÆ]OXKÆLXUS ZKXSOTGRÆÉÆUT NUXYKVU]KXÆROSOZKX HUGXJÆZUÆZKXSOTGRÆÉÆUT ZNKÆJXO\KÆPU_YZOIQ )UTTKIZÆZNKÆVUYOZ\K RKGJÆLXUSÆGÆ\URZSKZKXÆZU < ZKXSOTGRÆÉÆUTÆZNK PU_YZOIQÆGTJÆZNKÆTKMGZO\K RKGJÆZUÆZKXSOTGRÆÉÆUT ZNKÆPU_YZOIQÆ'IZO\GZKÆZNK LUUZÆY]OZINÆGTJÆNURJÆZNK JXO\KÆPU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆGTJ INKIQÆZNKÆ\URZGMK GIXUYYÆZNKÆÉÆGTJÆÉ ZKXSOTGRYÆUTÆZNKÆJXO\K PU_YZOIQÆIUTZXURRKX < )UTTKIZÆZNKÆVUYOZ\K RKGJÆLXUSÆGÆ\URZSKZKXÆZU < ZKXSOTGRÆÉÆUTÆZNK PU_YZOIQÆGTJÆZNKÆTKMGZO\K RKGJÆZUÆZKXSOTGRÆÉÆUT ZNKÆPU_YZOIQÆ'IZO\GZKÆZNK LUUZÆY]OZINÆGTJÆNURJÆZNK JXO\KÆPU_YZOIQÆOTÆZNKÆL[RR XK\KXYKÆVUYOZOUTÆGTJ INKIQÆZNKÆ\URZGMK GIXUYYÆZNKÆÉÆGTJÆÉ ZKXSOTGRYÆUTÆZNKÆJXO\K PU_YZOIQÆIUTZXURRKX )NKIQÆIUTZOT[OZ_ÆLXUS ZKXSOTGRÆÉÆUTÆJXO\K PU_YZOIQÆZUÆMXU[TJ IUTZOT[OZ_ 8KVRGIKÆJXO\KÆPU_YZOIQ IUTZXURRKXÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ TU IUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆLXUS ZKXSOTGRÆÉÆUTÆJXO\K PU_YZOIQÆZUÆMXU[TJ )NKIQÆIUTZOT[OZ_ÆLXUS ZKXSOTGRÆÉÆUTÆJXO\K PU_YZOIQÆZUÆMXU[TJ IUTZOT[OZ_ 8KVRGIKÆJXO\KÆPU_YZOIQ IUTZXURRKXÆ58ÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ TU IUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆHXU]T MXU[TJÆ]OXKÆIOXI[OZÆLXUS ZKXSOTGRÆÉÆUTÆJXO\K PU_YZOIQÆZUÆMXU[TJ < )UTZOT[KJÆUTÆZNKÆTK^Z VGMK 5 . 73 . 52709 Genie Z-45/25 & Genie Z-45/25J 5 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts CHART 33 )UTZOT[KJÆLXUSÆZNK VXK\OU[YÆVGMK 'IZO\GZKÆZNKÆLUUZÆY]OZIN GTJÆNURJÆZNKÆJXO\K PU_YZOIQÆOTÆZNKÆL[RR < LUX]GXJÆVUYOZOUTÆGTJ INKIQÆZNKÆ\URZGMK GIXUYYÆZNKÆ]NZÆÉÆ]OXK GTJÆZNKÆ]NZHRQÆÉÆ]OXK UTÆ+*) =OZNÆZNKÆLUUZÆY]OZIN GIZO\GZKJÆGTJÆZNKÆJXO\K PU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆSU\K < ZNKÆJXO\KÆKTGHRKÆZUMMRK Y]OZINÆ:9ÆZUÆKOZNKX YOJKÆGTJÆINKIQÆZNK \URZGMKÆGIXUYYÆZNKÆ]NZ ÉÆ]OXKÆGTJÆZNKÆ]NZHRQ ÉUTÆ+*) < )UTTKIZÆZNKÆVUYOZ\K RKGJÆLXUSÆGÆ\URZSKZKXÆZU < ZKXSOTGRÆÉÆUTÆZNK PU_YZOIQÆGTJÆ]OZNÆZNKÆLUUZ Y]OZINÆGIZO\GZKJÆGTJÆZNK JXO\KÆPU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆSU\K ZNKÆJXO\KÆKTGHRKÆZUMMRK Y]OZINÆ:9ÆZUÆKOZNKX YOJKÆGTJÆNURJÆZNK TKMGZO\KÆRKGJÆLXUSÆZNK \URZSKZKXÆUTZUÆZNK HR[]NZÆ]OXKÆUTÆ:9 GTJÆINKIQÆZNKÆ\URZGMK 8KVGOXÆUVKTÆOTÆ]NZÆ]OXK LXUSÆZKXSOTGRÆÉÆUT JXO\KÆPU_YZOIQÆZUÆ:9ÆZU :6ÆZUÆ:(ÆZNXU[MN JXO\KÆKTGHRKÆROSOZÆY]OZIN 29ÆZUÆ:(ÆZUÆ]NZ ÉÆ]OXKÆUTÆ+*)ÆW[OIQ JOYIUTTKIZÆVR[M 8KVGOXÆUVKTÆOTÆHR[]NZ ]OXKÆLXUSÆ:9ÆZUÆ:6 ZUÆ:( < < )UTTKIZÆZNKÆVUYOZ\K RKGJÆLXUSÆGÆ\URZSKZKXÆZU ZKXSOTGRÆÉÆUTÆZNK PU_YZOIQÆGTJÆ]OZNÆZNKÆLUUZ < Y]OZINÆGIZO\GZKJÆGTJÆZNK JXO\KÆPU_YZOIQÆOTÆZNKÆL[RR LUX]GXJÆVUYOZOUTÆNURJ ZNKÆTKMGZO\KÆRKGJÆULÆZNK \URZSKZKXÆUTZUÆZNK IKTZKXÆZKXSOTGRÆULÆZNK JXO\KÆKTGHRKÆZUMMRK Y]OZINÆ:9ÆGTJÆINKIQ ZNKÆ\URZGMK < 8KVRGIKÆJXO\KÆKTGHRK ZUMMRKÆY]OZINÆ:9 8KVGOXÆUVKTÆOTÆ]OXKÆLXUS ZKXSOTGRÆÉÆLXUSÆJXO\K PU_YZOIQÆ*6ÆZUÆJXO\K KTGHRKÆZUMMRKÆY]OZIN :9Æ58ÆXKVRGIKÆJXO\K PU_YZOIQÆIUTZXURRKXÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ :XU[HRKYNUUZÆJXO\K LUX]GXJÆGTJÆJXO\K XK\KXYKÆL[TIZOUTY YKVGXGZKR_Æ58ÆXKVRGIK V[SVÆ58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ Part No. 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 34 Drive Forward Or Reverse Function Inoperative Be sure all other functions operate normally including drive in opposite direction of malfunction.G[RZ_Æ9[TJYZXGTJÆJXO\K V[SVÆIUTZGIZ 9[TJYZXGTJÆG[ZNUXO`KJ XKVGOXÆLGIOROZ_ Y_SVZUSYÆOSVXU\K 8KGJP[YZÆJXO\KÆPU_YZOIQ IUTZXURRKXÆ58ÆOLÆVXUHRKS YZORRÆVKXYOYZYÆIUTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 5 .74 Genie Z-45/25 & Genie Z-45/25J Part No. *OYIUTTKIZÆZNKÆ+*) ]OXKÆIUTTKIZUXÆLXUSÆZNK JXO\KÆV[SVÆYZGXZ KTMOTKÆSU\KÆZNKÆJXO\K IUTZXURRKXÆZUÆL[RRÆLUX]GXJ VUYOZOUTÆGTJÆTUZKÆZNK \URZGMKÆGIXUYYÆZNKÆ]NZ ÉÆGTJÆZNKÆ]NZHRQÆÉ ]OXKÆZKXSOTGRYÆUTÆZNK +*)Æ8K\KXYKÆZNKÆ\URZ SKZKXÆRKGJYÆGTJÆSU\K ZNKÆJXO\KÆIUTZXURRKXÆZUÆL[RR XK\KXYKÆVUYOZOUTÆGTJ TUZKÆZNKÆ\URZGMK \URZGMKÆXKGJOTMYÆJOLLKXKTZ 8KVGOXÆUXÆXKVRGIKÆZNK JXO\KÆIUTZXURRKXÆ*6 \URZGMKÆXKGJOTMY ZNKÆYGSK ÆUX OTLOTOZK )NKIQÆZNKÆXKYOYZGTIKÆUL UNSY ZNKÆ+*) ÆZUÆÆUNSY 'JP[YZÆZNKÆJXO\KÆV[SV T[RRÆTK[ZXGRÆ)UTY[RZ -KTOKÆ/TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 8KVRGIKÆZNKÆ+*) TUÆOSVXU\KSKTZ . 'T_ÆZ_VKÆULÆZXGIZOUT VXUHRKSÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 5 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 35 Traction Function Inoperative Be sure all other functions operate normally.75 . Be sure the wiring to limit switches is intact and show no sign of damage or corrosion. 8KVGOXÆYNUXZÆZUÆMXU[TJ =OZNÆZNKÆHUUSÆOTÆZNK YZU]KJÆVUYOZOUTÆINKIQ IUTZOT[OZ_ OTÆ]NZÆ]OXKYÆZUÆROSOZ Y]OZINKYÆ29Æ29ÆGTJ IUTZOT[OZ_ÆLXUSÆ:(ÆZU 29Æ58ÆXKVGOXÆUX MXU[TJ XKVRGIKÆVXOSGX_ÆHUUSÆROLZ JXO\KÆROSOZÆY]OZIN YKIUTJGX_ÆHUUSÆJXO\K ROSOZÆY]OZINÆUXÆVXOSGX_ HUUSÆK^ZKTJÆROSOZ TUÆIUTZOT[OZ_ Y]OZIN =OZNÆZNKÆHUUSÆOTÆZNK 8KVGOXÆYNUXZÆZUÆMXU[TJ YZU]KJÆVUYOZOUTÆINKIQ OTÆUXGTMKÆ]OXKÆLXUS IUTZOT[OZ_ :(ÆZUÆ:6ÆZU ZKXSOTGRÆÉÆUT NUXYKVU]KXÆROSOZKX ZKXSOTGRÆÉÆUT HUGXJÆLUXÆIUTZOT[OZ_ÆZU NUXYKVU]KXÆROSOZKX MXU[TJ IOXI[OZÆHUGXJ TUÆIUTZOT[OZ_ 8KGJP[YZÆUXÆXKVRGIK NUXYKVU]KXÆROSOZKX HUGXJÆ58ÆINKIQÆLUX SOYGROMTSKTZÆULÆROSOZ Y]OZINKYÆ29Æ29ÆGTJ 29Æ58ÆIUTY[RZÆ-KTOK /TJ[YZXOKYÆ9KX\OIK *KVGXZSKTZ 5 . Be sure the machine is not raised above or extended beyond the drive limit switches. Be sure the freewheel valve is closed on the drive pump. Be sure the secondary boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position. Be sure that the primary boom extend drive limit switch arm is being activated when the boom is fully retracted. 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 36 Machine Will Not Drive At Full Speed Be sure all other functions operate normally.76 Genie Z-45/25 & Genie Z-45/25J Part No. Be sure the primary boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position. 8KVRGIKÆNUXYKVU]KX +^ZKTJÆZNKÆHUUSÆVGYZ ROSOZKXÆHUGXJÆ58ÆXK ZNKÆJXO\KÆROSOZÆY]OZINÆGTJ IUTZOT[OZ_ GJP[YZÆNUXYKVU]KX INKIQÆIUTZOT[OZ_ÆLXUS ROSOZKXÆHUGXJÆ58ÆIUTY[RZ MXU[TJÆZUÆZKXSOTGRÆÉÆUT -KTOKÆ/TJ[YZXOKYÆ9KX\OIK ZNKÆNUXYKVU]KXÆROSOZKX *KVGXZSKTZ HUGXJ TUÆIUTZOT[OZ_ )NKIQÆIUTZOT[OZ_ÆLXUS MXU[TJÆZUÆ:( TUÆIUTZOT[OZ_ :KYZÆROSOZÆY]OZINKYÆ9KK VXUIKJ[XKÆ'ÆOTÆZNK 3GOTZKTGTIKÆ9KIZOUT MUUJ 8KVGOXÆUVKTÆLXUSÆ]NZ ]OXKYÆGZÆ:(ÆZUÆJXO\K ROSOZÆY]OZINKYÆ29Æ29 GTJÆ29ÆZNKTÆLXUS HXU]TÆMXU[TJÆ]OXKYÆZU MXU[TJ IUTZOT[OZ_ 8KVGOXÆUVKTÆOTÆUXMÆ]OXK IOXI[OZÆLXUSÆ:(ÆZU :6ÆZUÆZKXSOTGRÆÉÆUT NUXYKVU]KXÆROSOZKX IOXI[OZÆHUGXJ HGJ 8KVRGIKÆLG[RZ_ÆROSOZ Y]OZINÆIUTZGIZÆ58 XKVRGIKÆROSOZÆY]OZIN Part No. Be sure that the primary boom extend drive limit switch is not being held down or being activated when the primary boom is extended. 52709 Genie Z-45/25 & Genie Z-45/25J 5 . Be sure secondary boom drive limit switch is being activated by the cam on the compression link when the secondary boom is raised. Be sure the wiring to limit switches is intact and show no sign of damage or corrosion.77 .First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 37 Machine Drives At Full Speed With Platform Raised or Extended Be sure primary boom drive limit switch is being activated by the cam on the primary boom when the primary boom is raised. =OZNÆQK_ÆY]OZINÆOT VRGZLUXSÆVUYOZOUTÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV TU H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆGTJÆZNK HUUSÆXUZGZKJÆHKZ]KKT ZNKÆTUTYZKKXÆZOXKY GIZO\GZKÆLUUZÆY]OZINÆGTJ JXO\KÆIUTZXURRKXÆOT LUX]GXJÆJOXKIZOUTÆ=ORR [TOZÆJXO\K% _KY =OZNÆQK_ÆY]OZINÆOT VRGZLUXSÆVUYOZOUTÆGTJ HUZNÆ+SKXMKTI_Æ9ZUV TU H[ZZUTYÆV[RRKJÆU[ZÆZUÆZNK 54ÆVUYOZOUTÆGTJÆZNK HUUSÆXUZGZKJÆHKZ]KKT ZNKÆYZKKXÆKTJÆZOXKY GIZO\GZKÆLUUZÆY]OZINÆGTJ JXO\KÆIUTZXURRKXÆOT LUX]GXJÆJOXKIZOUTÆ=ORR [TOZÆJXO\K% _KY )NKIQÆLUXÆIUTZOT[OZ_ LXUSÆ:(ÆZUÆ:( TUÆIUTZOT[OZ_ 8KVGOXÆUVKTÆLXUSÆ:( ZUÆ29ÆZNKTÆLXUSÆ29ÆZU :( 'IZO\GZKÆLUUZÆY]OZINÆGTJ < JXO\KÆIUTZXURRKXÆOT LUX]GXJÆJOXKIZOUTÆGTJ INKIQÆ\URZGMKÆGZ ZKXSOTGRÆÉÆUTÆJXO\K IUTZXURRKXÆ*6 <ÆUXÆSUXK 8KVGOXÆUVKTÆLXUS ZKXSOTGRÆÉÆUTÆ*6ÆZU IKTZKXÆZKXSOTGRÆUTÆ:9 58ÆXKLKXÆZUÆ)NGXZÆÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ . 52709 .Section 5 • Troubleshooting Flow Charts First Edition • Second Printing Chart 38 Drive Enable System Is Malfunctioning Be sure the boom is in the stowed position.URJÆZNKÆJXO\KÆKTGHRK Y]OZINÆ:9ÆZUÆKOZNKX YOJKÆGTJÆGIZO\GZKÆZNK LUUZÆY]OZINÆGTJÆJXO\K LUX]GXJÆL[TIZOUTÆ=ORR [TOZÆJXO\K% TU 8KVGOXÆUVKTÆOTÆHR[]NZ ]OXKÆLXUSÆJXO\KÆKTGHRK ZUMMRKÆY]OZINÆ:9ÆZU :6ÆZUÆ:(Æ58 XKVRGIKÆJXO\KÆKTGHRK ZUMMRKÆY]OZINÆ:9 8KVGOXÆUVKTÆOTÆVU]KX Y[VVR_ÆIOXI[OZÆLXUS :6 _KY :NKÆSGINOTKÆOY UVKXGZOTMÆIUXXKIZR_Æ/L SGINOTKÆJUKYÆTUZ UVKXGZKÆVXUVKXR_ IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ IUTZOT[OZ_ 'IZO\GZKÆROSOZÆY]OZINÆH_ 8KVRGIKÆJXO\KÆKTGHRK IUTZOT[OZ_ ROSOZÆY]OZINÆIUTZGIZÆ58 NGTJÆGTJÆINKIQ IUTZOT[OZ_ÆLXUSÆ:(ÆZU XKVRGIKÆJXO\KÆKTGHRK :( ROSOZÆY]OZINÆ29 TUÆIUTZOT[OZ_ 6RKGYKÆHKMOT ZXU[HRKYNUUZOTMÆLXUS HKMOTTOTMÆULÆINGXZÆ58 IUTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 5 .78 Genie Z-45/25 & Genie Z-45/25J Part No. First Edition • Second Printing Section 5 • Troubleshooting Flow Charts Chart 39 Auxiliary Functions Inoperative Be sure all other functions operate normally. Be sure engine is not running when using auxiliary power. Note: Operating auxiliary power with the engine running should immediately kill the engine. Be sure key switch is in the appropriate position and both Emergency Stop buttons are pulled out to the ON position. 52709 Genie Z-45/25 & Genie Z-45/25J 5 . 2OLZÆZNKÆXKJÆG[^OROGX_ SUZUX V[SVÆY]OZINÆIU\KXÆOL KW[OVVKJÆNURJÆG[^OROGX_ UVKXGZKY Y]OZINÆGTJÆROYZKTÆLUX YU[TJÆULÆG[^OROGX_ÆV[SV SUZUXÆUVKXGZOTM /TYZGRRÆGÆÆZUÆÆVYO ÆZUÆÆHGXÆVXKYY[XK MG[MKÆOTZUÆZNKÆVXKYY[XK VUXZÆULÆZNKÆG[^OROGX_ V[SVÆGTJÆNURJÆZNK G[^OROGX_ÆVU]KXÆZUMMRK Y]OZINÆGTJÆTUZKÆZNK VXKYY[XK RKYYÆZNGT ÆVYO )NKIQÆLUXÆGÆVUYOZO\K IUTTKIZOUTÆHKZ]KKT KRKIZXOIÆSUZUXÆGTJÆZNK V[SVÆH_ÆXKSU\OTMÆZNK V[SVÆLXUSÆZNKÆSUZUX H[ZÆRKG\KÆGRRÆZNKÆNUYKY IUTTKIZKJÆ<OY[GRR_ INKIQÆIU[VROTM IUTTKIZOUT HGJ 8KVRGIKÆZNKÆG[^OROGX_ VU]KXÆ[TOZ MUUJ 8KVGOXÆUXÆXKVRGIKÆV[SV 58ÆXKVRGIKÆXKROKLÆ\GR\K )UTY[RZÆ-KTOKÆ/TJ[YZXOKY 9KX\OIKÆ*KVGXZSKTZ 8KIUTTKIZÆVXKYY[XK ROTKÆGTJÆINKIQÆHGZZKX_ ÆÆVYO IUTJOZOUTÆ:NKXKÆOY VUYYOHR_ÆTUZÆKTU[MN HGZZKX_ÆIGVGIOZ_ÆZU UVKXGZKÆHUZNÆG[^ÆV[SV GTJÆL[TIZOUTÆ\GR\KY SUZUXÆJUKY TUZÆUVKXGZK =OZNÆZNKÆQK_ÆY]OZIN Z[XTKJÆZUÆMXU[TJÆIUTZXUR GTJÆHUZNÆ+SKXMKTI_ 9ZUVÆH[ZZUTYÆV[RRKJÆU[Z ZUÆZNKÆ54ÆVUYOZOUT GIZO\GZKÆZNKÆG[^OROGX_ V[SVÆZUMMRKÆY]OZINÆGTJ INKIQÆZNKÆ\URZGMKÆUTÆZNK XKJÆIGHRKÆUTÆZNK G[^OROGX_ÆVU]KXÆ[TOZ < 'IZO\GZKÆZNKÆG[^OROGX_ V[SVÆZUMMRKÆY]OZINÆGTJ INKIQÆZNKÆ\URZGMKÆGZ :( < 'IZO\GZKÆZNKÆG[^OROGX_ V[SVÆZUMMRKÆY]OZINÆGTJ INKIQÆZNKÆ\URZGMKÆGZÆZNK IKTZKXÆZKXSOTGRÆULÆ:9 <ÆUXÆSUXK <ÆUX SUXK 8KVGOXÆUVKTÆLXUSÆ:( ZUÆ68Æ58ÆXKVGOXÆUVKT OTÆHXU]TÆMXU[TJÆ]OXK IOXI[OZÆZUÆ68Æ58 XKVRGIKÆ68 < 8KVGOXÆUVKTÆOTÆXKJ VU]KXÆY[VVR_Æ]OXKÆLXUS QK_ÆY]OZINÆ19ÆZU G[^OROGX_ÆZUMMRKÆY]OZIN :9 < 8KVGOXÆUVKTÆOTÆXKJÆÉ ]OXKÆLXUSÆ:9ÆZUÆ:( 58ÆXKVRGIKÆ:9 )NKIQÆIUTZOT[OZ_ÆLXUS TKMGZO\KÆZKXSOTGRÆUT G[^OROGX_ÆVU]KXÆ[TOZÆZU MXU[TJ MUUJ 8KVRGIKÆG[^OROGX_ÆV[SV SUZUX HGJ 8KVRGIKÆTKMGZO\KÆIGHRK LXUSÆG[^OROGX_ÆV[SVÆZU MXU[TJ Part No.79 . Section 5 • Troubleshooting Flow Charts First Edition • Second Printing This page intentionally left blank.80 Genie Z-45/25 & Genie Z-45/25J Part No. 5 . 52709 . Remove all rings. 52709 Genie Z-45/25 & Genie Z-45/25J 6-1 . Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Spraying hydraulic oil can penetrate and burn skin. General Repair Process Before Troubleshooting: Read. Hydraulic Schematics Bodily injury hazard. Contact with electrically charged circuits may result in death or serious injury. Be sure that all necessary tools and test equipment are available and ready for use. Repair any machine damage or malfunction before operating the machine. Do not allow oil to squirt or spray. Immediately tag and remove from service a damaged or malfunctioning machine. Electrocution hazard. understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 & Genie Z-45/25J Operator's Manual. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Malfunction discovered Identify symptoms Troubleshoot problem still exists Return to service problem solved Inspect and test Perform repair Part No.First Edition • Second Printing Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. watches and other jewelry. ........................ SPDT.... Motorola .............. XB-09-630-Q ... Battery.2..... 2.... 12V DC ................ Telemecanique .......... Potter-Brumfield ................................................ intermittent ... 24018 ............. Motorola ...... 12V DC ................. Hourmeter ........ 1 KS1 ....... 1 H1 ......... 36872 ........ MOTMR752 ...............................12. 34052 .. Relay.... 1 H3 ..............................7............. VF4-15F11-CO5 .. 12V DC ....... 4 L1....... LED ........... ................................. 32335 ............. XESP2051 . ...... Alarm....... Curtis Instruments ................ SPDT................3 (Diesel) ................ 34052 .. ............. 19274 .... Alarm..... 52709 ....2........... Circuit breaker ............... 32335 ..................................3... CR7. 45782 .....8 CR7..... 12V DC ........ (Gas/LPG) ...... 20189 ............ Floyd Bell Inc.........Limit switch....... 45462 ......................... Wolo Industries.... 200 PIV ..... Arctolectric Corp.................... 1 H2 ................... ZB2-BE101 ...... Potter-Brumfield ............... 1 HM .. 25 DP1 ............ EJS5DM11179 ................. chime tone ............. 6 amp.............................. Warble tone .... Joystick controller... Joystick controller .......... N.. 19491 ....... N..................................... 18963 ........ Diode.........Section 6 • Schematics First Edition • Second Printing Electrical Components Item Description Genie Part Number Manufacturer Manufacturer Part Number Qty BAT .. 300ST .. ECCO Electronic Controls ........... ETA ..... 632-S ........ 130 dB .................... MW-09-616-Q .............. Relay.Red............. 12V DC .................Red............................ Dual axis ...H......................................... 45782 ......4 (Gas/LPG) ............. Footswitch ... LE177C39007 ....4... MOTMR752 .O......C...12 GEN ..... 2 L1........... 200 PIV .... 56264 ..................... 3 LS1...... .... Contact .. 56100 ..... Horn..... 3 This list continues on the next page..... ..... SPDT........... CB2 .......... (Diesel) .. VF4-15F11-CO5 ........ VF4-15F11-CO5 ...... 8......... 45081 ...... Diode......... 45-700-IG1-P10 ............. 17305666 .....Drive ............ Contact ........... 6-2 Genie Z-45/25 & Genie Z-45/25J Part No...... CH-09-525-Q . 1 BP1 ... 6 CR1through 5........... Potter-Brumfield .2......... 1 FB .....Keyswitch. Floyd Bell Inc. .... Telemecanique ........................ Flashing beacon ...... 8........ LE177C39007 ........ Floyd Bell Inc......... 12V DC..........5.......................................................... 34DT78 .. Alarm. Delco ... OEM Controls .. 25 Diode (Diesel) ............. LED ....... 19270 .. 12V DC .............. Linemaster Switch Corp...... 1 H4 .. 2 Diode (Gas/LPG) ..... 7 CR7.... 3 ....... 20424 .................. ...................... ............. ............................O.............................. 900 CCA... 6400A-GEN ....... 1 FS1 .................... 2 CR1.. OEM Controls . Relay... 6 amp... 1 CB1.... 13482 .................13 and 14 (Diesel) .. 53073 ... Arctolectric Corp.. MCH1159AD1386 .. .. 13038 .......................... 4.....15..... TS51 (Diesel) ....... SPDT 3 position momentary ............ N........... 44586 ... 10 TS14 .. 1 R4.......... Telemecanique ........... ..... ............... Resistor................................. .. (after serial number 13098) Resistor.. 3...First Edition • Second Printing Section 6 • Schematics ELECTRICAL COMPONENTS Item Description Genie Part Number Manufacturer Manufacturer Part Number Qty Level sensor ......... .. ZB2-BE101 .... 70-902 ..... 1 R3 .....50R-1% .... Resistor.. 13480 .. RH25-100R-1% ...... Toggle switch............. .............. .................. 59..... Power Comp... 61...13...... 1 TS7.......... 100Ω 25 watt .............. Dale ........... LS36 ............... DPDT 3 position momentary ..............O.13..5° .. 4 P3 .............. 1 R2 ..... 1 PR1 ............ ........................ Toggle switch...................... 1 R1 .... 10Ω 25 watt ...... 59....... 5 Part No.. (before serial number 13099) Resistor............. ........ 52709 Genie Z-45/25 & Genie Z-45/25J 6-3 ...................................54. 49866 ...... Toggle switch..... SPDT 3 position momentary .250R-1% ........ Toggle switch...............52....... 1 P1.... 1 TS4 ............ RH25-15R-1% ...... 1 R5 ............ 15Ω 25 watt .....................8....... 62................................. 57........................... 2NT1-7 . 2NT1-1 .............. 1NT1-7 .. Microswitch Control Inc....... Microswitch Control Inc.. 63 (Diesel) ............... 1 R4....................... Dale .......... N.............. DPDT 3 position maintained .... 50Ω 5 watt .... 54516 ........ Toggle switch.... 9 TS2..... Resistor................................ 2NT1-3 ........... 2 TS2............ Dale .............. 27287 ...... Microswitch Control Inc..... Dale .... 45836 .. ........................ 1 TS1............ Microswitch Control Inc..... RH5. Microswitch Control Inc.......58..... 9. 2NT1-8 ........ .........C.......54 58... Microswitch Control Inc............. 27378 .. 10Ω 25 watt .................................... DPST 2 position momentary ........... Relay. 9.......... Dale .... 13037 ... Toggle switch.... 1NT1-7 .... DPST 2 position maintained ..... RH5... TS64 (Gas/LPG) .. 13480 ....... D25K10R ...15............ 250Ω 5 watt . of Midwest .... 3 TS1.............. Resistor..... DPST 2 position momentary ................................................. 12V DC continuous ........... 60.. P2 ................................. Toggle switch........................ Telemecanique ................. 27155 ...... 29732 ........... 63 (Gas/LPG) .... ZB2-BE102 ....... 52........ 27116 ....... 16397 .......... Contact.. RH25-10R-1% ..... 2NT1-8 ......... Stancor .. 13037 ... Microswitch Control Inc...................... 45081 ....... 27117 .............. Dale ............................................ Contact................ Level sensor.... TS51....... 52709 .Section 6 • Schematics First Edition • Second Printing Electrical Symbols Legend 6-4 Genie Z-45/25 & Genie Z-45/25J Part No. . Resistor TB ....................... 52709 Genie Z-45/25 & Genie Z-45/25J 6-5 ................. Keyswitch L ...................................... Power switch PR ........ Terminal platform location TS ...........First Edition • Second Printing Section 6 • Schematics Abbreviation Legend LABEL DESCRIPTION BAT ................. Battery BP .......................... Drive proportional controller FB .. Boom Proportional controller CB ......................... Circuit breaker CR ......... Power relay R .......... Hour meter KS .... Foot switch H ........................... LED LS .... Toggle switch Part No.... Terminal base location TP .... Horn or Alarm HM ......... Control relay DP . Limit switch P ........................ Flashing beacon FS ........................ Section 6 • Schematics First Edition • Second Printing 6-6 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 . Section 6 • Schematics First Edition • Second Printing Ford LRG-425 EFI Engine Wire Harness (before serial number 13099) . DATA LINK DRIVE BY WIRE SIGNAL INPUT AUXILARY INPUT WHT/PUR 18awg SELF TEST INPUT * TAN/LB 18awg GOV. 52709 . CONT. SPD. SWITCH VPWR * PINK/BLK 16awg FUEL PUMP OUTPUT VREF BLK/WHT 10awg BATT. AND WIRE GUAGE EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74. BLK/Y 18awg GOV. GREY WIRE WITH LIGHT BLUE STRIPE. BLK/WHT 10awg BATT. SPD. COLOR.Section 6 • Schematics Service Manual Ford LRG-425 EFI Engine Wire Harness (before serial number 13099) A 1 THROTTLE ACTUATOR/ POSITION SENSOR FUEL INJECTOR VALVES POWER CR-FA 87A B C D E F G H I J K L M N FORD WIRING HARNESS WIRE COLOR CODE FUEL PUMP CR-FB 87A STARTER CR-FC 87A CODE BL COLOR BLUE BLACK BROWN DARK BLUE DARK GREEN GREEN CODE GY LB LG N O PK COLOR GREY LIGHT BLUE LIGHT GREEN NATURAL ORANGE PINK CODE P R T W Y COLOR PURPLE RED TAN WHITE YELLOW 30 30 30 #4 WATER TEMP. SWITCH (NO) #3 #2 #1 BK BR 87 87 86 86 87 86 85 85 85 DB DG GN 2 37CY16 361ER16 926ALB/O16 787APK/BK16 37AY12 16BR/LG18 570DBK/W18 361R12 359CGY/R18 355GY/W18 351BBR/W18 361DR14 558BR/LB18 570BK/W12 39RW20 361CR14 557BR/Y18 361JR14 264W/LB18 32R/LB16 16R/LG16 342LG/P16 32ADKBL16 361AR14 555T18 361BR14 556W18 FORD ENGINE CONTROL MODULE (ECM) QUICK DISCONNECTS (TO ECM) 95TW18 361LR18 37BY18 X1 F1 K1 F2 H1 A3 G1 H2 J1 C1 F3 Y3 Y2 W3 S3 S2 S1 T1 A2 R2 B3 C2 X2 X3 W1 W2 C3 E3 G2 G3 M1 A1 L1 H3 J2 K2 R3 K3 M2 N2 P3 L2 M3 B2 N1 N3 P1 D1 B1 D2 T2 L3 E1 R1 D3 J3 T3 P2 Y1 E2 IGNITION COIL 1 NOT USED VPWR KEEP ALIVE PWR NOT USED NOT USED CRANKSHAFT SENSOR RETURN (+) CRANKSHAFT SENSOR RETURN (-) CAMSHAFT SENSOR FEED (+) THROTTLE POSITION SENSOR INPUT FUEL PUMP MONITOR NOT USED NOT USED NOT USED FUEL INJECTOR #1 FUEL INJECTOR #2 FUEL INJECTOR #3 FUEL INJECTOR #4 VREF DRY FUEL MODULATOR NOT USED NOT USED POWER GROUND POWER GROUND POWER GROUND POWER GROUND NOT USED NOT USED NOT USED NOT USED DATA LINK DRIVE BY WIRE AUXILLARY INPUT SELF TEST INPUT GOVERNOR SELECT #1 GOVERNOR SELECT #2 MALFUNCTION INDICATOR LAMP FUEL SELECT DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) FUEL PUMP RELAY CONTROL NOT USED NOT USED SINGLE RETURN NOT USED NOT USED NOT USED INTAKE AIR TEMP SENSOR MAP SENSOR INPUT ECT SENSOR NO USAGE STARTER LOCKOUT NOT USED IDLE AIR CONTROL DRY FUEL SENSOR OIL PRESSURE GROUND DRYFUEL LOCKOFF IGNITION COIL 2 HO2S SENSOR SIDE MATING FACE SHOWN A B C D E 3 349DB18 350GY18 282DB/O18 355GY/W18 238ADG/Y18 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 1) TACH LEAD RED 10awg KEEP ALIVE PWR * YELLOW 10awg KEEP ALIVE PWR * WATER TEMP. 18 GUAGE WIRE 2. WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER. * BRN/WHT 20awg FUEL SELECT * DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) DB/BL 16awg STARTER INPUT DRIVE BY WIRE SIGNAL RETURN RED/LB 16awg STARTER OUTPUT OIL PRESSURE SWITCH * NOTE: * SHOWS USED WIRES 2 1 8 16 9 5 31 34 42 22 14 37 18 24 25 6 7 11 3 15 33 13 26 11T/Y20 16AR/LG16 37BY18 39RW20 37Y12 767PK/BK16 351DBR/W20 570CBK/W12 570EBK/W12 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 32ADKBL16 359LGY/Y20 32R/LB16 253DG/W20 555T18 556W18 557BR/Y18 558BR/LB18 351BR/W18 77DB/Y18 570BK/W18 570ABK/W18 570BBK/W18 570HBK/W18 F G H J K 1 2 3 4 5 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 926ALB/O16 359FGY/R20 1 2 3 L M N P R S T W X Y 9 42 743GY20 358LG/BK20 354LG/R18 342LG/P16 6 264W/LB18 225BK/Y20 253BDG/W20 57BK18 242DG18 96T/O18 74GY/LB18 MATING FACE SHOWN 1 34 354LG/R18 359DGY/Y20 74GY/LB18 89AO18 570NBK/W18 34LB/O18 658PK/LG20 570BK/W20 107P20 915PK/LB20 914T/O20 209W/P20 349DB18 350GY18 282DB/O18 359AGY/R18 743GY20 359JGY/R18 225BK/Y20 359MGY/Y20 361NR18 77DB/Y18 351CBR/W20 358LG/BK20 359KGY/Y20 253ADG/W20 96T/O18 16CR/LG16 95AT/W18 57BK18 361PR18 242DG18 7 MATING FACE SHOWN OIL PRESSURE SWITCH (NC) 8 HEATED OXYGEN SENSOR (HO2S) G COIL IGNITION SYSTEM CRANKSHAFT POSITION SENSOR (CKP) ENGINE COOLANT TEMPERATURE SENSOR (ECT) 86 85 87 87A 30 CR4 (LOCATED INSIDE THE GROUND CONTROL BOX) DIAGNOSTIC CONNECTOR NOTES: 1. INTERNAL SPLICES ARE NOT SHOWN G MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) INTAKE AIR TEMPERATURE SENSOR (IAT) CAMSHAFT POSITION SENSOR (CMP) LPG LOCKOUT RELAY AND VALVE 6-7 Genie Z-45/25 & Genie Z-45/25J Part No. PINK/LG 18awg FAULT LT. CONT. . * Y/BK FUEL SELECT * T/O DATA LINK CONNECTOR (+) PK/LB DATA LINK CONNECTOR (-) BL STARTER INPUT GY/R DRIVE BY WIRE SIGNAL RETURN R/LB STARTER OUTPUT GN/W OIL PRESSURE SWITCH NOTE: * SHOWS USED WIRES 2 1 8 16 9 5 31 34 42 22 14 37 18 24 25 6 7 11 3 15 33 13 26 11T/Y20 16AR/LG16 37BY18 39RW20 37Y12 787PK/BK16 351DBR/W20 570CBK/W12 570EBK/W12 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674Y/BK20 914T/O20 915PK/LB20 32ADKBL16 359LG/Y20 32R/LB16 253DG/W20 555T18 556W18 557BR/Y18 558BR/LB18 351BR/W18 77DB/Y18 570BK/W18 570ABK/W18 570BBK/W18 570HBK/W18 F G H J K 1 2 3 4 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 926ALB/O16 359FGY/R20 1 2 3 L M N P R 5 S T W X Y 9 42 743GY20 358LG/BK20 354LG/R18 342LG/P16 264W/LB18 225BK/Y20 253BDG/W20 57BK18 242DG18 96T/O18 74GY/LB18 6 MATING FACE SHOWN 1 34 354LG/R18 359DGY/Y20 74GY/LB18 89AO18 570NBK/W18 34LB/O18 658PK/LG20 570BK/W20 107P20 915PK/LB20 914T/O20 209W/P20 349DB18 350GY18 282DB/O18 359AGY/R18 361NR18 77DB/Y18 225BK/Y20 359MGY/Y20 743GY20 359JGY/R18 253ADG/W20 96T/O18 16CR/LG16 95AT/W18 351CBR/W20 358LG/BK20 359KGY/Y20 57BK18 361PR18 242DG18 MATING FACE SHOWN 7 NOTES: 1. SPD.* P DATA LINK DB/BK DRIVE BY WIRE SIGNAL INPUT GN/O AUXILARY INPUT W/P SELF TEST INPUT * T/LB GOV.* BK/W BATT. SPD. PK/LG FAULT LT.Section 6 • Schematics First Edition • Second Printing Ford LRG-425 EFI Engine Wire Harness (after serial number 13098) N M L K J I THROTTLE ACTUATOR/ POSITION SENSOR FUEL INJECTOR VALVES H G F E D C FORD WIRING HARNESS WIRE COLOR CODE B A 1 POWER CR-FA 87A FUEL PUMP CR-FB 87A STARTER CR-FC 87A CODE BL COLOR BLUE BLACK BROWN DARK BLUE DARK GREEN GREEN CODE GY LB LG N O PK COLOR GREY LIGHT BLUE LIGHT GREEN NATURAL ORANGE PINK CODE P R T W Y COLOR PURPLE RED TAN WHITE YELLOW 30 30 30 #4 WATER TEMP. AND WIRE GUAGE EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74. . CONT. GREY WIRE WITH LIGHT BLUE STRIPE. 18 GUAGE WIRE 2. INTERNAL SPLICES ARE NOT SHOWN OIL PRESSURE SWITCH (NC) HEATED OXYGEN SENSOR (HO2S) G COIL CRANKSHAFT POSITION SENSOR (CKP) IGNITION SYSTEM 30 CR4 (LOCATED INSIDE THE GROUND CONTROL BOX) DIAGNOSTIC CONNECTOR ENGINE COOLANT TEMPERATURE SENSOR (ECT) 87 87A MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) LPG LOCKOUT RELAY AND VALVE INTAKE AIR TEMPERATURE SENSOR (IAT) CAMSHAFT POSITION SENSOR (CMP) G 8 86 85 Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 6-8 . COLOR. * BK/Y GOV. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER. SWITCH Y VPWR * PK/BK FUEL PUMP OUTPUT * VREF BK/W BATT. SWITCH (NO) #3 #2 #1 BK BR 87 87 86 85 86 87 86 85 85 DB DG GN 2 37CY16 361ER16 926ALB/O16 787APK/BK16 37AY12 16BR/LG18 570DBK/W18 361R12 359CGY/R18 355GY/W18 351BBR/W18 361DR14 558BR/LB18 570BK/W12 39RW20 361CR14 557BR/Y18 361JR14 264W/LB18 32R/LB16 16R/LG16 342LG/P16 32ADKBL16 361BR14 556W18 361AR14 555T18 FORD ENGINE CONTROL MODULE (ECM) QUICK DISCONNECTS (TO ECM) 95TW18 361LR18 37BY18 349DB18 350GY18 282DB/O18 355GY/W18 238ADG/Y18 X1 F1 K1 F2 H1 A3 G1 H2 J1 C1 F3 Y3 Y2 W3 S3 S2 S1 T1 A2 R2 B3 C2 X2 X3 W1 W2 C3 E3 G2 G3 M1 A1 L1 H3 J2 K2 R3 K3 M2 N2 P3 L2 M3 B2 N1 N3 P1 D1 B1 D2 T2 L3 E1 R1 D3 J3 T3 P2 Y1 E2 IGNITION COIL 1 NOT USED VPWR KEEP ALIVE PWR NOT USED NOT USED CRANKSHAFT SENSOR RETURN (+) CRANKSHAFT SENSOR RETURN (-) CAMSHAFT SENSOR FEED (+) THROTTLE POSITION SENSOR INPUT FUEL PUMP MONITOR NOT USED NOT USED NOT USED FUEL INJECTOR #1 FUEL INJECTOR #2 FUEL INJECTOR #3 FUEL INJECTOR #4 VREF DRY FUEL MODULATOR NOT USED NOT USED POWER GROUND POWER GROUND POWER GROUND POWER GROUND NOT USED NOT USED NOT USED NOT USED DATA LINK DRIVE BY WIRE AUXILLARY INPUT SELF TEST INPUT GOVERNOR SELECT #1 GOVERNOR SELECT #2 MALFUNCTION INDICATOR LAMP FUEL SELECT DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) FUEL PUMP RELAY CONTROL NOT USED NOT USED SINGLE RETURN NOT USED NOT USED NOT USED INTAKE AIR TEMP SENSOR MAP SENSOR INPUT ECT SENSOR NO USAGE STARTER LOCKOUT NOT USED IDLE AIR CONTROL DRY FUEL SENSOR OIL PRESSURE GROUND DRY FUEL LOCKOFF IGNITION COIL 2 HO2S SENSOR SIDE MATING FACE SHOWN A B C D E 3 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 T/Y TACH LEAD R/GN KEEP ALIVE PWR * Y KEEP ALIVE PWR * R/W WATER TEMP. CONT. First Edition • Second Printing Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness (after serial number 13908) . . LINK GRD./START RELAY BLK#R1-E./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR.H.H.H. RED STA.H. ON IGN. CB1 CB2 FUSE TB20 RED RED#20-C.H. BAT. TB23 TILT ALARM LEVEL SENSOR Electrical Schematic.#1 TP41 TB41 RED-E. 15AMP./FUEL ON 10 ENG. 8 KEY BYPASS 9 IGN. CR5 NO BLK-2 HORN GRND WHT#21-E. 52709 STARTER .#1 ORG/BLK-1 RED 500 ORG/BLK#41-C. Z-45/25 Ford Models (before serial number 13099) BLK BLK TB22 BLK/RED-3 BLK/RED#9 CR5 C TP22 HORN RELAY BLK/RED#R5-C. 12 V DC 6-9 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J BLK P3 HORN TP23 P1 RED KS1 PLAT TP9 TB9 + B P2 TP26 Part No.H.H. FAULT CHECK ENGINE TP33 RUN/TEST SWITCH TEST TEST RUN TS2 BLK-1 TS52 TS64 START START TB33 ENGINE ENGINE BLK H CR2 POWER RELAY PINK/LG FEH(658) PIN6 TB21 TB25 WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 BR/WT FEH(674) PIN7 BRN/BLU FEH(253) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 F CR1 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 G CR2 NO First Edition • Second Printing IGNITION. A S I Section 6 • Schematics ALTERNATOR 15AMP.#1 GENERATOR OPTION K TS3 TP39 J BLU/RED-1 LP GAS TS53 FUEL LP 1 TB39 FB RED/WHT#23-E.#1 FLASHING BEACON OPTION TP38 L3 GAS HOUR METER BLU/WHT-1 L2 HM 2 FUEL WHT#21 3 CHECK ENGINE BLU/WHT#38 LED TB38 CHECK ENGINE I 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.H.#1 WHT WHT RED CR1 NO E STARTER MOTOR TP25 TP21 TS51 RED RED-1 TP24 PR1 AUXILIARY PUMP RED TP27 AUXILIARY PUMP TB27 TS1 RED#27-C. H/L HIGH RPM TS54 LOW RPM HIGH RPM BRN/BLU TB35 FUNCTION ENABLE L TS47 OFF GENERATOR ON GRN/WHT-1 TP45 TB45 GRN/WHT#45-E.H.N ORG/BLK WHT WHT RED RED M SELECTOR TS50 BRN OPTION LIFT/DRIVE SELECTOR OPTION (REQUIRED CE MODELS) LIFT/ DRIVE BLK/RED-1 ENGINE SPEED TP35 TS4 LOW RPM FOOTSW. REGULATOR A FLD.H. AUXILIARY POWER RELAY AUX PUMP RED AUXILIARY PUMP PR1 TB28 NO FS1 BLK D TP28 WHT WHT-2 RED/BLK-1 RED/BLK#28-C. RED/WHT#23-C.H. H. PLATFORM ROTATE RIGHT M TB18 DESCENT ALARM OPTION N ORG/BLK RED WHT WHT RED BRN BRN Part No. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP TB2 RED/BLK#2-M. TP14 SECONDARY BOOM FLOW CONTROL K ORG-3 TS9 ORG/BLK-3 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC TP15 ORG#14-M. TB30 ORG/RED#16-C.H. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M.H. DRIVE ENABLE LIMIT SWITCH TS15 NOHC TB16 TP31 TP16 WHT#12-C. Z-45/25 Ford Models (before serial number 13099) First Edition • Second Printing 8 BRN-2 GROUND TP13 TB13 L1 NCHO A BLU/RED-3 BLU/RED#13-C. UP PLATFORM DOWN LEVEL PLAT LEVEL UP ORG/BLK#15-M. PWM A + X R TS60 BLU/BLK BP2 SECONDARYBOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M.H. PWM A + X PRIMARY BOOM DOWN R 10 TB3 TP1 R5 RED/WHT#3-M. PLAT LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) L TP17 GRN-3 GRN/BLK-3 TS7 LEFT TS57 TB17 RIGHT PLAT ROTATE TP18 GRN#17-M.H.H. PWM A + X TS62 R LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT 15 TB5 H R4 WHT/RED#6-M. DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 WHT/BLK#31-C.H.H. SECONDARY BOOM UP BLU/BLK#11-M.10 .H.H. BRN LS4 TP30 WHT-1 WHT#30-C. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M.H. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C.H. LEFT RIGHT PLAT ROTATE CR8 NC PLATFORM ROTATE LEFT GRN/BLK#18-M. D HIGH (2WD) TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 E 50 WHT#40-6 LS1 NCHO BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 EXTEND TB7 RETRACT BOOM TP8 BLK#7-M.H. STEER RIGHT BLU-1 BLU#36-M.H.H. DRIVE EDC TP32 TB32 WHT/RED-1 WHT/RED#32-C. WHT/BLK#5-M.H.H.1 2 3 4 5 6 7 Electrical Schematic.H.H.H. 52709 TP40 F 1 2 3 HORSE.H. BOOM RETRACT G TP6 WHT/RED-3 WHT/BLK-3 TP5 TP4 TB4 WHT-3 TB8 WHT#4-M. EXTEND BOOM EXTEND TS63 RETRACT BOOM BLK/WHT#8-M.4 POWER 5 LIMITER 6 BOARD 7 8 9 10 TP7 LS2 NO Genie Z-45/25 & Genie Z-45/25J B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB37 6 .H.H.H. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 J TB10 BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU#10-M. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25 Ford Models (before serial number 13099) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099) . BU/BK-S. RD/WT-S. BLK-S. ENGINE. AUX. 3 BLU/WHT #12 TS61 PRIMARY BOOM UP/DOWN TS63 2 BRN ISM5 RED-EXT. BOOM F.#1 BLK/RED-E. PLAT.C. R TURN.P. RD/BK-C. L.P. TS64 WHT#40-R7 WHT-PRIM. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 . RD/WT-C.H.H.M. ENA.H BLK/WHT-M. BOOM DOWN PRI. TURN. PK/GR-EH#2 BRN/WHT-EH2 OG/BK-C.P. FORD EFI. FAULT RED-27B BRN-GRD. TS59 BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33 HIGH/LOW RPM GRN/WHT #19 GRN/BLK #18 GRN #17 PLAT. LT.H.P.P.H R/W-M.H.P. ROT. WHT-TST.H. UP PLAT.H.#1 ORANGE-M. TILT ALARM 2WD/4WD (DRIVE RANGE) E.DOWN (CE MODELS ONLY) BRN TO H. DRV. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: 8 EH#1 EH#2 C.P.H. 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR. WHT-S.#1 CR5 CR4 WHT-E.P. M. ROT.P.#5 D BASE TERMINATION BLOCK C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S. RED-M. TS62 BLK/RED #35 WHT/RED #6 TURNTABLE ROTATE RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4 5 RD/GRN-EH#1 1 RED-C. OPTION START SEC. CONTROLS. SW.H BLU/BLK-M. BOOM EXTEND BOOM RETRACT HORN SEC. PLAT.P. BLK-ISM#3 BR/BLU-EH2 BLU-M.35D 6 . JIB VALVE 12V BATT. PWR.H WHT-M. GRN-S.C.H BLK-M.P.H.H GROUND STUD (-12 VOLTS) 7 RED-E. F.#1 BLK-E. WT/BK-C. ROT. BOOM UP PRI. DRV. SUPPLY IGNITION PWR.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS BLK-R1#86 ORG/BLK-41A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 R5 L2 CR1 CR2 BLU/WHT #38 K DESCRIPTION L M N KS1 1 START RELAY 2 BLK-33D M.#1 GRN-E. LEVEL DN. TO PLAT. GR/WT-S. BRAKE START GLOW PLUG BK/RD-S. 52709 .H BLU-M.H.C. WHT-S.CB2 YEL (12GA) #9 .#4 6 BU/WT-S.#6 R4 R5 TS52 PRIMARY BOOM EXTEND/ RETRACT TS60 WHT #4 WHT/BLK #5 BLK-R1 TO ISM#1 BLK-R1 TO E. PWR. 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.#6 OG/BK-ISM#2 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 GRN/WHT-C. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 CR2 EXT#6 WHT-R2#86 8 9 10 P1 NC NO KS1 NO AUXILIARY PUMP SEC. 3 4 START INPUT AUX.H BLK/RED-C. ORG/BLK-M./FUEL ON ENG.H.P.H. RED-20C NO 2 TACHOMETER EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH NO 5 6 7 IGN.P.CB2 WHT/PRP #18 .H RED-C.38D BRN/WHT #7 . OR/BK-M. RED-S. ROT.H. KEYSWITCH PWR.H. BLK-S.P.H RED/BLK-M. LEVEL ORG CR7 CR8 ORG/BLK EH2 BRN-GRD. GR/BK-S. BOOM TS54 RED-ISM#4 CB1 CB2 WHT ISM7 RUN/TEST WHT#30-C.H W/R-M. E.P. BOOM DN SEC.P. BOOM F.#5 TS57 PLATFORM ROTATE ORG #14 ORG/BLK #15 ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE MODLES ONLY) BU/BK-M. ORG/RED-CH GRN-M.P. (FUEL SELECT) LIMIT SWITCH SIG. ENA. L TURN.H.P. WT/RD-S. SENDER RED-S. BLU/WT-S.C.H.#4 WHT-EXT. SW. 15A CIRCUIT BREAKER.P. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OIL PRESSURE SENDER WATER TEMP.H. 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR.H.H.M. BLK-S. WHT-SEC.#4 3 PRIM.H GRN/BLK-M.TST SW BRN/BLU #26 .P. LEVEL. BK/WT-S. PULSE PICKUP SPARE SPARE SPARE GEN.. WHT-S.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . S. RD/BK-S. SW.25D PNK/GRN #6 .H.H./START MODULE WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS PRI. WT/RD-C.P.11 Genie Z-45/25 & Genie Z-45/25J Part No.H.P OG/BK-S.P. R.H WHT/BLK-M.H.P WHT#12-C. WT/BLK-S.P. ON GROUND BATTERY KEY PWR.H. RPM STEER RIGHT STEER LEFT TEST LIGHT L.H RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2 NC STOP TS51 WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 SPLICE L2 1 2 TS53 BLU/RED #39 RED/WHT #3 RED/BLK #2 RED #1 BLK #7 BLK/WHT #8 CR4 CR5 CR7 CR8 3 HOUR METER 4 WHT/PRP EH2 CHECK ENGINE LIGHT RED FUEL SELECT BL/RED#13-C.H. R or CR ISM H.H.H.39D YEL (18GA) #8 . ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER ENGINE HARNESS # 2.H BLU/WHT-M. BK/RD-R5 BLU-S.D. BLACK-SEC.P. PLAT. KEY BYPASS IGN.P. TST. ROT.C. BU/RD-S.#1 BLK-E. CIRCUIT BREAKER. BOOM UP SEC.D.#1 WHT-TEST SW BLK-TEST SW BLK 25B WHT 23B RD/WT-C. ORG-M. ORG-S.H. S.P.D.) PWR. SEC.P.12 . WHT-24 TO H.) WHT (F. PWR. (CONT. (START) PWR. SEC. TO F. ROT.P. PWR.C. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG.P. BLU-10 BLU/BLK-11 RED/WHT-29 TURNTABLE ROTATE WHT/BLK-5 PLATFORM LEVEL TS9 WHT-4 PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 R2 R3 RED/BLK-2 A RED-1 BLK-7 BLK/WHT-8 PRIMARY BOOM EXTEND/ RETRACT GRN-17 GRN/BLK-18 BLU/WHT-12 RED-27 GEN. PWR. OPT.BOOM BP2 6 + . LT. ENA.L. 5 BLU/WHT-38 BLU-36 BRN TO GRD.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC TS14 8 HIGH/LOW (2WD/4WD) PLATFORM CONTROL SWITCH PANEL Part No. 2WD/4WD TILT ALARM AUX.C.D. DN.) RED (F. GEN.C.L. BOOM DN. PLAT. OPTION WIRE HORN RETRACT EXTEND SWING F.C. DRV. FRM PLAT. PWR. E.) WHT-2 BLK-2 WHT 3 GRD. PRIMARY DN. BOOM F. H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PLATFORM LEVEL SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . WHT/BLK-31 BLU/RED-39 BLK-22 BLK-26 WHT-23 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 BLK-33 BLU/BLK-37 WHT/RED-32 WHT-30 BLK/RED-9 ORG-14 P3 NC NO R R NC . OPT. STUD CR12 50 R1 RED/BLK-28 H1 + TILT ALARM EFI RELAY 4 _ CABLE #3 CABLE #2 CABLE #1 110 F. LVL. UP DRV.L. LVL.BOOM UP JIB VALVE PLAT.S. SWING RIGHT SWING LEFT PRIMARY F. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD TILT ALARM WHT-24 2 1 2 3 4 5 6 7 8 9 10 PLAT.S. TO PLAT.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099) N M L K J I H G F E D C B A 1 PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS3 TS7 TS10 TS13 TS11 TS12 TS9 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 H. SEC. OG/BK-41 ORG-40 HORSEPOWER LIMITER BOARD 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.C. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L. ROT.X BP1 NO TS13 - X A A NC NO + + 2 3 4 5 6 7 L1 8 1 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 ORG/BLK-15 HORN WHT/RED-6 RED/WHT-3 GRN/WHT-19 RED-10 TO H. L. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .X R 7 DRIVE DRV. R. START BRAKE E.S. PRIMARY UP SEC. ENA. PLAT.S. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099) . . #1 BLK#22 BLK/RED#9 RED/WHT#23-C. RED P1 RED KS1 PLAT GRND GENERATOR P3 HORN BLK FUEL ENGINE TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 ENGINE SPEED TP35 RED RED WHT-2 BLU/WHT-1 BLU/RED-1 ORG/BLK-1 BLK/RED-3 RED/BLK-1 RED-1 BLK-1 GRN/WHT-1 BLK/RED-1 3 TS51 START AUXILIARY POWER TS52 TS53 TS54 LOW RPM FUNCTION ENA. ON IGN. FAULT RED/WHT#23-E. Z-45/25 Ford Models (from serial number 13099 to 16303) A 1 B C D E SEE NOTE 1 F G H I J K L M SEE NOTE 2 N ORG/BLK TP22 P2 BLK TP26 BLK FS1 BLK RED RED TP25 TP21 RED WHT WHT TS50 WHT WHT LIFT/ DRIVE SELECTOR OPTION TP24 TS1 BLK-2 WHT START AUXILIARY POWER TS2 CHECK ENGINE L3 GAS TS3 TS47 OFF ON TS4 LOW RPM FOOTSW. RED/BLK#28-C. RED#27-C. 8 KEY BYPASS 9 IGN. REGULATOR PINK/BLK FEH(787) PIN5 PINK/LG FEH(658) PIN6 Y FEH(37) PIN9 Y FEH(37B) PIN8 TAN/BLU FEH(306) PIN24 YEL/BLK FEH(674) PIN7 RD/LG FEH(16A) PIN1 WT/PUR FEH(209) PIN18 TB38 A S I FUEL PUMP 1 HM 2 BRN FLASHING BEACON OPTION GENERATOR OPTION HOUR METER RUN/TEST SWITCH CHECK ENGINE LED CE MODELS) LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR POWER RELAY BLK AUX PUMP STARTER 3 BLK 7 8 NOTE: 1) The connection to TP24 is for units without generator option.13 BRN HORN RELAY AUXILIARY POWER RELAY STARTER MOTOR LEVEL SENSOR TILT ALARM IGNITION/START RELAY FUEL PUMP Genie Z-45/25 & Genie Z-45/25J HORN AUXILIARY PUMP FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 Part No. RED CR1 NO CR1 CR2 NO TB21 CR2 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. RED-E. BLK#R1-E.#1 WHT#21 WHT FUSE LINK ALTERNATOR BAT. HIGH RPM GAS LP RED TB39 TB45 FUEL ENGINE BLK 4 TB28 RED TB27 TB33 TB9 TB41 CB2 TB23 TB20 RED#20-C.H.H. 3) All switches and contacts are shown with the boom in the stowed position and the key switch off.#1 FB CR5 CR5 NO BLK/RED#R5-C.H. PR1 NO WHT PR1 TB25 500 AMP RED 6 12 V DC + (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 FLD./FUEL ON 10 ENG.H.Section 6 • Schematics First Edition • Second Printing Electrical Schematic.H. 2) The foot switch power is connected to both white wires without the lift/drive selector option./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. STA.H. H/L HIGH RPM LP 2 TP41 CB1 15AMP.H. 52709 .#1 TB35 TAN/BLU 5 WHT#21-E. TS64 PK/BLK TEST TEST RUN CHECK ENGINE BLU/WHT#38 L2 GRN/WHT#45-E.H.#1 ORG/BLK#41-C. GRD.H. 6 .H. 15AMP.H. BOOM RETRACT TP6 G WHT/RED-3 WHT/BLK-3 TB5 TP5 WHT-3 TP4 TB8 WHT/BLK#5-M.H. TB3 PWM A + X PRIMARY BOOM DOWN R TP1 RED/WHT#3-M. DRIVE EDC TP32 B BRAKE RELEASE VALVE TRAVEL ALARM OPTION TP37 TB37 BLU/BLK-1 BLU/BLK#37-M. EXTEND BOOM EXTEND TS63 RETRACT BOOM BLK/WHT#8-M.H. 52709 ORG-1 TP40 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 1 2 3 4 5 6 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J WHT/RED-1 WHT/RED#32-C.H. CR7 NC SECONDARY BOOM FLOW CONTROL ORG-3 TS9 ORG/BLK-3 TS59 TP15 TB14 UP PLATFORM DOWN LEVEL K ORG#14-M. TB2 UP PRIMARY BOOM UP TS61 DOWN PRIMARY BOOM RED/BLK#2-M.H.H.H. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M. LEFT RIGHT PLATFORM ROTATE CR8 NC PLATFORM ROTATE RIGHT GRN#17-M. HIGH (2WD) D TS14 LOW (4WD) DRIVE RANGE (2WD/4WD) RED 250 R3 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 E 50 WHT#40-6 LS1 NCHO BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO WHT#40-5 HORSEPOWER LIMITER BOARD BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 TB7 EXTEND BOOM RETRACT TP8 BLK#7-M.14 .H. STEER RIGHT BLU-1 BLU#36-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C. TB17 PLATFORM ROTATE LEFT M DESCENT ALARM OPTION ORG/BLK N WHT WHT RED RED BRN BRN Part No. TS15 TP31 TP16 DRIVE ENABLE ORG/RED-3 TB31 DRIVE ENABLE SWITCH WHT/BLK-1 WHT/BLK#31-C.H.H. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK#11-M. TB15 PLATFORM LEVEL DOWN PLATFORM LEVEL CUTOUT (CE MODELS ONLY) TP18 L GRN/BLK-3 TS7 LEFT GRN-3 TS57 TB18 RIGHT PLATFORM ROTATE TP17 GRN/BLK#18-M.H.H. C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB32 6 .H. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M.H. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M.H.H.H.1 2 3 4 5 6 7 First Edition • Second Printing Electrical Schematic.H. PWM A + X TS62 R LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R4 10 WHT#4-M. Z-45/25 Ford Models (from serial number 13099 to 16303) 8 BRN-2 GROUND TB13 NCHO TP13 L1 BLU/RED-3 BLK-7 BRN-7 A LS4 TP30 WHT-1 WHT-7 TB30 RED-7 NOHC DRIVE ENABLE LIMIT SWITCH TB16 WHT#12-C.H.H. TB4 WHT/RED#6-M. TB11 TB12 BP2 SECONDARY BOOM DOWN BLU/WHT TP14 BLU/WHT#12-M.H.H. Z-45/25 Ford Models (from serial number 13099 to 16303) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303) . H GROUND STUD (-12 VOLTS) 7 RED-E. S.H.15 Genie Z-45/25 & Genie Z-45/25J Part No.P.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303) A 1 BASE CONTROL BOX BASE CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 ORG/BLK-41A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2 BLU/WHT #38 BLU/RED #39 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH L M N NO 1 2 3 4 5 6 7 8 START RELAY NO TACHOMETER START INPUT AUX.CB2 YEL (12GA) #9 . RD/GRN-EH#1 WHT-S.H. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-S.H.P. BLK-S.P.H RED/BLK-M. BOOM UP/DOWN PRIMARY BOOM EXTEND/ RETRACT WHT #4 WHT/BLK #5 RED-EXT. BLU/WT-S. ON GROUND BATTERY KEY PWR.H WHT-M.H RED-C.H.39D YEL (18GA) #8 .UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .P.H BLK-ENA. TS64 WHT#40-R7 WHT-PRIM. GR/WT-S. FORD EFI.35D 6 .#1 CR2 CR5 CR4 3 4 WHT/PRP EH2 2 BRN ISM5 HOUR METER 3 BLU/WHT #12 CHECK ENGINE TS61 TS60 TS63 PRI.H.TST SW TAN/BLU #24 . GRN-M. BRAKE START ENGINE GLOW PLUG BK/RD-S. SW.P OG/BK-S.38D YEL/BLK #7 . WT/RD-S.H.H.H RED-ENA. WHT-S. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 BLK-R1 TO ISM#1 BLK-R1 TO E. RD/WT-S. SW.#1 BLK/RED-E. P1 AUXILIARY PUMP TS51 KS1 NO NO SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER. RD/BK-C. R or CR ISM H. 52709 .H.#6 WHT-E. WT/RD-C.P. RED-20C WHT-TST.H BLU/BLK-M./START MODULE WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (UNUSED) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.P. TS54 CB1 CB2 PLATFORM LEVEL TS59 TS57 PLATFORM ROTATE RUN/TEST GRN/WHT #19 GRN/BLK #18 GRN #17 ORG CR7 CR8 ORG/BLK EH2 BRN-GRD.P. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.#6 OG/BK-ISM#2 GRN/WHT-C.P. ENGINE./FUEL ON ENG.H. PK/GR-EH#2 YEL/BLK-EH2 6 BU/WT-S. TST.H. BU/BK-S.H.H.H BLU-M. BLK-S. RED-27B BRN-GRD.P. RED-M. WHT-S. KEY BYPASS IGN.CB2 WHT/PRP #18 . GR/BK-S.P.H.P.H. E. GRN-S.C.#1 ORANGE-M.M.#1 BLK-E.#1 BLK-E.H.P.P.H. RD/WT-C.P.H.H.C. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: 8 EH#1 EH#2 C.#5 HIGH/LOW RPM BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33 ORG #14 ORG/BLK #15 ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BU/BK-M.H.. OR/BK-M. ORG-S. CONTROLS. RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2 WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 SPLICE L2 1 2 LED + CR4 CR5 CR7 CR8 RED/WHT #3 TS53 FUEL SELECT RED/BLK #2 RED #1 BLK #7 BLK/WHT #8 BRN TO H. ORG-M.P.DOWN (CE MODELS ONLY) IGN.H. WT/BLK-S. M.P. RED-S.P. FAULT 2 BLK-33D M. BLK/RED #35 START WHT ISM7 WHT-ENA. RD/BK-S.H BLK-M. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER ENGINE HARNESS # 2.P.#4 3 PRIM.H.H GRN/BLK-M.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4 BLK 25B WHT 23B RD/WT-C. BU/RD-S. R4 TS52 SECONDARY BOOM TS62 TURNTABLE ROTATE WHT/RED #6 RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4 5 1 RED-C. 15A CIRCUIT BREAKER.P.P.H BLK/RED-C. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 .D.H BLK/WHT-M.P WHT#12-C. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NC NC STOP EXT#6 WHT-R2#86 9 10 SEC. WT/BK-C.D.#4 WHT-EXT. ORG/BLK-M.P. BLK-S. BLK-ISM#3 BR/BLU-EH2 BLU-M.P.H.#1 GRN-E.H. WHT-SEC. BK/RD-R5 BLU-S.H W/R-M.P.H R/W-M.M.H.H WHT/BLK-M.#5 D BASE TERMINATION BLOCK C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S.P.25D PNK/GRN #6 . BK/WT-S. BLU-10 BLU/BLK-11 RED/WHT-29 GRN/WHT-19 RED-1 BLK/RED-35 RED-25 RED/WHT-3 WHT/BLK-31 BLU/RED-39 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLU/WHT-38 NC NO 7 L1 8 R R NC . LEVEL UP DRIVE ENA.S. TO F.D. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.L. F. PRIMARY DOWN PRIMARY UP SEC.X TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED 1 2 TS13 A A NC NO + + 3 4 5 6 NO 100 250 BLK/RED-9 BLK-33 WHT-4 WHT/RED-6 PRIMARY BOOM EXTEND/ RETRACT GEN.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD. BLU-36 BRN TO GRD.C.C. PWR. L.) KEYSW.P. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . BOOM UP (UNUSED) JIB VALVE PLAT. +12 V TO PLAT.S. BOOM DN. SEC. BOOM F. GEN. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.) WHT (F.X R R2 R3 DRV.S. (CONT. 4 5 WHT-23 WHT/RED-32 WHT-30 BLK-22 BLK-26 RED/BLK-2 WHT-24 TO H. F. TURN ROT. BLU/RED-13 BLU/BLK-37 ORG-14 P3 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H. PUMP SEL.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS3 TS7 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 H.P. LT. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L. PWR. R.X BP1 NO .S. E.P. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . UP POWER PWR.C. PLAT. PRIMARY F. R. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN.S. TURN ROT.ENA TS15 L3 TS14 CHECK ENGINE TS2 START TS4 HIGH/LOW RPM DRIVE DP1 7 PLATFORM LEVEL TS9 NC TS3 FUEL SELECT NC HORN HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. ROT.P.D.L. LEVEL DN. SEC.S.16 .L. 2WD/4WD TILT ALARM AUX. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD TIME DELAY ( JIB ONLY ) TILT ALARM I H G F E D C B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 PLAT.C. ROT.BOOM BP2 6 A + . SEC.) RED (F.C. PLAT. OPT. STUD R1 50 RED-10 LIMITING RELAY CABLE #3 3 RED/BLK-28 H1 + TILT ALARM _ CABLE #2 CABLE #1 110 F. L. ROT. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303) . . 52709 CR1 NO STARTER WHT WHT RED TP25 TP21 TS51 E - + .H.#1 K TP45 GENERATOR OPTION TB45 TS3 TP39 J BLU/RED-1 LP GAS FUEL TB39 TS53 WHT LP GAS FB RED/WHT#23-E. 15AMP.H.17 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J BLK P3 HORN P2 TP9 TB9 P1 RED GRND KS1 PLAT CR5 NO Part No./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. A S Section 6 • Schematics ALTERNATOR 15AMP.H.H. RED AUXILIARY POWER RELAY AUX PUMP RED AUXILIARY PUMP PR1 FS1 BLK TP28 Electrical Schematic.H.N WHT WHT BRN ORG/BLK RED RED RED CR13 RED BRN JIB CUTOUT RELAY (CR13) JIB VALVE RELAY (CR-14) JIB VALVES LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR CE MODELS) JIB CUTOUT RELAY SEE NOTE 2 JIB VALVE RELAY JIB VALVES M SELECTOR TS50 OPTION LIFT/ DRIVE CR14 NO CR14 BLK/RED-1 ENGINE SPEED TP35 TS4 HIGH RPM LOW RPM FOOTSW. HORN B WHT#21-E. LINK GRD. BLK LEVEL SENSOR TP23 TP26 TB23 BLK BLK/RED-3 BLK/RED#9 TP22 TB22 CR5 HORN RELAY BLK#22 C BLK-2 BLK/RED#R5-C.H. ON IGN. NO TILT ALARM WHT-2 RED/WHT#23-C.H. I 12 V DC 6 .#1 ORG/BLK-1 500 ORG/BLK#41-C. CB1 CB2 A FUSE TB20 RED RED#20-C.H. BAT. 8 KEY BYPASS 9 IGN.#1 FLASHING BEACON OPTION TP38 HM FUEL L3 WHT#21 3 1 2 HOUR METER BLU/WHT-1 L2 CHECK ENGINE CHECK ENGINE BLU/WHT#38 LED I 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. FAULT CHECK ENGINE TB38 TP33 RUN/TEST SWITCH TEST TEST RUN TS2 BLK-1 START START ENGINE H TS52 TB33 BLK TS64 ENGINE CR2 POWER RELAY PINK/LG FEH(658) PIN6 WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 BR/WT FEH(674) PIN7 BRN/BLU FEH(253) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 F CR1 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 TB21 G CR2 NO TB25 First Edition • Second Printing IGNITION/START RELAY BLK#R1-E.#1 SEE NOTE 1 STARTER MOTOR TP27 RED RED-1 TP24 PR1 AUXILIARY PUMP AUXILIARY PUMP TB27 TS1 RED#27-C. Z-45/25J Ford Models (before serial number 13099) D WHT RED/BLK-1 TB28 RED/BLK#28-C.H. REGULATOR FLD./FUEL ON 10 ENG.H.H. H/L TS54 LOW RPM FUNCTION HIGH RPM ENABLE L BRN/BLU TS47 OFF GENERATOR ON TB35 GRN/WHT-1 GRN/WHT#45-E. RED RED STA.#1 TP41 TB41 RED-E. DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 WHT/BLK#31-C.H.H.H.H. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M. UP CR8 NC LEFT JIB BOOM PLATFORM ROTATE LEFT/ JIB BOOM UP GRN/BLK#18-M.H.H.H.1 2 3 4 5 6 7 Electrical Schematic. PRIMARY BOOM FLOW CONTROL RED-3 TP2 I RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 BLU-3 J TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M.H.18 .H. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK#11-M.H. Z-45/25J Ford Models (before serial number 13099) 8 First Edition • Second Printing BRN-2 GROUND TP30 TP13 TB13 L1 NCHO BLU/RED-3 BLU/RED#13-C.H.H. STEER RIGHT BLU-1 BLU#36-M. BOOM RETRACT TP6 WHT/RED-3 WHT/BLK-3 G TP5 TP4 TB4 WHT-3 TB8 WHT#4-M. HIGH (2WD) MOTOR STROKE TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 E 50 WHT#40-6 LS1 NCHO BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH BLK-3 BLK/WHT-3 EXTEND BOOM TB7 RETRACT TP8 BLK#7-M.4 POWER 5 LIMITER 6 BOARD 7 8 9 10 TS13 F TP7 LS2 NO Genie Z-45/25 & Genie Z-45/25J B BRAKE RELEASE VALVE TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 . PWM A + X TS62 R RIGHT TURNTABLE LEFT ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT 15 TB5 H R4 WHT/RED#6-M. STEER LEFT RED/WHT-1 RED/WHT#29-C.H. PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) CR13 NC TP17 L GRN-3 GRN/BLK-3 UP TS8 LEFT TS58 TB17 JIB BOOM TP18 GRN#17-M.H. DRIVE ENABLE LIMIT SWITCH A TS15 NOHC TB16 TP31 TP16 WHT#12-C. WHT/BLK#5-M. BRN LS4 WHT-1 WHT#30-C.H.H.H. EXTEND BOOM EXTEND TS63 RETRACT BOOM BLK/WHT#8-M.H. PWM A + X PRIMARY BOOM DOWN R 10 TB3 TP1 R5 RED/WHT#3-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M.H. 52709 ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 1 2 3 HORSE. TS57 M TS7 LEFT RIGHT PLAT ROTATE RIGHT LEFT PLAT ROTATE TB18 PLATFORM ROTATE RIGHT/ JIB BOOM DOWN CR9 NC DESCENT ALARM OPTION TP19 BRN GRN/WHT-3 TB19 + ORG/BLK N WHT WHT RED RED RED CR9 TI BRN BRN Part No.H.H.H. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 TS9 ORG/BLK-3 TS59 TB14 UP PLATFORM DOWN LEVEL K CR7 NC TP15 ORG#14-M. TB30 ORG/RED#16-C. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M.H.H. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M. DRIVE EDC TP32 WHT/RED-1 WHT/RED#32-C. TS61 DOWN TB2 UP PRIMARY BOOM PRIMARY BOOM UP RED/BLK#2-M. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25J Ford Models (before serial number 13099) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099) . P.D. SW.H RED/BLK-M.CB2 WHT/PRP #18 . LT. WHT-S. 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.P.C.H WHT-M. DRV. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C. BU/BK-S. E. FORD EFI.H.M.P.D. SW. ORG/RED-CH GRN-M. WT/BLK-S.TST SW BRN/BLU #26 . ORG/BLK-M. ON GROUND BATTERY KEY PWR.CB2 YEL (12GA) #9 . ROT. ORG-S.H.H.#1 BLK-E. UP PLAT.H./START MODULE NO TACHOMETER NO PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER.H RED-C.H BL/RED#13-C. S.P. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 . BRAKE START GLOW PLUG BK/RD-S.#5 ORG #14 ORG/BLK #15 ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BU/BK-M. TST.P. M..H.H.H. ROT. L.H. CONTROLS.H WHT/BLK-M.M. START INPUT AUX. LEVEL. RD/GRN-EH#1 WHT-S.C. KEYSWITCH PWR. WT/RD-C. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 CR2 CR5 CR4 EXT#6 WHT-R2#86 9 10 3 PRIM.P.H.H W/R-M. PLAT.P. BU/RD-S.C. L TURN.19 Genie Z-45/25 & Genie Z-45/25J Part No. WHT#40-R7 WHT-PRIM. RD/WT-S. GR/BK-S.#4 BASE TERMINATION BLOCK RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2 WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS P1 NC KS1 AUXILIARY PUMP NC STOP SPLICE TS51 RED-M.H GRN/BLK-M.#6 OG/BK-ISM#2 GRN/WHT-C.H BLU-M.H.H.#1 BLK-E.P. PK/GR-EH#2 BRN/WHT-EH2 6 BU/WT-S.#4 WHT-EXT.H.H. BLK-S. TO PLAT.DOWN (CE MODELS ONLY) BRN TO H.P.H.H. BK/RD-R5 BLU-S.P. PLAT. PRI.#1 ORANGE-M. 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR.P OG/BK-S.P.39D YEL (18GA) #8 . IGN. PULSE PICKUP SPARE SPARE SPARE GEN. BOOM UP/DOWN 2 R4 R5 TS52 PRIMARY BOOM EXTEND/ RETRACT TS60 WHT #4 WHT/BLK #5 BLK-R1 TO ISM#1 BLK-R1 TO E.P. 15A CIRCUIT BREAKER. ROT. BOOM UP PRI.P.#1 GRN-E.H BLU/WHT-M. 52709 . WT/RD-S.25D PNK/GRN #6 . ORG-M.H.H GROUND STUD (-12 VOLTS) 7 RED-E. WHT-S. F.H. OR/BK-M.P. RED-S. AUX. GRN-S. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: ENGINE HARNESS # 2.H R/W-M. RPM STEER RIGHT STEER LEFT TEST LIGHT L. ENA.H.P. BK/WT-S. PLAT.H BLK/RED-C.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . RD/WT-C.#4 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 WHT ISM7 WHT#30-C. 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR.P.P. R or CR ISM H. TILT ALARM 2WD/4WD (DRIVE RANGE) E. BOOM F. BOOM DN SEC.H.P WHT#12-C.P.H BLK-M.H.#5 D C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S.C. BLK-S. R. BLK-ISM#3 BR/BLU-EH2 BLU-M. (FUEL SELECT) LIMIT SWITCH SIG.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4 BLK 25B WHT 23B RD/WT-C. JIB VALVE 12V BATT.H.P. GR/WT-S.H. RD/BK-S.H BLK/WHT-M.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099) A 1 GROUND CONTROL BOX B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60 TS61 TS62 TS63 TS64 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH L M N GROUND CONTROL SWITCH PANEL STACKED CONTACTS BLK-R1#86 ORG/BLK-41A KS1 1 2 3 4 5 6 7 8 START RELAY 2 BLK-33D M. BRN-GRD. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 6 . BOOM DOWN PRI. LEVEL TS57 PLATFORM ROTATE GRN/WHT #19 GRN/BLK #18 GRN #17 ORG CR7 CR8 ORG/BLK EH2 BLK-S. ROT. BLACK-SEC.#1 BRN ISM5 RED-EXT. WHT-SEC. BOOM EXTEND BOOM RETRACT HORN SEC.H.C.H. ENGINE.H BLU/BLK-M. SENDER RED-S. NO SEC.P. BLU/WT-S. ROT. RED-20C WHT-TST. RD/BK-C.P. PWR.H.38D BRN/WHT #7 .H. TS58 TS62 WHT/RED #6 BLK/RED #35 OIL PRESSURE SENDER WATER TEMP. ENA. KEY BYPASS IGN. TURN. SW.H./FUEL ON ENG. LEVEL DN. OPTION START SEC. BOOM UP SEC.P. BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33 HIGH/LOW RPM PLAT.P. BOOM TS54 CB1 CB2 TS59 JIB TURNTABLE ROTATE RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4 5 1 RED-C. PWR.#1 BLK/RED-E. R TURN.P. FAULT RED-27B BRN-GRD.P.#6 WHT-E.35D 8 EH#1 EH#2 C. BOOM F. WT/BK-C. DRV. WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 BLU/WHT #38 CB1 CB2 HM R4 R5 L2 CR1 CR2 CR4 CR5 CR7 CR8 RED L2 1 2 NO TS53 FUEL SELECT BLU/RED #39 RED/WHT #3 RED/BLK #2 RED #1 BLK #7 BLK/WHT #8 3 HOUR METER 3 BLU/WHT #12 CHECK ENGINE LIGHT 4 WHT/PRP EH2 TS61 TS63 PRI. SUPPLY IGNITION PWR. BOOM BP2 R CR13 CR14 7 L1 8 6 TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 JIB R2 R3 1 R GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1 7 PLATFORM LEVEL P3 NO TS9 TS8 TS1 AUXILIARY PUMP DRIVE SPEED 100 250 DRV.DEL.S.) RED (F. SWING RIGHT SWING LEFT PRIMARY F. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . LVL.S. PRIMARY UP SEC.L.) WHT (F.) PWR. PLAT. OPTION WIRE HORN RETRACT EXTEND SWING F. PWR. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG.20 . PWR. SEC. OPT. UP DRV. TO F. SEC. SEC.D. OPT. ENA. PWR.C.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC HORN TS14 HIGH/LOW (2WD/4WD) 8 PLATFORM CONTROL SWITCH PANEL Part No.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 3 GRD. RED TO JIB CABLE BLU-36 BRN TO GRD. LT. H1 + TILT _ ALARM CABLE #3 4 5 RED-1 WHT-23 RED TO STOP SW RED TILT AL. BLU/RED-13 BLU/BLK-37 ORG-14 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H. PRIMARY DN.C. E. (START) PWR. PLAT.C. DN. START BRAKE E. ROT. R. 2WD/4WD TILT ALARM AUX.S.P.P. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 WHT-24 TO H.P. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L. LVL.D.L.P. FRM PLAT. BOOM F. ENA. DRV. (CONT. BOOM DN.C. GEN. TO PLAT.L. BLU-10 BLU/BLK-11 RED/WHT-29 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 BLU/RED-39 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLU/WHT-38 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6 RED/WHT-3 NC R NO A + - NC X BP1 X TS13 NO JIB VALVE RELAY NC NO X A + - A + - 2 JIB CUTOUT RELAY 3 4 5 6 PRIMARY BOOM EXTEND/ RETRACT GEN. L. ROT.C. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM PLATFORM CONTROL BOX WHT-24 1 2 3 4 5 6 7 8 9 10 PLAT. RED TIM. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . PWR.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099) N M L K J I H G F E D C B A 1 LABEL P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 H. STUD CR12 50 R1 RED/BLK-28 EFI RELAY WHT JIB CABLE BLK JIB CABLE CABLE #2 CABLE #1 110 JIB CABLE F.S.BOOM UP JIB VALVE PLAT. OG/BK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099) . . RED P1 RED KS1 PLAT GRND LP RED P3 HORN FUEL GENERATOR ENGINE RED BLK TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 ENGINE SPEED TP35 CR14 NO CR14 RED RED WHT-2 BLU/WHT-1 ORG/BLK-1 BLK/RED-3 RED/BLK-1 RED-1 BLK-1 GRN/WHT-1 BLK/RED-1 BLU/RED-1 3 TS51 TS52 TS53 TS54 LOW RPM FUNCTION HIGH RPM ENABLE START AUXILIARY PUMP TB27 GAS LP RED TB39 TB45 FUEL ENGINE 4 TB28 TB33 BLK RED CB2 TB20 15AMP. RED#27-C. H/L AUXILIARY PUMP GAS 2 TP41 CB1 15AMP.H. ON IGN.#1 BLK#22 BLK/RED#9 RED/WHT#23-C.H. FAULT TB35 RED/WHT#23-E. TAN/BLU 5 ORG/BLK#41-C.H. Z-45/25J Ford Models (from serial number 13099 to 16303) A 1 TP22 B C D E SEE NOTE 1 F G H I J K L M SEE NOTE 2 N ORG/BLK P2 BLK TP26 BLK FS1 BLK RED RED TP25 TP21 RED WHT WHT TS50 LIFT/ DRIVE WHT BRN WHT TP24 TS1 TS2 CHECK ENGINE L3 TS3 TS47 TS4 SELECTOR OPTION CR13 JIB VALVES JIB CUTOUT RELAY JIB VALVE RELAY BLK-2 WHT OFF START ON HIGH RPM LOW RPM FOOTSW. 6 . WHT#21 WHT TS64 CHECK ENGINE L2 GRN/WHT#45-E. BLK#R1-E.H.#1 RED#20-C.H. WHT#21-E.H. GRD.#1 FUSE LINK ALTERNATOR BAT.H. 52709 ./FUEL ON 10 ENG. (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 6 12 V DC + FLD.H.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. 8 KEY BYPASS 9 IGN.#1 RED-E.H. REGULATOR A S I Y FEH(37) PIN9 Y FEH(37B) PIN8 YEL/BLK FEH(674) PIN7 RD/LG FEH(16A) PIN1 WT/PUR FEH(209) PIN18 PINK/BLK FEH(787) PIN5 TAN/BLU FEH(306) PIN24 PINK/LG FEH(658) PIN6 TB38 FUEL PUMP 1 HM 2 BRN 3 BLK AUX PUMP STARTER BLK 7 8 NOTE: 1) The connection to TP24 is for units without generator option.#1 FB BLU/WHT#38 PK/BLK TEST TEST RUN CR5 CR5 NO PR1 NO PR1 TB25 500 RED WHT BLK/RED#R5-C.H. 3) All switches and contacts are shown with the boom in the stowed position and the key switch off. RED TB9 TB41 TB23 CR1 NO CR1 CR2 NO TB21 CR2 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.21 - BRN STARTER MOTOR AUXILIARY POWER RELAY LED FLASHING BEACON OPTION RUN/TEST SWITCH HOUR METER HORN RELAY TILT ALARM IGNITION/START RELAY FUEL PUMP Genie Z-45/25 & Genie Z-45/25J HORN LEVEL SENSOR CHECK ENGINE GENERATOR OPTION OPTION (REQUIRED FOR JIB BOOM VALVE RELAY (CR-14) CE MODELS) LIFT/DRIVE SELECTOR JIB BOOM CUTOUT RELAY (CR13) JIB BOOM VALVES POWER RELAY AUXILIARY PUMP FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 Part No. STA. RED/BLK#28-C./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR.H. 2) The foot switch power is connected to both white wires without the lift/drive selector option. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M. TB15 PLATFORM LEVEL DOWN PLATFORM LEVEL CUTOUT (CE MODELS ONLY) CR13 NC TP18 L GRN/BLK-3 TS8 UP GRN-3 TS58 TB18 DOWN JIB BOOM TP17 GRN/BLK#18-M. TB2 TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP RED/BLK#2-M.H.H.H. TB3 PWM A + X PRIMARY BOOM DOWN R RED/WHT#3-M.H. TP1 PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M.H. EXTEND BOOM EXTEND TS63 RETRACT BOOM BLK/WHT#8-M.H.H. B BRAKE RELEASE VALVE TRAVEL ALARM OPTION TP37 TB37 BLU/BLK-1 BLU/BLK#37-M.H.H. 52709 ORG-1 TP40 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 1 2 3 HORSE.H. HIGH (2WD) D TS14 LOW (4WD) DRIVE RANGE (2WD/4WD) RED RED BLK 100 CE MODELS ONLY 250 R2 R3 Section 6 • Schematics R1 E 50 WHT#40-6 LS1 NCHO BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 TB7 EXTEND BOOM RETRACT TP8 BLK#7-M.22 . STEER RIGHT BLU-1 BLU#36-M. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M. DOWN UP JIB BOOM CR8 NC PLATFORM ROTATE RIGHT / JIB DOWN GRN#17-M. DRIVE EDC TP32 TB32 WHT/RED-1 WHT/RED#32-C. TB4 10 WHT/RED#6-M.H. CR7 NC SECONDARY BOOM FLOW CONTROL ORG-3 K UP TS9 DOWN ORG/BLK-3 TP15 TS59 TB14 PLATFORM LEVEL ORG#14-M.H.H. PWM A + X TS62 R LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R4 WHT#4-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C.H. TB11 TB12 BP2 SECONDARY BOOM DOWN BLU/WHT TP14 BLU/WHT#12-M.H.H. A TS15 TP31 TP16 DRIVE ENABLE ORG/RED-3 TB31 DRIVE ENABLE SWITCH WHT/BLK-1 WHT/BLK#31-C.4 POWER 5 LIMITER 6 BOARD 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 6 .H. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK#11-M.H.1 2 3 4 5 6 7 First Edition • Second Printing Electrical Schematic. TS57 TB17 PLATFORM ROTATE LEFT / JIB UP M TS7 LEFT RIGHT PLAT ROTATE RIGHT LEFT PLAT ROTATE CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 TB19 + BRN ORG/BLK N WHT WHT RED RED RED CR9 TI BRN BRN Part No.H. BOOM RETRACT TP6 G WHT/RED-3 WHT/BLK-3 TB5 TP5 WHT-3 TP4 TB8 WHT/BLK#5-M. Z-45/25J Ford Models (from serial number 13099 to 16303) 8 BRN-2 GROUND TB13 NCHO TP13 L1 BLU/RED-3 BLK-7 BRN-7 LS4 TP30 WHT-1 WHT-7 TB30 RED-7 NOHC DRIVE ENABLE LIMIT SWITCH TB16 WHT#12-C.H.H. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25J Ford Models (from serial number 13099 to 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303) . LEVEL ROTATE GRN/WHT #19 GRN/BLK #18 GRN #17 ORG CR7 CR8 ORG/BLK RUN/TEST EH2 BRN-GRD. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 .P. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: 8 EH#1 EH#2 C.M. RED-S.H. BRAKE START ENGINE GLOW PLUG BK/RD-S.H. WT/BLK-S.38D YEL/BLK #7 .#6 WHT-E. WT/RD-S.H.P.39D YEL (18GA) #8 .#4 WHT-EXT. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-S.#6 OG/BK-ISM#2 GRN/WHT-C. 52709 .P.H.35D 6 .H GROUND STUD (-12 VOLTS) 7 RED-E.H R/W-M./START MODULE SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4 BLK 25B WHT 23B RD/WT-C. BK/WT-S. 15A CIRCUIT BREAKER. S.H.H.M.#1 R4 TS52 SECONDARY BOOM TS62 TURNTABLE ROTATE JIB WHT-40 RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4 5 1 RED-C.P.D. BLK/RED #35 START WHT ISM7 WHT-ENA.P. PRIMARY BOOM UP RED-M. FORD EFI.H.H BLK/RED-C.P. BLK-S.P. BOOM UP/DOWN TS58 PRIMARY BOOM EXTEND/ RETRACT WHT #4 WHT/BLK #5 WHT/RED #6 BLK-R1 TO ISM#1 BLK-R1 TO E.H. BU/BK-S. BLK-S.H BLU-M.H RED/BLK-M.P. GR/WT-S.P.P WHT#12-C.P.CB2 YEL (12GA) #9 . RD/BK-C. SW.#1 BLK-E.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . KEY BYPASS IGN.H BLK-ENA.H BLU/BLK-M.#1 BLK/RED-E.P. CONTROLS.H GRN/BLK-M.P.P.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 ORG/BLK-41A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH L M N 2 3 4 5 6 7 8 TACHOMETER START INPUT AUX.H.P. RED-27B BRN-GRD. RD/WT-C. PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E. RD/BK-S. PK/GR-EH#2 YEL/BLK-EH2 6 BU/WT-S.H. BK/RD-R5 BLU-S. WHT-S. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER ENGINE HARNESS # 2.P. RD/WT-S.P. GRN-S. ORG/BLK-M. BU/RD-S. BLK-S.#1 BLK-E.H. GR/BK-S..DOWN (CE MODELS ONLY) BRN TO H. WT/RD-C. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.P.H. GRN-M. ORG-M. RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2 3 4 WHT/PRP EH2 2 BRN ISM5 RED-EXT./FUEL ON ENG.H W/R-M. ON GROUND BATTERY KEY PWR.H RED-C.H.H.P.H WHT-M.P. E. SW. M.D.P.H.H.#4 3 PRIM.P.P OG/BK-S. WHT-S.C. OR/BK-M. WT/BK-C. BLK-ISM#3 BR/BLU-EH2 BLU-M. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 SPLICE BLU/WHT #38 BLU/RED #39 L2 1 2 LED + RED/WHT #3 CR4 CR5 CR7 CR8 TS53 FUEL SELECT RED/BLK #2 RED #1 BLK #7 BLK/WHT #8 HOUR METER 3 BLU/WHT #12 CHECK ENGINE TS61 TS60 TS63 PRI. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 CR2 CR5 CR4 NC NC WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS EXT#6 WHT-R2#86 STOP 9 10 SEC. TST.H.P.H. WHT-SEC. P1 AUXILIARY PUMP TS51 KS1 NO NO IGN.#1 GRN-E. BLU/WT-S.#5 D BASE TERMINATION BLOCK C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S. TS54 CB1 CB2 TS59 TS57 PLATFORM PLAT. ENGINE. RED-20C WHT-TST.H.#5 HIGH/LOW RPM BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33 ORG #14 ORG/BLK #15 ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE VERSION ONLY) BU/BK-M.25D PNK/GRN #6 . FAULT NO 1 START RELAY NO 2 BLK-33D M. TS64 WHT#40-R7 WHT-PRIM.TST SW TAN/BLU #24 . ORG-S.H. R or CR ISM H.H RED-ENA.H BLK-M.H.H.H BLK/WHT-M.P.C. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY.H.H.CB2 WHT/PRP #18 . RD/GRN-EH#1 WHT-S.23 Genie Z-45/25 & Genie Z-45/25J Part No.#1 ORANGE-M.H WHT/BLK-M.P. ) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 3 GRD.C. 2WD/4WD TILT ALARM AUX.24 . +12 V TO PLAT. TO F. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN.C. TURN ROT.) KEYSW. L. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L.S. TURN ROT.L.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC HORN TS14 HIGH/LOW (2WD/4WD) 8 PLATFORM CONTROL SWITCH PANEL Part No.) WHT (F.C. RED TIM. PRIMARY DOWN PRIMARY UP PLAT.P.S. + TILT _ ALARM H1 CABLE #3 CABLE #2 4 5 WHT-23 RED TO STOP SW RED TILT AL. PWR.S. ROT.S. R. F. (CONT.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 H. OPT.P. PRIMARY F.L. BLU-10 BLU/BLK-11 RED/WHT-29 GRN/WHT-19 RED-1 BLK/RED-35 RED-25 RED/WHT-3 WHT/BLK-31 BLU/RED-39 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLU/WHT-38 NC R NO A R CR13 7 L1 JIB VALVE RELAY 8 NC . TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM I H G F E D C B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 GEN. L.P.S. PWR. E. F.C.S. BOOM UP ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. ROT. RED TO JIB CABLE BLU-36 BRN TO GRD. ROT.C. PLAT.D. LEVEL UP DRIVE ENA.DEL. LEVEL DN. BOOM DN. LT. SEC. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 RED/BLK-2 WHT-24 TO H. DRIVE ENABLE SEC.X A A TS13 NC NO + + 2 JIB CUTOUT RELAY 3 4 5 6 1 P3 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 BLK-33 WHT-4 WHT/RED-6 PRIMARY BOOM EXTEND/ RETRACT GEN. PLAT. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIBBOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN.X BP1 NO .P. UP POWER PWR. STUD R1 50 RED-10 LIMITING RELAY RED/BLK-28 WHT JIB CABLE BLK JIB CABLE CABLE #1 110 JIB CABLE F.BOOM BP2 CR14 6 TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 + .) RED (F. SEC.D. BLU/RED-13 BLU/BLK-37 ORG-14 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H. BOOM F.L. (UNUSED) JIB VALVE PLAT. SEC.X R GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1 7 PLATFORM LEVEL TS9 JIB R2 R3 TS8 DRV. R. PUMP SEL. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303) . . RED CR1 NO CR1 CR2 NO CR2 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.H. RED-E. TS64 PK/BLK CHECK ENGINE BLU/WHT-38 L2 GRN/WHT-45-E.H. 52709 .#1 TAN/BLU TB21 5 FUSE LINK ORG/BLK-41-C./START RELAY HORN RELAY HORN LEVEL SENSOR GENERATOR OPTION POWER RELAY AUXILIARY PUMP FS1 BLK-(FS) RED-(FS) WHT-(FS) C B+ TP26 LOAD SENSOR BOX GND 8 BLK-26 LOAD WHT-LOAD TP24 WHT-24 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 6) Genie Z-45/25 & Genie Z-45/25J ORG-LOAD Part No. WHT-21-E. RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP38 TP39 TP45 ENGINE SPEED TP35 RED RED WHT-2 BLU/WHT-1 BLK/RED-1 GRN/WHT-1 BLK-1 BLU/RED-1 RED/BLK-1 RED-1 ORG/BLK-1 BLK/RED-3 3 TS51 START TS52 TS53 TS54 LOW RPM FUNCTION HIGH RPM ENABLE AUXILIARY PUMP RED GAS LP TB39 TB45 FUEL ENGINE BLK TB28 TB27 TB33 4 RED TB9 TB41 CB2 TB23 TB20 RED#20-C.#1 RED/BLK-28-C./START MODULE 5 GROUND 6 BATTERY 7 KEY PWR. H/L LOW RPM HIGH RPM AUXILIARY PUMP GENERATOR 2 TP41 P3 HORN BLK FUEL ENGINE CB1 15AMP. Z-45/25 Ford Models (after serial number 16303) A 1 B C D E F G H I J K L M ORG/BLK N LOAD SENSE OPTION (SEE DETAIL) TP22 P2 BLK TP26 FS1 RED-(FS) WHT-(FS) TP25 TP24 RED WHT RED WHT BLK-(FS) WHT TS1 WHT TS2 CHECK ENGINE TS3 TS47 OFF ON TS4 L3 GAS LP BLK-2 START FOOTSW. 6 FLD.#1 BLK/RED-9 RED/WHT-23-C.H.H.H. 8 KEY BYPASS 9 IGN. FAULT TB35 RED/WHT-23-E. BLK-22 BLK-R1-E.H. GRD. RED-27-C.H.H. ON IGN.25 BRN BRN CHECK ENGINE LED STARTER MOTOR FLASHING BEACON OPTION FUEL PUMP TILT ALARM RUN/TEST SWITCH AUXILIARY POWER RELAY HOUR METER IGNITION.#1 FB TEST TEST RUN CR5 CR5 NO BLK/RED-R5-C.Section 6 • Schematics First Edition • Second Printing Electrical Schematic.H. 15AMP. PR1 NO WHT RED PR1 TB25 500 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 STA./FUEL ON 10 ENG.#1 WHT WHT-21 ALTERNATOR BAT. 12 V DC TAN/BLU FEH(306) PIN24 PINK/LG FEH(658) PIN6 Y FEH(37) PIN9 Y FEH(37B) PIN8 YEL/BLK FEH(674) PIN7 RD/LG FEH(16A) PIN1 WT/PUR FEH(209) PIN18 REGULATOR + TB38 PINK/BLK FEH(787) PIN5 A S I PUMP FUEL AUX PUMP STARTER 1 BLK HM 2 3 BLK 7 LOAD SENSE OPTION P2 BLK-26 TP22 8 6 .H.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.H. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M.1 2 3 4 5 6 7 First Edition • Second Printing Electrical Schematic. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M.H. RIGHT TB8 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A TS62 + X R LEFT R4 10 TURNTABLE ROTATE TB4 WHT/RED-6-M. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK-2-M.H.H. PWM A + X R TB3 RED/WHT-3-M.H.H. PLATFORM LEVEL UP PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) L WHT TP18 GRN/BLK-3 GRN-3 RIGHT TS7 LEFT TS57 TB18 PLAT ROTATE TP17 GRN/BLK-18-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C. HIGH (2WD) TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 50 WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 E TB40 LS3 NO LS1 NCHO ORG-1 WHT-40-4 BRN-4 WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH F BLK-3 BLK/WHT-3 EXTEND TB7 RETRACT BOOM TP8 BLK-7-M.26 . TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK-31-C.H. CR8 NC PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT M TB17 DESCENT ALARM OPTION N ORG/BLK RED BRN WHT RED BRN Part No. EXTEND TS63 RETRACT BOOM TP6 WHT/RED-3 WHT/BLK-3 G TP5 TP4 TB5 WHT-3 WHT/BLK-5-M.H.H. RIGHT LEFT PLAT ROTATE GRN-17-M.H.H. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 ORG/BLK-3 K UP TS9 DOWN TS59 TB14 PLATFORM LEVEL CR7 NC TP15 ORG-14-M.H. WHT#4-M.H.H.H. STEER RIGHT BLU-1 BLU-36-M. TP1 PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TP10 TB10 J BLU-3 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU-10-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M. SECONDARY BOOM UP PWM A + R X TS60 BLU/BLK-11-M.H.H.H. UP PLATFORM LEVEL DOWN ORG/BLK-15-M. Z-45/25 Ford Models (after serial number 16303) 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TP30 A TB30 LS4 TP31 TP16 WHT-12-C. TP32 WHT/RED-1 WHT/RED-32-C.H. 52709 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 TS13 TP7 NO Genie Z-45/25 & Genie Z-45/25J BRAKE RELEASE VALVE B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB37 6 .H. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25 Ford Models (after serial number 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303) . #1 BLK/RED-E. GR/BK-S.#1 BLK-E.H WHT/BLK-M.27 Genie Z-45/25 & Genie Z-45/25J Part No. LEVEL ROTATE GRN/BLK-18 GRN-17 ORG ORG/BLK CR7 CR8 EH2 BRN-GRD. RED-M.P.H. ORG/BLK-M. RED-20C WHT-TST.P. GRN-S.H. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NC NC STOP EXT#6 WHT-R2#86 9 10 SEC.H W/R-M.H.H.P. BLK/RED-35 START WHT ISM7 GRN/WHT-19 WHT-ENA.M.H BLU-M. ON GROUND BATTERY KEY PWR.#5 D BASE TERMINATION BLOCK C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S. FAULT P1 AUXILIARY PUMP TS51 KS1 NO NO IGN.H RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2 WHT-23 BLK-22 RED-27 BRN TO R4 BRN TO GRD WHT-21 WHT-21TO R2 SPLICE L2 1 2 LED + CR4 CR5 CR7 CR8 RED/WHT-3 TS53 FUEL SELECT RED/BLK-2 RED-1 BLK-7 BLK/RED-9 BLK-22 WHT-R2 RED-R1 BRN TO H. BK/RD-R5 BLU-S.CB2 YEL (12GA) #9 .P.H.P. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-S. 4 3 HOUR METER 3 BLU/WHT-12 CHECK ENGINE TS61 TS60 WHT/PRP EH2 BLK/WHT-8 2 BRN ISM5 RED-C.P. RD/GRN-EH#1 WHT-S.P. BLK-S. GR/WT-S.25D PNK/GRN #6 . ORG-S. 1 2 3 4 5 6 7 8 START RELAY NO TACHOMETER START INPUT AUX. R or CR ISM H. GRN-M. RD/WT-C.P.H.H BLK/WHT-M.H BLK-M. BLK/RED-35GEN TS64 WHT#40-R7 WHT-PRIM.H BLU/BLK-M. WHT-SEC.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY ./FUEL ON ENG. WT/RD-S.P. BLK-R1#86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD. BLU/WT-S.H RED/BLK-M.H.P. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.M.P OG/BK-S.#5 HIGH/LOW RPM BLU-10 BLU/BLK-11 RED-20 RED-R1 RED TO EH2 BLK-33 ORG-14 ORG/BLK-15 ORG/BLK-15 ORG-14 BU/BK-M..H.#1 GRN-E. BLK-S.H WHT-M.H RED-ENA.DOWN (CE MODELS ONLY) GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 NO 2 M. CONTROLS.H.#4 3 PRIM.H BLK-ENA. BLK-ISM#3 BR/BLU-EH2 BLU-M. ORG-M. RED-EXT.P. 15A CIRCUIT BREAKER.H R/W-M.H BLK/RED-35GEN GROUND STUD (-12 VOLTS) 7 RED-E.#1 ORANGE-M.H.P.H.H BLK/RED-C.C.35D 8 EH#1 EH#2 C. WT/BLK-S. ENGINE. S.H.H.P.D. TST.D.P.H.TST SW TAN/BLU #24 .39D YEL (18GA) #8 .H.P. BRAKE START ENGINE GLOW PLUG BK/RD-S. BU/RD-S. WT/BK-C. RD/WT-S.#6 OG/BK-ISM#2 PLATFORM LEVEL CUTOUT (CE VERSION ONLY) GRN/WHT-C.H. KEY BYPASS IGN. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: ENGINE HARNESS # 2. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 6 . RD/BK-S. PK/GR-EH#2 YEL/BLK-EH2 6 BU/WT-S.CB2 WHT/PRP #18 . TS54 CB1 CB2 TS59 TS57 PLATFORM PLAT. RD/BK-C. SW. BK/WT-S.P.#1 BLK-E.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4 BLK 25B WHT 23B RD/WT-C.P.P. SW.H.38D YEL/BLK #7 .P. WT/RD-C.H. OR/BK-M. WHT-S.P.H.#4 WHT-EXT. R4 TS52 SECONDARY BOOM WHT/RED-6 TURNTABLE ROTATE WHT-40 RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4 5 RUN/TEST 1 RED-C. BLK-S.P.H.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303) A 1 GROUND CONTROL BOX B C D E F G H I J K L M N LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2 BLU/WHT-38 BLU/RED-39 DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER.H GRN/BLK-M. WHT-S.H. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 .P WHT#12-C.H.#6 PRIMARY BOOM EXTEND/ RETRACT PRIMARY BOOM UP/DOWN TS62 TS63 WHT-4 WHT/BLK-5 BLK-R1 TO ISM#1 BLK-R1 TO E. FORD EFI. BU/BK-S. 52709 .H./START MODULE WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E. RED-S.C.P.P.P.#1 CR1 CR2 CR5 CR4 WHT-E. E.H. M. L. + TILT _ ALARM H1 4 GRN/WHT-45 WHT-4 RED/BLK-2 ORG-14 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 BLU/RED-13 RED-10 TO H.S. BOOM F.P. SEC.C.S. STUD 3 R1 50 RED-10 LIMITING RELAY CABLE #3 CABLE #2 CABLE #1 RED/BLK-28 NC NO R R .X A A NO TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 PLATFORM LEVEL R2 R3 DRV.S. E.L. PWR.) WHT (F. BLK-26 BRN TO GRD. SEC.BOOM BP2 TS47 DP1 DRIVE 8 7 6 5 4 3 2 1 RED-GEN A + .S. TURN ROT. R. DRIVE ENABLE JIB VALVE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-1 BLK (F. F.C. BOOM DN. L.D.C.L. BLU/RED-39 BLK-22 WHT-23 RED-TILT PRIMARY BOOM EXTEND/ RETRACT SEC. OPTION WIRE (UNUSED) PULSE PICKUP LIMIT SWITCH L. F. PRIMARY F. +12 V TO PLAT.C. GAS (SPARE) GEN.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 TS47 R1 R2 R3 L1 L3 BP1 BP2 CR12 GENERATOR SWITCH ( OPTION ) EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . ROT. TO F.X BP1 . BLU-10 BLU/BLK-11 RED/WHT-29 ORG/BLK-15 BLK/RED-35 RED-25 WHT/BLK-5 GRN/WHT-19 GRN-17 BLK/RED-9 RED/WHT-3 ORG/RED-16 WHT/RED-6 RED-1 BLU/WHT-38 BLK-33 GEN.P. (CONT.P. PLAT.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 ORG-40 CR12 RED-10 WHT-24 GRD. BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN. R. ROT.S. PRIMARY DOWN PRIMARY UP PLAT.C. PWR. PUMP SEL. LEVEL DN. LEVEL UP DRIVE ENA. SIDE VIEW OF DP1 WHT TO PLATFORM ROTATE BLU/BLK-37 WHT-30 WHT/BLK-31 BLU-36 WHT/RED-32 5 WHT-24 TO H.28 .X R 6 7 NC TS9 L3 DRIVE SPEED TS14 CHECK ENGINE TS2 START TS4 HIGH/LOW RPM HORN TS3 FUEL SELECT EMERGENCY STOP P2 HIGH/LOW (2WD/4WD) 8 PLATFORM CONTROL SWITCH PANEL Part No. TURN ROT. PLAT. H1 110 DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM F. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . (OPTION) (SPARE) (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. 2WD/4WD TILT ALARM AUX. L.P. LT.) RED (F. UP POWER PWR. ROT.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303) N M L K J I H G F E D C B A PLATFORM CONTROL BOX COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS7 TS9 TS10 TS11 TS12 TS13 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH 1 WHT-24 1 2 3 4 5 6 7 8 9 10 PLAT.S.ENA TS15 NC 1 2 TS13 NC NO SEE SIDE VIEW DP1 + + 3 4 5 NC 6 7 L1 8 P3 NO TS1 AUXILIARY PUMP 100 250 RED-TILT DP1 H. SEC. OPT.) KEYSW.D. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303) . . FAULT CHECK ENGINE TB38 I TP33 RUN/TEST SWITCH TEST TEST RUN TS2 BLK-1 START TS52 H START ENGINE TB33 BLK TS64 ENGINE CR2 POWER RELAY PINK/LG FEH(658) PIN6 WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 YEL/BLK FEH(674) PIN7 TAN/BLU FEH(306) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 PINK/BLK FEH(787) PIN5 F CR1 PK/BLK FUEL PUMP BLK First Edition • Second Printing IGNITION. A S I B+ RED-E.#1 TP41 TB41 RED-(FS) RED WHT-(FS) ORG/BLK-1 ORG/BLK-41-C.H. BAT./START RELAY BLK-R1-E.H./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. GRND CR5 NO P1 RED LOAD SENSOR BOX WHT-LOAD KS1 PLAT TP24 HORN WHT-24 TP22 TB22 HORN RELAY LOAD SENSE OPTION B WHT-21-E. FS1 BLK-(FS) FLD. CB1 CB2 GRD. RED/WHT-23-C.H.H./FUEL ON 10 ENG.H. RED C Section 6 • Schematics ALTERNATOR REGULATOR 15AMP. 52709 STARTER FUEL PUMP WHT RED CR1 NO FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 6) TB21 G CR2 NO TB25 - + . ON IGN. NO WHT RED BLK BRN TILT ALARM LEVEL SENSOR BLK-(FS) TP23 TB23 BLK BLK/RED-3 BLK/RED-9 CR5 C BLK-2 BLK-22 BLK/RED-R5-C.N BRN WHT ORG/BLK RED RED RED CR13 RED JIB CUTOUT RELAY JIB VALVE RELAY JIB BOOM VALVE RELAY (CR-14) CR14 BRN JIB BOOM CUTOUT RELAY (CR13) JIB BOOM VALVES BLK/RED-1 JIB VALVES M ENGINE SPEED TP35 L TS4 FOOTSW.H.29 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J P3 HORN TP9 TB9 P2 BLK TP26 Part No. 8 KEY BYPASS 9 IGN.H. HIGH RPM TAN/BLU OFF GENERATOR GRN/WHT-1 GRN/WHT-45-E. FUSE TB20 LINK RED RED#20-C. Z-45/25J Ford Models (after serial number 16303) D WHT RED/BLK-1 WHT-2 TB28 RED/BLK-28-C.H. 15AMP.#1 500 GND 8 ORG-LOAD 6 . AUXILIARY POWER RELAY AUX PUMP LOAD SENSE OPTION (SEE DETAIL) AUXILIARY PUMP PR1 TP28 FS1 Electrical Schematic. H/L LOW RPM HIGH RPM CR14 NO TS54 LOW RPM FUNCTION ENA.#1 TS3 TP39 BLU/RED-1 LP GAS FUEL TB39 FLASHING BEACON OPTION J TS53 WHT LP GAS HOUR METER FUEL WHT-21 FB TP38 BLU/WHT-1 L2 1 HM 3 2 L3 CHECK ENGINE BLU/WHT-38 LED CHECK ENGINE 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.#1 E STARTER MOTOR TP25 TP24 TS51 WHT-(FS) RED-(FS) RED-1 PR1 AUXILIARY PUMP TP27 AUXILIARY PUMP RED TB27 TS1 RED-27-C.H.H.#1 GENERATOR OPTION K WHT RED TS47 ON TP45 TB45 TB35 RED/WHT-23-E.H. 12 V DC TP22 P2 BLK-26 TP26 A BLK-26 LOAD STA. H. PWM A + X R TB3 TP1 RED/WHT-3-M. D HIGH (2WD) TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 Section 6 • Schematics CE MODELS ONLY R2 R1 E 50 WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO LS1 NCHO ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TP7 BLK-3 BLK/WHT-3 EXTEND TS13 TB7 RETRACT BOOM TP8 BLK-7-M.First Edition • Second Printing Electrical Schematic. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK-11-M. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M.H.H.H.H. WHT/RED-1 WHT/RED-32-C.H. PLATFORM LEVEL UP PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT CR13 NC TP18 L GRN/BLK-3 GRN-3 TS8 TS58 TB18 DOWN JIB BOOM UP TP17 GRN/BLK-18-M.H.30 .H. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M.H.3 4 POWER 5 LIMITER 6 7 BOARD 8 9 10 NO Genie Z-45/25 & Genie Z-45/25J TP37 TP32 B DP1 RED TP36 C 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB37 TB32 6 . CR8 NC PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM ROTATE LEFT / JIB BOOM UP TS57 M WHT TS7 RIGHTPLATFORM LEFT ROTATE LEFT RIGHT PLATFORM ROTATE TB17 CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 BRN + TB19 N ORG/BLK WHT RED RED RED CR9 TI BRN BRN Part No. Z-45/25J Ford Models (after serial number 16303) 1 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB13 L1 NCHO A BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TP30 TB30 LS4 TP31 TP16 WHT-12-C. UP PLATFORM DOWN LEVEL ORG/BLK-15-M.H. WHT#4-M. TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK-31-C. EXTEND TS63 RETRACT BOOM G TP6 WHT/RED-3 WHT/BLK-3 TP5 TB5 WHT-3 TB8 TP4 WHT/BLK-5-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M.H.H. PRIMARY BOOM FLOW CONTROL I RED-3 TP2 RED/BLK-3 REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 J TB10 BLU-3 TP10 BLU UP DOWN SECONDARY BOOM BLU/BLK BLU-10-M. STEER RIGHT BLU-1 BLU-36-M.H.H.H.H.H. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK-2-M.H.H. 52709 TP40 LS2 F 1 2 HORSE.H. DOWN UP JIB BOOM GRN-17-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C. TP14 SECONDARY BOOM FLOW CONTROL K ORG-3 ORG/BLK-3 TS9 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC TP15 ORG-14-M. PWM A + X TS62 R LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R4 10 H TB4 WHT/RED-6-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25J Ford Models (after serial number 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303) . BLK/RED-35GEN TS64 WHT#40-R7 WHT-PRIM.CB2 WHT/PRP #18 . BK/RD-R5 BLU-S.H./START NC NC WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS TS51 TS61 TS62 MODULE KS1 NO NO TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2 PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER.35D 8 6 . ORG/BLK-M. WT/BK-C.P.P.#1 CR2 CR5 CR4 WHT/BLK-5 KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE) TS52 SECONDARY BOOM TS58 TS62 WHT/RED-6 BLK-TEST SW RED-ISM#4 RED-S.39D YEL (18GA) #8 .P. PK/GR-EH#2 YEL/BLK-EH2 6 BU/WT-S.P. RED-S. BLU/WT-S.P WHT#12-C.P. BRAKE START ENGINE GLOW PLUG BK/RD-S.P.P.P.H BLK/WHT-M.H BLK-ENA. RD/WT-C.P.H R/W-M.H.25D PNK/GRN #6 .P.38D YEL/BLK #7 . ON GROUND BATTERY KEY PWR. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.#5 D BASE TERMINATION BLOCK 10 C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 A RED-S. KEY BYPASS IGN. 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 . ORG-M. HIGH/LOW RPM BLU-10 BLU/BLK-11 RED-20 RED-R1 RED TO EH2 BLK-33 PLAT.H W/R-M.P.D.#4 3 PRIM.H.P.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303) A 1 GROUND CONTROL BOX B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN L M N GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 ORG/BLK-41A NO 1 2 START RELAY NO 2 TACHOMETER BLK-33D M.#5 BR/BLU-EH2 BLU-M.H.P. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH#1 EH#2 C.H. 41 WHT-EXT. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER ENGINE HARNESS # 2.H.H.H. GRN-S. 52709 . WHT-S.H.H 42 43 44 45 ALTERNATOR PULSE PICKUP (SPARE) (SPARE) PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BLK/RED-35GEN (SPARE) GENERATOR OPTION GROUND STUD (-12 VOLTS) 7 RED-E.H RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 3 BLK/RED-C.C. BLK-ISM#3 TS54 CB1 CB2 TS59 GRN/WHT-19 GRN/BLK-18 GRN-17 ORG ORG/BLK CR7 CR8 BLK-S.H..H. RD/BK-C. GR/BK-S. BLK-S.#1 BLK 25B WHT 23B RD/WT-C. 15A CIRCUIT BREAKER.#6 OG/BK-ISM#2 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 GRN/WHT-C.#1 BLK/RED-E.CB2 YEL (12GA) #9 . TST.31 Genie Z-45/25 & Genie Z-45/25J Part No.D.H RED/BLK-M.P.H. BLK/RED-9 BLK-22 WHT-R2 RED-R1 7 8 EXT#6 WHT-R2#86 STOP 9 SEC.DOWN (CE MODELS ONLY) BRN TO H.H. SW. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E. WHT-ENA.P.H. RD/BK-S. RD/WT-S.TST SW TAN/BLU #24 .#1 BLK-E. WT/RD-C. RD/GRN-EH#1 WHT-TEST SW WHT-S.H GRN/BLK-M.P./FUEL ON ENG.H. BK/WT-S. 3 4 5 6 START INPUT AUX. M. GRN-M. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED BLK/RED-35 START WHT ISM7 EH2 BRN-GRD.H.H.C.#1 BLK-E.H. ENGINE.H.H. BLK-S. GR/WT-S. E. S.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .P. SW.#4 CH+EH1 OG/BK-C.M. BU/RD-S.M.P. BOOM UP/DOWN TS60 R4 PRIMARY BOOM EXTEND/ RETRACT WHT-4 CR1 BLK-R1 TO ISM#1 BLK-R1 TO E. WHT-S.H WHT-M. BU/BK-S.#6 RED-ISM#6 BLK-2 WHT-2 WHT-E. CONTROLS.P. TURNTABLE ROTATE JIB WHT-40 RED-R4 WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4 5 RUN/TEST 1 RED-C.H BLU/BLK-M. RED-20C WHT-TST.P. WT/RD-S. WT/BLK-S.H RED-ENA.#1 ORANGE-M.H WHT/BLK-M.P. LEVEL TS57 PLATFORM BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ROTATE ORG-14 ORG/BLK-15 ORG/BLK-15 ORG-14 BU/BK-M.H BLU-M. ORG-S.P OG/BK-S.H RED-C. P1 AUXILIARY PUMP IGN. 2 BRN ISM5 RED-EXT.H.P.P. FAULT PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH RED-27B BRN-GRD. R or CR ISM H. FORD EFI.H. PRIMARY BOOM UP RED-M. PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM WHT-23 BLK-22 RED-27 BRN TO R4 BRN TO GRD WHT-21 WHT-21TO R2 SPLICE BLU/WHT-38 BLU/RED-39 L2 LED + 1 2 RED/WHT-3 TS53 FUEL SELECT CR4 CR5 CR7 CR8 RED/BLK-2 RED-1 BLK-7 BLK/WHT-8 HOUR METER 3 BLU/WHT-12 CHECK ENGINE TS61 TS63 PRI. WHT-SEC.H BLK-M.H.#1 GRN-E.P. 4 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 WHT/PRP EH2 OR/BK-M.H. D. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . WHT-24 TO H.L.C.P. TS47 RED-GEN SEC. SEC. F. STUD R1 50 RED-10 LIMITING RELAY RED-TILT 3 RED/BLK-28 WHT JIB CABLE BLK JIB CABLE CABLE #1 110 JIB CABLE F.C. BOOM F. E.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 (UNUSED) JIB VALVE PLAT.S.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC 7 HORN TS14 HIGH/LOW (2WD/4WD) 8 PLATFORM CONTROL SWITCH PANEL Part No.32 . PWR.) RED (F. BOOM UP ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD RED FROM CR14 TS10 TS11 TS12 TS13 TS47 R1 SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. F. ROT.S. LEVEL DN. L. 2WD/4WD TILT ALARM AUX. BLU-10 BLU/BLK-11 RED/WHT-29 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 BLK-33 RED-STP RED-TILT RED TIM. L. ROT. + TILT _ ALARM H1 CABLE #3 CABLE #2 TIME DELAY TILT ALARM 4 SIDE VIEW FOR DP1 WHT/BLK-5 WHT-4 RED/BLK-2 RED-1 BLK-7 BLK/WHT-8 GRN-17 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H. PWR. TURN ROT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. R. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L. R.DEL. TO F.S.X BP1 NO JIB VALVE RELAY CR14 5 6 7 L1 8 2 TS13 A A NC NO + + JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 1 SEE SIDE VIEW DP1 3 4 P3 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 ORG-14 ORG/BLK-15 WHT/RED-6 RED/WHT-3 GRN/WHT-19 BLU/WHT-38 RED TO JIB CABLE RED JUMP BLU-36 BRN TO GRD. PRIMARY F.S. DRIVE ENABLE PLAT.C.) WHT (F. LEVEL UP DRIVE ENA. BOOM DN. PUMP SEL. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.L. (CONT.C. ROT.S. WHT/BLK-31 BLU/RED-39 BLK-22 BLK-26 WHT-23 5 WHT TO PLATFORM ROTATE PRIMARY BOOM EXTEND/ RETRACT GEN. PRIMARY DOWN PRIMARY UP SEC. UP POWER PWR. PLAT.X 6 R PLATFORM LEVEL TS9 TS8 JIB R2 R3 DRV. T1 H1 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN .D. PLAT. SEC.L. +12 V TO PLAT. LT.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD GRD. OPT.P.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 DP1 H.) KEYSW. GEN.BOOM BP2 DP1 DRIVE GRN/WHT + RED OUTPUT BRN TIME DELAY T1 8 7 6 5 4 3 2 1 + .X . TURN ROT.P.P.C.S. BLU/BLK-37 WHT/RED-32 WHT-30 RED-STP GRN/WHT-45 NC R NO A R CR13 NC . First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Ford Models (after serial number . . - Section 6 • Schematics RED RED ALTERNATOR 15AMP.N ORG/BLK WHT WHT RED RED SELECTOR M BRN LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR CE MODELS) BLK/RED-1 TS50 OPTION LOW RPM FOOTSW.H. BAT. NO TILT ALARM RED/WHT#23-E. RED RED#20-E. FLASHING BEACON OPTION TP34 TB34 TS6 BLK-1 BLK/WHT#34-E./START RELAY BLK#R1-E.H. RPM SOLENOID L TB35 CR3 NO CR3 CR4 NO OFF GENERATOR ON CR4 TS47 K GRN/WHT-1 GRN/WHT#45-E./FUEL ON 10 ENG. WHT#21-E.H. 15AMP. LEVEL SENSOR WHT-2 BLK TP26 TP23 BLK BLK/RED-3 BLK/RED HORN TP22 TB22 RELAY CR5 NO BLK#22 BLK/RED#R5-E. GLOW PLUG OPTION TS56 GLOW PLUG GLOW PLUG BLK I L3 OIL TEMP. KEY BYPASS IGN. FAULT 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. A CB2 CB1 TB20 BAT.33 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J TB23 P3 HORN TP9 P1 RED GRND KS1 PLAT BLK B C P2 TB9 TP41 TB41 CR5 Part No. Z-45/25 Deutz Models (before serial number 13099) BLK WHT RED/BLK-1 TB28 RED/BLK#28-E./START MODULE H TP33 TS2 BLK-1 WHT/RED#26 E.H. EXCT. GENERATOR OPTION TP45 TB45 J FB RED/WHT#23-E.H.H. GROUND BATTERY KEY PWR. H/L HIGH RPM LIFT/ DRIVE TP35 TS54 ENGINE SPEED TS4 LOW RPM HIGH RPM FUNCTION ENABLE BLK/RED HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY BLK/RED#R4-E. 52709 CR1 NO STARTER WHT WHT RED - + . 12 V DC IND. + REG. WHT/RED PR2 NO PR2 L2 OIL PRES.H. STA. ON TB26 OTS NO TS52 START WHT/BLK#25 E.H. 6 .H. RED AUXILIARY POWER RELAY AUX PUMP RED AUXILIARY PUMP PR1 D FS1 TP28 Electrical Schematic.H.H.H. HORN BLK-2 ORG/BLK-1 ORG/BLK#41-E. OIL TEMPERATURE LED WHT/BLK OIL PRESSURE LED IGN.H. E TP25 TP21 TS51 STARTER MOTOR TP27 RED RED-1 TP24 PR1 AUXILIARY PUMP AUXILIARY PUMP TB27 TS1 RED#27-E. TB24 TB25 ENGINE OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH START ENGINE 5 6 7 8 9 G TB33 CR2 NC BLK OPS POWER RELAY TB21 FUEL SOLENOID CR2 NO WHT F 3 HM WHT#21 1 2 HOUR METER First Edition • Second Printing CR1 IGNITION.H. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK#11-M.H. CR8 NC PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT M TB18 DESCENT ALARM OPTION N ORG/BLK RED WHT WHT BRN RED BRN Part No. BRN ORG/RED#16-C. DRIVE ENABLE LIMIT SWITCH WHT#30-C. TS61 DOWN RED/BLK#2-M.H. 52709 ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 1 2 3 HORSE.4 POWER 5 LIMITER 6 BOARD 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J BRAKE RELEASE VALVE B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 .H.Electrical Schematic. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M. TP32 WHT/RED-1 WHT/RED#32-C.H.H. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 ORG/BLK-3 TS9 TS59 TB14 UP PLATFORM LEVEL DOWN K CR7 NC TP15 ORG#14-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C. RIGHT TURNTABLE TB8 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A + X TS62 R LEFT ROTATE 15 TB5 H R4 WHT/RED#6-M.H.H. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H. STEER RIGHT BLU-1 BLU#36-M. TB2 UP PRIMARY BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN PWM A + X R 10 TB3 TP1 R5 RED/WHT#3-M.H.H. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M.H.H.H.H. Z-45/25 Deutz Models (before serial number 13099) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLU/RED#13-C. LEFT RIGHT PLATFORM ROTATE GRN/BLK#18-M.H.H.H.H.H.H.34 . PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLATFORM LEVEL TB15 CUTOUT (CE MODELS ONLY) L TP17 GRN-3 GRN/BLK-3 TS8 LEFT TS58 TB17 RIGHT PLATFORM ROTATE TP18 GRN#17-M. EXTEND TS63 RETRACT BOOM TP6 WHT/RED-3 WHT/BLK-3 G TP5 TP4 TB4 WHT-3 WHT#4-M. WHT/BLK#5-M. HIGH (2WD) TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH E TB40 LS3 NO LS1 NCHO WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 TB7 EXTEND BOOM RETRACT TP8 BLK#7-M. BP2 SECONDARYBOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M. WHT-1 TP30 TS15 TB30 A LS4 NOHC TB16 TP31 TP16 WHT#12-C. UP DOWN PLATFORM LEVEL ORG/BLK#15-M.H.H. DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK#31-C.H.H. Z-45/25 Deutz Models (before serial number 13099) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099) . P.P. GR/BK-S.P. GR/WT-S. PLAT.DOWN (CE MODELS ONLY) 3 SECON. BRAKE START GLOW PLUG RPM STEER RIGHT STEER LEFT TEST LIGHT L.1 RED-1 RED/BLK-1 R/W-1 6 WHT/RED-C.#5 7 CH+EH1 OG/BK-E. BOOM UP SEC.35 Genie Z-45/25 & Genie Z-45/25J Part No.1 RD/WT-C. 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR. BOOM DOWN PRI. ROT. DRV. BOOM F. TURN. 15A CIRCUIT BREAKER. UP PLAT.P.P. L TURN.1 WT/RD-E.P. L.H. JIB VALVE 12V BATT./FUEL ON ENG. S.H. PLAT.H RED/WHT-C.H. F.C.1 GRN-S. WHT-S. BLK-S.H 10 11 12 13 14 15 16 17 18 19 20 21 22 WHT-S.P. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER ORG-M./START MODULE P1 NC NO PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER. BOOM F. BLU/WT-S.P.P.H.P. DRV. M.C.H. NC WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 TS51 RED-4 RED/BLK-4 R/W-4 RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 1 2 3 4 5 6 7 8 9 STOP WHT/BLK # 25 PRIM. LEVEL.C.5 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 WHT/RED #26 L2 1 RED 4 3 BLU-4 BLU/BLK-4 BLU/WHT-4 RED BLU/RED-C. 2 OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 BLK/WHT #8 TS61 TS63 HOUR METER 3 BLK/RED#35B BLU/WHT #12 L3 OIL TEMP. 23 24 25 26 RED-ISM#4 27 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4 41 42 43 44 45 BLU-S. WHT-ISM#10 1 WHT/BLK-EH.H.P. LIMIT SWITCH SIG. ROT.P. BOOM DN SEC. R.#6 OG/BK-IM2 ORG/BLK-15 GRD-HOLE ORG-14 8 BLK/RED-EH BLK/RED-EH BLK-E. ROT.H. BU/BK-M.H RED/BLK-C.H ORG/BLK-M.6 9 10 WHT-24D BASE TERMINATION BLOCK D C B A RED-S. RD/BK-S. PULSE PICKUP SPARE SPARE SPARE GEN.P. SUPPLY IGNITION PWR. R TURN.H WT/BK-E.M CR7 CR8 BLK-S. WT/BK-S. LEVEL DN. BK/RD-R5 PRI. PWR.H WHT#21 BLK/RED#R4-EH WHT-40B WHT/BLK-SP WHT/RED-SP RED-S.P.1 BLK-SEC#4 GR/WT-C.H ORG-4/R7 ORG/BLK-4/R8 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT. TILT ALARM 2WD/4WD E.H BLK/RED-R4 BLK/RED-R5 BLK-R1 WIRE CONNECTION ABBREVIATION KEY: EH C.H. BK/RD-SP RED #20 RED-R1 TS57 PLATFORM ROTATE ORG #14 ORG/BLK #15 BLK#22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BLK #33 WHT-EXT.D.H. BOOM EXTEND BOOM RETRACT HORN SEC.H WHT-30 C. ENA.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .H BLK-ISM#3 BLK/WHT-E. OPTION BLK/RED #35 START TURNTABLE ROTATE SEC. ENGINE FAULT OIL PRESSURE SENDER WATER TEMP. RD/WT-S. BLK-33D RED-27B BRN-GRD. FAULT IGN. 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY. KEY BYPASS IGN. BK/WT-S. TO PLAT.#6 BLK-2 WHT-2 2 ORG/RED-C. CONTROLS.P.1 BLU-M.H. BLK-S. WHT-ISM#7 R4 R5 TS52 EXTEND RETRACT PRIMARY BOOM TS62 TS60 WHT-ISM#9 RED-CB1 RED-ISM#6 WHT #4 WHT/BLK #5 WHT/RED #6 CR1 CR2 CR3 CR4 BLK-ISM#1 BLK#R1-E. KEYSWITCH PWR. 52709 . ROT. BOOM UP PRI.P. 5 WHT-E.4 KS1 NO AUXILIARY WHT-R2#86 EXT.P. ON GROUND BATTERY KEY PWR.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 ORG/BLK-41A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 R5 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH L M N M.H.M.P. WHT-S. ENA. SENDER AUX. PWR.1 RED-C. WT/RD-S. WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 WHT#40-R7 WHT-PRIM.P. 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR.H. RED-R2 # 30 WHT-23A 2 3 4 5 6 7 8 TACHOMETER START INPUT NO 2 1 START RELAY NO AUX.H. RED-S. E. R or CR ISM H. ROT. ENGINE.P. PLAT.H ORG-R7 ORG/BLK-R8 6 . ORG-SP OG/BK-SP WHT#12-E. BU/BK-S. BOOM TS54 CB1 CB2 TS59 BLU #10 BLU/BLK #11 FUNCTION ENABLE PLAT.C.P.D.C. GRN/WHT #19 GRN/BLK #18 GRN #17 LEVEL BLK/RED#R5-AH ORG-4 ORG/BLK-4 CR5 BRN GRND H.P.H GRN-4 GRN/BLK-4 RED-C. LT. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L. TS4 HIGH/LOW RPM Part No. FRM PLAT.1 2 3 4 5 6 7 Platform Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099) First Edition • Second Printing 8 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN. PLAT.L. T1 H1 R2 R3 L1 BP1 BP2 CR12 P2 P3 TS1 TS2 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS50 TIME DELAY TILT ALARM 6 . TO PLAT. PLAT.P.C. OPTION WIRE GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.C. E.S.D.C. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY B A D WHT-23 Section 6 • Schematics BLK-22 EMERGENCY STOP P2 BLK-26 NC E WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H. PWR. R.S.P.C. PLAT. PWR. ENA.P. SEC.S.L. BOOM DN. OPT.X .C.ENA TS15 H ORG/RED-16 TS2 START BLK-33 GEN. PWR. GRN/BLK-18 GRN-17 GRN/WHT-19 PLATFORM CONTROL BOX JIB VALVE PLAT. LVL. SEC. DRV. ENA. ROT. DN.) RED (F. (START) PWR.36 .L.) WHT (F. BOOM F. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. PRIMARY DN.BOOM UP GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 PRIMARY BOOM EXTEND/ RETRACT 110 BLK/WHT-8 BLK-7 RED-1 TS13 K TS9 NC AUXILIARY PUMP TS1 OG/BK-41 WHT-24 RED-10 ORG-40 RED/BLK-28 GRD. BLU-36 BLU/BLK-37 DRIVE DP1 G BLU/RED-13 RED/WHT-29 BLU/BLK-11 F. STUD ORG/BLK-15 + TILT _ ALARM H1 ORG-14 BLK/RED-9 N P3 HORN PLATFORM CONTROL SWITCH PANEL SEC. ROT.D. 2WD/4WD TILT ALARM AUX. PWR. LT.BOOM BP2 J HIGH/LOW (2WD/4WD) R2 DRIVE SPEED TS14 A A NC NO 100 I 250 + + .X R GEN. (CONT. SWING RIGHT SWING LEFT PRIMARY F.S.) PWR. START BRAKE E. 52709 NC Genie Z-45/25 & Genie Z-45/25J 1 2 3 4 5 6 R 7 8 HORSEPOWER LIMITER BOARD LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DESCRIPTION C LABEL H. PRIMARY UP RED/WHT-3 CABLE #1 A RED/BLK-2 L + NO .S. F BRN TO GRD. OPT. UP DRV. L. CABLE #2 WHT-4 WHT/BLK-5 NC M 1 2 3 4 5 6 7 8 9 10 CABLE #3 NO WHT/RED-6 TURNTABLE ROTATE HORSEPOWER LIMITER BOARD PLATFORM LEVEL BP1 HORN RETRACT EXTEND SWING F. BLU-10 BLU/WHT-12 RED-27 RED-10 TO H. TO F.P.) WHT-2 BLK-2 WHT BLK/RED-35 RED-25 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L1 R3 DRV. LVL.X R PRIMARY BOOM UP/DOWN NO PLATFORM ROTATE TS7 SEC. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099) . . CR5 PR1 N. PR2 RED 6 12 V DC BAT.O.C. CR4 GRN/WHT#45-E. HM 2 BLK BRN N. Part No. H/L HIGH RPM SELECTOR OPTION BLK-2 START 2 AUXILIARY PUMP GENERATOR P3 HORN BLK ENGINE TP41 CB1 15AMP.O. BLK/RED CR1 N.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. 5 TB21 WHT/RED WHT/BLK BLK#22 CR3 N.NO.O.H. 3) All switches and contacts are shown with the boom in the stowed position and the key switch off. CR2 L2 OIL PRES.37 - + REGULATOR STA. CR4 . WHT/BLK#25 E. BLK/WHT#34-E.H.O. BLK/RED RED/WHT#23-E. ON MODULE GROUND BATTERY KEY PWR. OIL TEMPERATURE SWITCH N.H. RED#27-E.O. L3 OIL TEMP. RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED TP35 RED RED 3 WHT-2 BLK-1 BLK/RED-1 GRN/WHT-1 BLK-1 RED/BLK-1 RED-1 BLK/RED-3 ORG/BLK-1 TS51 START TS52 TS56 GLOW PLUG TS54 LOW RPM FUNCTION HIGH RPM ENABLE AUXILIARY PUMP RED TB45 ENGINE BLK BLK 4 TB28 RED TB27 TB33 1 2 3 4 5 6 7 8 9 10 TB34 START RELAY TACHOMETER START INPUT IGN.H. WHT PR1 TB25 TB26 WHT/RED#26 E.H. - 7 8 6 . 2) The foot switch power is connected to both white wires without the lift/drive selector option. RED CR1 CR2 N.H.H. RED/BLK#28-E. BLK/RED#R5-E. CR5 N. TB24 WHT WHT#21 WHT#21-E.O. FB BLK/RED#R4-E.H.H./FUEL ON ENG. Z-45/25 Deutz Models (from serial number 13099 to 16303) A B C D SEE NOTE 1 E F G H I J K L M SEE NOTE 2 N 1 TP22 P2 ORG/BLK BLK TP26 BLK FS1 BLK RED RED TP25 TP21 RED WHT WHT TS50 WHT WHT LIFT/ DRIVE TP24 TS2 TS1 WHT TS6 GLOW PLUG TS47 OFF ON TS4 LOW RPM FOOTSW. 1 OPS 3 AUX PUMP STARTER IND./START AUX.H.H. CR3 BLK#R1-E.H. BRN GLOW PLUG TILT ALARM OPTION (REQUIRED FOR CE MODELS) LIFT/DRIVE SELECTOR FLASHING BEACON OPTION HIGH IDLE CUTOUT RELAY HIGH IDLE RELAY RPM SOLENOID OIL PRESSURE SWITCH OIL PRESSURE LED OIL TEMPERATURE SWITCH FUEL SOLENOID OIL TEMPERATURE LED AUXILIARY POWER RELAY GENERATOR OPTION POWER RELAY HOUR METER IGNITION.O. + BAT. 52709 . PR2 N. TB35 RED/WHT#23-E. FAULT TB9 TB41 TB23 CB2 TB20 RED#20-E./START RELAY AUXILIARY PUMP STARTER MOTOR HORN RELAY LEVEL SENSOR Genie Z-45/25 & Genie Z-45/25J HORN NOTE: 1) The connection to TP24 is for units without the generator option. KEY BYPASS IGN. ALTERNATOR EXCT.H.H. 15AMP. ORG/BLK#41-E. TB17 PLATFORM ROTATE LEFT M DESCENT ALARM OPTION ORG/BLK RED WHT WHT BRN RED N BRN Part No.H.O.H.H. 52709 1 2 3 4 5 6 7 8 9 10 F TS13 TP7 N.C.O.H.H.H. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C.O.38 . TB32 BRAKE RELEASE VALVE B TRAVEL ALARM OPTION TP37 TB37 BLU/BLK-1 BLU/BLK#37-M.H. E ORG-1 TP40 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT#40-5 HORSEPOWER LIMITER BOARD BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH BLK-3 BLK/WHT-3 TB7 EXTEND BOOM RETRACT TP8 BLK#7-M.H.H.Electrical Schematic. TB4 WHT/RED#6-M.C.H. BOOM RETRACT TP6 WHT/RED-3 WHT/BLK-3 TB5 G TP5 WHT-3 TP4 TB8 WHT/BLK#5-M.H. TB15 PLATFORM LEVEL DOWN PLATFORM LEVEL CUTOUT (CE MODELS ONLY) TP18 GRN/BLK-3 RIGHT TS7 L LEFT GRN-3 TS57 TP17 TB18 PLAT ROTATE GRN/BLK#18-M. DRIVE ENABLE LIMIT SWITCH TB16 WHT#12-C.H.H.H. RIGHT LEFT PLAT ROTATE CR8 NC PLATFORM ROTATE RIGHT GRN#17-M. PWM A TS62 + LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT X R R4 10 WHT#4-M.H. Z-45/25 Deutz Models (from serial number 13099 to 16303) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 N. TB11 TB12 BP2 SECONDARY BOOM DOWN BLU/WHT TP14 BLU/WHT#12-M. CR7 NC SECONDARY BOOM FLOW CONTROL ORG-3 K TS9 ORG/BLK-3 TS59 TP15 TB14 UP PLATFORM DOWN LEVEL ORG#14-M. TS15 TP16 DRIVE ENABLE ORG/RED-3 TB31 DRIVE ENABLE SWITCH TP31 WHT/BLK-1 WHT/BLK#31-C. TB3 PWM A PRIMARY BOOM DOWN X R + TP1 RED/WHT#3-M. EXTEND BOOM EXTEND TS63 RETRACT BOOM BLK/WHT#8-M. GROUND LS4 TP13 BLU/RED-3 BLK-7 BRN-7 TB13 L1 TP30 WHT-1 WHT-7 TB30 A RED-7 N.H.H. TB2 TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP RED/BLK#2-M. CE MODELS ONLY 250 R2 D WHT#40-6 BRN-6 Section 6 • Schematics PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH TB40 LS3 N.O. DRIVE EDC TP32 WHT/RED-1 WHT/RED#32-C.H.C.O. PRIMARY BOOM FLOW CONTROL RED-3 TP2 RED/BLK-3 I TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 BLU-3 TP10 TS60 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M. HIGH (2WD) TS14 LOW (4WD) DRIVE RANGE (2WD/4WD) RED RED BLK 100 LS1 N. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M. SECONDARY BOOM UP J PWM A + X R BLU/BLK#11-M.H.H.H.H. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL H RED#1-M.H.H. STEER RIGHT BLU-1 BLU#36-M. LS2 Genie Z-45/25 & Genie Z-45/25J C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 6 . First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25 Deutz Models (from serial number 13099 to 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303) . P. WT/BK-S. RD/BK-S.D.P.1 WHT/RED-C. WT/BK-E.fem-ORG-R7 r.#5 BU/BK-M.H.C. GRN-4 2 BLK/WHT #8 WHT#12-E. WHT#40-R7 WHT-PRIM. RED-S.1 GRN-S. L3 OIL TEMP. BLK-S.H.1 RED-C./START MODULE P1 NC NO 7 KEY PWR.1 RD/WT-C. GR/BK-S. ORG-SP OG/BK-SP NC PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.6 9 BASE TERMINATION BLOCK 10 ENG.P. 15A CIRCUIT BREAKER.fem-ORG/BLK-R8 8 BLK/RED-EH-r./FUEL ON KS1 NO AUXILIARY WHT-R2#86 WHT-24D 3 EXT.P. WHT-ISM#9 RED-CB1 GRN/BLK-4 RED-C.#6 BLK-2 WHT-2 TS62 WHT-ISM#7 WHT/BLK-SP WHT/RED-SP RED-S.H.P.P. LEVEL PLAT.H.C. BK/RD-R5 BLU-S.fem BLK-E.P.male r. R or CR ISM H.P.-r.1 BLU-M. BK/WT-S.#6 CH+EH1 OG/BK-E. RED-R2 # 30 2 3 NO PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER. WHT/BLK-EH.H GRN/WHT-1 ORG/BLK-15 GRD-HOLE ORG-14 BLK/RED-EH-r.P.M BLU/BLK #11 RED #20 RED-R1 BLK #33 BLK#22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE VERSION ONLY) WHT-EXT. M. FAULT D PRIM.P. BLK/RED #35 GLOW PLUG START SEC.H. BLU/WT-S.H-r. CR5 GRN/BLK #18 GRN #17 ORG-4 CR7 ORG/BLK-4 CR8 6 BLK-S.1 OG/BK-IM2 7 GR/WT-C. ON GROUND BATTERY 2 M. TS57 ROTATE ORG #14 ORG/BLK #15 BRN GRND H. 52709 .H RED/BLK-C. WHT-ISM#10 RED-EXT.H.H.P.H BLK-ISM#3 BLK/WHT-E.P.DOWN (CE MODELS ONLY) 4 3 BLU-4 BLU/BLK-4 BLK-ENA.male-BLK/RED-R5 r.P.H WHT-ENA.H. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION TS51 WHT/BLK # 25 WHT/RED #26 LED RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8 + L2 HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY.-r. GR/WT-S.H. SECON. RD/WT-S. ORG-4/R7 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 1 2 OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 HOUR METER RED BLK/RED#35B RED-ISM#6 3 BLU/WHT #12 BLK/WHT-34 R4 TS56 ORG/BLK-4/R8 RED-ENA. TS61 PRIMARY BOOM TS63 EXTEND RETRACT WHT #4 WHT/BLK #5 WHT/RED #6 BLK#R1-E.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 1 B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS55 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 K DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH L M N START RELAY TACHOMETER START INPUT AUX.male-BLK-R1 r. BOOM GRN/WHT #19 WHT#21 BLK/RED#R4-EH WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 TS54 CB1 CB2 TS59 BLK/RED#R5-AH.P. WT/RD-S. ORG/BLK-41A BLK-33D RED-27B BRN-GRD.P. 24 25 26 27 RED-ISM#4 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4 41 42 43 44 45 A RED-S.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 6 . 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY NO 4 5 6 WHT-23A IGN.P. WHT-S.male ORG/BLK-M.H RED/WHT-C.4 8 KEY BYPASS IGN. S.H. BLK/WHT-34 BK/RD-SP BLU #10 FUNCTION ENABLE PLAT. ENGINE.fem ORG-M.1 TURNTABLE ROTATE WT/RD-E.5 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 1 B 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 WHT-S.P.H.H. CR1 BLK-ISM#1 CR2 CR3 CR4 5 1 TS60 TS52 WHT-E. E.H.H. WHT-S.P.H.D. CONTROLS. BU/BK-S.H.P. BLK-S.fem-BLK/RED-R4 r.male WIRE CONNECTION ABBREVIATION KEY: EH C.P.39 Genie Z-45/25 & Genie Z-45/25J Part No.P.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . F BLU-36 BLU/BLK-37 HIGH/LOW RPM DRIVE BRN TO GRD. H1 P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 L3 BP1 BP2 TILT ALARM 6 . DRIVE ENABLE PLAT.C. PUMP SEL. F.) WHT-2 BLK-2 WHT BLK/RED-35 RED-25 ORG/RED-16 R3 GLOW PLUG TS6 TS2 START 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BLK-33 H GENERATOR OPTION TS4 G Part No. PLAT. ROT.) WHT (F. PLAT.P. SEC.S.X NC R NO PLATFORM ROTATE TS7 SEC. STUD ORG/BLK-15 _ ALARM + TILT H1 ORG-14 BLK/RED-9 N P3 HORN PLATFORM CONTROL SWITCH PANEL PLATFORM CONTROL BOX AUXILIARY PUMP J TS1 HIGH/LOW (2WD/4WD) R2 I DRIVE SPEED TS14 100 250 A A + + . L.P.S.1 2 3 4 5 6 7 Platform Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303) First Edition • Second Printing 8 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN. BOOM DN. TURN ROT.S.) KEYSW. SEC. PWR. LEVEL DN. 2WD/4WD TILT ALARM AUX. TURN ROT. BOOM UP GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 PRIMARY BOOM EXTEND/ RETRACT K BLK/WHT-8 BLK-7 RED-1 TS13 TS9 WHT-24 RED/BLK-28 GRD. +12 V TO PLAT. R. L. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. PWR. R.D. BLK/WHT-34 L1 RED/WHT-29 BLU/BLK-11 SEC. ROT.C.) RED (F. OPTION WIRE BLU/RED-13 DRV.X R (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. 110 CABLE #2 WHT-4 WHT/BLK-5 NC M 1 2 3 4 5 6 7 8 9 10 ORG/BLK-41 CABLE #3 NO WHT/RED-6 ORG-40 RED-10 TURNTABLE ROTATE HORSEPOWER LIMITER BOARD PLATFORM LEVEL BP1 HORN BOOM RETRACT BOOM EXTEND TURN. 52709 Genie Z-45/25 & Genie Z-45/25J 1 2 3 4 5 6 R 7 8 HORSEPOWER LIMITER BOARD DESCRIPTION C LABEL D H.S. BOOM F. ROT. PRIMARY DOWN PRIMARY UP RED/WHT-3 CABLE #1 PRIMARY BOOM UP/DOWN A RED/BLK-2 L + NO . F. PRIMARY F.L. LT.40 . LEVEL UP DRIVE ENA. BLU-10 BLU/WHT-12 RED-27 RED-10 TO H.L.S.C.X .P. E.ENA TS15 GEN.C.BOOM BP2 NC NO F.S. GRN/BLK-18 GRN-17 GRN/WHT-19 (UNUSED) JIB VALVE PLAT.C. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN B A WHT-23 EMERGENCY STOP P2 Section 6 • Schematics BLK-26 BLK-22 E NC NC WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H. (CONT. UP POWER PWR. TO F.D.L. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303) . . CB2 CB1 TB20 BAT. - RED RED Section 6 • Schematics ALTERNATOR 15AMP.H.H. TB26 OTS NO TS52 START WHT/BLK#25 E. 12 V DC IND. OIL TEMPERATURE LED WHT/BLK OIL PRESSURE LED 1 START RELAY 2 TACHOMETER 3 START INPUT IGN. Z-45/25J Deutz Models (before serial number 13099) FS1 TP28 BLK D WHT RED/BLK-1 TB28 RED/BLK#28-E.N WHT BRN WHT ORG/BLK RED RED RED CR13 RED BRN JIB BOOM CUTOUT RELAY (CR-13) JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR CE MODELS) BLK/RED-1 JIB VALVES SELECTOR M TS50 LIFT/ DRIVE OPTION ENGINE SPEED TS4 LOW RPM FUNCTION HIGH RPM ENABLE BLK/RED HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY BLK/RED#R4-E. BAT. EXCT.H. GENERATOR OPTION K TP45 TB45 J FB RED/WHT#23-E./FUEL ON 10ENG. GLOW PLUG OPTION TS56 GLOW PLUGS GLOW PLUGS BLK I L3 OIL TEMP. 6 . KEY BYPASS IGN. TB24 TB25 ENGINE OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH START ENGINE 5 6 7 8 9 G TB33 CR2 NC BLK OPS POWER RELAY TB21 FUEL SOLENOID CR2 NO WHT 3 F HM WHT#21 1 2 HOUR METER First Edition • Second Printing CR1 IGNITION.H. STA. RED PUMP PR1 RED AUXILIARY POWER RELAY PUMP TP24 AUX RED AUXILIARY PUMP PR1 Electrical Schematic.H. 52709 CR1 NO STARTER E WHT WHT RED + - . + A REG.H. WHT/RED PR2 NO PR2 L2 OIL PRES. H/L HIGH RPM CR14 NO CR14 TP35 TS54 OFF TS47 ON GRN/WHT-1 GENERATOR GRN/WHT#45-E. ON MODULE H TP33 GROUND BATTERY KEY PWR. 15AMP./START 4 AUX.H.H. WHT#21-E.H. FLASHING BEACONS OPTION CR4 TP34 TB34 TS6 BLK-1 BLK/WHT#34-E.H./START RELAY BLK#R1-E. RED RED#20-E.H.41 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J P3 HORN TP9 BLK TP22 TB9 P1 RED KS1 PLAT GRND TP41 TB41 B CR5 NO CR5 Part No. LEVEL SENSOR WHT-2 BLK TP26 TP23 TB23 BLK BLK/RED-3 BLK/RED HORN P2 TB22 RELAY BLK#22 BLK/RED#R5-E.H.H.H. FAULT TS2 BLK-1 WHT/RED#26 E. NO TILT ALARM RED/WHT#23-E. TP25 TP21 TS51 STARTER MOTOR TP27 AUXILIARY AUXILIARY PUMP RED-1 TB27 TS1 RED#27-E. RPM SOLENOID L TB35 CR3 NO CR3 CR4 NO LOW RPM FOOTSW. HORN C BLK-2 ORG/BLK-1 ORG/BLK#41-E. H.H. STEER LEFT RED/WHT-1 RED/WHT#29-C. TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) PLATFORM LEVEL DOWN CR13 NC TP17 L GRN/BLK-3 TB17 UP TS8 DOWN JIB BOOM GRN-3 TS58 TP18 UP DOWN GRN/BLK#18-M.H. TB2 UP TS61 PRIMARY BOOM UP PRIMARY BOOM DOWN DOWN RED/BLK#2-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.H.H.H. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M.H. STEER RIGHT BLU-1 BLU#36-M.42 L1 . LS4 TP30 A WHT-1 TB30 WHT#30-C.H. TB8 EXTEND TS63 RETRACT BOOM TP6 WHT/RED-3 WHT/BLK-3 TB4 TP5 G WHT-3 TP4 WHT#4-M. DRIVE ENABLE LIMIT SWITCH TS15 TP31 TP16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 WHT/BLK#31-C. TS57 TB18 PLATFORM ROTATE RIGHT/ JIB BOOM DOWN RIGHT LEFT M TS7 LEFT RIGHT PLAT ROTATE PLAT ROTATE CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 TB19 + BRN ORG/BLK N RED WHT WHT RED RED CR9 TI BRN BRN Part No. BP2 SECONDARY BOOM DOWN BLU/WHT TP14 BLU/WHT#12-M. Z-45/25J Deutz Models (before serial number 13099) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 GROUND TB13 NCHO TP13 BLU/RED-3 BLU/RED#13-C. DRIVE EDC TP32 WHT/RED-1 TB32 WHT/RED#32-C.H. TB3 PRIMARY BOOM PWM A + X R 10 TP1 R5 RED/WHT#3-M. RIGHT TS62 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A + X R LEFT TB5 TURNTABLE ROTATE 15 R4 WHT/RED#6-M.H.H.H.H. WHT/BLK#5-M.H. TB1 TB6 TURNTABLE ROTATE FLOW CONTROL H BP1 RED#1-M. JIB BOOM CR8 NC PLATFORM ROTATE LEFT/ JIB BOOM UP GRN#17-M. NOHC TB16 WHT#12-C.H. 52709 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 F TS13 TP7 NO Genie Z-45/25 & Genie Z-45/25J B DP1 C RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 . SECONDARY BOM UP PWM A + X R BLU/BLK#11-M. MOTOR STROKE HIGH (2WD) TS14 LOW (4WD) DRIVE RANGE (2WD/4WD) RED RED BLK 100 CE MODELS ONLY 250 R2 D Section 6 • Schematics WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH TB40 E LS3 NO LS1 NCHO ORG-1 WHT#40-4 BRN-4 WHT#40-5 1 2 3 HORSE.H.4 POWER 5 LIMITER 6 BOARD 7 8 9 10 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH BLK-3 BLK/WHT-3 TB7 EXTEND RETRACT TP8 BOOM BLK#7-M.H.H.H.Electrical Schematic.H. CR7 NC SECONDARY BOOM FLOW CONTROL ORG-3 ORG/BLK-3 TS59 TB14 TS9 UP PLATFORM DOWN LEVEL K TP15 ORG#14-M. PRIMARY BOOM FLOW CONTROL RED-3 TP2 I RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 BLU-3 J TS60 BLU UP SECONDARY DOWN BOOM BLU/BLK TB11 TB12 TP10 BLU#10-M.H. BRN ORG/RED#16-C.H. BRAKE RELEASE VALVE TRAVEL ALARM OPTION TP37 BLU/BLK-1 BLU/BLK#37-M. Z-45/25J Deutz Models (before serial number 13099) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099) . H. OPTION TS51 RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLU/WHT-4 BLU/RED-C.P. BLK-S./FUEL ON KS1 NO AUXILIARY WHT-R2#86 WHT-24D 3 EXT./START MODULE P1 NC NO NO NO WHT-23A 7 KEY PWR. BOOM TURNTABLE ROTATE JIB WHT#21 BLK/RED#R4-EH WHT-40B 6 WT/RD-E.H.H. LEVEL TS57 PLATFORM ROTATE BRN GRND H. ROT.C.P.1 BLU-M.H ORG/BLK-15 GRD-HOLE ORG-14 BLK/RED-EH BLK/RED-R4 BLK/RED-R5 BLK-R1 ORG-R7 ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C. TURN.P.H.H RED/WHT-C.#5 ORG #14 ORG/BLK #15 BLK#22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT-EXT. E.H. ENGINE.H.H.H ORG-4/R7 ORG/BLK-4/R8 ORG/RED-C.H WHT-30 C. 6 . F. CONTROLS.#6 CH+EH1 OG/BK-E.H RD/WT-C. 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR. DRV.D. ROT.4 8 KEY BYPASS IGN. R TURN.P. ON GROUND BATTERY 2 M.C.1 RED-C. ENGINE FAULT OIL PRESSURE SENDER WATER TEMP.D. DRV. BOOM UP SEC. GR/BK-S. ORG/BLK-M.1 WHT-S.6 9 BASE TERMINATION BLOCK 10 ENG.P. SECON.P. PLAT.P.1 START SEC. R. BLK-S. BLK-S.H RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 TS54 CB1 CB2 GRN/WHT #19 TS59 BLK/RED#R5-AH CR5 BLU #10 FUNCTION ENABLE GRN/BLK #18 GRN #17 ORG-4 CR7 ORG/BLK-4 CR8 BLK-ISM#3 BLK/WHT-E. FAULT D PRIM. SUPPLY IGNITION PWR.H. ORG/BLK-41A BLK-33D RED-27B BRN-GRD.P.P.P. BOOM F.P.P.H. LIMIT SWITCH SIG. UP PLAT.1 BLK-SEC#4 OG/BK-IM2 7 GR/WT-C. BOOM EXTEND BOOM RETRACT HORN SEC. PLAT. LEVEL DN.H. WT/BK-S. BRAKE START GLOW PLUG RPM STEER RIGHT STEER LEFT TEST LIGHT L.H.P.H. BK/WT-S. BOOM UP PRI. PWR. BOOM F. S.P.H. PLAT.P. 15A CIRCUIT BREAKER. TS61 TS63 WHT #4 WHT/BLK #5 WHT/RED #6 R4 5 R5 TS52 RED-C. L3 OIL TEMP. 15A M N START RELAY TACHOMETER START INPUT AUX. WHT-ISM#10 1 WHT-ISM#7 WHT/BLK-SP WHT/RED-SP RED-S.#6 BLK-2 WHT-2 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 WHT-S.1 WHT/RED-C. NC PRI. LEVEL. RED-R2 # 30 2 3 4 5 6 IGN.1 GRN-S. ROT.P. TO PLAT.P.C.M WHT#40-R7 WHT-PRIM.43 Genie Z-45/25 & Genie Z-45/25J Part No. BU/BK-M. R or CR ISM H. L TURN. LT. BK/RD-SP BLU/BLK #11 RED #20 RED-R1 BLK #33 PLAT. ENA.C. JIB VALVE 12V BATT. 23 24 25 26 RED-ISM#4 27 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4 41 42 43 44 45 A RED-S. L.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 1 B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 R5 L2 L3 CR1 CR2 WHT/BLK # 25 WHT/RED #26 K DESCRIPTION L EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER. BLK/RED #35 WHT/BLK-EH. RED-S.M.P. WHT-E. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 BLK/RED-EH BLK-E. WHT-S.H GRN-4 GRN/BLK-4 WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR. M. ORG-SP OG/BK-SP 1 2 OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 CR3 CR4 CR5 CR7 CR8 HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY. ROT.H ORG-M. SENDER AUX. KEYSWITCH PWR. BU/BK-S.P.H.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . GR/WT-S.P. ROT.5 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT. 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY 4 3 L2 BK/RD-R5 BLU-S. EXTEND PRIMARY RETRACT BOOM TS62 TS60 TS58 CR1 BLK-ISM#1 CR2 CR3 CR4 BLK#R1-E. PWR. TILT ALARM 2WD/4WD E. BOOM DOWN PRI.P.H RED/BLK-C. ENA.P. 52709 . RD/WT-S. PULSE PICKUP SPARE SPARE SPARE GEN.DOWN (CE MODELS ONLY) HOUR METER RED RED 3 BLU/WHT #12 BLK/RED#35B WHT-ISM#9 RED-CB1 RED-ISM# BLK/WHT #8 2 WHT#12-E.C. BLU/WT-S.H WT/BK-E.H. RD/BK-S. WT/RD-S. BOOM DN SEC. R. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L. PWR. FRM PLAT. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . OPTION WIRE HORN RETRACT EXTEND SWING F.ENA TS15 GRN/WHT + RED OUTPUT BRN TIME DELAY T1 7 PLATFORM LEVEL P3 NO TS9 R3 250 NC TS2 START TS4 NC 8 HORN TS14 HIGH/LOW (2WD/4WD) HIGH/LOW RPM EMERGENCY STOP P2 PLATFORM CONTROL SWITCH PANEL Part No. 2WD/4WD TILT ALARM AUX.44 .C. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6 NC R NO A R CR13 NC . SEC. TO F. PRIMARY DN.X BP1 NO TS13 . RED TIM.X R DRIVE DP1 DRV. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . GEN. RED TO JIB CABLE BLU-36 BRN TO GRD. PLAT. ROT. DN. SEC. PWR.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 3 GRD. BOOM F. PRIMARY UP SEC. ROT.C.) WHT (F. LT.) RED (F. UP DRV. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 WHT-24 TO H.D. LVL. START BRAKE E. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM WHT-24 1 2 3 4 5 6 7 8 9 10 PLAT.DEL.P.P. TO PLAT.L.D.C.P. SEC.S. STUD RED/BLK-28 WHT JIB CABLE BLK JIB CABLE CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.BOOM UP JIB VALVE PLAT. SWING RIGHT SWING LEFT PRIMARY F. ENA.S. 2 OG/BK-41 ORG-40 HORSEPOWER LIMITER BOARD RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. OPT.L. PWR.C. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. (START) PWR.X JIB VALVE RELAY NC NO JIB CUTOUT RELAY CR14 + + A A 3 4 5 6 7 L1 8 RED/WHT-3 PRIMARY BOOM EXTEND/ RETRACT GEN. BLU/RED-13 BLU/BLK-37 ORG-14 RED-10 TO H.BOOM BP2 6 2 TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 JIB TS8 TS1 AUXILIARY PUMP DRIVE SPEED R2 100 1 + .S.L. DRV. LVL. PLAT.) PWR.S. ENA. 4 H1 + TILT _ ALARM 5 RED-1 WHT-23 RED TO STOP SW RED TILT AL.S.P. L.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099) N M L K J I H G F E D C B A 1 PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR12 CR13 CR14 H. E. BOOM DN. OPT. (CONT. PWR.C. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099) . . TB24 WHT#21 WHT WHT#21-E.H.H. BLK#R1-E. BLK/WHT#34-E. PR2 RED 6 12 V DC + BAT.H. ALTERNATOR EXCT. RED#27-E.H.H.45 - BRN STARTER MOTOR AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY HORN RELAY TILT ALARM FUEL SOLENOID Genie Z-45/25 & Genie Z-45/25J HORN LEVEL SENSOR AUXILIARY PUMP Part No.H. + BAT. 1 REGULATOR OPS 3 NC AUX PUMP STARTER HM 2 BLK IND. 8 KEY BYPASS 9 IGN. TB35 RED/WHT#23-E. CR5 NO BLK/RED#R5-E.H. ON IGN.H. 6 .H.H.H. 52709 . CR5 PR1 NO WHT PR1 TB25 TB26 WHT/RED#26 E. L3 OIL TEMP.H.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. RED CR1 CR2 NO TB21 CR2 L2 OIL PRES. 8 3) All switches and contacts are shown with the boom in the stowed position and the key switch off./START 5 GROUND 6 BATTERY MODULE 7 KEY PWR. - STA. Z-45/25J Deutz Models (from serial number 13099 to 16303) A B C D E SEE NOTE 1 F G H I J K L M SEE NOTE 2 N ORG/BLK 1 TP22 P2 BLK TP26 BLK FS1 BLK RED RED TP24 TP25 TP21 RED WHT WHT TS50 WHT WHT LIFT/ DRIVE TS2 TS1 BLK-2 WHT START GLOW PLUG TS6 TS47 TS4 SELECTOR OPTION GENERATOR AUXILIARY PUMP 2 CB1 15AMP. WHT/BLK WHT/RED BLK#22 BLK/RED RED/WHT#23-E. OIL TEMPERATURE SWITCH NO BRN FLASHING BEACON OPTION OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH OIL TEMPERATURE LED OIL PRESSURE LED CE MODELS) HIGH IDLE CUTOUT RELAY OPTION (REQUIRED FOR HIGH IDLE RELAY GENERATOR OPTION RPM SOLENOID LIFT/DRIVE SELECTOR GLOW PLUG 7 NOTE: 1) The connection to TP24 is for units without the generator option. 15AMP. FB BLK/RED#R4-E./FUEL ON 10 ENG.H. RED TP41 P1 RED TB22 P3 HORN BLK ENGINE KS1 PLAT GRND TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED TP35 RED RED WHT-2 BLK/RED-3 RED/BLK-1 RED-1 BLK-1 BLK-1 GRN/WHT-1 BLK/RED-1 ORG/BLK-1 3 TS51 START AUXILIARY PUMP TS52 TS56 GLOW PLUG TS54 LOW RPM HIGH RPM RED TB45 ENGINE BLK BLK FUNCTION ENABLE TB28 RED TB27 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.H. ORG/BLK#41-E. PR2 NO WHT/BLK#25 E. FAULT TB34 4 TB9 TB41 CB2 TB23 TB20 RED#20-E. 2) The foot switch power is connected to both white wires without the lift/drive selector option. BLK/RED CR1 NO 5 CR3 NO CR3 CR4 NO CR4 GRN/WHT#45-E. RED/BLK#28-E. STEER LEFT D TP29 TB29 RED/WHT-1 MOTOR STROKE RED/WHT#29-C. UP DOWN JIB BOOM CR8 NC JIB BOOM DOWN GRN#17-M.Electrical Schematic.H.H. UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK#15-M.H. I TP1 PRIMARY BOOM FLOW CONTROL RED-3 TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP10 TP11 BLU/BLK-3 J TB10 BLU-3 BLU BLU#10-M. PWM A UP SECONDARY SECONDARY BOOM UP TS60 DOWN BOOM + X R BLU/BLK BLU/BLK#11-M. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK#2-M. HIGH (2WD) TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) RED BLK 100 Section 6 • Schematics CE MODELS ONLY 250 R2 R3 E WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS1 NCHO ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH HORSEPOWER LIMITER BOARD TS13 TP7 BLK-3 BLK/WHT-3 BOOM TB7 RETRACT TP8 EXTEND BLK#7-M.H.H.H.H.H. PWM A + X R TB3 RED/WHT#3-M.H. WHT#4-M.H.H. WHT/RED-1 WHT/RED#32-C. STEER RIGHT C BLU-1 BLU#36-M.H.H.H.46 . BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M. SECONDARY BOOM FLOW CONTROL TP14 K ORG-3 ORG/BLK-3 TP15 TS9 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC ORG#14-M. Z-45/25J Deutz Models (from serial number 13099 to 16303) First Edition • Second Printing 1 2 3 4 5 6 7 8 A BRN-2 GROUND TB30 TB13 TP13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TS15 TP30 LS4 NOHC TB16 WHT#12-C. PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) CR13 NC TP18 L GRN/BLK-3 GRN-3 TP17 TS8 UP TS58 TB18 DOWN JIB BOOM GRN/BLK#18-M. EXTEND G TP6 TP4 TP5 TS63 RETRACT WHT/RED-3 WHT/BLK-3 TB5 WHT-3 WHT/BLK#5-M.H.H. 52709 TB40 TP40 LS2 F 1 2 3 4 5 6 7 8 9 10 NO LS3 NO Genie Z-45/25 & Genie Z-45/25J TP32 TP37 TP36 DP1 1 2 3 4 5 6 7 8 RED TB36 TB37 TB32 6 . BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M.H.H.H. TP16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TP31 TB31 B WHT/BLK-1 DRIVE EDC WHT/BLK#31-C. JIB BOOM UP TS57 M TS7 LEFT RIGHT PLAT ROTATE LEFT RIGHT PLAT ROTATE TB17 CR9 NC DESCENT ALARM OPTION TP19 BRN + GRN/WHT-3 TB19 N ORG/BLK RED WHT WHT BRN RED RED CR9 TI BRN Part No. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M. RIGHT TURNTABLE ROTATE TB8 BOOM TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A TS62 + R LEFT X R4 10 H TB4 WHT/RED#6-M. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M.H.H. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25J Deutz Models (from serial number 13099 to 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303) . RD/WT-C.P.H. E. CONTROLS. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED IGNITION / START RELAY POWER RELAY WHT-23A 7 KEY PWR.H 7 ORG/BLK-15 GRD-HOLE ORG-14 BLK/RED-EH-r.P.H. BLK-S.DOWN (CE MODELS ONLY) HOUR METER 3 RED BLK/RED#35B RED-ISM#6 2 WHT#12-E.C. BK/RD-R5 BLU-S.H.P.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 M.fem-ORG-R7 r.male WIRE CONNECTION ABBREVIATION KEY: EH C.H RED/WHT-C. 15A CIRCUIT BREAKER. GR/WT-S.H.P.P. R or CR ISM H. BLU/WHT #12 BLK/WHT-34 R4 TS56 L3 OIL TEMP. BU/BK-M.H BLK-ISM#3 BLK/RED #35 GLOW PLUG START SEC.H.P. ORG-SP OG/BK-SP NC PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .P. WHT-S. WT/BK-E. ORG-4/R7 ORG/BLK-4/R8 RED-ENA.H WHT-ENA.male-BLK-R1 r.H. B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS63 TS61 TS62 TS60 CB1 CB2 HM R4 L2 CR1 CR2 K DESCRIPTION L M N 1 START RELAY TACHOMETER START INPUT AUX. WHT-ISM#9 RED-CB1 CR1 BLK-ISM#1 CR2 CR3 CR4 RED-C. GR/BK-S.P. 52709 .1 TS60 TS52 5 1 WHT-S. RED-R2 # 30 2 3 2 4 IGN.H.P. WHT-S.P.P.H RED/BLK-C.H.M BLU-M.1 RED-C.#6 BLK-2 WHT-2 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A RED-S. BLU/WT-S.#5 BLK/WHT-E. M.P.P.D.fem ORG-M.1 TURNTABLE ROTATE WT/RD-E.C.D.1 GRN-S.P. GRN-4 GRN/BLK-4 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT. BU/BK-S.fem-BLK/RED-R4 r. ORG #14 ORG/BLK #15 BLK#22 BLK/RED-9A WHT-SEC#4 WHT-EXT. LEVEL BLU/BLK #11 RED #20 RED-R1 BLK #33 TS57 PLATFORM ROTATE BRN GRND H. RED-S.1 BLK-S. ON GROUND BATTERY ORG/BLK-41A BLK-33D RED-27B BRN-GRD.-r. FAULT D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA.P.P.H.H-r.P.H. BLK-S. WHT-E. BOOM WHT#21 BLK/RED#R4-EH WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-ISM#4 TS54 CB1 CB2 TS59 GRN/WHT #19 BLK/RED#R5-AH.male-BLK/RED-R5 r.P.47 Genie Z-45/25 & Genie Z-45/25J Part No. RD/BK-S.H.P.H.H.P.male ORG/BLK-M. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION TS51 WHT/BLK # 25 WHT/RED #26 LED WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP + L2 4 3 1 2 OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 CR3 CR4 CR5 CR7 CR8 HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.1 OG/BK-IM2 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) GR/WT-C. TS61 PRIMARY BOOM TS58 EXTEND RETRACT BLK/WHT #8 TS63 WHT #4 WHT/BLK #5 WHT/RED #6 BLK#R1-E.H. RD/WT-S. S.P.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 6 .H.#6 CH+EH1 OG/BK-E.male BLK/RED-EH-r. WHT-ISM#10 WHT-ISM#7 WHT/BLK-SP WHT/RED-SP RED-S./START MODULE 5 6 EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH CIRCUIT BREAKER.fem-ORG/BLK-R8 8 BLK-E. NO NO SECON.H.1 WHT/RED-C. ENGINE. BLK/WHT-34 BK/RD-R3#35 BK/RD-SP BLU #10 FUNCTION ENABLE PLAT. WT/BK-S./FUEL ON P1 NC NO KS1 NO AUXILIARY WHT-R2#86 WHT-24D 9 3 PRIM.6 8 KEY BYPASS IGN.4 EXT. WT/RD-S.-r.5 BASE TERMINATION BLOCK 10 ENG.fem r. BK/WT-S. CR5 GRN/BLK #18 GRN #17 ORG-4 CR7 ORG/BLK-4 CR8 6 WHT#40-R7 WHT-PRIM. TS62 JIB WHT/BLK-EH. F.C. TO F.X JIB VALVE RELAY NC NO JIB CUTOUT RELAY CR14 7 L1 8 + + 2 TS13 A A 3 4 5 6 1 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6 RED/WHT-3 PRIMARY BOOM EXTEND/ RETRACT GEN.) RED (F. LT.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 3 GRD. TURN ROT. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER |BOARD 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.BOOM BP2 TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 A 6 + . +12 V TO PLAT.48 . BOOM UP (UNUSED) JIB VALVE PLAT. STUD RED/BLK-28 H1 + TILT _ ALARM CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F. PWR. PLAT. L.X R TS8 JIB R2 R3 TS6 DRV.S.S.L. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 NC NO R R CR13 NC .D. 2WD/4WD TILT ALARM AUX.S. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN.C. WHT JIB CABLE BLK JIB CABLE 4 5 RED-1 WHT-23 RED TO STOP SW RED TILT AL.C. BOOM F. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 BLK/WHT-34 WHT-24 TO H. SEC. BLU/RED-13 BLU/BLK-37 ORG-14 P3 RED-10 TO H.X BP1 NO .S.P. LEVEL DN. GEN. R.P. BOOM DN. SEC. RED TIM.S. L. F. LEVEL UP DRIVE ENA.DEL. OPT.C.P. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM I H G F E D C B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.L. PWR. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) SEC.) WHT (F. R. PRIMARY F.S.L. ROT. PLAT.ENA TS15 TS2 START TS14 GLOW PLUG GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1 PLATFORM LEVEL TS9 7 NC TS4 NC HORN HIGH/LOW (2WD/4WD) HIGH/LOW RPM EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. PUMP SEL. RED TO JIB CABLE BLU-36 BRN TO GRD. ROT. (CONT. PRIMARY DOWN PRIMARY UP PLAT. TURN ROT.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR13 CR14 H.) KEYSW. SEC. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .D. ROT. UP POWER PWR. E.C. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303) . UP POWER PWR.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram. (CONT. PRIMARY F.C. RED TO JIB CABLE WHT-21 5 BLU-36 BRN TO GRD.X JIB VALVE RELAY CR14 6 7 L1 8 2 TS13 A A NC NO JIB CUTOUT RELAY + + TURNTABLE ROTATE PRIMARY BOOM UP/DOWN TS50 LIFT/ DRIVE SEL. PLAT.P. BOOM DN.L. STUD RED/BLK-28 CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.P.) WHT (F.P. L. BLU/BLK-37 BLU/RED-13 ORG-14 P3 RED-10 TO H. +12 V TO PLAT. PRIMARY DOWN PRIMARY UP PLAT.C.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 3 GRD.C.ENA TS15 NC NC 7 GLOW PLUG TS2 START TS4 HIGH/LOW RPM HORN TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. SEC.S. R.Lift/Drive SelectOption. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . LT. TURN ROT. PWR. L. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. BOOM F. LEVEL DN. R. SEC. F. BOOM UP ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 NC NO R R CR13 NC .D.S.DEL.S. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) SEC. TURN ROT.D. 3 4 5 1 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6 RED/WHT-3 PRIMARY BOOM EXTEND/ RETRACT GEN.49 .S. 2WD/4WD TILT ALARM AUX. SEC. (UNUSED) JIB VALVE PLAT. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 BLK/WHT-34 WHT-24 TO H.) RED (F.X R PLATFORM ROTATE TS7 PLATFORM LEVEL TS9 6 GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1 TS8 JIB R2 R3 TS6 DRV. WHT JIB CABLE BLK JIB CABLE + TILT _ ALARM H1 4 RED-1 WHT-23 RED TO STOP SW RED TILT AL.L. RED TIM. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM I H G F E D C B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. Z-45/25J Deutz Models (from serial number 13099 to 16303) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 L3 BP1 BP2 CR13 CR14 H. F.C. PWR. OPT. DRIVE ENABLE GEN.S.C. ROT. ROT. TO F. PUMP SEL. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN . PLAT. ROT. E.BOOM BP2 A + . LEVEL UP DRIVE ENA.X BP1 NO .L.S.) KEYSW. Lift/Drive Select Option.First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram. Z-45/25J Deutz Models (from serial number 13099 to 16303) . . TB35 RED/WHT-23-E. BLK/WHT-34-E. RED P1 RED KS1 PLAT GRND P3 HORN BLK ENGINE TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED TP35 RED RED WHT-2 BLK/RED-3 RED/BLK-1 RED-1 BLK-1 BLK-1 GRN/WHT-1 BLK/RED-1 ORG/BLK-1 3 TS51 START TS52 TS56 GLOW PLUG TS54 LOW RPM FUNCTION HIGH RPM ENABLE AUAXILIARY PUMP RED TB45 ENGINE BLK BLK TB28 TB27 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. Z-45/25 Deutz Models (after serial number 16303) A B C D LOAD SENSE OPTION (SEE DETAIL BELOW) ORG/BLK E F G H I J K L M N 1 TP22 P2 BLK TP26 FS1 BLK-(FS) RED-(FS) WHT-(FS) TP25 TP24 RED WHT WHT WHT TS2 TS1 BLK-2 WHT GLOW PLUG START AUAXILIARY PUMP TS6 TS47 OFF GENERATOR ON TS4 FOOT SW H/L LOW RPM HIGH RPM 2 TP41 CB1 15AMP. + BAT. ALTERNATOR EXCT. L3 OIL TEMP. PR2 NO WHT/BLK-25 E. WHT/RED WHT/BLK BLK-22 BLK/RED RED/WHT-23-E. CR5 NO BLK/RED-R5-E. 52709 .H.H. TB24 WHT WHT-21 WHT-21-E.H.H. BLK/RED CR1 NO 5 CR3 NO CR3 CR4 NO CR4 GRN/WHT-45-E. RED/BLK-28-E.H. CR5 WHT RED PR1 NO PR1 TB25 TB26 WHT/RED-26 E. OTS NO BRN BRN STARTER MOTOR FLASHING BEACON OPTION LEVEL SENSOR OIL PRESSURE LED HORN RELAY TILT ALARM AUXILIARY POWER RELAY FUEL SOLENOID OIL PRESSURE SWITCH OIL TEMPERATURE LED HORN OIL TEMPERATURE SWITCH POWER RELAY HOUR METER IGNITION/START RELAY HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY GENERATOR OPTION RPM SOLENOID AUXILIARY PUMP GLOW PLUG OPTION TP26 LOAD SENSOR BOX WHT-LOAD GND 8 TP24 WHT-24 Genie Z-45/25 & Genie Z-45/25J ORG-LOAD Part No. RED CR1 CR2 NO TB21 CR2 L2 OIL PRES. 8 KEY BYPASS 9 IGN.Section 6 • Schematics First Edition • Second Printing Electrical Schematic.H. - 7 LOAD SENSE OPTION TP22 P2 BLK-26 FS1 BLK-(FS) RED-(FS) WHT-(FS) BLK-26 LOAD C B+ 8 6 .H. 15AMP. FB BLK/RED-R4-E.H.H.H.H. PR2 6 12 V DC BAT. BLK-R1-E. RED-27-E./FUEL ON 10 ENG. FAULT TB34 4 RED TB9 TB41 CB2 TB23 TB20 RED-20-E./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. ON IGN. ORG/BLK-41-E.H.50 - + REGULATOR STA.H. AUX PUMP STARTER 1 HM 2 3 OPS NC BLK IND.H. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M.H.H. PLATFORM LEVEL UP PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL MODELS ONLY) CUTOUT (CE L WHT TP18 GRN/BLK-3 GRN-3 TS7 LEFT TS57 TB18 RIGHT PLATFORM ROTATE TP17 GRN/BLK-18-M. UP DOWN PLATFORM LEVEL ORG/BLK-15-M. PWM A + X TS62 R LEFT RIGHT TURNTABL E ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R4 10 TB4 WHT/RED-6-M. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK-11-M.H.3 4 POWER 5 LIMITER 6 BOARD 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J BRAKE RELEASE VALVE B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 .H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.H. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M. TS61 DOWN RED/BLK-2-M.H.H. TB2 UP PRIMARY BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN PWM A + X R TB3 REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) TP1 RED/WHT-3-M.H.Electrical Schematic. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 ORG/BLK-3 K UP TS9 DOWN TS59 TB14 PLATFORM LEVEL CR7 NC TP15 ORG-14-M. STEER RIGHT BLU-1 BLU-36-M. TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK-31-C. TP32 WHT/RED-1 WHT/RED-32-C.H. Z-45/25 Deutz Models (after serial number 16303) 1 First Edition • Second Printing 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TP30 TB30 A LS4 TP31 TP16 WHT-12-C.H. EXTEND BOOM TS63 RETRACT TP6 G WHT/RED-3 WHT/BLK-3 TP5 TB5 WHT-3 TB8 TP4 WHT/BLK-5-M.H.H.51 . 52709 ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 1 2 HORSE.H. WHT#4-M. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU UP DOWN SECONDARY BOOM BLU/BLK BLU-10-M.H.H.H.H. LEFT RIGHT PLATFORM ROTATE GRN-17-M.H. CR8 NC PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT M TB17 DESCENT ALARM OPTION N ORG/BLK RED BRN WHT RED BRN Part No. HIGH (2WD) TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH E TB40 LS3 NO LS1 NCHO WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 EXTEND TB7 RETRACT BOOM TP8 BLK-7-M.H.H. Z-45/25 Deutz Models (after serial number 16303) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303) . 1 GRN-S. BOOM BLK/RED-R4 WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 RED-ISM-4 TS54 CB1 CB2 TS59 6 WHT#40-R7 WHT-PRIM. BLK-R1-86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD.C.1 WT/RD-E. ENGINE.male ORG/BLK-M. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP TS51 4 3 L2 1 2 LED + OIL PRESS RED/WHT-3 RED/BLK-2 RED-1 BLK-7 CR3 CR4 CR5 CR7 CR8 HOUR METER 3 RED BLK/RED-35B RED-R2 WHT-R2 RED-R1 BLK/WHT-8 TS61 PRIMARY BOOM TS60 TS63 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TS62 TURNTABLE ROTATE BLU/WHT-12 BLK/WHT-34 L3 OIL TEMP.H. LEVEL TS57 PLATFORM ROTATE BRN-(GRND H. M.M.P.P. R or CR ISM H.H BLK/RED-35GEN ORG/BLK-15 GRD-HOLE ORG-14 BLK/RED-EH-r. GR/WT-S.H WHT-ENA.fem-BLK/RED-R4 r.H.H.P.H.P. WT/RD-S. ORG-14 ORG/BLK-15 BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT-SEC#4 CH+EH1 OG/BK-E.P.1 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C. BK/RD-R3#35 BK/RD-SP BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33 FUNCTION ENABLE BLU-M.D. BLK/RED-35 GLOW PLUG START SEC.H.#5 WHT/RED-C. 2 R4 TS56 CR1 BLK-R1 BLK-R1-E.H.H RED/BLK-C./FUEL ON ENG. BU/BK-S.male 6 . PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E. FAULT NO EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S.H.male-BLK/RED-R5 r.P.P.P.1 RD/WT-C.P.H BLK-ISM-3 GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT.male BLK/RED-EH-r.P.H RED/WHT-C. BU/BK-M. BK/WT-S. S.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .P.H-r. 52709 .1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 BLK-S.M) BLK/RED-R5 CR5 CR7 ORG-4 CR8 ORG/BLK-4 BLK-1 BLK/WHT-E.P. E.P.-r.1 RED-C.D.P.P.1 WHT-EXT. WHT-ISM-10 1 WHT/BLK-EH.fem r.52 Genie Z-45/25 & Genie Z-45/25J Part No. GRN-4 GRN/BLK-4 RED-C. RD/BK-S. WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S. WHT-E.#6 OG/BK-IM2 7 GR/WT-C. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. WT/BK-E.C. WHT-S. BLK-S. BK/RD-R5 BLU-S. WHT-S. ORG-SP OG/BK-SP WHT-12-E.H.H.-r.P.H. 15A CIRCUIT BREAKER. RED-R2#30 WHT-23A 1 2 3 4 5 6 7 8 START RELAY TACHOMETER START INPUT AUX.P.H.H.6 KS1 NO WHT-R2#86 WHT-24D AUXILIARY 9 10 BASE TERMINATION BLOCK D RED-4 RED/BLK-4 R/W-4 PRIM.male-BLK-R1 r. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY. RD/WT-S. BLU/WT-S.P.4 EXT.H.P.DOWN (CE MODELS ONLY) NO IGN. BLK-S.fem ORG-M./START MODULE P1 NC NO 3 SECON.5 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA.P. WHT-21 CR2 CR3 CR4 5 TS52 WHT-S. GR/BK-S. RED-S.H.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 WHT/BLK-25 WHT/RED-26 K DESCRIPTION L M N 2 M. ON GROUND BATTERY KEY PWR. CONTROLS. KEY BYPASS IGN.H.P.fem-ORG-R7 r. WT/BK-S. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 BLK-E.H. LEVEL UP DRIVE ENA. L.) WHT-2 BLK-2 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 GRD. TURN ROT.) KEYSW.C. LEVEL DN.X A A TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 100 1 2 TS13 NC NO + SEE SIDE VIEW DP1 3 4 5 P3 NO 250 BLK/RED-9 BLU-36 RED-TILT WHT/RED-6 BLU/BLK-37 BLK-22 WHT-23 WHT/BLK-31 BRN TO GRD. WHT-24 TO H. (UNUSED) JIB VALVE PLAT. PUMP SEL.C.D.S.ENA TS15 TS6 GLOW PLUG TS2 7 NC TS4 NC AUXILIARY PUMP START HIGH/LOW RPM HORN DRIVE SPEED TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No.P. PRIMARY DOWN PRIMARY UP PLAT. PWR. L.S.S.C. F. STUD RED-TILT R2 R3 L1 L3 BP1 BP2 CR12 CR13 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN . TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY ( JIB ONLY ) 3 RED/BLK-28 CABLE #3 CABLE #2 CABLE #1 110 F. UP POWER PWR. PLAT. ROT. PRIMARY F. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 BLK/RED-35 RED-25 ORG-14 WHT/BLK-5 GRN-17 ORG/RED-16 ORG/BLK-15 BLK-33 RED-1 NC R NO A R 6 7 L1 8 - . R. TURN ROT. ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD RED-10 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) HORN BOOM RETRACT BOOM EXTEND TURN.X BP1 NO + .BOOM BP2 GENERATOR OPTION TS47 NC 8 7 6 5 4 3 2 1 RED-GEN + X R 6 DP1 DRIVE PLATFORM LEVEL TS9 DRV.53 .C. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . PLAT. DRIVE ENABLE (UNUSED) (SPARE) STEER RIGHT STEER LEFT OPTION WIRE (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH START ENGINE BRAKE E. F.P.S.C. R. ROT. T1 JIB VALVE RELAY ( JIB ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD 4 TIME DELAY ( JIB ONLY ) TILT ALARM GRN/WHT-45 SIDE VIEW DP1 WHT TO PLATFORM ROTATE WHT-4 RED/BLK-2 GRN/WHT-19 RED/WHT-3 BLK/WHT. ROT.) RED (F.S. LT. +12 V TO PLAT. 2WD/4WD HIGH/LOW RPM GLOW PLUG SEC. BOOM UP GEN. SEC.34 BLU/RED-13 RED-10 TO H. TO F.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS47 R1 1 WHT-24 1 2 3 4 5 6 7 8 9 10 TILT ALARM AUX. BOOM F. (CONT.L. BOOM DN.D. SEC. (OPTION) 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 WHT RED/BLK-1 RED-1 BLK (F.L.) WHT (F. PWR. E.S. TILT ALARM CR14 DP1 H. BLK-26 WHT-30 WHT/RED-32 5 PRIMARY BOOM EXTEND/ RETRACT SEC.P.L. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303) . Z-45/25 Deutz Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A 1 COMPONENT INDEX P2 P3 TS1 TS2 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS47 WHT-24 1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.54 . LT.Lift/Drive SelectOption.S. PLAT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN.S.S. PLAT. SEC. ROT.S. PUMP SEL.P.S. F. (UNUSED) JIB VALVE PLAT. LEVEL UP DRIVE ENA.S. TURN ROT. R. PWR. +12 V TO PLAT.L.P. PWR. L. F.C.) RED (F. E. 2WD/4WD TILT ALARM AUX. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN .BOOM BP2 GENERATOR OPTION TS47 8 7 6 5 4 3 2 1 RED-GEN 6 + X R DP1 DRIVE 7 PLATFORM LEVEL TS9 R3 TS6 DRIVE ENABLE TS2 NC TS4 NC GLOW PLUG START HIGH/LOW RPM HORN TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. PRIMARY F. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .C.C. WHT/BLK-31 BLK-22 BLK-26 WHT-23 WHT/RED-32 PRIMARY BOOM EXTEND/ RETRACT SEC.L. BOOM DN. 4 + TILT ALARM 5 SIDE VIEW FOR DP1 WHT TO PLATFORM ROTATE GRN/WHT-45 WHT-4 RED/BLK-2 BLK/WHT. LEVEL DN. TURN ROT. BOOM UP 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.D. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (UNUSED) SEC.) WHT (F.C.C. WHT-24 TO H. TO F. R.X BP1 NO + . ROT. (CONT. H1 3 RED/BLK-28 H1 CABLE #3 CABLE #2 CABLE #1 110 F.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM GEN. L. BLU-10 BLU/BLK-11 RED/WHT-29 GRN/WHT-19 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 RED/WHT-3 BLK/RED-35 RED-25 ORG/BLK-15 WHT/BLK-5 GRN-17 ORG/RED-16 NC R NO A R 7 L1 8 - NC . SEC. ROT. UP POWER PWR.) KEYSW.X TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED TS15 R2 100 1 2 TS13 A A NC NO + SEE SIDE VIEW DP1 3 4 5 6 P3 NO 250 BLK/RED-9 BLK-33 RED-1 WHT/RED-6 BLU-36 BLU/BLK-37 RED-TILT WHT-30 BRN TO GRD. STUD RED-TILT R2 R3 L1 L3 BP1 BP2 DP1 H.L.P.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 GRD.D. PRIMARY DOWN PRIMARY UP PLAT.34 BLU/RED-13 ORG-14 RED-10 TO H. BOOM F. Z-45/25 Deutz Models (after serial number 16303) .First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram.Lift/Drive Select Option. . FLASHING BEACON OPTION TP34 TS6 BLK-1 GLOW PLUG OPTION BLK/WHT-34-E.H.H. START ENGINE TB24 TB25 ENGINE TB26 TB33 BLK G CR2 OPS NC OTS NO H POWER RELAY TB21 FUEL SOLENOID CR2 NO WHT 3 HM WHT-21 1 2 HOUR METER F CR1 IGNITION. H/L LOW RPM HIGH RPM TP35 TS54 CR4 BLK/RED-R4-E. OFF GENERATOR CR4 NO RPM SOLENOID TS47 ON GRN/WHT-1 GRN/WHT-45-E.H. NO WHT BLK-(FS) TILT ALARM Electrical Schematic.H.H.H.H. 12 V DC TP22 P2 BLK-26 TP26 A BLK-26 LOAD REGULATOR B+ GND 8 ORG-LOAD 6 . GENERATOR OPTION TP45 TB45 K J TB34 FB RED/WHT-23-E. RED-(FS) WHT-(FS) C 15AMP. TS56 GLOW PLUG GLOW PLUG BLK I WHT/RED PR2 NO PR2 L2 OIL PRES.H. CB1 FS1 BLK-(FS) BAT.H. WHT-21-E. ON 5 GROUND 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN. OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH TS52 START WHT/BLK-25 E. Section 6 • Schematics CB2 15AMP./START MODULE TS2 BLK-1 WHT/RED-26 E. LOAD SENSE OPTION (SEE DETAIL BELOW) RED-1 WHT-(FS) RED-(FS) PR1 AUXILIARY PUMP RED AUXILIARY POWER RELAY AUX PUMP AUXILIARY PUMP PR1 FS1 TP28 WHT RED/BLK-1 TB28 RED/BLK-28-E. RED RED IND./START RELAY First Edition • Second Printing BLK-R1-E. RED BLK BRN D LEVEL SENSOR BLK TP26 TP23 TB23 TB22 TP22 CR5 NO HORN GRND C KS1 PLAT LOAD SENSOR BOX RED WHT-LOAD BLK-2 BLK-22 BLK/RED-R5-E. STARTER MOTOR E TP27 AUXILIARY PUMP RED-27-E. 52709 CR1 NO STARTER RED WHT WHT TP25 TP24 TS51 TB27 TS1 - + . + TB20 RED RED-20-E. OIL TEMPERATURE LED WHT/BLK OIL PRESSURE LED TP33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX.H. L3 OIL TEMP. LOAD SENSE OPTION B BAT.55 1 2 3 4 5 6 7 8 Genie Z-45/25 & Genie Z-45/25J P3 HORN TP9 P2 TB9 WHT-24 CR5 Part No.H./FUEL ON 10 ENG. Z-45/25J Deutz Models (after serial number 16303) WHT-2 RED/WHT-23-E.H. FAULT IGN. ALTERNATOR EXCT.BRN WHT ORG/BLK RED RED RED N CR13 RED BRN JIB BOOM CUTOUT RELAY (CR-13) JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES JIB CUTOUT RELAY JIB VALVE RELAY JIB VALVES M CR14 NO CR14 BLK/RED-1 ENGINE SPEED LOW RPM FUNCTION HIGH RPM ENABLE TS4 BLK/RED HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY TB35 L CR3 NO CR3 FOOTSW.H. TP24 BLK BLK/RED-3 BLK/RED HORN RELAY P1 TP41 TB41 ORG/BLK-1 ORG/BLK-41-E. - STA.H. CR8 NC PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM ROTATE LEFT / JIB BOOM UP TS57 M WHT TS7 LEFT RIGHT PLAT ROTATE RIGHT LEFT PLAT ROTATE TB17 CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 BRN TB19 + N ORG/BLK WHT RED RED RED CR9 TI BRN BRN Part No.H. PWM A + X R TB3 REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) TP1 RED/WHT-3-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C. SECONDARY BOOM UP PWM A X R + TS60 BLU/BLK-11-M.H. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 J TB10 BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU-10-M. WHT#4-M. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M.H. RIGHT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A + X TS62 R LEFT TURNTABLE ROTATE R4 10 TB4 H WHT/RED-6-M.H.H. Z-45/25J Deutz Models (after serial number 16303) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TP30 TB30 LS4 A TP31 TP16 WHT-12-C. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK-2-M. DOWN JIB BOOM UP GRN-17-M.H. TP32 TB32 WHT/RED-1 WHT/RED-32-C. TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK-31-C. STEER RIGHT BLU-1 BLU-36-M. PLATFORM LEVEL UP PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT L CR13 NC TP18 GRN/BLK-3 GRN-3 TS8 TS58 TB18 DOWN JIB BOOM UP TP17 GRN/BLK-18-M.H. TP14 SECONDARY BOOM FLOW CONTROL K ORG-3 ORG/BLK-3 TS9 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC TP15 ORG-14-M.H.H.Electrical Schematic. 52709 TP40 LS2 F HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 NO Genie Z-45/25 & Genie Z-45/25J B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB37 6 .H. BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M. UP PLATFORM DOWN LEVEL ORG/BLK-15-M.56 .H.H.H.H. D HIGH (2WD) TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 Section 6 • Schematics CE MODELS ONLY R2 WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH E TB40 LS3 NO LS1 NCHO ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 TP7 BLK-3 BLK/WHT-3 EXTEND BOOM TB7 RETRACT TP8 BLK-7-M.H.H.H.H.H. EXTEND TS63 RETRACT BOOM G TP6 WHT/RED-3 WHT/BLK-3 TP5 TB5 WHT-3 TB8 TP4 WHT/BLK-5-M.H. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M.H. Z-45/25J Deutz Models (after serial number 16303) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303) . H. R or CR ISM H.P. ORG-SP OG/BK-SP WHT-12-E.D.H RED/BLK-C.1 RD/WT-C. WT/BK-E. WHT-S.1 WT/RD-E. M. 52709 .6 KS1 NO AUXILIARY 3 PRIM. 5 WHT-ISM-10 1 WHT/BLK-EH. ENGINE. S.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S.1 WHT/RED-C. ORG/BLK-41A BLK-33D RED-27B BRN-GRD.H. WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S. E.P. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP TS51 WHT/BLK-25 WHT/RED-26 LED + L2 1 2 OIL PRESS RED/WHT-3 RED/BLK-2 RED-1 BLK-7 3 4 HOUR METER 3 RED BLK/WHT-8 TS61 TS63 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TS62 TURNTABLE ROTATE BLU/WHT-12 BLK/WHT-34 L3 OIL TEMP.H.male GRD-HOLE ORG-14 r.1 RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-35 GLOW PLUG START SEC.P. GRN-4 GRN/BLK-4 RED-C. WT/RD-S. KEY BYPASS IGN. 2 R4 TS56 TS52 PRIMARY BOOM TS60 TS58 CR1 BLK-R1 BLK-R1-E.P. BK/WT-S.M.P.-r. BLK-S.4 EXT.male-BLK/RED-R5 r.male BLK/RED-EH-r. ON GROUND BATTERY KEY PWR.P.male-BLK-R1 r.P.C.P.P.P. BLU-1 BU/BK-M. FAULT B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8 BLK/RED-35B RED-R2 WHT-R2 RED-R1 K DESCRIPTION L M N NO EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 ORG/BLK-M.male 6 .fem BLK-E.1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 WHT-SEC#4 WHT-EXT.P. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.H.H WHT-ENA. BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-14 ORG/BLK-15 BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) CH+EH1 OG/BK-E. WHT-S.C.P.57 Genie Z-45/25 & Genie Z-45/25J Part No./START MODULE P1 NC NO SECON.#5 BLK/RED-35GEN BLK/RED-1 BLU-M. BU/BK-S.#6 OG/BK-IM2 GR/WT-C.P. 15A CIRCUIT BREAKER.P.fem-BLK/RED-R4 r.P.P.H. RD/BK-S.H. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.M) BLK/RED-R5 CR5 CR7 ORG-4 CR8 ORG/BLK-4 BLK-S.5 BASE TERMINATION BLOCK D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. BK/RD-R5 BLU-S. BLU/WT-S.H. WHT-E.D.fem-ORG-R7 r.P.H.H. GR/BK-S. RD/WT-S.-r.H RED/WHT-C.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C./FUEL ON ENG.H.P. C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT. LEVEL TS57 PLATFORM ROTATE BRN-(GRND H. RED-R2#30 WHT-23A 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX.1 GRN-S.P.H BLK-ISM-3 BLK/WHT-E.H. CONTROLS. RED-S.H-r.P. GR/WT-S.fem ORG-M.P. WHT-21 CR2 CR3 CR4 WHT-S. BOOM JIB WHT-40B BLK/RED-R4 RED-ISM-4 TS54 CB1 CB2 TS59 GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT.1 RED-C. BK/RD-R3#35 BK/RD-SP BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33 FUNCTION ENABLE 6 WHT#40-R7 WHT-PRIM.H.H. BLK-S.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1-86 M.DOWN (CE MODELS ONLY) NO 2 IGN.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .H.H.H.H BLK/RED-35GEN ORG/BLK-15 7 BLK/RED-EH-r. WT/BK-S. F. SEC. ROT.C. PRIMARY DOWN PRIMARY UP PLAT. +12 V TO PLAT.S.C. F. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY ( JIB ONLY ) RED/BLK-28 CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE 4 F. TURN ROT. STUD RED-TILT WHT JIB CABLE BLK JIB CABLE R2 R3 L1 L3 BP1 BP2 CR12 CR13 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN .ENA TS15 NC GLOW PLUG AUXILIARY PUMP TS2 START TS4 NC HORN DRIVE SPEED TS14 HIGH/LOW (2WD/4WD) HIGH/LOW RPM 8 EMERGENCY STOP P2 PLATFORM CONTROL SWITCH PANEL Part No.S.X JIB VALVE RELAY CR14 TS13 NC NO 2 JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 SEE SIDE VIEW DP1 3 4 5 6 7 1 P3 NO TS1 100 250 BLK/RED-9 BLK-33 RED-1 WHT/RED-6 BLU-36 BLU/BLK-37 WHT-30 WHT/BLK-31 RED-STP BLK-22 WHT-23 BRN TO GRD.C. SEC. L.58 . TO F.L. BOOM F. PLAT. HORN BOOM RETRACT BOOM EXTEND TURN. ROT.S.S. PWR. DRIVE ENABLE (UNUSED) (SPARE) STEER RIGHT STEER LEFT OPTION WIRE (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH HIGH/LOW RPM GLOW PLUG SEC.D.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303) N M L K J I H G F E D C B A 1 COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS47 R1 PLATFORM CONTROL BOX EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) WHT-24 1 2 3 4 5 6 7 8 9 10 START ENGINE BRAKE E.L. BLK-26 WHT/RED-32 NC NO A + . R. TURN ROT. T1 JIB VALVE RELAY ( JIB ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TIME DELAY ( JIB ONLY ) TILT ALARM 5 GRN/WHT-45 RED-STP RED-TILT RED TIM. ROT.BOOM BP2 CR13 L1 DP1 DRIVE GRN/WHT + RED OUTPUT BRN TIME DELAY T1 8 7 6 5 4 3 2 1 6 7 PLATFORM LEVEL TS9 TS8 JIB TS6 DRV.DEL. PRIMARY F. TILT ALARM CR14 DP1 H. E. BOOM DN.P.) WHT-2 BLK-2 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 3 GRD. BOOM UP GEN.P. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .) RED (F. PUMP SEL. LT.X BP1 NO A + . PWR. UP POWER PWR. LEVEL UP DRIVE ENA. (UNUSED) JIB VALVE PLAT.) WHT (F. PLAT. L. R. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 BLK/WHT-34 BLK/RED-35 RED-25 ORG-14 WHT/BLK-5 GRN-17 ORG/BLK-15 ORG/RED-16 8 R R NC A + . OPT. (CONT.L. TS47 RED-GEN SEC. WHT-24 TO H. RED JUMP RED TO JIB CABLE WHT-4 RED/BLK-2 GRN/WHT-19 RED/WHT-3 SIDE VIEW DP1 WHT TO PLATFORM ROTATE BLU/RED-13 RED-10 TO H.S.D.C.) KEYSW.P.X R PRIMARY BOOM EXTEND/ RETRACT GEN. LEVEL DN. 2WD/4WD TILT ALARM AUX. (OPTION) ORG/BLK-41 2 ORG-40 HORSEPOWER LIMITER BOARD RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 WHT RED/BLK-1 RED-1 BLK (F.S.C. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303) . (CONT.S. SEC.C.S.C.D. PWR.Lift/Drive SelectOption. WHT-4 RED/BLK-2 RED JUMP RED TO JIB CABLE BLU/RED-13 ORG-14 RED-10 TO H.S.L.DEL.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD RED/BLK-28 BLK JIB CABLE CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.59 . PUMP SEL.L. UP POWER PWR. WHT-24 TO H.S. PRIMARY F.S. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (UNUSED) SEC. T1 H1 3 DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN. BOOM DN.L. TS47 RED-GEN SEC.P. BOOM F. PRIMARY DOWN PRIMARY UP PLAT.C. LT. ROT. ROT. R. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) LOW SPEED RESISTOR LOW SPEED RESISTOR GEN.BOOM BP2 CR14 DP1 DRIVE GRN/WHT + RED OUTPUT BRN TIME DELAY T1 8 7 6 5 4 3 2 1 6 R PLATFORM LEVEL TS9 P3 NO 7 R3 TS6 DRIVE ENABLE NC NC GLOW PLUG TS2 START TS4 HIGH/LOW RPM HORN TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. PWR. ROT. LEVEL UP DRIVE ENA. OPT. Z-45/25J Deutz Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A 1 COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS47 WHT-24 1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. PLAT.C. TURN ROT.S. L. (UNUSED) JIB VALVE PLAT. F. TURN ROT. H1 + TILT ALARM TIME DELAY TILT ALARM 4 SIDE VIEW FOR DP1 WHT TO PLATFORM ROTATE 5 GRN/WHT-45 RED-STP RED-TILT RED TIM. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .) WHT-2 BLK-2 WHT GRD.X R CR13 7 L1 8 NC A + . STUD RED-TILT WHT JIB CABLE R2 R3 L1 L3 BP1 BP2 CR13 CR14 DP1 H.C. L. TO F.) WHT (F. F.P.P. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/WHT-34 BLK/RED-35 RED-25 RED/WHT-3 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 NC R NO A + .X BP1 NO A + .) RED (F. SEC. E. BOOM UP 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-10 GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. R. +12 V TO PLAT. PLAT. LEVEL DN.X JIB VALVE RELAY TS13 NC NO 2 JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS15 TS8 JIB TS1 AUXILIARY PUMP DRIVE SPEED R2 100 250 SEE SIDE VIEW DP1 3 4 5 6 1 BLK/RED-9 BLK-33 RED-1 WHT/RED-6 BLU/BLK-37 WHT-30 WHT/BLK-31 BLU-36 WHT/RED-32 RED-STP BRN TO GRD.D.) KEYSW. BLK-22 BLK-26 WHT-23 PRIMARY BOOM EXTEND/ RETRACT GEN. 2WD/4WD TILT ALARM AUX. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram. Z-45/25J Deutz Models (after serial number 16303) .Lift/Drive Select Option. . 52709 . ORG/BLK-1 WHT-2 BLK/RED-3 RED/BLK-1 RED-1 AUXILIARY PUMP RED BLK-1 BLK-1 GRN/WHT-1 BLK/RED-1 TS51 TS52 ENGINE START TS56 ON GLOW PLUG TS54 LOW RPM HIGH RPM TB45 BLK BLK FUNCTION ENABLE 4 TB28 RED TB27 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. TB24 WHT#21 WHT WHT#21-E. RED CR1 CR2 NO TB21 CR2 L2 OIL PRES. W 7 BLK REGULATOR 1 AUX PUMP STARTER HM 3 OIL PRESSURE SWITCH NC IND.H. CR5 PR1 NO WHT PR1 TB25 TB26 WHT/RED#26 E.H.H. FB 6 ALTERNATOR BLK/RED#R4-E./FUEL ON 10 ENG. 15AMP.H.H.H.H. H/L LOW RPM SELECTOR OPTION 2 AUXILIARY PUMP GLOW PLUG GENERATOR P3 HORN BLK TP41 CB1 RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED TP35 RED RED 3 15AMP. - 12 V DC + STA. PR2 RED EXCT. BAT. RED#27-E. WHT/BLK WHT/RED BLK#22 BLK/RED RED/WHT#23-E. Z-45/25 Perkins Models (before serial number 16304) A B C D E SEE NOTE 1 F G H I J K L M SEE NOTE 2 N ORG/BLK 1 TP22 P2 BLK TP26 BLK FS1 BLK RED RED TP25 TP21 RED WHT WHT TS50 WHT WHT TP24 LIFT/ DRIVE TS2 TS1 ENGINE BLK-2 WHT ON START TS6 TS47 OFF ON TS4 HIGH RPM FOOTSW. BLK/RED 5 CR1 NO CR3 NO CR3 CR4 NO CR4 GRN/WHT#45-E. FAULT TB34 TB9 TB41 CB2 TB23 TB20 RED#20-E. + BAT. 3) All switches and contacts are shown with the boom in the stowed position and the key switch off 6 . ORG/BLK#41-E.H.60 - BRN STARTER MOTOR AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY OIL PRESSURE SWITCH HORN RELAY TILT ALARM FUEL SOLENOID Genie Z-45/25 & Genie Z-45/25J HORN LEVEL SENSOR AUXILIARY PUMP Part No. L3 OIL TEMP. CR5 NO BLK/RED#R5-E.H. PR2 NO WHT/BLK#25 E./START MODULE 5 GROUND 6 BATTERY 7 KEY PWR. TB35 RED/WHT#23-E.H. BLK#R1-E.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. 2 OIL TEMPERATURE SWITCH NO BRN GLOW PLUG FLASHING BEACON OPTION OIL TEMPERATURE SWITCH OIL TEMPERATURE LED OIL PRESSURE LED GENERATOR OPTION HIGH IDLE CUTOUT RELAY RPM SOLENOID LIFT/DRIVE SELECTOR HIGH IDLE RELAY OPTION (REQUIRED FOR CE MODELS) 8 NOTE: 1) The connection to TP24 is for units without the generator option 2) The foot switch power is connected to both white wires without the lift/drive selector option. 8 KEY BYPASS 9 IGN.H. BLK/WHT#34-E. RED/BLK#28-E.H. ON IGN.H.H. H.H.H.H. PWM A + X R TS60 BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M.H.H. TS61 UP PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK#2-M. DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK#31-C. PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) L TP18 GRN-3 GRN/BLK-3 RIGHT TS7 LEFT TP17 TS57 TB18 PLATFORM ROTATE GRN/BLK#18-M. K SECONDARY BOOM FLOW CONTROL TP14 ORG-3 ORG/BLK-3 UP TS9 DOWN TP15 TS59 TB14 PLATFORM LEVEL CR7 NC ORG#14-M.H. TP1 PRIMARY BOOM FLOW CONTROL I RED-3 TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP10 TP11 J BRN BLU/BLK-3 TB10 BLU-3 BLU UP SECONDARY BOOM DOWN BLU/BLK BLU#10-M. PWM A + X R TB3 RED/WHT#3-M. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.61 . BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED#1-M.H.H. STEER RIGHT BLU-1 BLU#36-M.H.H. HIGH (2WD) D TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 Section 6 • Schematics CE MODELS ONLY R2 R1 WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH E 50 CR12 LS1 NCHO ORG-1 WHT#40-4 BRN-4 TP40 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 TP7 BLK-3 BLK/WHT-3 EXTEND BOOM TP8 TB7 RETRACT BLK#7-M. UP PLATFORM LEVEL DOWN PLATFORM LEVEL UP ORG/BLK#15-M. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M.H.H.First Edition • Second Printing Electrical Schematic.H. TB8 PWM A + X TS62 LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R R4 H TB4 WHT/RED#6-M. SECONDARY BOOM UP BLU/BLK#11-M.H. PLATFORM ROTATE LEFT M TB17 DESCENT ALARM (OPTION) ORG/BLK N WHT WHT RED RED BRN Part No. Z-45/25 Perkins Models (before serial number 16304) 1 2 3 4 5 6 7 8 BRN-2 TP13 GROUND TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 A TP30 TS15 TB30 LS4 NOHC TB16 TP31 TP16 WHT#12-C.H.H. TP32 TB32 B WHT/RED-1 WHT/RED#32-C. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C.H. WHT#4-M. 52709 TB40 LS2 F HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 NO LS3 NO Genie Z-45/25 & Genie Z-45/25J TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 TP29 TB29 TB36 TB37 6 . RIGHT PLATFORM ROTATE LEFT CR8 NC PLATFORM ROTATE RIGHT GRN#17-M.H. EXTEND BOOM TS63 RETRACT G TP6 WHT/RED-3 WHT/BLK-3 TP5 TP4 TB5 WHT-3 WHT/BLK#5-M.H. Z-45/25 Perkins Models (before serial number 16304) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring Diagram. Z-45/25 Perkins Models (before serial number 16304) . P. BK/WT-S.male ORG/BLK-M.H 7 ORG/BLK-15 GRD-HOLE ORG-14 BLK/RED-EH-r. 52709 . IGN. ORG-4/R7 ORG/BLK-4/R8 RED-ENA.P. WHT#21 CR2 CR3 CR4 5 1 TS62 RD/WT-C.M BLK/RED#R5-AH.H.C./FUEL ON ENG. WHT-S. BK/RD-R3#35 BLK/WHT-34 BK/RD-SP BLU #10 BLU/BLK #11 RED #20 RED-R1 BLK #33 FUNCTION ENABLE 6 WHT#40-R7 WHT-PRIM./START MODULE NO NO SECON.male-BLK-R1 r. R or CR ISM H. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NO NO NC WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP TS51 L2 1 2 LED + OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 CR3 CR4 CR5 CR7 CR8 4 3 HOUR METER 3 BLK/RED#35B RED-ISM#6 WHT-ISM#9 RED-CB1 RED BLK/WHT #8 TS61 PRIMARY BOOM TS60 EXTEND RETRACT TS63 WHT #4 WHT/BLK #5 WHT/RED #6 TURNTABLE ROTATE BLU/WHT #12 BLK/WHT-34 L3 OIL TEMP.1 WHT/RED-C.H.H. LEVEL PLATFORM ROTATE ORG #14 ORG/BLK #15 BRN GRND H.H BLK-ISM#3 BLK/WHT-E.1 WHT-S.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring Diagram. FAULT ORG/BLK-41A BLK-33D RED-27B BRN-GRD.4 EXT.P.H. E.H RED/BLK-C. M.fem r. 15A CIRCUIT BREAKER.H.H-r.H. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.-r.H.P.1 WHT-EXT. WT/BK-S.male 6 .P.1 GRN-S. WHT-ISM#10 WHT/BLK-EH.H. WT/BK-E.H.H.H.H.#5 BLU-M.C.1 RED-C. Z-45/25 Perkins Models (before serial number 16304) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1#86 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX.P.H.P. WT/RD-S. GR/BK-S. RD/WT-S.P. RED-S.P. BLK/RED #35 GLOW PLUG START SEC.P. BU/BK-S.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . BLK-S.H WHT-ENA.P.P.P.H. WHT-ISM#7 WHT/BLK-SP WHT/RED-SP RED-S.male-BLK/RED-R5 r. S.P.#6 OG/BK-IM2 GR/WT-C.P. BU/BK-M.male BLK/RED-EH-r.D. CONTROLS. WHT-S.62 Genie Z-45/25 & Genie Z-45/25J Part No. RD/BK-S.1 WT/RD-E.DOWN (CE MODELS ONLY) 2 M.P.P. BK/RD-R5 BLU-S. RED-R2 # 30 WHT-23A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 WHT/BLK # 25 WHT/RED #26 K DESCRIPTION L M N EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER.H. BLK-S.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C.fem-BLK/RED-R4 r. WHT-E. ON GROUND BATTERY KEY PWR.P.P.5 BASE TERMINATION BLOCK D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-SP OG/BK-SP WHT#12-E. BLU/WT-S. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E. ENGINE. CR5 CR7 ORG-4 CR8 ORG/BLK-4 BLK-S.-r. BOOM TS57 BLK/RED#R4-EH WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-ISM#4 TS54 CB1 CB2 TS59 GRN/WHT #19 GRN/BLK #18 GRN #17 PLAT.D.H RED/WHT-C. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 ORG-M. KEY BYPASS IGN.fem BLK-E. BLK#22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE VERSION ONLY) WHT-SEC#4 CH+EH1 OG/BK-E.H. 2 R4 TS56 TS52 CR1 BLK-ISM#1 BLK#R1-E.M. GR/WT-S.6 P1 NC KS1 AUXILIARY 3 PRIM.P.1 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S.fem-ORG-R7 r. GRN-4 GRN/BLK-4 RED-C.P. C. LEVEL DN.S. F. ROT. GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 PRIMARY BOOM EXTEND/ RETRACT 110 BLK/WHT-8 BLK-7 RED-1 RED/WHT-3 RED-10 LIMITING RELAY CABLE #2 WHT-4 WHT/BLK-5 NC R1 50 M ORG-40 WHT-24 RED-10 1 2 3 4 5 6 7 8 9 10 CABLE #3 ORG/BLK-41 NO WHT/RED-6 RED/BLK-28 TURNTABLE ROTATE HORSEPOWER LIMITER BOARD CR12 PLATFORM LEVEL BP1 HORN BOOM RETRACT BOOM EXTEND TURN. PRIMARY DOWN PRIMARY UP CABLE #1 A RED/BLK-2 L + . TURN ROT. ROT.D. PWR.) RED (F.D. PWR.P.C.) WHT-2 BLK-2 WHT L1 DRV. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD A LABEL TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR12 H. PUMP SEL. BOOM UP TS13 K NO TS9 WHT-24 ORG-40 GRD. (CONT. F. PLAT. 2WD/4WD TILT ALARM AUX.C. L. TS9 TS10 P2 P3 TS1 TS2 TS6 TS7 D H1 WHT-23 Section 6 • Schematics BLK-22 EMERGENCY STOP P2 BLK-26 E NC WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H.C. R.) WHT (F. SEC. BLU-10 BLU/WHT-12 RED-27 RED-10 TO H. TO F. 52709 NC Genie Z-45/25 & Genie Z-45/25J 1 2 3 4 5 6 R 7 8 B EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DESCRIPTION C TILT ALARM 6 .Platform Control Box Wiring DiagramZ-45/25 Perkins Models (before serial number 16304) 1 2 3 4 5 6 7 First Edition • Second Printing 8 DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN. L. +12 V TO PLAT.S. PLAT. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. OPTION WIRE BLK/RED-35 RED-25 BLK/WHT-34 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. STUD ORG/BLK-15 _ ALARM + TILT ORG-14 H1 N BLK/RED-9 P3 HORN PLATFORM CONTROL SWITCH PANEL PLATFORM CONTROL BOX SEC.63 .X R GEN. E. UP POWER PWR.L.P. LT. PRIMARY F.L. LEVEL UP DRIVE ENA.S. BOOM DN.S.X NC R PRIMARY BOOM UP/DOWN NO PLATFORM ROTATE TS7 SEC. DRIVE ENABLE PLAT. F BLU-36 BLU/BLK-37 DRIVE BRN TO GRD.S.X .ENA TS15 ORG/RED-16 H BLU/RED-13 R3 TS6 GLOW PLUG TS2 START BLK-33 GENERATOR OPTION TS4 HIGH/LOW RPM Part No. BOOM F.S.C. ROT.) KEYSW.BOOM BP2 AUXILIARY PUMP J TS1 HIGH/LOW (2WD/4WD) R2 DRIVE SPEED TS14 A A NC NO 100 I 250 + + . TURN ROT. GRN/BLK-18 GRN-17 GRN/WHT-19 (UNUSED) JIB VALVE PLAT. R.P. SEC.L. G RED/WHT-29 BLU/BLK-11 F. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Perkins Models (before serial number 16304) . . H. 2) The foot switch power is connected to both white wires without the lift/drive selector option. L3 OIL TEMP.H. BLK/WHT#34-E. PR2 RED 6 12 V DC BAT.Section 6 • Schematics First Edition • Second Printing Electrical Schematic.H. RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED CR14 NO TP35 CR14 RED RED BLK-1 WHT-2 BLK/RED-1 GRN/WHT-1 BLK-1 RED/BLK-1 RED-1 BLK/RED-3 ORG/BLK-1 3 TS51 START TS52 TS56 GLOW PLUGS TS54 LOW RPM FUNCTION HIGH RPM ENABLE AUXILIARY PUMP RED TB45 ENGINE BLK BLK TB28 TB27 4 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. 52709 . Part No. FB BLK/RED#R4-E.H. ORG/BLK#41-E. PR2 NO WHT/BLK#25 E.H.H. RED/BLK#28-E. TB35 RED/WHT#23-E. CR5 NO BLK/RED#R5-E. BLK/RED RED/WHT#23-E.H. CR4 NO CR4 GRN/WHT#45-E. ON IGN. H/L LOW RPM SELECTOR OPTION CR13 JIB CUTOUT RELAY JIB VALVE RELAY JIB VALVES BLK-2 START ON 2 TP41 RED AUXILIARY PUMP P3 HORN BLK GENERATOR ENGINE RED CB1 15AMP./FUEL ON 10 ENG. 15AMP.H. 3) All switches and contacts are shown with the boom in the stowed position and the key switch off. 8 KEY BYPASS 9 IGN.64 - + REGULATOR STA.H. TB24 WHT WHT#21 WHT#21-E. RED#27-E.H.H. + BAT. OIL TEMPERATURE SWITCH NO BRN BRN JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES FLASHING BEACON OPTION STARTER MOTOR TILT ALARM CE MODELS) JIB BOOM CUTOUT RELAY (CR-13) OPTION (REQUIRED FOR LIFT/DRIVE SELECTOR OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH OIL PRESSURE LED HIGH IDLE CUTOUT RELAY HIGH IDLE RELAY RPM SOLENOID FUEL SOLENOID OIL TEMPERATURE LED AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY GENERATOR OPTION HORN RELAY LEVEL SENSOR Genie Z-45/25 & Genie Z-45/25J HORN AUXILIARY PUMP GLOW PLUGS NOTE: 1) The connection to TP24 is for units without the generator option./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. W 1 OPS 3 AUX PUMP STARTER HM 2 BLK NC IND. ALTERNATOR EXCT. - 7 8 6 .H. FAULT TB34 RED TB9 TB41 TB23 CB2 TB20 RED#20-E. BLK/RED CR1 NO 5 TB21 WHT/BLK WHT/RED BLK#22 CR3 NO CR3 BLK#R1-E. RED CR1 CR2 NO CR2 L2 OIL PRES. CR5 PR1 NO WHT PR1 TB25 TB26 WHT/RED#26 E.H.H. Z-45/25J Perkins Models (before serial number 16304) A B C D E SEE NOTE 1 F G H I J K L M SEE NOTE 2 N ORG/BLK 1 TP22 P2 BLK TP26 BLK FS1 BLK RED RED TP25 TP21 RED WHT WHT TS50 LIFT/ DRIVE WHT BRN WHT TP24 TS2 TS1 WHT TS6 GLOW PLUGS TS47 OFF TS4 HIGH RPM FOOTSW. H.H.H.H. 52709 TB40 LS2 F HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 NO LS3 NO Genie Z-45/25 & Genie Z-45/25J TP37 TP32 C DP1 1 2 3 4 5 6 7 8 RED TP36 TP29 TB29 TB36 TB37 TB32 B 6 .Electrical Schematic. Z-45/25J Perkins Models (before serial number 16304) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB30 TB13 L1 NCHO A BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TS15 TP30 LS4 NOHC TB16 WHT#12-C. TP16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TP31 TB31 WHT/BLK-1 DRIVE EDC WHT/BLK#31-C.H.H.H. TP1 PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP10 TP11 BLU/BLK-3 J TB10 BLU-3 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU#10-M.H.H.65 .H. G TP6 TP4 TP5 TS63 RETRACT BOOM WHT/RED-3 WHT/BLK-3 TB5 WHT-3 WHT/BLK#5-M.H. RIGHT TURNTABLE ROTATE TB8 EXTEND TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A TS62 R X + LEFT R4 10 TB4 TB6 H WHT/RED#6-M. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP PRIMARY BOOM DOWN TB2 RED/BLK#2-M.H. JIB BOOM UP TS57 M TS7 LEFT RIGHT PLAT ROTATE LEFT RIGHT PLAT ROTATE TB17 CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 BRN + TB19 ORG/BLK N RED WHT WHT BRN RED RED CR9 TI BRN Part No. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H. TURNTABLE ROTATE FLOW CONTROL BP1 TB1 RED#1-M. PWM A R + X TB3 RED/WHT#3-M. WHT#4-M.H.H. DOWN UP JIB BOOM CR8 NC JIB BOOM DOWN GRN#17-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT#12-M. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT#29-C.H. BRAKE RELEASE VALVE TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK#37-M. SECONDARY BOOM FLOW CONTROL TP14 K ORG-3 ORG/BLK-3 TS9 DOWN TS59 TB14 PLATFORM LEVEL TP15 UP CR7 NC ORG#14-M. WHT/RED-1 WHT/RED#32-C. D HIGH (2WD) TS14 LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 R3 RED BLK 100 Section 6 • Schematics CE OPTION ONLY R2 R1 E 50 WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TP40 LS1 NCHO ORG-1 WHT#40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH WHT#40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 TP7 BLK-3 BLK/WHT-3 TB7 RETRACT BOOM TP8 EXTEND BLK#7-M.H.H. PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) L CR13 NC TP18 GRN/BLK-3 GRN-3 TP17 TS8 UP TS58 TB18 DOWN JIB BOOM GRN/BLK#18-M. STEER RIGHT BLU-1 BLU#36-M.H. UP DOWN PLATFORM LEVEL PLATFORM LEVEL UP ORG/BLK#15-M. SECONDARY BOOM UP PWM A + R X TS60 BLU/BLK#11-M.H.H. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25J Perkins Models (before serial number 16304) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304) . KS1 BLK-R1#86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD.P. WHT-S.5 4 3 L2 LED + 1 2 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT. RD/BK-S.P. WHT-S.male 6 . WHT-S.H. ENGINE. TS54 CB1 CB2 GRN/WHT #19 TS59 BLK/RED#R5-AH.H 7 GRD-HOLE ORG/BLK-15 ORG-14 BLK/RED-EH-r.P.P.P. WT/BK-E.H.fem-ORG-R7 r. BLK-S. 15A CIRCUIT BREAKER.P.H. RED-S.4 EXT.#6 BLK-2 WHT-2 BK/RD-R5 BLU-S.fem-BLK/RED-R4 r./FUEL ON AUXILIARY WHT-R2#86 WHT-24D 9 BASE TERMINATION BLOCK 10 D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA.male ORG/BLK-M.male-BLK/RED-R5 r.fem r.H.1 BLU-M.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY . ON GROUND BATTERY 2 3 NO NO 4 5 6 WHT-23A IGN.#6 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) CH+EH1 OG/BK-E.H.P. GRN-4 BLK/WHT #8 WHT#12-E.H. GR/BK-S. BLU/WT-S. NO ENG.C.P.male BLK/RED-EH-r. CR1 BLK-ISM#1 CR2 CR3 CR4 TS60 TS52 5 1 WHT-E. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION TS51 WHT/BLK # 25 WHT/RED #26 WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP PRIM.P. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 ORG-M.H.H. CR5 GRN/BLK #18 GRN #17 ORG-4 CR7 ORG/BLK-4 CR8 6 WHT#40-R7 WHT-PRIM.P.D.1 GRN-S.P. 3 SECON.H.P.P.M ORG #14 ORG/BLK #15 BLK#22 BLK/RED-9A WHT-SEC#4 WHT-EXT. WT/RD-S.P. CONTROLS.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304) A 1 LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 B C D E F G H I J K L M N DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS 2 M.H.H RED/WHT-C.66 Genie Z-45/25 & Genie Z-45/25J Part No. BOOM JIB WHT#21 BLK/RED#R4-EH WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 RED-ISM#4 RED-S. GR/WT-S. 52709 . RD/WT-S. LEVEL BLU/BLK #11 RED #20 RED-R1 BLK #33 TS57 PLATFORM ROTATE BRN GRND H.H RED/BLK-C. BU/BK-M.#5 BLK-ISM#3 BLK/WHT-E.P.6 8 KEY BYPASS IGN.1 RED-C.1 RD/WT-C.P. WT/BK-S. RED-R2 # 30 1 START RELAY TACHOMETER START INPUT AUX. ORG-SP OG/BK-SP OIL PRESS RED/WHT #3 RED/BLK #2 RED #1 BLK #7 CR3 CR4 CR5 CR7 CR8 HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.1 WHT/RED-C. R or CR ISM H.P.1 OG/BK-IM2 GR/WT-C.M.-r. BLU/WHT #12 BLK/WHT-34 R4 TS56 L3 OIL TEMP. E.P.H-r.male-BLK-R1 r.P. FAULT NO NC PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E. BU/BK-S.H. WHT-ISM#7 WHT/BLK-SP WHT/RED-SP WHT/BLK-EH.P. BLK-S. ORG-4/R7 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C. BK/WT-S.H. BLK/WHT-34 BK/RD-R3#35 BK/RD-SP BLU #10 FUNCTION ENABLE PLAT.C.H START SEC. TS61 PRIMARY BOOM TS58 EXTEND RETRACT TS63 WHT #4 WHT/BLK #5 WHT/RED #6 WHT-ISM#9 RED-CB1 2 GRN/BLK-4 RED-C. WHT-ISM#10 TS62 BLK/RED #35 GLOW PLUG BLK#R1-E. BLK-S.H WHT-ENA.P. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY 7 KEY PWR.H. M.H.fem BLK-E.DOWN (CE MODELS ONLY) HOUR METER 3 BLK/RED#35B RED-ISM#6 RED ORG/BLK-4/R8 RED-ENA./START MODULE P1 NC KS1 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER.-r. S.H.H.1 TURNTABLE ROTATE WT/RD-E.D. F.S. PWR. T1 H1 I H G F E D C B A 1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN . PLAT. PRIMARY F.P.C. BLU-10 BLU/BLK-11 RED/WHT-29 ORG/BLK-15 BLK/WHT-34 BLK/RED-35 RED-25 BLU-36 WHT/BLK-5 GRN/WHT-19 GRN-17 NC R NO A R CR13 7 L1 8 .L.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 H. PUMP SEL. BOOM F. STUD 3 R1 50 RED/BLK-28 RED-10 LIMITING RELAY CABLE CABLE #2 CABLE #1 WHT JIB CABLE BLK JIB CABLE 110 H1 + TILT _ ALARM #3 JIB CABLE F. R. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .S.L. WHT/RED-32 WHT-30 WHT-23 BLK-22 RED JUMP BLK-26 WHT-24 TO H. TURN ROT. TURN ROT. PULSE PICKUP LIMIT SWITCH (SPARE) GEN.D. LT. ORG-14 BLU/BLK-37 RED TO STOP SW RED TILT AL.S.ENA TS15 NC TS9 NC GLOW PLUG DRIVE SPEED TS14 TS2 START TS4 HIGH/LOW RPM HORN HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. ROT.67 . SEC. L. LEVEL UP DRIVE ENA. F. PLAT. OPTION WIRE (UNUSED) PLAT. ROT.P.C.S. BOOM DN. UP POWER PWR.P. PRIMARY DOWN PRIMARY UP GLOW PLUG START ENGINE BRAKE E.L. +12 V TO PLAT. LEVEL DN.) WHT (F. (OPTION) (SPARE) (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM PLAT.DEL. RED TO JIB CABLE BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 BRN TO GRD. BLU/RED-13 RED-10 TO H.) KEYSW.X R DRIVE DP1 JIB GRN/WHT + RED OUTPUT BRN TIME DELAY T1 PLATFORM LEVEL 7 TS8 R2 R3 TS6 DRV. BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN.X BP1 .) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 ORG-40 CR12 RED-10 WHT-24 GRD.C. SEC. L. ROT.S. 4 5 RED-1 RED TIM.C. R.D. (CONT. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM WHT-24 1 2 3 4 5 6 7 8 9 10 PWR. E. DRIVE ENABLE JIB VALVE (SPARE) ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-1 BLK (F. 2WD/4WD TILT ALARM AUX.) RED (F.BOOM BP2 CR14 6 + .S. SEC. TO F.C.X A A NO 2 TS13 NC NO + + JIB CUTOUT RELAY 3 4 5 NC JIB VALVE RELAY 6 1 P3 NO TS1 AUXILIARY PUMP 100 250 BLK/RED-9 WHT/BLK-31 ORG/RED-16 WHT/RED-6 BLK-33 WHT-4 TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 RED/BLK-2 RED/WHT-3 PRIMARY BOOM EXTEND/ RETRACT GENERATOR OPTION SEC. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304) . C.D. UP POWER PWR. TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM I H G F E D C B A 1 WHT-24 1 2 3 4 5 6 7 8 9 10 GEN.C. E. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 WHT/BLK-31 GRN-17 RED-1 ORG-14 ORG/BLK-15 WHT/BLK-5 NC R NO A R CR13 7 L1 JIB VALVE RELAY CR14 8 NC X +- BP1 NO .S. ROT. PWR.68 .S. L. PRIMARY F. PUMP SEL. TO F. BOOM UP (UNUSED) JIB VALVE PLAT. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. F. TURN ROT. RED TO JIB CABLE WHT-21 BLU-36 BRN TO GRD. F. RED TIM.C.DEL.BOOM BP2 6 + . Z-45/25J Perkins Models (before serial number 16304) N M L K J PLATFORM CONTROL BOX LABEL P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R1 R2 R3 L1 BP1 BP2 CR12 CR13 CR14 H.) KEYSW. SEC. (CONT. PWR.) WHT (F. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 BLK/WHT-34 ORG/RED-16 BLK-33 BLK/RED-35 RED-25 WHT-24 TO H. SEC. OPT. PLAT.L. SEC.S. SEC. PRIMARY DOWN PRIMARY UP PLAT. BOOM F. BOOM DN. BLU/RED-13 BLU/BLK-37 GRN/WHT-19 RED-10 TO H.S. ROT. LT.P.L. R. 2WD/4WD TILT ALARM AUX.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD. ROT.C.P. R.P. LEVEL DN.L.S.ENA TS15 NC NC GLOW PLUG TS14 TS2 START TS4 HIGH/LOW RPM HORN HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No. DRIVE ENABLE ORG/BLK-41 2 ORG-40 HORSEPOWER LIMITER BOARD RED FROM CR14 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.X R DRIVE DP1 GRN/WHT + RED OUTPUT BRN TIME DELAY T1 7 TS8 JIB R2 R3 TS6 DRV. PLAT. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . 3 4 5 6 1 P3 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 WHT/RED-6 PLATFORM LEVEL TS9 WHT-4 RED/BLK-2 RED/WHT-3 PRIMARY BOOM EXTEND/ RETRACT GEN.Lift/Drive SelectOption.X 2 TS13 A A NC NO + JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN TS50 PLATFORM ROTATE TS7 LIFT/ DRIVE SEL. +12 V TO PLAT. L. STUD R1 50 RED-10 LIMITING RELAY CABLE #3 RED/BLK-28 3 WHT JIB CABLE BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.) RED (F.C.D. TURN ROT. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN . H1 + TILT _ ALARM CABLE #2 4 5 WHT-23 RED TO STOP SW RED TILT AL. LEVEL UP DRIVE ENA. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram. Z-45/25J Perkins Models (before serial number 16304) .Lift/Drive Select Option. . H./FUEL ON 10 ENG. 15AMP. OTS NO RED-(FS) WHT-(FS) BLK-26 LOAD BRN BRN STARTER MOTOR FLASHING BEACON OPTION TILT ALARM OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH OIL PRESSURE LED FUEL SOLENOID OIL TEMPERATURE LED AUXILIARY POWER RELAY IGNITION/START RELAY POWER RELAY HOUR METER HORN RELAY HORN LEVEL SENSOR HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID GENERATOR OPTION AUXILIARY PUMP GLOW PLUGS LOAD SENSE OPTION C B+ LOAD SENSOR BOX GND 8 WHT-LOAD TP24 WHT-24 Genie Z-45/25 & Genie Z-45/25J ORG-LOAD Part No. H/L LOW RPM HIGH RPM GLOW PLUGS AUXILIARY PUMP 2 TP41 P3 HORN BLK ENGINE CB1 15AMP. ALTERNATOR EXCT. BLK/RED RED/WHT-23-E.H. CR4 NO CR4 GRN/WHT-45-E. TB35 RED/WHT-23-E.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. 52709 .H. BLK/WHT-34-E.H. FB BLK/RED-R4-E. 8 KEY BYPASS 9 IGN. RED CR1 CR2 NO CR2 L2 OIL PRES. PR2 NO WHT/BLK-25 E. - W AUX PUMP STARTER 1 HM 2 3 OPS NC BLK IND. FAULT TB34 4 TB9 TB41 TB23 CB2 TB20 RED-20-E. RED-27-E.H.H. CR5 RED WHT PR1 NO PR1 TB25 TB26 WHT/RED-26 E.H. ON MODULE 5 GROUND 6 BATTERY 7 KEY PWR.H. RED/BLK-28-E.H. Z-45/25 Perkins Models (after serial number 16303) A B C D E F G H I J K L M N ORG/BLK LOAD SENSE OPTION (SEE DETAIL BELOW) 1 TP22 P2 BLK TP26 FS1 RED-(FS) WHT-(FS) TP25 TP24 BLK-(FS) RED WHT WHT WHT TS2 TS1 WHT TS6 TS47 ON OFF GENERATOR TS4 BLK-2 START FOOTSW. BLK/RED CR1 NO TB21 WHT/BLK WHT/RED BLK-22 CR3 NO CR3 BLK-R1-E.H. CR5 NO BLK/RED-R5-E. L3 OIL TEMP.69 + STA. REGULATOR 6 12 V DC BAT. ORG/BLK-41-E. + BAT.H. RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED TP35 RED RED WHT-2 BLK-1 BLK/RED-1 GRN/WHT-1 BLK-1 RED/BLK-1 RED-1 BLK/RED-3 ORG/BLK-1 3 TS51 START TS52 TS56 TS54 LOW RPM FUNCTION HIGH RPM ENABLE AUXILIARY PUMP RED GLOW PLUGS TB45 ENGINE BLK BLK TB28 RED TB27 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT IGN.H.H. PR2 7 TP22 P2 BLK-26 FS1 BLK-(FS) TP26 8 6 ./START 4 AUX. 5 TB24 WHT WHT-21 WHT-21-E.H. H.H.H.H.H. TB4 WHT/RED-6-M.H. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 K TS9 ORG/BLK-3 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC TP15 ORG-14-M.H.1 2 3 4 5 6 7 First Edition • Second Printing Electrical Schematic. HIGH (2WD) TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 E 50 WHT-40-6 LS1 NCHO BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 EXTEND BOOM TB7 RETRACT TP8 BLK-7-M.H. DRIVE EDC TP32 WHT/RED-1 WHT/RED-32-C. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C.H. 52709 ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J BRAKE RELEASE VALVE B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 . UP PLATFORM DOWN LEVEL PLATFORM LEVEL UP ORG/BLK-15-M. BOOM EXTEND TS63 RETRACT BOOM RETRACT TP6 G WHT/RED-3 WHT/BLK-3 TP5 TB5 WHT-3 TB8 TP4 WHT/BLK-5-M. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU BLU-10-M.H. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M. TS61 UP PRIMARY DOWN BOOM PRIMARY BOOM UP TB2 RED/BLK-2-M.H.H. PWM A + X UP SECONDARY BOOM UP TS60 DOWN SECONDARY BOOM BLU/BLK R BLU/BLK-11-M.H. PWM A + X PRIMARY BOOM DOWN R TB3 REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) TP1 RED/WHT-3-M.H.H.H. RIGHT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT PWM A + X TS62 R LEFT TURNTABLE ROTATE R4 10 WHT#4-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M. STEER RIGHT BLU-1 BLU-36-M.H. Z-45/25 Perkins Models (after serial number 16303) 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 LS4 TP30 WHT-1 WHT-7 TB30 RED-7 DRIVE ENABLE LIMIT SWITCH A TP31 TP16 WHT-12-C. TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 WHT/BLK-31-C. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M. PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) L WHT TP18 GRN/BLK-3 RIGHT TS7 LEFT GRN-3 TS57 TB18 PLAT ROTATE TP17 GRN/BLK-18-M.70 .H. PLATFORM ROTATE LEFT M TB17 DESCENT ALARM OPTION N ORG/BLK WHT RED RED BRN BRN Part No. EXTEND BOOM BLK/WHT-8-M.H.H. CR8 NC RIGHT LEFT PLATFORM ROTATE RIGHT PLAT ROTATE GRN-17-M.H. First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Z-45/25 Perkins Models (after serial number 16303) . Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303) . WT/BK-S.P.H. BK/WT-S. ON GROUND BATTERY KEY PWR. BK/RD-R3#35 BK/RD-SP BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33 FUNCTION ENABLE BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT-SEC#4 CH+EH1 OG/BK-E.H RED/BLK-C.P.1 RD/WT-C.-r.1 WT/RD-E.H. RED-R2#30 WHT-23A 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 K L M N TACHOMETER START INPUT AUX.fem-ORG-R7 r. GR/WT-S.1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 BLK-S.fem BLK-E. WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.1 RED-C. ENGINE.DOWN (CE MODELS ONLY) NO IGN.male-BLK/RED-R5 r. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E. WHT-21 CR2 CR3 CR4 WHT-S. 52709 . WT/RD-S. WHT-S.P./START MODULE P1 NC NO SECON.P.P.H. BU/BK-M. 5 WHT-ISM-10 1 WHT/BLK-EH. RD/BK-S.6 KS1 NO AUXILIARY 3 PRIM.H.H RED/WHT-C. WHT-S.male-BLK-R1 r.fem ORG-M.P. BK/RD-R5 BLU-S. GR/BK-S.P.P.P.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S.H. C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .D.male BLK/RED-EH-r.5 BASE TERMINATION BLOCK D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. BOOM TS57 BLK/RED-R4 WHT-40B RED-ISM-4 TS54 CB1 CB2 TS59 GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT.P. RED-S. BLU/WT-S.1 WHT-EXT.P.H.D.H BLK/RED-35GEN ORG/BLK-15 7 BLK/RED-EH-r./FUEL ON ENG. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP TS51 WHT/BLK-25 WHT/RED-26 LED TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8 + L2 1 2 OIL PRESS RED/WHT-3 RED/BLK-2 RED-1 BLK-7 3 4 2 HOUR METER 3 RED BLK/RED-35B RED-R2 WHT-R2 RED-R1 BLK/WHT-8 TS61 EXTEND RETRACT TS63 PRIMARY BOOM TS62 WHT-4 WHT/BLK-5 WHT/RED-6 TURNTABLE ROTATE BLU/WHT-12 BLK/WHT-34 L3 OIL TEMP.M) BLK/RED-R5 CR5 CR7 ORG-4 CR8 ORG/BLK-4 6 WHT#40-R7 WHT-PRIM.H. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY.P. KEY BYPASS IGN.male GRD-HOLE ORG-14 r.P.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303) A 1 GROUND CONTROL SWITCH PANEL GROUND CONTROL BOX STACKED CONTACTS KS1 BLK-R1-86 M. WT/BK-E. BU/BK-S.H.M.H.P.H. LEVEL PLATFORM ROTATE ORG-14 ORG/BLK-15 BRN-(GRND H.male 6 .H. ORG/BLK-41A BLK-33D RED-27B BRN-GRD.71 Genie Z-45/25 & Genie Z-45/25J Part No.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C.C. TS60 TS56 R4 TS52 CR1 BLK-R1 BLK-R1-E. ORG-SP OG/BK-SP WHT-12-E.P.4 EXT.P. E. 15A CIRCUIT BREAKER. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.P.H.H-r.fem-BLK/RED-R4 r.H WHT-ENA. FAULT 2 NO DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER. WHT-E.H BLK-ISM-3 RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK/RED-35 GLOW PLUG START SEC.H. RD/WT-S.P. BLK-S.H.P.C. M.#5 BLK-1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU-M.1 GRN-S.H.-r.P.1 WHT/RED-C.H. R or CR ISM H. BLU/BLK-1 BLU/WHT-1 BLU/RED-1 BLK/WHT-E. CONTROLS. BLK-S. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 ORG/BLK-M.P. S.#6 OG/BK-IM2 GR/WT-C. P. BOOM DN. F. (CONT. PWR.) WHT (F.S.P. BLU-10 BLU/BLK-11 RED/WHT-29 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 BLK-33 BLU/BLK-37 WHT/RED-32 WHT-30 WHT/BLK-5 PLATFORM LEVEL TS9 WHT-4 RED/BLK-2 RED-1 BLK-7 BLK/WHT-8 GRN-17 GRN/BLK-18 BLU/WHT-12 RED-27 PRIMARY BOOM EXTEND/ RETRACT SEC. 4 SIDE VIEW FOR DP1 WHT TO PLATFORM ROTATE 5 RED-TILT GRN/WHT-45 BLK/WHT-34 RED/WHT-3 BRN TO GRD. L.S.X BP1 NO A + . SEC. ROT.S. LEVEL DN.C. TURN ROT. ROT. TURN ROT. F. R.C. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .) KEYSW. H1 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN.X R TS47 5 6 7 L1 8 A + .) RED (F. WHT/BLK-31 BLK-22 BLK-26 WHT-23 NC R NO A + . +12 V TO PLAT. OPTION WIRE PLAT. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) SEC. PRIMARY F.C.P.72 .Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS47 R1 1 WHT-24 1 2 3 4 5 6 7 8 9 10 HORN BOOM RETRACT BOOM EXTEND TURN.D. PWR.L.L. PLAT.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM 3 RED/BLK-28 + TILT _ ALARM H1 CABLE #3 CABLE #2 CABLE #1 110 F.S. 2WD/4WD TILT ALARM AUX. PLAT. LEVEL UP DRIVE ENA. R.C. PUMP SEL.S.S. WHT-24 TO H. (UNUSED) JIB VALVE PLAT. UP POWER PWR. LT.X TS13 NC NO TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED SEE SIDE VIEW DP1 1 2 3 4 P3 NO 100 250 BLK/RED-9 ORG-14 ORG/BLK-15 WHT/RED-6 GRN/WHT-19 BLU-36 RED-10 TO H.ENA TS15 NC GLOW PLUG NC TS2 START TS4 HIGH/LOW RPM HORN REMOVE FOR LIFT/ DRIVE SELECT VERSION TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No.D. STUD R1 50 RED-10 LIMITING RELAY RED-TILT R2 R3 L1 BP1 BP2 CR12 DP1 H. BOOM F. SEC. ROT. L. E.L. TO F. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. BOOM UP 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.C. PRIMARY DOWN PRIMARY UP GEN.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD.BOOM BP2 GENERATOR OPTION RED-GEN NC DP1 DRIVE 8 7 6 5 4 3 2 1 6 R 7 R2 R3 TS6 DRV. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303) . C.) WHT (F. F. SEC. TURN ROT. PRIMARY DOWN PRIMARY UP SEC. OPTION WIRE (UNUSED) JIB VALVE PLAT. BOOM DN.S. L. GEN. LEVEL DN. PLAT. H1 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DN.X TS13 NC NO TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED SEE SIDE VIEW DP1 PLATFORM LEVEL TS9 P3 NO R2 100 R3 TS6 250 DRV. PUMP SEL.ENA TS15 NC NC 1 2 3 4 5 BLK/RED-9 ORG-14 ORG/BLK-15 WHT/RED-6 GRN/WHT-19 SIDE VIEW FOR DP1 5 WHT TO PLATFORM ROTATE PRIMARY BOOM EXTEND/ RETRACT SEC.Lift/Drive SelectOption. ROT.L.S. F.L. R.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM 1 WHT-24 1 2 3 4 5 6 7 8 9 10 PLAT. 2WD/4WD TILT ALARM AUX. L.L.P.C.) KEYSW. STUD R1 50 RED-10 LIMITING RELAY RED-TILT 3 RED/BLK-28 H1 + TILT _ ALARM CABLE #3 CABLE #2 CABLE #1 110 F.C. PRIMARY F. ROT. TURN ROT.X R NC A + .C.P. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . LEVEL UP DRIVE ENA.BOOM BP2 DP1 DRIVE 8 7 6 5 4 3 2 1 RED-GEN 6 R 7 GLOW PLUG TS2 START TS4 HIGH/LOW RPM HORN TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No.S.D.) RED (F. BOOM UP ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. ROT.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram.S. DRIVE ENABLE HORN BOOM RETRACT BOOM EXTEND TURN. E. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.S.P. TO F. PWR. WHT-24 TO H. (CONT.S. +12 V TO PLAT. LT.C.X TS47 6 7 L1 GENERATOR OPTION 8 BP1 NO A + . Z-45/25 Perkins Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A COMPONENT INDEX P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS47 R1 R2 R3 L1 BP1 BP2 CR12 DP1 H.D. 4 BLU/BLK-11 RED/WHT-29 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 BLK-33 BLU/BLK-37 WHT/RED-32 WHT-30 RED-TILT BLK/WHT-34 GRN/WHT-45 BLU-36 BRN TO GRD. SEC.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD. BLU-10 RED/WHT-3 NC R NO A + . BOOM F. WHT/BLK-31 BLK-22 BLK-26 WHT-23 WHT/BLK-5 WHT-4 RED/BLK-2 RED-1 BLK-7 BLK/WHT-8 GRN-17 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H. PLAT. UP POWER PWR.73 . PWR. R. First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram.Lift/Drive Select Option. Z-45/25 Perkins Models (after serial number 16303) . . H. BLK/RED CR1 NO TB21 WHT/RED WHT/BLK BLK-22 CR3 NO CR3 BLK-R1-E. + BAT./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR.H.H. - STA. BLK/RED RED/WHT-23-E.H. FAULT TB34 4 TB9 TB41 TB23 CB2 TB20 RED-20-E. RED P1 RED KS1 PLAT GRND TB22 TP9 TP23 TP28 TP27 TP33 TP34 TP45 ENGINE SPEED CR14 NO TP35 CR14 RED RED WHT-2 BLK-1 BLK/RED-1 GRN/WHT-1 BLK-1 RED/BLK-1 RED-1 BLK/RED-3 ORG/BLK-1 3 TS51 AUXILIARY PUMP START TS52 TS56 GLOW PLUG TS54 LOW RPM FUNCTION HIGH RPM ENABLE RED TB45 ENGINE BLK BLK TB28 RED TB27 TB33 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. RED-27-E. 8 KEY BYPASS 9 IGN. OTS NO BRN BRN JIB BOOM VALVE RELAY (CR-14) STARTER MOTOR JIB BOOM VALVES FLASHING BEACON OPTION TILT ALARM OIL PRESSURE LED OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH FUEL SOLENOID OIL TEMPERATURE LED JIB BOOM CUTOUT RELAY (CR-13) RPM SOLENOID HIGH IDLE CUTOUT RELAY HIGH IDLE RELAY AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY HORN RELAY HORN LEVEL SENSOR GENERATOR OPTION AUXILIARY PUMP GLOW PLUGS LOAD SENSE OPTION FS1 BLK-(FS) RED-(FS) WHT-(FS) BLK-26 LOAD C B+ TP26 LOAD SENSOR BOX WHT-LOAD TP24 WHT-24 GND 8 Genie Z-45/25 & Genie Z-45/25J ORG-LOAD Part No.H. ALTERNATOR EXCT.H. PR2 7 TP22 P2 BLK-26 8 6 . H/L LOW RPM HIGH RPM START GLOW PLUG AUXILIARY PUMP RED GENERATOR 2 TP41 P3 HORN BLK ENGINE RED CB1 15AMP. CR5 NO BLK/RED-R5-E. TB35 RED/WHT-23-E.H. CR4 NO CR4 GRN/WHT-45-E.H. RED/BLK-28-E. RED CR1 CR2 NO CR2 L2 OIL PRES.H.H. ON IGN.H. 5 TB24 WHT WHT-21 WHT-21-E.H. W 1 OPS 3 AUX PUMP STARTER HM 2 BLK NC IND. L3 OIL TEMP. ORG/BLK-41-E. 15AMP.74 - + REGULATOR 6 12 V DC BAT. Z-45/25J Perkins Models (after serial number 16303) A B C D LOAD SENSE OPTION (SEE DETAIL BELOW) ORG/BLK E F G H I J K L M N 1 TP22 P2 BLK TP26 FS1 BLK-(FS) RED-(FS) WHT-(FS) TP25 TP24 RED WHT WHT BRN WHT TS2 TS1 WHT TS6 TS47 OFF ON TS4 CR13 JIB CUTOUT RELAY JIB VALVE RELAY JIB VALVES BLK-2 FOOTSW. CR5 RED WHT PR1 NO PR1 TB25 TB26 WHT/RED-26 E. FB BLK/RED-R4-E. BLK/WHT-34-E. PR2 NO WHT/BLK-25 E.Section 6 • Schematics First Edition • Second Printing Electrical Schematic. 52709 .H./FUEL ON 10 ENG.H. H.H.H.75 .H. STEER LEFT RED/WHT-1 MOTOR STROKE RED/WHT-29-C.H.H.H.H. TS61 DOWN RED/BLK-2-M. HIGH (2WD) TS14 D LOW (4WD) RED DRIVE RANGE (2WD/4WD) 250 RED BLK 100 CE MODELS ONLY R2 Section 6 • Schematics R1 E 50 WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH CR12 TB40 LS3 NO LS1 NCHO WHT-40-5 BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH TS13 BLK-3 BLK/WHT-3 EXTEND TB7 RETRACT BOOM TP8 BLK-7-M. Z-45/25J Perkins Models (after serial number 16303) First Edition • Second Printing 1 2 3 4 5 6 7 8 BRN-2 GROUND TP13 TB13 L1 NCHO BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1 TP30 TB30 A LS4 TP31 TP16 WHT-12-C.H.H.H. STEER RIGHT BLU-1 BLU-36-M. CR8 NC PLATFORM ROTATE RIGHT / JIBBOOM DOWN PLATFORM ROTATE LEFT / JIBBOOM UP TS57 M WHT TS7 RIGHT PLATFORM LEFT ROTATE LEFT RIGHT PLATFORM ROTATE TB17 CR9 NC TP19 DESCENT ALARM OPTION GRN/WHT-3 BRN TB19 + N ORG/BLK WHT RED RED RED CR9 TI BRN BRN Part No.H. PWM A + X TS62 R LEFT RIGHT TURNTABLE ROTATE TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT R4 10 TB4 WHT/RED-6-M. UP PLATFORM DOWN LEVEL ORG/BLK-15-M. DOWN JIB BOOM UP GRN-17-M. SECONDARY BOOM UP PWM A + X R TS60 BLU/BLK-11-M. TS15 NOHC TB16 DRIVE ENABLE ORG/RED-3 DRIVE ENABLE SWITCH TB31 WHT/BLK-1 DRIVE EDC WHT/BLK-31-C. TB32 TRAVEL ALARM OPTION BLU/BLK-1 BLU/BLK-37-M. BP2 SECONDARY BOOM DOWN TB11 TB12 BLU/WHT BLU/WHT-12-M. PLATFORM LEVEL UP PLATFORM LEVEL DOWN TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT CR13 NC L TP18 GRN/BLK-3 GRN-3 TS8 TS58 TB18 DOWN JIB BOOM UP TP17 GRN/BLK-18-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.H.H.H. PRIMARY BOOM TB2 UP PRIMARY BOOM UP PRIMARY BOOM DOWN REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY) PWM A + X R TB3 TP1 RED/WHT-3-M. TP14 SECONDARY BOOM FLOW CONTROL ORG-3 ORG/BLK-3 K TS9 TS59 TB14 UP PLATFORM DOWN LEVEL CR7 NC TP15 ORG-14-M. WHT#4-M.H.Electrical Schematic. PRIMARY BOOM FLOW CONTROL RED-3 I TP2 RED/BLK-3 TP3 RED/WHT-3 TP12 BLU/WHT-3 TP11 BLU/BLK-3 TB10 J BLU-3 TP10 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU-10-M. 52709 ORG-1 WHT-40-4 BRN-4 SECONDARY BOOM UP DRIVE LIMIT SWITCH TP40 LS2 HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 F TP7 NO Genie Z-45/25 & Genie Z-45/25J BRAKE RELEASE VALVE B TP37 C DP1 RED TP36 1 2 3 4 5 6 7 8 R3 TP29 TB29 TB36 TB37 6 . TP32 WHT/RED-1 WHT/RED-32-C. EXTEND TS63 RETRACT BOOM TP6 G WHT/RED-3 WHT/BLK-3 TP5 TB5 WHT-3 TB8 TP4 WHT/BLK-5-M. H BP1 TB1 TB6 TURNTABLE ROTATE FLOW CONTROL RED-1-M.H.H.H. Z-45/25J Perkins Models (after serial number 16303) .First Edition • Second Printing Section 6 • Schematics Electrical Schematic. Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303) . UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY .P. WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.Section 6 • Schematics First Edition • Second Printing Ground Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303) A 1 GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL STACKED CONTACTS KS1 BLK-R1-86 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX.P.H-r.fem r.fem-ORG-R7 r.#5 BLK-1 BLK/WHT-E. BU/BK-S. 52709 . WHT-S.1 WT/RD-E.76 Genie Z-45/25 & Genie Z-45/25J Part No.C.P.P.male-BLK-R1 r.fem-BLK/RED-R4 r. RED-S.P. WHT-ISM-10 WHT/BLK-EH.P.-r.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.4 EXT.fem BLK-E. BLK-S.P. E.H. 15A CIRCUIT BREAKER.P.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 B A RED-S. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION NO NO NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP TS51 WHT/BLK-25 WHT/RED-26 L2 1 2 LED + OIL PRESS RED/WHT-3 RED/BLK-2 RED-1 BLK-7 4 3 HOUR METER 3 BLK/RED-35B RED BLK/WHT-8 TS61 TS63 PRIMARY BOOM TS58 TS62 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TURNTABLE ROTATE BLU/WHT-12 BLK/WHT-34 L3 OIL TEMP.#6 OG/BK-IM2 GR/WT-C.H BLK/RED-35GEN 7 GRD-HOLE ORG/BLK-15 ORG-14 BLK/RED-EH-r. ENGINE. WT/RD-S.P. GR/WT-S.male 6 . BLU/BLK-1 BU/BK-M.H. BLK-S.DOWN (CE MODELS ONLY) NO IGN. WHT-E.1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1 BLK-S. BLU/WT-S.P. GR/BK-S. ORG-SP OG/BK-SP WHT-12-E.P.1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU-M. KEY BYPASS IGN.H RED/WHT-C.M. ON GROUND BATTERY KEY PWR. BK/WT-S. R or CR ISM H. LEVEL TS57 PLATFORM ROTATE BRN-(GRND H.-r. RED-R2#30 WHT-23A B C D E F G H I J LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8 RED-R2 WHT-R2 RED-R1 K DESCRIPTION L M N 2 M.D. BLU/WHT-1 BLU/RED-1 OG/BK-E.H RED/BLK-C. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER 8 ORG-M. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. FAULT ORG/BLK-41A BLK-33D RED-27B BRN-GRD. BK/RD-R5 BLU-S.1 RED-C.H.H.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY: EH C.1 GRN-S. BLK/RED-35 GLOW PLUG START SEC. S. RD/WT-S. WT/BK-E.H. 2 R4 TS56 CR1 BLK-R1 BLK-R1-E. M. BOOM JIB BLK/RED-R4 WHT-40B RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 RED-ISM-4 TS54 CB1 CB2 TS59 GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT. 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY. GRN-4 GRN/BLK-4 RED-C.H. BK/RD-R3#35 BK/RD-SP BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33 FUNCTION ENABLE ORG-14 ORG/BLK-15 BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) WHT-SEC#4 CH+EH1 WHT-EXT.male-BLK/RED-R5 r. WT/BK-S.P./FUEL ON ENG.1 WHT/RED-C.P.H.H WHT-ENA.H.H BLK-ISM-3 WHT-S.H. WHT-S.P.P.H.H.M) BLK/RED-R5 CR5 CR7 ORG-4 CR8 ORG/BLK-4 6 WHT#40-R7 WHT-PRIM.H.H.P. WHT-21 CR2 CR3 CR4 TS60 TS52 5 1 RD/WT-C.P.male ORG/BLK-M. NO EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER.1 C RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.P.H.H.P./START MODULE P1 NC KS1 AUXILIARY SECON. RD/BK-S.male BLK/RED-EH-r.H.D. CONTROLS.5 BASE TERMINATION BLOCK D RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA.P.C.6 3 PRIM. S. RED-10 TO H. BOOM F. SEC.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD 3 RED/BLK-28 BLK JIB CABLE CABLE #1 110 JIB CABLE F.) WHT (F. LT. L.BOOM BP2 GEN. WHT/BLK-31 BLK-22 BLK-26 WHT-23 NC R NO A + . ROT.L.P. TURN ROT. +12 V TO PLAT.X R CR13 NC A + . WHT-24 TO H.77 . PRIMARY F.S. (UNUSED) JIB VALVE PLAT.D.C. PRIMARY DOWN PRIMARY UP GEN.) RED (F. OPTION WIRE PLAT. PWR. UP POWER PWR. 2WD/4WD TILT ALARM AUX. BOOM DN. TURN ROT.C. ROT. F. PLAT.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD.ENA TS15 NC NC 7 TS4 GLOW PLUG TS2 START HIGH/LOW RPM HORN REMOVE FOR LIFT/ DRIVE SELECT VERSION TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No.C. DRIVE ENABLE ORG/BLK-41 ORG-40 HORSEPOWER LIMITER BOARD EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) SEC. BOOM UP RED FROM CR14 2 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.) KEYSW. 52709 Genie Z-45/25 & Genie Z-45/25J 6 . TS47 RED-GEN BLK-33 BLU/BLK-37 WHT-30 WHT/RED-32 RED TO JIB CABLE RED JUMP BLU-36 SIDE VIEW FOR DP1 5 WHT TO PLATFORM ROTATE DP1 DRIVE GRN/WHT + RED OUTPUT BRN TIME DELAY T1 8 7 6 5 4 3 2 1 6 R PLATFORM LEVEL TS9 TS8 JIB R2 R3 TS6 DRV. (CONT.P. BLU-10 BLU/BLK-11 RED/WHT-29 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 PRIMARY BOOM EXTEND/ RETRACT SEC. H1 CABLE #3 CABLE #2 + TILT ALARM TIME DELAY TILT ALARM 4 RED-STP BLK/WHT-34 GRN/WHT-45 WHT/BLK-5 WHT-4 RED/BLK-2 RED-1 BLK-7 BLK/WHT-8 GRN-17 GRN/BLK-18 BLU/WHT-12 RED-27 RED/WHT-3 BRN TO GRD. PWR. SEC.S.P. PLAT. TO F. OPT. LEVEL UP DRIVE ENA.C. R. F.L.DEL. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. E.L. ROT.D. R.C.X BP1 NO JIB VALVE RELAY CR14 5 6 7 L1 8 TS13 NC NO 2 JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 SEE SIDE VIEW DP1 3 4 1 P3 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 ORG-14 ORG/BLK-15 WHT/RED-6 GRN/WHT-19 RED-STP RED-TILT RED TIM.S. LEVEL DN. T1 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303) N M L K J PLATFORM CONTROL BOX I H G F E D C B A COMPONENT INDEX P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS47 R1 1 WHT-24 1 2 3 4 5 6 7 8 9 10 HORN BOOM RETRACT BOOM EXTEND TURN.S. STUD R1 50 RED-10 LIMITING RELAY RED-TILT WHT JIB CABLE R2 R3 L1 BP1 BP2 CR12 CR13 CR14 DP1 H. L. PUMP SEL.X A + . First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303) . S. (UNUSED) JIB VALVE PLAT. 2WD/4WD TILT ALARM AUX.) KEYSW. WHT-24 TO H.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram. Z-45/25J Perkins Models (after serial number 16303) N M L K J I H G F E D C B A PLATFORM CONTROL BOX 1 COMPONENT INDEX P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS47 R1 WHT-24 ORG/BLK-41 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB BOOMUP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) 1 2 3 4 5 6 7 8 9 10 GEN. R. L.TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD 3 RED/BLK-28 BLK JIB CABLE CABLE #1 110 JIB CABLE F. PRIMARY DOWN PRIMARY UP PLAT.DEL. BOOM F.S.P.) WHT (F. ROT.D.C. F. TURN ROT. DRIVE ENABLE SEC. TURN ROT.Lift/Drive SelectOption. BOOM UP 2 RED FROM CR14 ORG-40 HORSEPOWER LIMITER BOARD 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F. TO F. BLK-22 BLK-26 WHT-23 PRIMARY BOOM EXTEND/ RETRACT GEN. L.BOOM BP2 CR14 DP1 DRIVE GRN/WHT + RED OUTPUT BRN TIME DELAY T1 8 7 6 5 4 3 2 1 A + - 6 X R PLATFORM LEVEL TS9 TS8 JIB 7 R2 R3 TS6 DRV. LT. PLAT. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.S. SEC.P. E. BOOM DN. F. LEVEL UP DRIVE ENA.C.) RED (F. PRIMARY F. (CONT.S. STUD R1 50 RED-10 LIMITING RELAY RED-TILT WHT JIB CABLE R2 R3 L1 BP1 BP2 CR12 CR13 CR14 DP1 H. PUMP SEL. SEC.L.S. ROT. PLAT. R.S. +12 V TO PLAT. WHT-4 RED/BLK-2 BLK/WHT-34 RED JUMP RED TO JIB CABLE BLU/RED-13 ORG-14 RED-10 TO H.D.L.ENA TS15 NC NC GLOW PLUG TS2 START TS4 HIGH/LOW RPM HORN TS14 HIGH/LOW (2WD/4WD) EMERGENCY STOP P2 8 PLATFORM CONTROL SWITCH PANEL Part No.C. OPT. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .L.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 ORG-40 CR12 RED-10 WHT-24 GRD.C. LEVEL DN.P. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. TS47 RED-GEN SEC. PWR. H1 + TILT ALARM CABLE #3 CABLE #2 4 TIME DELAY TILT ALARM SIDE VIEW FOR DP1 WHT TO PLATFORM ROTATE 5 GRN/WHT-45 RED-STP RED-TILT RED TIM. PWR.78 . T1 H1 LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/RED-35 RED-25 RED/WHT-3 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 NC NO R R CR13 7 L1 8 X X NC - - BP1 NO JIB VALVE RELAY A + A + 2 TS13 NC NO JIB CUTOUT RELAY TURNTABLE ROTATE PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 SEE SIDE VIEW DP1 3 4 5 6 1 P3 NO TS1 AUXILIARY PUMP DRIVE SPEED 100 250 BLK/RED-9 BLK-33 RED-1 WHT/RED-6 BLU/BLK-37 WHT-30 WHT/BLK-31 BLU-36 WHT/RED-32 RED-STP BRN TO GRD.C. ROT. UP POWER PWR. Lift/Drive Select Option.First Edition • Second Printing Section 6 • Schematics Platform Control Box Wiring Diagram. Z-45/25J Perkins Models (after serial number 16303) . All Models (after serial number 16303) .Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram.Load Sensor Option. WHITE JUMP WIRE ASSY LDSENSE. TO F. R. 3 GROUND BOLT WHT-LOAD (P/N 54908) 12 VOLTS 1 2 3 4 5 6 7 8 9 RED LED OVER LOAD YELLOW LED PREALARM (NOT USED) RELAY OVER LOAD ADJUST 4 TILT ALARM CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F. PLAT.C. ROT.S. C. LEVEL DN.S.LOAD SENSE.) WHT (F. LOAD SENSOR LOAD CELL BENDING TYPE MODULE.C. OPTION WIRE GEN. LT. TURN ROT.) RED (F. All Models (after serial number 16303) A 1 B C D E PLATFORM CONTROL BOX PART NUMBER 54904 54905 54906 54907 54908 54909 32335 48716 56765 56766 F G H I J K L M N BILL OF MATERIALS DESCRIPTION WIRE ASSY FOOTSWITCH. (CONT. SERV LOOP WIRE ASSY LOADSENSE. ORANGE LED WIRE ASSY FTSWTCH/LDSENSOR. UP POWER PWR.) KEYSW. TURN ROT. LEVEL UP DRIVE ENA. LED. PWR WIRE ASSY. 52709 P N 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.ENA 7 P3 TS15 HORN NO PLATFORM LEVEL TS9 TS7 PLATFORM ROTATE TS8 JIB AUXILIARY PUMP TS1 TS14 TS6 DRIVE SPEED GLOW PLUG START TS2 TS4 HIGH/LOW RPM L4 BRN + 1 BRN (P/N 54907) 2 3 4 TS13 . (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E. PLAT. SEC. PRIMARY DOWN PRIMARY UP SEC. N.79 Genie Z-45/25 & Genie Z-45/25J Part No. PWR. LABEL.S.1/12V RELAY BRN-LOAD BLK-26 LOAD (P/N 54906) ORG-LOAD (P/N 54905) (UNUSED) JIB VALVE PLAT.ENA LED 6 PRIMARY BOOM EXTEND/ RETRACT SEC. BOOM UP PLAT.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3 + B V R N WHT GRN RED BLK ORG-LOAD (P/N 54905) BLK-26 LOAD (P/N 54906) BLK-26 (P/N 54906) + . BROWN.) (P/N 54904) CABLE TO LOAD CELL (P/N 56765) 5 GENERATOR OPTION DRIVE DP1 8 TURNTABLE ROTATE R NC NO PRIMARY BOOM UP/DOWN A 6 . GROUND WIRE ASSY LDSENS/FS.BOOM BP2 R 7 L1 TS47 + HIGH/LOW (2WD/4WD) OVER LOAD LED (P/N 32335) 8 PLATFORM CONTROL SWITCH PANEL 6 .O.C.X R NC NC EMERGENCY STOP P2 . PUMP SEL. L.C. LDSENSE.RED 12V LARGE DECAL.X NC BP1 NO + + A A DRV.S. BOOM F. 2WD/4WD TILT ALARM AUX.D.S. SEC. DRIVE ENABLE HORN BOOM RETRACT BOOM EXTEND TURN. BOOM DN. E.Load Sensor Option. 500 mA - 2 BRN-LOAD (P/N 54909) PREALARM ADJUST (NOT USED) N. ROT.X 5 DRV. L.D.Section 6 • Schematics First Edition • Second Printing Platform Control Box Wiring Diagram.C. GROUND LED. PRIMARY F. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH HORSEPOWER LIMITER BOARD 1 2 3 4 5 6 7 8 9 10 LOAD SENSOR MODULE (COVER REMOVED) (P/N 56766) FUSE.S. +12 V TO PLAT. F. ROT.C. WHT-(F. R. PWR. F. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .80 .First Edition • Second Printing Section 6 • Schematics Hydraulic Symbols Legend Part No. 81 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 .Section 6 • Schematics First Edition • Second Printing 6 . 3 L/min) 1 GPM (3.8 bar) V1 3 1:1 ATMOS 3000 PSI.030” (0.6 L/min) W REAR LEFT LB E FUNCTION PUMP 7 GPM (26. 1500 PSI (103.9 bar) OO 3:1 1500 PSI (103.Section 6 • Schematics First Edition • Second Printing 2WD Hydraulic Schematic N M L K J I H G F E D C B A JIB BOOM CYLINDER PLATFORM ROTATE CYLINDER TURNTABLE ROTATE PRIMARY BOOM CYLINDER 1 1.8 bar) KK U V BB T 4. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .4 L/min) QQ AA T2 LIFT FUNCTION MANIFOLD OPTIONAL OSCILLATE CLYINDERS 6 T XX YY PP 3200 PSI (220.4 bar) HIGH PRESSURE FILTER MASTER CYLINDER OPTIONAL MOTOR/ GENERATOR 4 ST1 GG ST2 PR1 PR2 PL1 R PL2 Q SW1 SW2 S1 0.6 bar) 25 PSI (1.9 bar) 5:1 ATMOS.5 L/min) PRESSURE 0.4 bar) 2 R2 0.3 bar) This valve was removed after serial number 12603 J 2300 PSI (159 bar) P FF II DD K 0.5:1 1000 PSI (67 bar) 7 STEERING CYLINDERS OPTIONAL OSCILLATE DIRECTIONAL VALVE 8 NOTE #1: 250 PSI (17.6 GPM (2.18 mm) LA RR 50% PB GENERATOR SELECT 3500 PSI (241.1 bar) E P1 P2 EXTEND RETRACT VV RB UU 360 PSI (24.5:1 3500 PSI (241.1 GPM (0.76 mm) 0. 1000 PSI (68.76 mm) SECONDARY BOOM CYLINDERS R1 JIB BOOM MANIFOLD V2 V1 V2 3:1 SEMI RESTRICTIVE SEALED PILOT 3000 PSI.3 bar) after serial number 12603 Part No.3 bar) X TEST F S C CC 50% TT WW X 1.5:1 3800 PSI (262 bar) semi restricted J2 J1 V2 V1 3:1 2000 PSI (137.76 mm) S1 X 0.070” (1.2 bar) before serial number 12604 280 PSI (19. (206.030” (0.030” (.6 bar) EE O 0.030” (0.8 L/min) Z N A G D B Y LL M X TEST DRIVE PUMP TANK N 3200 PSI (220.82 .7 bar) 2 SPEED BRAKE 0. (206.76 mm) See Note #1 M T2 TANK APU 4.7 L/min) I L 5 2 GPM (7.8 bar) DRIVE MANIFOLD REAR RIGHT RA PA 50 PSI (3.4 bar) EXTENSION CYLINDER NN SLAVE CYLINDER MM X 1.5:1 3800 PSI (262 bar) semi restricted 3:1 ATMOS.5 GPM (5.040” (1 mm) JJ HH S2 1800 PSI (124. First Edition • Second Printing Section 6 • Schematics 2WD Hydraulic Schematic . 7 L/min) CC E FUNCTION PUMP 7 GPM (26. 52709 Genie Z-45/25 & Genie Z-45/25J 6 .83 .5 GPM (5.3 L/min) 1 GPM (3.2 GPM (0.5:1 3500 PSI (241.2 bar) before serial number 12604 280 PSI (19.5:1 1000 PSI (67 bar) REAR RIGHT RFA RA AS AQ FRONT RIGHT TANK LFB 50% LB 67% AR 33% 50% AD AB 50% 0.1 bar) E P1 P2 EXTEND RETRACT 360 PSI (24.76 mm) SECONDARY BOOM CYLINDERS R1 2 JIB BOOM MANIFOLD V2 V1 V2 3:1 SEMI RESTRICTIVE SEALED PILOT 3000 PSI.6 L/min) W DRIVE MANIFOLD RB AG DRIVE PUMP TANK N 3200 PSI (220.76 mm) 0.9 bar) 5:1 ATMOS.025” (0.76 L/min) AT 0.5 L/min) PRESSURE 0.Section 6 • Schematics First Edition • Second Printing 4WD Hydraulic Schematic N M L K J I H JIB BOOM CYLINDER G PLATFORM ROTATE CYLINDER F E D TURNTABLE ROTATE C B PRIMARY BOOM CYLINDER A 1.030” (0.3 bar) after serial number 12603 8 Part No.6 bar) 25 PSI (1. 1500 PSI (103.7 bar) A RFB M 6 APU 4.052” AP (1. (206.040” (1 mm) JJ HH S2 1800 PSI (124.8 GPM (3.76 mm) TANK See Note #2 BRAKE 2 SPEED AK AI NOTE #1: 2 GPM (7.6 L/min) before serial number 14775 0.6 GPM (2.3 bar) X TEST F L I 1. (206.5:1 3800 PSI (262 bar) semi restricted 3:1 ATMOS.5:1 3800 PSI (262 bar) semi restricted J2 J1 V2 V1 1 3:1 2000 PSI (137. 1000 PSI (68.4 bar) R2 0.1 GPM (0.8 L/min) Z N A G D B Y LL M X 2 GPM (7.030” (0.8 bar) V1 1:1 ATMOS 3000 PSI.64 mm) LFA X TEST AE AF AH AM AL T2 AJ 0.6 bar) EE O 0.76 mm) S1 X 0.4 bar) HIGH PRESSURE FILTER MASTER CYLINDER OPTIONAL MOTOR/ GENERATOR ST1 GG ST2 PR1 PR2 PL1 R PL2 Q SW1 SW2 S1 0.4 L/min) 5 B AA T2 LIFT FUNCTION MANIFOLD OPTIONAL OSCILLATE CLYINDERS 3200 PSI (220.030” (.3 bar) This valve was removed after serial number 12603 J 2300 PSI (159 bar) 4 K P S FF II C DD GENERATOR SELECT 3500 PSI (241.32 mm) 50% See Note #1 FRONT LEFT STEERING CYLINDERS OPTIONAL OSCILLATE DIRECTIONAL VALVE 7 REAR LEFT AC AO 0.8 bar) 3 50 PSI (3.8 bar) KK U V BB T 4.02 L/min) after serial number 14774 NOTE #2: 250 PSI (17.4 bar) EXTENSION CYLINDER NN SLAVE CYLINDER MM X 1.030” (0.9 bar) OO 3:1 1500 PSI (103. First Edition • Second Printing Section 6 • Schematics 4WD Hydraulic Schematic . First Edition • Second Printing Section 7 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Green—used to indicate operation or maintenance information. perform the disassembly steps in reverse order. Attempting shortcuts may produce hazardous conditions. Red—used to indicate the presence of an imminently hazardous situation which. Repair any machine damage or malfunction before operating the machine. will result in death or serious injury. Select the appropriate repair procedure after troubleshooting the problem. Read each procedure completely and adhere to the instructions. may cause minor or moderate injury. Perform disassembly procedures to the point where repairs can be completed. if not avoided. Immediately tag and remove from service a damaged or malfunctioning machine. level surface · Boom in stowed position · 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 Part No. Orange—used to indicate the presence of a potentially hazardous situation which. 52709 Genie Z-45/25 & Genie Z-45/25J 7-1 . Before Repairs Start: Read. Unless otherwise specified. may result in property damage. Then to re-assemble. Indicates that a specific result is expected after performing a series of steps. Obey all safety messages that follow this symbol to avoid possible injury or death. could result in death or serious injury. Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which. Be sure that all necessary tools and parts are available and ready for use. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which. understand and obey the safety rules and operating instructions in the Genie Z-45/25 & Genie Z-45/25J Operator’s Manual. if not avoided. if not avoided. perform each repair procedure with the machine in the following configuration: · Machine parked on a flat. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. if not avoided. 7-2 Genie Z-45/25 & Genie Z-45/25J Part No. Individual trim potentiometers (trimpots) are used to adjust various output signals from the drive and boom function controllers. • Max out trim potentiameter (max out trimpot) High range trim potentiameter (max out trimpot) Lo range trim potentiometer (lo range trimpot) Dual range trim potentiometer (lo range trimpot) Threshold trim potentiometer (threshold trimpot) Ramp rate trim potentiometer (ramp rate rimpot) f e d c • • Platform control box a horsepower limiter board b terminal strip c drive proportional controller d secondary boom proportional controller e primary boom proportional controller f turntable rotate proportional controller • • • 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion.5V DC output.6 to 14. Contact with electrically charged circuits could result in death or serious injury. 52709 .Section 7 • Repair Procedures First Edition • Second Printing Platform Controls 1-1 Joystick Controllers Maintaining joystick controllers at the proper settings is essential to safe machine operation. Remove all rings. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13. watches and other jewelry. The trimpots will be identified as the following. a b Primary Boom Up/Down Controller Adjustments Electrocution hazard. Do not start the engine. First Edition • Second Printing Section 7 • Repair Procedures PLATFORM CONTROLS 2 Open the platform control box lid and locate the primary boom up/down controller. Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. check the relief valve pressure. a b c d e f g h i j 6 Set the hi range: Press down the foot switch.5V DC. Part No.85V DC. then slowly move the control handle off center until the moment a voltage reading appears. then move the control handle all the way to the DOWN position. 12 Pull out the Emergency Stop button to the ON position. Connect the black (-) lead to ground. 5 Set the threshold: Press down the foot switch. Adjust the voltage to 5. Valve Adjustments . 8 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). then move the control handle all the way to the UP position. 10 Start a timer and record how long it takes for the boom to fully lower. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Set the lo range: Press down the foot switch. Adjust the voltage to 2. If the function cycle time is not achievable. a b c d e f g h i j ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" activates hi range (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot 3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed.5V DC. 52709 Genie Z-45/25 & Genie Z-45/25J 7-3 . 4 Connect the red (+) lead from a volt meter to the “A” terminal on the controller printed circuit board. See 12-2. 9 Start a timer and record how long it takes for the primary boom to fully raise. Adjust the voltage to 6.Function Manifold. Adjust the lo range trimpot to achieve an 32 to 37 second cycle time. 11 Turn the engine OFF. Adjust the hi range trimpot to achieve a 24 to 27 second cycle time. 6 to 14.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM CONTROLS 13 Press down the foot switch and then move the control handle all the way to the UP position. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 52709 .lo range Cycle time Ramp rate 2. 7-4 Genie Z-45/25 & Genie Z-45/25J Part No. 15 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. Contact with electrically charged circuits could result in death or serious injury.5V DC 24 to 27 seconds 5. Note how long it takes to reach the maximum voltage recorded in step 14. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13.85V DC 6. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time. Boom up/down specifications Threshold Primary boom up . watches and other jewelry. This is the ramp rate.5V DC output. Do not start the engine. Remove all rings.5V DC 32 to 37 seconds 3 to 4 seconds Secondary Boom Up/Down Controller Adjustments Electrocution hazard. Record the maximum voltage reading. 14 Start a timer and simultaneously move the control handle all the way to the UP position.hi range Cycle time Primary boom down . 9 Start a timer and record how long it takes for the secondary boom to fully raise. a b c d e f g h i j ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" activates hi range (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot 3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. 52709 Genie Z-45/25 & Genie Z-45/25J 7-5 .5V DC. then move the control handle all the way to the DOWN position. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. then slowly move the control handle off center until the moment a voltage reading appears.5V DC. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. Adjust the voltage to 6. 8 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. See 12-2.Function Manifold. 4 Connect the red (+) lead from a volt meter to the “A” terminal on the controller printed circuit board. If the function cycle time is not achievable. check the relief valve pressure. a b c d e f g h i j 6 Set the hi range: Press down the foot switch. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Adjust the dual range trimpot to achieve an 23 to 27 second cycle time. then move the control handle all the way to the UP position. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Set the lo range: Press down the foot switch.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM CONTROLS 2 Open the platform control box lid and locate the secondary boom up/down controller. Valve Adjustments . Adjust the voltage to 2. Connect the black (-) lead to ground. 10 Start a timer and record how long it takes for the secondary boom to fully lower. 5 Set the threshold: Press down the foot switch. 12 Pull out the Emergency Stop button to the ON position. Adjust the max-out trimpot to achieve a 23 to 27 second cycle time. Part No. 11 Turn the engine off.85V DC. Adjust the voltageto 5. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13. Contact with electrically charged circuits could result in death or serious injury. Remove all rings. 52709 . Secondary boom up/down specifications Threshold Secondary boom up .6 to 14.5V DC output. Record the maximum voltage reading. Do not start the engine. watches and other jewelry. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time. 7-6 Genie Z-45/25 & Genie Z-45/25J Part No. Note how long it takes to reach the maximum voltage recorded in step 14. 14 Start a timer and simultaneously move the control handle all the way to the UP position.hi range Cycle time Secondary boom down .85V DC 6. This is the ramp rate.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM CONTROLS 13 Press down the foot switch and then move the control handle all the way to the UP position. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls.5V DC 23 to 27 seconds 5.lo range Cycle time Ramp rate 2.5V DC 40 seconds 3 to 4 seconds Turntable Rotation Controller Adjustments Electrocution hazard. 15 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. 52709 Genie Z-45/25 & Genie Z-45/25J 7-7 . Connect the black (-) lead to ground. 5 Set the threshold: Press down the foot switch.5V DC. Adjust the voltage to 5. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM CONTROLS 2 Open the platform control box lid and locate the turntable rotation controller. Rotate the turntable to the FULL RIGHT position. 8 Start a timer and record how long it takes the turntable to rotate to the FULL LEFT position. then move the control handle all the way to the left or right. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. Refer to the platform control box illustration. fully retract the boom. Adjust the voltage to 2. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Turntable rotation specifications Threshold Turntable rotation hi range Cycle time Ramp rate 2. 9 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. 4 Connect the red (+) lead from a volt meter to the “A” terminal on the controller printed circuit board. a b c d e f g h i j 6 Set the hi range: Press down the foot switch. 5.5V DC 73 to 78 seconds 5 seconds Part No.85V DC. page 7-2.85V DC a b c d e f g h i j ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" (not used) (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot 3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. 7 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). Adjust the max-out trimpot to achieve a 73 to 78 second cycle time. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time. then slowly move the control handle off center until the moment a voltage reading appears. It senses engine rpm from the alternator. Ford models: Perform this procedure in gasoline mode. Contact with electrically charged circuits could result in death or serious injury.5 to 14. a How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure. Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12. thereby reducing pump output to maintain optimum engine rpm and horsepower. The horsepower limiter board senses drops in rpm normally due to increased drive resistance (rough terrain or incline). Electrocution hazard. OR see B-10 for Ford and Deutz Engine Models.5V DC output. Check and Adjust the Engine RPM. See Maintenance Procedure A-22.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM CONTROLS 1-2 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output. for Perkins Diesel Models. Three adjustments are required for optimum performance. watches and other jewelry. Platform control box a horsepower limiter board 7-8 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Remove the fasteners from the platform control box lid. and decreases voltage to the drive controller which in turn decreases voltage to the drive pump. 52709 . Remove all rings. 2 Open the control box lid and locate the horsepower limiter board. all models Voltage setting 9 to 10V DC Part No. and the red (+) lead to the number 10 terminal. then drive the machine and observe how the engine rpm reacts to drive control handle movement. Under an extreme load. b c Horsepower limiter board a "A" potentiometer maximum voltage output to the controller in the stowed position "B" potentiometer maximum voltage output to the drive controller in the boom raised or extended position "C" potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm b c 4 Start the engine from the platform controls. 8 Press down the foot switch and then adjust the "C" potentiometer to obtain a 0. a 12V DC or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller 7 Move the engine idle control switch to low idle (turtle symbol). 5 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). If the engine surges or hunts. The "C" potentiometer adjustment is a compromise between engine stability (surging) and engine rpm drop. 6 Press down the foot switch and adjust the "A" potentiometer counterclockwise to increase voltage or clockwise to decrease voltage. 52709 Genie Z-45/25 & Genie Z-45/25J 7-9 . 11 Be sure that the boom is in the stowed position. 12 Disconnect the volt meter.5V DC voltage reading.1V DC to 0. 13 Raise the primary boom above horizontal.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM CONTROLS 3 Connect the black (-) lead from a DC volt meter to the number 2 terminal. 10 Press down the foot switch and re-adjust the "A" potentiometer to the previous voltage setting in step 6. adjust the "C" potentiometer counterclockwise until surging is minimized. an excessive counterclockwise adjustment to the "C" potentiometer will cause the engine to stall. 9 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). "A" potentiometer specifications . Standard Base Models Drive speed. 16 Close the platform control box lid and install the fasteners. Narrow Base Models 7 . 1 Remove the foot switch cover plate fasteners from the platform. boom raised or extended.2 m/45 sec 0.10 Genie Z-45/25 & Genie Z-45/25J Part No. Drive speed.36 mph 0. Repeat this step in the opposite drive direction.7 sec 12.2 m/79 sec 1-3 Foot Switch How to Test the Foot Switch Perform this procedure with the keyswitch in the OFF position.2 m/5. 52709 .6 mph 1 km/h 40 ft/45 sec 12.2 m 40 ft/5. Drive speed specifications Stowed position drive speed: All models distance: 40 ft/12. Connect the leads from an ohmmeter or continuity tester to each terminal combination listed and check for continuity. 3 Remove the foot switch mounting fasteners that attach the foot switch to the foot switch guard. Turn the "B" potentiometer counterclockwise to decrease voltage or clockwise to increase voltage. 2 Remove the foot switch guard mounting fasteners from the platform.58 km/h 40 ft/79 sec 12. 5 Do not press down the foot switch. 15 Adjust the "B" potentiometer to obtain the correct raised drive speed (see specifications below). 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals. boom raised or extended.7 sec 0.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM CONTROLS 14 Drive the machine for 40 feet (12 m) and record the elapsed time. O. to N. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . C to N. Connect the leads from an ohmmeter or continuity tester to each terminal combination listed below and check for continuity.C.O.O. Part No. N.11 . to C Desired result continuity (zero Ω) no continuity (infinite Ω) no continuity (infinite Ω) 1-4 Toggle Switches Toggle switches used for single function switching are single pole double throw (SPDT) switches. Test N.O. 6 Press down the foot switch.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM CONTROLS Test N.C.C. to C Desired result no continuity (infinite Ω) no continuity (infinite Ω) continuity (zero Ω) N.C. 1 Turn the key switch to the OFF position. A simple continuity tester may not accurately test the switch. This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches. Tag and disconnect all wiring from the toggle switch to be tested. How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms. Dual function switching requires a double pole double throw (DPDT) switch. to N. C to N. 4. 52709 . 4. 5 & 6 terminal 3 to 4.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM CONTROLS 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed to check for continuity.12 Genie Z-45/25 & Genie Z-45/25J Part No. 4. 5 & 6 terminal 2 to 3. 5 & 6 terminal 4 to 5 terminal 4 to 6 terminal 5 to 6 continuity (zero W) no continuity (infinite W) no continuity (infinite W) no continuity (infinite W) continuity (zero W) no continuity (infinite W) no continuity (infinite W) 7 . 3. 5 & 6 Desired result Left Center Right no continuity (infinite W) continuity (zero W) no continuity (infinite W) no continuity (infinite W) no continuity (infinite W) continuity (zero W) terminal 2 to 3 terminal 2 to 4. 5 & 6 terminal 3 to 4. 5 & 6 1 2 3 1 2 3 1 2 3 terminal 4 to 5 & 6 terminal 5 to 6 Single pole double throw (SPDT) Double pole double throw (DPDT) 1 4 2 5 3 6 1 4 2 5 3 6 1 4 2 5 3 6 Center position There are no terminal combinations that will produce continuity (infinite W) 1 2 3 1 2 3 1 2 3 Right position terminal 1 to 2 terminal 1 to 3. Test Left position terminal 1 to 2. First Edition • Second Printing Section 7 • Repair Procedures Platform Components 2-1 Platform How to Remove the Platform 1 Remove the foot switch cover plate from the platform. 4 Remove the platform control box mounting fasteners. 5 Raise the primary boom slightly and place blocks under the platform. Then lower the control box and set it aside. 2 Remove the foot switch guard mounting fasteners from the platform. Do not rest the entire weight of the boom on the blocks. The platform may become unstable and fall if it is not properly supported. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 3 Remove the footswitch and guard through the back of the platform through the access hole and set it aside. the airline must be disconnected from the platform before removal. 6 Remove the platform mounting fasteners and remove the platform from the machine.13 . If your machine is equipped with an airline to platform option. Crushing hazard. Then lower the primary boom until the platform is resting on the blocks just enough to support the platform. Part No. 14 Genie Z-45/25 & Genie Z-45/25J Part No. Do not remove the pin. Z-45/25 Models: Tag. Do not allow oil to squirt or spray.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM COMPONENTS 2-2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. Z-45/25 Models: Remove the pin retaining fastener from the slave cylinder barrel-end pivot pin. Bodily injury hazard. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Do not rest the entire weight of the boom on the blocks. The slave cylinder keeps the platform level through the entire range of boom motion. disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the jib/rotate manifold and connect them together using a connector. Connect the hoses from the cylinder together using a connector. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Spraying hydraulic oil can penetrate and burn skin. It operates in a closed-circuit hydraulic loop with the master cylinder. How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered. Spraying hydraulic oil can penetrate and burn skin. Hydraulic Hose and Fitting Torque Specifications. 1 Z-45/25J Models: Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. 5 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. disconnect and plug the hydraulic hoses from the slave cylinder and connect the hoses together using a connector. Then pull the slave cylinder hoses out through the primary extension boom. 7 . 4 Z-45/25J Models: Tag. 6 Z-45/25J Models: Remove the external snap rings from the barrel-end pivot pin. bleed the slave cylinder to be sure there is no air in the closed loop. Do not allow oil to squirt or spray. Cap the fittings on the cylinder. Bodily injury hazard. 2 Raise the primary boom slightly and place blocks under the platform for support. 52709 . When removing a hose assembly or fitting. Refer to Section Two. Do not remove the pin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Component damage hazard. How to Bleed the Slave Cylinder Do not start the engine. 1 Remove the platform. How to Remove the Platform Rotator Component damage hazard. When removing a hose assembly or fitting. Crushing hazard. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . The slave cylinder rod may become damaged if it is allowed to fall if it is not properly supported by the lifting device. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. helical gear assembly used to rotate the platform 160 degrees. 8 Z-45/25J Models: Support the jib boom bell crank with a suitable lifting device. Refer to Section Two. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment.15 . If a new rotator is installed or the rotator is disassembled. 9 Use a soft metal drift to drive the rod-end pivot pin out. Use auxiliary power for all machine functions in this procedure. 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system. proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position. 10 Use a soft metal drift and drive the barrel-end pin out. See 2-1. 11 Carefully pull the cylinder out of the primary boom. How to Remove the Platform. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. 1 Raise the primary boom to a horizontal position.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM COMPONENTS 7 Support the slave cylinder with a lifting device. Hydraulic Hose and Fitting Torque Specifications. 2-3 Platform Rotator The platform rotator is a hydraulically-activated. Part No. The jib boom bell crank may fall when the slave cylinder rod-end pivot pin is removed if it is not properly supported. The platform mounting weldment may become unbalanced and fall if it is not properly supported. 8 Use a soft metal drift to drive both pins out. Do not remove the pins. Z-45/25J Models: 6 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins. 7 Support the jib boom and jib boom leveling arms with a overhead crane. 7 . 8 Use a soft metal drift to drive both pins out. The platform rotator may become unbalanced and fall if it is not properly supported. Z-45/25 Models: 6 Support the rod end of the platform leveling slave cylinder. 4 Remove the six mounting bolts from the platform mounting weldment. Crushing hazard. Cap the fittings on the manifold. The platform rotator may become unbalanced and fall if it is not properly supported. Do not apply any lifting pressure. 52709 . Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. then remove the center bolt and slide the platform mounting weldment off of the platform rotator. but do not apply any lifting pressure. 7 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin and the rotator pivot pin.Section 7 • Repair Procedures First Edition • Second Printing PLATFORM COMPONENTS 2 Tag and disconnect the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator and connect them together using a connector.16 Genie Z-45/25 & Genie Z-45/25J Part No. then remove the platform rotator from the machine. Crushing hazard. 3 Support the platform mounting weldment with a lifting device. Crushing hazard. Bodily injury hazard. Do not allow oil to squirt or spray. then remove the platform rotator from the machine. Spraying hydraulic oil can penetrate and burn skin. 5 Support the platform rotator with a lifting device. Crushing hazard. Secure the container to the boom. Crushing hazard. d a b c d c top bleed valve bottom bleed valve container clear hose b Part No. Then close the bleed valve. Then close the bleed valve. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. Keep clear of the platform during rotation. Use auxiliary power for all machine functions in this procedure. 8 Rotate the platform full right then left and inspect the bleed valves for leaks. a 4 Move the function enable toggle switch to either side and hold the platform rotate switch to the LEFT position until the platform is fully rotated. but do not remove it. 3 Open the top bleed valve on the rotator.First Edition • Second Printing Section 7 • Repair Procedures PLATFORM COMPONENTS How to Bleed the Platform Rotator This procedure will require two people.17 . then hold the switch to the RIGHT position until the platform is fully rotated to the right. Keep clear of the platform during rotation. Do not remove the bleed valve. Place the other end of the hose in a container to collect any drainage. Continue holding the switch until air stops coming out of the bleed valve. 6 Move the function enable toggle switch to either side and hold the platform rotate switch to the RIGHT position until the platform is fully rotated. 1 Move the function enable toggle switch to either side and activate the platform rotate switch to the right then the left through two platform rotation cycles. 5 Connect the clear hose to the bottom bleed valve and open the valve. Do not start the engine. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Continue holding the switch until air stops coming out of the bleed valve. 2 Connect a clear hose to the top bleed valve. Crushing hazard.Section 7 • Repair Procedures First Edition • Second Printing Jib Boom Components. Do not allow oil to squirt or spray. 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. 10 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. 6 Support the barrel end of the cylinder with a suitable lifting device. 8 Use a soft metal drift to remove the pin and let the cylinder hang down. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. 4 Attach a lifting strap from an overhead crane to the jib boom. Refer to Section Two. Do not remove the pin. Use a soft metal drift to remove the pin.18 Genie Z-45/25 & Genie Z-45/25J Part No. Bodily injury hazard. 3 Remove the hose and cable cover from the side of the jib boom. Z-45/25J Models How to Remove the Jib Boom Perform this procedure with the boom in the stowed position. See 2-3. Spraying hydraulic oil can penetrate and burn skin. How to Remove the Platform. How to Remove the Platform Rotator. Z-45/25J Models 3-1 Jib Boom. 1 Remove the platform. 9 Remove the pin retaining fastener from the jib boom pivot pin. 7 . 52709 . When removing a hose assembly or fitting. 2 Remove the platform mounting weldment and the platform rotator. Cap the fittings on the cylinder. then remove the jib boom from the primary boom bellcrank. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Hydraulic Hose and Fitting Torque Specifications. 5 Tag. See 2-1. disconnect and plug the jib boom lift cylinder hydraulic hoses. Refer to Section Two. then remove the jib boom lift cylinder from the primary boom bellcrank.First Edition • Second Printing Section 7 • Repair Procedures JIB BOOM COMPONENTS. Do not rest the entire weight of the boom on the blocks. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. 12 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. Crushing hazard. Z-45/25J MODELS 11 Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Z-45/25J Models How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Hydraulic Hose and Fitting Torque Specifications. Part No.19 . the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. When removing a hose assembly or fitting. 3-2 Jib Boom Lift Cylinder. 13 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. disconnect and plug the jib boom lift cylinder hydraulic hoses. Do not remove the pin. 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 52709 . 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Then lower one of the leveling arms to the ground. Z-45/25J MODELS 2 Tag. Tap the pin the other direction and lower the opposite leveling arm. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.20 Genie Z-45/25 & Genie Z-45/25J Part No. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not remove the pin. Do not allow oil to squirt or spray. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Remove the cylinder from the machine. Cap the fittings on the cylinder. Crushing hazard. 7 .Section 7 • Repair Procedures First Edition • Second Printing JIB BOOM COMPONENTS. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. 5 Support the jib boom lift cylinder with a lifting device. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. AV ..21 ... Platform rotate/jib boom select ....030 inch (0... 2 position 3 way . Z-45/25J MODELS 3-3 Jib Boom / Platform Rotate Manifold Components..... 4 Hex Size 1/ 8 3/16 Valve Coil Resistance Specifications Torque Valve coil specification 50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 2 position 3 way valve (schematic item AV) 5 to 7Ω Part No.... AU .... 0.... 2 SAE No... 8-10 ft-lbs (11-14 Nm) 1 1 AU AU 2 2 AV AV Plug Torque Specifications Description SAE No..........First Edition • Second Printing Section 7 • Repair Procedures JIB BOOM COMPONENTS......76 mm) .. Platform rotate circuit Solenoid valve. Z-45/25J Models 1 2 Orifice. 52709 Genie Z-45/25 & Genie Z-45/25J 7 ... 7 Tag. It can be repaired link by link without removing the cables and hoses that run through it. Refer to Section Two. Spraying hydraulic oil can penetrate and burn skin. Number each cable and its entry location at the platform control box. 7 . Contact with electrically charged circuits could result in death or serious injury. 2 Open the platform control box. Z-45/25 Models When removing a hose assembly or fitting. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom. Hydraulic Hose and Fitting Torque Specifications. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Label and disconnect each wire of the cables that enter the platform control box. Bodily injury hazard. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. watches and other jewelry. 52709 .22 Genie Z-45/25 & Genie Z-45/25J Part No. How to Remove the Cable Track.Section 7 • Repair Procedures First Edition • Second Printing Primary Boom Components 4-1 Plastic Cable Track The primary boom cable track guides the cables and hoses running up the boom. Do not pull out the hydraulic hoses. Remove all rings. Eletrocution hazard. disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. 4 Pull all of the cables out of the platform control box. 1 Locate the cables from the primary boom cable track to the platform control box. 5 Pull all of the electrical cables out of the plastic cable track. 6 Raise the primary boom to a horizontal position. Cap the fittings on the unions. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. the cable track may become unbalanced and fall when it is removed from the machine. 15 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 11 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder. Spraying hydraulic oil can penetrate and burn skin. Do not allow oil to squirt or spray. Spraying hydraulic oil can penetrate and burn skin. Component damage hazard. Do not allow oil to squirt or spray. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cables and hoses can be damaged if they are kinked or pinched.First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 8 Tag. 10 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder and connect them together using a connector. 9 Tag. If the upper and lower cable tracks are not properly secured together. Part No. Cap the fittings on the cylinder. 12 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together.23 . Bodily injury hazard. Do not allow oil to squirt or spray. 13 Remove all hose and cable clamps from the underside of the primary boom. Crushing hazard. Crushing hazard. 16 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. Cap the fittings on the manifold. Bodily injury hazard. 14 Attach a strap from an overhead crane to the cable track. disconnect and plug the hydraulic hoses from the platform leveling master cylinder. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 17 Remove the cable track from the machine and place it on a structure capable of supporting it. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Cap the fittings on the cylinder. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. The cable track may become unbalanced and fall if it is not properly attached to the overhead crane. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Hydraulic Hose and Fitting Torque Specifications. Cap the fittings on the manifold. 2 Remove the foot switch access hole cover plate fasteners. 52709 . disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Z-45/25J Models When removing a hose assembly or fitting. Spraying hydraulic oil can penetrate and burn skin. Bodily injury hazard. Do not allow oil to squirt or spray. Bodily injury hazard. 4 Remove the foot switch through the back of the platform through the access hole and set it aside. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Remove the cover plate. Refer to Section Two. Spraying hydraulic oil can penetrate and burn skin.24 Genie Z-45/25 & Genie Z-45/25J Part No. Do not allow oil to squirt or spray. Cap the fittings on the manifold. 6 Tag. 3 Remove the foot switch mounting fasteners from the platform. 7 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder at the union and connect them together using a connector. 8 Tag. 5 Remove the platform control box and set it aside. Spraying hydraulic oil can penetrate and burn skin. Do not allow oil to squirt or spray. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Connect the hoses from the cylinder together using a connector.Section 7 • Repair Procedures First Edition • Second Printing PRIMARY BOOM COMPONENTS How to Remove the Cable Track. Bodily injury hazard. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 7 . disconnect and plug the hydraulic hoses from the jib boom/platform rotate manifold. 1 Remove the platform control box mounting fasteners. 13 Remove the hose clamp on the primary boom bellcrank. 20 Use a soft metal drift to remove the primary boom lift cylinder rod-end pivot pin. Bodily injury hazard.536 kg) capacity crane to the platform end of the primary boom for support. 17 Support the rod end of the primary boom lift cylinder with a lifting device. 14 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. 11 Raise the boom to a horizontal position. the cable track may become unbalanced and fall when it is removed from the machine.25 . Crushing hazard. The primary boom lift cylinder may become unbalanced and fall if it is not properly supported by the lifting device.First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 9 Tag. Cap the fittings on the unions. Spraying hydraulic oil can penetrate and burn skin. 18 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Do not allow oil to squirt or spray. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Do not lift it. Part No. 10 Tag. Crushing hazard. 12 Remove the hose and cable cover from the side of the jib boom. disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the cylinder. disconnect and plug the hydraulic hoses from the platform leveling master cylinder. 19 Raise the primary boom slightly with the overhead crane to relieve the pressure on the primary boom lift cylinder rod-end pivot pin. Do not remove the pin. 16 Remove all hose and cable clamps from the underside of the primary boom. 15 Attach a lifting strap from an overhead 5 ton (4. If the upper and lower cable tracks are not properly secured together. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 26 Genie Z-45/25 & Genie Z-45/25J Part No. 3 Repeat steps 1 and 2 for each link. 22 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder. Component damage hazard. open the lower clip and then use a screw driver to pry the link to the side.Section 7 • Repair Procedures First Edition • Second Printing PRIMARY BOOM COMPONENTS 21 Lower the rod end of the primary boom lift cylinder approximately 12 inches (30. The cable track may become unbalanced and fall if it is not properly attached to the overhead crane. A 7 link repair section of cable track is available through the Genie Industries Service Parts Department (Genie part number 58919). 52709 . 26 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. The primary boom cable track can be damaged if it is twisted. 7 . a b a b link separation point lower clip 1 Use a slotted screwdriver to pry down on the lower clip. 2 To remove a single link. 23 Raise the rod end of the primary boom lift cylinder back into position and install the rodend pivot pin. Then install the pin retaining fastener. Crushing hazard. Cables and hoses can be damaged if they are kinked or pinched. 27 Remove the cable track from the machine and place it on a structure capable of supporting it.5 cm). How to Repair the Primary Boom Cable Track Component damage hazard. 25 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 24 Attach a strap from an overhead crane to the cable track. 3 mm) thick. See 2-3. 2 Remove the platform rotator and platform mounting weldment. Part No. Check for tight spots that may cause binding or scraping of the boom. This procedure requires specific repair skills. If the pad is more than 9/16 inch (14. How to Remove the Platform Rotator. When removing a hose assembly or fitting. lifting equipment and a suitable workshop. Always maintain squareness between the outer and inner boom tubes. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Dealer service is strongly recommended.27 . 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 4 Install the new shims under the wear pad to obtain zero clearance and zero drag. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. 2 Measure each wear pad. Perform this procedure with the boom in the stowed position.3 mm) thick. How to Remove the Primary Boom Bodily injury hazard. 5 Tighten the mounting fasteners. See 2-1. How to Remove the Platform. Replace the pad if it is less than 9/16 inch (14.First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 4-2 Primary Boom How to Shim the Primary Boom 1 Extend the primary boom until the wear pads are accessible. Refer to Section Two. 1 Remove the platform. 6 Extend and retract the primary boom through an entire cycle. shim as necessary. 3 Loosen the wear pad mounting fasteners. Hydraulic Hose and Fitting Torque Specifications. Then lower the cylinder and let it hang down. See 2-2. Use a soft metal drift to remove the pin. 13 Tag. Do not allow oil to squirt or spray. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. 19 Lower the rod end of the primary boom lift cylinder onto support blocks. See 4-1. 12 Pull the limit switch and the wiring out of the extension tube and move it out of the way. 5 Raise the primary boom to a horizontal position. How to Remove the Platform Leveling Slave Cylinder. 8 Locate the primary boom drive speed limit switch inside of the upper mid-pivot.Section 7 • Repair Procedures First Edition • Second Printing PRIMARY BOOM COMPONENTS 3 Z-45/25 Models: Remove the platform leveling slave cylinder. Do not disconnect the wiring. The boom lift cylinder and primary boom will fall unless they are properly supported. When lowering the master cylinder down. Z-45/25J Models: Remove the jib boom. disconnect and plug the primary boom extension cylinder hydraulic hoses.28 Genie Z-45/25 & Genie Z-45/25J Part No. 16 Attach a similar lifting device to the primary boom lift cylinder. Component damage hazard. How to Remove the Cable Track. Cap the fittings on the cylinder. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 17 Place support blocks under the primary boom lift cylinder. 7 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. 6 Remove the hose and cable cover from the upper mid-pivot. 18 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. 7 . be sure not to damage the master cylinder hoses or fittings. 52709 . Do not disconnect the wiring. 15 Attach a 5 ton (4. How to Remove the Jib Boom. 20 Remove the pin retaining fastener from the primary boom pivot pin. Crushing hazard. Protect the cylinder rod from damage. 4 Remove the cable track. 14 Remove the hose clamp at the pivot end of the boom. 11 Remove the primary boom extension drive speed limit switch mounting fasteners. Use a soft metal drift to remove the pin. 10 Locate the primary boom extension drive speed limit switch inside of the extension boom. 9 Remove the primary boom drive speed limit switch mounting fasteners.536 kg) overhead crane to the center point of the primary boom. See 3-1. Place the extension cylinder on blocks for support. How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced. 2 Place blocks under the barrel end of the primary boom extension cylinder for support. How to Remove the Primary Boom Extension Cylinder. 1 Remove the primary boom. See 4-2. 4 Remove and label the location of the wear pads from the platform end of the primary boom. Crushing hazard. 7 Support and slide the extension cylinder out of the base end of the extension tube. Use a soft metal drift to remove the pin. The extension cylinder can be removed without completely disassembling the boom. then carefully remove the primary boom from the machine and place it on a structure capable of supporting it. During removal. The extension cylinder may become unbalanced and fall when it is removed from primary boom extension tube if it is not properly supported. Part No. the boom and may become unbalanced and fall when it is removed from the machine. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . the overhead crane strap will need to be carefully adjusted for proper balancing. 6 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. 3 Remove the pin retaining fastener from the extension cylinder barrel-end pivot pin at the pivot end of the primary boom. How to Remove the Primary Boom. Pay careful attention to the location and amount of shims used with each wear pad. See 4-4.First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 21 Remove the primary boom pivot pin with a soft metal drift. 5 Support and slide the extension tube out of the boom tube. The primary boom extension tube may become unbalanced and fall when it is removed from the primary boom tube if it is not properly supported.29 . Crushing hazard. Crushing hazard. Use a soft metal drift to remove the pin. During removal. If the overhead crane is not properly attached. the overhead crane strap will need to be carefully adjusted for proper balancing. Crushing hazard.30 Genie Z-45/25 & Genie Z-45/25J Part No. Refer to Section Two. 6 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. 9 Remove the primary boom lift cylinder barrelend pivot pin retaining fasteners. Cap the fittings on the cylinder. 52709 . 3 Attach a 5 ton (5000 kg) overhead crane to the primary boom for support. Carefully remove the primary boom lift cylinder from the machine. Do not allow oil to squirt or spray. The primary boom will fall if it is not properly supported when the primary boom rod-end pivot pin is removed. 4 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device. Bodily injury hazard. 2 Raise the secondary boom until the primary boom lift cylinder barrel-end pivot pin is above the turntable covers. lifting equipment and a suitable workshop. Crushing hazard. 5 Tag. 1 Raise the primary boom until the primary boom is horizontal. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure. Do not lift the boom. This procedure requires specific repair skills. Protect the cylinder rod from damage. The primary boom lift cylinder may fall if it is not properly supported. 8 Z-45/25J Models: Lower the lift cylinder onto the block. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. How to Remove the Primary Boom Lift Cylinder Bodily injury hazard. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. 10 Use a slide hammer to remove the barrel-end pivot pin. When removing a hose assembly or fitting. The lift cylinder may become unbalanced and fall if it is not properly supported and secured to the lifting device.Section 7 • Repair Procedures First Edition • Second Printing PRIMARY BOOM COMPONENTS 4-3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom. Use a soft metal drift to remove the pin. 7 Place a support block across both turntable covers under the primary boom lift cylinder. Dealer service is strongly recommended. Hydraulic Hose and Fitting Torque Specifications. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. disconnect and plug the primary boom lift cylinder hydraulic hoses. 7 . Spraying hydraulic oil can penetrate and burn skin. Do not remove the pin. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Bodily injury hazard. This procedure requires specific repair skills. Do not allow oil to squirt or spray. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.31 . 5 Remove the external snap rings from the extension cylinder rod-end pivot pin (at the platform end).First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 4-4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube. Part No. lifting equipment and a suitable workshop.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 2 Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube. Spraying hydraulic oil can penetrate and burn skin. Refer to Section Two. 1 Raise the primary boom to a horizontal position. Use a soft metal drift to remove the pin. Dealer service is strongly recommended. 6 Remove the barrel-end pivot pin retaining fasteners. When removing a hose assembly or fitting. Cap the fittings on the cylinder. 3 Remove the hose and cable guard from the upper pivot. 4 Tag. Hydraulic Hose and Fitting Torque Specifications. disconnect and plug the primary boom extension cylinder hydraulic hoses. How to Remove the Primary Boom Extension Cylinder Bodily injury hazard. It’s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. 1 Raise the secondary boom until both the rodend and barrel-end pivot pins on the master cylinder are accessible. Do not allow oil to squirt or spray. 4-5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder. Spraying hydraulic oil can penetrate and burn skin. disconnect and plug the master cylinder hydraulic hoses. Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them. Cap the fittings on the cylinder.32 Genie Z-45/25 & Genie Z-45/25J Part No. Component damage hazard. Note the length of the cylinder after removal. Hydraulic Hose and Fitting Torque Specifications. Crushing hazard. The extension cylinder will fall when it is removed from the extension boom if it is not properly supported.Section 7 • Repair Procedures First Edition • Second Printing PRIMARY BOOM COMPONENTS 7 Place a rod through the barrel-end pivot pin and twist to remove the pin. 7 . Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom. Component damage hazard. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Bodily injury hazard. The master cylinder is located at the base of the primary boom. 2 Tag. 8 Support and slide the extension cylinder out of the upper pivot. The cylinder must be at the same length for installation. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting. 52709 . Refer to Section Two. First Edition • Second Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 3 Attach overhead crane or similar lifting device to the master cylinder. 4 Remove the pin retaining fasteners from the master cylinder barrel-end pivot pin. Do not remove the pin. 5 Place a rod through the barrel-end pivot pin and twist to remove the pin. 7 Place a rod through the rod-end pivot pin and twist to remove the pin. 8 Remove the master cylinder from the machine. Crushing hazard. The master cylinder may become unbalanced and fall if it is not properly attached to the overhead crane. 6 Remove the pin retaining fastener from the rodend pivot pin. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 - 33 Section 7 • Repair Procedures First Edition • Second Printing Secondary Boom Components a b c j i h d e g 5-1 Secondary Boom f How to Disassemble the Secondary Boom The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required. Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps 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 lower mid-pivot e compression link f secondary boom lift cylinder (2) g lower secondary boom (number 4 arm) h turntable pivot i boom rest j upper mid-pivot 7 - 34 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 1 Remove the platform. See 2-1, How to Remove the Platform. 2 Z-45/25J Models: Remove the jib boom. See 3-1, How to Remove the Jib Boom. 3 Remove the primary boom. See 3-2, How to Remove the Primary Boom. 4 Remove the master cylinder. See 4-5, How to Remove the Master Cylinder. 5 Attach a lifting strap from an overhead crane to to the lug on the rod end of the primary boom lift cylinder. Then raise the primary boom lift cylinder with the crane, to a vertical position. 6 Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. 7 Remove the pin retaining fastener from the primary boom lift cylinder barrel-end pivot pin. 8 Use a slide hammer to remove the pin. Remove the primary boom lift cylinder from the machine. Crushing hazard. The primary boom lift cylinder may become unbalanced and fall if it is not properly supported by the overhead crane. 9 Tag, disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Remove the pin retaining fasteners from both sides of the secondary boom lift cylinder rodend pivot pin and barrel-end pivot pin. Do not remove the pins. 11 Attach a strap from an overhead crane to the lug on the rod end of one of the secondary boom lift cylinders for support. Do not apply any lifting pressure. 12 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 13 Use a soft metal drift to drive the rod-end pivot pin half way out. 14 Remove the secondary boom lift cylinder from the machine. 15 Repeat steps 10 through 13 for the other secondary boom lift cylinder. Crushing hazard. The secondary boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder. 16 Attach a lifting strap from an overhead crane to the upper mid-pivot for support. Do not lift it. 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid-point between the upper and lower mid-pivots. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 - 35 Section 7 • Repair Procedures First Edition • Second Printing SECONDARY BOOM COMPONENTS 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the lower mid-pivot and the upper mid-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 1 arm may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Crushing hazard. The upper midpivot may fall when the number 1 arm is removed from the machine if it is not properly supported by the overhead crane. 21 Using the overhead crane attached to upper mid-pivot, raise the secondary boom assembly approximately 30 inches (76 cm). 22 Insert a 4 x 4 x 11 inch (10.2 x 10.2 x 28 cm) block between the number 2 arm and the boom rest. Then lower the secondary boom assembly onto the block. Crushing hazard. The secondary boom assembly may fall if it is not properly supported by the 4 x 4 x 11 inch (10.2 x 10.2 x 28cm) block. 23 Locate the 4 cables that enter the platform control box. Number each cable and its entry location at the platform control box. 24 Open the platform control box. 25 Label and disconnect each wire of the cables that enter the platform control box. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 26 Pull all of the cables out of the platform control box. 27 Pull all of the cables and hoses out through the upper mid-pivot. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 28 Remove the hose and cable covers from the top of the number 2 arm. 29 Pull all of the hoses and cables out of the upper mid-pivot and out through the lower mid-pivot. Lay the hoses and cables on the ground. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 30 Remove the pin retaining fastener from the number 2 arm pivot pin at the upper mid-pivot. Use a soft metal drift to remove the pin. 31 Remove the upper mid-pivot from the machine. Crushing hazard. The upper midpivot may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. 7 - 36 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 32 Attach the lifting strap from an overhead crane to the number 2 arm at the upper mid-pivot end. 33 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch (10.2 x 10.2 x 28 cm) block. 34 Lower the number 2 arm onto the boom rest pad. 35 Insert a 4 x 4 x 81/2 inch (10.2 x 10.2 x 21.6 cm) block between the number 3 arm and the number 4 arm at the lower mid-pivot end. 36 Attach a lifting strap from the overhead crane to the lower mid-pivot for support. Do not lift it. 37 Remove the pin retaining fasteners from the number 2, 3 and 4 arm pivot pins at the lower mid-pivot. Do not remove the pins. 38 Use a soft metal drift to drive each pin out. Then remove the lower mid-pivot from the secondary boom assembly. Crushing hazard. The lower midpivot may become unbalanced and fall when it is removed from the secondary boom assembly if it is not properly supported by the overhead crane. 39 Attach the lifting strap from an overhead crane to the center point of the number 2 arm for support. Do not lift it. 40 Remove the pin retaining fasteners from both compression link pivot pins. Do not remove the pins. 41 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm. 42 Support the compression link with an appropriate lifting device. 43 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm. Remove the compression link from the machine. Crushing hazard. The number 2 arm may fall when the compression link is disconnected from the number 2 arm if it is not properly supported by the overhead crane. Crushing hazard. The compression link may fall if it is not properly supported when it is removed from the secondary boom assembly. 44 Remove the number 2 arm from the machine. Crushing hazard. The number 2 arm may become unbalanced and fall when it is removed from the secondary boom assembly if it is not properly supported by the overhead crane. 45 Remove the upper and lower hose and cable covers from the number 3 arm. 46 Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 - 37 Section 7 • Repair Procedures First Edition • Second Printing SECONDARY BOOM COMPONENTS 47 Open the ground controls side turntable cover. 48 Remove the fuel tank. See 13-1, How to Remove the Fuel Tank. 49 Remove the retaining fastener from the ground control box and function manifold pivot plate. 50 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin. 51 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support. Do not lift it. 52 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable pivot. 53 Remove the pin retaining fasteners from the number 3 arm at the turntable pivot. Do not remove the pin. 54 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box. 55 Remove the number 3 arm from the machine. Crushing hazard. The number 3 arm may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. 56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid-pivot end. Do not disconnect the wiring. 57 Remove the pin retaining fasteners from the number 4 arm at the turntable pivot. Do not remove the pin. 58 Attach a lifting strap from the overhead crane to the center point of the number 4 arm. Do not lift it. 59 Use a slide hammer to remove the number 4 arm from the turntable pivot through the ground controls side bulkhead. 60 Remove the number 4 arm from the machine. Crushing hazard. The number 4 arm may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. 7 - 38 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 5-2 Secondary Boom Lift Cylinders There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly. These cylinders operate in parallel and require hydraulic pressure to extend and retract. Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure. 3 Tag, disconnect and plug the hydraulic hoses on the secondary boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the pin retaining fasteners from the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do not remove the pins. 5 Attach a strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder for support. Do not apply any lifting pressure. 6 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 7 Use a soft metal drift to drive the rod-end pivot pin half way out. 8 Remove the secondary boom lift cylinder from the machine. Crushing hazard. The secondary boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder. How to Remove a Secondary Boom Lift Cylinder This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 1 Lower the secondary boom to the stowed position. 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod-end pivot pin. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 - 39 Section 7 • Repair Procedures First Edition • Second Printing Turntable Covers 6-1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover. Support and secure the open cover to an overhead crane or forklift. Do not lift it. Component damage hazard. Protect the cover from damage by using carpet or padding on the crane or fork lift forks. 2 Engine side cover: Remove the upper and lower retaining clips from the gas strut. 3 Engine side cover: Gently pry the strut pivot sockets off of the ball studs and remove the strut. Protect the strut cylinder rod from damage. 4 Engine side cover: Mark the location of the hinge on the support bracket on the cover to ensure proper cover alignment during installation. Ground controls side cover: Mark the location of the hinge on the cover to ensure proper cover alignment during installation. 5 Engine side cover: Remove the cover hinge fasteners that fasten the hinge to the support bracket on the cover. Ground controls side cover: Remove the cover hinge fasteners that fasten the hinge to the cover. 6 Carefully lift and remove the cover from the machine. Crushing hazard. The turntable cover may become unbalanced and fall if it is not properly supported and secured to a appropriate lifting device. Bodily injury hazard. If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Alignment adjustments may be necessary when a new cover is installed. 7 - 40 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 Do not force the drive pump during installation or the flex plate teeth may become damaged. f a b c d e f pump pump shaft pump coupler flex plate with raised spline engine flywheel 7/16 inch gap Part No. How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller (EDC). Torque the set screw to 45 ft-lbs (61 Nm). 2 Install the pump coupler onto the pump shaft with the set screw toward the pump. Then remove all of the pump mounting plate to engine bell housing bolts. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . located on the drive pump. then remove the flex plate from the engine flywheel. Torque the flex plate mounting bolts to 34 ft-lbs (46 Nm). Check and Adjust the Engine RPM. B-10. Leave a 7/16 inch (11 mm) gap between the pump coupler and pump end plate. 2 Support the drive pump with an appropriate lifting device. 4 Remove the flex plate mounting fasteners. 3 Apply Loctite® removable thread sealant to the pump coupler set screw.Ford and Deutz Diesel Models. 7-2 Flex Plate The flex plate acts as a coupler between the engine and the pump. 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm).41 . a b c d e How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. 3 Carefully pull the pump away from the engine and secure it from moving. Component damage hazard.First Edition • Second Printing Section 7 • Repair Procedures Deutz Engine F3L 1011F 7-1 RPM Adjustment Refer to Maintenance Procedures. Component damage hazard. then remove the cover.Section 7 • Repair Procedures First Edition • Second Printing DEUTZ ENGINE F3L 1011F 7-3 Oil Temperature and Oil Pressure Switches The oil temperature switch is a normally open switch that closes at approximately 220° F (104° C). Contact with hot engine fluids or components may result in severe burns Always use pipe thread sealant when installing a switch. Do not over tighten. When the switch closes. Do not crank the engine with the over-temperature light on. 7 . If the oil pressure drops below the switch point. Burn hazard. Do not crank the engine with the low oil pressure light on. 4 Disconnect the wiring from the desired switch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. and then install the new switch. An over-temperature indicator light at the ground controls should turn on when the switch closes. The oil pressure switch is a normally closed switch that opens at approximately 15 psi (1 bar). 3 Oil temperature switch: Remove the fasteners from the engine side cover. Component damage hazard. Oil temperature switch specifications Torque Hex size Temperature switch point Oil pressure switch specifications Torque Hex size Oil pressure switch point 15 psi 8-18 ft-lbs 11-24 Nm 1-1/16 inch 1 bar 8-18 ft-lbs 11-24 Nm 13/16 inch 220° F (104° C) How to Remove the Oil Temperature and Oil Pressure Switches Perform this procedure with the engine off. the switch opens and shuts off the engine to prevent damage. 52709 . 5 Remove the switch from the engine block. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. A low oil pressure indicator light at the ground controls should turn on when the switch opens. the engine will shut off to prevent damage and will not start until the temperature drops below the switch point.42 Genie Z-45/25 & Genie Z-45/25J Part No. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller (EDC). Check and Adjust the Engine RPM. 3 Apply Loctite® removable thread sealant to the pump coupler set screw. It is bolted to the engine flywheel and has a splined center to drive the pump. Torque the set screw to 45 ft-lbs (61 Nm). Leave a 1/16 inch (1.43 . 3 Carefully pull the pump away from the engine and secure it from moving. Component damage hazard.5 mm) gap Part No. A-22. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Do not force the drive pump during installation or the flex plate teeth may become damaged. 4 Remove the flex plate mounting fasteners. located on the drive pump. 8-2 Flex Plate The flex plate acts as a coupler between the engine and the pump. 2 Support the drive pump with an appropriate lifting device.5 mm) gap between the pump coupler and pump end plate. f a b c d e f pump pump shaft coupler flex plate with raised spline flywheel 1/16 inch (1. 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Then remove all of the pump mounting plate to engine bell housing bolts. Torque the flex plate mounting bolts to 34 ft-lbs (46 Nm). a b c d e How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump.First Edition • Second Printing Section 7 • Repair Procedures Perkins 104-22 Engine 8-1 RPM Adjustment Refer to Maintenance Procedures. 2 Install the pump coupler onto the pump shaft with the set screw toward the pump. then remove the flex plate from the engine flywheel. 2 psi (0. Always use pipe thread sealant when installing a sending unit.3 bar 7 . 2 Install the new sending unit. Do not over tighten. When the contacts close. Engine oil pressure will be indicated on the gauge when the engine is running. When the contacts close. Engine coolant temperature will be indicated on the gauge when the key is ON and the Emergency Stop Button is pulled out to the ON position.44 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 . Component damage hazard. Water temperature sending unit specifications Torque Hex size Temperature switch point 8-18 ft-lbs 11-24 Nm 7 /8 inch 221° F (105° C) Oil pressure sending unit specifications Torque Hex size Oil pressure switch point 4.3 bar). 1 Tag and disconnect the wiring from the desired sending unit. Do not crank the engine with the low oil pressure light on. How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off. The engine oil presure sending unit has limit contacts that are factory set.Section 7 • Repair Procedures First Edition • Second Printing PERKINS 104-22 ENGINE 8-3 Coolant Temperature and Oil Pressure Gauges The engine coolant temperature gauge is an electrical gauge. Contact with hot engine fluids or components may result in severe burns. the engine will shut off to prevent damage and will not start until the temperature drops below the contact point. The engine coolant temperature sending unit has limit contacts that are factory set.2 psi 8-18 ft-lbs 11-24 Nm 7 /8 inch 0. The engine oil pressure gauge is an electrical gauge. Remove the sending unit from the engine block. Burn hazard. The contacts will close at approximately 221o F (105o C). The contacts will close at approximately 4. Do not crank the engine with the over-temperature light on. the engine will shut off to prevent damage. 3 Connect the wires to the new sending unit. Component damage hazard. If timing adjustment or service is required. 9-3 Flex Plate The flex plate acts as a coupler between the engine and the pump. a b c d e f f pump pump shaft pump coupler flex plate with raised spline engine flywheel 1/16 inch (1.First Edition • Second Printing Section 7 • Repair Procedures Ford LRG-425 EFI Engine 9-1 Timing Adjustment The ignition timing is controlled by the ECM and can only be adjusted by re-programming the ECM. please contact Genie Industries Service Department OR your local Ford dealer.5 mm) gap Flex Plate Removal 1 Disconnect the wiring plug at the electronic displacement controller (EDC). 2 Support the drive pump with an appropriate lifting device.45 . 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Part No. Check and Adjust the Engine RPM. a b c d e 9-2 RPM Adjustment Refer to Maintenance Procedures.Ford and Deutz Diesel Models. located on the drive pump. Then remove all of the pump mounting plate to engine bell housing bolts. It is bolted to the engine flywheel and has a splined center to drive the pump. B-10. Leave a 1/16 inch (1.34 bar). 52709 . If the oil pressure drops below the switch point. The oil pressure switch is a normally closed switch that opens at approximately 3 to 5 psi (0. Torque the flex plate mounting bolts to 34 ft-lbs (46 Nm). The check engine light will turn on. 7 . Component damage hazard. 4 Remove the flex plate mounting fasteners. then remove the flex plate from the engine fly wheel. the switch opens and shuts off the engine to prevent damage. See Repair Procedure 10-5. How to Retrieve Engine Fault Codes. Component damage hazard. 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). 9-4 Water Temperature and Oil Pressure Switches The water temperature switch is a normally open switch that closes at approximately 230° F (112° C).5 mm) gap between the pump coupler and pump end plate. Torque the set screw to 45 ft-lbs (61 Nm).46 Genie Z-45/25 & Genie Z-45/25J Part No. 2 Install the pump coupler onto the pump shaft with the set screw towards the pump.21 to 0. Component damage hazard. The check engine light will turn on. Component damage hazard. How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. Hoses can be damaged if they are kinked or pinched. Do not continue to run the engine with the check engine light on. When the switch closes. How to Retrieve Engine Fault Codes. Do not force the drive pump during installation or the flex plate teeth may become damaged. See Repair Procedure 10-5.Section 7 • Repair Procedures First Edition • Second Printing FORD LRG-425 EFI ENGINE 3 Carefully pull the pump away from the engine and secure it from moving. Do not continue to run the engine with the check engine light on. the engine will shut off to prevent damage and will not start until the temperature drops below the switch point.1 3 Apply Loctite® removable thread sealant to the pump coupler set screw. Water temperature switch specifications Torque Hex size Temperature switch point Oil pressure switch specifications Torque Hex size Oil pressure switch point 3-5 psi 8-18 ft-lbs 11-24 Nm 1-1/16 inch 0. 1 Open the engine side turntable cover and locate the water temperature and oil pressure switches. 52709 Genie Z-45/25 & Genie Z-45/25J 7 .21-0.47 . 2 Disconnect the wiring from the desired switch. and then install the new switch. Contact with hot engine fluids or components may result in severe burns Always use pipe thread sealant when installing a switch.First Edition • Second Printing Section 7 • Repair Procedures FORD LRG-425 EFI ENGINE How to Remove the Water Temperature and Oil Pressure Switches Perform this procedure with the engine off. 3 Remove the switch from the engine block. Burn hazard. Do not over tighten.34 bar 8-18 ft-lbs 11-24 Nm 13/16 inch 230° F (112° C) Part No. 87a . watches and other jewelry.N.common terminal no.Section 7 • Repair Procedures First Edition • Second Printing Ground Controls 10-1 Control Relays Relays used for single function switching are single pole double throw (SPDT) relays. Test terminal 87 to 87a & 30 Desired result no continuity (infinite Ω) continuity (zero Ω) How to Test a Single Pole Double Throw Relay Electrocution hazard.N. Test terminal 85 to 86 terminal 87 to 87a & 30 Desired result 75 to 85Ω no continuity (infinite Ω) continuity (zero Ω) terminal 87 to 30 terminal no. Terminals 85 and 86 represent the coil and should not be tested in any other combination. 87 .C. 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. 1 Label and then disconnect all the wiring from the relay to be tested. Remove all rings. Control Relay Schematic terminal 87a to 30 7 . Contact with electrically charged circuits could result in death or serious injury. 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86. 85 .coil terminal no.O. 30 .ground terminal no. 52709 .48 Genie Z-45/25 & Genie Z-45/25J Part No. 86 . terminal no. then test the following terminal combinations. 4 Use a small screwdriver to gently pry up on the tab of the component and remove it.First Edition • Second Printing Section 7 • Repair Procedures GROUND CONTROLS 10-2 Toggle Switches See 1-5. watches and other jewelry. Toggle Switches. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 1 Label the wiring from the component to be removed.49 . Contact with electrically charged circuits could result in death or serious injury. 2 Use a small screwdriver to push in and release the wire from the component. Wago® tools are available from the Genie Service Parts Department (Genie part number 33996). 3 Locate the removal tab on the bottom or top of the component. 10-3 Wago® Components Electrocution hazard. Part No. Remove all rings. Once a fault code has been retrieved and the repair has been completed. 3 Pull out the ground controls red Emergency Stop button to the ON position. The ECM is able to store up to six individual fault codes. Use the following procedure to retrieve the engine fault code to determine the engine malfunction.Section 7 • Repair Procedures First Edition • Second Printing GROUND CONTROLS 10-4 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes When a engine malfunction is detected by the Electronic Control Module (ECM).2 seconds and then blinks 1 time. 7 . Fault codes are two digits.2 seconds and then blink the second digit. See 10-5. 5 Continue to hold the run/test toggle switch in the test position and count the blinks. That would indicate code 51. 1 Open the ground controls side turntable cover. Result: The check engine light should turn on.50 Genie Z-45/25 & Genie Z-45/25J Part No. 52709 . How to Clear Engine Fault Codes. Perform this procedure with the key switch in the OFF position. 6 Refer to the Troubleshooting Section for definition of engine fault codes.4 second pause between codes. The check engine light should begin to blink. 4 Hold the run/test toggle switch to the test position and turn the key switch to the ground controls position. a fault code is recorded and the check engine light will turn ON at the ground and platform controls. The check engine light will blink the first digit of a two digit code then will pause for 1. There will be a 2. the ECM memory must be reset to clear the fault code from the ECM. 2 Locate the run/test toggle switch located on the left side of the ground control box. For example: the check engine light blinks 5 consecutive times then pauses for 1. 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes.51 . watches and other jewelry. Part No.First Edition • Second Printing Section 7 • Repair Procedures GROUND CONTROLS How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the OFF position. Remove all rings. Contact with electrically charged circuits could cause death or serious injury. 3 Connect the negative battery cable to the battery. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 1 Open the engine side turntable cover and locate the battery. Electrocution hazard. disconnect and plug the lift/steer pump hydraulic hoses. Cap the fittings on the pump.52 Genie Z-45/25 & Genie Z-45/25J Part No.Section 7 • Repair Procedures First Edition • Second Printing Hydraulic Pumps 11-1 Lift/Steer Pump How to Remove the Lift/Steer Pump When removing a hose assembly or fitting. open closed Component damage hazard. then close the valves. Component damage hazard. If the tank valves are closed. 7 . Carefully remove the pump. 3 Remove the pump mounting bolts. 1 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Spraying hydraulic oil can penetrate and burn skin. 52709 . remove the key from the key switch and tag the machine to inform personnel of the condition. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. Hydraulic Hose and Fitting Torque Specifications. Do not allow oil to squirt or spray. 2 Tag. Refer to Section Two. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Bodily injury hazard. Dealer service is recommended. 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 1 Disconnect the electrical connection at the electronic displacement controller (EDC) located on the drive pump. Component damage hazard. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. Any internal service to the pump should only be performed at an authorized Sundstrand-Sauer service center. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Part No. Bodily injury hazard.First Edition • Second Printing Section 7 • Repair Procedures HYDRAULIC PUMPS 11-2 Drive Pump The drive pump is a bi-directional variable displacement piston pump. 4 Support the pump with a lifting device and remove the two drive pump mounting fasteners. open closed How to Remove the Drive Pump Component damage hazard. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. then close the valves. remove the key from the key switch and tag the machine to inform personnel of the condition. When removing a hose assembly or fitting. Hydraulic Hose and Fitting Torque Specifications. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Refer to Section Two. The pump output is controlled by the electronic displacement controller (EDC). Call Genie Industries Service Department to locate your local authorized service center. located on the pump. 3 Tag and disconnect and plug the hydraulic hoses from the drive and lift/steer pumps. Do not allow oil to squirt or spray. Cap the fittings on the pumps. The only adjustment that can be made to the pump is the neutral or null adjustment.53 . Spraying hydraulic oil can penetrate and burn skin. If the tank valves are closed. Perkins Diesel models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump. How to Prime the Pump 1 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 the engine pivot plate latch. Component damage hazard. a a manual fuel shutoff valve 7 . The hydraulic pump may become unbalanced and fall if it is not properly supported. 4 Ford models: Close the valve on the LPG tank then disconnect the hose from the tank. Component damage hazard. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 52709 . Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.Section 7 • Repair Procedures First Edition • Second Printing HYDRAULIC PUMPS 6 Remove the drive pump from the machine. Deutz Diesel models: Hold the manual fuel shutoff valve clockwise to the CLOSED position.54 Genie Z-45/25 & Genie Z-45/25J Part No. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Then move the fuel select switch to the LPG position. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 7 Start the engine from the ground controls and check for hydraulic leaks. wait 15 seconds.55 .First Edition • Second Printing Section 7 • Repair Procedures HYDRAULIC PUMPS 5 Have another person crank the engine with the starter motor for 15 seconds. Perkins Diesel models: Connect the engine wiring harness to the fuel solenoid. This page intentionally left blank. 6 Ford models: Connect the LPG hose to the LPG tank and open the valve on the tank. then crank the engine an additional 15 seconds or until the pressure reaches 320 psi (22 bar). ....... Turntable rotate left/right ...... D ..... 10-12 ft-lbs (14-6 Nm) Relief valve. Please turn the page Plug Torque Specifications Description SAE No... 1800 psi (124 bar) ........... 1........ Index No.......... 10-12 ft-lbs (14-16 Nm) Flow regulator valve ..... Primary boom up/down (prevents overflowing the proportional valve) ....... 52709 ......................7 L/min) . Secondary boom up/down (prevents overflowing the proportional valve) .... 2 Hex size 1/8 Torque 50 in-lbs (6 Nm) SAE No... F .......................... Secondary boom up/down ................... B .....Section 7 • Repair Procedures First Edition • Second Printing Manifolds 12-1 Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover..5 gpm (5........................ I .... 10-12 ft-lbs (14-16 Nm) Flow regulator valve ................... 25-30 ft-lbs (34-41 Nm) Priority flow regulator valve.... C ................... 11-13 ft-lbs (15-18 Nm) Relief valve................................6 bar) .......... Turntable rotate left/right (prevents overflowing the proportional valve) ............... 10-12 ft-lbs (14-6 Nm) 4 5 6 7 8 9 This list continues... G . System relief . E ..... A ............................... Secondary boom down .. 6 3/16 1/4 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 7 ....................... 10-12 ft-lbs (14-16 Nm) Proportional solenoid valve .................................. Steer left/right circuit . H ................................... 10-12 ft-lbs (14-6 Nm) Check valve . Differential sensing circuit..... secondary boom up/down ..56 Genie Z-45/25 & Genie Z-45/25J Part No.......... 3200 psi (220. 35-40 ft-lbs (47-54 Nm) Flow regulator valve .............................................. 1 2 3 Description Schematic Item Function Torque Proportional solenoid valve .............................. 4 SAE No....... 52709 Genie Z-45/25 & Genie Z-45/25J 7 .First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No.57 . ... Bleeds off check valves in differential sensing circuits to tank ...... S .6 L/min) .. 2 Hex size 1/8 Torque 50 in-lbs (6 Nm) SAE No............ 11-13 ft-lbs (15-18 Nm) Check valve ........ primary boom retract . 11-13 ft-lbs (15-18 Nm) Counterbalance valve .. 11-13 ft-lbs (15-18 Nm) Check valve .............................................. Differential sensing circuit...........Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS Function Manifold Components.............. Differential sensing circuit............ Primary boom extend ................... O ....................... Platform level up ........... continued Index No......................... 1 gpm (3................... 35-40 ft-lbs (47-54 Nm) Solenoid valve....... 25-30 ft-lbs (34-41 Nm) Solenoid valve... 6 3/16 1/4 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 7 ...... W ................................ 10-12 ft-lbs (14-16 Nm) Check valve .................. Differential sensing circuit............. 2300 psi (158................ jib boom up/platform rotate left .......... 35-40 ft-lbs (47-54 Nm) Counterbalance valve ................. L .................... Platform level down ........ 4 SAE No... 11-13 ft-lbs (15-18 Nm) Check valve .......................................... 25-30 ft-lbs (34-41 Nm) Solenoid valve..................... Please turn the page Plug Torque Specifications Description SAE No...... P ............ Q . Primary boom retract ................. 11-13 ft-lbs (15-18 Nm) 16 17 18 19 20 21 22 23 This list continues....38 L/min) ..........................1 gpm (0. 10-12 ft-lbs (14-16 Nm) Flow regulator valve... Primary boom extend/retract circuit ...........8 L/min) ................... 25-30 ft-lbs (34-41 Nm) Flow regulator valve............... N ........... 10-12 ft-lbs (14-16 Nm) Flow regulator valve........ platform level up .....6 bar) ....................................... 2 gpm (7......................... Differential sensing circuit.. 25-30 ft-lbs (34-41 Nm) Check valve .............................. T .................. J ....... 3 position 4 way .... platform level down ...... 52709 ................. K ........... Platform level up/down ... V .58 Genie Z-45/25 & Genie Z-45/25J Part No.. 0............. 2 position 3 way ..... R .. Differential sensing circuit...... M .... U ................. jib boom down/platform rotate right ........... 10 11 12 13 14 15 Description Schematic Item Function Torque Relief valve...... Primary boom down . 2 position 3 way .......... Platform level circuit . 59 .First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . ..................... 3 position 4 way .......... FF ................ 25-30 ft-lbs (34-41 Nm) Solenoid valve............ Y ...... 3 position 4 way .................... II .. 11-13 ft-lbs (15-18 Nm) Check valve ........ 2 Hex size 1/8 Torque 50 in-lbs (6 Nm) SAE No.....................3 L/min) ..................................................040 in (1 mm) ............... KK ...................... Differential sensing circuit... 11-13 ft-lbs (15-18 Nm) Check valve ......60 Genie Z-45/25 & Genie Z-45/25J Part No........... Turntable rotate left/right ............ Meters flow to functions ................... AA ............ CC .... 25-30 ft-lbs (34-41 Nm) Orifice......... 25-30 ft-lbs (34-41 Nm) Flow regulator valve.... Z .................... 0....................... 3 position 4 way .. primary boom extend .................. 11-13 ft-lbs (15-18 Nm) Diagnostic nipple . 25-30 ft-lbs (34-41 Nm) Solenoid valve............ continued Index No...............Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS Function Manifold Components....................... Testing port Proportional solenoid valve .. Primary boom up/down .............................. 25-30 ft-lbs (34-41 Nm) Differential sensing valve ...... 6 3/16 1/4 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 7 ..... 3 position 4 way ................ turntable rotate left/right ....... Differential sensing circuit.... EE ........ Jib boom up/down and platform rotate left/right ...... BB . 10-12 ft-lbs (14-16 Nm) Solenoid valve............... 4 SAE No......... JJ .... Secondary boom up/down ................ 24 25 26 27 28 29 Description Schematic Item Function Torque Check valve . primary boom up/down ................ Differential sensing circuit.............. 25-30 ft-lbs (34-41 Nm) Check valve ......... Primary boom up/down .......... Testing Solenoid valve.....6 gpm (2. X ................ 52709 .... 10-12 ft-lbs (14-16 Nm) Diagnostic nipple ................... GG ..... DD ........ HH ........ LL .............. Secondary boom circuit ................ Steer left/right ..... Secondary boom circuit Solenoid valve................ 3 position 4 way ................. Jib boom up/down and platform rotate left/right . 0...................... 10-12 ft-lbs (14-16 Nm) 30 31 32 33 34 35 36 37 38 Plug Torque Specifications Description SAE No...................... First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No.61 . 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Observe the pressure reading on the pressure gauge. 4 Turn the engine off. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 2 Start the engine from the ground controls. Then install the relief valve cap. 7 . 52709 . Primary boom down relief valve specifications Pressure 2300 psi 158. Observe the pressure reading on the pressure gauge. 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the retract switch with the boom fully retracted. 6 Repeat steps 2 through 5 and recheck relief valve pressure. Do not adjust the relief valve higher than specified.6 bar How to Adjust the Primary Boom Down Relief Valve (before serial number 11819) Perform this procedure with the boom in the stowed position. 5 Adjust the internal hex socket. Tip-over hazard. Use a wrench to hold the relief valve and remove the cap (item 10). 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the primary boom down switch with the primary boom fully lowered.62 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 2 Start the engine from the ground controls. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Do not adjust the relief valve higher than specified. Then install the relief valve cap.6 bar 4 Turn the engine off. System relief valve specifications Pressure 3200 psi 220. 6 Repeat steps 2 through 5 and recheck relief valve pressure. 5 Adjust the internal hex socket. Tip-over hazard. Use a wrench to hold the relief valve and remove the cap (item 8).Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position. 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the secondary boom down switch with the secondary boom fully lowered. Use a wrench to hold the relief valve and remove the cap (item 5). 52709 Genie Z-45/25 & Genie Z-45/25J 7 . GG and II) 2 position 3 way solenoid valve. Tip-over hazard. 10V (schematic items S. 2 Start the engine from the ground controls. B and LL) 3 position 4 way directional valve. BB. FF. 10V (schematic items K and L) 4 to 5Ω 5 to 7Ω 5 to 7Ω 4 Turn the engine off. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Observe the pressure reading on the pressure gauge.First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position. DD. Secondary boom down relief valve specifications Pressure 1800 psi 124 bar Valve Coil Resistance Specifications Valve coil specifications Proportional solenoid valve. Part No. 6 Repeat steps 2 through 5 and recheck relief valve pressure. 5 Adjust the internal hex socket. Do not adjust the relief valve higher than specified.63 . Then install the relief valve cap. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 12V (schematic items A. .............Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-3 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment.......... OO ............. 1 2 3 Schematic Item Description Function Torque Shuttle valve 2 position 3 way ...... 35-40 ft-lbs (47-54Nm) Counterbalance valve ..... Turntable rotate left .......... 10-13 ft-lbs (14-18 Nm) Counterbalance valve ...64 Genie Z-45/25 & Genie Z-45/25J Part No.. Turntable rotate right ........... 2 SAE No.. Index No........................... MM . Turntable rotation brake release .... 52709 ..... 35-40 ft-lbs (47-54Nm) 1 2 3 NN OO MM Plug Torque Specifications Description SAE No......... 4 SAE No.. 6 Hex size 1/8 3/16 1/4 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 7 ............ NN ............ ......First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS 12-4 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non-steer end......................................65 .................................................................. 20-25 ft-lbs (27-33 Nm) Spool valve .......... Breather ..... Directional control 1 2 Part No.... Index No..... 52709 Genie Z-45/25 & Genie Z-45/25J 7 .................... 1 2 Description Function Torque Cap ................ 5 Place a "bubble type" level across the drive chassis non-steer end. 6 To level the drive chassis.66 Genie Z-45/25 & Genie Z-45/25J Part No. 10 Check to be sure the drive chassis is completely level. If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level. 11 Measure the distance between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis). 8 Verify that the ground and drive chassis are completely level. 9 Tighten the nuts on both sides of the urethane springs until they are snug. 2 Use a "bubble type" level to be sure the floor is completely level. repeat steps 6 through 10 OR consult Genie Industries Service Department. 4 Remove the drive chassis cover and the nonsteer axle covers. 1 Lower the boom to the stowed position. Failure to perform this procedure on a level floor will compromise the stability of the machine and could result in the machine tipping over. 7 . 52709 . Check to be sure the drive chassis is completely level. 7 Push up or pull down on the threaded rod until the machine is completely level. start the engine and loosen the lock nuts on both sides of the urethane cushions. Then tighten the locknuts. 3 Check the tire pressure in all four tires and add air if needed to meet specification. Tip-over hazard.Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS How to Set Up the Directional Valve Linkage Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced. 52709 Genie Z-45/25 & Genie Z-45/25J 7 .67 . Part No.First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS This page intentionally left blank. ........... XX . SS ..... Index No... Brake and 2-speed circuit Solenoid valve....... 6 SAE No.... 10-12 ft-lbs (14-16 Nm) 8 9 10 Plug Torque Specifications Description SAE No........ 15-18 ft-lbs (20-24 Nm) Diagnostic fitting ..................... Controls flow to drive motors in forward and reverse .................................................................070 in (1.......................... 0............................... PP . 4 SAE No... 250 psi (17............... QQ ..... 1 2 3 4 5 6 7 Description Schematic Item Function Torque Solenoid valve.. 12 Hex size 1/8 3/16 1/4 5/16 9/16 5/8 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 50 ft-lbs (68 Nm) Valve coil specifications 55 ft-lbs (75 Nm) 75 ft-lbs (102 Nm) 2 position 3 way solenoid valve....... Drive circuit . 25-30 ft-lbs (34-41 Nm) Orifice........ 2 position 3 way ...................... Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift . YY ...... WW ... Testing Orifice.... 25-30 ft-lbs (34-41 Nm) Check valve ........ 0. 10-12 ft-lbs (14-16 Nm) Flow divider/combiner valve ......................................... 3 position 3 way ..68 Genie Z-45/25 & Genie Z-45/25J Part No...... Drive circuit .........2 bar) .... 10-12 ft-lbs (14-16 Nm) Relief valve...................... 25-30 ft-lbs (34-41 Nm) Shuttle valve..... 2 SAE No.............. UU ......... Charge pressure circuit ................... 2 position 3 way ................... Braking .. 8 SAE No............... Drive circuit Check valve ............030 in (0..78 mm) .. 10 SAE No...76 mm) ........................ TT .......... VV ...... 2-speed motor shift ................ 52709 ... 10V (schematic item PP and YY) 5 to 7Ω Valve Coil Resistance Specifications 7 ..... RR ....Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-5 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non-steer end......... 52709 Genie Z-45/25 & Genie Z-45/25J 7 .First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No.69 . 5 Adjust the internal hex socket. 52709 . then remove the pressure gauge. 6 Restart the engine. Then install the valve cap. 8 Turn the engine off.70 Genie Z-45/25 & Genie Z-45/25J Part No. Drive the machine in either direction and recheck the valve pressure.Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-6 Valve Adjustments. 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port (item 8) located on the drive manifold. Charge Pressure Relief valve specifications Pressure 250 psi 17.2 bar 4 Turn the engine off. 7 . 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge. 2 Start the engine from the platform controls. Hold the charge pressure relief valve and remove the cap (item 2). Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. 7 Repeat steps 2 through 6 until the specified charge pressure is achieved. 71 . Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 7 .First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS This page intentionally left blank. .... AM ...... 0..2 bar) .................... 8 SAE No..... Braking . 2 speed motor shift circuit/ High speed bypass .. 25-30 ft-lbs (34-41 Nm) 2 3 4 5 6 7 8 9 10 11 12 13 This list continues..... AC ............. 10-12 ft-lbs (14-16 Nm) Orifice......................................... AG ............. 6 SAE No. Steer end drive motor circuit ............................... 10-12 ft-lbs (14-16 Nm) Check valve .......... 10 1/4 5/16 9/16 18 ft-lbs (24 Nm) 50 ft-lbs (68 Nm) 55 ft-lbs (75 Nm) 7 ........... 2 speed motor shift circuit ...................................76 mm) ............ 15-18 ft-lbs (20-24 Nm) Relief valve.............................. 2-speed motor shift . Charge pressure circuit .................Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-7 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non-steer end............................... 10-12 ft-lbs (14-16 Nm) Diagnostic fitting .......................................... Non-steer end drive motor circuit . 2 SAE No.... AB .............. AF ....... 2 speed motor shift circuit Flow divider/combiner valve ..... 0... AI ............... 2 gpm (7.... 1 Description Schematic Item Function Torque Flow divider/combiner valve ....... AD .......................... 3 position 3 way ..............8 L/min) ........................... 25-30 ft-lbs (34-41 Nm) Bi-directional flow control valve...... 52709 ..... Controls flow to non-steer end drive motors in forward and reverse . AH ...... 2 position 3 way ..2 gpm (0... AL .... Testing Shuttle valve.................. 25-30 ft-lbs (34-41 Nm) Directional control valve . 25-30 ft-lbs (34-41 Nm) Bi-directional flow control valve..................... Please turn the page Plug Torque Specifications Description SAE No.. Brake and 2-speed circuit Solenoid valve..... AE ... 2 position 3 way .... Index No.....030 inch (0..... AJ .. AK .. Controls flow to flow divider/combiner valves 1 and 18 . 10-12 ft-lbs (14-16 Nm) Solenoid valve...64 mm) ........ 4 Hex size 1/8 3/16 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) SAE No........025 inch (0..... 10-12 ft-lbs (14-16 Nm) Orifice..... 250 psi (17............. Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ... 0...72 Genie Z-45/25 & Genie Z-45/25J Part No.6 L/min) .. AN . First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No.73 . 52709 Genie Z-45/25 & Genie Z-45/25J 7 . .. 10-12 ft-lbs (14-16 Nm) Check valve .................. 10V (schematic items AI and AK) 5 to 7Ω Valve Coil Resistance Specifications 7 ........... 8 SAE No........... 4 SAE No..... 0.... Steer end drive motor circuit ......................................... AR . 14 15 16 17 Description Schematic Item Function Torque Check valve ..............................Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 4WD Drive Manifold Components........ 6 SAE No............... Controls flow to steer end drive motors in forward and reverse ..................... 2 SAE No............ Drive circuit Check valve .......... continued Index No... AT . Non-steer end drive motor circuit . AO . Non-steer end drive motor circuit ....74 Genie Z-45/25 & Genie Z-45/25J Part No. 10-12 ft-lbs (14-16 Nm) Orifice............... 10 Hex size 1/8 3/16 1/4 5/16 9/16 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) Valve coil specifications 50 ft-lbs (68 Nm) 55 ft-lbs (75 Nm) 2 position 3 way solenoid valve............... 10-12 ft-lbs (14-16 Nm) Flow divider/combiner valve ................ 25-30 ft-lbs (34-41 Nm) Check valve ...... Steer end drive motor circuit ................ 10-12 ft-lbs (14-16 Nm) 18 19 Plug Torque Specifications Description SAE No.............052 in (1...... AP ............ 52709 ..32 mm) .............. AQ .... AS ........ 52709 Genie Z-45/25 & Genie Z-45/25J 7 .First Edition • Second Printing Section 7 • Repair Procedures MANIFOLDS Part No.75 . Hold the charge pressure relief valve and remove the cap (index 7). 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port (item 5) located on the drive manifold. Charge Pressure Relief valve specifications Pressure 250 psi 17.Section 7 • Repair Procedures First Edition • Second Printing MANIFOLDS 12-8 Valve Adjustments. 8 Turn the engine off. 6 Restart the engine. 7 . Then install the valve cap. Drive the machine in either direction and recheck the valve pressure. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge. 2 Start the engine from the platform controls. 5 Adjust the internal hex socket.2 bar 4 Turn the engine off. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. 7 Repeat steps 2 through 6 until the specified charge pressure is achieved. 52709 .76 Genie Z-45/25 & Genie Z-45/25J Part No. then remove the pressure gauge. Engine fuels are combustible. When transferring fuel. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Explosion and fire hazard. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. clean and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter mounted to the engine side bulkhead. 3 Remove the fuel tank from the machine. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. wellventilated area away from heaters. then close the valves. flames and lighted tobacco. Always have an approved fire extinguisher within easy reach.77 . 13-2 Hydraulic Tank The primary functions of the hydraulic tank are to cool. 1 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. When removing a hose assembly or fitting. open closed Part No. drain and plug the supply and return fuel hoses. connect a grounding wire between the machine and pump or container. Remove the fuel tank in an open. The hydraulic return filter incorporates a filter condition indicator. 2 Remove the mounting fasteners from the top and bottom of the fuel tank. All models: 1 Disconnect. Cap the fuel return fitting on the fuel tank. How to Remove the Hydraulic Tank Component damage hazard. Hydraulic Hose and Fitting Torque Specifications. Refer to Section Two. sparks.First Edition • Second Printing Section 7 • Repair Procedures Fuel and Hydraulic Tanks 13-1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard. 10 Remove the hydraulic tank from the machine. Hydraulic Specification Hydraulic fluid capacity All models 24 gallons 91 liters 7 . 3 Remove the drain plug from the hydraulic tank. 6 Disconnect and plug the return filter hydraulic hose at the hydraulic tank. Cap the fitting on the hydraulic tank. Cap the fitting on the tank. 7 Disconnect and plug the supply hose for the auxiliary power unit through the access hole underneath the turntable. See capacity specifications below. 52709 . Component damage hazard. See capacity specifications below.78 Genie Z-45/25 & Genie Z-45/25J Part No. The hydraulic tank may become unbalanced and fall if it is not properly supported by the lifting device. 5 Tag. 9 Remove the hydraulic tank mounting fasteners.Section 7 • Repair Procedures First Edition • Second Printing FUEL AND HYDRAULIC TANKS 2 Place a suitable container underneath the hydraulic tank. Crushing hazard. 8 Support the hydraulic tank with an appropriate lifting device. disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. remove the key from the key switch and tag the machine to inform personnel of the condition. If the tank valves are closed. 4 Completely drain the tank into a suitable container. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. 79 . Part No.First Edition • Second Printing Section 7 • Repair Procedures This page intentionally left blank. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 52709 . Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Unlocked position Locked position 7 .Section 7 • Repair Procedures First Edition • Second Printing Turntable Rotation Components 14-1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting. 1 Secure the turntable from rotating with the turntable rotation lock pin. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. 2 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation motor. 4 Remove the turntable rotation motor mounting fasteners.80 Genie Z-45/25 & Genie Z-45/25J Part No. Spraying hydraulic oil can penetrate and burn skin. Hydraulic Hose and Fitting Torque Specifications. Do not allow oil to squirt or spray. disconnect and plug the hydraulic hoses from the turntable rotation motor manifold. 3 Tag. Cap the fittings on the manifold. 5 Remove the turntable rotation motor from the machine. then remove the motor from the brake. Bodily injury hazard. Refer to Section Two. 6 Remove the brake mounting bolts.81 . 3 Tag.First Edition • Second Printing Section 7 • Repair Procedures TURNTABLE ROTATION COMPONENTS How to Remove the Turntable Rotation Brake 1 Secure the turntable from rotating with the turntable rotation lock pin. then remove the motor from the brake. Bodily injury hazard. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Part No. Do not allow oil to squirt or spray. 5 Remove the turntable rotation motor from the machine. 4 Remove the turntable rotation motor mounting fasteners. disconnect and plug the hydraulic hoses from the turntable rotation motor manifold and the brake. Spraying hydraulic oil can penetrate and burn skin. and then remove the turntable rotation brake from the machine. Cap the fittings on the manifold and the brake. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Unlocked position Locked position 2 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation motor and brake. 1 Remove the cotter pin from the steering cylinder rod-end clevis pin and remove the cotter pin from the tie rod clevis pin. a b c d 2 Loosen the wheel lug nuts.Section 7 • Repair Procedures First Edition • Second Printing 2WD Steering Axle Components 15-1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings in the axle and a thrust washer that may require periodic replacement. g a b c d e f g f f e tie rod steer axle yoke pivot pin yoke hub pivot pin steering cylinder 7 . and then center a lifting jack of ample capacity under the steering axle. Do not remove the pins.82 Genie Z-45/25 & Genie Z-45/25J Part No. 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. 5 Remove the lug nuts. 3 Block the non-steering wheels. 6 Remove the pin retaining fasteners from the yoke pivot pins. 52709 . Do not remove them. 7 Support and secure the yoke/hub assembly to a lifting jack. Then remove the tire and wheel assembly. Remove the clevis pins. Always use a new cotter pin when installing a clevis pin. 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Torque specifications Lug nut torque. Crushing hazard. Remove the rear bearing.4 Nm 5 Remove the dust cap. The yoke/hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack. cotter pin and castle nut. dry Lug nut torque. Then remove the tire and wheel assembly. 3 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . then use a soft metal drift to drive the lower yoke pivot pin down and out.5 Nm 127. 2 Block the non-steering wheels and place a lifting jack of ample capacity under the steering axle.83 . 6 Pull the hub off the spindle. How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts. 4 Remove the lug nuts. lubricated 125 ft-lbs 94 ft-lbs 169. Do not remove them. Always use a new cotter pin when installing a castle nut. Part No. The washer and outer bearing should fall loose from the hub.First Edition • Second Printing Section 7 • Repair Procedures 2WD STEERING AXLE COMPONENTS 8 Place a rod through the upper yoke pivot pin and twist to remove the pin. Bend the cotter pin to lock it in. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.Section 7 • Repair Procedures First Edition • Second Printing 2WD STEERING AXLE COMPONENTS How to Install the Hub and Bearings When replacing a wheel bearing. 10 Install the dust cap. Spraying hydraulic oil can penetrate and burn skin. 7 . Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Cap the fittings on the cylinder. The tie rod maintains equal movement of the tires. 4 Slide the hub onto the yoke spindle. Refer to Section Two. Bodily injury hazard. 6 Install the washer and castle nut. 15-2 Steering Cylinders How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel. but move in opposite directions. 2 Place the large inner bearing into the rear of the hub. 1 Tag. Hydraulic Hose and Fitting Torque Specifications.84 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Be sure that both bearings are packed with clean. 3 Press the bearing seal evenly into the hub until it is flush. They are part of the same hydraulic circuit. fresh grease. Do not allow oil to squirt or spray. Do not apply excessive force or damage to the lip of the seal may occur. 8 Loosen the castle nut. Torque the wheel lug nuts to 125 ft-lbs (169. disconnect and plug the hydraulic hoses from the steering cylinder. When removing a hose assembly or fitting. then the tire and wheel assembly. then re-tighten to 8 ft-lbs (11 Nm). 7 Tighten the castle nut to 35 ft-lbs (47 Nm) to seat the bearing. 9 Install a new cotter pin. Component damage.5 Nm). 52709 . both the inner and outer bearings including the pressed-in races must be replaced. 5 Place the outer bearing into the hub. First Edition • Second Printing Section 7 • Repair Procedures 2WD STEERING AXLE COMPONENTS 2 Remove the cotter pin from the rod-end clevis pin of the steer cylinder. Part No. 2 Remove the tie rod. Remove the clevis pin. Always use a new cotter pin when installing a clevis pin. 4 Remove the steering cylinder from the machine. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . then remove the clevis pins. Always use a new cotter pin when installing a clevis pin. 3 Remove the cotter pin from the barrel-end clevis pin of the steer cylinder then remove the clevis pin.85 . 15-3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pins from the clevis pins at each end of the tie rod. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. 7 . 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. a b c g f a b c d e f g e d oscillate cylinder yoke pivot pin drive hub yoke pivot pin steer cylinder tie rod 2 Loosen the wheel lug nuts.Section 7 • Repair Procedures First Edition • Second Printing 4WD Steering Axle Components 16-1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may require periodic replacement.86 Genie Z-45/25 & Genie Z-45/25J Part No. 1 Remove the cotter pin from the steering cylinder rod-end clevis pin and remove the cotter pin from the tie rod clevis pin. 3 Block the non-steering wheels. Do not remove them. Hydraulic Hose and Fitting Torque Specifications. Remove the clevis pins. When removing a hose assembly or fitting. 52709 . Refer to Section Two. and then center a lifting jack of ample capacity under the steering axle. The yoke must be removed before the drive hub can be removed. 7 Remove the drive motor mounting fasteners. disconnect and plug the hydraulic hoses from the drive motor. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . Secure the yoke/drive hub assembly to the lifting jack. Do not allow oil to squirt or spray. Part No. 6 Tag. Cap the fittngs on the drive motor. 8 Slide the drive motor shaft out of the drive hub and then remove the drive motor from the machine. then remove the tire and wheel assembly. Do not remove the pins. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. The yoke/hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack. 10 Support the yoke/drive hub assembly with a lifting jack. Bodily injury hazard. 9 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. Crushing hazard. 11 Place a rod through the upper yoke pivot pin and twist to remove the pin. Spraying hydraulic oil can penetrate and burn skin. 12 Place the yoke/drive hub assembly on a flat surface with the drive hub facing down.87 . then use a soft metal drift to drive the lower yoke pivot pin down and out.First Edition • Second Printing Section 7 • Repair Procedures 4WD STEERING AXLE COMPONENTS 5 Remove the lug nuts. Remove the yoke weldment from the drive hub.5 Nm 127. Replace the thrust washer when installing the yoke/drive hub assembly onto the axle. dry lubricated Drive motor mounting bolts. dry lubricated Drive hub mounting bolts. 52709 . See repair procedure 15-2.Section 7 • Repair Procedures First Edition • Second Printing 4WD STEERING AXLE COMPONENTS 13 Remove the drive hub mounting fasteners that attach the yoke to the drive hub. See Repair Procedure 15-3. Torque specifications Lug nut. 7 .88 Genie Z-45/25 & Genie Z-45/25J Part No. How to Remove the Tie Rod. dry lubricated 16-2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure. 125 ft-lbs 94 ft-lbs 169.4 Nm 120 ft-lbs 90 ft-lbs 163 Nm 122 Nm 16-3 Tie Rod How to Remove the Tie Rod 75 ft-lbs 56 ft-lbs 102 Nm 76 Nm This procedure is the same as the 2WD procedure. How to Remove a Steering Cylinder. Dealer service is strongly recommended. level surface with the boom in the stowed position. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Use a soft metal drift to remove the pin. The oscillate cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. When removing a hose assembly or fitting. Use a soft metal drift to remove the pin. 5 Remove the cylinder from the machine. 4 Remove the pin retaining fasteners from the barrel-end pivot pin. This procedure requires specific repair skills and a suitable workshop.89 . the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Cap the fittings on the oscillate cylinder. Perform this procedure on a firm. Hydraulic Hose and Fitting Torque Specifications. Crushing hazard. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. How to Remove an Oscillating Axle Cylinder Bodily injury hazard. The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . 1 Tag. Refer to Section Two. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Part No. The valves are not adjustable. Do not allow oil to squirt or spray. 2 Remove the pin retaining fasteners from the rod-end pivot pin.First Edition • Second Printing Section 7 • Repair Procedures Oscillating Axle Components 17-1 Oscillating Axle Lock-out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle. 3 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. disconnect and plug the oscillating axle cylinder hydraulic hoses. Torque specifications Drive motor mounting bolts 75 ft-lbs 102 Nm 7 . disconnect and plug the hydraulic hoses from the drive motor. 2 Tag.Section 7 • Repair Procedures First Edition • Second Printing Non-steering Axle Components 18-1 Drive Motor How to Remove a Drive Motor Component damage hazard. Spraying hydraulic oil can penetrate and burn skin. Do not allow oil to squirt or spray. Refer to Section Two. 3 Remove the drive motor mounting fasteners. 52709 . Bodily injury hazard. When removing a hose assembly or fitting. Component damage hazard. 1 Remove the fasteners from cover on the nonsteer axle. Repairs to the motor should only be performed by an authorized Sundstrand-Sauer dealer. Cap the fittings on the drive motor. 4 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.90 Genie Z-45/25 & Genie Z-45/25J Part No. Remove the cover. Dealer service is recommended. Hydraulic Hose and Fitting Torque Specifications. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. dry lubricated Drive hub mounting bolts. dry lubricated Drive motor mounting bolts.4 Nm 120 ft-lbs 90 ft-lbs 163 Nm 122 Nm 75 ft-lbs 56 ft-lbs 102 Nm 76 Nm Part No. 1 Remove the drive motor. 2 Tag. Then remove the hydraulic fitting and the bleed valve. See 18-1. Torque specifications Lug nut. Refer to Section Two. 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack. 52709 Genie Z-45/25 & Genie Z-45/25J 7 . The drive hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack. 4 Center a lifting jack of ample capacity under the non-steering axle. Do not remove them. dry lubricated 125 ft-lbs 94 ft-lbs 169.First Edition • Second Printing Section 7 • Repair Procedures NON-STEERING AXLE COMPONENTS 18-2 Drive Hub How to Remove a Drive Hub When removing a hose assembly or fitting.5 Nm 127.91 . Raise the machine approximately 6 inches (15 cm) and place blocks under the drive chassis for support. the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. 3 Loosen the wheel lug nuts. Crushing hazard. 7 Remove the drive hub mounting bolts that attach the drive hub to the non-steer axle. disconnect and plug the hydraulic hose from the brake. 8 Remove the drive hub from the non-steer axle. Hydraulic Hose and Fitting Torque Specifications. How to Remove a Drive Motor. 5 Remove the wheel lug nuts. then the tire and wheel assembly. 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