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Service Manual Serial Number Range Z-45/25 Z-45/25J Deutz models: from 23041 to 34010 Ford models: from 23190 to 34010 Perkins models: from 23009 to 34010 All models: from A34011 to A47000 All models: from B101 to B3300 IC Power Part No. 107846 Rev C5 June 2012 Introduction June 2012 Introduction Important Serial Number Information Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 and Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure. Genie Industries offers the following Service Manuals for these models: This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes 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 an authorized Genie dealer service center. Title Part No. Z-45/25 and Z-45/25J Service Manual ................. 52709 From serial number 9998 to 21179 Z-45/25 and Z-45/25J Service Manual ................. 77809 Deutz models: from 21180 to 23040 Ford models: from 21180 to 23189 Perkins models: from 21180 to 23008 Z-45/25 and Z-45/25J Service Manual ............... 107846 Deutz models: from 23041 to 34010 Ford models: from 23190 to 34010 Perkins models: from 23009 to 34010 All models: from A34011 to A47000 All models: from B101 Z-45/25 and Z-45/25J Service Manual ............... 219418 From serial number 13A-47001 Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper opeation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: Copyright © 2011 Terex Corporation 107846 Rev C August 2006 Third Edition, Third Printing "Genie" and "Z" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper http://www.genielift.com e-mail: [email protected] ii Printed in U.S.A. Z-45/25 • Z-45/25J Part No. 107846 June 2012 INTRODUCTION Serial Number Legend Z452506-12345 Serial number: Model year: 2006 Manufacture date: 04/12/06 Electrical schematic number: ES0274 Machine unladen weight: Rated work load (including occupants): 500 lb / 227 kg Maximum number of platfrm occupants: 2 Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg Z4525 06 - 12345 Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 45 ft 6 in/ 13.8 m Maximum platform reach : 25 ft 3 in/ 7.7 m Gradeability: N/A Model Sequence number Model year Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries Serial label (located under cover) 18340 NE 76th Street Redmond, WA 98052 Serial number stamped on chassis USA PN - 77055 Part No. 107846 Z-45/25 • Z-45/25J iii June 2012 This page intentionally left blank. iv Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie Z-45/25 and Genie Z-45/25J Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 107846 Z-45/25 • Z-45/25J v Section 1 • Safety Rules June 2012 SAFETY RULES Be sure to wear protective eye wear and other protective clothing if the situation warrants it. 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. 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. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. 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. 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 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. Used to indicate operation or maintenance information. vi Z-45/25 • Z-45/25J Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Part No. 107846 June 2012 Table of Contents Introduction Important Information .................................................................................................. ii Serial Number Information ........................................................................................... ii Serial Number Legend ................................................................................................ iii Section 1 Safety Rules General Safety Rules ................................................................................................. v Section 2 Rev H Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 2 Hydraulic Specifications ........................................................................................ 2 - 3 Manifold Component Specifications ....................................................................... 2 - 5 Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6 Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7 Deutz F3L-2011 / D2011 L03i Engine Specifications .............................................. 2 - 8 Perkins 404-22 Engine Specifications .................................................................. 2 - 10 Machine Torque Specifications ............................................................................ 2 - 12 Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13 SAE and Metric Fastener Torque Chart ............................................................... 2 - 14 Part No. 107846 Z-45/25 • Z-45/25J vii June 2012 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 D Checklist A Procedures A-1 Perform Pre-operation Inspection ................................................................. 3 - 7 A-2 Perform Function Tests ................................................................................ 3 - 7 A-3 Perform Engine Maintenance ....................................................................... 3 - 8 A-4 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9 A-5 Test the Oscillate Axle (if equipped) ............................................................. 3 - 9 A-6 Perform 30 Day Service ............................................................................. 3 - 10 A-7 Perform Engine Maintenance - Ford Models ............................................... 3 - 10 A-8 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11 A-9 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13 A-10 Perform Engine Maintenance - Ford Models ............................................... 3 - 13 C viii Checklist B Procedures B-1 Inspect the Battery ..................................................................................... 3 - 14 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 15 B-3 Check the Exhaust System ....................................................................... 3 - 16 B-4 Inspect the Engine Air Filter ....................................................................... 3 - 17 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 17 B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 18 B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 19 B-8 Check the Oil Level in the Drive Hubs ........................................................ 3 - 19 Z-45/25 • Z-45/25J Part No. 107846 June 2012 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued B-9 Check and Adjust the Engine RPM - All Models ........................................ 3 - 20 B-10 Test the Ground Control Override .............................................................. 3 - 22 B-11 Check the Directional Valve Linkage ......................................................... 3 - 23 B-12 Test the Platform Self-leveling ................................................................... 3 - 23 B-13 Test the Engine Idle Select ........................................................................ 3 - 24 B-14 Test the Fuel Select Operation - Ford Models ........................................... 3 - 25 B-15 Test the Drive Brakes ................................................................................ 3 - 26 B-16 Test the Drive Speed - Stowed Position .................................................... 3 - 26 B-17 Test the Drive Speed - Raised or Extended Position ................................. 3 - 27 B-18 Test the Alarm Package (if equipped) ........................................................ 3 - 28 B-19 Perform Hydraulic Oil Analysis .................................................................. 3 - 29 B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ...................... 3 - 29 B-21 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 30 B-22 Perform Engine Maintenance - Perkins Models ......................................... 3 - 32 B-23 Replace the Engine Air Filter Element - Ford Models ................................ 3 - 32 B-24 Perform Engine Maintenance - Ford Models .............................................. 3 - 33 D Part No. 107846 Checklist C Procedures C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34 C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 34 C-3 Test the Platform Overload System (if equipped) ...................................... 3 - 35 C-4 Replace the Fuel Filter/Water Separator - Perkins Models ........................ 3 - 38 C-5 Replace the Engine Air Filter Element - Deutz and Perkins Models ........... 3 - 40 C-6 Perform Engine Maintenance - Perkins Models ......................................... 3 - 40 C-7 Perform Engine Maintenance - Ford Models .............................................. 3 - 41 Z-45/25 • Z-45/25J ix June 2012 TABLE OF CONTENTS Section 3 Rev D D Section 4 Rev Scheduled Maintenance Procedures, continued Checklist D Procedures D-1 Check the Boom Wear Pads ...................................................................... 3 - 42 D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42 D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 44 D-4 Replace the Drive Hub Oil .......................................................................... 3 - 46 D-5 Check the Free-wheel Configuration ........................................................... 3 - 46 D-6 Replace the Hydraulic Filters ...................................................................... 3 - 48 D-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 49 Checklist E Procedures E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50 E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52 E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 53 E-4 Perform Engine Maintenance - Deutz Models ............................................. 3 - 54 Repair Procedures Introduction ............................................................................................................ 4 - 1 B C x Platform Controls 1-1 ALC-500 Circuit Board .................................................................................. 4 - 2 1-2 Joysticks ..................................................................................................... 4 - 3 Platform Components 2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 7 2-2 Platform Rotator ........................................................................................... 4 - 8 2-3 Platform Overload System ......................................................................... 4 - 10 Z-45/25 • Z-45/25J Part No. 107846 June 2012 TABLE OF CONTENTS Section 4 Rev B B B B B Part No. 107846 Repair Procedures, continued Jib Boom Components, Z-45/25J 3-1 Jib Boom .................................................................................................... 4 - 12 3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 13 Primary Boom Components 4-1 Cable Track ................................................................................................ 4 - 15 4-2 Primary Boom ............................................................................................ 4 - 19 4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 21 4-4 Primary Boom Extension Cylinder .............................................................. 4 - 23 4-5 Platform Leveling Master Cylinder .............................................................. 4 - 24 Secondary Boom Components 5-1 Secondary Boom ........................................................................................ 4 - 27 5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 32 Engines 6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 33 6-2 RPM Adjustment - Perkins Models ............................................................. 4 - 33 6-3 Flex Plate ................................................................................................... 4 - 33 6-4 Engine Fault Codes - Ford Models ............................................................. 4 - 37 Hydraulic Pumps 7-1 Lift/Steer Pump .......................................................................................... 4 - 38 7-2 Drive Pump ................................................................................................ 4 - 39 Z-45/25 • Z-45/25J xi June 2012 TABLE OF CONTENTS Section 4 Rev E Repair Procedures, continued Manifolds 8-1 Function Manifold Components (before serial number 27001) ..................................................................... 4 - 42 8-2 Valve Adjustments - Function Manifold (before serial number 27001) ..................................................................... 4 - 46 8-3 Function Manifold Components (after serial number 27000) ........................................................................ 4 - 48 8-4 Valve Adjustments - Function Manifold (after serial number 27000) ........................................................................ 4 - 52 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 27001) ..................................................................... 4 - 53 8-6 Jib Boom / Platform Rotate Manifold Components (after serial number 27000) ........................................................................ 4 - 54 8-7 Turntable Rotation Manifold Components (before serial number 27001) ..................................................................... 4 - 55 8-8 Turntable Rotation Manifold Components (after serial number 27000) ........................................................................ 4 - 56 8-9 Directional Valve Manifold Components .................................................... 4 - 57 8-10 Traction Manifold Components, 2WD (before serial number 27001) ..................................................................... 4 - 60 8-11 Traction Manifold Components, 2WD (after serial number 27000) ........................................................................ 4 - 62 8-12 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 64 8-13 Traction Manifold Components, 4WD (before serial number 27001) ..................................................................... 4 - 66 8-14 Traction Manifold Components, 4WD (after serial number 27000) ........................................................................ 4 - 68 8-15 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 70 8-16 Valve Coils ................................................................................................. 4 - 70 xii Z-45/25 • Z-45/25J Part No. 107846 June 2012 TABLE OF CONTENTS Section 4 Rev C Repair Procedures, continued Turntable Rotation Components 9-1 C Turntable Rotation Assembly ..................................................................... 4 - 72 Axle Components 10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 73 10-2 Oscillate Lock-out Cylinders ....................................................................... 4 - 74 Section 5 Rev Fault Codes Introduction ............................................................................................................ 5 - 1 Section 6 A Fault Codes - Control System ................................................................................ 5 - 2 B Fault Codes - Ford LRG-425 EFI Models ............................................................... 5 - 6 A Fault Codes - Ford DSG-423 EFI Models ............................................................. 5 - 12 Rev Schematics Introduction ............................................................................................................ 6 - 1 A Electrical Symbols Legend .................................................................................... 6 - 2 A Hydraulic Symbols Legend .................................................................................... 6 - 3 A Ford Engine Relay Layout ...................................................................................... 6 - 4 Ford models A Ford LRG-425 EFI Engine Harness ........................................................................ 6 - 5 A Ford DSG-423 EFI Engine Harness ....................................................................... 6 - 6 C Electrical Schematic, Z-45/25 Ford LRG-425 EFI (before serial number 30142) ........................................ 6 - 7 A Electrical Schematic, Z-45/25 Ford DSG-423 EFI (after serial number 30141) ........................................... 6 - 9 Part No. 107846 Z-45/25 • Z-45/25J xiii June 2012 TABLE OF CONTENTS Section 6 Rev Schematics, continued Ford models, continued A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 11 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 12 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 13 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 14 C Electrical Schematic, Z-45/25J Ford LRG-425 EFI (before serial number 30142) ...................................... 6 - 15 A Electrical Schematic, Z-45/25J Ford DSG-423 EFI (after serial number 30141) ......................................... 6 - 17 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 19 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 20 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 21 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 22 Deutz F3L-2011 models xiv C Electrical Schematic, Z-45/25 .............................................................................. 6 - 23 C Electrical Schematic, Z-45/25 CE models ........................................................................................................... 6 - 25 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 27 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 28 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 CE Models ........................................................................................................... 6 - 29 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 CE Models ........................................................................................................... 6 - 30 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 31 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 32 Z-45/25 • Z-45/25J Part No. 107846 June 2012 TABLE OF CONTENTS Section 6 Rev Schematics, continued Deutz F3L-2011 models, continued C Electrical Schematic, Z-45/25J ............................................................................ 6 - 33 C Electrical Schematic, Z-45/25J CE models ........................................................................................................... 6 - 35 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 37 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 38 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J CE Models ........................................................................................................... 6 - 39 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J CE Models ........................................................................................................... 6 - 40 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 41 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 42 Perkins 404-22 models C Electrical Schematic, Z-45/25 .............................................................................. 6 - 44 A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 ................................ 6 - 48 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................. 6 - 49 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 52 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 53 C Electrical Schematic, Z-45/25J ............................................................................ 6 - 56 B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J .............................. 6 - 60 B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J ................................ 6 - 61 A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 63 A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 65 Hydraulic Schematics D Hydraulic Schematic, 2WD Models (before serial number 27001) ......................... 6 - 67 B Hydraulic Schematic, 2WD Models (after serial number 27000) ........................... 6 - 69 C Hydraulic Schematic, 4WD Models (before serial number 27001) ......................... 6 - 71 B Hydraulic Schematic, 4WD Models (after serial number 27000) ........................... 6 - 73 Part No. 107846 Z-45/25 • Z-45/25J xv June 2012 This page intentionally left blank. xvi Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications Specifications REV H Machine Specifications Tires and wheels Rough terrain Industrial 355/55 D625 9-14.5 LT 14 Tread 8 Sidewall 6 390 lbs 177 kg 175 lbs 79 kg 36.9 in 93.7 cm 28 in 71 cm 24.5 inches 62.2 cm 14.5 inches 36.8 cm 11.75 inches 29.8 cm 7 inches 17.8 cm Tire size Tire ply rating Tire weight, new foam-filled (minimum) Overall tire diameter Wheel diameter Wheel width Tires and wheels Wheel lugs Lug nut torque (lubricated) (dry) Tire pressure (air-filled tires) 9@ 5/8 -18 9@ 5/8 Tire size 50 psi 3.45 bar 100 psi 6.9 bar 10 Overall tire diameter Wheel diameter 33 in 84 cm 19.5 inches 49.5 cm Wheel width 14 inches 35.6 cm Wheel lugs 9 @ 5/8 -18 Lug nut torque (lubricated) (dry) Tire pressure 94 ft-lbs 127.4 Nm 125 ft-lbs 169.5 Nm 33/16LL500 Tire ply rating -18 94 ft-lbs 127.4 Nm 125 ft-lbs 169.5 Nm Hi-flotation (option) 94 ft-lbs 127.4 Nm 125 ft-lbs 169.5 Nm 38 psi 2.6 bar For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 107846 Z-45/25 • Z-45/25J 2-1 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Performance Specifications Fluid capacities LPG tank 33.5 pounds 15.2 kg Fuel tank 17 gallons 64.4 liters Hydraulic tank 24 gallons 91 liters Hydraulic system (including tank) 30 gallons 113.6 liters Drive hubs, 2WD models (before serial number 24690) 17 fl oz 0.5 liters Drive hubs, 2WD models (after serial number 24689) 24 fl oz 0.7 liters Drive hubs - Steer end, 4WD models 17 fl oz 0.5 liters Drive hubs, 48:1, Non-steer end, 4WD models (before serial number 23812) 17 fl oz 0.5 liters Drive hubs with brake, 57:1, Non-steer end, 4WD models (after serial number 23811) 24 fl oz 0.7 liters Drive speed, maximum Stowed position 4.8 mph 7.7 km/h 40 ft / 5.7 sec 12.2 m / 5.7 sec Raised or extended position 0.6 mph 0.98 km/h 40 ft / 45 sec 12.2 m / 45 sec Raised or extended position (narrow models) 0.38 mph 0.6 km/h 40 ft / 70 sec 12.2 m / 70 sec Gradeability See Operator's Manual Braking distance, maximum High range on paved surface Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 3 to 6 ft 0.9 to 1.8 m Boom function speeds, maximum from platform controls Primary boom up 24 to 28 seconds Primary boom down 24 to 28 seconds Secondary boom up 24 to 28 seconds Secondary boom down (before serial number 27001) 38 to 42 seconds Secondary boom down (after serial number 27000) 24 to 28 seconds Turntable rotate, 359° primary boom retracted 62 to 68 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2-2 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Hydraulic Specifications Drive pump Hydraulic Oil Specifications Type: Hydraulic oil type Viscosity grade Viscosity index Flow rate @ 2500 rpm Chevron Rykon MV equivalent Multi-viscosity 200 Cleanliness level, minimum Water content, maximum 15/13 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and have a minimum viscosity index greater than 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Fire resistant Mineral based 32 gpm 121 L/min 3500 psi 241 bar Charge pump Type: Displacement Flow rate @ 2500 rpm Charge pressure @ 2500 rpm gear 0.84 cu in 13.76 cc 9.1 gpm 34.4 L/min 315 psi 21.7 bar Function pump Optional fluids Biodegradable Drive pressure, maximum bi-directional, variable displacement piston pump Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S UCON Hydrolube HP-5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Type: Displacement Flow rate @ 2500 rpm 0.67 cu in 11 cc 7.25 gpm 27.4 L/min Auxiliary pump Type: Displacement per revolution Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0°F / -18°C. gear Auxiliary pump relief pressure gear, fixed displacement 0.067 cu in 1.1 cc 3200 psi 220.6 bar Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C. Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use. Part No. 107846 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Z-45/25 • Z-45/25J 2-3 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Function manifold System relief valve pressure Hydraulic filters 3200 psi 220.6 bar Secondary boom down relief valve pressure 2100 psi 145 bar Platform level relief valve pressure 2500 psi 172 bar Steer flow regulator 1.5 gpm 5.7 L/min Boom extend flow regulator 2 gpm 7.6 L/min Jib boom / platform rotate flow regulator 0.4 gpm 1.5 L/min High pressure filter Beta 3 ≥ 200 High pressure filter bypass pressure 100 psi 6.89 bar Medium pressure filter Beta 3 ≥ 200 Medium pressure filter bypass pressure 50 psi 3.4 bar Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass Drive manifold Hot oil relief pressure 250 psi 17.2 bar Steer end drive motors (4WD models) Displacement per revolution 1.53 cu in 25 cc Non-steer end drive motors Displacement per revolution, variable 0.12 to 2.14 cu in 4WD (2 speed motor) 1.97 to 35 cc (before serial number 23812) Displacement per revolution, variable 0.01 to 1.83 cu in 4WD (2 speed motor) 1.61 to 30 cc (after serial number 23811) Displacement per revolution, variable 1.37 to 2.14 cu in 2WD (before serial number 24690) 22.5 to 35 cc Displacement per revolution, variable 0.99 to 1.83 cu in 2WD (after serial number 24689) 16.2 to 30 cc Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2-4 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Manifold Component Specifications Plug torque SAE No. 2 36 in-lbs / 4 Nm SAE No. 4 10 ft-lbs / 13 Nm SAE No. 6 14 ft-lbs / 19 Nm SAE No. 8 38 ft-lbs / 51 Nm SAE No. 10 41 ft-lbs / 55 Nm SAE No. 12 56 ft-lbs / 76 Nm Valve Coil Resistance Specification Proportional directional solenoid valve, 10V DC 6 to 8Ω (schematic items A, C, D, BP, BU and BY) 3 position 4 way directional valve, 10V DC (schematic items B, F, H, BF, BM, CG) 6 to 8Ω 2 position 3 way solenoid valve, 10V DC (schematic items E, G, CA, CC, AD, OO, XX, AF, AG, AI and AK) 6 to 8Ω Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 107846 Z-45/25 • Z-45/25J 2-5 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Ford LRG-425 EFI Engine Displacement Electronic fuel pump 153 cu in 2.5 liters Number of cylinders 4 Bore & stroke Horsepower Fuel flow rate 70 @ 2500 rpm 52 kW @ 2500 rpm 1-3-4-2 Low function idle (computer controlled) High function idle (computer controlled) 0.58 gpm 2.2 L/min Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. 1600 rpm 27 Hz Ignition system Spark plug type Motorcraft AGSF-32-FM 2500 rpm 42 Hz Spark plug gap 0.042 to 0.046 inches 1.07 to 1.17 mm Compression ratio 9.4:1 Compression pressure (approx.) Pressure (psi or bar) of lowest cylinder must be at least 75% of highest cylinder Engine coolant Capacity 0.035 to 0.055 inches 0.889 to 1.397 mm Oil pressure (operating temperature @ 2500 rpm) 40 to 60 psi 2.75 to 4.1 bar 4.5 quarts 4.3 liters 11.5 quarts 10.9 liters Coolant temperature switch Temperature switch point Lubrication system Oil capacity (including filter) 63 psi 4.3 bar 3.78 x 3.4 inches 96.01 x 86.36 mm Firing order Valve clearances collapsed tappet Fuel pressure, static 230°F 110°C Starter motor Normal engine cranking speed Current draw, normal load Current draw, maximum load 200 to 250 rpm 140-200A 800A Oil pressure switch Alternator Oil pressure switch point 7.5 psi 0.51 bar Output Oil viscosity requirements Battery Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Type Quantity 95A, 14.5V DC 12V DC, Group 34/78 1 Cold cranking ampere @ 0°F 900A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2-6 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Ford DSG-423 EFI Engine Displacement Electronic fuel pump 140.4 cu in 2.3 liters Number of cylinders Bore & stroke Horsepower 4 3.44 x 3.7 inches 87.5 x 94 mm 59 @ 2500 rpm 44 kW @ 2500 rpm Firing order Low function idle (computer controlled) High function idle (computer controlled) 0.43 gpm 1.6 L/min Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. 1600 rpm 27 Hz Spark plug type Motorcraft AGSF-32-FEC Spark plug gap 0.044 to 0.045 inches 1.125 to 1.135 mm 2500 rpm 42 Hz 9.7:1 Engine coolant Capacity 10 quarts 9.5 liters Cylinder head temperature sending unit Lubrication system 29 to 39 psi 2 to 2.7 bar 4 quarts 3.8 liters Fault code set temperature 280°F 138°C Engine shut-down temperature 300°F 149°C Starter motor Normal engine cranking speed Oil pressure switch Oil pressure switch point Fuel flow rate Ignition system Compression pressure (approx.) Pressure (psi or bar) of lowest cylinder must be at least 75% of highest cylinder Oil capacity (including filter) 64 psi 4.4 bar 1-3-4-2 Compression ratio Oil pressure (at operating temperature @ 2500 rpm) Fuel pressure, static 7.5 psi 0.51 bar Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Current draw, normal load Current draw, maximum load 200 to 250 rpm 140-200A 800A Alternator Output 95A, 13.8V DC Battery Type Quantity 12V DC, Group 34/78 1 Cold cranking ampere @ 0°F 900A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 107846 Z-45/25 • Z-45/25J 2-7 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Deutz F3L 2011 Engine Deutz D2011L03i Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio Compression pressure Governor Lubrication system Oil pressure 142 cu in 2.33 liters 3 3.7 x 4.4 inches 94 x 112 mm 48 @ 2800 rpm 36 kW @ 2800 rpm 1-2-3 1500 rpm 25 Hz 2500 rpm 42 Hz 19:1 362 to 435 psi 25 to 30 bar centrifugal mechanical Oil capacity (including filter) (Deutz F3L 2011 Engine) 8.5 quarts 8 liters Oil capacity (including filter) (Deutz D2011L03i Engine) 9.5 quarts 9 liters Oil viscosity requirements -22° F to 86° F/ -30° C to 30° C Intake 0.012 in 0.3 mm Exhaust 0.020 in 0.5 mm 5W-30 (synthetic) -4° F to 90° F / -20° C to 32° C 10W-40 Above 23° F / -5° C 20W-50 Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil temperature switch Temperature switch point Valve clearance, cold 20 to 44 psi 1.4 to 3 bar 300°F 149°C Oil pressure switch Oil pressure switch point (Deutz F3L 2011 Engine) 7 psi 0.5 bar Oil pressure switch point (Deutz D2011L03i Engine) 22 psi 1.5 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2-8 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Fuel injection system Injection pump make Bosch Injection pump pressure, maximum 15000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Starter motor Current draw, no load 90A Brush length, new 0.72 in 18.5 mm Brush length, minimum 0.27 in 7 mm Battery Type 12V DC, Group 34/78 Quantity 1 Cold cranking ampere Reserve capacity @ 25A rate Alternator output Fan belt deflection 900A 200 minutes 60A @ 14V DC 3/8 to 1/2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 107846 Z-45/25 • Z-45/25J 2-9 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Perkins 404-22 Engine Displacement 134 cu in 2.2 liters Number of cylinders Bore and stroke Horsepower Lubrication system 4 3.31 x 3.94 inches 84 x 100 mm 51 @ 2500 rpm 38 kW @ 2500 rpm Firing order 1-3-4-2 Low idle 1300 rpm 22 Hz High idle 2500 rpm 42 Hz Compression ratio 23.3:1 Compression pressure 426 psi 29.4 bar Pressure (psi) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder Governor Oil pressure, cold (at 2500 rpm) Oil capacity (including filter) 60 psi 4.1 bar 9.3 quarts 8.8 liters Oil viscosity requirements Below 86°F / 30°C 5W-20 -4°F to 104°F / -20°C to 40°C 10W-30 Above 14°F / -10°C 15W-40 Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil pressure sending unit Oil pressure switch point 14.2 psi 1 bar Fuel injection system centrifugal mechanical Injection pump make Injection pressure Valve clearance, cold Intake 0.008 in 0.2 mm Exhaust 0.008 in 0.2 mm Zexel 2133 psi 147 bar Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Alternator output Fan belt deflection 55A @ 12V DC 3/8 in 10 mm Starter motor Current draw, no load 90A Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 10 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Battery Type 12V DC, Group 34/78 Quantity Cold cranking ampere Reserve capacity @ 25A rate 1 900A 200 minutes Engine coolant Capacity 7.7 quarts 7.3 liters Coolant temperature sending unit Temperature switch point 221° F 105° C Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 107846 Z-45/25 • Z-45/25J 2 - 11 Section 2 • Specifications January 2011 SPECIFICATIONS REV H Machine Torque Specifications Platform rotator 3 /4 -10 center bolt, GR 8 3 /8 -16 bolts, GR 8 380 ft-lbs 515 Nm 44 ft-lbs 60 Nm Turntable rotate assembly Rotate bearing mounting bolts, lubricated 180 ft-lbs 244 Nm Drive motor/brake mounting bolts, dry 110 ft-lbs 149 Nm Drive motor/brake mounting bolts, lubricated 80 ft-lbs 108 Nm Drive motor and hubs Drive hub mounting bolts, lubricated Drive motor mounting bolts, lubricated 180 ft-lbs 244 Nm 55 ft-lbs 75 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 12 Z-45/25 • Z-45/25J Part No. 107846 January 2011 Section 2 • Specifications REV H SPECIFICATIONS Seal-Lok® fittings Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok® fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. The O-rings used in the Parker Seal Lok® fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). SAE O-ring Boss Port (tube fitting - installed into Aluminum) SAE Dash size Torque -4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation. -6 23 ft-lbs / 31.2 Nm -8 40 ft-lbs / 54.2 Nm 3 Be sure that the face seal O-ring is seated and retained properly. -10 69 ft-lbs / 93.6 Nm -12 93 ft-lbs / 126.1 Nm -16 139 ft-lbs / 188.5 Nm -20 172 ft-lbs / 233.2 Nm -24 208 ft-lbs / 282 Nm 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table. 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. SAE O-ring Boss Port Seal-Lok Fittings (tube fitting - installed into Steel) (hose end) ® SAE Dash size Torque SAE Dash size -4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm -6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm -8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm -10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm -12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm -16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm -20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm -24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm Part No. 107846 Z-45/25 • Z-45/25J Torque 2 - 13 Section 2 • Specifications January 2011 SPECIFICATIONS REV H SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • SIZE Grade 5 THREAD LUBED 20 28 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 1/2 LUBED DRY DRY in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm 80 90 9 10.1 100 120 11.3 13.5 110 120 12.4 13.5 140 160 15.8 18 130 140 14.7 15.8 LUBED 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 A574 High Strength Black Oxide Bolts LUBED Grade 8 DRY LUBED DRY LUBED ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm 13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190 23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560 33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826 21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000 28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067 METRIC FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • Class 4.6 Size (m m ) 5 6 7 LUBED 2 - 14 DRY LUBED Class 10.9 8.8 DRY LUBED Class 12.9 10.9 DRY LUBED 12.9 DRY in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm 16 19 45 1.8 3.05 5.12 21 36 60 2.4 4.07 6.83 41 69 116 4.63 7.87 13.2 54 93 155 6.18 10.5 17.6 58 100 167 6.63 11.3 18.9 78 132 223 8.84 15 25.2 68 116 1.95 7.75 13.2 22.1 91 155 260 10.3 17.6 29.4 LUBED 8 10 12 14 16 18 20 22 24 Class 8.8 4.6 DRY LUBED DRY LUBED DRY LUBED DRY f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm 5.4 10.8 18.9 30.1 46.9 64.5 91 124 157 7.41 14.7 25.6 40.8 63.6 87.5 124 169 214 7.2 14.4 25.1 40 62.5 86.2 121 166 210 9.88 19.6 34.1 54.3 84.8 117 165 225 285 14 27.9 48.6 77.4 125 171 243 331 420 19.1 37.8 66 105 170 233 330 450 570 18.8 37.2 64.9 103 166 229 325 442 562 25.5 50.5 88 140 226 311 441 600 762 20.1 39.9 69.7 110 173 238 337 458 583 27.3 54.1 94.5 150 235 323 458 622 791 26.9 53.2 92.2 147 230 317 450 612 778 36.5 72.2 125 200 313 430 610 830 1055 23.6 46.7 81 129 202 278 394 536 682 32 63.3 110 175 274 377 535 727 925 31.4 62.3 108 172 269 371 525 715 909 42.6 84.4 147 234 365 503 713 970 1233 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety information and step-by-step instructions. Observe and Obey: Symbols Legend 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. 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. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Immediately tag and remove from service a damaged or malfunctioning machine. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. 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: Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. · Machine parked on a firm, level surface · Boom in stowed position Used to indicate operation or maintenance information. · Turntable rotated with the boom between the non-steer wheels · Turntable secured with the turntable rotation lock Indicates that a specific result is expected after performing a series of steps. · Key switch in the off position with the key removed Indicates that an incorrect result has occurred after performing a series of steps. · Wheels chocked · All external AC power disconnected from the machine Part No. 107846 Z-45/25 • Z-45/25J 3-1 Section 3 • Scheduled Maintenance Procedures August 2006 SCHEDULED MAINTENANCE PROCEDURES Pre-delivery Preparation Report 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. Indicates that tools will be required to perform this procedure. Indicates that new parts will be required to perform this procedure. Indicates that a cold engine will be required to perform this procedure. The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required. Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, every 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 Quarterly or every 250 hours Indicates that a warm engine will be required to perform this procedure. Six months or every 500 hours Annual or every 1000 hours Indicates that dealer service is required to perform this procedure. Table or Checklist Two years or every 2000 hours A A+B A+B+C A+B+C+D A+B+C+D+E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3-2 Z-45/25 • Z-45/25J Part No. 107846 Pre-Deliver Pre-Deliveryy Preparation August 2006 Section 3 • Scheduled Maintenance Procedures Fundamentals Instructions It is the responsibility of the dealer to perform the Pre-delivery Preparation. Use the operator’s manual on your machine. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual. If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments Pre-Delivery Preparation Y N Pre-operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond, WA 98073-9730 (425) 881-1800 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev B Part No. 107846 Z-45/25 • Z-45/25J 3-3 R Section 3 • Scheduled Maintenance Procedures August 2006 This page intentionally left blank. 3-4 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev D Serial number A-1 Pre-operation inspection B-1 Battery Date A-2 Functions tests B-3 Exhaust system A-3 Engine maintenance B-4 Inspect air filter A-4 Filter condition indicator A-5 Oscillate axle B-5 Oil cooler and finsDeutz models Perform after 40 hours: B-6 Tires and wheels A-6 30 day service B-7 Brake configuration Perform every 100 hours: B-8 Drive hub oil level A-7 Engine maintenance Ford models B-9 Engine RPM All models A-8 Fuel filter/separator Diesel models B-10 Ground control override A-9 Rotation bearing B-12 Platform leveling Perform every 200 hours: B-13 Engine idle select A-10 Engine maintenance Ford models B-14 Fuel select Ford models Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions · Make copies of both pages to use for each inspection. Y N R · Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: Checklist B - Rev C B-2 Electrical wiring B-11 Directional valve B-15 Drive brakes B-16 Drive speed stowed position B-17 Drive speed raised position A B-18 Alarm package A+B B-19 Hydraulic oil analysis Six Month or 500 hour Inspection: A+B+C B-20 Fuel and hydraulic tank cap venting Annual or 1000 hours Inspection: A+B+C+D B-21 Replace fuel filter Perkins models 2 Year or 2000 hour Inspection: A+B+C+D+E B-22 Engine maintenance Perkins models B-23 Air filter - Ford models · Place a check in the appropriate box after each inspection procedure is completed. · Use the step-by-step procedures in this section to learn how to perform these inspections. · If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 107846 Y N R Perform every 400 hours: B-24 Engine maintenance Ford models Comments Z-45/25 • Z-45/25J 3-5 Section 3 • Scheduled Maintenance Procedures August 2006 MAINTENANCE INSPECTION REPORT Model Checklist C - Rev D Serial number C-1 Engine maintenance Deutz models D-1 Boom wear pads Date C-2 Grease platform overload (if equipped) D-3 Turntable bearing wear Hour meter C-3 Test platform overload (if equipped) Machine owner C-4 Fuel filter/separator Perkins models Inspected by (print) C-5 Air filter - Deutz and Perkins models Inspector signature Y N R Perform every 600 hours: Inspector title C-6 Engine maintenance Perkins models Inspector company Perform every 800 hours: C-7 Engine maintenance Ford models Instructions · Make copies of both pages to use for each inspection. Quarterly or 250 hour Inspection: Y N R D-2 Turntable bearing bolts D-4 Drive hub oil D-5 Free-wheel configuration D-6 Hydraulic filters D-7 Engine maintenance Deutz models Checklist E - Rev D Y N R E-1 Hydraulic oil E-2 Grease steer axle wheel bearings, 2WD models Perform every 3000 hours: E-3 Engine maintenance Deutz models · Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Checklist D - Rev D Perform every 12,000 hours: E-4 Engine maintenance Deutz models 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 Comments · Place a check in the appropriate box after each inspection procedure is completed. · Use the step-by-step procedures in this section to learn how to perform these inspections. · If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3-6 Z-45/25 • Z-45/25J Part No. 107846 August 2006 REV D Section 3 • Scheduled Maintenance Procedures Checklist A Procedures A-1 Perform Pre-operation Inspection A-2 Perform Function Tests Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required. Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. Part No. 107846 Z-45/25 • Z-45/25J 3-7 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES REV D A-3 Perform Engine Maintenance Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020) OR the Deutz FL 2011 Operation Manual (Deutz part number 0297-9929) OR the Perkins 400 Series Operation Manual (Perkins part number TPD 1443S). Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 Deutz FL 2011 Operation Manual Genie part number 84794 Perkins 400 Series Operation Manual Genie part number 94890 3-8 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV D A-4 Check the High Pressure Hydraulic Filter Condition Indicator A-5 Test the Oscillate Axle (if equipped) Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Maintaining the high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation. The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. If the filter is not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. 1 Open the engine side turntable cover. 2 Start the engine from the ground controls. 3 Change the engine idle to high rpm (rabbit symbol). 4 Visually inspect the filter condition indicator. Result: The filter condition indicator should be operating with the plunger in the green area. Result: If the indicator displays the plunger in the red area, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. See D-6, Replace the Hydraulic Filters. Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper axle oscillation is essential to safe machine operation. If the axle oscillation system is not operating correctly, the stability of the machine is compromised and it may tip over. 1 Start the engine from the platform controls. 2 Drive the right steer tire up onto a 6 inch / 15 cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. 3 Drive the left steer tire up onto a 6 inch / 15 cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. 4 Drive both steer tires up onto a 6 inch / 15 cm block or curb. Result: The non-steer tires should stay in firm contact with the ground. If the chassis does not remain level during test, refer to Repair Procedure 8-9, How to Set Up the Directional Valve Linkage. Part No. 107846 Z-45/25 • Z-45/25J 3-9 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES REV D A-6 Perform 30 Day Service A-7 Perform Engine Maintenance Ford Models The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage, whichever comes first. After this interval, refer to the maintenance checklist for continued scheduled maintenance. Engine specifications require that this procedure be performed every 100 hours. Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation. 1 Perform the following maintenance procedures: • A-9 Grease the Turntable Rotation Bearing and Rotate Gear • A-10 Perform Engine Maintenance Ford Models • B-6 Inspect the Tires, Wheels and Lug Nut Torque • B-8 Check the Oil Level in the Drive Hubs • C-1 Perform Engine Maintenance Deutz Models • D-2 Check the Turnable Rotation Bearing Bolts • D-6 Replace the Hydraulic Filters 3 - 10 Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV D A-8 Inspect the Fuel Filter/ Water Separator - Diesel Models 4 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 5 Locate the fuel filter/water separator mounted to the rear engine mounting bracket. 6 Visually inspect the filter bowl for water buildup. Genie specifications require that this procedure be performed every 100 hours or monthly, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and/or hard starting, and continued use may result in component damge. Extremely dirty conditions may require this procedure be performed more often. 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. Result: If water is present in the filter bowl, continue with steps 7 through 11. 7 Loosen the vent plug located on the fuel filter/ water separator head. a d c b a b c d Perform this procedure with the engine off. Perkins models: 8 Loosen the drain plug located at the bottom of the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. 1 Put on protective clothing and eye wear. 2 Open the engine side turntable cover. 3 Remove the safety pin from the engine pivot plate latch. 9 Tighten the vent plug. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Part No. 107846 vent plug drain plug filter bowl separator head Z-45/25 • Z-45/25J If the fuel filter/water separator is completely drained, you must prime the fuel filter/water separator before starting the engine. See C-4, Replace The Fuel Filter/ Water Separator Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 3 - 11 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES REV D 10 Clean up any fuel that may have spilled. 11 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. 5 Loosen the drain plug located at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Do not completely drain the filter. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 12 Swing the engine back to its original position and close the engine pivot plate latch. a 13 Install the engine pivot plate safety pin. b Deutz models: 1 Put on protective clothing and eye wear. a b 2 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. fuel filter/water separator drain valve 6 Clean up any fuel that may have spilled. 7 Start the engine from the ground controls and check the fuel filter/water separator 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. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Locate the fuel filter/water separator next to the oil filter. 8 Swing the engine back to its original position and close the engine pivot plate latch. 9 Install the engine pivot plate safety pin. 3 - 12 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES REV D A-9 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent 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 Before serial number 27001: Locate the grease fitting on the front turntable cover. After serial number 27000: Locate the grease fitting near the ground control box. 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. A-10 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 200 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 To access the engine: Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 107846 Z-45/25 • Z-45/25J 3 - 13 Section 3 • Scheduled Maintenance Procedures August 2006 Checklist B Procedures REV C 4 Be sure that the battery separator wire connections are tight (if equipped). B-1 Inspect the Battery 5 Fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. 1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 11. Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 8. 8 Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 3 Be sure that the battery hold downs and cable connections are tight. 3 - 14 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: B-2 Inspect the Electrical Wiring • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display a specific gravity of 1.277 or greater. The battery is fully charged. Proceed to step 13. Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is less than 1.177. Replace the battery. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. 11 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 12 Install the vent caps and neutralize any electrolyte that may have spilled. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Open the engine side turntable cover. 2 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Inspect the following areas for burnt, chafed, corroded and loose wires: · Engine wiring harness · Hydraulic manifold wiring Part No. 107846 Z-45/25 • Z-45/25J 3 - 15 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 5 Open the ground controls side turntable cover. 6 Inspect the following areas for burnt, chafed, corroded and loose wires: B-3 Check the Exhaust System Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. · Ground control box wire harnesses · Inside of the ground control box · Hydraulic manifold wiring 7 Inspect for a liberal coating of dielectric grease at the following location: · All wire harnesses connectors to the ground control box Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. 8 Start the engine from the ground controls and raise the secondary boom above the turntable covers. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. 9 Remove the center turntable cover retaining fasteners. Remove the center turntable cover from the machine. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 10 Inspect the turntable area for burnt, chafed and pinched cables. 11 Lower the boom to the stowed position and turn the engine off. 12 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Ford models: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. · Cable track on the primary boom · Cables on the primary, and jib booms · Jib boom/Platform rotate manifold · Inside of the platform control box 13 Inspect for a liberal coating of dielectric grease at the following location: · All wire harnesses connectors to the platform control box 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine to access the exhaust system. All models: 3 Be sure that all nuts and bolts are tight. 14 Swing the engine back to its original position and close the engine pivot plate latch. 15 Install the engine pivot plate safety pin. 16 Install the center turntable cover and tighten the retaining fasteners. 4 Inspect all welds for cracks. 5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. Ford models: 6 Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin. 3 - 16 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-4 Inspect the Engine Air Filter B-5 Check the Oil Cooler and Cooling Fins - Deutz Models Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the oil cooler in good condition is essential for good engine performance. Operating a machine with a damaged oil cooler may result in engine damage. Also, restricting air flow through the oil cooler will affect the performance of the cooling system. 1 Release the latches from the air cleaner canister end cap. Remove the end cap. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. 2 Remove the filter element. 3 Clean the inside of the canister and the end cap with a damp cloth. 4 Inspect the air filter element. If needed, blow from the inside out using low pressure dry compressed air, or carefully tap out dust. Replace the filter if needed. 5 Install the filter element. 6 Install the air filter canister end cap and secure the end cap latches. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. Oil cooler: 1 Remove the safety pin from the engine pivot plate latch. Be sure the discharge valve is pointing down when the cap is instaled. Part No. 107846 Z-45/25 • Z-45/25J The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 - 17 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Remove the fasteners from the engine side cover, then remove the cover. B-6 Inspect the Tires, Wheels and Lug Nut Torque 4 Inspect the oil cooler for leaks and physical damage. a b Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. c Maintaining the tires and wheels, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. a b c Bodily injury hazard. An overinflated tire can explode and could cause death or serious injury. oil cooler cylinder head cooling fins fan blower fins Tip-over hazard. Do not use temporary flat tire repair products. 5 Clean the oil cooler of debris and foreign material. The tires on some machines are foam-filled and do not need air added to them. Cooling and fan blower fins: 6 Inspect the fan blower fins for physical damage. 7 Clean the fan blower fins of debris and foreign material. 1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 8 Inspect the head cooling passages and fins for physical damage or foreign material, using a flashlight. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. 9 Clean the cylinder head cooling passages of debris and foreign material. 4 Check the pressure in each air-filled tire. Refer to Section 2, Specifications. 10 Install the engine side cover. 11 Swing the engine back to its original position and close the engine pivot plate latch. 12 Install the engine pivot plate safety pin. 3 - 18 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-7 Confirm the Proper Brake Configuration B-8 Check the Oil Level in the Drive Hubs Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake configuration is essential to safe operation and good machine performance. Hydrostatic brakes and hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees. 1 Check each drive hub disconnect cap to be sure it is in the engaged position. a brake disengaged position brake engaged position a drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level. Result: The oil level should be even with the bottom of the side plug hole. 3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. 4 Install the plug(s) into the drive hub. 5 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications. 6 Repeat this procedure for each drive hub. Part No. 107846 Z-45/25 • Z-45/25J 3 - 19 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C Deutz models: B-9 Check and Adjust the Engine RPM - All Models This procedure will require two people. 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. Ford LRG-425 EFI models: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact the Genie Industries Service Department OR your local Ford dealer. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Connect a tachometer to the engine, and then start the engine from the ground controls and check the rpm. Refer to Section 2, Specifications. Skip to step 5 if the low idle rpm is correct. 4 Loosen the low idle lock nut, then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the low idle lock nut and recheck the rpm. Ford DSG-423 EFI models: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact your local EDI distributor. Refer to the engine operator's handbook on your machine for EDI distributor locations. f e a b a b c d e f 3 - 20 Z-45/25 • Z-45/25J c d solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST B PROCEDURES 5 Move the function enable/rpm select toggle switch to the high idle (rabbit symbol) position at the ground controls and check the rpm. Refer to Section 2, Specifications. If high idle rpm is correct, disregard adjustment step 6. 5 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm, or counterclockwise to decrease the rpm. Tighten the low idle lock nut and confirm the rpm. 6 Loosen the yoke lock nut, then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Be sure the solenoid fully retracts when activating high idle. 7 Swing the engine back to its original position and close the engine pivot plate latch. 8 Install the engine pivot plate safety pin. Perkins models: This procedure will require two people. a 1 Open the engine side turntable cover. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. c a b c d 2 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. b d solenoid boot high idle adjustment nut yoke low idle lock nut and adjustment screw 6 Move the function enable toggle switch to the high idle (rabbit symbol) position. Refer to Section 2, Specifications. If high idle rpm is correct, disregard adjustment step 7. 4 Connect a tachometer to the engine. Start the engine from the ground controls. Refer to Section 2, Specifications. Skip to step 6 if the low idle rpm is correct. Part No. 107846 Z-45/25 • Z-45/25J 3 - 21 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 7 Loosen the yoke lock nut, then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. B-10 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Be sure the solenoid fully retracts when activating high idle. 8 Swing the engine back to its original position and close the engine pivot plate latch. 9 Install the engine pivot plate safety pin. A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button on the platform controls is in the on or off position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the platform red Emergency Stop button to the off position. 2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate. 3 - 22 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-11 Check the Oscillate Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this test only on models equipped with an oscillating axle. Proper axle oscillation is essential to safe machine operation. If the oscillate directional valve linkage is not operating correctly, the stability of the machine is compromised and it may tip over. 1 Remove the drive chassis cover and the axle covers from the non-steer end of the drive chassis. 2 Locate the oscillate directional valve inside of the non-steer 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 Part No. 107846 B-12 Test the Platform Self-leveling Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 1 Start the engine from the ground controls and lower the boom into the stowed position. 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch. 3 Raise and lower the primary boom through a full cycle. Result: The platform should remain level at all times to within ±5 degrees. Z-45/25 • Z-45/25J 3 - 23 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 5 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). B-13 Test the Engine Idle Select Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are two settings. Foot switch activated low idle (turtle symbol) allows the operator to control individual boom functions. Drive functions will operate at low idle, but at reduced performance. Result: The engine should not change to high idle. 6 Press down the foot switch. Result: The engine should change to high idle. 7 Move the engine idle control switch to foot switch activated low idle (turtle symbol). Result: The engine should change to low idle. Foot switch activated high idle (rabbit symbol) should be used for normal machine operation. This selection activates high idle only when the foot switch is pressed down. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 Start the engine from the ground controls then move the function enable toggle switch to the high idle (rabbit symbol) position and hold in the on position. Result: The engine should change to high idle. 3 Release the function enable toggle switch. Result: The engine should return to low idle. 4 Turn the key switch to platform controls. 3 - 24 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-14 Test the Fuel Select Operation Ford Models 4 Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position. 5 Move the fuel select switch to LPG. 6 Restart the engine and allow it to run at low idle. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 7 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation. A fuel selection can be made when the engine is running or not. 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. 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. Perform this test after checking the gasoline and LPG fuel levels, and warming the engine to normal operating temperature. 1 At the platform controls, move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 2 Start the engine from the platform controls and allow it to run at low idle. 3 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. Part No. 107846 Z-45/25 • Z-45/25J 3 - 25 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C B-15 Test the Drive Brakes B-16 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. See B-7, Confirm the Proper Brake Configuration. Select a test area that is firm, level and free of obstructions. 1 Mark a test line on the ground for reference. 2 Start the engine from the platform controls. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Start the engine from the platform controls. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol), then lower the boom into the stowed position. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol), then lower the boom into the stowed position. 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. 5 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 5 Bring the machine to top drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line. 6 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. 6 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb. 3 - 26 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-17 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. 7 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. 8 Lower the boom to the stowed position and extend the boom 1 foot / 30 cm. 9 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 10 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. 11 Continue at top speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Start the engine from the platform controls. 3 Move the engine idle select switch to foot switch activated high idle (rabbit and foot switch symbol). 4 Press down the foot switch and raise the primary boom above horizontal. 5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 6 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. Part No. 107846 Z-45/25 • Z-45/25J 3 - 27 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 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. B-18 Test the Alarm Package (if equipped) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. The alarm package includes: · Travel alarm · Descent alarm · Flashing beacon Result: The descent alarm should sound when the switch is held down. 4 Z-45/25J: Move the function enable toggle switch to either side and activate the jib boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the turntable covers. The alarms and beacon will operate with the engine running or not running. 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Result: The flashing beacon should be on and flashing. 2 Move the function enable switch to either side and activate the primary boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. 5 Turn the key switch to platform control. Result: The flashing beacon should be on and flashing. 6 Press down the foot switch. Move the primary boom control handle to the down position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 7 Press down the foot switch. Move the secondary boom control handle to the down position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 8 Z-45/25J: Press down the foot switch. Activate the jib boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. 9 Press down the foot switch. Move the drive control handle off center, hold for a moment and then release it. Move the drive control handle off center in the opposite direction, hold for a moment and then release it. Result: The travel alarm should sound when the drive control handle is moved off center in either direction. 3 - 28 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-19 Perform Hydraulic Oil Analysis B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. For hydraulic oil specifications, refer to Section 2, Specifications. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the caps be inspected more often. 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. Perform this procedure with the engine off. 1 Remove the cap from the fuel tank. 2 Check for proper venting. Result: Air passes through the fuel tank cap. Proceed to step 4. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. When checking for positive tank cap venting, air should pass freely through the cap. Part No. 107846 Z-45/25 • Z-45/25J 3 - 29 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C 3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. B-21 Replace the Fuel Filter Element Perkins Models 4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 6 Check for proper venting. Result: Air passes through the fuel tank cap. Proceed to step 8. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7. When checking for positive tank cap venting, air should pass freely through the cap. Replacing the diesel fuel filter element is essential for 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 required that the filter be replaced more often. 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. 7 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank. Perform this procedure with the engine off. 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 - 30 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures REV C CHECKLIST B PROCEDURES 3 Thoroughly clean the outside surfaces of the fuel filter assembly. Prime the fuel system: 10 Loosen the vent plug on top of the fuel injection pump. 4 Place a suitable container under the fuel filter element. 5 Disconnect and plug the fuel line from the fuel pump to the fuel filter element. a b c a b c a b c a b c fuel line filter head fuel filter element 6 Remove the fuel filter element with a filter wrench. 7 Apply a thin layer of fuel to the new fuel filter element O-ring. 8 Install the new fuel filter element and tighten it securely by hand. Clean up any fuel that may have spilled during the installation procedure. vent plug fuel injection pump fuel lift pump 11 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel, free from air, comes from the vent plug. Tighten the vent plug. 12 Clean up any fuel that may have spilled during this procedure. 13 Operate the starter motor for intervals of 15 seconds until the engine starts. 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the fuel filter housing. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leak in the low pressure side of the system. Part No. 107846 Z-45/25 • Z-45/25J 3 - 31 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES REV C B-22 Perform Engine Maintenance Perkins Models B-23 Replace the Engine Air Filter Element - Ford Models Engine specifications require that this procedure be performed every 250 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Engine specifications require that this procedure be performed every 400 hours. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual (Perkins part number TPD 1443S). 1 Locate the engine air filter assembly. Perkins 400 Series Operation Manual Genie part number 3 Remove and discard the filter element. 94890 2 Release the latches from the air cleaner canister end cap. Remove the end cap. 4 Clean the inside of the canister and the end cap with a damp cloth. 5 Install the new filter element. 6 Install the air filter canister end cap and secure the end cap latches. Be sure the discharge valve is pointing down when the cap is instaled. 3 - 32 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES REV C B-24 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 400 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 Part No. 107846 Z-45/25 • Z-45/25J 3 - 33 Section 3 • Scheduled Maintenance Procedures August 2006 Checklist C Procedures C-1 Perform Engine Maintenance Deutz Models C-2 Grease the Platform Overload Mechanism (if equipped) Deutz engine specifications require that this procedure be performed every 500 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual (Deutz part number 0297-9929). Deutz FL 2011 Operation Manual Genie part number REV D Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist. Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage. 1 Locate the grease fittings on each pivot pin of the platform overload assembly. 84794 To access the engine: 2 Thoroughly pump grease into each grease fitting. Grease Specification 1 Remove the safety pin from the engine pivot plate latch. Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent 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. 3 - 34 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES REV D The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link. This isolates platform loads into a shear or vertical state, which translates into a compressive load. A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform. C-3 Test the Platform Overload System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over. The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on. When activated, the system halts all normal boom operation, giving visual and audible warning to the operator. As weight is added to the platform, the spring will compress until, when the platform is overloaded, the lower arm contacts a limit switch and thereby activating the overload signal. When adjusted correctly, the platform overload system will deactivate normal boom operation at platform capacity. Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Models equipped with the platform overload option are provided with additional machine components: an adjustable spring-loaded platform support subassembly, a limit switch, an electronic module which receives the overload signal and interrupts power, and an audio/visual warning indication to alert the operator of the overload. Part No. 107846 Z-45/25 • Z-45/25J Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test. 3 - 35 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES REV D 4 Using a suitable lifting device, place a test weight equal to that of the available capacity one of the locations shown. Refer to Illustration 1. Result: The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Proceedure 2-3, How to Calibrate the Platform Overload System (if equipped). 5 Carefully move the test weight to each remaining location. Refer to Illustration 1. Result: The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Proceedure 2-3, How to Calibrate the Platform Overload System (if equipped). 6 Using a suitable lifting device, place an additional 50 lbs / 23 kg of weight onto the platform. Result: The alarm should sound. The platform overload indicator lights should be flashing at both the ground and platform controls. Result: The alarm does not sound and the platform overload indicator lights are not flashing. Calibrate the platform overload system. Refer to Repair Proceedure 2-3, How to Calibrate the Platform Overload System (if equipped). There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. 7 Carefully move the test weights to each remaining location on the platform. Refer to Illustration 1. Result: The alarm should sound. The platform overload indicator lights should be flashing at both the ground and platform controls. Result: The alarm does not sound and the platform overload indicator lights are not flashing. Calibrate the platform overload system. Refer to Repair Proceedure 2-3, How to Calibrate the Platform Overload System (if equipped). There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. Illustration 1 3 - 36 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES REV D 8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 15 Turn the key switch to platform control. 16 Test all machine functions from the platform controls. Result: All platform control functions should operate. 10 Test all machine functions from the ground controls. If the platform overload system is not operating properly, Refer to Repair Procedure 2-3, How to Calibrate the Platform Overload System (if equipped). Result: All ground control functions should not operate. 11 Activate the auxiliary power toggle switch. The engine will turn off when the auxiliary power is activated. 17 Using a suitable lifting device, remove the remaining test weights from the platform. 12 Using auxiliary power, test all machine functions from the ground controls. Result: All ground control functions should operate. 13 Using a suitable lifting device, lift the additional test weight from the platform. Result: The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound. There may be an 2 second delay before the overload indicator lights and alarm turn off. 14 Start the engine and test all machine functions from the ground controls. Result: All ground control functions should operate normally. Part No. 107846 Z-45/25 • Z-45/25J 3 - 37 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES REV D C-4 Replace the Fuel Filter/Water Separator - Perkins Models Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Regular replacement of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and/or hard starting, and continued use may result in component damge. Extremely dirty conditions may require this procedure be performed more often. 4 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 5 Locate the fuel filter/water separator mounted to the rear engine mounting bracket. 6 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter/water separator. 7 Loosen the vent plug located on the fuel filter/ water separator head. a f e d c 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. a b c d e f Perform this procedure with the engine off. 1 Put on protective clothing and eye wear. 2 Open the engine side turntable cover. 3 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 - 38 b vent plug main fuel line drain plug filter bowl filter element separator head 8 Place a suitable container under the filter bowl. Loosen the drain plug located at the bottom of the bowl. Completely drain the fuel. 9 Rotate the filter bowl counterclockwise and remove it from the element. Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES REV D 17 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel, free from air, comes from the vent plug. Tighten the vent plug. 10 Rotate the filter element counterclockwise and remove it from the filter head. 11 Install the bowl onto the new filter element. 12 Apply a thin layer of oil onto the element gasket. Install the filter/bowl assembly onto the filter head. Tighten the drain plug and vent plug. Component damage hazard. The drain plug and vent plug can be damaged if they are overtightened. 18 Clean up any fuel that may have spilled during this procedure. 19 Operate the starter motor for intervals of 15 seconds until the engine starts. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. 13 Clean up any diesel fuel that may have spilled during the installation procedure. 14 Install the fuel supply hose from the fuel tank to the fuel filter/water separator. Tighten the clamp. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leak in the low pressure side of the system. 15 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter element housing. Prime the fuel system: 16 Loosen the vent plug on top of the fuel injection pump. 20 Swing the engine back to its original position and close the engine pivot plate latch. 21 Install the engine pivot plate safety pin. a b c a b c Part No. 107846 vent plug fuel injection pump fuel lift pump Z-45/25 • Z-45/25J 3 - 39 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES REV D C-5 Replace the Engine Air Filter Element - Deutz and Perkins Models Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. C-6 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 600 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual (Perkins part number TPD 1443S). 1 Locate the engine air filter assembly. 2 Release the latches from the air cleaner canister end cap. Remove the end cap. Perkins 400 Series Operation Manual Genie part number 94890 3 Remove and discard the filter element. 4 Clean the inside of the canister and the end cap with a damp cloth. 5 Install the new filter element. To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 6 Install the air filter canister end cap and secure the end cap latches. Be sure the discharge valve is pointing down when the cap is instaled. 3 - 40 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES REV D C-7 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Ford LRG-425 EFI Operator Handbook Genie part number Ford DSG-423 EFI Operator Handbook Genie part number 84792 119488 To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 107846 Z-45/25 • Z-45/25J 3 - 41 Section 3 • Scheduled Maintenance Procedures August 2006 Checklist D Procedures D-1 Check the Boom Wear Pads D-2 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn wear pads may result in component damage and unsafe operating conditions. 1 Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness. If the wear pad is still within specification, shim as necessary to obtain minimum clearance with zero binding. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. 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 a safety chock on the lift cylinder rods. Carefully lower the boom onto the lift cylinder safety chock. Crushing hazard. Keep hands away from the cylinder and all moving parts when lowering the boom. 2 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. Always maintain squareness between the outer and inner boom tubes. Primary boom wear pad specifications 2 Turn the engine off. 3 Remove the safety pin from the engine pivot plate latch. 5 /8 inch 15.9 mm Side and bottom wear pads (pivot end of boom) 1/2 inch 12.7 mm 3 - 42 The lift cylinder safety chock is available through the Genie Service Parts Department. Minimum Top, bottom and side wear pads (platform end of boom) Top wear pads (pivot end of boom) REV D The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 5 /8 inch 15.9 mm Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES REV D 4 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Counterweight 3 5 Remove the center turntable cover retaining fasteners. Remove the center turntable cover from the machine. 18 6 13 10 11 1 8 6 Be sure that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications. 15 7 12 16 2 9 14 5 17 4 Bolt torque sequence (after serial number 27000) 7 Start the engine from the ground controls. 8 Raise the secondary boom and remove the safety chocks. 9 Lower the boom to the stowed position. 10 Remove drive chassis covers from both the steer end and the non-steer end of the machine. Bolt torque sequence (before serial number 23332) 13 10 1 15 11 Remove the lower chassis cover mounting fasteners from inside of the drive chassis (if equipped). 19 6 12 Remove the lower chassis cover to access the lower turntable bearing bolts under the drive chassis. 7 18 12 3 4 11 17 8 5 20 16 2 9 14 Bolt torque sequence (from serial number 23332 to 27000) Part No. 107846 Z-45/25 • Z-45/25J 3 - 43 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST D PROCEDURES REV D 13 Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to specification. Refer to Section 2, Specifications. D-3 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Bolt torque sequence (before serial number 23332) 10 1 13 Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 15 7 6 4 12 11 5 3 14 8 16 2 9 Bolt torque sequence (after serial number 23331) 3 - 44 Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage. 1 Grease the turntable bearing. See A-10, Grease the Turntable Bearing and Rotate Gear. 2 Torque the turntable bearing bolts to specification. See D-2, Check the Turntable Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the primary and secondary booms to full height. Do not extend the primary boom. Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES REV D 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing. To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing. a 7 Note the reading on the dial indicator. Result: The measurement is less than 0.055 inch / 1.4 mm. The bearing is good. Result: The measurement is more than 0.055 inch / 1.4 mm. The bearing is worn and needs to be replaced. 8 Fully retract the primary boom. Raise the primary and secondary booms to full height. Visually inspect the the dial indicator to be sure the needle returns to the "zero" position. 9 Remove the dial indicator and rotate the turntable 90°. 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart. b 11 Lower the primary and secondary booms to the stowed position and turn the machine off. c 12 Remove the dial indicator from the machine. d a b c d turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator, adjust it to "zero" the indicator. 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom. Part No. 107846 Z-45/25 • Z-45/25J 3 - 45 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST D PROCEDURES REV D D-4 Replace the Drive Hub Oil D-5 Check the Free-wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. 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. 1 Select the drive hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. 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. 2 Remove both plugs and drain the oil. Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. 3 Drive the machine until one plug is at the top and the other is at 90 degrees. a Non-steer wheels: All models 1 Chock the steer wheels to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the non-steer tires. 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support. a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole. Install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs. 6 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications. 3 - 46 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES REV D 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub. disengaged position disengaged position engaged position engaged position 5 Manually rotate each non-steer wheel. 11 Manually rotate each steer wheel. Result: Each non-steer wheel should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Raise the machine, remove the jack stands and lower the machine. Result: Each steer wheel should rotate with minimum effort. 12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Raise the machine, remove the jack stands and lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. Steer wheels: 4WD models 7 Chock the non-steer wheels to prevent the machine from rolling. 8 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the steer tires. 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support. Part No. 107846 Z-45/25 • Z-45/25J 3 - 47 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST D PROCEDURES REV D D-6 Replace the Hydraulic Filters 5 Install the new filter element into the filter housing. 6 Push the filter element down to be sure the O-ring on the element is fully seated into the housing. Genie requires that this procedure be performed yearly or every 1000 hours, whichever comes first. Perform this procedure more often if dusty conditions exist. Replacement of the hydraulic filters is essential for 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 filters 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. 7 Rotate the filter element clockwise to lock it in place. 8 Install the filter housing cap. 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing. Medium and high pressure filters The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit. 10 Open the engine side turntable cover and locate the medium and high pressure filters. The medium pressure filter is mounted near the pump. The high pressure filter, with filter condition indicator, is mounted to the bulkhead. Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank. 11 Place a suitable container under each filter. 2 Remove the cap from the filter housing. 3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing. 4 Remove the filter element from the filter housing. 3 - 48 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings. 13 Remove the filter elements from the housings. 14 Inspect the housing seals and replace them if necessary. Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES REV D 15 Install the new filter elements into the housings and tighten them securely. The medium and high pressure filters use the same elements. D-7 Perform Engine Maintenance Deutz Models 16 Clean up any oil that may have spilled during the installation procedure. Engine specifications require that this procedure be performed every 1000 hours. 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings. 18 Start the engine from the ground controls. 19 Inspect the filter housings and related components to be sure that there are no leaks. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual (Deutz part number 0297-9929). Deutz FL 2011 Operation Manual Genie part number 84794 To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 107846 Z-45/25 • Z-45/25J 3 - 49 Section 3 • Scheduled Maintenance Procedures August 2006 Checklist E Procedures E-1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours or every two years, whichever comes first. Perform this procedure more often if dusty conditions exist. REV D 1 Ford models: Turn the valve on the LPG tank clockwise to the off position (if equipped). Then slowly disconnect the hose from the LPG tank. 2 Ford models: Open the clamps from the LPG tank straps and remove the LPG tank from the machine (if equipped). 3 Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. open closed 4 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. Perform this procedure with the boom in the stowed position. 3 - 50 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES REV D 5 Tag, disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank. Cap the fittings on the tank. The hoses can be accessed through the access hole under the turntable. 6 Disconnect and plug the return filter hydraulic hose at the return filter. Cap the fitting on the filter housing. 7 Remove the ground controls side turntable cover. 16 Install the hydraulic return filter housing onto the hydraulic tank. 17 Install the hydraulic tank onto the machine. 18 Install the two suction hoses to the suction strainers. 19 Install the supply hose for the auxiliary power unit and the return filter hose. 20 Models with hydraulic tank shut-off valves: Open the two hydraulic tank valves at the hydraulic tank. 9 Remove the hydraulic tank mounting fasteners. 21 Fill the tank with the proper hydraulic oil for your machine until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. Refer to Section 2, Specifications. 10 Remove the hydraulic tank from the machine. 22 Clean up any oil that may have spilled. 8 Support the hydraulic tank with an appropriate lifting device. Crushing hazard. The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine. 23 Prime the pump. Refer to Repair Procedure 7-2, How to Prime the Pump. 11 Remove the hydraulic return filter housing mounting fasteners. Remove the hydraulic return filter housing from the hydraulic tank. Always use pipe thread sealant when installing the suction hose fittings and the drain plug. 12 Remove the suction strainers from the tank and clean them using a mild solvent. 13 Rinse out the inside of the tank using a mild solvent. 14 Install the suction strainers using a thread sealant on the threads. 15 Install the drain plug using a thread sealant on the threads. Part No. 107846 Z-45/25 • Z-45/25J 3 - 51 Section 3 • Scheduled Maintenance Procedures August 2006 CHECKLIST E PROCEDURES REV D E-2 Grease the Steer Axle Wheel Bearings, 2WD Models 6 Remove the dust cap from the hub. Remove the cotter pin from the castle nut. 7 Tighten the castle nut to 35 ft-lbs / 47 Nm to seat the bearings. 8 Loosen the castle nut and re-tighten to 8 ft-lbs / 11 Nm. Genie requires that this procedure be performed every 2000 hours or every two years, whichever comes first. Perform this procedure more often if dusty conditions exist. Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often. 1 Loosen the wheel lug nuts. Do not remove them. 2 Block the non-steer wheels, then center a lifting jack under the steer axle. 9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: If there is no side to side or up and down movement, continue with step 11 and grease the wheel bearings. Result: If there is side to side or up and down movement, continue to step 11 and replace the wheel bearings with new ones. When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced. 10 Remove the dust cap from the hub. Remove the cotter pin from the castle nut. 11 Remove the castle nut. 3 Raise the machine 6 inches / 15 cm and place blocks under the drive chassis for support. 12 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub. 4 Remove the lug nuts. Remove the tire and wheel assembly. 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: There should be no side to side or up and down movement. 14 Pack both bearings with clean, fresh grease. 15 Place the large inner bearing into the rear of the hub. Skip to step 10 if there is no movement. 3 - 52 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES REV D 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush. 17 Slide the hub onto the yoke spindle. E-3 Perform Engine Maintenance Deutz Models Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur. Engine specifications require that this procedure be performed every 3000 hours. 18 Place the outer bearing into the hub. 19 Install the washer and castle nut. 20 Tighten the slotted nut to 35 ft-lbs / 47 Nm to seat the bearings. 21 Loosen the castle nut and re-tighten to 8 ft-lbs / 11 Nm. 22 Install a new cotter pin. Bend the cotter pin to lock it in. Always use a new cotter pin when installing a castle nut. 23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual (Deutz part number 0297-9929). Deutz FL 2011 Operation Manual Genie part number 84794 To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 107846 Z-45/25 • Z-45/25J 3 - 53 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES August 2006 REV D E-4 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 12,000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual (Deutz part number 0297-9929). Deutz FL 2011 Operation Manual Genie part number 84794 To access the engine: 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 - 54 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Perform disassembly procedures to the point where repairs can be completed. To re-assemble, perform the disassembly steps in reverse order. Symbols Legend Immediately tag and remove from service a damaged or malfunctioning machine. 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. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Be sure that all necessary tools and parts are available and ready for use. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Turntable rotated with the boom between the non-steer wheels Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Turntable secured with the turntable rotation lock Used to indicate operation or maintenance information. Machine parked on a firm, level surface Boom in stowed position Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No. 107846 Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Z-45/25 • Z-45/25J 4-1 Section 4 • Repair Procedures August 2006 Platform Controls The platform control box contains one printed circuit board. The ALC-500 circuit board inside the platform control box controls all proportional machine functions from the platform. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls. If a joystick error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. See 1-2, How to Calibrate a Joystick. Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. a REV B 1-1 ALC-500 Circuit Board Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. When the ALC-500 circuit board is replaced, the joystick controllers will need to be calibrated. See 1-2, How to Calibrate a Joystick. How to Remove the ALC-500 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box lid retaining fasteners. Open the control box lid. 3 Locate the ALC-500 circuit board mounted to the inside of the platform control box. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. c d a b c d 4-2 b ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures PLATFORM CONTROLS REV B 4 Attach a grounded wrist strap to the ground screw inside the platform control box. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 1-2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control. If a joystick is disconnected or replaced, it must be calibrated before that particular machine function will operate. 5 Carefully disconnect the wire connectors from the circuit board. The joystick must be calibrated before the threshold, max-out or ramp rate can be set. 6 Remove the ALC-500 circuit board mounting fasteners. 7 Carefully remove the ALC-500 circuit board from the platform control box. Perform this procedure with the engine off. 1 Open the platform control box. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Turn the key switch to platform control. Do not start the engine. 4 Select a joystick to calibrate. 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds. Connect the wire harness connector to the joystick. 6 Move the joystick full stroke in either direction and hold for 5 seconds. 7 Return the joystick to the neutral position, pause for a moment, then move the joystick full stroke in the opposite direction. Hold for 5 seconds and return the joystick to the neutral position. Result: The alarm should sound indicating successful joystick calibration. 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 107846 Z-45/25 • Z-45/25J 4-3 Section 4 • Repair Procedures August 2006 PLATFORM CONTROLS REV B 8 Start the engine from the platform controls and press down the foot switch. How to Adjust the Joystick Max-out Setting The max-out setting of a joystick controls the maximum speed of a joystick-controlled machine function. Whenever a hydraulic cylinder, drive motor or hydraulic pump is replaced, the max-out setting should be adjusted to maintain optimum performance. The max-out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 9 Start a timer and activate the machine function that needs to be adjusted. Record the time it takes for that function to complete a full cycle (ie; boom up). 10 Compare the machine function time with the function times listed in Section 2, Specifications. Determine whether the function time needs to increase or decrease. 11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle time. Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed. 2 Turn the key switch to platform control. Do not start the engine. Each time the drive enable toggle switch is momentarily moved, the function speed will change in 2% increments. 3 Push in the platform controls red Emergency Stop button to the off position. 12 Repeat steps 9 through 11 for each joystick controlled machine function. 4 Do not press down the foot switch. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. 6 When the alarm sounds, release the drive enable toggle switch. 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. Result: The alarm should sound indicating that the settings have been saved in memory. 7 Momentarily activate the drive enable toggle switch in the right direction 4 times. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. 4-4 Z-45/25 • Z-45/25J Do not operate any machine function during the 10 second waiting time. Part No. 107846 August 2006 Section 4 • Repair Procedures PLATFORM CONTROLS REV B How to Adjust the Joystick Ramp Rate Setting 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease. The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. 11 While the joystick is activated, set the ramp rate. Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time. Each time the drive enable toggle switch is momentarily moved, the time will change in 10% increments. Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 Turn the key switch to platform control. Do not start the engine. 3 Push in the platform controls red Emergency Stop button to the off position. 4 Do not press down the foot switch. 12 Repeat steps 9 through 11 for each joystick controlled machine function. 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. Result: The alarm should sound indicating that the settings have been saved in memory. Do not operate any machine function during the 10 second waiting time. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. 6 When the alarm sounds, release the drive enable toggle switch. Ramp rate (factory settings) 7 Momentarily activate the drive enable toggle switch in the right direction 6 times. Primary boom up/down accelerate decelerate 4 seconds 0.5 second Secondary boom up/down accelerate decelerate 2 seconds 0.5 second Turntable rotate accelerate decelerate 2 seconds 0.5 second Result: There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode. 8 Start the engine from the platform controls and press down the foot switch. 9 Start a timer and simultaneously move the joystick in either direction full stroke. Note how long it takes the function to reach maximum speed. This is the ramp rate. Part No. 107846 Drive accelerate accelerate (narrow models) decelerate to neutral decelerate, change of direction decelerate, coasting decelerate, braking decelerate, shift from low to high speed decelerate, shift from high to low speed Z-45/25 • Z-45/25J 3.3 seconds 3.8 seconds 0.5 second 0.5 second 0.75 second 1 second 1 second 2 seconds 4-5 Section 4 • Repair Procedures August 2006 PLATFORM CONTROLS REV B How to Adjust the Joystick Threshold Setting 10 Slowly move the joystick off center in either direction just until the function begins to move. The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate. 11 Slowly move the joystick back to the neutral position. Just before the function stops moving, move the drive enable toggle switch to either side to set the threshold. Perform this procedure with the boom in the stowed position. Result: The alarm should sound indicating a successful calibration. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 12 Repeat steps 9 through 11 for each boom joystick controlled machine function (boom up/ down, boom extend/retract and turntable rotate). 2 Turn the key switch to platform control. Do not start the engine. 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. 3 Push in the platform controls red Emergency Stop button to the off position. 4 Do not press down the foot switch. Result: The alarm should sound indicating that the settings have been saved in memory. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. Do not operate any machine function during the 10 second waiting time. 6 When the alarm sounds, release the drive enable toggle switch. 7 Momentarily activate the drive enable toggle switch in the right direction 8 times. Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. 8 Start the engine from the platform controls and press down the foot switch. 9 Select a boom function joystick to set the threshold. 4-6 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures Platform Components REV C 2-1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. 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. Do not rest the entire weight of the boom on the blocks. 4 Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector. Connect the hoses from the cylinder together using a connector. 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. How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.. 1 Z-45/25J: Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the primary boom slightly and place blocks under the platform for support. Part No. 107846 5 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not remove the pin. 6 Z-45/25J: Remove the external snap rings from the slave cylinder barrel-end pivot pin. Do not remove the pin. Z-45/25: Remove the pin retaining fastener from the slave cylinder barrel-end pivot pin. Do not remove the pin. 7 Place a block under the slave cylinder for support. Protect the cylinder rod from damage. Z-45/25 • Z-45/25J 4-7 Section 4 • Repair Procedures August 2006 PLATFORM COMPONENTS REV C 8 Z-45/25: Support the platform rotator with a suitable lifting device. 9 Use a soft metal drift to drive the rod-end pivot pin out. Crushing hazard. The platform could fall when the slave cylinder rod-end pivot pin is removed if not properly supported. Component damage hazard. The slave cylinder rod may become damaged if it is allowed to fall if not properly supported by the lifting device. 10 Use a soft metal drift and drive the barrel-end pin out. 11 Carefully pull the cylinder out of the primary boom. How to Bleed the Slave Cylinder 1 Simultaneously activate the boom up function and the platform level up function until the boom is fully raised. 2 Simultaneously activate the boom down function and the platform level down function until the boom is fully lowered. 2-2 Platform Rotator How to Bleed the Platform Rotator This procedure will require two people. Do not start the engine. Use auxiliary power for this procedure. 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right. Before serial number 24304: 2 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container to collect any drainage. Secure the container to the boom. 3 Open the top bleed valve on the rotator, but do not remove it. a d c a b c d 4-8 Z-45/25 • Z-45/25J b top bleed valve bottom bleed valve container clear hose Part No. 107846 August 2006 Section 4 • Repair Procedures PLATFORM COMPONENTS REV C 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. Crushing hazard. Keep clear of the platform during rotation. 5 Connect the clear hose to the bottom bleed valve and open the valve. Do not remove the bleed valve. 5 Open the bottom bleed screw on the rotator, but do not remove it. 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. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. After serial number 24303: 2 Place a suitable container underneath the platform rotator. 3 Open the top bleed screw on the rotator, but do not remove it. 7 Clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks. 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. Part No. 107846 Z-45/25 • Z-45/25J 4-9 Section 4 • Repair Procedures August 2006 PLATFORM COMPONENTS REV C 5 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. 2-3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over. Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 6. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Slowly tighten the load spring adjustment nut in a clockwise direction in 10° increments until the overload indicator light turns off, and the alarm does not sound. Proceed to step 8. The platform will need to be moved up and down and allowed to settle between each adjustment. Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. There may be a 2 second delay before the platform overload indicator light and alarm responds. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Failure to remove all weight, tools and accessories from the platform will result in an incorrect calibration. 4 Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor. 6 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. Result: The overload indicator lights are off at the platform and ground controls, and the alarm does not sound. Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10° increments until the overload indicator light flashes at both the platform and ground controls, and the alarm sounds. Proceed to step 7. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5. The platform will need to be moved up and down and allowed to settle between each adjustment. There may be a 2 second delay before the platform overload indicator lights and alarm responds. 4 - 10 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures REV C PLATFORM COMPONENTS 7 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 8. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5. There may be a 2 second delay before the platform overload indicator light and alarm responds. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 12 Using a suitable lifting device, lift the test weight off the platform floor. Result: The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound. There may be a 2 second delay before the overload indicator lights and alarm turn off. 8 Add an additional 10 lb / 4.5 kg test weight to the platform. Result: The overload indicator light is flashing at both the ground and platform controls, and the alarm is sounding. Proceed to step 9. Result: The overload indicator light is off at both the ground and platform controls, and the alarm does not sound. Remove the additional 10 lb / 4.5 kg test weight. Repeat this procedure beginning with step 6. There may be a 2 second delay before the platform overload indicator light and alarm responds. 13 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 14 Turn the key switch to platform control. 15 Test all machine functions from the platform controls. Result: All platform control functions should operate normally. 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. Part No. 107846 Z-45/25 • Z-45/25J 4 - 11 Section 4 • Repair Procedures August 2006 Jib Boom Components, Z-45/25J REV B 3-1 Jib Boom 5 Attach a lifting strap from an overhead crane to the platform rotator for support. How to Remove the Jib Boom 6 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 7 Remove the pin retaining fasteners from both platform rotator pivot pins. Do not remove the pins. 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down. 9 Use a soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the machine. 1 Remove the platform. 10 Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. 2 Disconnect the electrical connector from the jib boom/platform rotate select valve manifold mounted to the platform support. 11 Remove the hose and cable cover from the side of the jib boom. Remove the hose and cable separators. 3 Tag, disconnect and plug all of the hydraulic hoses from the jib boom/platform rotate select valve manifold. Cap the fittings on the manifold and pull the hoses out through the platform rotator. 12 Attach a lifting strap from an overhead crane to the jib boom. 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. 13 Support the barrel end of the jib boom lift cylinder with a suitable lifting device. 14 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 4 Remove the platform mounting weldment. 4 - 12 Z-45/25 • Z-45/25J 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. Part No. 107846 August 2006 Section 4 • Repair Procedures JIB BOOM COMPONENTS, Z-45/25J REV B 15 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. 16 Use a soft metal drift to remove the pin and let the cylinder hang down. Crushing hazard. The jib boom could fall when when the barrel-end pivot pin is removed if not properly supported by the overhead crane. 3-2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position. 17 Remove the pin retaining fastener from the jib boom pivot pin. Use a soft metal drift to remove the pin, then remove the jib boom from the bellcrank. Crushing hazard. The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 18 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. 19 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the bellcrank. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Part No. 107846 Do not rest the entire weight of the boom on the blocks. 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Z-45/25 • Z-45/25J 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 - 13 Section 4 • Repair Procedures August 2006 JIB BOOM COMPONENTS, Z-45/25J REV B 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 5 Support the jib boom lift cylinder with a suitable lifting device. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down. Crushing hazard. The jib boom could fall when the barrel-end pivot pin is removed if not properly supported by the overhead crane. 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 4 - 14 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures Primary Boom Components REV B 4-1 Cable Track The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom. How to Remove the Cable Track, Z-45/25 When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 2 Disconnect the cables from the platform control box. 5 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. 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. 6 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Tag, disconnect and plug the hydraulic hoses from the platform leveling master cylinder. Cap the fittings on the cylinder. 3 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 4 Raise the primary boom to a horizontal position. Part No. 107846 Z-45/25 • Z-45/25J 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 - 15 Section 4 • Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 8 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder and connect them together using a connector. Cap the fittings on the 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. 9 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder. 15 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. How to Remove the Cable Track, Z-45/25J When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 10 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 11 Remove all hose and cable clamps from the underside of the primary boom. 1 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 12 Attach a strap from an overhead crane to the cable track. 2 Disconnect the cables from the platform control box. 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 3 Remove the hose and cable cover from the side of the jib boom. Remove the hose and cable separators. 14 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 4 Remove the hose clamp on the primary boom bellcrank. 4 - 16 5 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS REV B 6 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder at the union and connect them together using a connector. Connect the hoses from the cylinder together using a connector. 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. 8 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate manifold. Cap the fittings on the manifold. 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. Part No. 107846 9 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. 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 Tag, disconnect and plug the hydraulic hoses from the platform leveling master cylinder. Cap the fittings on the 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. 11 Raise the boom to a horizontal position. 12 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 13 Attach a lifting strap from an overhead 5 ton / 5,000 kg capacity crane to the platform end of the primary boom for support. Do not lift it. Z-45/25 • Z-45/25J 4 - 17 Section 4 • Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 14 Remove all hose and cable clamps from the underside of the primary boom. 25 Remove the cable track from the machine and place it on a structure capable of supporting it. 15 Support the rod end of the primary boom lift cylinder with a suitable lifting device. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. 16 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Do not remove the pin. 17 Raise the primary boom slightly with the overhead crane to relieve the pressure on the primary boom lift cylinder rod-end pivot pin. 18 Use a soft metal drift to remove the primary boom lift cylinder rod-end pivot pin. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. How to Repair the Primary Boom Cable Track Component damage hazard. The primary boom cable track can be damaged if it is twisted. Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device. A 7 link repair section of cable track is available through the Genie Industries Service Parts Department. 19 Lower the rod end of the primary boom lift cylinder approximately 12 inches / 30 cm. 20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder. 21 Raise the rod end of the primary boom lift cylinder back into position and install the rodend pivot pin. Install the pin retaining fasteners. a b 22 Attach a strap from an overhead crane to the cable track. 23 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 24 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 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, open the lower clip and then use a screw driver to pry the link to the side. 3 Repeat steps 1 and 2 for each link. 4 - 18 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS REV B 4-2 Primary Boom 4 Raise the primary boom to a horizontal position. How to Remove the Primary Boom 6 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. Then lower the cylinder and let it hang down. 5 Remove the hose and cable cover from the upper pivot. Bodily injury hazard. 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. Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. 2 Z-45/25: Remove the platform rotator and platform mounting weldment. Component damage hazard. When lowering the master cylinder down, be sure not to damage the master cylinder hoses or fittings. 7 Locate the primary boom drive speed limit switch inside of the upper pivot. 8 Remove the primary boom drive speed limit switch mounting fasteners. Do not disconnect the wiring. 9 Locate the primary extension boom drive speed limit switch inside of the extension boom. 10 Remove the primary extension boom drive speed limit switch mounting fasteners. Do not disconnect the wiring. 11 Pull the limit switch and the wiring out of the extension tube and move it out of the way. 12 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Z-45/25J: Remove the jib boom. See 3-1, How to Remove the Jib Boom. 3 Remove the cable track. See 4-1, How to Remove the Cable Track. Part No. 107846 Z-45/25 • Z-45/25J 4 - 19 Section 4 • Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 13 Remove the hose clamp at the pivot end of the boom. How to Disassemble the Primary Boom 14 Attach a 5 ton / 5,000 kg overhead crane to the center point of the primary boom. Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Primary Boom Extension Cylinder. 15 Attach a similar lifting device to the primary boom lift cylinder. 16 Place support blocks under the primary boom lift cylinder. 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom lift cylinder and primary boom will fall if not properly supported. 18 Lower the rod end of the primary boom lift cylinder onto support blocks. Protect the cylinder rod from damage. 19 Remove the pin retaining fasteners from the primary boom pivot pin. 20 Remove the primary boom pivot pin with a soft metal drift, then carefully remove the primary boom from the machine and place it on a structure capable of supporting it. Crushing hazard. The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 1 Remove the primary boom. See How to Remove the Primary Boom. 2 Place blocks under the barrel end of the primary boom extension cylinder for support. 3 Remove the pin retaining fastener from the extension cylinder barrel-end pivot pin at the pivot end of the primary boom. Use a soft metal drift to remove the pin. 4 Remove and label the location of the wear pads from the platform end of the primary boom. Pay careful attention to the location and amount of shims used with each wear pad. 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube. Crushing hazard. The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 4 - 20 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS REV B 6 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin. 7 Support and slide the extension cylinder out of the base end of the extension tube. Place the extension cylinder on blocks for support. Crushing hazard. The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported. 4-3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure. How to Remove the Primary Boom Lift Cylinder Bodily injury hazard. 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. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to a horizontal position. 2 Raise the secondary boom until the primary boom lift cylinder barrel-end pivot pin is above the turntable covers. 3 Attach a 5 ton / 5000 kg overhead crane to the primary boom for support. Part No. 107846 Z-45/25 • Z-45/25J 4 - 21 Section 4 • Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 4 Raise the primary boom with the overhead crane slightly to take the pressure off the primary boom lift cylinder pivot pins. 10 Remove the primary boom lift cylinder barrel-end pivot pin retaining fasteners. Do not remove the pin. 5 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device. 11 Use a slide hammer to remove the barrel-end pivot pin. Carefully remove the primary boom lift cylinder from the machine. 6 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. 7 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The primary boom will fall if not properly supported when the primary boom rod-end pivot pin is removed. 8 Place a support block across both turntable covers under the primary boom lift cylinder. 9 Lower the rod end of the lift cylinder onto the block. Protect the cylinder rod from damage. Crushing hazard. The primary boom lift cylinder could fall if not properly supported. 4 - 22 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS REV B 4 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. 4-4 Primary Boom Extension 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. The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. How to Remove the Primary Boom Extension Cylinder Bodily injury hazard. 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. 5 At the platform end of the boom, remove the external snap rings from the extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 6 Remove the barrel-end pivot pin retaining fasteners. 7 Place a rod through the barrel-end pivot pin and twist to remove the pin. 8 Support and slide the extension cylinder out of the upper pivot. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to a horizontal position. 2 Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube. 3 Remove the hose and cable guard from the upper pivot. Part No. 107846 Z-45/25 • Z-45/25J Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported. Component damage hazard. 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. Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them. Note the length of the cylinder after removal. The cylinder must be at the same length for installation. 4 - 23 Section 4 • Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 4-5 Platform Leveling Master Cylinder 4 Remove the pin retaining fasteners from the master cylinder barrel-end pivot pin. The master cylinder acts as a pump for the slave cylinder. It’s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. The master cylinder is located at the base of the primary boom. 6 Remove the pin retaining fastener from the rodend pivot pin. 5 Place a rod through the barrel-end pivot pin and twist to remove the pin. How to Remove the Platform Leveling Master Cylinder 7 Place a rod through the rod-end pivot pin and twist to remove the pin. 8 Remove the master cylinder from the machine. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane. 1 Raise the secondary boom until both the rod-end and barrel-end pivot pins on the master cylinder are accessible. 2 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder. 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. 3 Attach overhead crane or similar lifting device to the master cylinder. 4 - 24 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures This page intentionally left blank. Part No. 107846 Z-45/25 • Z-45/25J 4 - 25 Section 4 • Repair Procedures August 2006 Secondary Boom Components a b REV B c j i d h e g f Secondary Boom components a b c d e f g h i j 4 - 26 upper secondary boom (number 1 arm) upper tension link (number 2 arm) lower tension link (number 3 arm) mid-pivot compression link secondary boom lift cylinder (2) lower secondary boom (number 4 arm) turntable pivot boom rest upper pivot Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS REV B 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. 5-1 Secondary Boom How to Disassemble the Secondary Boom Bodily injury hazard. 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. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 6 Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. Cap the fittings on the 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. 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 could become unbalanced and fall if not properly supported by the overhead crane. 9 Tag, disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders. Cap the fittings on the cylinders. 1 Remove the platform. 2 Z-45/25J: Remove the jib boom. See 3-1, How to Remove the Jib Boom. 3 Remove the primary boom. See 3-2, How to Remove the Primary Boom. 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 master cylinder. See 4-5, How to Remove the Master Cylinder. Part No. 107846 Z-45/25 • Z-45/25J 4 - 27 Section 4 • Repair Procedures August 2006 SECONDARY BOOM COMPONENTS REV B 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. 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid-point between the upper pivot and mid-pivot. 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid-pivot and the upper pivot. Do not remove the pins. 19 Use a soft metal drift to drive both pins out. 20 Remove the number 1 arm from the machine. Crushing hazard. The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 13 Use a soft metal drift to drive the rod-end pivot pin half way out. Crushing hazard. The upper pivot could fall when the number 1 arm is removed from the machine if not properly supported by the overhead crane. 14 Remove the secondary boom lift cylinder from the machine. 15 Repeat steps 11 through 14 for the other secondary boom lift cylinder. Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if 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. 21 Using the overhead crane attached to the upper pivot, raise the secondary boom assembly approximately 30 inches / 76 cm. 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block between the number 2 arm and the boom rest. Then lower the secondary boom assembly onto the block. 16 Attach a lifting strap from an overhead crane to the upper pivot for support. Do not lift it. 4 - 28 Z-45/25 • Z-45/25J Crushing hazard. The secondary boom assembly could fall if not properly supported by the 4 x 4 x 11 inch / 10 x 10 x 28 cm block. Part No. 107846 August 2006 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS REV B 23 Pull all of the cables and hoses out through the upper pivot. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid-pivot end. 32 Attach a lifting strap from the overhead crane to the mid-pivot for support. Do not lift it. 24 Remove the hose and cable covers from the top of the number 2 arm. 33 Remove the pin retaining fasteners from the number 2, 3 and 4 arm pivot pins at the mid-pivot. Do not remove the pins. 25 Pull all of the hoses and cables out of the upper pivot and out through the mid-pivot. Lay the hoses and cables on the ground. 34 Use a soft metal drift to drive each pin out. Then remove the mid-pivot from the secondary boom assembly. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 26 Remove the pin retaining fastener from the number 2 arm pivot pin at the upper pivot. Use a soft metal drift to remove the pin. 27 Remove the upper pivot from the machine. Crushing hazard. The upper pivot could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 28 Attach the lifting strap from an overhead crane to the number 2 arm at the upper pivot end. Crushing hazard. The mid-pivot could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane. 35 Attach the lifting strap from an overhead crane to the center point of the number 2 arm for support. Do not lift it. 36 Remove the pin retaining fasteners from both compression link pivot pins. Do not remove the pins. 37 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm. 38 Support the compression link with an appropriate lifting device. 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch / 10 x 10 x 28 cm block. 30 Lower the number 2 arm onto the boom rest pad. Part No. 107846 Z-45/25 • Z-45/25J 4 - 29 Section 4 • Repair Procedures August 2006 SECONDARY BOOM COMPONENTS REV B 39 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 could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane. 43 Open the ground controls side turntable cover. 44 Remove the fuel tank filler cap. 45 Using an approved hand-operated pump, drain the fuel tank into a container of suitable capacity. Refer to Section 2, Specifications. 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. Crushing hazard. The compression link may fall if not properly supported when removed from the secondary boom assembly. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. 40 Remove the number 2 arm from the machine. Crushing hazard. The number 2 arm could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane. 41 Remove the upper and lower hose and cable covers from the number 3 arm. 42 Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight. Be sure to only use a handoperated pump suitable for use with gasoline and diesel fuel. 46 Tag, disconnect and plug the fuel hoses from the fuel tank. Clean up any fuel that may have spilled. 47 Remove the fuel tank mounting fasteners. Carefully remove the fuel tank from the machine. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 4 - 30 Z-45/25 • Z-45/25J Component damage hazard. The fuel tank is plastic and may become damaged if allowed to fall. Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine. Part No. 107846 August 2006 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS REV B 48 Remove the retaining fastener from the ground control box and function manifold pivot plate. 49 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin. 50 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support. Do not lift it. 51 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 riser. 57 Remove the pin retaining fasteners from the number 4 arm at the turntable riser. 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 riser through the ground controls side bulkhead. 60 Remove the number 4 arm from the machine. 52 Remove the pin retaining fasteners from the number 3 arm at the turntable riser. Do not remove the pin. Crushing hazard. The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 53 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box. 54 Remove the number 3 arm from the machine. Crushing hazard. The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 55 Remove the upper and lower hose and cable covers from the number 3 arm. 56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid-pivot end. Do not disconnect the wiring. Part No. 107846 Z-45/25 • Z-45/25J 4 - 31 Section 4 • Repair Procedures August 2006 SECONDARY BOOM COMPONENTS REV B 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. How to Remove a Secondary Boom Lift Cylinder Bodily injury hazard. 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. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 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. 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. 4 - 32 Z-45/25 • Z-45/25J Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if 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. Part No. 107846 August 2006 Section 4 • Repair Procedures Engines REV B 6-1 RPM Adjustment - Ford and Deutz Models 6-3 Flex Plate Refer to Maintenance Procedure B-9, Check and Adjust the Engine RPM - All Models. The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. How to Remove the Flex Plate 1 Disconnect the positive battery cable from the battery. 6-2 RPM Adjustment - Perkins Models Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Refer to Maintenance Procedure B-9, Check and Adjust the Engine RPM - All Models. 2 Disconnect the electrical connectors at the electrical proportional controller, located on the drive pump. Ford LRG-425 EFI and Perkins models: 3 Remove the engine starter mounting fasteners. Remove the starter from the engine. Do not disconnect the wiring. 4 Support the drive pump with an appropriate lifting device. Then remove all of the bell housing to engine mounting bolts. Leave the pump connected to the bell housing. Part No. 107846 Z-45/25 • Z-45/25J 4 - 33 Section 4 • Repair Procedures August 2006 ENGINES REV B 5 Carefully pull the pump and bell housing away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 6 Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel. Ford DSG-423 EFI models: 3 Support the drive pump assembly with an overhead crane or other suitable lifting device. Do not apply any lifting pressure. 11 Remove the engine mounting plate to bell housing fasteners. 12 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support. 13 Remove all of the engine bell housing retaining fasteners. 14 Carefully remove the bell housing from the engine. 15 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. 4 Remove the drive pump retaining fasteners. 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 6 Disconnect the electrical connector from the oxygen sensor at the tailpipe. Do not remove the oxygen sensor. 7 Support the muffler and bracket assembly with a suitable lifting device. 8 Remove the exhaust pipe fasteners at the muffler. 9 Remove the muffler bracket mounting fasteners from the bell housing. Carefully remove the muffler and bracket assembly from the engine. 10 Support the engine with an overhead crane or other suitable lifting device. Do not lift it. 4 - 34 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures ENGINES REV B How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. 3 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine. 2 Ford models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm. a b Deutz models: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm. a b c d e f 1 3 4 5 d e f Perkins models: Torque the flex plate mounting bolts in sequence to 49 ft-lbs / 66 Nm. Then torque the flex plate mounting bolts in sequence to 70 ft-lbs / 95 Nm. 6 c pump pump shaft pump coupler flex plate with raised spline engine flywheel 3/16 inch / 4.8 mm gap - Diesel Models 1/16 inch / 1.5 mm gap - Ford LRG-425 0.080 inch / 2 mm gap - Ford DSG-423 4 Apply Loctite® removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. 2 Ford and Deutz models 1 2 3 Perkins models Part No. 107846 Z-45/25 • Z-45/25J 4 - 35 Section 4 • Repair Procedures August 2006 ENGINES REV B 6 5 Install the pump and bell housing assembly. 1 Ford LRG-425 and Deutz models: Torque the bell housing mounting bolts labeled "C" in sequence to 28 ft-lbs / 38 Nm. Then torque the bell housing mounting bolts labeled "C" in sequence to 40 ft-lbs / 54 Nm. Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur. A 4 C C 7 5 B 2 Ford DSG-423 EFI models 6 1 C 10 C 4 11 C C C C C 7 C 5 C Deutz models A 8 C C 3 1 A 7 12 9 2 6 C 3 C C 6 C 8 C Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 1 3 A Ford DSG-423 models: Torque the bell housing mounting bolts labeled "A" and "B" in sequence to 28 ft-lbs / 38 Nm and the mounting bolts labeled "C" to 49 ft-lbs / 66 Nm. Then torque the bell housing mounting bolts labeled "A" and "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "C" to 70 ft-lbs / 95 Nm. Perkins models: Torque the bell housing mounting bolts labeled "B" in sequence to 28 ft-lbs / 38 Nm and the mounting bolts labeled "A" to 49 ft-lbs / 66 Nm. Then torque the bell housing mounting bolts labeled "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "A" to 70 ft-lbs / 95 Nm. B B C C 9 4 B B 4 B 5 C 9 C 5 B B C 8 2 B B 3 2 Ford LRG-425 EFI models 7 Perkins models 4 - 36 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures ENGINES REV B 6-4 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. Refer to Section 5, How to Retrieve Engine Fault Codes for your specific model of engine. Use the Fault Code Chart within Section 5 to aid in identifying the fault. Part No. 107846 Z-45/25 • Z-45/25J 4 - 37 Section 4 • Repair Procedures August 2006 Hydraulic Pumps REV B 2 Tag, disconnect and plug the lift/steer pump hydraulic hoses. Cap the fittings on the pump. 7-1 Lift/Steer Pump 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. How to Remove the Lift/Steer Pump When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Models without hydraulic tank shut-off valves: Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. 3 Remove the pump mounting bolts. Carefully remove the pump. Models without hydraulic tank shut-off valves: Component damage hazard. Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump. Models with hydraulic tank shut-off valves: Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. open 4 - 38 closed Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures HYDRAULIC PUMPS REV B 7-2 Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electro-proportional controller, located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service center. 2 Models without hydraulic tank shut-off valves: Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container. See capacity specifications. Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. How to Remove the Drive Pump Component damage hazard. 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. Dealer service is recommended. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. open 3 Tag and disconnect and plug the hydraulic hoses from the drive and lift/steer pumps. Cap the fittings on the pumps. 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump. Part No. 107846 closed Z-45/25 • Z-45/25J 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 - 39 Section 4 • Repair Procedures August 2006 HYDRAULIC PUMPS REV B 4 Support the pump with a lifting device and remove the two drive pump mounting fasteners. 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 6 Remove the drive pump from the machine. 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. The hydraulic pump may become unbalanced and fall if not properly supported. Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur. Models without hydraulic tank shut-off valves: Component damage hazard. Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump. Models with hydraulic tank shut-off valves: The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Ford models: Close the valve on the LPG tank then disconnect the hose from the tank. Then move the fuel select switch to the LPG position. Perkins models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump. Deutz models: Hold the manual fuel shutoff valve clockwise to the closed position. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. a a 4 - 40 Z-45/25 • Z-45/25J manual fuel shutoff valve Part No. 107846 August 2006 Section 4 • Repair Procedures REV B HYDRAULIC PUMPS 5 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 320 psi / 22 bar. 6 Ford models: Connect the LPG hose to the LPG tank and open the valve on the tank. Perkins models: Connect the engine wiring harness to the fuel solenoid. 7 Start the engine from the ground controls and check for hydraulic leaks. Part No. 107846 Z-45/25 • Z-45/25J 4 - 41 Section 4 • Repair Procedures June 2012 Manifolds REV E 8-1 Function Manifold Components (before serial number 27001) The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index No. Description Schematic Item Function Torque 1 Proportional directional solenoid valve, 3 position 4 way ....... A ........... Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm 2 Solenoid valve, 3 position 4 way ...... B ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm 3 Proportional directional solenoid valve, 3 position 4 way ....... C ........... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm 4 Proportional directional solenoid valve, 3 position 4 way ....... D ........... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm 5 Solenoid valve, 2 position 3 way ...... E ........... Primary boom extend .................................. 20 ft-lbs / 27 Nm 6 Solenoid valve, 3 position 4 way ...... F ........... Platform rotate left/right and jib boom up/down (Z-45/25J) ...................... 25 ft-lbs / 34 Nm 7 Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm 8 Solenoid valve, 3 position 4 way ...... H ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm 9 Check valve, dual pilot operated ...... I ............ Platform level circuit .................................... 20 ft-lbs / 27 Nm 10 Check valve ....................................... J ............ Differential sensing circuit, platform rotate right and jib boom up (Z-45/25J) ..................... 12-14 ft-lbs / 16-19 Nm 11 Check valve ....................................... K ........... Differential sensing circuit, platform rotate left and jib boom down (Z-45/25J) ................ 12-14 ft-lbs / 16-19 Nm 12 Differential sensing valve .................. L ........... Meters flow to functions ............................... 25 ft-lbs / 34 Nm 13 Check valve ....................................... M .......... Differential sensing circuit, secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm 14 Check valve ....................................... N ........... Differential sensing circuit, secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm 15 Priority flow regulator valve, 1.5 gpm / 5.7 L/min ............................ O ........... Steer circuit .................................................. 25 ft-lbs / 34 Nm 16 Relief valve, 3200 psi / 220.6 bar ..... P ........... System relief ................................................ 20 ft-lbs / 27 Nm 17 Flow regulator valve, 0.1 gpm / 0.38 L/min .......................... Q ........... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm 18 Shuttle valve ...................................... R ........... Primary boom circuit .................................. 4-5 ft-lbs / 5-7 Nm 19 Flow regulator valve, 2 gpm / 7.6 L/min ............................... S ........... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm 20 Flow regulator valve, 0.4 gpm / 1.5 L/min ............................ T ........... Jib boom and platform rotate circuit ................................................. 20 ft-lbs / 27 Nm This list continues. Please turn the page. 4 - 42 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 2 A 29 3 B C 4 D 5 E 6 F 7 G AC H I 28 27 26 9 AB AA J Z K 25 Y 24 X 23 22 8 L 10 11 12 W V M N U 21 Part No. 107846 T 20 S 19 R 18 Q P 17 16 13 14 O 15 Z-45/25 • Z-45/25J 4 - 43 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E Function Manifold Components (before serial number 27001), continued Index No. Description 21 Needle valve ..................................... U ........... Platform level flow control ........................... 20 ft-lbs / 27 Nm Schematic Item Function Torque 22 Relief valve, 2500 psi / 172 bar ........ V ........... Platform level circuit .................................... 25 ft-lbs / 34 Nm 23 Check valve ....................................... W .......... Differential sensing circuit, platform level up ............................... 12-14 ft-lbs / 16-19 Nm 24 Check valve ....................................... X ........... Differential sensing circuit, platform level down .......................... 12-14 ft-lbs / 16-19 Nm 25 Shuttle valve ...................................... Y ........... Platform level circuit .................................. 4-5 ft-lbs / 5-7 Nm 26 Check valve ....................................... Z ........... Differential sensing circuit, boom retract ...................................... 12-14 ft-lbs / 16-19 Nm 27 Check valve ....................................... AA ......... Differential sensing circuit, turntable rotate right ......................... 12-14 ft-lbs / 16-19 Nm 28 Check valve ....................................... AB ......... Differential sensing circuit, turntable rotate left ............................ 12-14 ft-lbs / 16-19 Nm 29 Relief valve, 2100 psi / 145 bar ........ AC ........ Secondary boom down ............................... 25 ft-lbs / 34 Nm 4 - 44 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 2 A 29 3 B C 4 D 5 E 6 F 7 G AC H I 28 27 26 9 AB AA J Z K 25 Y 24 X 23 22 8 L 10 11 12 W V M N U 21 Part No. 107846 T 20 S 19 R 18 Q P 17 16 13 14 O 15 Z-45/25 • Z-45/25J 4 - 45 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-2 Valve Adjustments Function Manifold (before serial number 27001) How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST1 port on the function manifold. How to Adjust the System Relief Valve 2 Start the engine from the ground controls. Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST1 port on the function manifold. 3 Hold the function enable switch to the high rpm position and activate and hold the secondary boom down switch with the secondary boom fully lowered. 2 Start the engine from the ground controls. 4 Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 3 Hold the function enable switch to the high rpm position and activate and hold the primary boom retract switch with the boom fully retracted. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item AC). 4 Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item P). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 46 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E This page intentionally left blank. Part No. 107846 Z-45/25 • Z-45/25J 4 - 47 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-3 Function Manifold Components (after serial number 27000) The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index No. Description 1 Solenoid valve, 3 position 4 way ...... BM ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm 2 Solenoid valve, 3 position 4 way ...... CG ........ Platform rotate left/right and jib boom up/down ........................................ 25 ft-lbs / 34 Nm 3 Flow regulator valve, 2 gpm / 7.6 L/min ............................... BZ ......... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm Schematic Item Function Torque 4 Solenoid valve, 2 position 3 way ...... CA ........ Primary boom extend .................................. 20 ft-lbs / 27 Nm 5 Proportional directional solenoid valve, 3 position 4 way ....... BY ......... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm 6 Differential sensing valve 160 psi / 11 bar ................................. BG ........ Meters flow to functions ............................... 25 ft-lbs / 34 Nm 7 Proportional directional solenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm 8 Proportional directional solenoid valve, 3 position 4 way ....... BU ........ Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm 9 Solenoid valve, 3 position 4 way ...... BF ......... Steer left/right ............................................... 25 ft-lbs / 34 Nm 10 Relief valve, 2100 psi / 145 bar ........ BV ......... Secondary boom down ............................... 20 ft-lbs / 27 Nm 11 Orifice, 0.046 inch / 1.17 mm ............ CF ......... Secondary boom down circuit 12 Check valve, 5psi / 0.3 bar ................ BT ......... Differential sensing circuit, secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm 13 Check valve, 5psi / 0.3 bar ................ BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm 14 Check valve, 5psi / 0.3 bar ................ BS ......... Differential sensing circuit, secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm 15 Priority flow regulator valve, 1.5 gpm / 5.7 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm 16 Relief valve, 3200 psi / 220.6 bar ..... BA ......... System relief ................................................ 20 ft-lbs / 27 Nm 17 Shuttle valve ...................................... BO ........ Turntable rotate circuit ...................... 12-14 ft-lbs / 16-19 Nm 18 Check valve, 5psi / 0.3 bar ................ BQ ........ Differential sensing circuit, turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm 19 Check valve, 5psi / 0.3 bar ................ CB ........ Differential sensing circuit, primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm 20 Check valve, 5psi / 0.3 bar ................ BC ........ Differential sensing circuit, platform rotate left and jib boom up .................................................. 25 ft-lbs / 34 Nm This list continues. Please turn the page. 4 - 48 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 BM 33 32 31 30 29 3 2 CG 4 BZ 5 CA 6 BY 7 BG 8 BP BU BJ BI CC BF BL BV 27 26 25 24 23 22 10 BK CF 28 9 11 BH BN BE CE BT BR 12 CD BX BW BD 21 Part No. 107846 BC 20 CB 19 BQ 18 BO BA BB 17 16 15 Z-45/25 • Z-45/25J 13 BS 14 4 - 49 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E Function Manifold Components (after serial number 27000), continued Index No. Description Schematic Item Function Torque 21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit, platform rotate right and jib boom down ............................................. 25 ft-lbs / 34 Nm 22 Flow regulator valve, 0.1 gpm / 0.38 L/min .......................... BX ......... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm 23 Counterbalance valve, 3000 psi / 207 bar ............................. CD ........ Primary boom down circuit ............... 30-35 ft-lbs / 45-50 Nm 24 Pressure compensator valve, 80 psi / 5.5 bar ................................... BR ........ Turntable rotate circuit ................................. 25 ft-lbs / 34 Nm 25 Shuttle valve ...................................... CE ........ Differential sensing circuit, primary boom up/down ..................... 12-14 ft-lbs / 16-19 Nm 26 Flow regulator valve, 0.4 gpm / 1.5 L/min ............................ BE ......... Jib boom and platform rotate circuit ................................................. 20 ft-lbs / 27 Nm 27 Needle valve ..................................... BN ........ Platform level flow control ........................... 20 ft-lbs / 27 Nm 28 Relief valve, 2500 psi / 172 bar ........ BH ........ Platform level circuit .................................... 20 ft-lbs / 27 Nm 29 Check valve, 5psi / 0.3 bar ................ BK ......... Differential sensing circuit, platform level up ............................... 12-14 ft-lbs / 16-19 Nm 30 Check valve, 5psi / 0.3 bar ................ BL ......... Differential sensing circuit, platform level down .......................... 12-14 ft-lbs / 16-19 Nm 31 Solenoid valve, 2 position 3 way ...... CC ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm 32 Shuttle valve ...................................... BI .......... Platform level circuit ......................... 12-14 ft-lbs / 16-19 Nm 33 Check valve, dual pilot operated, 135 psi / 9.3 bar ................................. BJ ......... Platform level circuit .................................... 20 ft-lbs / 27 Nm 4 - 50 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 BM 33 32 31 30 29 3 2 CG 4 BZ 5 CA 6 BY 7 BG 8 BP BU BJ BI CC BF BL BV 27 26 25 24 23 22 10 BK CF 28 9 11 BH BN BE CE BT BR 12 CD BX BW BD 21 Part No. 107846 BC 20 CB 19 BQ 18 BO BA BB 17 16 15 Z-45/25 • Z-45/25J 13 BS 14 4 - 51 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-4 Valve Adjustments Function Manifold (after serial number 27000) How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST1 port on the function manifold. How to Adjust the System Relief Valve 2 Start the engine from the ground controls. Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST1 port on the function manifold. 3 Hold the function enable switch to the high rpm position and activate and hold the secondary boom down switch with the secondary boom fully lowered. 2 Start the engine from the ground controls. 4 Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 3 Hold the function enable switch to the high rpm position and activate and hold the primary boom retract switch with the boom fully retracted. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item BV). 4 Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item BA). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 52 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 27001) The jib boom / platform rotate manifold is mounted to the platform support. Index No. Description 1 Solenoid valve, 2 position 3 way ..... AD ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm Schematic Item Function Torque 1 AD Part No. 107846 Z-45/25 • Z-45/25J 4 - 53 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-6 Jib Boom / Platform Rotate Manifold Components (after serial number 27000) The jib boom / platform rotate manifold is mounted to the platform support. Index No. Description 1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm Schematic Item Function Torque 1 G 4 - 54 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 8-7 Turntable Rotation Manifold Components (before serial number 27001) The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No. Description 1 Counterbalance valve .................... MM .......... Turntable rotate right 2 Counterbalance valve .................... NN ........... Turntable rotate left Schematic Item 1 MM Part No. 107846 Function 2 NN Z-45/25 • Z-45/25J 4 - 55 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-8 Turntable Rotation Manifold Components (after serial number 27000) The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No. Description 1 Counterbalance valve ...................... L ............ Turntable rotate right 2 Counterbalance valve ...................... J ............ Turntable rotate left Schematic Item 1 L 4 - 56 Function 2 J Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 8-9 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index No. Description 1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm 2 Spool valve ...................................................... Directional control Function Torque 1 2 Part No. 107846 Z-45/25 • Z-45/25J 4 - 57 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 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. 1 Lower the boom to the stowed position. 2 Use a "bubble type" level to be sure the floor is completely level. 8 Verify that the ground and drive chassis are completely level. 9 Tighten the nuts on both sides of the urethane cushions until they are snug. Tighten the locknuts. 10 Check to be sure the drive chassis is completely level. 11 Measure the distance between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis). Tip-over hazard. Failure to perform this procedure on a level floor could compromise the stability of the machine resulting in the machine tipping over. 3 Check the tire pressure in all four tires and add air if needed to meet specification. If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level, repeat steps 6 through 10 OR consult Genie Industries Service Department. 4 Remove the drive chassis cover and the nonsteer axle covers. 5 Place a "bubble type" level across the drive chassis non-steer end. Check to be sure the drive chassis is completely level. 6 To level the drive chassis, start the engine and loosen the lock nuts on both sides of the urethane cushions. 7 Push up or pull down on the threaded rod until the machine is completely level. 4 - 58 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E This page intentionally left blank. Part No. 107846 Z-45/25 • Z-45/25J 4 - 59 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-10 Traction Manifold Components, 2WD (before serial number 27001) The traction manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description Schematic Item 1 Solenoid valve, 2 position 3 way ...... XX ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm 2 Relief valve, 250 psi / 17.2 bar ......... PP ......... Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm 3 Flow divider/combiner valve ............. QQ ........ Controls flow to drive motors in forward and reverse ..................... 25-30 ft-lbs / 34-41 Nm Function Torque 4 Orifice, 0.070 in / 1.78 mm ................ RR ........ Drive circuit 5 Check valve ....................................... SS ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm 6 Check valve ....................................... TT ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm 7 Shuttle valve, 3 position 3 way ......... UU ........ Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs / 20-24 Nm 8 Diagnostic fitting ................................ VV ......... Testing 9 Orifice, 0.030 in / 0.76 mm ................ WW ....... Brake circuit 10 Solenoid valve, 2 position 3 way ...... OO ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm 4 - 60 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 XX 10 2 PP 3 QQ OO RR 4 SS 9 5 WW TT VV 8 Part No. 107846 Z-45/25 • Z-45/25J 6 UU 7 4 - 61 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-11 Traction Manifold Components, 2WD (after serial number 27000) The traction manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description 1 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm 2 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm 3 Flow divider/combiner valve ............. U ........... Controls flow to drive motors in forward and reverse ..................... 25-30 ft-lbs / 34-41 Nm 4 Orifice, 0.070 in / 1.78 mm ................ AL ......... Drive circuit 5 Check valve ....................................... S ........... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm 6 Check valve ....................................... AA ......... Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm 7 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs / 20-24 Nm 8 Diagnostic fitting ............................................... Testing 9 Orifice, 0.030 in / 0.76 mm ................ AE ......... Brake circuit 10 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm 4 - 62 Schematic Item Function Z-45/25 • Z-45/25J Torque Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 AF 10 2 AD 3 U AG AL 4 S 9 5 AE AA 6 R 8 Part No. 107846 Z-45/25 • Z-45/25J 7 4 - 63 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-12 Valve Adjustments, 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to the test port on the drive pump. 2 Hold the charge pressure relief valve and remove the cap (item PP or AD). 3 Turn the internal hex socket clockwise fully until it stops. Install the cap. 4 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. Note the reading on the pressure gauge. 5 Turn the engine off. 6 Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold. 7 Hold the charge pressure relief valve and remove the cap (item PP or AD). 8 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. 9 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi / 2.8 bar less than the pressure reading on the pump. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 64 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E This page intentionally left blank. Part No. 107846 Z-45/25 • Z-45/25J 4 - 65 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-13 Traction Manifold Components, 4WD (before serial number 27001) The traction manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description Schematic Item Function Torque 1 Flow divider/combiner valve .............. AB ......... Controls flow to non-steer end drive motors in forward and reverse ....................................... 25-30 ft-lbs / 34-41 Nm 2 Bi-directional flow control valve, 2 gpm / 7.6 L/min ............................... AC ........ Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm 3 Bi-directional flow control valve, 1 gpm / 3.8 L/min ............................... AD ........ Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm 4 Directional control valve ................... AE ......... 2 speed motor shift circuit/ High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm 5 Diagnostic fitting ................................ AF ......... Testing 6 Shuttle valve, 3 position 3 way ......... AG ........ Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs / 20-24 Nm 7 Relief valve, 250 psi / 17.2 bar ......... AH ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm 8 Solenoid valve, 2 position 3 way ...... AI .......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm 9 Orifice, 0.030 inch / 0.76 mm ............ AJ ......... Brake and 2-speed motor shift circuit 10 Solenoid valve, 2 position 3 way ...... AK ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm 11 Check valve ....................................... AL ......... 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm 12 Orifice, 0.025 inch / 0.64 mm ............ AM ........ 2 speed motor shift circuit 13 Flow divider/combiner valve ............. AN ........ Controls flow to flow divider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm 14 Check valve ....................................... AO ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm 15 Orifice, 0.052 in / 1.32 mm ................ AP ......... Drive circuit 16 Check valve ....................................... AQ ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm 17 Flow divider/combiner valve ............. AR ........ Controls flow to steer end drive motors in forward and reverse ....................................... 25-30 ft-lbs / 34-41 Nm 18 Check valve ....................................... AS ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm 19 Check valve ....................................... AT ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm 4 - 66 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 AB 2 AC 3 AD 4 AE 5 AF 6 AG 7 AH 8 AI 9 AJ AK 19 18 17 10 AT AS AR AL AM AN AO AP AQ Part No. 107846 Z-45/25 • Z-45/25J 11 12 13 14 15 16 4 - 67 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-14 Traction Manifold Components, 4WD (after serial number 27000) The traction manifold is mounted inside the drive chassis at the non-steer end. Index No. Description Schematic Item Function Torque 1 Flow divider/combiner valve ............. U ........... Controls flow to non-steer end drive motors in forward and reverse ....................................... 25-30 ft-lbs / 34-41 Nm 2 Bi-directional flow control valve, 2 gpm / 7.6 L/min ............................... Z ........... Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm 3 Bi-directional flow control valve, 1 gpm / 3.8 L/min ............................... X ........... Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm 4 Directional control valve ................... AV ......... 2 speed motor shift circuit/ High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm 5 Diagnostic fitting ............................................... Testing 6 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs / 20-24 Nm 7 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm 8 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm 9 Orifice, 0.030 inch / 0.76 mm ............ AE ......... Brake and 2-speed motor shift circuit 10 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm 11 Check valve ....................................... AH ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm 12 Orifice, 0.025 inch / 0.64 mm ............ AI .......... 2 speed motor shift circuit 13 Flow divider/combiner valve ............. V ........... Controls flow to flow divider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm 14 Check valve ....................................... AC ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm 15 Orifice, 0.052 in / 1.32 mm ................ Y ........... Drive circuit 16 Check valve ....................................... T ........... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm 17 Flow divider/combiner valve ............. W .......... Controls flow to steer end drive motors in forward and reverse ....................................... 25-30 ft-lbs / 34-41 Nm 18 Check valve ....................................... S ........... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm 19 Check valve ....................................... AA ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm 4 - 68 Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E 1 U 2 Z 3 X 4 AV 5 6 R 7 AD 8 AG 9 AE AF 19 18 17 10 AA S W AH AI V AC Y T Part No. 107846 Z-45/25 • Z-45/25J 11 12 13 14 15 16 4 - 69 Section 4 • Repair Procedures June 2012 MANIFOLDS REV E 8-15 Valve Adjustments, 4WD Traction Manifold 8-16 Valve Coils How to Test a Coil How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to the test port on the drive pump. A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Hold the charge pressure relief valve and remove the cap (item AH or AD). 3 Turn the internal hex socket clockwise fully until it stops. Install the cap. 4 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. Note the reading on the pressure gauge. 2 Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. 5 Turn the engine off. 6 Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold. 7 Hold the charge pressure relief valve and remove the cap (item AH or AD). 8 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. 9 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi / 2.8 bar less than the pressure reading on the pump. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 70 1 Tag and disconnect the wiring from the coil to be tested. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Valve Coil Resistance Specification (before serial number 27001) Proportional directional solenoid valve, 10V DC 6 to 8Ω (schematic items A, C and D) 3 position 4 way directional valve, 10V DC (schematic items B, F and H) 6 to 8Ω 2 position 3 way solenoid valve, 10V DC 6 to 8Ω (schematic items E, G, AD, OO, XX, AI and AK) Valve Coil Resistance Specification (after serial number 27000) Proportional directional solenoid valve, 10V DC 6 to 8Ω (schematic items BP, BU and BY) 3 position 4 way directional valve, 10V DC (schematic items BF, BM and CG) 6 to 8Ω 2 position 3 way solenoid valve, 10V DC (schematic items CA, CC, AF and AG) 6 to 8Ω Z-45/25 • Z-45/25J Part No. 107846 June 2012 Section 4 • Repair Procedures MANIFOLDS REV E COIL How to Test a Coil Diode + c 10 W RESISTOR c a b c d 27287 The battery should read 9V DC or more when measured across the terminals. multimeter 9V DC battery 10Ω resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 1 Test the coil for resistance. See, How to Test a Coil. Ω Resistor, 10Ω Genie part number b - Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Connect a 10Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. b 9V BATTERY + Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. a MULTI METER d 3 Set a multimeter to read DC current. The multimeter, when set to read DC current, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 107846 Z-45/25 • Z-45/25J 4 - 71 Section 4 • Repair Procedures August 2006 Turntable Rotation Components 9-1 Turntable Rotation Assembly 3 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. How to Remove the Turntable Rotation Assembly When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the secondary boom until the upper pivot is above the turntable covers. Turn the machine off. 4 Remove the center turntable cover retaining fasteners. Remove the center turntable cover from the machine. 5 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 6 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor manifold. Cap the fittings on the manifold. 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. 2 Secure the turntable from rotating with the turntable rotation lock. Tip-over hazard. The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position. REV C 7 Attach a lifting strap from and overhead crane or other suitable lifting device to the turntable rotator assembly. 8 Remove the turntable rotation assembly mounting fasteners. 9 Carefully remove the turntable rotation assembly from the machine. Unlocked position Tip-over hazard. The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position. Crushing hazard. The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Locked position 4 - 72 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 4 • Repair Procedures Axle Components REV C 10-1 Hub and Bearings, 2WD Models How to Install the Hub and Bearings, 2WD Models When replacing a wheel bearing, both the inner and outer bearings including the pressed-in races must be replaced. How to Remove the Hub and Bearings, 2WD Models 1 Loosen the wheel lug nuts. Do not remove them. 2 Block the non-steer wheels and place a lifting jack of ample capacity under the steer axle. 3 Raise the machine 6 inches / 15 cm and place blocks under the chassis for support. Crushing hazard. The machine may fall if not properly supported. 4 Remove the lug nuts. Remove the tire and wheel assembly. 5 Remove the dust cap, cotter pin and castle nut. Always use a new cotter pin when installing a castle nut. 1 Be sure that both bearings are packed with clean, fresh grease. 2 Place the large inner bearing into the rear of the hub. 3 Press the bearing seal evenly into the hub until it is flush. 4 Slide the hub onto the yoke spindle. Component damage. Do not apply excessive force or damage to the lip of the seal may occur. 5 Place the outer bearing into the hub. 6 Install the washer and castle nut. 6 Pull the hub off the spindle. The washer and outer bearing should fall loose from the hub. 7 Tighten the castle nut to 35 ft-lbs / 47 Nm to seat the bearing. 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. 8 Fully loosen the castle nut, then re-tighten to 8 ft-lbs / 11 Nm. 8 Remove the rear bearing. 9 Install a new cotter pin. Bend the cotter pin to secure the castle nut. Always use a new cotter pin when installing a castle nut. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. Part No. 107846 Z-45/25 • Z-45/25J 4 - 73 Section 4 • Repair Procedures August 2006 AXLE COMPONENTS REV C 2 Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to remove the pin. 10-2 Oscillating Axle Lock-out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle. The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. The valves are not adjustable. 3 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. 4 Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The oscillate cylinder may become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. How to Remove an Oscillating Axle Cylinder Perform this procedure on a firm, level surface with the boom in the stowed position. 5 Remove the oscillate cylinder from the machine. When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on the oscillate 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 - 74 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 and Genie Z-45/25J Operator’s Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Immediately tag and remove from service a damaged or malfunctioning machine. Be aware of the following hazards and follow generally accepted safe workshop practices. Repair any machine damage or malfunction before operating the machine. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Boom in stowed position · Turntable rotated with the boom between the non-steer wheels Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. · Turntable secured with the turntable rotation lock · Key switch in the off position with the key removed · Wheels chocked · All external AC power disconnected from the machine Perform all troubleshooting on a firm level surface. Two persons will be required to safely perform some troubleshooting procedures. Part No. 107846 Z-45/25 • Z-45/25J 5-1 Section 5 • Fault Codes August 2006 FAULT CODES REV A Control System How to Retrieve Control System Fault Codes At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes. Perform this procedure with the engine off, the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls. 3 Determine the error source: The red LED indicates the error source and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second. When the red LED is flashing the code, the yellow LED will be on solid. 4 Determine the error type: The yellow LED indidates the error type and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second. When the yellow LED is flashing the code, the red LED will be on solid. 1 Open the platform control box lid. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected. 2 Locate the red and yellow fault LEDs on the ALC-500 circuit board inside the platform control box. Do not touch the circuit board. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. If the circuit board does need to be handled, maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap. 5-2 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 5 • Fault Codes REV A FAULT CODES Error Source ID 21 22 23 31 32 Name Boom 1 Joystick (primary boom up/ down) Error Type ID 11 12 15 16 Name Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 18 Just calibrated 21 Fault 12 15 Value too high Value too low 17 Not calibrated 18 Just calibrated 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 18 Just calibrated 21 Fault Boom 1 directional valves Boom 1 flow control valve Boom 2 Joystick (secondary boom up/down or primary boom extend/retract) Boom 2 directional valves Condition Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Joystick speed and direction frozen at zero and neutral. Initiate 1-second beep of alarm. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Normal function except threshold for one or both directions is zero. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Joystick speed and direction frozen at zero and neutral. Initiate 1 second beep of alarm. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Solution Power up controller with problem corrected. Calibrate joystick. Self-clearing. (transient) Power up controller with problem corrected. Power up controller with problem corrected. Calibrate valve thresholds. Self-clearing. (transient) Power up controller with problem corrected. Calibrate joystick. Self-clearing. (transient) Power up controller with problem corrected. Continued on next page Part No. 107846 Z-45/25 • Z-45/25J 5-3 Section 5 • Fault Codes August 2006 FAULT CODES REV A Error Source ID 33 41 42 43 44 5-4 Name Boom 2 flow control valve Turntable rotate joystick Error Type ID Name 12 15 Value too high Value too low 17 Not calibrated 18 Just calibrated 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 18 Just calibrated 21 Fault 12 15 Value too high Value too low 17 Not calibrated 18 Just calibrated 21 Fault Turntable rotate directional valves Turntable rotate flow control valve Drive enable override switches Condition Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Normal function except threshold for one or both directions is zero. Solution Power up controller with problem corrected. Calibrate valve thresholds. Self-clearing. (transient) Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Joystick speed and direction frozen at zero and neutral. Initiate 1-second beep of alarm. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Normal function except threshold for one or both directions is zero. Enable override direction is frozen at neutral. Z-45/25 • Z-45/25J Power up controller with problem corrected. Calibrate joystick. Self-clearing. (transient) Power up controller with problem corrected. Power up controller with problem corrected. Calibrate valve thresholds. Self-clearing. (transient) Power up controller with problem corrected. Part No. 107846 August 2006 Section 5 • Fault Codes REV A FAULT CODES Error Source ID 51 53 54 55 61 62 Name Drive joystick Drive flow valve (EDC) Error Type ID 11 12 15 16 Name Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 18 Just calibrated 12 15 Value too high Value too low 17 Not calibrated 18 Just calibrated 21 Fault 21 Fault 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 18 Just calibrated 21 Fault Drive brake valve High speed drive motor Valve Steer joystick Steer directional valves Part No. 107846 Condition Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Joystick speed and direction frozen at zero and neutral. Initiate 1-second beep of alarm. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Normal function except threshold for one or both directions is zero. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Motor speed frozen in the low state. Alarm sounds indicating fault. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Joystick speed and direction frozen at zero and neutral. Initiate 1-second beep of alarm. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault. Z-45/25 • Z-45/25J Solution Power up controller with problem corrected. Calibrate joystick Self-clearing. (transient) Power up controller with problem corrected. Calibrate valve thresholds Self-clearing. (transient) Power up controller with problem corrected. Power up controller with problem corrected. Power up controller with problem corrected. Calibrate Joystick Self-clearing. (transient) Power up controller with problem corrected. 5-5 Section 5 • Fault Codes August 2006 FAULT CODES REV B 5 Continue to hold the run/test toggle switch in the test position and count the blinks. Ford LRG-425 EFI Engine How to Retrieve Ford Engine Fault Codes Before the fault codes are displayed, the check engine light will blink a code 123 three times. After the fault codes, the check engine light will blink a code 123 three times again indicating the end of the stored codes. The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. If any fault codes are present, the ECM will blink a three digit code three times for each code stored in memory. It will blink the first digit of a three digit code, pause, blink the second digit, pause, and then blink the third digit. For example: the check engine light blinks 5 consecutive times, blinks 3 times and then 1 time. That would indicate code 531. Perform this procedure with the key switch in the off position. 1 Locate the run/test toggle switch on the side of the ground control box. Once a fault code has been retrieved and the repair has been completed, the ECM memory must be reset to clear the fault code from the ECM. See How to Clear Engine Fault Codes from the ECM. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Quickly activate and release the start toggle switch/button. Do not start the engine. 4 Move and hold the run/test toggle switch to the test position. How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position. Result: The check engine light should turn on. The check engine light should begin to blink. 1 Open the engine side turntable cover and locate the battery. 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 5-6 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 5 • Fault Codes REV B FAULT CODES Code Problem Cause Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks. Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty. Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty. The post cat heated oxygen sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer. Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing. MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electromagnetic interference from a faulty crankshaft and/or camshaft position sensor. Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty. 111 Closed loop multiplier high (LPG) 112 113 HO2S open/inactive (bank 1) HO2S open/inactive (bank 2) 114 Post-cat oxygen sensor open 121 Closed loop multiplier high (gasoline) 122 Closed loop multiplier low (gasoline) 124 Closed loop multiplier low (LPG) 133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level. 134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level. 135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level. 141 Adaptive lean fault - High limit (Gasoline) 142 Adaptive rich fault - Low limit (Gasoline) 143 Adaptive learn high (LPG) 144 Adaptive learn low (LPG) 161 162 System voltage low 211 IAT high voltage 212 IAT low voltage System voltage high Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low. MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electromagnetic interference from a faulty crankshaft and/or camshaft position sensor. Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty. Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty. Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted. Alternator is overcharging the battery when engine RPM is greater than 1500 rpm. IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold. IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot. Solution Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks. Repair wiring and/or connections OR replace sensor. Repair wiring and/or connections OR replace sensor. Repair wiring and/or connections OR replace the post cat oxygen sensor. Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors. Adjust or replace sensors OR clean or repair fuel injectors. Repair wiring and/or connections OR replace sensor OR replace fuel OR test and repair the fuel system components. Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance. Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance. Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance. Repair heated oxygen sensor wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors. Adjust or replace sensors OR clean or repair fuel injectors. Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components. Repair short in engine wire harness OR test and repair the fuel system components. Replace battery OR repair alternator OR repair battery supply wiring to ECM. Repair or replace the alternator. Repair wiring and/or connections OR replace sensor OR direct warmer air into air intake. Repair wiring and/or connections OR replace sensor OR direct cooler air into air intake. Continued on next page Part No. 107846 Z-45/25 • Z-45/25J 5-7 Section 5 • Fault Codes August 2006 FAULT CODES Code REV B Problem 213 IAT higher than expected (1) 214 IAT higher than expected (2) 215 Oil pressure low 221 CHT/ECT high voltage 222 CHT/ECT low voltage 223 CHT higher than expected (1) 224 CHT higher than expected (2) 231 232 234 235 MAP high pressure MAP low voltage BP high pressure BP low pressure Cause Solution Air intake temperature is greater than 200° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty. Air intake temperature is greater than 210° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty. Faulty oil pressure sensor OR sensor wiring and/or connections open or shorted OR engine oil level too low. Engine cooling system is malfunctioning OR sensor wires and/or connections open or shorted OR sensor is faulty. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low. Coolant temperature at the cylinder head is 240° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low. Coolant temperature at the cylinder head is 250° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low. Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty. Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty. Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor. Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor. Replace oil pressure sensor OR repair sensor wiring and/or connections OR fill engine oil level to specification. Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor. Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification. MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM. MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM. Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty. Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty. Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty. Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty. Knock sensor wiring and/or connections open or shorted OR sensor is faulty. Knock sensor wiring and/or connections open or shorted OR there is excessive engine vibration OR sensor is faulty. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor. Repair wiring and/or connections to knock sensor OR replace knock sensor. Check for excessive engine vibration OR repair wiring and/or connections to knock sensor OR replace knock sensor. Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM. Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM. Repair wiring and/or connections to fuel injector #2 OR replace fuel injector #2 OR replace the ECM. Repair wiring and/or connections to fuel injector #2 OR replace fuel injector #2 OR replace the ECM. 242 Crank sync noise 243 Never crank synced at start 244 Camshaft sensor loss 245 Camshaft sensor noise 253 Knock sensor open 254 Excessive knock signal 311 Injector driver #1 open Open wiring and/or connections to fuel injector #1 OR fuel injector #1 is faulty OR ECM is faulty. 312 Injector driver #1 shorted Wiring and/or connections to fuel injector #1 shorted OR fuel injector #1 is faulty OR ECM is faulty. 313 Injector driver #2 open Open wiring and/or connections to fuel injector #2 OR fuel injector #2 is faulty OR ECM is faulty. 314 Injector driver #2 shorted Wiring and/or connections to fuel injector #2 shorted OR fuel injector #2 is faulty OR ECM is faulty. 5-8 Z-45/25 • Z-45/25J Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification. Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification. Repair wiring and/or connections to sensor OR replace MAP sensor. Repair wiring and/or connections to sensor OR replace MAP sensor. Part No. 107846 August 2006 Section 5 • Fault Codes REV B FAULT CODES Code Problem Cause 315 Injector driver #3 open Open wiring and/or connections to fuel injector #3 OR fuel injector #3 is faulty OR ECM is faulty. 316 Injector driver #3 shorted Wiring and/or connections to fuel injector #3 shorted OR fuel injector #3 is faulty OR ECM is faulty. 321 Injector driver #4 open Open wiring and/or connections to fuel injector #4 OR fuel injector #4 is faulty OR ECM is faulty. 322 Injector driver #4 shorted 351 Fuel pump loop open or high side short to ground 352 Fuel pump high side shorted to power 353 MegaJector delivery pressure higher than expected 354 Megajector delivery pressure lower than expected 355 MegaJector communication lost 361 MegaJector voltage supply high 362 MegaJector voltage supply low 363 Megajector internal actuator fault detection The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s 364 Megajector internal circuitry fault detection The MegaJector detects an internal circuitry failure. Open or short in power, ground or CAN circuits. 365 MegaJector internal communication fault detection The MegaJector detects an internal communications failure. Open or short in power, ground or CAN circuits. 411 412 413 414 Coil driver #1 open Coil driver #1 shorted Coil driver #2 open Coil driver #2 shorted Wiring and/or connections to fuel injector #4 shorted OR fuel injector #4 is faulty OR ECM is faulty. Open wiring and/or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty. Wiring and/or connections to fuel pump shorted to power OR fuel pump is faulty. Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty. Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty. The ECM doesn’t get any response from the MegaJector, or an incorrect response for 500ms period or longer. The MegaJector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running. The MegaJector detects voltage less than 9.5 volts for 5 seconds anytime the engine is cranking or running. Open wiring and/or connections to ignition coil #1 OR ignition coil #1 is faulty. Wiring and/or connections to ignition coil #1 shorted OR ignition coil #1 is faulty. Open wiring and/or connections to ignition coil #2 OR ignition coil #2 is faulty. Wiring and/or connections to ignition coil #2 shorted OR ignition coil #2 is faulty. Solution Repair wiring and/or connections to fuel injector #3 OR replace fuel injector #3 OR replace the ECM. Repair wiring and/or connections to fuel injector #3 OR replace fuel injector #3 OR replace the ECM. Repair wiring and/or connections to fuel injector #4 OR replace fuel injector #4 OR replace the ECM. Repair wiring and/or connections to fuel injector #4 OR replace fuel injector #4 OR replace the ECM. Repair wiring and/or connections to fuel pump OR replace fuel pump. Repair wiring and/or connections to fuel pump OR replace fuel pump. Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector. Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector. Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector. Repair charging system OR replace the MegaJector. Repair VBAT power or ground circuit to ECM and MegaJector OR replace battery OR repair charging system OR replace the MegaJector. Check power, ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance. Check power, ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance. Check Power, Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance. Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1. Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1. Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1. Repair wiring and/or connections to ignition coil #2 OR replace ignition coil #2. Continued on next page Part No. 107846 Z-45/25 • Z-45/25J 5-9 Section 5 • Fault Codes August 2006 FAULT CODES Code REV B Problem Cause 511 512 513 514 521 522 FPP1 high voltage Not used. FPP1 low voltage Not used. FPP1 higher than IVS Limit Not used. FPP1 lower than IVS Limit Not used. FPP2 high voltage Not used. FPP2 low voltage Not used. 531 TPS1 (signal voltage) high 532 TPS1 (signal voltage) low 533 TPS2 (signal voltage) high 534 TPS2 (signal voltage) low 535 TPS1 higher than TPS2 536 TPS1 lower than TPS2 537 Throttle unable to open 538 Throttle unable to close 545 Governor interlock failure 551 Max governor speed override 552 Fuel rev limit 553 Spark rev limit 611 COP failure Loose wire connections to ECM OR ECM is faulty. 612 Invalid interrupt Loose wire connections to ECM OR ECM is faulty. 613 A/D loss Loose wire connections to ECM OR ECM is faulty. 5 - 10 The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty. The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty. The #2 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #2 is faulty. The #2 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #2 is faulty. The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty. The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty. Governor actuator is stuck closed OR wiring and/or connections open or shorted OR governor actuator is faulty. Governor actuator is stuck open OR wiring and/or connections open or shorted OR governor actuator is faulty. Engine harness wiring and/or connections open or shorted OR there is a poor system ground connection OR ECM is faulty. ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head. ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head. ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head. Z-45/25 • Z-45/25J Solution If this fault appears on your machine, contact Genie Industries Service Department. If this fault appears on your machine, contact Genie Industries Service Department. If this fault appears on your machine, contact Genie Industries Service Department. If this fault appears on your machine, contact Genie Industries Service Department. If this fault appears on your machine, contact Genie Industries Service Department. If this fault appears on your machine, contact Genie Industries Service Department. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #1. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #1. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #2. Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #2. Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors. Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors. Repair wiring and/or connections to governor actuator OR replace the governor actuator. Repair wiring and/or connections to governor actuator OR replace the governor actuator. Repair wiring and/or connections in engine harness OR replace the ECM. Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head. Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head. Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Part No. 107846 August 2006 Section 5 • Fault Codes REV B FAULT CODES Code Problem Cause 614 RTI 1 loss Loose wire connections to ECM OR ECM is faulty. 615 Flash checksum invalid Loose wire connections to ECM OR ECM is faulty. 616 RAM failure Loose wire connections to ECM OR ECM is faulty. 631 External 5V DC ref lower than expected Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty. 632 External 5V DC ref higher than expected Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty. 655 RTI 2 loss Loose wire connections to ECM OR ECM is faulty. 656 RTI 3 loss Loose wire connections to ECM OR ECM is faulty. Part No. 107846 Z-45/25 • Z-45/25J Solution Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM. Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM. 5 - 11 Section 5 • Fault Codes August 2006 REV A FAULT CODES 5 Continue to hold the run/test toggle switch in the test position and count the blinks. Ford DSG-423 EFI Engine How to Retrieve Ford Engine Fault Codes Before the fault codes are displayed, the check engine light will blink a code 123 three times. After the fault codes, the check engine light will blink a code 123 three times again indicating the end of the stored codes. The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. If any fault codes are present, the ECM will blink a three digit code three times for each code stored in memory. It will blink the first digit of a three digit code, pause, blink the second digit, pause, and then blink the third digit. For example: the check engine light blinks 5 consecutive times, blinks 3 times and then 1 time. That would indicate code 531. Perform this procedure with the key switch in the off position. 1 Locate the run/test toggle switch on the side of the ground control box. Once a fault code has been retrieved and the repair has been completed, the ECM memory must be reset to clear the fault code from the ECM. See How to Clear Engine Fault Codes from the ECM. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Quickly activate and release the start toggle switch/button. Do not start the engine. 4 Move and hold the run/test toggle switch to the test position. How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position. Result: The check engine light should turn on. The check engine light should begin to blink. 1 Open the engine side turntable cover and locate the battery. 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 5 - 12 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 5 • Fault Codes REV A Code 111 112 113 114 115 121 122 124 133 134 FAULT CODES Description Code CL (Closed Loop) high LPG 211 EGO open / lazy pre-cat 1 EGO open / lazy pre-cat 2/post-cat 1 212 EGO open / lazy post-cat 1 213 EGO open / lazy post-cat 2 CL (Closed Loop) high gasoline bank 1 214 CL (Closed Loop) low gasoline bank 1 215 CL (Closed Loop) low LPG 221 Gasoline catalyst monitor 1 222 LPG catalyst monitor 141 AL (Adaptive Learn) high gasoline bank1 142 AL (Adaptive Learn) low gasoline bank 1 143 144 161 162 163 164 165 166 167 168 171 172 173 174 181 182 183 184 185 186 AL (Adaptive Learn) high LPG 223 224 225 226 AL (Adaptive Learn) low LPG 231 Battery Voltage high Battery Voltage low AUX analog PD1 high AUX analog PD1 low AUX analog PU3 high AUX analog PU3 low AUX analog PUD1 high AUX analog PUD1 low AUX analog PUD2 high AUX analog PUD2 low AUX analog PUD3 high AUX analog PUD3 low 232 234 Description IAT (Intake Air Temperature) high voltage IAT (Intake Air Temperature) low voltage IAT (Intake Air Temperature) higher than expected 1 IAT (Intake Air Temperature) higher than expected 2 Oil pressure low ECT / CHT (Engine/Cylinder Head Coolant Temperature) high voltage ECT / CHT (Engine/Cylinder Head Coolant Temperature) low voltage CHT higher than expected 1 CHT higher than expected 2 ECT higher than expected 1 ECT higher than expected 2 MAP (Manifold Absolute Pressure) high pressure MAP (Manifold Absolute Pressure) low voltage BP (Barometric Pressure) high pressure 235 BP (Barometric Pressure) low pressure 242 243 244 245 246 253 254 Crank sync noise Never crank synced at start Cam loss Cam sync noise Crank loss Knock1/2 sensor open 1 Knock1/2 excessive signal 1 AUX DIG1 high AUX DIG1 low AUX DIG2 high AUX DIG2 low AUX DIG3 high AUX DIG3 low Part No. 107846 For further engine fault code troubleshooting and diagnostic information, refer to the Ford DSG-423 EFI Service Manual (EDI part number 1060040). Ford DSG 423 EFI Service Manual Genie part number Z-45/25 • Z-45/25J 119494 5 - 13 Section 5 • Fault Codes August 2006 FAULT CODES Code 261 262 271 272 273 274 311 312 313 314 315 316 321 322 351 352 353 354 355 359 361 362 363 364 365 411 412 5 - 14 REV A Description Code FP (Fuel Pressure) high voltage 413 FP (Fuel Pressure) low voltage FT (Fuel Temperature) gasoline high voltage FT (Fuel Temperature) gasoline low voltage FT (Fuel Temperature) gaseous fuel high voltage FT (Fuel Temperature) gaseous fuel low voltage Injector Loop Open or Low-Side Short to Ground 1 Injector Coil Shorted 1 Injector Loop Open or Low-Side Short to Ground 2 Injector Coil Shorted 2 Injector Loop Open or Low-Side Short to Ground 3 Injector Coil Shorted 3 Injector Loop Open or Low-Side Short to Ground 4 Injector Coil Shorted 4 FPump motor loop open or high-side shorted to ground FPump motor high-side shorted to power EPR delivery pressure higher than expected EPR delivery pressure lower than expected EPR comm lost Fuel run-out longer than expected EPR voltage supply high EPR voltage supply low EPR internal actuator fault detection EPR internal circuitry fault detection EPR internal comm fault detection Primary Loop Open or Low-Side Short to Ground 1 Primary Coil Shorted 1 414 415 416 421 422 531 532 533 534 535 536 537 538 539 541 542 543 544 551 552 553 Description Primary Loop Open or Low-Side Short to Ground 2 Primary Coil Shorted 2 Primary Loop Open or Low-Side Short to Ground 3 Primary Coil Shorted 3 Primary Loop Open or Low-Side Short to Ground 4 Primary Coil Shorted 4 TPS1 (Throttle Position Sensor) high voltage TPS1 (Throttle Position Sensor) Low voltage TPS2 (Throttle Position Sensor) high voltage TPS2 (Throttle Position Sensor) low voltage TPS1 (Throttle Position Sensor) higher than TPS2 TPS1 (Throttle Position Sensor) lower than TPS2 Unable to reach higher TPS (Throttle Position Sensor) Unable to reach lower TPS (Throttle Position Sensor) TPS1/2 simultaneous voltages AUX analog PU1 high AUX analog PU1 low AUX analog PU2 high AUX analog PU2 low Max govern speed override Fuel rev limit Spark rev limit For further engine fault code troubleshooting and diagnostic information, refer to the Ford DSG-423 EFI Service Manual (EDI part number 1060040). Ford DSG 423 EFI Service Manual Genie part number Z-45/25 • Z-45/25J 119494 Part No. 107846 August 2006 Section 5 • Fault Codes REV A Code 611 612 613 614 615 616 631 632 633 634 635 641 642 643 644 646 647 648 655 656 711 712 713 714 715 716 721 722 723 731 732 733 734 735 FAULT CODES Description Code 736 741 742 743 744 COP failure Invalid interrupt A/D loss RTI 1 loss Flash checksum invalid RAM failure 761 5VE1 low voltage 5VE1 high voltage 762 5VE2 high voltage 763 5VE2 low voltage 5VE1/2 simultaneous out-of-range Rx Inactive Rx Noise Invalid Packet Format Shutdown Request 771 772 1629 1630 Description PWM3-Gauge3 short to power PWM4 open / ground short PWM4 short to power PWM5 open / ground short PWM5 short to power MIL (Malfunction Indicator Light) control ground short MIL (Malfunction Indicator Light) open MIL (Malfunction Indicator Light) control short to power Tach output ground short Tach output short to power J1939 TSC1 message receipt lost J1939 ETC message receipt lost For further engine fault code troubleshooting and diagnostic information, refer to the Ford DSG-423 EFI Service Manual (EDI part number 1060040). CAN Tx failure CAN Rx failure CAN address conflict failure Ford DSG 423 EFI Service Manual Genie part number RTI 2 loss 119494 RTI 3 loss Relay control ground short Relay coil open Relay coil short to power FPump relay control ground short Fpump relay coil open Fpump relay coil short to power Start relay control ground short Start relay coil open Start relay coil short to power PWM1-Gauge1 open / ground short PWM1-Gauge1 short to power PWM2-Gauge2 open / ground short PWM2-Gauge2 short to power PWM3-Gauge3 open / ground short Part No. 107846 Z-45/25 • Z-45/25J 5 - 15 Section 5 • Fault Codes August 2006 This page intentionally left blank. 5 - 16 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Hydraulic Schematics 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. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. General Repair Process Identify symptoms Malfunction discovered Troubleshoot problem still exists Return to service Part No. 107846 Z-45/25 • Z-45/25J problem solved Inspect and test Perform repair 6-1 Section 6 • Schematics August 2006 Electrical Symbols Legend REV A FS1 BLK BLK P3 WHT Quick disconnect terminal N.O.H.C Coil solenoid or relay N.C.H.O Limit switch Horn button normally open P1 KS1 TB21 WHT #21 Foot switch LS3 PLATFORM OTS2 N.O. GROUND T-circuits connect at terminal H1 Horn or alarm Key switch (before serial number 22051) Oil temperature switch normally open T-circuits connect Emergency Stop button normally closed FAN FB PR1 CTS1 N.O. Flashing beacon Power relay Coolant temperature switch normally open Connection no terminal G1 TS2 START ENGINE Gauge Aux Pump Auxiliary pump OPS1 N.C. Circuits crossing no connection 510 HM Diode Hydraulic oil cooling fan Toggle switch SPDT Oil pressure switch normally closed Resistor with ohm value Hour meter TS6 + PLATFORM LEVEL - Battery LED F1 UP DOWN L3 Gauge sending unit Tilt sensor Toggle switch DPDT 15A Fuse with amperage CR4 N.O. Circuit breaker with amperage Control relay contact normally open B C HOLD CB1 A PULL IN KS1 25A Key switch (after serial number 22050) Fuel or RPM solenoid Starting aid: glow plug or flame ignitor Coil 6-2 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 6 • Schematics Hydraulic Symbols Legend REV A 25 psi (1.7 bar) .035" (0.89 mm) Orifice with size Solenoid operated 3 position, 4 way, directional valve Filter with bypass valve relief setting Solenoid operated 3 position, 4 way, proportional directional valve Check valve 200 psi (13.8 bar) 2 position, 3 way, shuttle valve Pump fixed displacement Relief valve with pressure setting Priority flow regulator valve o Brake Pump bi-directional, variable displacement Solenoid operated 2 position, 3 way, directional valve Directional valve (mechanically activated) 3000 psi (206.8 bar) 3:1 50% Motor bi-directional Motor 2-speed, bi-directional Shut off valve 50% Flow divider/combiner valve with pressure balancing orifice and flow percentages Counterbalance valve with pressure and pilot ratio Pilot operated 3 position, 3 way, shuttle valve 2 position, 2 way solenoid valve E Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve Part No. 107846 Z-45/25 • Z-45/25J 6-3 Section 6 • Schematics August 2006 Ford Engine Relay Layout REV A Ford LRG-425 EFI (before serial number 30142) F5-15A Power Relay F4-15A F3-20A F2-5A Starter Relay F1-30A Fuel Pump Relay Ford DSG-423 EFI (after serial number 30141) Starter Relay Fuel Pump Relay Power Relay Empty F1-10A F2-5A F3-10A F4-15A F5-15A 6-4 Z-45/25 • Z-45/25J Part No. 107846 August 2006 Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness Section 6 • Schematics August 2006 REV A Ford LRG-425 EFI Engine Wire Harness A B INJ + 1 INJ 1 INJ 3 INJ 4 INJ 2 INJ 5 INJ 6 AUX OUT 2 EGR AUX ANA PD1 MAP FPP 1 2 IAT ECT IVS AUX ANA PU1 FPP 2 EGR PWM EGR RECIRC POWER GROUND POWER GROUND ANA_RTN 5 VOLT REF 3 VSW CRANK CRANK + CAM CAM + VBAT VBAT EGO 2 EGO 1 EGO 3 KNK + 4 KNK - C D E F G H I 361 R 16 6 361 R 16 7 555 T 16 8 557 BR-Y 16 557 BR-Y 16 9 558 BR-LB 16 558 BR-LB 16 10 556 W 16 361 R 16 743 GY 18 12 359 GY-R 18 21 18 O-Y 18 19 198 DG-O 18 20 358 LG-BK 18 15 151 LB-BK 18 COIL 3 COIL 4 COIL 5 COIL 6 STARTER LOCKOUT FUEL LOCKOFF FUEL PUMP RELAY CONTROL TPS1 6 TPS2 DBW + DBW BRAKE SWITCH OIL PRESSURE TACH MIL FUEL PUMP MON AUX OUT 1 FUEL SELECT AUX ANA PU2 7 GOV SELECT 1 GOV SELECT 2 ROAD SPEED + ROAD SPEED GASEOUS TRIM OVERSPEED CAN + CAN RS 485 + RS 485 RS 232 TX 8 RS 232 RX 27 743 GY 18 307 BK-Y 18 28 354 LG-R 18 354 LG-R 18 INJECTOR #1 17 307 BK-Y 18 18 150 DG-W 18 16 114 LB-Y 18 22 352 BR-LG 18 INJECTOR #2 570 BK-W 16 39 R-W 18 N FORD 42 PIN CONNECTOR 16 WATER TEMP 23 360 BR-PK 18 1 570 BK-W 16 570 BK-W 16 2 570 BK-W 16 570 BK-W 16 WATER TEMP 151 LB-BK 307 BK-Y 18 570 BK-W 16 570 BK-W 12 570 BK-W 12 5A 16 R-LG 18 MAP_CONN 359 GY-R 18 570 BK-W 16 351 BR-W 18 351 BR-W 18 3 16 R-LG 18 33 350 GY 18 358 LG-BK 18 358 LG-BK 18 32 349 DB 18 359 GY-R 18 359 GY-R 18 35 452 GY-R 18 18 O-Y 18 34 282 DB-O 18 198 DG-O 18 198 DG-O 18 4 361 R 16 150 DG-W 18 150 DG-W 18 5 361 R 16 114 LB-Y 18 114 LB-Y 18 25 392 R-LG 18 352 BR-LG 18 352 BR-LG 18 24 74 GY-LB 18 360 BR-PK 18 360 BR-PK 18 361 R 14 O2 SENSOR B A 18 O-Y 18 359 GY-R 18 30 359 GY-R 18 351 BR-W 18 351 BR-W 18 O2 SENSOR 361A R 16 361A R 16 MTRTWR6 MTRSHD6 570 BK-W 16 570 BK-W 16 74 GY-LB 18 392 R-LG 18 151 LB-BK 18 359 GY-R 18 359 GY-R 18 317 GY-O 18 355 GY-W 18 351 BR-W 18 570 BK-W 16 1 850 Y-BK 18 2 851 Y-R 18 TWR 1 COIL 1 361A R 16 3 1 2 VBAT 2 3 A B 242 DG 18 361A R 16 LOCKOFF SOLENOID 24 25 SHD TWR A A B B C C D D E E F F 16 R-LG 18 THROTTLE 355 GY-W 18 357 Y-W 18 151 LB-BK 18 317 GY-O 18 351 BR-W 18 359 GY-R 18 FUEL PUMP RELAY 6 5 4 1 32 R-LB 16 86 38 EGR ANA IN 32 ANA AUX PD1 37 ANA AUX PU1 12 FPP2 40 EGR PWM 41 EGR REC 85 86 87 30 2 87 32 R-LB 16 87A 359 GY-R 18 D 351 BR-W 18 C B 458 O-BK 18 A FPP_COMM 787A PK-BK 16 RTN F4 15A 787A PK-BK 16 RX TWR 86 POWER RELAY 30 23 242 DG 18 9 926A LB-O 18 32 15 R-Y 18 30 355 GY-W 18 31 357 Y-W 18 28 151 LB-BK 18 29 317 GY-O 18 6 511 LG-R 18 511 LG-R 18 511 LG-R 18 7 253 DG-W 18 253 DG-W 18 253 DG-W 18 8 11 T-Y 18 11 T-Y 18 11 T-Y 18 27 658 PK-LG 18 658 PK-LG 18 658 PK-LG 18 10 238 DG-Y 18 238 DG-Y 18 5 71 O-LG 18 71 O-LG 18 71 O-LG 18 14 72 Y-BK 18 72 Y-BK 18 72 Y-BK 18 15 148 Y-R 18 148 Y-R 18 148 Y-R 18 16 306 T-LB 18 17 307 BK-Y 18 11 169 LG-BK 18 12 26 85 926A LB-O 18 87 87A F5 15A 15 R-Y 18 361 R 16 OIL PRESSURE 361 R 16 253 DG-W 18 306 T-LB 18 306 T-LB 18 307 BK-Y 18 307 BK-Y 18 169 LG-BK 18 169 LG-BK 18 172 LB-R 18 172 LB-R 18 172 LB-R 18 33 77 DB-Y 18 349A DB 18 349A DB 18 349A DB 18 18 662 DG-P 18 662 DG-P 18 662 DG-P 18 19 459 O-LG 18 459 O-LG 18 459 O-LG 18 20 642 DG-O 18 642 DG-O 18 642 DG-O 18 21 461 O 18 461 O 18 461 O 18 34 669 DG-W 18 669 DG-W 18 35 458 O-BK 18 458 O-BK 18 669 DG-W 18 458 O-BK 18 570 BK-W 16 361A R 16 459 O-LG 18 662 DG-P 18 MTRTWR4 Z-45/25 • Z-45/25J Part No. 107846 5 FUEL PUMP TX 342 LG-P 18 361A R 16 39 STARTER IN (AUTOCRANK) 5V 22 361A R 16 15 STARTER IN (INTERUPT) 342 LG-P 18 669 DG-W 18 77 DB-Y 18 31 VREF 13 STARTER CONTROL 87A 32 R-LB 16 85 33 ANA RTN STARTER RELAY 30 3 342 LG-P 18 3 COIL 2 13 9 VBATT 361 R 14 361 R 14 29 4 361 R 12 C 16 R-LG 18 26 361 R 14 TWR 351 BR-W 18 1 VSW F3 20A 13 14 361 R 14 34 GROUND 570 BK-W 16 16 R-LG 18 CRANK 25 IVS F1 30A F2 CAM 14 FPP1 359 GY-R 18 ECT WPTWR2_GY 6-5 INJECTOR #4 570 BK-W 16 A B INJECTOR #3 151 LB-BK TRIM VALVE TWR 361 R 16 ACT J2 GREY COIL 1 M 31 359 GY-R 18 COIL 2 361 R 16 L 556 W 16 11 357 Y-W 18 5 K 555 T 16 J1 BLACK SPK PWR GROUND J TWR 4 BRAKE 26 OIL PRES 2 TACH 6 MIL 21 AUX OUT1 7 FUEL SELECT 10 AUX ANA PU2 24 GOV SELECT 1 23 GOV SELECT 2 35 ROADSPEED + 36 ROADSPEED 30 OVERSPEED 28 CAN + 29 CAN 11 RS 485+ 3 RS 48520 RS 232+ 18 RS 232- SHD A A PLUG (GROUND) B B PLUG (RELAY POWER) C C PLUG (CAN -) D D PLUG (CAN +) MTRSHD4 August 2006 Section 6 • Schematics REV A N Ford DSG-423 EFI Engine Wire Harness M L K J R 16 ENGINE ECM CONNECTOR SPK_COIL1A SPK_COIL1B SPARK_COIL2A SPK_GND SPK_COIL2B SPK_COIL3A SPK_COIL3B UEGOS UEGOC UEGOP UEGPR AUX ANA PD1 (FRP) AUX ANA PD2 CAN1 + CAN1 CAN2 CAN2 + AUX ANA PD3 5V EXT 1 5V RTN EGO1 EGO2 MAP AUX ANA PUD3 CRANK + CRANK CAM + CAM SPEED + SPEED 5V EXT 2 5V RTN 2 PULSE IN GOV 1 OIL PRESS IAT ECT (FRT) AUX ANA PU1 (LPTEMP) AUX ANA PU2 (IVS) AUX ANA PU3 (BRAKE) AUX DIG 3 (GOV2) AUX DIG 4 TACH VSW AUX ANA PUD2 AUX ANA PUD1 TPS 1 TPS 2 (FUELSELECT)AUX DIG1 AUX DIG 2 KNOCK + KNOCK FPP1 FPP2-IVS (FPP2) PC TX PC RX KNOCK 2+ KNOCK 2VBAT PROT VBAT EGOH 2 EGOH 1 INJ HS INJ1 LS INJ2 LS INJ3 LS INJ4 LS INJ5 LS GROUND INJ6 LS AUX PWM8 STARTER RELAY MIL UEGO H AUX PWM7 LOCKOFF AUX PWM6 (FUEL PUMP) VBAT DBW + GROUND DBW AUX PWM5 REC AUX PWM5 AUX PWM1 AUX PWM4 AUX PWM2 AUX PWM4 REC AUX PWM3 REC FP REC AUX PWM3 FUEL PUMP I H G F E D HO2S #1 IGNITION COILS R 16 Y/BK 18 W/PK 18 Y/RD 18 BK/W 16 DG/P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GY/LB 18 DG/P 18 GY/R 18 GY/YL 18 R 16 BK/LB 18 BK/LG 18 GY/LB 18 GY/R 18 DB/O 18 GY/R 18 CYL #2 CYL #3 CYL #4 A 1 SHD A B C D GY/Y 18 CYL #1 W/LG 18 DG/O 18 W/LG 18 DG/P 18 O/LG 18 DG/P 18 O/LG 18 BR/W 18 GY/R 18 GY/LB 18 GY/Y 18 LG/BK 18 TWR A B C D GY/R 18 LG/W 18 BR/W 18 W/LG 18 CAM 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 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 B HO2S #2 R 16 Y/BK 18 W/PK 18 Y/RD 18 C GASOLINE SENSOR INTERFACE FORD 42 PIN CONNECTOR MTRTWR4 BR/W 18 LG/R 18 LG/R 18 GY/R 18 GY/R 18 GROUND BR 16 BR 16 2 34 GND BK/W 12 BOSCH TMAP GY 18 DBL 18 GY/R 18 DB/O 18 DG/BK LB/R 18 LG/BK 18 BR/W 18 GY 18 GY/R 18 RING 4 3 2 1 CHT LG/W DG/BK LB/R 18 T/LB 18 T/LB 18 DG/W 18 GY 18 LG/R 18 LG/W W/R 18 BK/O 18 W/LB 18 BK/Y 18 T/Y 18 R/LG 18 DB/W 18 P/LB 18 GY/W 18 Y/W 18 Y/DB 18 LB/R 18 LG/BK 18 T/LB 18 BK/W 16 BK/W 16 LB/BK 18 BK/LB 18 36 ROADSPEED 35 ROADSPEED + 24 GOV SELECT 1 LB/BK 18 R/LG 18 BK/Y 18 R/LG 18 R/T 14 R/T 14 F2 14 FPP1 R/LG 18 R/LG 18 3 C128 RPM 1 VSW P23 BAT 23 GOV SELECT 2 C35 RPM VSW 5A F3 R 14 4 ECM 10A BK/Y 18 Y/R 18 DG/P 18 LB/BK 18 LB/Y 18 DG 18 O 18 GY 18 DBL 18 O/LG 18 DG/P 18 CRANK DG/O 18 DG/O 18 DB/W 18 LB/Y 18 DB/W 18 29 CAN 28 CAN + 32 ANA AUX PD1 37 AUX ANA PU2B LB/Y 18 12 FPP2 RD/T 14 R/T 16 BK/LB 18 BK/LG 18 GY/R 18 BR/W 18 GY/R 18 BR/W 18 GY/R 18 BR/W 18 33 ANA RTN 31 VREF R 14 T 16 BR/Y 16 BR/LB 16 W 16 BK/W 16 BK/W 16 LG/P 18 R/Y 18 PK/LG 18 BK/R 16 W/BK 18 LB/O 18 R/T 16 LB/DG 18 BK/W 16 GY/O 18 BOSCH THROTTLE GY/W 18 Y/W 18 LB/DG 18 BR/W 18 GY/R 18 GY/O 18 GY/W 18 Y/W 18 LB/DG 18 BR/W 18 GY/R 18 GY/O 18 W 16 W/R 18 INJECTOR CYL #2 R/LG 18 3 2 1 R/BK 18 R/W 18 BK/O 18 DG/W 18 T/Y 18 PK/LG 18 BK/R 16 O/LG 18 Y/DB 18 P/LB 18 T/GN 18 W/LB 18 DG 18 O 18 BK/O 18 DG/W 18 T/Y 18 PK/LG 18 BK/R 16 O/LG 18 Y/DB 18 P/LB 18 T/GN 18 W/LB 18 DG 18 O 18 25 IVS 26 OIL PRES 2 TACH 6 MIL 18 FUEL PUMP 39 AUX OUT1 7 FUEL SELECT 10 AUX ANA PD1B 27 AUX OUT 2 4 BRAKE 11 RS 232+ 3 RS 232- LB/PK 16 W/PK 16 15 START IN INTERUPT 19 START IN AUTOCRANK R33 STR PK/BK 16 5 FUEL PUMP + C135 FP+ A BN/LB 16 INJECTOR CYL #4 A B LPG LOCKOFF BR/Y 16 PK/BK 16 GY/R 18 BR/W 18 DG 18 O 18 DG/P 18 Y/R 18 KNOCK SENSOR DG/P 18 O/LG 18 1 2 3 4 5 6 7 8 ANA RTN 5V REF PC TX PC RX UNUSED UNUSED CAN + CAN - PK/BK 16 LB/O 18 LB/O 18 85 R 16 PK/BK 16 30 C127 TSW R/LG 18 DIAGNOSTIC CONNECTOR 7 LB/PK 16 87A LB/PK 16 87 W/PK 16 30 86 SHD RING 87A R/LG 18 CAN TERMINATION CONNECTOR STARTER RELAY STARTER SOLENOID 87 W 18 R/LG 18 LG/P 18 INJECTOR CYL #3 86 RELAY OMRON FPP 85 PK/BK 16 TWR W 18 2 DG/P 18 O/LG 18 BK/W 18 3 1 6 4 5 8 PK/BK 16 F1 R16 R/Y 18 INJECTOR CYL #1 R 16 C41 RPM C10 BESL C21 IGN C135 FP C39 LP 15A FUEL PUMP RELAY R 16 T 16 21 AUX PWM 5 16 AUX PWM 4 FUEL PUMP F4 LPG TEMPERATURE W/BK 18 R/LG 18 6 R/BK 18 R/W 18 GY/R 18 TWR R 16 5 ALTERNATOR R 16 DG/W 18 B R 16 R 12 RING OIL PRESSURE BK/R 16 R 16 R 12 BATT(+) 6 5 4 3 2 1 LG/P 18 R/Y 18 R/BK 18 O/LG 18 R/W 18 T/GN 18 R 16 BK/LG 18 R 16 POWER RELAY R 16 30 R 16 87 R/T 18 86 87A Part No. 107846 R/LB 16 10A 85 EPR F5 R 16 R/LB 16 7 CAN + TERM CAN + CAN GROUND UNUSED UNUSED UNUSED 8 POWER EPR CONNECTOR R 16 15A RELAYED POWER Z-45/25 • Z-45/25J 6-6 August 2006 Section 6 • Schematics Ford DSG-423 EFI Engine Wire Harness WH-(FS) FUSE 10A (ONLY ON WORKLIGHTS) C7P-1 C41RPM OR/BK P26ESTP BK P26ESTP BK FOOTSW. LOW FOOTSW. HIGH REV C Electrical Schematic, Z-45/25 C1P-9 C2P-4 C2P-7 C3P-4 C1P-7 C1P-1 C1P-2 RD C2P-5 C7P-2 BK C3P-9 C7B-1 C22LS RD L30 C2P-1 LIGHTS FUEL SELECT C2P-11 C2P-12 WORK LIGHT DRIVE LIGHT GAS LP ENGINE START AUXILIARY POWER C28TTA RD/BK WH P22BAT BK C128RPM OR/RD C35RPM BK/RD C2B-4 C1B-9 FUNCTION ENA. C2B-7 HIGH RPM LOW RPM C45GEN GR/WH C2B-1 C3B-4 C7B-2 C3B-9 C2B-5 C1P-2 C1P-1 C1B-7 FUEL SELECT DLITE WH C2P-10 C2P-9 C39LP BL/RD GAS LP C33STR BK ENGINE START AUXILIARY POWER C27AUX RD C28TTA RD/BK C134PWR GR C46HRN BK/RD P23BAT WH P134BAT RD C6-27 C5-24 C5-17 CR23 BAT-RD C5-12 C4B-11 C4B-12 RD RD C5-19 C5-11 C5-10 C5-18 C5-2 C5-5 C135FP C33STR BK BL/WH C27AUX RD C107AF WH P22HRN BK C46HRN BK/RD P134TTS RD C28TTA RD/BK BAT-RD TEST C108ESL BL/WH C21IGN WH C128RPM OR/RD C6-34 CR23 NO L2 BAT-RD 510 WH RD C45GEN GR/WH BR P20BAT RD FEH(361) PIN9 (GND) BR FEH(570) PIN34 C41RPM OR/BK FEH(11) PIN2 BL/RD FEH(72) PIN7 BK/RD FEH(307A) PIN23 BL/WH FEH(658) PIN6 GR FEH(458) PIN18 OR/RD FEH(306) PIN24 C21IGN WH FEH(71) PIN21 P23BAT WH FEH(16) PIN1 HM BK BK C6-9 BRN BRN R33STR BK FEH(32) PIN15 C33STR BK FEH(32) PIN13 BL/WH FEH(787A) PIN5 R46HRN BK/RD GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION FLASHING BEACONS OPTION CHECK ENGINE LED HOUR METER RUN/TEST SWITCH AUXILLARY POWER RELAY IGNITION/START RELAY FUEL PUMP STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN NOTE: Part No. 107846 Z-45/25 • Z-45/25J + 6-7 B H2 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 1) All switches and contacts are shown with the boom in the stowed position and the keyswitch off. _ M2 C39LP BL/RD C7B-4 8 + STARTER AUX PUMP B1 M4 M3 I PBOX GND C2B-3 P20BAT RD FLD. FB1 TB38 C127TSW GR FUSE 10A TB21 C5-3 TB39 L29 S8 S 7 TB33 TB35 CR2 CR2 NO CR1 CR1 NO CR39 CR39 NC C41RPM OR/BK L29 FUEL PUMP A REGULATOR 12 V DC WH TB27 C5-8 C5-13 C5-9 STA. PR1 PR1 CR5 NO C A R16 CR5 NO GND. L4 TS4 TS47 TS48 TS54 TS53 TS52 TS51 ENGINE FUSE BAT. LINK 6 TB42 P134BAT RD TB134 TB23 CHECK D1 RD RD C41RPM OR/BK 4 TS64 ALTERNATOR H1 RD RD TS1 L30 PLAT ENGINE SPEED P3 HORN P24BAT RD TB24 RD 15A TB20 5 TB41 CB1 KS1 P1 RD RD 15A BK-(FS) C9P-1 BK TS3 TS2 2 P24FS WH RD WH P25FS RD P24FS WH C9P-3 C9P-2 RD-(FS) FS1 P2 C28TTA RD/BK C28TTA RD/BK 1 N M L K J I H G F E D C B A TB22 CB2 3 August 2006 Section 6 • Schematics Ford LRG-425 EFI Models (before serial number 30142) BL/RD GRND C35RPM BK/RD - Electrical Schematic, Z-45/25 REV C P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD CDE1 BL LEFT 3 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 7 YOUT 4 BRN YEL OR BRN BRN C41RPM OR/BK 15 8 16 7 6 5 4 13 14 2 1 11 12 3 9 10 1 2 4 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 3 C7P-3 C30FWD WH BATGND C1P-4 C31REV WH/BK C2P-3 C1P-5 C29MS RD/WH BOOM C11-4 C11-1 OR BK-6 SECONDARY BOOM PRIMARY BOOM TURNTABLE ROTATE C37SCW BL/BK C6TRF WH/RD C36SCC BL C3P-6 C10SBU BL UP DOWN C16PDRE OR/RD C2B-2 C7PBE BK P22LS BK C8PBR BK/WH EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP PLATFORM LEVEL C6-40 C11SBD BL/BK C12SBF BL/WH C3PBF RD/WH C2PBD RD/BK C1PBU RD DOWN UP LEFT RIGHT C5TRR WH/BK C1P-10 C1P-11 C1P-3 C32BRK WH/RD RD C1P-6 BK C3P-5 C3P-1 C3P-2 C3P-3 C3P-12 C3P-11 C3P-10 C4P-4 C2P-2 C3P-7 C3P-8 C4P-2 C4P-3 C18JD GR/BK C17JU GR 21 C10-3 C7B-3 C1B-4 C1B-5 C1B-6 C1B-3 C1B-11 C1B-10 C3B-6 C3B-5 C3B-1 C3B-3 C3B-2 C3B-12 C3B-11 C3B-10 C4B-4 WH-6 BK-4 C3B-7 C3B-8 C4B-2 C4B-3 C4B-6 C4B-5 TB2 TB32 C6-16 C11-2 WH-7 WH-4 C6-32 C6-33 C5-20 C5-21 C29MS RD/WH C32BRK WH/RD C32TA WH/RD C31REV WH/BK C30FWD WH RD BK C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 C6-29 C37SCW BL/BK R5TRR WH/BK R4TRL WH R1PBU RD R2PBD RD/BK R10SBU BL R11SBD BL/BK WH-6 C11-3 C6-20 BK-5 C16-1 C17-1 C20-1 C21-1 C23-1 C6-19 C22-1 U4 C6-13 C6-37 C6-2 C6-10 C6-11 C10-2 BK-7 C10-1 C17 JU GR C18JD GR/BK C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK RD C36SCC BL C6-1 7 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C6-18 C6-17 13 6 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN 5 LS1 4 TS62 TS61 BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 DESCENT ALARM OPTION 6-8 Z-45/25 • Z-45/25J Part No. 107846 6 PWR XOUT 3 2 5 6 7 1 GND OUT 3 4 PWR 2 1 GND P24FS WH P24FS WH 3 4 BOOM C4P-6 C4P-5 PLATFORM ROTATE LS3 JC3 DRIVE & STEERING 3 PLATFORM LEVEL PLATFORM ROTATE RETRACT EXTEND UP DOWN LEFT RIGHT RIGHT LEFT 14 30 CR32 85 C129DA BK H3 22 7.5 D3 H4 2 87a 87 87a 87 LS2 6 14 R14 C40LSS OR 86 86 30 CR37 85 21 TB3 TB12 TB5 TB10 21 20 R4 RD J1 J1 J1 J1 J3 TB6 22 TB7 TB18 J2 U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION TB11 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. CR30 NO TB1 TB8 TB15 TB17 P26ESTP BK TS8 TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE L1 WH TS15 JC1 SECONDARY BOOM UP/DOWN P24FS WH 2 CR27 NC TS60 TS63 TS59 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. BK TS58 TS13 TS9 P26ESTP BK P26ESTP BK 1 C28TTA RD/BK C28TTA RD/BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Ford LRG-425 EFI Models (before serial number 30142) C41RPM OR/BK BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25 Ford LRG-425 EFI Models (before serial number 30142) WH-(FS) FUSE 10A (ONLY ON WORKLIGHTS) C7P-1 C41RPM OR/BK P26ESTP BK 1 C28TTA RD/BK C28TTA RD/BK P26ESTP BK FOOTSW. LOW FOOTSW. HIGH C1P-9 C2P-4 C2P-7 C3P-4 RD C2P-5 C1P-2 C1P-1 C1P-7 C2P-1 LIGHTS C2P-11 C2P-12 WORK LIGHT DRIVE LIGHT LP FUEL SELECT C22LS RD L30 C7P-2 BK C3P-9 C7B-1 C128RPM OR/RD C35RPM BK/RD C2B-4 C1B-9 FUNCTION ENA. C2B-7 HIGH RPM LOW RPM C45GEN GR/WH C2B-1 C3B-4 C7B-2 C3B-9 C2B-5 C1P-2 C1P-1 C1B-7 FUEL SELECT DLITE WH C2P-10 C2P-9 C39LP BL/RD LP GAS C33STR BK ENGINE START AUXILIARY POWER C27AUX RD C28TTA RD/BK C134PWR GR C46HRN BK/RD P23BAT WH P134BAT RD C6-27 C5-24 C5-17 C6-34 C5-12 C4B-11 C4B-12 RD RD C128RPM OR/RD C21IGN WH BL/WH C45GEN GR/WH A B C D BR GY/RD GY/YL RD BK/BL RD/GN WH/BK P23BAT WH FEH(16) PIN1 OR/RD FEH(306) PIN24 C21IGN WH FEH(71) PIN16 BL/WH FEH(658) PIN6 GR FEH(458) PIN3 (GND) BR FEH(570) PIN34 C41RPM OR/BK FEH(11) PIN2 BL/RD FEH(72) PIN7 BK/RD FEH(307A) PIN23 C5-2 BK C6-9 BRN BRN BK PIN18 BL/WH FEH(787A) PIN5 R33STR BK FEH(32) PIN15 WH R46HRN BK/RD RD C5-5 C135FP C5-10 C5-18 C5-11 C5-19 TEST C108ESL BL/WH BAT-RD C27AUX RD BAT-RD C28TTA RD/BK P134TTS RD C46HRN BK/RD P22HRN BK HM _ M2 GAS ENGINE START AUXILIARY POWER C28TTA RD/BK WH P22BAT BK FORD ENGINE HARNESS B H2 GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION FLASHING BEACONS OPTION HOUR METER CHECK ENGINE LED GASOLINE SENSOR LPG LOCKOUT RUN/TEST SWITCH AUXILLARY POWER RELAY IGNITION/START RELAY FUEL PUMP START (FEH) STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN Part No. 107846 Z-45/25 • Z-45/25J + 6-9 ALTERNATOR FIELD (FEH) NOTE: + STARTER AUX PUMP B1 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 1) All switches and contacts are shown with the boom in the stowed position and the keyswitch off. L29 L29 S8 S CR39 CR23 BAT-RD FLD. M4 M3 I 7 TB21 C7B-4 8 FB1 TB38 C127TSW GR ENGINE TS64 PBOX GND C2B-3 P20BAT RD STA. CR1 NO FUSE 10A C39LP BL/RD TB35 CR2 CR2 NO CR1 C5-8 C5-13 C5-9 NO C A PR1 PR1 CR5 CR5 NO GND. FUEL PUMP A REGULATOR 12 V DC BAT. LINK 6 TB33 CR23 NO ALTERNATOR FUSE L4 TS4 TS47 TS48 TS54 TS53 TS52 TS51 L2 CHECK D1 TB42 P134BAT RD TB134 TB23 WH TB27 CR39 NC C41RPM OR/BK 15A TB20 RD RD C41RPM OR/BK 4 P24BAT RD TB24 RD 5 H1 RD RD TS1 L30 PLAT ENGINE SPEED P3 HORN TB39 TB41 CB1 TB22 KS1 CB2 BK-(FS) C9P-1 BK TS3 TS2 2 P24FS WH RD WH P25FS RD P24FS WH C9P-3 C9P-2 RD-(FS) FS1 P2 N M L K J I H G F E D C B A P1 RD RD 15A 3 August 2006 Section 6 • Schematics REV A Electrical Schematic, Z-45/25 Ford DSG-423 EFI Models (after serial number 30141) BL/RD GRND C35RPM BK/RD - Electrical Schematic, Z-45/25 REV A P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD 3 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 YOUT 4 BRN YEL OR BRN TS8 C41RPM OR/BK 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 1 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 3 C7P-3 BATGND C1P-11 C1P-3 C1P-6 C1P-5 C1P-4 C36SCC BL C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP DOWN C1PBU RD C3PBF RD/WH C2PBD RD/BK C11SBD BL/BK C12SBF BL/WH C10SBU BL UP DOWN C16PDRE OR/RD OR BK-6 SECONDARY BOOM PRIMARY BOOM TURNTABLE ROTATE C3P-6 RD C5TRR WH/BK BK C3P-5 C3P-1 C3P-2 C3P-3 C3P-12 C3P-11 C3P-10 C4P-4 C11-1 C11-4 BOOM PLATFORM LEVEL C6-40 C15PLD OR/BK C14PLU OR RETRACT EXTEND C8PBR BK/WH C7PBE BK P22LS BK C2B-2 C4P-3 C4P-2 DOWN UP 21 C10-3 LS1 C4B-4 C4B-6 C4B-3 C4B-2 C3B-8 C3B-7 BK-4 WH-6 C3B-10 C3B-11 C3B-12 C3B-3 C3B-2 C3B-1 C3B-5 C3B-6 C1B-10 C1B-11 C1B-3 C1B-6 C1B-5 C1B-4 C7B-3 5 C4B-5 TB32 C6-16 C11-2 WH-7 WH-4 C6-32 C6-33 C5-20 C5-21 C29MS RD/WH C32BRK WH/RD C32TA WH/RD C31REV WH/BK C30FWD WH RD BK C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 C6-29 C37SCW BL/BK R5TRR WH/BK R4TRL WH R1PBU RD R2PBD RD/BK R10SBU BL R11SBD BL/BK WH-6 C11-3 C6-20 BK-5 C16-1 C17-1 C20-1 C21-1 C23-1 C6-19 C22-1 U4 C6-13 C6-37 C6-2 C6-10 C6-11 C10-2 BK-7 C10-1 C17 JU GR C18JD GR/BK C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK RD C36SCC BL C6-1 7 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C6-18 C6-17 13 6 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 DESCENT ALARM OPTION 6 - 10 Z-45/25 • Z-45/25J Part No. 107846 7 XOUT 3 6 PWR 2 1 GND 7 6 5 4 3 OUT PWR 1 2 BRN 2 3 4 C2P-2 C3P-8 C3P-7 TS62 TS61 C18JD GR/BK C17JU GR PLATFORM ROTATE LS3 GND P24FS WH P24FS WH P26ESTP BK 4 BOOM C4P-5 C4P-6 PLATFORM LEVEL PLATFORM ROTATE RETRACT EXTEND UP DOWN LEFT RIGHT RIGHT LEFT 14 CR32 85 CR37 C129DA BK H3 22 7.5 D3 86 30 86 30 87a 87 87a 87 LS2 TB2 TB11 6 14 R14 C40LSS OR H4 2 85 21 TB3 TB12 TB5 TB10 21 20 R4 RD J1 J1 J1 J1 J3 TB6 22 TB7 TB18 TB1 TB8 TB15 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. DRIVE & STEERING 4 BK J2 U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION TS60 TS63 TS59 CR30 NO PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE 2 CR27 NC SECONDARY BOOM UP/DOWN L1 WH TS14 JC3 3 TS58 TS13 TS9 P26ESTP BK P26ESTP BK TS15 JC2 P24FS WH JC1 1 C28TTA RD/BK C28TTA RD/BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Ford DSG-423 EFI Models (after serial number 30141) C41RPM OR/BK BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25 Ford DSG-423 EFI Models (after serial number 30141) Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Ford Models 86 87A 30 87 85 6 - 11 C3B 6 C3B 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C7B 12V DCTO PLAT C6 C4B C7B C7B-3 C6-29 C6-36 C6-40 C6-37 C6-16 C6 C16DRE OR/RD FUNCTIONS Part No. 107846 C4B C3B C29MS RD/WH C37STC BL/BK C36STCC BL C40LS1 OR C3B C5 7 C2B 19/18 CABLES C1B C3B BRN C2B C6 C4B C5 FUNCTION HARNESS RELAY HARNESS C4B C3B C2B-7 BRN C45 GEN GR/WH C5-12 C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 C5-8 C2B-2 ENGINE C127TSW KEYSWITCH POWER CB1 POWER (UNUSED) (UNUSED) AUXILIARY PUMP BRAKE START ENGINE (UNUSED) HIGH RPM CHECK ENGINE LED LIQUID PROPANE FUEL ALTERNATOR PULSE PICKUP LOW RPM JIB DOWN DESCENT ALARM KS POWER 23 24 25 26 27 32 33 34 35 38 39 41 42 44 134 BRN C5-11 WH BRN BRN TS64 RUN/TEST SWITCH CR23 DRIVE LIGHT OPTION RELAY CR32 PRIMARY BOOM RELAY CR2 POWER RELAY C4B CR5 HORN RELAY BK-33B BRN R27AUX C5-6 RD RD-27B BRN-GND WH-21C C6-13 BK BRN BK-22B BATGND BRN C6 ENGINE HARNESS C19JSV GR/WH TS57 BK-ALARM CR33 TURNTABLE ROTATE RELAY WH/RD-32A BRN C5-19 BK-ALARM RD/WH-3B RD-1B WH/RD-6B WH/BK-5B BK-ALARM WH/RD-ALARM BRN BL-10B BRN CR37 SECONDARY BOOM RELAY BL/WH-12B L C4B-7 GR/WH BRN BK-ALARM C6-33 WH/RD-ALARM RD-24B RD KS1 GR/BK-TS58 BK-ALARM OR/RD-TS54 OR/BK-IS2 BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 WH/RD-ALARM C6-33 RD-TS51 RD-CR39 RD-CB1 RD-CR2 WH-KS BK-KSI 1 BRN 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 WH-HM BK-CR5 K RD-20C DRIVE LIGHTS +12 VOLT TO PLATFORM 22 21 RD-CB1 BRN J C6-9 BK/RD IGNITION POWER 21 20 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 F19 10A FUSE C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH C6-5 WH/BK CR1 IGNITION START RELAY C6-11 BL/BK +12 VOLT POWER 20 18 CR39 AUXILLARY RELAY BRN R43DLITE1 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 17 BL/BK-TS60 CR37 #30 BL/WH I C6-10 BL 5 R43DLITE2 RD PLATFORM ROTATE LEFT/JIB UP 17 15 14 12 11 BL-TS60 BK H C6-38 C6-39 PLATFORM LEVEL DOWN 15 3 C5-5 BK PLATFORM LEVEL UP 14 KS POWER SECONDARY BOOM FUNCTION CTRL 12 134A SECONDARY BOOM DOWN 11 10 BK/WH-TS63 CR37 #86 BL G C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD C5-9 OR/RD C5-2 OR/BK SECONDARY BOOM UP 10 8 BK-TS63 F C2B-3 OR/BK C2B-1 BL/RD C5-10 BL/RD C5-13 BL/WH C1B-9 BK/RD C5-18 BK/RD C1B-8 BK/WH PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 E C1B-7 BK BK-CR1 C6-32 WH/RD C1B-6 WH/RD PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK D C1B-1 RD C6-27 RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD C CR23 RD C4B-6 GR/BK C6-18 GR/BK TURNTABLE ROTATE RIGHT 5 4 3 A BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH PRIMARY BOOM FUNCTION CONTROL 3 2 1 B B C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) A C3B-6 WH/RD C3B-5 WH/BK C 4 C3B-3 RD/WH D 2 C3B-2 RD/BK C3B-1 RD Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Ford Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD F.H. C1B C3B-4 P20DLITE RD C4B E.H. C3B GR C7B3 BRN C4B-4 BRN-TS 8 C5 GROUND BOLT NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford Models G F E D RD C19JSV GR/WH RD TS62 TURNTABLE ROTATE WH/RD-6A RD WH/BK-5A RD RD RD GR/BK-18A OR-14A RD GR-17A C4B-7 GR/WH RD OR/BK-15A TS59 PLATFORM LEVEL 4 RD 5 R14 G-BOX CB2 CIRCUIT BREAKER CONTROLS 15A L2 + CHECK ENGINE LED WH-23 RD NOTE: DASHED LINES INDICATE OPTION WIRES RD TS60 SECONDARY BOOM UP/DOWN P-BOX RD RD RD RD RD RD RD-20B D2 RD RD RD START RD RD OR/RD-42A 8 TS54 FUNCTION ENABLE RD RD RD RD 6 14 BK/RD-35A RD RD RD 7 RD R4 BASE BOX HARNESS (TO TERMINAL STRIP) RD HOUR METER P1 STOP SWITCH RD FUNCTION SPEED CONTROL VARIABLE RESISTER, 20 BRN WH-21A BRN RD-20A WH-CR2 RD-24A C32-7 RD C23-7 RD RD 6 CB1 CIRCUIT BREAKER ENGINE 15A RUN/TEST TOGGLE SWITCH 3 RD RD TS64 RD BK-22A BL-10A PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH BK-33A TURNTABLE ROTATE TOGGLE SWITCH TS63 RD PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 BL/BK-11A TS61 TS52 SECONDARY BOOM UP/DOWN TOGGLE SWITCH KS1 PLATFORM LEVEL TOGGLE SWITCH TS60 WH/RD-6A PLATFORM ROTATE TOGGLE SWITCH TS59 BL/WH-12A TS57 WH/BK-5A FUNCTION ENABLE TOGGLE SWITCH BK/WH-8A FUEL SELECT TOGGLE SWITCH TS54 BK-7A ENGINE START TOGGLE SWITCH TS53 RD-1A AUXILIARY TOGGLE SWITCH TS52 RD TS51 RD UP/DOWN SPEED RESISTER 7.5 OHMS 2 RD RD SPEED LIMITING VARIABLE RESISTOR 20 OHMS R14 RD TS61 PRIMARY BOOM UP/DOWN R4 1 RD RED EMERGENCY STOP BUTTON RD CHECK ENGINE LED P1 RD/WH-3A L2 RD RD KEY SWITCH RD/BK-2A KS1 RD RD D3 RD HOUR METER RD RD A BK-7A RD HM BK/WH-8A RD D4 BL/RD-39A HORN RELAY BL/WH-38 CR5 RD RD HIGH IDLE RELAY B RD TS53 FUEL SELECT INGITION POWER RELAY CR4 RD 134A CR2 WH-23A IGNITION / START RELAY RD-27 CIRCUIT BREAKER, CONTROLS, 15A CR1 RD-27A CB2 WH CIRCUIT BREAKER, ENGINE, 15A TS63 PRIMARY BOOM EXTEND/RETRACT DESCRIPTION CB1 C TS57 PLATFORM ROTATE H GR/BK-18 I RD J GR-17 K SWITCH L TS51 AUXILIARY POWER LABEL M ENGINE N Part No. 107846 Z-45/25 • Z-45/25J 6 - 12 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford Models Section 6 • Schematics August 2006 Platform Control Box Wiring Diagram, Z-45/25 Ford Models C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 RD-P2 RD-H1 BRN C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C128LS OR/RD C2P-4 C39LP BL/RD C2P-1 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 1 TS1 WH 11 1 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 P24FS WH BRN JC1-3 OR C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN JC2-4 RD 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 BRN Part No. 107846 Z-45/25 • Z-45/25J 6 - 13 9 LS18 CE OPTION ONLY 12V DC BATTERY SUPPY 19/18 CONTROL CABLE 3 JIB C9 7 C1P C28TTA RD/BK C1P-2 C7P TILT ALARM C7P C7P BATGRN C7P-3 C2P WLITE BRN C2P-9 WLITE BRN C2P-10 J3 GR/BK C4P-1 3 P24FS WH U13 ALC-500 RED-TILT BRN 6 C4P 5 BRN BRN PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION 2 J2 BRN J1 CR27 CR30 P26ESTP BK 1 N M L K J I H G F E D C B A August 2006 Section 6 • Schematics REV A Platform Box Wiring Diagram, Z-45/25 Ford Models 4 F.S. August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford Models N M L K J I H G F E D C B A 1 TS47 GENERATOR (OPTION) JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT JC1 7 SECONDARY BOOM UP/DOWN 5 5 3 L48 TILT ALARM LED 1 1 3 RD 2 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 2 5 + GR/WH 4 TS13 PRIMARY BOOM EXTEND/ RETRACT BK 4 7 6 RD 6 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT TS15 DRIVE ENABLE BK 6 JC3 GR/WH RD BK 7 PLATFORM CONTROL HARNESS (TO CONTROL BOX) 2 1 + BK RD BK 4 RD L1 DRIVE ENABLE LED 3 F18 FUSE 10A GENERATOR OPTION CWLITE RD C2P-12 C3P-4 DLITE WH RD TS1 AUXILIARY PUMP RD LS18 BK C7P-1 BK J3-3 WH TS2 ENGINE START 2 P2 EMERGENCY STOP DRIVE SPEED TS9 PLATFORM LEVEL WH C7P-2 BK C9P-1 NO 3 4 P3 HORN 7 TS3 FUEL SELECT TS14 HIGH/LOW (2WD/4WD) 6 BK WH TS7 PLATFORM ROTATE BK BK C39LP BL/RD C2P-1 PDLITE RD P24FS WH C9-2 C128LS OR/RD C2P-4 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 C29MS RD/WH J1-8 C27AUX RD C1P-1 C17PRL GR C4P-5 C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 BK WH 5 BL J1-5 WH J1-4 BL J1-5 OR J1-13 BRN J1-14 RD CWLITE RD C2P-11 RD/BK H1 RD C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 BL/BK-DE2 J1-7 BK YEL J1-3 OR J1-9 BRN J1-10 C8PBR BK/WH C3P-8 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C7PBE BK C3P-7 BK TS4 HIGH/LOW RPM 2 2 NC NC NC 1 1 1 RD WH-24 8 RD RD RD RD RD RD NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6 - 14 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford Models C9P-2 P24FS WH WH LOW RPM HIGH RPM ENGINE SPEED GENERATOR C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK 1 C1P-9 C2P-4 C2P-7 C3P-4 C35RPM BK/RD C2B-4 C1B-9 FUNCTION ENABLE C128RPM OR/RD LOW RPM C45GEN GR/WH C3B-4 C2B-7 HIGH RPM DLITE WH C2B-1 P134BAT RD C6-34 RD C5-12 C4B-12 RD C45GEN GR/WH BR P23BAT WH FEH(16) PIN1 OR/RD FEH(306) PIN24 C21IGN WH FEH(71) PIN21 GR FEH(458) PIN18 BL/WH FEH(658) PIN6 BL/RD FEH(72) PIN7 BK/RD FEH(307A) PIN23 P20BAT RD FEH(361) PIN9 (GND) BR FEH(570) PIN34 C41RPM OR/BK FEH(11) PIN2 R33STR BK FEH(32) PIN15 BK BL/WH FEH(787A) PIN5 C33STR BK FEH(32) PIN13 RD WH C4B-11 C128RPM OR/RD C21IGN WH TEST C5-2 C5-5 C33STR BK BL/WH C135FP C5-18 C5-10 C5-11 C5-19 C108ESL BL/WH BAT-RD C27AUX RD BAT-RD C28TTA RD/BK P134TTS RD L29 L29 DRIVE LIGHTS C2P-10 C2P-9 C39LP BL/RD C6-27 C5-24 FUSE 10A C39LP BL/RD WORK LIGHTS C2P-1 FUEL SELECT C1B-7 C1P-1 CR39 C2P-12 C2P-11 FUEL SELECT GAS LP C33STR BK C27AUX RD C1P-2 C5-17 C46HRN BK/RD BK BRN GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION CHECK ENGINE LED HOUR METER RUN/TEST SWITCH AUXILLARY RELAY IGNITION/START RELAY FUEL PUMP STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR TILT ALARM HORN RELAY HORN ENGINE HARNESS #2 + C6-9 FORD 42 PIN QUICK DISCONNECT GAS C1P-7 ENGINE START C28TTA RD/BK C2B-5 AUXILIARY POWER C134PWR GR C3B-9 R46HRN BK/RD _ M2 LP ENGINE START AUXILIARY POWER C1P-1 C46HRN BK/RD C7B-2 C41RPM OR/BK TS4 TS3 RD C28TTA RD/BK C1P-2 C2P-5 P23BAT WH TB33 RD WH RD C3P-9 C7P-2 P22HRN BK 510 M3 AUX PUMP FB1 TB38 C5-8 C127TSW GR TS53 NO L2 C107AF WH ALTERNATOR NOTE: C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN 1) All switches and contacts are shown with the boom in the stowed position and the keyswitch off. B H2 Part No. 107846 Z-45/25 • Z-45/25J 6 - 15 M4 I 7 FUEL PUMP S8 S CR39 NC ENGINE BAT-RD FLD. TB21 C5-3 TB35 CR2 CR2 CR1 C5-9 STA. PR1 CR5 C5-13 NO C A NO R16 PR1 CR5 GND. BK C7B-1 C2B-3 REGULATOR A B1 12V DC RD C41RPM OR/BK 6 NO NO C7B-4 FUSE WH TB27 TB23 P20BAT RD 8 BAT. LINK WH-(FS) TS54 TS52 TS51 CR23 CR23 CHECK D1 TB42 P134BAT RD TB134 CR1 5 L4 TS64 ALTERNATOR H1 P24BAT RD TB24 RD 15AMP. TB20 RD TS47 TS48 TS2 P22BAT BK P3 PBOX GND 4 FUSE 10A (ONLY ON WORKLIGHTS) C7P-1 HORN L30 L30 P1 TB39 TB41 CB1 KS1 TB22 CB2 P25FS RD P24FS WH C9P-3 BK-(FS) RD-(FS) C9P-1 BK TS1 2 FS1 P2 N M L K J I H G F E D C B A C22LS RD PLAT RD RD 15AMP. 3 August 2006 Section 6 • Schematics REV C Electrical Schematic, Z-45/25J Ford LRG-425 EFI Models (before serial number 30142) P26ESTP BK P26ESTP BK BL/RD GRND RD C35RPM BK/RD BRN + - Electrical Schematic, Z-45/25J REV C P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD CDE1 BL LEFT 3 5 RD BK BRN OR BL WH BL DRIVE ENABLE CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 YOUT 4 OR C41RPM OR/BK 5 15 16 19 20 17 18 9 11 10 6 7 8 14 13 C7P-3 BATGND C1P-11 C1P-3 C1P-6 C1P-5 C1P-4 C36SCC BL C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP DOWN C2PBD RD/BK C1PBU RD C3PBF RD/WH C12SBF BL/WH C11SBD BL/BK C10SBU BL PRIMARY BOOM TURNTABLE ROTATE C3P-6 RD C5TRR WH/BK BK C3P-5 C3P-1 C3P-2 C3P-3 C3P-12 C3P-11 C3P-10 21 C10-3 C7B-3 C1B-4 C1B-5 C1B-6 C1B-3 C1B-11 C1B-10 C3B-6 C3B-5 C3B-2 C3B-1 C3B-3 C3B-12 C3B-10 C3B-11 C4B-4 WH-6 BK-4 C3B-7 C3B-8 C4B-2 C4B-3 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH C37SCW BL/BK C29MS RD/WH C6-37 C10-2 BK-7 RD C32BRK WH/RD 7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-11 C6-10 C6-2 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR BK C6-13 RD C26-1 C28-1 C25-1 C24-1 C15-1 C14-1 C12-1 C13-1 C18-1 C19-1 C11-3 BK-5 C16-1 C17-1 C20-1 C21-1 C23-1 C6-19 C22-1 U4 C6-20 H4 15 8 16 7 6 5 4 13 14 2 1 11 12 3 9 OR BK-6 SECONDARY BOOM C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL C4B-6 C6-18 C6-17 C129DA BK 13 86 30 6 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND DESCENT ALARM OPTION PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 JIB BOOM VALVE 6 - 16 Z-45/25 • Z-45/25J Part No. 107846 7 XOUT 3 BRN YEL OR 12 UP DOWN C16PDRE OR/RD C2B-2 C7PBE BK P22LS BK C8PBR BK/WH EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP C2B-6 LS1 5 C4B-5 87a 87 6 PWR 2 5 6 7 1 GND OUT 3 4 BRN 10 C4P-4 C2P-2 C3P-7 C3P-8 C4P-2 C4P-3 C129DA GR/BK C18JD GR/BK C17JU GR JIB BOOM PLATFORM ROTATE DOWN UP RIGHT LEFT C4B-7 LS3 TS62 C19JSV GR/WH 14 CR32 85 CR37 85 PWR GND 1 1 3 4 BOOM C4P-5 C4P-6 C2P-6 PLATFORM LEVEL PLATFORM ROTATE C4P-7 7.5 D3 86 30 86 30 2 BRN 2 4 3 RETRACT EXTEND UP DOWN J2 JIB BOOM GR/BK-44 DOWN UP LEFT RIGHT WH 22 P24FS WH TS8 JIB BOOM VALVE H3 2 87a 87 LS2 TB3 TB12 TB5 TB10 21 6 14 R14 C40LSS OR TB6 22 TB7 TB18 21 TB2 TB11 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. TB1 TB8 TB15 TB17 DRIVE & STEERING 4 BK TS58 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. TB44 20 R4 RD J1 J1 J1 J1 J3 TS61 TS60 TS63 TS59 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE 3 TS57 CR30 NO P24FS WH BK NC U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS9 TS7 P26ESTP BK CR13 TS14 SECONDARY BOOM UP/DOWN TS15 JC3 2 CR27 NC CR13 P26ESTP BK P26ESTP BK L1 WH WH JC2 P24FS WH JC1 1 C28TTA RD/BK C28TTA RD/BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Ford LRG-425 EFI Models (before serial number 30142) C41RPM OR/BK BRN BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25J Ford LRG-425 EFI Models (before serial number 30142) WH-(FS) FUSE 10A (ONLY ON WORKLIGHTS) C7P-1 C41RPM OR/BK P26ESTP BK 1 C28TTA RD/BK C28TTA RD/BK P26ESTP BK FOOTSW. LOW FOOTSW. HIGH C1P-9 C2P-4 C2P-7 C3P-4 RD C2P-5 C1P-2 C1P-1 C1P-7 C2P-1 LIGHTS C2P-11 C2P-12 WORK LIGHT DRIVE LIGHT LP FUEL SELECT C22LS RD L30 C7P-2 BK C3P-9 C7B-1 C128RPM OR/RD C35RPM BK/RD C2B-4 C1B-9 FUNCTION ENA. C2B-7 HIGH RPM LOW RPM C45GEN GR/WH C2B-1 C3B-4 C7B-2 C3B-9 C2B-5 C1P-2 C1P-1 C1B-7 FUEL SELECT DLITE WH C2P-10 C2P-9 C39LP BL/RD LP GAS C33STR BK ENGINE START AUXILIARY POWER C27AUX RD C28TTA RD/BK C134PWR GR C46HRN BK/RD P23BAT WH P134BAT RD C6-27 C5-24 C5-17 C6-34 C5-12 C4B-11 C4B-12 RD RD C128RPM OR/RD C21IGN WH BL/WH C45GEN GR/WH A B C D BR GY/RD GY/YL RD BK/BL RD/GN WH/BK P23BAT WH FEH(16) PIN1 OR/RD FEH(306) PIN24 C21IGN WH FEH(71) PIN16 BL/WH FEH(658) PIN6 GR FEH(458) PIN3 (GND) BR FEH(570) PIN34 C41RPM OR/BK FEH(11) PIN2 BL/RD FEH(72) PIN7 BK/RD FEH(307A) PIN23 C5-2 BK C6-9 BRN BRN BK PIN18 BL/WH FEH(787A) PIN5 R33STR BK FEH(32) PIN15 WH R46HRN BK/RD RD C5-5 C135FP C5-10 C5-18 C5-11 C5-19 TEST C108ESL BL/WH BAT-RD C27AUX RD BAT-RD C28TTA RD/BK P134TTS RD C46HRN BK/RD P22HRN BK HM _ M2 GAS ENGINE START AUXILIARY POWER C28TTA RD/BK WH P22BAT BK FORD ENGINE HARNESS B H2 GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION FLASHING BEACONS OPTION HOUR METER CHECK ENGINE LED GASOLINE SENSOR LPG LOCKOUT RUN/TEST SWITCH AUXILLARY POWER RELAY IGNITION/START RELAY FUEL PUMP START (FEH) STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN Part No. 107846 Z-45/25 • Z-45/25J + 6 - 17 ALTERNATOR FIELD (FEH) NOTE: + STARTER AUX PUMP B1 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 1) All switches and contacts are shown with the boom in the stowed position and the keyswitch off. L29 L29 S8 S CR39 CR23 BAT-RD FLD. M4 M3 I 7 TB21 C7B-4 8 FB1 TB38 C127TSW GR ENGINE TS64 PBOX GND C2B-3 P20BAT RD STA. CR1 NO FUSE 10A C39LP BL/RD TB35 CR2 CR2 NO CR1 C5-8 C5-13 C5-9 NO C A PR1 PR1 CR5 CR5 NO GND. FUEL PUMP A REGULATOR 12 V DC BAT. LINK 6 TB33 CR23 NO ALTERNATOR FUSE L4 TS4 TS47 TS48 TS54 TS53 TS52 TS51 L2 CHECK D1 TB42 P134BAT RD TB134 TB23 WH TB27 CR39 NC C41RPM OR/BK 15A TB20 RD RD C41RPM OR/BK 4 P24BAT RD TB24 RD 5 H1 RD RD TS1 L30 PLAT ENGINE SPEED P3 HORN TB39 TB41 CB1 TB22 KS1 CB2 BK-(FS) C9P-1 BK TS3 TS2 2 P24FS WH RD WH P25FS RD P24FS WH C9P-3 C9P-2 RD-(FS) FS1 P2 N M L K J I H G F E D C B A P1 RD RD 15A 3 August 2006 Section 6 • Schematics REV A Electrical Schematic, Z-45/25J Ford DSG-423 EFI Models (after serial number 30141) BL/RD GRND C35RPM BK/RD - Electrical Schematic, Z-45/25J REV A P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD 3 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 YOUT 4 BRN YEL OR BRN C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C7P-3 BATGND C1P-11 C1P-3 C1P-6 C1P-5 C1P-4 C36SCC BL C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP DOWN C1PBU RD C3PBF RD/WH C2PBD RD/BK C11SBD BL/BK C12SBF BL/WH C10SBU BL PRIMARY BOOM TURNTABLE ROTATE C3P-6 RD C5TRR WH/BK BK C3P-5 C3P-1 C3P-3 C3P-2 C3P-11 C3P-12 C3P-10 UP OR BK-6 SECONDARY BOOM C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL 21 C10-3 C7B-3 C1B-4 C1B-5 C1B-6 C1B-3 C1B-11 C1B-10 C3B-6 C3B-5 C3B-1 C3B-3 C3B-2 C3B-12 C3B-11 C3B-10 C4B-4 WH-6 BK-4 C3B-8 C3B-7 C4B-3 C4B-2 C4B-6 TB32 C6-16 C11-2 WH-7 WH-4 C6-29 C6-32 C6-33 C5-20 C5-21 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C32TA WH/RD C31REV WH/BK C30FWD WH RD BK R5TRR WH/BK R4TRL WH R1PBU RD R2PBD RD/BK R10SBU BL R11SBD BL/BK WH-6 C26-1 C28-1 C25-1 C24-1 C15-1 C14-1 C12-1 C13-1 C18-1 C19-1 C11-3 C6-20 BK-5 C16-1 C17-1 C20-1 C21-1 C23-1 C6-19 C22-1 U4 C6-13 C6-37 C6-2 C6-10 C6-11 C10-2 BK-7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK RD C36SCC BL C6-1 7 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 DOWN C16PDRE OR/RD C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP C2B-6 LS1 5 C4B-5 C6-18 C6-17 13 86 30 6 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND DESCENT ALARM OPTION PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 JIB BOOM VALVE 6 - 18 Z-45/25 • Z-45/25J Part No. 107846 7 XOUT 3 6 PWR 2 1 GND 7 6 5 4 3 OUT PWR 1 1 C4P-4 C2P-2 C3P-8 C3P-7 C4P-3 C4P-2 C129DA GR/BK C18JD GR/BK C17JU GR CR32 85 CR37 C129DA BK LS3 2 BRN 2 3 4 BOOM PLATFORM LEVEL C4P-6 C2P-6 C4P-5 JIB BOOM PLATFORM ROTATE DOWN UP RIGHT LEFT C4B-7 14 TB2 TB11 86 30 86 30 GND P24FS WH 3 4 RETRACT EXTEND UP DOWN PLATFORM ROTATE C19JSV GR/WH 22 TB3 TB12 TB5 TB10 21 87a 87 87a 87 LS2 J2 JIB BOOM GR/BK-44 DOWN UP LEFT C4P-7 H3 2 85 21 7.5 D3 TB6 22 TB7 TB18 TB1 TB8 TB15 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 6 14 R14 C40LSS OR TS62 TS61 TS60 TS63 TS59 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. TB44 20 R4 RD J1 J1 J1 J1 J3 RIGHT WH JIB BOOM VALVE TS8 4 BK TS58 JC3 DRIVE & STEERING 3 TS57 CR30 NO P24FS WH BK NC U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS9 TS7 P26ESTP BK CR13 TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE TS15 JC1 2 CR27 NC CR13 P26ESTP BK P26ESTP BK L1 WH WH SECONDARY BOOM UP/DOWN P24FS WH 1 C28TTA RD/BK C28TTA RD/BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Ford DSG-423 EFI Models (after serial number 30141) C41RPM OR/BK BRN BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25 Ford DSG-423 EFI Models (after serial number 30141) Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Ford Models 86 87A 30 87 85 6 - 19 C3B C3B 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J 7 C7B 12V DCTO PLAT C6 C4B C7B C6-29 C7B-3 C6-36 C6-37 C6-40 C6-16 C6 C16DRE OR/RD FUNCTIONS Part No. 107846 C4B C3B C29MS RD/WH C37STC BL/BK C36STCC BL C40LS1 OR C3B C5 C2B 19/18 CABLES C1B C3B BRN C2B 6 C6 C4B C5 FUNCTION HARNESS RELAY HARNESS C4B C3B C2B-7 C45 GEN GR/WH C5-12 C1B-3 C1B-2 BRN C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 C5-8 C2B-2 ENGINE C127TSW KEYSWITCH POWER CB1 POWER (UNUSED) (UNUSED) AUXILIARY PUMP BRAKE START ENGINE (UNUSED) HIGH RPM CHECK ENGINE LED LIQUID PROPANE FUEL ALTERNATOR PULSE PICKUP LOW RPM JIB DOWN DESCENT ALARM KS POWER 23 24 25 26 27 32 33 34 35 38 39 41 42 44 134 WH-HM BRN C5-11 WH BRN BRN TS64 RUN/TEST SWITCH CR23 DRIVE LIGHT OPTION RELAY CR32 PRIMARY BOOM RELAY CR2 POWER RELAY C4B CR5 HORN RELAY BK-33B BRN R27AUX C5-6 RD RD-27B BRN-GND WH-21C C6-13 BK BRN BK-22B BATGND BRN C6 ENGINE HARNESS C19JSV GR/WH TS57 BK-ALARM CR33 TURNTABLE ROTATE RELAY WH/RD-32A BRN C5-19 BK-ALARM RD/WH-3B RD-1B WH/RD-6B WH/BK-5B BK-ALARM WH/RD-ALARM BRN BL-10B BRN CR37 SECONDARY BOOM RELAY BL/WH-12B L C4B-7 GR/WH BRN 1 C6-33 WH/RD-ALARM RD-24B RD KS1 GR/BK-TS58 BK-ALARM OR/RD-TS54 OR/BK-IS2 BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 WH/RD-ALARM C6-33 RD-TS51 RD-CR39 RD-CB1 RD-CR2 WH-KS BK-KSI BK-CR5 BK-ALARM BRN 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 RD-CB1 BRN K RD-20C DRIVE LIGHTS +12 VOLT TO PLATFORM 22 21 GR/BK-TS57 RD-CB2 J C6-9 BK/RD IGNITION POWER 21 20 18 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 F19 10A FUSE C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH CR1 IGNITION START RELAY C6-5 WH/BK +12 VOLT POWER 20 3 C6-11 BL/BK PLATFORM ROTATE RIGHT/JIB DOWN 18 17 CR39 AUXILLARY RELAY BRN R43DLITE1 RD PLATFORM ROTATE LEFT/JIB UP 17 15 BL/BK-TS60 CR37 #30 BL/WH I C6-10 BL 5 R43DLITE2 RD PLATFORM LEVEL DOWN 15 14 12 11 BL-TS60 BK H C6-38 C6-39 C5-5 BK PLATFORM LEVEL UP 14 KS POWER SECONDARY BOOM FUNCTION CTRL 12 134A SECONDARY BOOM DOWN 11 10 BK/WH-TS63 CR37 #86 BL G C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD C5-9 OR/RD C5-2 OR/BK SECONDARY BOOM UP 10 8 BK-TS63 F C2B-3 OR/BK C2B-1 BL/RD C5-10 BL/RD C5-13 BL/WH C1B-9 BK/RD C5-18 BK/RD C1B-8 BK/WH PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 E C1B-7 BK BK-CR1 C6-32 WH/RD C1B-6 WH/RD PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK D C1B-1 RD C6-27 RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD C CR23 RD C4B-6 GR/BK C6-18 GR/BK TURNTABLE ROTATE RIGHT 5 4 3 A BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH PRIMARY BOOM FUNCTION CONTROL 3 2 1 B B C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) A C3B-6 WH/RD C3B-5 WH/BK C 4 C3B-3 RD/WH D 2 C3B-2 RD/BK C3B-1 RD Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J REV A Ford Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD C3B-4 F.H. C1B C4B P20DLITE RD E.H. C3B GR C7B3 BRN C4B-4 BRN-TS 8 C5 GROUND BOLT NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Ford Models F E D RD TS54 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP/DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN RD RD RD RD RD RD-27 TS59 PLATFORM LEVEL RD C4B-7 GR/WH TS58 JIB BOOM UP/DOWN GR/BK-44A WH/RD-6A WH/BK-5A BK/WH-8A BK-7A RD-1A RD RD/BK-2A RD/WH-3A TS53 FUEL SELECT RD RD BL-10A RD RD 5 RD L2 + CHECK ENGINE LED WH-23 RD NOTE: DASHED LINES INDICATE OPTION WIRES G-BOX RD TS60 SECONDARY BOOM UP/DOWN P-BOX BL/BK-11A BL/WH-12A RD D2 RD RD RD RD RD RD RD SWITCH START RD RD RD 7 RD RD 8 RD R4 RD RD RD 6 14 BASE BOX HARNESS (TO TERMINAL STRIP) RD HOUR METER P1 STOP SWITCH RD FUNCTION SPEED CONTROL VARIABLE RESISTER, 20 BRN WH-21A BRN ENGINE WH-CR2 BK-33A RD C23-7 C32-7 RD RD 6 TS52 RUN/TEST TOGGLE SWITCH 4 RD RD RD PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH TS64 BL/RD-39A TS63 RD BK-22A BL/WH-38 TURNTABLE ROTATE TOGGLE SWITCH RD 134A PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 WH-23A TS61 RD-27A SECONDARY BOOM UP/DOWN TOGGLE SWITCH WH PLATFORM LEVEL TOGGLE SWITCH TS60 KS1 TS59 3 RD FUEL SELECT TOGGLE SWITCH R14 ENGINE START TOGGLE SWITCH TS53 GR OR/RD-42A TS52 GR/BK-18 AUXILIARY TOGGLE SWITCH RD GR GR/BK-18A TS51 RD UP/DOWN SPEED RESISTER 7.5 OHMS GR/BK RD RD R14 GR/BK BK/RD-35A SPEED LIMITING VARIABLE RESISTOR 20 OHMS TS54 FUNCTION ENABLE R4 RD GR RED EMERGENCY STOP BUTTON 2 OR-14A CHECK ENGINE LED P1 RD RD L2 D3 CB2 CIRCUIT BREAKER CONTROLS 15A KEY SWITCH RD-20A KS1 RD OR/BK-15A HOUR METER RD-20B HM RD D4 RD-24A HORN RELAY GR-17A CR5 RD CB1 CIRCUIT BREAKER ENGINE 15A HIGH IDLE RELAY 1 RD TS62 TURNTABLE ROTATE INGITION POWER RELAY CR4 RD A BK-7A WH/RD-6A CR2 RD WH/BK-5A IGNITION / START RELAY GR/BK RD RD CIRCUIT BREAKER, CONTROLS, 15A CR1 B RD CB2 RD BK/WH-8A RD CIRCUIT BREAKER, ENGINE, 15A TS63 PRIMARY BOOM EXTEND/RETRACT DESCRIPTION CB1 C TS57 PLATFORM ROTATE G GR H GR-17 I C19JSV GR/WH J RD K GR/BK L TS51 AUXILIARY POWER LABEL M RD N Part No. 107846 Z-45/25 • Z-45/25J 6 - 20 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Ford Models Section 6 • Schematics August 2006 Platform Control Box Wiring Diagram, Z-45/25J Ford Models C19JSV 1 C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 BRN RD-P2 RD-H1 WH BRN C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. LS18 CE OPTION ONLY H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C44JDALARM GR/BK C2P-6 C128LS OR/RD C2P-4 C39LP BL/RD C2P-1 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 1 TS1 WH 11 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 P24FS WH BRN JC1-3 OR C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN JC2-4 RD 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 BRN Part No. 107846 Z-45/25 • Z-45/25J 6 - 21 9 JIB 12V DC BATTERY SUPPY 19/18 CONTROL CABLE 3 JIB JIB JIB BK JIB BK C9 TILT ALARM C2P WLITE BRN C2P-9 WLITE BRN C2P-10 C7P 7 C7P C7P BATGRN C7P-3 C1P C28TTA RD/BK C1P-2 J3 GR/BK C4P-1 3 P24FS WH U13 ALC-500 RED-TILT BRN 6 C4P 5 BRN BRN PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION 2 J2 J1 CR27 CR30 P26ESTP BK 1 N M L K J I H G F E D C B A August 2006 Section 6 • Schematics REV A Platform Control Box Wiring Diagram, Z-45/25J Ford Models 4 F.S. August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Ford Models N M L K J I H G F E D C B A 1 TS47 GENERATOR (OPTION) JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT JC1 7 SECONDARY BOOM UP/DOWN 7 5 5 3 L48 TILT ALARM LED 3 RD 2 CR13 JIB BOOM RELAY 1 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 1 2 5 + GR/WH 4 TS13 PRIMARY BOOM EXTEND/ RETRACT BK 4 7 6 RD 6 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT TS15 DRIVE ENABLE BK 6 JC3 GR/WH RD BK PLATFORM CONTROL HARNESS (TO CONTROL BOX) 2 1 + BK RD BK 4 RD L1 DRIVE ENABLE LED 3 F18 FUSE 10A GENERATOR OPTION CWLITE RD C2P-12 C3P-4 DLITE WH RD TS8 JIB BOOM TS1 AUXILIARY PUMP TS14 HIGH/LOW (2WD/4WD) RD LS18 BK C7P-1 BK J3-3 NO 3 4 TS7 PLATFORM ROTATE GR/BK 6 TS3 FUEL SELECT TS2 ENGINE START 2 P2 EMERGENCY STOP DRIVE SPEED WH WH C7P-2 BK C9P-1 WH GR TS9 PLATFORM LEVEL BK BK C39LP BL/RD C2P-1 PDLITE RD P24FS WH C9-2 C128LS OR/RD C2P-4 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 C29MS RD/WH J1-8 C27AUX RD C1P-1 WH-JIB GR/BK-44 C2P-6 C17PRL GR C4P-5 C19JSV GR/WH C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 P24FS WH C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 P3 HORN 5 BK BK WH BL J1-5 WH J1-4 BL J1-5 OR J1-13 BRN J1-14 RD CWLITE RD C2P-11 RD/BK H1 RD C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 BL/BK-DE2 J1-7 BK YEL J1-3 OR J1-9 BRN J1-10 BRN WH-JIB C8PBR BK/WH C3P-8 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C7PBE BK C3P-7 BK TS4 HIGH/LOW RPM 2 7 2 NC NC NC 1 1 1 RD WH-24 RD RD RD RD RD RD 8 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6 - 22 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Ford Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25 Deutz F3L-2011 Models A B C D E F G H I J K L M N C28TTA RD/BK 1 C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 TS2 TS48 TS6 TS47 C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 C1B-12 L30 ENGINE SPEED GENERATOR DRIVE LIGHTS C7B-1 C28TTA RD/BK C2P-12 5 D40 C2P-11 H1 WORK LIGHTS P3 HORN RD GLOW PLUG ENGINE START AUXILIARY POWER L48 HIGH RPM TS1 6 LOW RPM RD BK P22BAT BK C134PWR GN C132PLI BL/WH TB134 CB2 TS4 RD C2P-5 2 FUSE 10A (ONLY FOR WORKLIGHTS) L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 TB41 C1B-8 RD TB23 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH RD C7B-2 C1B-2 C4B-1 C3B-9 C2B-3 BRN C1B-7 BK C1B-1 D4 4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER 6 P23BAT WH 5 C32 RD C28TTA RD/BK 3 4 PLAT C133PLA BL/RD 1 TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 15A TB20 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF TB35 8 KEY BYPASS CR1 CR1 NO 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 RD + BK PUMP SW2 NC + M3 M2 U32 FB1 B L29 L29 BRN SW3 NO _ REGULATOR IND. Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG OIL TEMPERATURE LED OIL PRESSURE LED OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR 6 ANSI/CSA (Domestic machine) add L48. AUXILIARY POWER RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN ALTERNATOR NOTE: 5 Add D40 only if unit has L4 and L48. 6 - 23 C6-38 NO W H2 7 CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 BAT. TB26 C EXCT. B1 12V DC C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON Electrical Schematic, Z-45/25 REV C C28TTA RD/BK C28TTA RD/BK P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD 3 YOUT 4 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 7 XOUT 3 BRN YEL OR BRN C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C7P-3 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1P-11 C36SCC BL C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP DOWN C1PBU RD C3PBF RD/WH C2PBD RD/BK C11SBD BL/BK C12SBF BL/WH C10SBU BL OR BK-6 SECONDARY BOOM PRIMARY BOOM TURNTABLE ROTATE C3P-6 RD C5TRR WH/BK BK C3P-5 C3P-1 C3P-3 C3P-2 C3P-12 C3P-11 C3P-10 UP DOWN C16PDRE OR/RD C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL 21 LS1 C10-3 C7B-3 C1B-4 C1B-5 C1B-6 C1B-3 C1B-11 C1B-10 C3B-6 C3B-5 C3B-1 C3B-3 C3B-2 C3B-12 C3B-11 C3B-10 C4B-4 WH-6 BK-4 C3B-8 C3B-7 C4B-3 C4B-2 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 7 RD C32BRK WH/RD C29MS RD/WH C37SCW BL/BK C10-2 BK-7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C6-37 C6-11 C6-10 C6-2 C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 1 C4P-4 C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP C4B-6 C4B-5 13 86 30 6 CR33 BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 DESCENT ALARM OPTION 6 - 24 Z-45/25 • Z-45/25J Part No. 107846 6 PWR 2 6 7 1 GND OUT 5 3 4 PWR 1 2 BRN 2 3 C2P-2 C3P-8 C3P-7 C4P-3 C4P-2 C18JD GR/BK C17JU GR C6-18 C6-17 LS3 GND P24FS WH 4 3 4 BOOM C4P-6 C4P-5 PLATFORM ROTATE 14 85 87a 87 85 TS62 TS61 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN 3 PLATFORM LEVEL PLATFORM ROTATE RETRACT EXTEND UP DOWN LEFT RIGHT RIGHT LEFT 2 87a 87 LS2 7.5 D3 CR32 C129DA BK H3 22 TB2 TB11 6 14 R14 C40LSS OR 86 30 86 30 CR37 21 TB3 TB12 TB5 TB10 21 20 R4 RD J1 J1 J1 J1 J3 TB6 22 TB7 TB18 TB1 TB8 TB15 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. P24FS WH TS8 5 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. J2 U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION TS60 TS63 TS59 P26ESTP BK CR27 NC 4 BK TS58 CR30 NO 2 TS13 TS9 JC3 DRIVE & STEERING L1 WH TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE TS15 JC1 SECONDARY BOOM UP/DOWN P24FS WH 1 P26ESTP BK P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Deutz F3L-2011 Models C41RPM OR/BK BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25 Deutz F3L-2011 Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25, CE Models Deutz F3L-2011 Models A B C D E F G H I J K L M N C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK 1 C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 LS18 C1P-12 C2P-5 RD TS48 TS6 TS47 ENGINE SPEED C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 L30 HIGH RPM GENERATOR DRIVE LIGHTS WORK LIGHTS C28TTA RD/BK C2P-12 C7B-1 C2P-11 5 D40 GLOW PLUG H1 D39 ENGINE START AUXILIARY POWER P3 RD LOW RPM RD TS1 HORN C1B-12 TB134 CB2 TS4 TS2 L4 BK P22BAT BK C134PWR GN C132PLI BL/WH 2 FUSE 10A (ONLY FOR WORKLIGHTS) 4 L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 C1B-8 RD TB23 TB41 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH C1B-7 L45 H6 RD C7B-2 C1B-2 C4B-1 C3B-9 BRN C2B-3 4 BK C1B-1 D4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER U33 6 RD P23BAT WH PLAT 5 C28TTA RD/BK 3 4 C133PLA BL/RD TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF CR1 CR1 NO TB35 8 KEY BYPASS 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 RD + BK PUMP SW2 NC + M3 M2 FB1 B L29 L29 BRN U32 SW3 NO _ REGULATOR IND. Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG OIL TEMPERATURE LED OIL PRESSURE LED OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR 5 Add D40 only if unit has L4 and L48. HORN RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. HORN LOAD SENSE MODULE ALTERNATOR NOTE: 4 CE and platform overload option 6 - 25 C6-38 NO W H2 7 CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 B1 12V DC TB26 C EXCT. BAT. C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON 15A TB20 Electrical Schematic, Z-45/25, CE Models REV C C28TTA RD/BK C28TTA RD/BK P24FS WH P26ESTP BK C41RPM OR/BK RD/WH DRIVE MODE CDE3 BL/RD 3 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 5 C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1B-10 C1B-11 C1B-3 C1B-6 C1B-5 C1B-4 C7B-3 C7P-3 C1P-11 C36SCC BL C3B-6 C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP PRIMARY BOOM C1PBU RD C3B-1 C3B-12 C3B-3 C3B-11 C3B-2 C11SBD BL/BK C12SBF BL/WH C4B-4 BK-4 WH-6 C3B-10 C10-3 C10SBU BL C3PBF RD/WH SECONDARY BOOM C2PBD RD/BK DOWN TURNTABLE ROTATE C3P-6 LS1 C3B-5 21 C5TRR WH/BK RD C3P-5 C3P-1 C3P-3 C3P-2 C3P-12 C3P-11 C3P-10 UP DOWN BK-6 OR C3B-8 C3B-7 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 7 RD C32BRK WH/RD C29MS RD/WH C37SCW BL/BK C10-2 BK-7 C10-1 C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C6-37 C6-11 C6-10 C6-2 C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-36 C6-5 6 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C14PLU OR C15PLD OR/BK C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 1 C16PDRE OR/RD C11-1 C11-4 C6-40 BOOM C4B-3 C4B-2 C6-14 C6-15 13 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 DESCENT ALARM OPTION 6 - 26 Z-45/25 • Z-45/25J Part No. 107846 7 YOUT 4 BRN YEL OR BRN BRN 2 C4P-4 C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK PLATFORM LEVEL 87a 87 6 XOUT 3 6 7 1 2 PWR GND OUT 5 3 4 PWR 2 1 GND P24FS WH 4 3 C2P-2 C3P-7 C3P-8 C4P-3 C4P-2 DOWN UP C4B-6 C4B-5 C6-18 LS3 CR32 C6-17 14 86 30 86 30 TS62 TS61 C18JD GR/BK C17JU GR PLATFORM ROTATE 2 7.5 D3 85 87a 87 LS2 P24FS WH 3 4 BOOM C4P-6 C4P-5 BK 3 PLATFORM LEVEL PLATFORM ROTATE RETRACT EXTEND UP DOWN LEFT RIGHT RIGHT LEFT 22 TB2 TB11 6 14 R14 C40LSS OR TB6 TB3 TB12 TB5 TB10 21 CR37 85 21 C129DA BK H3 TB8 TB15 22 TB7 TB18 TB1 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 20 R4 RD J1 J1 J1 J1 J3 5 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. J2 U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION TS60 TS63 TS59 P26ESTP BK TS8 4 BK TS58 TS13 TS9 CR30 NO 2 CR27 NC JC3 DRIVE & STEERING L1 WH TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE TS15 JC1 SECONDARY BOOM UP/DOWN P24FS WH 1 P26ESTP BK P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Deutz F3L-2011 Models BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25, CE Models Deutz F3L-2011 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Deutz F3L-2011 Models 6 - 27 8 86 87A 30 87 7 GR/BK C4B-1 C3B I.S.M. 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B C6-18 GR/BK 12V DC TO PLAT C6 I.S.M. C7B H6 (CE OPTION ONLY) C7B 85 Part No. 107846 C4B C6-29 C6-37 C6-36 C6-40 C6-16 C6 FUNCTIONS C7B-3 C16DRE OR/RD C3B C29MS RD/WH C37STC BL/BK C36STCC BL C40LS1 OR C4B C5-22 BK/WH C3B C5 6 C2B 19/18 CABLES C5 C1B C3B I.S.M. BRN C2B C4B C6 HARNESS RELAY HARNESS C4B C4B C3B C2B-7 C45 GEN GR/WH BRN C5-12 C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 CB1 POWER OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 C3 RD-CB1 BRN C5-18 BK/RD WH-21C BRN BK-22B BRN CR5 HORN RELAY I.S.M. BATGND BRN C6 ENGINE HARNESS BRN C19JSV GR/WH TS57 RD-27B C6-13 BK BK-33B CR32 PRIMARY BOOM RELAY BK-IS3 BK/RD-35C OR/BK-41A CR33 TURNTABLE ROTATE RELAY BK-ALARM C5-11 WH RD-IS4 BRN-GND WH/RD-32A BRN C5-19 BK-ALARM + C6-33 WH/RD-ALARM RD/WH-3B RD-1B WH/RD-6B WH/RD-ALARM BRN BK-ALARM WH-23B BL-10B WH/BK-5B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 WH-IS7 CR37 SECONDARY BOOM RELAY BL/WH-12B BK-ALARM C4B-7 GR/WH BRN L OR/BK-IS2 RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 WH-HM BRN K RD-20C DRIVE LIGHTS KEYSWITCH POWER 23 BRN +12 VOLT TO PLATFORM 22 21 20 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH CR1 IGNITION START RELAY C6-5 WH/BK IGNITION POWER 21 CR2 POWER RELAY R43DLITE1 RD +12 VOLT POWER 20 18 BL/BK-TS60 CR37 #30 BL/WH J C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 17 BL-TS60 BK CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM ROTATE LEFT/JIB UP 17 15 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL DOWN 15 14 12 11 10 BK/WH-TS63 CR37 #86 BL I C6-10 BL FUNCTION C5-5 BK BK-IS1 PLATFORM LEVEL UP 14 WH SECONDARY BOOM FUNCTION CTRL 12 KS POWER SECONDARY BOOM DOWN 11 134A SECONDARY BOOM UP 10 8 BK-TS63 H RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD C5-2 OR/BK PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 G C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-CR4 C1B-8 BK/WH PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 C5-16 WH/RD TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD E C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD CR23 RD TURNTABLE ROTATE RIGHT 5 4 3 A BK C4B-6 GR/BK PRIMARY BOOM FUNCTION CONTROL 3 2 B D C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH C3B-11 BL/BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) 12 8 7 6 C C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD C 1 IGN OR FUEL ON 10 TEMP OR PRESS FAULT JUMP TO 7 (GAS ONLY) 9 BK C7B-1 GR/BK L45 C3B-5 WH/BK 2 8 5 C32 B GR/BK C32-8 9 TO KEY SW (DIESEL ONLY) 7 2 C3B-3 RD/WH C3B-2 RD/BK 10 BATTERY 6 3 RD H6 RD 134B RD C32-1 D 7 GROUND 5 4 BK 22B BK/WH C1B-12 1 RD TS51 C3B-1 RD 4 AUX PWR UNIT 4 7 A 12/24 Volt IGNITON/START MODULE P/N 56057 3 START INPUT 3 6 RD TS52 10 1 TACHOMETER 2 5 GR/BK H6 9 8 7 and lift Push gently 4 BRN GND WH-25D & 26D WH-R2 6 5 4 3 2 START RELAY 1 3 WH-23B RD-CR1 BRN-IS5 RD-27B TO REMOVE: Genie Industries 4 BK-33B 1 1 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV A Deutz F3L-2011 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD F.H. C1B C3B-4 C4B P20DLITE RD C3B E.H. I.S.M. C7B3 BRN C2B-2 C4B-4 C5 ENGINE GROUND BOLT NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-2011 Models D RD RD C19JSV GR/WH GR-17 RD RD RD WH/BK-5 WH-4 WH/RD-6 RD 1 RD RD RD RD A RD RD RD RD RD B GR/BK-18 BK/WH-8 RD BK-7 C RD TS63 PRIMARY BOOM EXTEND/ RETRACT - + E TS57 PLATFORM ROTATE F RD 2 RD 3 TS59 PLATFORM LEVEL GR/BK-18A OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B 7 RD-20A BK/RD-35A RD-24A 6 RD TS56 GLOW PLUG (OPTION) RD 5 RD 8 RD 6W 14W RD DALE RH-25 25W 7.5 ohm 1% CB2 CIRCUIT BREAKER CONTROLS 15A RD TS52 START ENGINE CB1 CIRCUIT BREAKER ENGINE 15A RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) HOUR METER WH-21 2 RD RD BK-33A RD RD RD 2 RD RD RD RD RD RD 1 NC BL/BK-11A RD BL-10A RD WH-CR4 BRN 1 BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A - RD RD NC RD WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 4 RD TS54 FUNCTION ENABLE RD G-BOX + + WH-23 WH-23 L43 OIL TEMP LED WH-23 P-BOX WH/BK-25A RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 H KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED OIL TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J TS62 TURNTABLE ROTATE K L42 OIL PRESSURE LED L BRN M P1 EMERGENCY STOP SWITCH N Part No. 107846 Z-45/25 • Z-45/25J 6 - 28 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-2011 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 CE Models Deutz F3L-2011 Models 6 - 29 8 86 87A 30 87 7 GR/BK C4B-1 I.S.M. C3B 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B C6-18 GR/BK 12V DC TO PLAT C6 I.S.M. C7B C7B 85 Part No. 107846 C4B C6-36 C6-29 C6-37 C6-16 C6-40 C6 FUNCTIONS C7B-3 C16DRE OR/RD C3B C29MS RD/WH C36STCC BL C37STC BL/BK C40LS1 OR C4B C5-22 BK/WH C3B C5 6 C2B 19/18 CABLES C5 C1B I.S.M. BRN C3B C2B C4B C2B-7 C45 GEN GR/WH C6 HARNESS RELAY HARNESS C4B C4B C3B BRN C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 CB1 POWER OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 C3 RD-CB1 BRN C5-18 BK/RD WH-21C BRN BK-22B BRN CR5 HORN RELAY I.S.M. BATGND BRN C6 ENGINE HARNESS BRN C19JSV GR/WH TS57 BK-33B C6-13 BK RD-27B CR32 PRIMARY BOOM RELAY BK-IS3 BK/RD-35C OR/BK-41A CR33 TURNTABLE ROTATE RELAY BK-ALARM C5-11 WH RD-IS4 BRN-GND WH/RD-32A BRN OR/BK-IS2 + C5-19 BK-ALARM RD/WH-3B RD-1B WH/RD-6B WH/RD-ALARM BRN BK-ALARM WH-23B BL-10B WH/BK-5B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models WH-IS7 CR37 SECONDARY BOOM RELAY BL/WH-12B BK-ALARM C4B-7 GR/WH BRN L C6-33 WH/RD-ALARM RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 WH-HM BRN K RD-20C DRIVE LIGHTS KEYSWITCH POWER 23 BRN +12 VOLT TO PLATFORM 22 21 20 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH CR1 IGNITION START RELAY C6-5 WH/BK IGNITION POWER 21 CR2 POWER RELAY R43DLITE1 RD +12 VOLT POWER 20 18 BL/BK-TS60 CR37 #30 BL/WH J C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 17 BL-TS60 BK CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM ROTATE LEFT/JIB UP 17 15 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL DOWN 15 14 12 11 10 BK/WH-TS63 CR37 #86 BL I C6-10 BL FUNCTION C5-5 BK BK-IS1 PLATFORM LEVEL UP 14 WH SECONDARY BOOM FUNCTION CTRL 12 KS POWER SECONDARY BOOM DOWN 11 134A SECONDARY BOOM UP 10 8 BK-TS63 H RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD C5-2 OR/BK PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 G C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-CR4 C1B-8 BK/WH PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 C5-16 WH/RD TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD E C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD CR23 RD TURNTABLE ROTATE RIGHT 5 4 3 A BK C4B-6 GR/BK PRIMARY BOOM FUNCTION CONTROL 3 2 B D C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH C3B-11 BL/BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) 12 8 7 6 C C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD C 1 IGN OR FUEL ON 10 TEMP OR PRESS FAULT JUMP TO 7 (GAS ONLY) 9 BK C7B-1 GR/BK L45 C3B-5 WH/BK 2 5 C32 B GR/BK C32-8 9 8 2 C3B-3 RD/WH C3B-2 RD/BK 10 TO KEY SW (DIESEL ONLY) 7 RD H6 RD 134B RD C32-1 D 7 BATTERY 6 3 RD TS51 C3B-1 RD 4 GROUND 5 4 BK 22B BK/WH C1B-12 1 A 12/24 Volt IGNITON/START MODULE P/N 56057 3 AUX PWR UNIT 4 RD TS52 10 1 START INPUT 3 GR/BK H6 9 8 7 TACHOMETER 2 BRN GND WH-25D & 26D WH-R2 6 5 and lift START RELAY 1 3 WH-23B RD-CR1 4 3 Push gently 1 BRN-IS5 RD-27B 2 Genie Industries TO REMOVE: U33 BK-33B 1 4 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV A Deutz F3L-2011 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD C3B-4 F.H. C1B P20DLITE RD C4B E.H. C3B C5-12 I.S.M. C7B3 BRN C4B-4 C2B-2 H6 C5 GROUND BOLT ENGINE NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models Deutz F3L-2011 Models D RD RD C19JSV GR/WH GR-17 RD RD RD WH/BK-5 WH-4 WH/RD-6 RD 1 RD RD RD RD A RD RD RD RD RD B GR/BK-18 BK/WH-8 RD BK-7 C RD TS63 PRIMARY BOOM EXTEND/ RETRACT - + E TS57 PLATFORM ROTATE F RD 2 RD TS59 PLATFORM LEVEL GR/BK-18A OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B RD-20A BK/RD-35A RD-24A 6 7 RD TS56 GLOW PLUG (OPTION) RD 5 RD 8 RD 6W 14W RD DALE RH-25 25W 7.5 ohm 1% CB2 CIRCUIT BREAKER CONTROLS 15A RD TS52 START ENGINE CB1 CIRCUIT BREAKER ENGINE 15A RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) HOUR METER WH-21 2 RD RD BK-33A RD RD RD 2 RD 4 RD RD RD RD RD 1 NC BL/BK-11A RD BL-10A RD WH-CR4 BRN 1 BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A - RD RD NC RD WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 3 RD TS54 FUNCTION ENABLE RD G-BOX + + WH-23 WH-23 L43 OIL TEMP LED WH-23 P-BOX WH/BK-25A RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 H KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED OIL TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J TS62 TURNTABLE ROTATE K L42 OIL PRESSURE LED L BRN M P1 EMERGENCY STOP SWITCH N Part No. 107846 Z-45/25 • Z-45/25J 6 - 30 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 CE Models Deutz F3L-2011 Models Section 6 • Schematics August 2006 Platform Control Box Wiring Diagram, Z-45/25 Deutz F3L-2011 Models 1 1 C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 RD-P2 RD-H1 BRN C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. LS18 CE OPTION ONLY H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 11 TS1 WH P24FS WH BRN JC1-3 OR C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN JC2-4 RD 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 9 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 3 JIB 12V DC BATTERY SUPPY 19/18 CONTROL CABLE J3 GR/BK C4P-1 BRN Part No. 107846 Z-45/25 • Z-45/25J 6 - 31 C2P WLITE BRN C2P-9 WLITE BRN C2P-10 C9 TILT ALARM C7P C7P BATGRN C7P-3 C1P C28TTA RD/BK C1P-2 P24FS WH U13 ALC-500 RED-TILT 3 C7P 7 BRN BRN PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION 2 J2 BRN J1 CR27 P26ESTP BK 1 N M L K J I H G F E D C B A CR30 BRN 6 C4P 5 August 2006 Section 6 • Schematics REV A Platform Control Box Wiring Diagram, Z-45/25 Deutz F3L-2011 Models 4 F.S. August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-2011 Models N M L K J I JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT JC1 7 SECONDARY BOOM UP/DOWN H 4 2 1 1 PLATFORM CONTROL HARNESS (TO CONTROL BOX) 7 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 BK RD BK F18 FUSE 10A 4 BK BL J1-5 RD WH J1-4 BL J1-5 OR J1-13 BRN J1-14 BK GENERATOR OPTION CWLITE RD C2P-12 C3P-4 DLITE WH GR/BK H1 (D39) RD/BK H1 RD CWLITE RD C2P-11 L4 PLATFORM OVERLOAD LED RD + C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 YEL J1-3 OR J1-9 BRN J1-10 BRN BL/BK-DE2 J1-7 JIB BOOM RELAY WH-JIB C7PBE BK C3P-7 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C8PBR BK/WH C3P-8 CR13 3 1 + L1 DRIVE ENABLE LED 2 5 + L48 TILT ALARM LED 3 2 A JC3 RD TS13 PRIMARY BOOM EXTEND/RETRACT B 1 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT RD 4 C 6 GR/WH 5 D GR/WH RD BK 5 E TS47 GENERATOR (OPTION) BK 6 F TS15 DRIVE ENABLE 7 6 3 G 5 RD LS18 BK C7P-1 BK J3-3 WH C7P-2 BK C9P-1 BK PDLITE RD P24FS WH C9-2 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 WH C34SA BK/WH C1P-8 C29MS RD/WH J1-8 C27AUX RD C1P-1 WH-JIB GR/BK-44 C2P-6 C17PRL GR C4P-5 C19JSV GR/WH C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 P24FS WH C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 White wire replaced by CR27 and CR30 on CE models 6 WH RD 3 4 NO DRIVE SPEED RD P3 HORN 2 GR TS9 PLATFORM LEVEL WH GR/BK RD TS7 PLATFORM ROTATE TS8 JIB BOOM RD TS1 AUXILIARY PUMP TS14 HIGH/LOW (2WD/4WD) TS6 GLOW PLUG (OPTION) P2 EMERGENCY STOP TS4 HIGH/LOW RPM TS2 ENGINE START RD 2 NC NC NC 1 1 7 1 RD RD WH-24 RD 2 RD RD 8 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6 - 32 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-2011 Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25J Deutz F3L-2011 Models A B C D E F G H I J K L M N C28TTA RD/BK 1 C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 TS2 TS48 TS6 TS47 C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 C1B-12 L30 ENGINE SPEED GENERATOR DRIVE LIGHTS C7B-1 C28TTA RD/BK C2P-12 5 D40 C2P-11 H1 WORK LIGHTS P3 HORN RD GLOW PLUG ENGINE START AUXILIARY POWER L48 HIGH RPM TS1 6 LOW RPM RD BK P22BAT BK C134PWR GN C132PLI BL/WH TB134 CB2 TS4 RD C2P-5 2 FUSE 10A (ONLY FOR WORKLIGHTS) L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 TB41 C1B-8 RD TB23 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH RD C7B-2 C1B-2 C4B-1 C3B-9 C2B-3 BRN C1B-7 BK C1B-1 D4 4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER 6 P23BAT WH 5 C32 RD C28TTA RD/BK 3 4 PLAT C133PLA BL/RD 1 TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 15A TB20 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF TB35 8 KEY BYPASS CR1 CR1 NO 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 RD + BK PUMP SW2 NC + M3 M2 U32 FB1 B L29 L29 BRN SW3 NO _ REGULATOR IND. Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG OIL TEMPERATURE LED OIL PRESSURE LED OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR 6 ANSI/CSA (Domestic machine) add L48. AUXILIARY POWER RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN ALTERNATOR NOTE: 5 Add D40 only if unit has L4 and L48. 6 - 33 C6-38 NO W H2 7 CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 BAT. TB26 C EXCT. B1 12V DC C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON Electrical Schematic, Z-45/25J REV C C28TTA RD/BK C28TTA RD/BK P24FS WH P26ESTP BK C41RPM OR/BK RD/WH DRIVE MODE CDE3 BL/RD 3 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 7 YOUT 4 BRN YEL OR BRN C41RPM OR/BK 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 1 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1B-10 C1B-11 C1B-3 C1B-6 C1B-5 C1B-4 C7B-3 C7P-3 C1P-11 C36SCC BL C3B-6 C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP PRIMARY BOOM C1PBU RD C3B-1 C3B-12 C3B-3 C3B-11 C3B-2 C11SBD BL/BK C4B-4 C4B-6 C4B-3 C4B-2 C3B-8 C3B-7 BK-4 WH-6 C12SBF BL/WH OR BK-6 C3B-10 C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL C10-3 C10SBU BL C3PBF RD/WH SECONDARY BOOM C2PBD RD/BK DOWN TURNTABLE ROTATE C3P-6 LS1 C3B-5 21 C5TRR WH/BK RD C3P-5 C3P-1 C3P-3 C3P-2 C3P-12 C3P-11 C3P-10 UP DOWN C16PDRE OR/RD C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP C2B-6 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 7 RD C32BRK WH/RD C29MS RD/WH C37SCW BL/BK C10-2 BK-7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C6-37 C6-11 C6-10 C6-2 C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-36 C6-5 6 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR H4 5 C4B-5 13 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND DESCENT ALARM OPTION PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 JIB BOOM VALVE 6 - 34 Z-45/25 • Z-45/25J Part No. 107846 6 XOUT 3 6 7 1 2 PWR GND OUT 5 3 4 PWR 1 2 BRN 2 C4P-4 C2P-2 C3P-7 C3P-8 C4P-3 C4P-2 C129DA GR/BK C18JD GR/BK C17JU GR C6-18 C6-17 LS3 85 87a 87 85 30 CR32 C129DA BK 14 TB2 TB11 86 86 30 GND P24FS WH 3 4 BOOM PLATFORM LEVEL C4P-6 C2P-6 C4P-5 JIB BOOM PLATFORM ROTATE DOWN UP RIGHT LEFT C4B-7 2 87a 87 LS2 4 3 RETRACT EXTEND UP DOWN PLATFORM ROTATE C19JSV GR/WH 22 7.5 D3 TB6 TB3 TB12 TB5 TB10 21 CR37 21 J2 JIB BOOM GR/BK-44 DOWN UP LEFT BK 3 C4P-7 H3 TB8 TB15 22 TB7 TB18 TB1 TB17 6 14 R14 C40LSS OR TS62 TS61 TS60 TS63 TS59 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. TB44 BK TS58 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 20 R4 RD J1 J1 J1 J1 J3 RIGHT WH JIB BOOM VALVE TS8 4 TS57 CR30 NO P24FS WH BK NC U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS9 TS7 P26ESTP BK CR13 JC3 DRIVE & STEERING 2 CR27 NC CR13 TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE TS15 JC1 L1 WH WH SECONDARY BOOM UP/DOWN P24FS WH 1 P26ESTP BK P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Deutz F3L-2011 Models BRN BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25J Deutz F3L-2011 Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25J, CE Models Deutz F3L-2011 Models A B C D E F G H I J K L M N C28TTA RD/BK 1 C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 LS18 C1P-12 C2P-5 RD TS48 TS6 TS47 ENGINE SPEED C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 L30 HIGH RPM GENERATOR DRIVE LIGHTS WORK LIGHTS C28TTA RD/BK C2P-12 C7B-1 C2P-11 5 D40 GLOW PLUG H1 D39 ENGINE START AUXILIARY POWER P3 RD LOW RPM TS1 L4 HORN C1B-12 TB134 CB2 TS4 TS2 RD BK P22BAT BK C134PWR GN C132PLI BL/WH 2 FUSE 10A (ONLY FOR WORKLIGHTS) 4 L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 TB41 C1B-8 RD TB23 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH C1B-7 RD C7B-2 C1B-2 C4B-1 C3B-9 BRN C2B-3 L45 H6 BK C1B-1 D4 4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER 6 P23BAT WH 5 U33 RD C28TTA RD/BK 3 4 PLAT C133PLA BL/RD 1 TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 15A TB20 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF TB35 8 KEY BYPASS CR1 CR1 NO 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 RD + BK PUMP SW2 NC + M3 M2 FB1 B L29 L29 BRN U32 SW3 NO _ REGULATOR IND. Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG OIL TEMPERATURE LED OIL PRESSURE LED OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR 5 Add D40 only if unit has L4 and L48. HORN RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. HORN LOAD SENSE MODULE ALTERNATOR NOTE: 4 CE and platform overload option 6 - 35 C6-38 NO W H2 7 CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 BAT. TB26 C EXCT. B1 12V DC C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON Electrical Schematic, Z-45/25J, CE Models REV C P24FS WH P26ESTP BK RD/WH DRIVE MODE CDE3 BL/RD 3 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 5 C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 C7P-3 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1P-11 C36SCC BL C2P-3 C1P-10 C6TRF WH/RD RIGHT LEFT UP DOWN C1PBU RD C3PBF RD/WH C2PBD RD/BK C11SBD BL/BK C12SBF BL/WH C10SBU BL PRIMARY BOOM TURNTABLE ROTATE C3P-6 RD C5TRR WH/BK BK C3P-5 C3P-1 C3P-2 C3P-3 C3P-12 C3P-11 C3P-10 21 C10-3 C7B-3 C1B-4 C1B-5 C1B-6 C1B-3 C1B-11 C1B-10 C3B-6 C3B-5 C3B-1 C3B-3 C3B-2 C3B-12 C3B-11 C3B-10 C4B-4 WH-6 BK-4 C3B-8 C3B-7 C4B-3 C4B-2 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C26-1 C28-1 C25-1 C24-1 C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 7 RD C32BRK WH/RD C37SCW BL/BK C29MS RD/WH C6-37 C10-2 BK-7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-11 C6-10 C6-2 C6-36 C6-5 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 6 7 8 14 13 12 OR BK-6 SECONDARY BOOM C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL C4B-6 C6-18 C6-17 C129DA BK 13 86 30 6 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN BK RD BRN BRN C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 C5-25 C22-2 GROUND DESCENT ALARM OPTION PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 JIB BOOM VALVE 6 - 36 Z-45/25 • Z-45/25J Part No. 107846 1 YOUT 4 BRN 12 3 9 UP DOWN C16PDRE OR/RD C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK DOWN UP C2B-6 LS1 5 C4B-5 CR32 85 CR37 7 XOUT 3 YEL OR BRN 10 C4P-4 C2P-2 C3P-8 C3P-7 C4P-3 C4P-2 C129DA GR/BK C18JD GR/BK C17JU GR JIB BOOM PLATFORM ROTATE DOWN UP RIGHT LEFT C4B-7 TB2 TB11 6 PWR 2 1 GND 7 6 5 4 3 OUT PWR 1 2 1 3 4 BOOM C4P-5 C4P-6 C2P-6 PLATFORM LEVEL PLATFORM ROTATE TS62 C19JSV GR/WH LS3 DRIVE & STEERING 3 C4P-7 14 GND BRN 2 3 4 RETRACT EXTEND UP DOWN J2 JIB BOOM GR/BK-44 DOWN UP LEFT RIGHT WH 22 7.5 D3 86 30 86 30 87a 87 87a 87 LS2 P24FS WH TS8 JIB BOOM VALVE H3 2 85 21 TB3 TB12 TB5 TB10 21 6 14 R14 C40LSS OR TB6 22 TB7 TB18 TB1 TB8 TB15 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 20 R4 RD J1 J1 J1 J1 J3 TS61 TS60 TS63 TS59 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. TB44 BK TS58 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE 4 TS57 CR30 NO P24FS WH BK NC U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS9 TS7 P26ESTP BK CR13 TS14 SECONDARY BOOM UP/DOWN TS15 JC3 2 CR27 NC CR13 P26ESTP BK P26ESTP BK L1 WH WH JC2 P24FS WH JC1 1 C28TTA RD/BK C28TTA RD/BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Deutz F3L-2011 Models C41RPM OR/BK BRN BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25J, CE Models Deutz F3L-2011 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Deutz F3L-2011 Models 6 - 37 8 86 87A 30 87 7 GR/BK C4B-1 C3B I.S.M. 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B H6 (CE OPTION ONLY) C7B 12V DC TO PLAT CR23 RD C6 C4B I.S.M. C7B C6-29 C6-36 C6-37 C6-16 C6-40 C6 85 FUNCTIONS Part No. 107846 C7B-3 C16DRE OR/RD C3B C29MS RD/WH C36STCC BL C37STC BL/BK C40LS1 OR C4B C3B C5 6 C2B 19/18 CABLES C5 I.S.M. BRN C3B C1B C2B C4B C6 HARNESS RELAY HARNESS C4B C4B C3B BRN C2B-7 C45 GEN GR/WH C5-12 C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 CB1 POWER OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 C3 WH-HM BRN C5-18 BK/RD WH-21C BRN I.S.M. BATGND BRN BRN BK-22B CR5 HORN RELAY RD/WH-3B RD-1B WH/RD-6B C6 ENGINE HARNESS Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J BRN WH/RD-ALARM WH-23B C19JSV GR/WH TS57 BK-33B C6-13 BK RD-27B CR32 PRIMARY BOOM RELAY OR/BK-41A BK/RD-35C BK-IS3 CR33 TURNTABLE ROTATE RELAY BK-ALARM C5-11 WH RD-IS4 BRN-GND OR/BK-IS2 BRN WH/RD-32A + C5-19 BK-ALARM BRN BL-10B WH/BK-5B BK-ALARM WH-IS7 CR37 SECONDARY BOOM RELAY BL/WH-12B L C4B-7 GR/WH BRN BK-ALARM C6-33 WH/RD-ALARM RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 K RD-20C DRIVE LIGHTS KEYSWITCH POWER 23 BRN +12 VOLT TO PLATFORM 22 21 BRN RD-CB1 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH IGNITION POWER 21 20 18 BL/BK-TS60 CR37 #30 BL/WH J C6-5 WH/BK CR1 IGNITION START RELAY R43DLITE1 RD +12 VOLT POWER 20 CR2 POWER RELAY C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 17 BL-TS60 BK CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM ROTATE LEFT/JIB UP 17 15 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL DOWN 15 14 12 11 10 BK/WH-TS63 CR37 #86 BL I C6-10 BL FUNCTION C5-5 BK PLATFORM LEVEL UP 14 WH SECONDARY BOOM FUNCTION CTRL 12 KS POWER SECONDARY BOOM DOWN 11 134A SECONDARY BOOM UP 10 8 BK-TS63 H BK-IS1 RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 G C2B-4 OR/RD C5-2 OR/BK C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-CR4 C1B-8 BK/WH C5-22 BK/WH PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD E C5-16 WH/RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD TURNTABLE ROTATE RIGHT 5 4 3 A D C4B-6 GR/BK C6-18 GR/BK PRIMARY BOOM FUNCTION CONTROL 3 2 B BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) C C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD C 2 GR/BK L45 IGN OR FUEL ON 9 1 JUMP TO 7 (GAS ONLY) 8 10 TEMP OR PRESS FAULT TO KEY SW (DIESEL ONLY) 7 RD H6 C3B-5 WH/BK 2 12 8 7 6 5 B GR/BK C32-8 9 BATTERY 6 3 BK/WH C1B-12 C3B-3 RD/WH 10 GROUND 5 4 BK 22B 1 C32 BK C7B-1 C3B-2 RD/BK 7 AUX PWR UNIT 4 A RD 134B RD C32-1 D 4 START INPUT 3 7 RD TS51 C3B-1 RD 3 TACHOMETER 2 6 RD TS52 12/24 Volt IGNITON/START MODULE P/N 56057 1 and lift Push gently 5 GR/BK H6 10 9 8 7 6 5 4 3 2 1 4 BRN GND WH-25D & 26D WH-R2 WH-23B RD-CR1 BRN-IS5 RD-27B BK-33B START RELAY 3 1 Genie Industries 4 TO REMOVE: 1 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV A Deutz F3L-2011 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD C3B-4 F.H. C1B P20DLITE RD C4B E.H. C3B I.S.M. C7B3 BRN C4B-4 C2B-2 C5 GROUND BOLT ENGINE NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-2011 Models D RD RD GR/BK GR/BK-18 RD RD GR/BK RD C19JSV GR/WH GR-17 RD RD 1 RD RD WH/BK-5 WH-4 WH/RD-6 RD RD RD RD A RD RD RD RD RD B GR BK/WH-8 RD BK-7 C GR TS63 PRIMARY BOOM EXTEND/ RETRACT - + E TS57 PLATFORM ROTATE F RD 2 GR/BK RD GR/BK RD GR GR 3 TS59 PLATFORM LEVEL GR/BK-18A OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A TS58 JIB BOOM UP/DOWN RD R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B DALE RH-25 25W 7.5 ohm 1% CB2 CIRCUIT BREAKER CONTROLS 15A RD BK/RD-35A RD-24A CB1 CIRCUIT BREAKER ENGINE 15A TS52 START ENGINE 6 7 RD TS54 FUNCTION ENABLE RD TS56 GLOW PLUG (OPTION) RD 5 8 RD 6W 14W RD RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) HOUR METER WH-21 2 RD RD BK-33A RD RD RD 2 RD RD RD RD RD RD 1 NC BL/BK-11A RD BL-10A RD WH-CR4 BRN 1 BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A - RD RD NC GR/BK-44A WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 4 RD RD-20A RD G-BOX + + WH-23 WH-23 L43 OIL TEMP LED WH-23 P-BOX WH/BK-25A RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP/DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 H KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED OIL TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J TS62 TURNTABLE ROTATE K L42 OIL PRESSURE LED L BRN M P1 EMERGENCY STOP SWITCH N Part No. 107846 Z-45/25 • Z-45/25J 6 - 38 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-2011 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J CE Models Deutz F3L-2011 Models 6 - 39 8 86 87A 30 87 7 GR/BK C4B-1 C3B I.S.M. 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B C6-18 GR/BK C7B 12V DC TO PLAT C6 C4B I.S.M. C7B C6-36 C6-29 C6-37 C6-16 C6-40 C6 FUNCTIONS 85 Part No. 107846 C7B-3 C16DRE OR/RD C3B C29MS RD/WH C36STCC BL C37STC BL/BK C40LS1 OR C4B C3B C5 6 C2B 19/18 CABLES C5 C1B I.S.M. BRN C3B C2B C4B C2B-7 C45 GEN GR/WH C6 HARNESS RELAY HARNESS C4B C4B C3B BRN C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 KEYSWITCH POWER CB1 POWER OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 23 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 21 C3 BRN C5-18 BK/RD WH-21C BRN CR32 PRIMARY BOOM RELAY C6-13 BK BK-22B BRN CR5 HORN RELAY I.S.M. BATGND BRN C6 ENGINE HARNESS BRN Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models BRN WH/RD-ALARM WH-23B C19JSV GR/WH TS57 BK-33B RD-27B BK/RD-35C OR/BK-41A CR33 TURNTABLE ROTATE RELAY RD-IS4 C5-11 WH BK-ALARM BRN-GND WH/RD-32A BRN OR/BK-IS2 + C5-19 BK-ALARM RD/WH-3B RD-1B WH/RD-6B WH/BK-5B BK-ALARM WH-IS7 BL-10B BK-IS3 CR37 SECONDARY BOOM RELAY BL/WH-12B BK-ALARM C4B-7 GR/WH BRN L C6-33 WH/RD-ALARM RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 WH-HM BRN RD-CB1 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 K RD-20C DRIVE LIGHTS +12 VOLT TO PLATFORM 22 BRN IGNITION POWER 21 20 BL/BK-TS60 CR37 #30 BL/WH F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH +12 VOLT POWER 20 18 17 BL-TS60 BK J C6-5 WH/BK CR1 IGNITION START RELAY R43DLITE1 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 CR2 POWER RELAY C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE LEFT/JIB UP 17 15 BK/WH-TS63 CR37 #86 BL CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM LEVEL DOWN 15 14 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL UP 14 12 11 10 8 BK-TS63 I C6-10 BL FUNCTION C5-5 BK BK-IS1 SECONDARY BOOM FUNCTION CTRL 12 WH SECONDARY BOOM DOWN 11 KS POWER SECONDARY BOOM UP 10 134A PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 H RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK G C5-2 OR/BK C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-CR4 C1B-8 BK/WH C5-22 BK/WH TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 TURNTABLE ROTATE RIGHT 5 4 3 A E C5-16 WH/RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD CR23 RD PRIMARY BOOM FUNCTION CONTROL 3 2 B D C4B-6 GR/BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH C C C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD IGN OR FUEL ON 1 JUMP TO 7 (GAS ONLY) 10 TEMP OR PRESS FAULT 9 BK C7B-1 GR/BK L45 C3B-5 WH/BK 2 12 8 7 6 B GR/BK C32-8 9 8 2 C3B-3 RD/WH C3B-2 RD/BK 10 TO KEY SW (DIESEL ONLY) 7 5 C32 A RD 134B RD C32-1 7 BATTERY 6 3 RD H6 C3B-1 RD D 4 GROUND 5 4 BK 22B BK/WH C1B-12 1 RD TS51 12/24 Volt IGNITON/START MODULE P/N 56057 3 AUX PWR UNIT 4 RD TS52 10 1 START INPUT 3 GR/BK H6 9 8 7 TACHOMETER 2 BRN GND WH-25D & 26D WH-R2 6 5 START RELAY 1 3 WH-23B RD-CR1 4 3 and lift Push gently TO REMOVE: 1 BRN-IS5 RD-27B 2 1 U33 BK-33B Genie Industries 4 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV A Deutz F3L-2011 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD C3B-4 F.H. C1B P20DLITE RD C4B E.H. C3B C5-12 I.S.M. C7B3 BRN C4B-4 C2B-2 H6 C5 GROUND BOLT ENGINE NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models Deutz F3L-2011 Models D RD RD GR/BK GR/BK-18 GR RD GR/BK RD C19JSV GR/WH GR-17 RD RD RD WH/BK-5 WH-4 WH/RD-6 RD 1 RD RD RD RD A RD RD RD RD RD B GR BK/WH-8 RD BK-7 C RD TS63 PRIMARY BOOM EXTEND/ RETRACT - + E TS57 PLATFORM ROTATE F RD 2 GR/BK RD GR/BK RD GR GR TS59 PLATFORM LEVEL GR/BK-18A OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A TS58 JIB BOOM UP/DOWN RD R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B BK/RD-35A RD-24A CB1 CIRCUIT BREAKER ENGINE 15A TS52 START ENGINE 6 7 RD TS54 FUNCTION ENABLE RD TS56 GLOW PLUG (OPTION) RD 5 8 RD 6W 14W RD DALE RH-25 25W 7.5 ohm 1% RD CB2 CIRCUIT BREAKER CONTROLS 15A RD RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) HOUR METER WH-21 2 RD RD BK-33A RD RD RD 2 RD BL/BK-11A RD BL-10A RD RD RD RD 1 NC BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A - RD WH-CR4 BRN 1 4 RD RD NC GR/BK-44A WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 3 RD RD-20A RD G-BOX + + WH-23 WH-23 L43 OIL TEMP LED WH-23 P-BOX WH/BK-25A RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP/DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 H KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED OIL TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J TS62 TURNTABLE ROTATE K L42 OIL PRESSURE LED L BRN M P1 EMERGENCY STOP SWITCH N Part No. 107846 Z-45/25 • Z-45/25J 6 - 40 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J CE Models Deutz F3L-2011 Models August 2006 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J Deutz F3L-2011 Models BRN BRN C19JSV C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 BRN RD-P2 RD-H1 WH C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C44JDALARM GR/BK C2P-6 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 TS1 WH 1 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 P24FS WH 1 LS18 CE OPTION ONLY 12V DC BATTERY SUPPY 19/18 CONTROL CABLE BRN JC1-3 OR JC2-4 RD C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 BRN Part No. 107846 Z-45/25 • Z-45/25J 6 - 41 11 JIB C9 TILT ALARM 3 JIB JIB JIB BK JIB BK C7P 7 C7P C7P BATGRN C7P-3 C2P WLITE BRN C2P-9 WLITE BRN C2P-10 J3 GR/BK C4P-1 BRN 6 C4P 5 C1P C28TTA RD/BK C1P-2 P24FS WH U13 ALC-500 RED-TILT BRN 3 9 2 CR27 CR30 P26ESTP BK 1 PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION J2 J1 REV A Platform Control Box Wiring Diagram, Z-45/25J 4 F.S. N M L K J I H G F E D C B A August 2006 Section 6 • Schematics Deutz F3L-2011 Models August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-2011 Models N M L K J I JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT JC1 7 SECONDARY BOOM UP/DOWN H 4 2 1 1 PLATFORM CONTROL HARNESS (TO CONTROL BOX) 7 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 BK RD BK F18 FUSE 10A 4 BK BL J1-5 RD WH J1-4 BL J1-5 OR J1-13 BRN J1-14 BK GENERATOR OPTION CWLITE RD C2P-12 C3P-4 DLITE WH GR/BK H1 (D39) RD/BK H1 RD CWLITE RD C2P-11 L4 PLATFORM OVERLOAD LED RD + C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 YEL J1-3 OR J1-9 BRN J1-10 BRN BL/BK-DE2 J1-7 JIB BOOM RELAY WH-JIB C7PBE BK C3P-7 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C8PBR BK/WH C3P-8 CR13 3 1 + L1 DRIVE ENABLE LED 2 5 + L48 TILT ALARM LED 3 2 A JC3 RD TS13 PRIMARY BOOM EXTEND/RETRACT B 1 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT RD 4 C 6 GR/WH 5 D GR/WH RD BK 5 E TS47 GENERATOR (OPTION) BK 6 F TS15 DRIVE ENABLE 7 6 3 G 5 RD LS18 BK C7P-1 BK J3-3 WH C7P-2 BK C9P-1 BK PDLITE RD P24FS WH C9-2 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 WH C34SA BK/WH C1P-8 C29MS RD/WH J1-8 C27AUX RD C1P-1 WH-JIB GR/BK-44 C2P-6 C17PRL GR C4P-5 C19JSV GR/WH C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 P24FS WH C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 White wire replaced by CR27 and CR30 on CE models 6 WH RD NO 3 4 DRIVE SPEED RD P3 HORN 2 GR TS9 PLATFORM LEVEL WH GR/BK RD TS7 PLATFORM ROTATE TS8 JIB BOOM RD TS1 AUXILIARY PUMP TS14 HIGH/LOW (2WD/4WD) TS6 GLOW PLUG (OPTION) P2 EMERGENCY STOP TS4 HIGH/LOW RPM TS2 ENGINE START RD 2 NC NC NC 1 1 7 1 RD RD WH-24 RD 2 RD RD 8 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6 - 42 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-2011 Models Section 6 • Schematics August 2006 Electrical Schematic, Z-45/25 Perkins 404-22 Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25 Perkins 404-22 Models A B C D E F G H I J K L M N C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK 1 C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 TS2 TS48 TS6 TS47 C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 C1B-12 L30 ENGINE SPEED GENERATOR C28TTA RD/BK DRIVE LIGHTS C7B-1 C2P-12 5 D40 C2P-11 H1 WORK LIGHTS P3 HORN RD GLOW PLUG ENGINE START AUXILIARY POWER L48 HIGH RPM TS1 6 LOW RPM RD BK P22BAT BK C134PWR GN C132PLI BL/WH TB134 CB2 TS4 RD C2P-5 2 FUSE 10A (ONLY FOR WORKLIGHTS) L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 TB41 C1B-8 RD TB23 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH C1B-7 RD C7B-2 C1B-2 C4B-1 C3B-9 BRN C2B-3 4 BK C1B-1 D4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER 6 P23BAT WH 5 C32 RD C28TTA RD/BK 3 4 PLAT C133PLA BL/RD 1 TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 15A TB20 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF TB35 8 KEY BYPASS CR1 CR1 NO 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 + FB1 L29 L29 BRN SW3 NO _ B Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG COOLANT TEMPERATURE LED OIL PRESSURE LED COOLANT TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR 6 ANSI/CSA (Domestic machine) add L48. AUXILIARY POWER RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN ALTERNATOR NOTE: 5 Add D40 only if unit has L4 and L48. 6-44 PUMP M2 REGULATOR IND. RD BK 7 NO U32 SW2 NC + M3 H2 C6-38 W CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 BAT. TB26 C EXCT. B1 12V DC C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON Electrical Schematic, Z-45/25 REV C P24FS WH P26ESTP BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK RD/WH DRIVE MODE CDE3 BL/RD 3 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 PWR 2 4 YOUT GND 1 4 BRN C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1B-10 C1B-11 C1B-3 C1B-6 C1B-5 C1B-4 C7B-3 C7P-3 C1P-11 C36SCC BL C3B-6 C2P-3 C1P-10 C6TRF WH/RD TURNTABLE ROTATE PRIMARY BOOM C1PBU RD C3B-1 C3B-12 C3B-3 C3B-11 C3B-2 C11SBD BL/BK C12SBF BL/WH C4B-4 BK-4 WH-6 C3B-10 C10-3 C10SBU BL C3PBF RD/WH SECONDARY BOOM C2PBD RD/BK DOWN UP LEFT RIGHT C3P-6 LS1 C3B-5 21 C5TRR WH/BK RD C3P-5 C3P-1 C3P-3 C3P-2 C3P-12 C3P-11 C3P-10 UP DOWN C16PDRE OR/RD BK-6 OR C3B-8 C3B-7 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 7 RD C32BRK WH/RD C37SCW BL/BK C29MS RD/WH C6-37 C10-2 BK-7 C10-1 C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-11 C6-10 C6-2 C6-36 C6-5 6 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C14PLU OR C15PLD OR/BK C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 1 C4P-4 C11-1 C11-4 C6-40 BOOM C4B-2 C4B-3 C6-14 C6-15 13 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN RD BK C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 BRN BRN C5-25 C22-2 GROUND PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 DESCENT ALARM OPTION 6-45 Z-45/25 • Z-45/25J Part No. 107846 6 XOUT YOUT 3 YEL OR BRN BRN 2 3 C2B-2 P22LS BK C8PBR BK/WH C7PBE BK EXTEND RETRACT C14PLU OR C15PLD OR/BK PLATFORM LEVEL 87a 87 7 PWR 2 1 GND 7 6 5 3 4 2 OUT GND PWR 1 P24FS WH P24FS WH 3 C2P-2 C3P-8 C3P-7 C4P-2 C4P-3 DOWN UP C4B-6 C4B-5 C6-18 LS3 CR32 C6-17 14 86 30 86 30 TS62 TS61 C18JD GR/BK C17JU GR PLATFORM ROTATE 2 7.5 D3 85 87a 87 LS2 4 4 BOOM C4P-6 C4P-5 BK 3 PLATFORM LEVEL PLATFORM ROTATE RETRACT EXTEND DOWN UP LEFT RIGHT RIGHT LEFT 22 TB2 TB11 6 14 R14 C40LSS OR TB6 TB3 TB12 TB5 TB10 21 CR37 85 21 C129DA BK H3 TB8 TB15 22 TB7 TB18 TB1 TB17 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 20 R4 RD J1 J1 J1 J1 J3 5 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. J2 U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION TS60 TS63 TS59 P26ESTP BK TS8 4 BK TS58 TS13 TS9 CR30 NO 2 CR27 NC JC3 DRIVE & STEERING L1 WH TS14 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE TS15 JC1 SECONDARY BOOM UP/DOWN P24FS WH 1 P26ESTP BK P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Perkins 404-22 Models BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25 Perkins 404-22 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Perkins 404-22 Models 8 6-48 86 87A 30 87 7 GR/BK C4B-1 GR/BK L45 C3B I.S.M. 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B C6-18 GR/BK C7B 12V DC TO PLAT C6 C4B I.S.M. C7B C6-29 C6-36 H6 (CE OPTION ONLY) C6-16 C6-37 C6-40 C6 85 FUNCTIONS Part No. 107846 C7B-3 C16DRE OR/RD C3B C29MS RD/WH C36STCC BL C37STC BL/BK C40LS1 OR C4B C3B C5 6 C2B 19/18 CABLES C5 C1B I.S.M. BRN C3B C2B C4B C6 HARNESS RELAY HARNESS C4B C4B C3B BRN C2B-7 C45 GEN GR/WH C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 KEYSWITCH POWER CB1 POWER OIL PRESSURE SWITCH COOLANT TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 23 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 21 C3 BRN C5-18 BK/RD WH-21C BRN BRN BK-22B CR5 HORN RELAY I.S.M. BATGND BRN C6 ENGINE HARNESS BRN C19JSV GR/WH TS57 BK-33B C6-13 BK RD-27B CR32 PRIMARY BOOM RELAY BK-IS3 BK/RD-35C OR/BK-41A CR33 TURNTABLE ROTATE RELAY RD-IS4 C5-11 WH BK-ALARM BRN-GND WH/RD-32A BRN OR/BK-IS2 + C5-19 BK-ALARM RD/WH-3B RD-1B WH/RD-6B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 BRN WH/RD-ALARM WH-23B BL-10B WH/BK-5B BK-ALARM WH-IS7 CR37 SECONDARY BOOM RELAY BL/WH-12B BK-ALARM C4B-7 GR/WH BRN L C6-33 WH/RD-ALARM RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 WH-HM BRN RD-CB1 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 K RD-20C DRIVE LIGHTS +12 VOLT TO PLATFORM 22 BRN IGNITION POWER 21 20 BL/BK-TS60 CR37 #30 BL/WH F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH +12 VOLT POWER 20 18 17 BL-TS60 BK J C6-5 WH/BK CR1 IGNITION START RELAY R43DLITE1 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 CR2 POWER RELAY C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE LEFT/JIB UP 17 15 BK/WH-TS63 CR37 #86 BL CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM LEVEL DOWN 15 14 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL UP 14 12 11 10 8 BK-TS63 I C6-10 BL FUNCTION C5-5 BK BK-IS1 SECONDARY BOOM FUNCTION CTRL 12 WH SECONDARY BOOM DOWN 11 KS POWER SECONDARY BOOM UP 10 134A PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 H RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK G C5-2 OR/BK C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-R4 C1B-8 BK/WH C5-22 BK/WH TURNTABLE ROTATE FUNCTION CTRL 6 5 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 TURNTABLE ROTATE RIGHT 5 4 3 A E C5-16 WH/RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD CR23 RD PRIMARY BOOM FUNCTION CONTROL 3 2 B D C4B-6 GR/BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH C C C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD IGN OR FUEL ON 1 JUMP TO 7 (GAS ONLY) 10 TEMP OR PRESS FAULT 9 2 C3B-5 WH/BK 2 8 B GR/BK C32-8 9 TO KEY SW (DIESEL ONLY) 7 12 8 7 6 5 RD H6 C3B-3 RD/WH 10 BATTERY 6 BK/WH C1-12 C3B-2 RD/BK 7 GROUND 5 4 BK 22B 3 C32 BK C7-1 1 7 A RD 134B RD C32-1 4 AUX PWR UNIT 4 6 RD TS51 C3B-1 RD D 3 START INPUT 3 5 RD TS52 12/24 Volt IGNITON/START MODULE P/N 56057 1 TACHOMETER 2 4 GR/BK H6 10 9 8 7 and lift Push gently START RELAY 1 BRN GND WH-25D & 26D WH-R2 6 5 4 3 2 TO REMOVE: 3 WH-23B RD-CR1 BRN-IS5 RD-27B BK-33B 1 4 Genie Industries 1 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV A Perkins 404-22 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD C3B-4 F.H. C1B P20DLITE RD C4B E.H. C3B I.S.M. C5-12 C7B3 BRN C4B-4 C2B-2 C5 GROUND BOLT ENGINE NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 404-22 Models RD C19JSV GR/WH GR-17 RD RD RD GR/BK-18 RD RD WH/BK-5 WH-4 WH/RD-6 RD RD 1 RD RD RD RD RD A RD TS63 PRIMARY BOOM EXTEND/ RETRACT BK/WH-8 RD BK-7 RD B TS57 PLATFORM ROTATE C RD + D TS62 TURNTABLE ROTATE E RD 2 RD GR/BK-18A TS59 PLATFORM LEVEL OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B 6 BK/RD-35A RD-24A 7 RD-20A CB1 CIRCUIT BREAKER ENGINE 15A TS52 START ENGINE 5 TS56 GLOW PLUG (OPTION) RD RD RD 8 RD 6W 14W RD DALE RH-25 25W 7.5 ohm 1% RD CB2 CIRCUIT BREAKER CONTROLS 15A RD RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) 2 RD HOUR METER WH-21 2 RD RD BK-33A RD RD RD NC BL/BK-11A RD BL-10A RD RD RD RD NC BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A - RD WH-CR4 BRN 1 4 RD RD 1 RD WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 3 RD TS54 FUNCTION ENABLE RD G-BOX + + WH-23 WH-23 L43 COOLANT TEMP LED WH-23 P-BOX WH/BK-25A RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH F L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 H KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED COOLANT TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J - K L42 OIL PRESSURE LED L BRN M P1 EMERGENCY STOP SWITCH N Part No. 107846 Z-45/25 • Z-45/25J 6-49 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 404-22 Models Section 6 • Schematics August 2006 Platform Control Box Wiring Diagram, Z-45/25 Perkins 404-22 Models 1 C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 RD-P2 RD-H1 BRN C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C34SA BK/WH C1P-8 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 1 TS1 WH P24FS WH BRN JC1-3 OR JC2-4 RD C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 11 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 J3 GR/BK C4P-1 BRN Part No. 107846 Z-45/25 • Z-45/25J 6-52 9 LS18 CE OPTION ONLY 12V DC BATTERY SUPPY 19/18 CONTROL CABLE 3 P26ESTP BK 1 JIB C9 TILT ALARM C2P WLITE BRN C2P-9 WLITE BRN C2P-10 C7P 7 C7P C7P BATGRN C7P-3 C1P C28TTA RD/BK C1P-2 P24FS WH U13 ALC-500 RED-TILT 3 BRN J1 CR27 CR30 BRN 6 C4P 5 BRN BRN PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION J2 2 REV A Platform Control Box Wiring Diagram, Z-45/25 4 F.S. N M L K J I H G F E D C B A August 2006 Section 6 • Schematics Perkins 404-22 Models August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 404-22 Models N M L K J JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT I JC1 7 SECONDARY BOOM UP/DOWN H 5 GR/WH 1 1 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT PLATFORM CONTROL HARNESS (TO CONTROL BOX) 7 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 3 1 + BK RD BK + F18 FUSE 10A 4 BK BL J1-5 RD WH J1-4 BL J1-5 OR J1-13 BRN J1-14 BK GENERATOR OPTION CWLITE RD C2P-12 CDLITE GR GR/BK H1 (D39) CWLITE RD C2P-11 RD/BK H1 RD C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 BL/BK-DE2 J1-7 YEL J1-3 OR J1-9 BRN J1-10 C7PBE BK C3P-7 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C8PBR BK/WH C3P-8 L4 PLATFORM OVERLOAD LED RD L1 DRIVE ENABLE LED 2 5 + RD 2 A 1 L48 TILT ALARM LED 3 2 B 6 BK 3 C JC3 GR/WH RD 4 TS13 PRIMARY BOOM EXTEND/RETRACT D TS47 GENERATOR (OPTION) RD 5 E BK 6 F TS15 DRIVE ENABLE 7 6 4 G 5 RD LS18 BK C7P-1 BK J3-3 WH C7P-2 BK C9P-1 BK PDLITE RD P24FS WH C9-2 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 C34SA BK/WH C1P-8 C29MS RD/WH J1-8 C27AUX RD C1P-1 C17PRL GR C4P-5 C19JSV GR/WH C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 WH 6 WH RD 3 4 NO RD P3 HORN 2 DRIVE SPEED TS9 PLATFORM LEVEL WH RD TS7 PLATFORM ROTATE TS1 AUXILIARY PUMP RD TS14 HIGH/LOW (2WD/4WD) TS6 GLOW PLUG P2 EMERGENCY STOP TS4 HIGH/LOW RPM TS2 ENGINE START RD 2 1 1 7 1 RD RD WH-24 RD 2 NC NC NC RD RD 8 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6-53 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 404-22 Models Section 6 • Schematics August 2006 Electrical Schematic, Z-45/25J Perkins 404-22 Models Section 6 • Schematics August 2006 REV C Electrical Schematic, Z-45/25J Perkins 404-22 Models A B C D E F G H I J K L M N C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK 1 C41RPM OR/BK P26ESTP BK P26ESTP BK P2 BK-(FS) C9P-1 BK RD-(FS) C9P-3 P25FS RD WH-(FS) C9P-2 P24FS WH P24FS WH FS1 C7P-1 TS2 TS48 TS6 TS47 C1P-9 C2P-7 C3P-4 C1P-8 C1P-7 C1P-1 C7P-2 C1P-2 C3P-9 C2B-5 C1B-12 L30 ENGINE SPEED GENERATOR C28TTA RD/BK DRIVE LIGHTS C7B-1 C2P-12 5 D40 C2P-11 H1 WORK LIGHTS P3 HORN RD GLOW PLUG ENGINE START AUXILIARY POWER L48 HIGH RPM TS1 6 LOW RPM RD BK P22BAT BK C134PWR GN C132PLI BL/WH TB134 CB2 TS4 RD C2P-5 2 FUSE 10A (ONLY FOR WORKLIGHTS) L30 BK P1 3 15A RD RD RD C35RPM BK/RD HIGH RPM FUNCTION ENABLE C2B-7 LOW RPM C45GEN GR/WH C1B-9 TB41 C1B-8 RD TB23 C3B-4 TB33 D2 TS54 PBOX GND TB27 GR/BK DLITE WH C2P-10 C2P-9 C34SA BK/WH C1B-7 RD C7B-2 C1B-2 C4B-1 C3B-9 BRN C2B-3 4 BK C1B-1 D4 TS56 GLOW PLUG D3 C33STR BK 8 GND TS52 ENGINE START 12 C27AUX RD 7 TS51 AUXILIARY POWER 6 P23BAT WH 5 C32 RD C28TTA RD/BK 3 4 PLAT C133PLA BL/RD 1 TB22 C46HRN BK/RD C41RPM OR/BK KS1 1 START RELAY 2 TACHOMETER CB1 3 START INPUT 5 GROUND TB24 RD 6 BATTERY L42 OIL PRES. TB34 7 KEY PWR. + C5-17 C3 3MF TB35 8 KEY BYPASS CR1 CR1 NO 9 IGN./FUEL ON CR2 NO 10 ENG. FAULT CR2 U1 L43 OIL TEMP. P20BAT RD C5-3 TB21 C21IGN WH C34SA BK/WH C26TSR WH/RD C25PSR WH/BK C21IGN2 WH C5-18 RD C5-12 C6-39 + M2 FB1 L29 L29 BRN SW3 NO _ B Q3 - BRN BRN HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHT OPTION FLASHING BEACONS OPTION GLOW PLUG COOLANT TEMPERATURE LED OIL PRESSURE LED COOLANT TEMPERATURE SWITCH OIL PRESSURE SWITCH POWER RELAY FUEL SOLENOID Part No. 107846 SUPRESSION DIODE Z-45/25 • Z-45/25J HOUR METER C1B & C1P = GRAY C2B & C2P = BLACK C3B & C3P = GREEN C4B & C4P = BROWN IGNITION/START RELAY STARTER MOTOR 6 ANSI/CSA (Domestic machine) add L48. AUXILIARY POWER RELAY 1. All switches and contacts are shown with the boom in the stowed position and the keyswitch off. AUXILIARY PUMP TILT ALARM LEVEL SENSOR HORN RELAY HORN ALTERNATOR NOTE: 5 Add D40 only if unit has L4 and L48. 6-56 PUMP REGULATOR IND. RD BK 7 NO U32 SW2 NC + M3 H2 C6-38 W CR4 NO BK/RD C6-34 P134FB RD PR3 STA. CR4 NO PR3 NO NO CR23 CR23 C5-22 C5-14 PR2 PR2 C5-16 PR1 PR1 S8 C5-11 - C21IGN WH BAT. + WH C6-9 BAT. TB26 C EXCT. B1 12V DC C5-5 A RD D1 C6-27 ALTERNATOR FUSE 10A TB25 C5-23 C5-2 CR5 NO R33STR BK C27AUX RD C28TTA RD/BK P134TTS WH C46HRN BK/RD P22BAT BK C41RPM OR/BK C107AF WH P20BAT RD 6 C45GEN GR/WH P134 RD 8 C35RPM BK/RD C7B-4 5 IGNITION/ START MODULE 4 AUX. ON 15A TB20 Electrical Schematic, Z-45/25J REV C P24FS WH P26ESTP BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK RD/WH DRIVE MODE CDE3 BL/RD 5 OR RD BK BRN OR BL WH BL DRIVE ENABLE CDE1 BL LEFT CDE2 BL/BK RIGHT 6 7 RKOUT 5 3 4 YOUT PWR 2 4 BRN YEL OR BRN C41RPM OR/BK 5 15 16 19 20 17 18 11 9 10 6 7 8 14 13 12 C1P-3 C1P-6 C1P-5 C1P-4 C37SCW BL/BK C29MS RD/WH C32BRK WH/RD C31REV WH/BK C30FWD WH BATGND C1B-10 C1B-11 C1B-3 C1B-6 C1B-5 C1B-4 C7B-3 C7P-3 C1P-11 C36SCC BL C3B-6 C2P-3 C1P-10 C6TRF WH/RD TURNTABLE ROTATE PRIMARY BOOM C3PBF RD/WH C2PBD RD/BK C1PBU RD C3B-11 C3B-12 C3B-3 C3B-2 C3B-1 C4B-4 C4B-3 C4B-2 C3B-8 C3B-7 BK-4 WH-6 C3B-10 BK-6 OR C10-3 C10SBU BL C11SBD BL/BK SECONDARY BOOM C12SBF BL/WH DOWN UP LEFT RIGHT C3P-6 LS1 C3B-5 21 C5TRR WH/BK RD C3P-5 C3P-1 C3P-2 C3P-3 C3P-12 C3P-11 C3P-10 UP DOWN C16PDRE OR/RD C11-1 C11-4 C6-40 BOOM PLATFORM LEVEL C4B-6 TB32 C6-16 C11-2 WH-7 WH-4 C5-20 C5-21 C32TA WH/RD C31REV WH/BK C30FWD WH BK RD C6-13 U4 C6-20 C6-19 C22-1 C23-1 C21-1 C20-1 C17-1 C16-1 BK-5 C11-3 C19-1 C18-1 C13-1 C12-1 C14-1 C15-1 C24-1 C25-1 C28-1 C26-1 7 RD C32BRK WH/RD C37SCW BL/BK C29MS RD/WH C6-37 C10-2 BK-7 C10-1 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK BK WH-6 R11SBD BL/BK R10SBU BL R2PBD RD/BK R1PBU RD R4TRL WH R5TRR WH/BK C36SCC BL C6-29 C6-32 C6-33 C6-1 C6-11 C6-10 C6-2 C6-36 C6-5 6 C6-4 BK-6 WH-5 C10-4 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK C17 JU GR H4 15 8 16 7 6 5 4 13 14 1 2 11 12 3 9 10 C4P-4 C2B-2 P22LS BK C8PBR BK/WH C7PBE BK RETRACT EXTEND C14PLU OR C15PLD OR/BK DOWN UP C2B-6 C4B-5 C6-18 C6-17 13 GND 1 XOUT YOUT 3 6 7 PWR 2 1 GND 7 6 5 3 4 2 OUT GND 1 3 C2P-2 C3P-8 C3P-7 C4P-2 C4P-3 C129DA GR/BK C18JD GR/BK C17JU GR 87a 87 86 30 CR33 85 87a 87 C1B & C1P - GRAY C2B & C2P - BLACK C3B & C3P - GREEN C4B & C4P - BROWN RD BK C26-2 C28-2 C25-2 C24-2 C15-2 C14-2 C12-2 C13-2 C18-2 C19-2 C16-2 C17-2 C20-2 C21-2 C23-2 BRN BRN C5-25 C22-2 GROUND DESCENT ALARM OPTION PLATFORM ROTATE LEFT / JIB BOOM UP PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP BOOM RETRACT BOOM EXTEND LS4 - SECONDARY BOOM UP DRIVE LIMIT SWITCH LS2 - PRIMARY BOOM UP DRIVE LIMIT SWITCH LS1 - PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH LS3 - DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM SELECT RELAY PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM SELECT RELAY TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE SELECT RELAY STEER LEFT STEER RIGHT MOTOR STROKE BRAKE RELEASE VALVE TRAVEL ALARM OPTION DRIVE EDC REVERSE DRIVE EDC FORWARD 8 JIB BOOM VALVE 6-57 Z-45/25 • Z-45/25J Part No. 107846 CR32 C129DA BK LS3 PWR 1 BRN 2 3 4 BOOM PLATFORM LEVEL C4P-6 C2P-6 C4P-5 JIB BOOM PLATFORM ROTATE DOWN UP RIGHT LEFT C4B-7 14 86 30 86 30 TS62 TS61 C19JSV GR/WH 2 7.5 D3 85 87a 87 LS2 4 RETRACT EXTEND DOWN UP PLATFORM ROTATE C4P-7 22 TB2 TB11 6 14 R14 C40LSS OR TB6 TB3 TB12 TB5 TB10 21 CR37 85 21 J2 JIB BOOM GR/BK-44 DOWN UP LEFT RIGHT WH H3 TB8 TB15 22 TB7 TB18 TB1 TB17 3 BK 5 22 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. TB44 LS4 TB14 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 20 R4 RD J1 J1 J1 J1 J3 4 BK TS58 P24FS WH CR13 TS60 TS63 TS59 P24FS WH TS8 JIB BOOM VALVE TS57 P26ESTP BK BK NC U13 JOYSTICK CONTROL CARD CE LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS9 TS7 CR30 NO 2 CR27 NC CR13 TS14 JC3 DRIVE & STEERING TS15 JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE L1 WH WH JC1 SECONDARY BOOM UP/DOWN P24FS WH 1 P26ESTP BK P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics August 2006 Perkins 404-22 Models BRN BRN August 2006 Section 6 • Schematics Electrical Schematic, Z-45/25J Perkins 404-22 Models Section 6 • Schematics August 2006 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Perkins 404-22 Models 6-60 8 86 87A 30 87 7 GR/BK C4B-1 C3B I.S.M. 30 = COMMON (12V DC IN) 87A = NC 87 = NO 85 = COIL NEGATIVE 86 = COIL POSITIVE Z-45/25 • Z-45/25J C3B C6-18 GR/BK 12V DC TO PLAT H6 C7B 85 Part No. 107846 C6 C4B I.S.M. C7B C6-29 C6-37 C6-36 C6-40 C6-16 C6 FUNCTIONS C7B-3 C16DRE OR/RD C3B C29MS RD/WH C37STC BL/BK C36STCC BL C40LS1 OR C4B C3B C5 6 C2B 19/18 CABLES C5 C1B C3B I.S.M. BRN C2B C4B C6 HARNESS RELAY HARNESS C4B C4B C3B BRN C2B-7 C45 GEN GR/WH C5-12 C1B-3 C1B-2 C28TTA RD/BK C5-24 C1B-10 C1B-4 C30FWD WH C5-21 C1B-11 C1B-5 C31REV WH/BK C5-20 KEYSWITCH POWER CB1 POWER OIL PRESSURE SWITCH COOLANT TEMPERATURE SWITCH AUXILIARY PUMP BRAKE START ENGINE GLOW PLUG HIGH RPM (SPARE) (SPARE) ALTERNATOR PULSE PICKUP (SPARE) JIB DOWN DESCENT ALARM KS POWER 23 24 25 26 27 32 33 34 35 38 39 41 42 44 134 134A 134 44 42 41 39 38 35 34 33 32 27 26 25 24 23 22 21 C3 BRN C5-18 BK/RD WH-21C BRN BK-22B BRN CR5 HORN RELAY I.S.M. BATGND BRN C6 ENGINE HARNESS BRN C19JSV GR/WH TS57 BK-33B C6-13 BK RD-27B CR32 PRIMARY BOOM RELAY BK-IS3 BK/RD-35C OR/BK-41A CR33 TURNTABLE ROTATE RELAY BK-ALARM C5-11 WH RD-IS4 BRN-GND WH/RD-32A BRN C5-19 BK-ALARM + C6-33 WH/RD-ALARM RD/WH-3B RD-1B WH/RD-6B WH/RD-ALARM BRN BK-ALARM WH-23B BL-10B WH/BK-5B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J WH-IS7 CR37 SECONDARY BOOM RELAY BL/WH-12B BK-ALARM C4B-7 GR/WH BRN L OR/BK-IS2 RD-24B RD H6 RD KS1 GR/BK-TS58 BK-ALARM OR/BK-IS2 BRN BL/RD-TS53 BL/WH-L2 (-) BK/RD-TS54 BK/WH-TS56 BK-33 TS52 BK-IS3 WH/RD-ALARM C6-33 RD-TS51 RD-IS4 WH/RD-L43 (-) WH/RD-L43- WH/BK-L42 (-) WH/BK-L42- RD-CB1 RD-CR2 WH-KS WH-IS7 BK-KSI BK-CR5 WH-HM BRN RD-CB1 RD-CB2 GR/BK-TS57 GR-TS57 OR/BK-TS59 OR-TS59 BL/WH-TS60 K RD-20C DRIVE LIGHTS +12 VOLT TO PLATFORM 22 BRN IGNITION POWER 21 20 18 BL/BK-TS60 CR37 #30 BL/WH F19 10A FUSE C6-9 BK/RD C3B-9 BK/RD C6-2 RD/BK C6-1 RD C6-4 WH CR1 IGNITION START RELAY C6-5 WH/BK +12 VOLT POWER 20 CR2 POWER RELAY R43DLITE1 RD PLATFORM ROTATE RIGHT/JIB DOWN 18 17 BL-TS60 BK J C6-11 BL/BK 5 R43DLITE2 RD PLATFORM ROTATE LEFT/JIB UP 17 15 BK/WH-TS63 CR37 #86 BL CR23 DRIVE LIGHT OPTION RELAY C6-38 C6-39 PLATFORM LEVEL DOWN 15 14 12 CR4 HIGH RPM SOLENOID RELAY WH-IS9 PLATFORM LEVEL UP 14 WH SECONDARY BOOM FUNCTION CTRL 12 11 10 8 BK-TS63 I C6-10 BL FUNCTION C5-5 BK BK-IS1 SECONDARY BOOM DOWN 11 KS POWER SECONDARY BOOM UP 10 134A PRIMARY BOOM RETRACT 8 7 WH/RD-TS62 H RD-IS6 C43DLITE GR C6-34 RD C3B-4 WH C5-17 WH C2B-6 GR/BK C2B-4 OR/RD C5-2 OR/BK PRIMARY BOOM EXTEND 7 6 CR33 #30 WH/RD WH/BK-TS62 CR33 #86 WH/BK G C2B-3 OR/BK C2B-1 BL/RD C1B-9 BK/RD BK/RD-R4 C1B-8 BK/WH C5-22 BK/WH TURNTABLE ROTATE FUNCTION CTRL 6 5 4 RD/WH-TS61 CR32 #30 RD/WH RD/BK-TS61 BK RD-TS61 CR32 #86 RD F C1B-7 BK C6-32 WH/RD C1B-6 WH/RD C1B-1 RD C6-27 RD C5-14 WH/RD WH-IS10 TURNTABLE ROTATE RIGHT 5 3 A E C5-16 WH/RD C7B-2 WH C32-4 BK C6-20 BK C5-3 WH WH-CR2 C7B-4 RD CR23 RD PRIMARY BOOM FUNCTION CONTROL 3 2 B D C4B-6 GR/BK PRIMARY BOOM DOWN 2 4 PRIMARY BOOM UP 1 TERMINAL BASE (TB) BK C4B-5 GR C6-17 GR C4B-3 OR/BK C6-15 OR/BK C4B-2 OR C6-14 OR C3B-12 BL/WH C 12 8 7 6 C C3B-11 BL/BK C3B-10 BL C3B-8 BK/WH C6-8 BK/WH C3B-7 BK C6-7 BK C3B-6 WH/RD IGN OR FUEL ON 1 JUMP TO 7 (GAS ONLY) 10 TEMP OR PRESS FAULT 9 BK C7-1 GR/BK L45 C3B-5 WH/BK 2 8 5 C32 B GR/BK C32-8 9 TO KEY SW (DIESEL ONLY) 7 2 C3B-3 RD/WH 10 BATTERY 6 3 1 RD H6 C3B-2 RD/BK 7 GROUND 5 4 BK 22B BK/WH C1-12 C3B-1 RD 4 AUX PWR UNIT 4 RD TS51 RD 134B RD C32-1 D 3 START INPUT 3 7 A 12/24 Volt IGNITON/START MODULE P/N 56057 1 TACHOMETER 2 6 RD TS52 10 and lift Push gently 5 GR/BK H6 9 8 7 6 5 4 3 2 1 4 BRN GND WH-25D & 26D WH-R2 WH-23B RD-CR1 BRN-IS5 RD-27B BK-33B START RELAY 3 1 Genie Industries 4 TO REMOVE: 1 OR/BK-41A BK-R1 Section 6 • Schematics August 2006 REV B Perkins 404-22 Models M N GROUND CONTROL HARNESS (TO SWITCH PANEL) GROUND CONTROL HARNESS RD F.H. C1B C3B-4 C4B P20DLITE RD C3B E.H. I.S.M. C7B3 BRN C2B-2 C4B-4 (CE OPTION ONLY) C5 ENGINE GROUND BOLT NOTE: DASHED LINES INDICATE OPTION WIRES August 2006 REV B Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 404-22 Models C C RD RD RD GR/BK-18 GR RD GR/BK RD C19JSV GR/WH GR-17 RD 11 RD RD RD A RD RD RD WH/BK-5 WH-4 WH/RD-6 RD RD A B GR/BK RD RD RD B TS57 PLATFORM ROTATE D D E TS62 TURNTABLE ROTATE TS63 PRIMARY BOOM EXTEND/ RETRACT BK/WH-8 RD BK-7 RD + E F GR F RD 22 GR/BK RD GR/BK RD GR GR TS59 PLATFORM LEVEL GR/BK-18A OR/BK-15A RD OR-14A C4B-7 GR/WH GR-17A TS58 JIB BOOM UP/DOWN RD R14 SECONDARY BOOM UP/DOWN SPEED RESISTOR RD-20B DALE RH-25 25W 7.5 ohm 1% CB2 CIRCUIT BREAKER CONTROLS 15A RD BK/RD-35A RD-24A CB1 CIRCUIT BREAKER ENGINE 15A TS52 START ENGINE 66 77 RD TS54 FUNCTION ENABLE RD TS56 GLOW PLUG (OPTION) RD 55 88 RD 6W 14W RD RD RD C23-7 BK/WH-34A RD RD RD RD RD R4 FUNCTION SPEED CONTROL VARIABLE RESISTER, 20W RD RD RD BASE BOX HARNESS (TO TERMINAL STRIP) WH-21 2 RD RD BK-33A RD RD RD 2 RD 44 RD RD RD RD RD 1 NC BL/BK-11A RD BL-10A RD WH-CR4 BRN 1 BL/WH-12A TS60 SECONDARY BOOM UP/DOWN WH/RD-26A RD RD NC GR/BK-44A WH/BK-5A WH-4A WH/RD-6A BK/WH-8A RD RD-1A BK-7A RD/WH-3A RD/BK-2A RD 33 RD RD-20A RD G-BOX - + WH-23 WH-23 + WH-23 P-BOX L43 COOLANT TEMP LED RD 134A RD WH-23A BK-22A RD C32-6 GR/BK H6 RD RD RD RD TS61 PRIMARY BOOM UP/DOWN RD RD-27 AUXILIARY POWER TOGGLE SWITCH ENGINE START TOGGLE SWITCH FUNCTION ENABLE TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH (OPTION) PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP/DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH L45 PLATFORM OVERLOAD LED (CE models) DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A G G WH RD-27A TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 H H I KS1 CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY IGNITION POWER RELAY HIGH IDLE RELAY HORN RELAY HOUR METER KEY SWITCH OIL PRESSURE LED COOLANT TEMPERATURE LED PLATFORM OVERLOAD RED EMERGENCY STOP BUTTON SPEED LIMITING VARIABLE RESISTOR 20 OHMS SECONDARY BOOM SPEED RESISTOR 7.5 OHMS I J TS51 AUXILIARY POWER LABEL CB1 CB2 CR1 CR2 CR4 CR5 HM KS1 L42 L43 L45 P1 R4 R14 J WH/BK-25A K HOUR METER K - L L42 OIL PRESSURE LED L BRN M M P1 EMERGENCY STOP SWITCH N N Part No. 107846 Z-45/25 • Z-45/25J 6-61 August 2006 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 404-22 Models Section 6 • Schematics August 2006 Platform Control Box Wiring Diagram, Z-45/25J Perkins 404-22 Models C19JSV C32BRK WH/RD C1P-6 C32BRK WH/RD J2-19 C40LSS OR C2P-2 C40LSS OR J2-4 P24FS WH C9P-2 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C9HRN BK/RD C3P-9 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26BAT BK C9-1 P25FS RD C9-3 P24FS WH C9-2 BRN CE LIFT/DRIVE OPTION RD-P2 RD-H1 WH BRN C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED - LS18 RED-TILT C2P-5 Y OPT. LS18 CE OPTION ONLY H1 FOOT SWITCH CDLITE GR CWLITE RD C2P-12 CWLITE RD C2P-11 C45GEN GR/WH C2P-7 C44JDALARM GR/BK C2P-6 C6TRF WH/RD C3P-6 C10SBU BL C3P-10 C16DRE OR/RD C4P-4 C11SBD BL/BK C3P-11 C40LSS OR C2P-2 C12SBF BL/WH C3P-12 C41RPM OR/BK C2P-3 C30FWD WH C1P-4 C1PBU RD C3P-1 C31REV WH/BK C1P-5 C2PBD RD/BK C3P-2 C37STC BL/BK C1P-11 C3PBF RD/WH C3P-3 C36STCC BK C1P-10 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C35HS BK/RD C1P-9 C34SA BK/WH C1P-8 C33STR BK C1P-7 C27AUX RD C1P-1 C28TTA RD/BK H1 C3P C3P TS7 TS1 WH P24FS WH BRN JC1-3 OR JC2-4 RD C13LED BL/RD DRE B BL/BK DRE A BL/WH JC3-4 BL * JC3-2 BRN JC3-3 OR JC3-5 WH JC2-2 BRN JC1-5 YEL JC2-3 OR JC2-5 BK JC1-2 BRN 1 C29MS RD/WH RD/BK-L48 (-) GR/BK-L4 1 ITEM DESCRIPTION H1 C7P C9 C1P - C4P TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY (CE OPTION) CONTROL RELAY (CE OPTION) LOAD SENSE LIMIT SWITCH 8 J3 GR/BK C4P-1 BRN Part No. 107846 Z-45/25 • Z-45/25J 6-64 11 1 JIB 12V DC BATTERY SUPPY 19/18 CONTROL CABLE 3 P26ESTP BK 1 JIB JIB JIB BK JIB BK C9 7 C1P C28TTA RD/BK C1P-2 C7P TILT ALARM C7P C7P BATGRN C7P-3 C2P WLITE BRN C2P-9 WLITE BRN C2P-10 P24FS WH U13 ALC-500 RED-TILT 3 9 CR27 CR30 BRN 6 C4P 5 BRN BRN PLATFORM CONTROL HARNESS (TO SWITCH PANEL) 2 J2 J1 REV A Platform Control Box Wiring Diagram, Z-45/25J 4 F.S. N M L K J I H G F E D C B A August 2006 Section 6 • Schematics Perkins 404-22 Models August 2006 REV A Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 404-22 Models N M L K J I JC2 PRIMARY BOOM UP/DOWN & TURNTABLE ROTATE LEFT/RIGHT H JC1 7 SECONDARY BOOM UP/DOWN 4 2 1 1 PLATFORM CONTROL HARNESS (TO CONTROL BOX) 7 4 TS48 DRIVE LIGHTS/ WORK LIGHTS (OPTION) 3 2 BK RD BK F18 FUSE 10A 4 BK BL J1-5 RD WH J1-4 BL J1-5 OR J1-13 BRN J1-14 BK GENERATOR OPTION CWLITE RD C2P-12 CDLITE GR GR/BK H1 (D39) RD/BK H1 RD CWLITE RD C2P-11 L4 PLATFORM OVERLOAD LED RD + C45GEN GR/WH C2P-7 BL/RD-DE3 J1-16 BL-DE1 J1-6 YEL J1-3 OR J1-9 BRN J1-10 BRN BL/BK-DE2 J1-7 JIB BOOM RELAY WH-JIB C7PBE BK C3P-7 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 C8PBR BK/WH C3P-8 CR13 3 1 + L1 DRIVE ENABLE LED 2 5 + L48 TILT ALARM LED 3 2 A 6 RD TS13 PRIMARY BOOM EXTEND/RETRACT B 1 DRIVE FORWARD/REVERSE & STEER LEFT/RIGHT RD 4 C JC3 GR/WH RD GR/WH 5 D TS47 GENERATOR (OPTION) BK 5 E BK 6 F TS15 DRIVE ENABLE 7 6 3 G 5 RD LS18 BK C7P-1 BK J3-3 WH C7P-2 BK C9P-1 BK PDLITE RD P24FS WH C9-2 C35RPM BK/RD C1P-9 C33STR BK C1P-7 RD P25FS RD C9-3 C34SA BK/WH C1P-8 C29MS RD/WH J1-8 C27AUX RD C1P-1 WH-JIB GR/BK-44 C2P-6 C17PRL GR C4P-5 C19JSV GR/WH C19JSV GR/WH C4P-7 C18PRR GR/BK C4P-6 P24FS WH C14PLU OR C4P-2 C15PLD OR/BK C4P-3 C9HRN BK/RD C3P-9 WH 6 WH RD 3 4 NO DRIVE SPEED RD P3 HORN 2 GR TS9 PLATFORM LEVEL WH GR/BK RD TS7 PLATFORM ROTATE TS8 JIB BOOM RD TS1 AUXILIARY PUMP TS14 HIGH/LOW (2WD/4WD) TS6 GLOW PLUG P2 EMERGENCY STOP TS4 HIGH/LOW RPM TS2 ENGINE START RD 2 NC NC NC 1 1 7 1 RD RD WH-24 RD 2 RD RD 8 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 107846 Z-45/25 • Z-45/25J 6-65 August 2006 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 404-22 Models June 2012 Section 6 • Schematics REV D Hydraulic Schematic, 2WD Models (before serial number 27001) N M L K J I H G F E D C B A 1 TURNTABLE ROTATE JIB BOOM 0.6 gpm / 2.27 L/min Orifice removed after serial number 22449 PRIMARY BOOM PLATFORM ROTATE 0.25 gpm / 0.95 L/min PRIMARY BOOM EXTENSION 0.025 inch 0.64 mm 1.5:1 3800 psi 262 bar 4.25:1 3625 psi 250 bar 3:1 3300 psi 228 bar NN SLAVE CYLINDER J2 PR2 V2 PR1 CHARGE FILTER 50 psi 3.4 bar V1 3 4.5:1 ATMOS. 3500 psi 241 bar MASTER CYLINDER OPTIONAL MOTOR/GEN ST1 ST2 PR1 PR2 PL2 PL1 SW1 SW2 Y TP1 DRIVE MANIFOLD REAR RIGHT K J T1/GEN S1 P1 S2 0.037 inch 0.9 mm B 315 psi 21.7 bar 2500 psi / 172 bar (set at 0.6 gpm / 2.27 L/min at TP2) EXTEN P2 RETRACT 4 R AC 2100 psi 144.8 bar I V AB AA N M (set at 2.5 gpm / 9.5 L/min at TP2) G F PRESS Z GENERATOR SELECT RA PA 1.5 gpm 5.7 L/min 3500 psi 241 bar E DRIVE PUMP 50% PB RR LA 3200 psi 220.6 bar (set at 7 gpm / 26.5 L/min at TP1) 5 H U Q 2 gpm 7.6 L/min S L T FUNCTION MANIFOLD 50% TT E C T P UU 0.070 inch 1.78 mm D 0.1 gpm 0.38 L/min RB SS 0.4 gpm 1.5 L/min A X W O AUX FUNCTION PUMP 7 gpm / 26.5 L/min 3200 psi 220.6 bar QQ LB TP2 OSCILLATE CYLINDERS (OPTION) 6 25 psi 1.7 bar REAR LEFT 2 SECONDARY BOOM CYLINDERS V1 V2 HIGH PRESSURE FILTER 100 psi 6.9 bar 3:1 ATMOS. 1500 psi 103 bar 3:1 3500 psi 241 bar AD JIB BOOM MANIFOLD 3:1 1000 psi 69 bar LL 0.030 inch 0.76 mm J1 3:1 3800 psi 262 bar MM X M TANK 250 psi 17.2 bar AUXILIARY POWER UNIT 5:1 ATMOS 1000 psi / 69 bar PP T1 T WW BRK 2SPD 0.030 inch 0.76 mm XX OO STEER CYLINDERS 7 OPTIONAL OSCILLATE DIRECTIONAL VALVE T2 8 Part No. 107846 Z-45/25 • Z-45/25J 6-67 June 2012 Section 6 • Schematics Hydraulic Schematic, 2WD Models (before serial number 27001) June 2012 Section 6 • Schematics REV B Hydraulic Schematic, 2WD Models (after serial number 27000) N M L K MEDIUM PRESSURE FILTER J I H HIGH PRESSURE FILTER G E D C B A 1 Z-45/25J MODELS JIB BOOM PLATFORM ROTATE 0.4 GPM 51 psi 3.5 bar F GENERATOR SELECT MANIFOLD 102 psi 7 bar SECONDARY BOOM ELEVATE CYLINDERS 0.4 GPM L C D 1.3 / 0.7 GPM R E F PLATFORM LEVEL B TURNTABLE ROTATE 1.0 GPM A M 0.60 GPM SLAVE 3750 psi 259 bar E PR2 R 2 PR1 TEST H I E J GENERATOR OPTION 310 psi 21.4 bar J2 J1 PR2 MASTER V1 V2 M 0.030 inch K V2 PR2 PR1 PL2 PL1 N O R E V1 SW1 SW2 S1 R E P1 S2 R E EXT P2 RET 4 BI TEST1 25 PSI 0.046 inch BC PRESS 2500 / 172.4 bar PSI SET .6 GPM @ TEST2 BD BO BJ 3200 psi / 221 bar SET @ 7 GPM @ TEST1 A TRACTION MANIFOLD A BB CB BY BP BL 0.1 gpm 0.4 L/min BM CA BX S BF BQ T TEST 250 psi 17.2 bar BR BN BZ 2.0 gpm 7.6 L/min LB 0.067 inch 1.7 mm AD A 6 BG 50% T T1 FUNCTION MANIFOLD 50% LEFT REAR 5 BW BE 1.5 gpm 5.7 L/min OSC CC CE BU BK 0.4 gpm 1.5 L/min GEN 2100 psi / 145 bar SET @ 2.5 GPM AT TEST CG BA R BT CD BH RIGHT REAR B BV CF BS TANK B 3 APU AUX RA Q R G DRIVE PUMP B 4.1 (regen) / 2.1 GPM L 7 B RB PRIMARY BOOM EXTENSION CYLINDER 3.2 / 2.4 GPM PR1 E JIB SELECT MANIFOLD A 7 PRIMARY BOOM LIFT CYLINDER P 3200 psi 221 bar FUNCTION PUMP E R ST2 ST1 TEST 2 U COUNTERBALANCE VALVES AA T1 STEER CYLINDERS LEFT RIGHT AJ AK P CD Q LA 0.030 inch 0.76 mm AE AJ BRK AF AK AG 2SPD A T B E R E R PRESSURE 5.0:1 1000 psi / 69 bar 3:1 1000 psi / 69 bar 3:1 1500 psi / 103 bar E F 3:1 3300 psi / 228 bar H I 3:1 3500 psi / 241 bar M N 4.5:1 3500 psi / 241 bar J L 4.25:1 3626 psi / 250 bar C D 1.5:1 3800 psi / 262 bar 3:1 3800 psi / 262 bar O P RATIO 1 HS0081D 1 COUNTERBALANCE VALVE CD CHANGED FROM 3000 PSI TO 1000 PSI AFTER SERIAL NUMBER 31414. 7 8 OSCILLATE AXLE CYLINDERS Part No. 107846 Z-45/25 • Z-45/25J 6-69 June 2012 Section 6 • Schematics Hydraulic Schematic, 2WD Models (after serial number 27000) June 2012 Section 6 • Schematics REV C Hydraulic Schematic, 4WD Models (before serial number 27001) N M L K J I H G F E D C B A TURNTABLE ROTATE Orifice removed after serial number 22449 JIB BOOM 0.6 gpm / 2.27 L/min 1 PRIMARY BOOM PLATFORM ROTATE 0.25 gpm / 0.95 L/min PRIMARY BOOM EXTENSION 0.025 inch 0.64 mm 1.5:1 3800 psi 262 bar 4.25:1 3625 psi 250 bar 3:1 3300 psi 228 bar A PR2 V2 PR1 CHARGE FILTER 50 psi 3.4 bar V1 ST1 ST2 PR2 PR1 PL1 PL2 SW1 SW2 Y TP1 315 psi 21.7 bar B K J S1 P1 S2 0.037 inch 0.9 mm EXTEN P2 RETRACT R AC 2500 psi / 172 bar (set at 0.6 gpm / 2.27 L/min at TP2) 4 2100 psi 144.8 bar T1/GEN I AB AA N M G (set at 2.5 gpm / 9.5 L/min at TP2) V F PRESS 3 4.5:1 ATMOS. 3500 psi 241 bar MASTER CYLINDER OPTIONAL MOTOR/GEN GENERATOR SELECT Z 1.5 gpm 5.7 L/min 3500 psi 241 bar E DRIVE MANIFOLD D 0.4 gpm 1.5 L/min T H 0.1 gpm 0.38 L/min DRIVE PUMP 3200 psi 220.6 bar (set at 7 gpm / 26.5 L/min at TP1) E C U P B RB A X W O AUX FUNCTION PUMP 7 gpm / 26.5 L/min 2 SECONDARY BOOM CYLINDERS V1 V2 HIGH PRESSURE FILTER 100 psi 6.9 bar 3:1 ATMOS. 1500 psi 103 bar 3:1 3500 psi 241 bar AD JIB BOOM MANIFOLD 3:1 1000 psi 69 bar LL 0.030 inch 0.76 mm J2 3:1 3800 psi 262 bar MM NN SLAVE CYLINDER J1 B Q 2 gpm 7.6 L/min 5 S L T FUNCTION MANIFOLD 3200 psi 220.6 bar TP2 OSCILLATE CYLINDERS (OPTION) 25 psi 1.7 bar AG 6 A M TANK RFB REAR RIGHT RFA RA FRONT RIGHT LFB AR 50% 50% 67% AD 1 gpm 3.8 L/min 33% AB 50% REAR LEFT LFA AO X TEST AE AM AH 250 psi 17.2 bar T2 TANK T AL AJ BRK 7 OPTIONAL OSCILLATE DIRECTIONAL VALVE FRONT LEFT 0.052 inch 1.3 mm 0.025 inch 0.64 mm LA STEER CYLINDERS 50% AP AC 2 gpm AT 7.6 L/min 5:1 ATMOS 1000 psi / 69 bar AQ AS AN LB AUXILIARY POWER UNIT AK 8 0.030 inch 0.76 mm AI 2SPD Part No. 107846 Z-45/25 • Z-45/25J 6-71 June 2012 Section 6 • Schematics Hydraulic Schematic, 4WD Models (before serial number 27001) June 2012 Section 6 • Schematics Hydraulic Schematic, 4WD Models REV B (after serial number 27000) N M L K J I H HIGH PRESSURE FILTER MEDIUM PRESSURE FILTER F E D C B A 1 Z-45/25J MODELS JIB BOOM PLATFORM ROTATE 0.4 GPM GENERATOR SELECT MANIFOLD 102 psi 7 bar 51 psi 3.5 bar G SECONDARY BOOM ELEVATE CYLINDERS 0.4 GPM L D C 1.3 / 0.7 GPM R E F PLATFORM LEVEL B TURNTABLE ROTATE 1.0 GPM A M 0.60 GPM 2 SLAVE 3750 psi 259 bar E PR2 R PR1 TEST H I E J GENERATOR OPTION 310 psi 21.4 bar J2 J1 PR2 0.030 inch K V2 PR2 PR1 AUX PL2 PL1 N SW1 2500 / 172.4 bar PSI SET .6 GPM @ TEST2 BD BC PRESS SW2 S1 3200 PSI / 221 bar SET @ 7 GPM @ TEST1 A TRACTION MANIFOLD B R RFA T S U 67% 33% 2.0 gpm 7.6 L/min LEFT REAR 50% Y 0.1 gpm 0.4 L/min AA LEFT FRONT BQ 2.0 gpm 7.6 L/min 6 T B FUNCTION MANIFOLD OSC ST2 ST1 TEST 2 LFA COUNTERBALANCE VALVES AB 0.025 inch / 0.64 mm RATIO PRESSURE AJ AK 5.0:1 1000 psi / 69 bar P CD 3:1 1000 psi / 69 bar TEST 250 psi 17.2 bar STEER CYLINDERS AD LEFT RIGHT Q AH 0.030 inch 0.76 mm LA T AE AK AJ BRK BR BG X AC AI 5 CA BZ A 0.052 inch 1.32 mm Z CB BY LFB B A CC CE BM BN 50% 50% 2100 PSI / 145 bar SET @ 2.5 GPM AT TEST BX 1.0 gpm 3.8 L/min LB BT CD BW W V RET BP BE 1.5 gpm 5.7 L/min A BV CF BS BL BF 50% EXT P2 BU BK 0.4 gpm 1.5 L/min BB RA P1 S2 R E CG RIGHT FRONT T1 A BO BH BA B R E 4 BJ TANK RFB R E V1 0.046 inch RIGHT REAR O BI TEST1 25 PSI B 3 APU DRIVE PUMP RB Q R MASTER V1 V2 M 4.1 (regen) / 2.1 GPM G 7 B PRIMARY BOOM EXTENSION CYLINDER 3.2 / 2.4 GPM PR1 E JIB SELECT MANIFOLD A 7 PRIMARY BOOM LIFT CYLINDER P 3200 psi 221 bar FUNCTION PUMP E R L AF AG 2SPD 3:1 1500 psi / 103 bar E F 3:1 3300 psi / 228 bar H I 3:1 3500 psi / 241 bar M N 4.5:1 3500 psi / 241 bar J L 4.25:1 3626 psi / 250 bar C D 1.5:1 3800 psi / 262 bar 3:1 3800 psi / 262 bar O T2 P A T B E R E R 7 1 HS0081D 1 COUNTERBALANCE VALVE CD CHANGED FROM 3000 PSI TO 1000 PSI AFTER SERIAL NUMBER 31414. 8 OSCILLATE AXLE CYLINDERS Part No. 107846 Z-45/25 • Z-45/25J 6-73 June 2012 Section 6 • Schematics Hydraulic Schematic, 4WD Models (after serial number 27000) California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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