Genie Z45.25 J Internal Combustion - Service Manual - Part No. 219418

Service Manual
Serial Number Range
Z-45/25
from Z452513A-47001
from Z452514B-3301
Z-45/25J
IC Power
Part No. 219418

Rev C
August 2013
Introduction August 2013
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate Operator's these models:
Manual on your machine before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled Z-45/25 and Z-45/25J Service Manual ................. 52709
maintenance information for the machine owner and From serial number 9998 to 21179
user. It also provides troubleshooting fault codes
Z-45/25 and Z-45/25J Service Manual ................. 77809
and repair procedures for qualified service Deutz models: from 21180 to 23040
professionals. Ford models: from 21180 to 23189
Basic mechanical, hydraulic and electrical skills are Perkins models: from 21180 to 23008
required to perform most procedures. However, Z-45/25 and Z-45/25J Service Manual ............... 107846
several procedures require specialized skills, tools, Deutz models: from 23041 to 34010
lifting equipment and a suitable workshop. In these Ford models: from 23190 to 34010
instances, we strongly recommend that Perkins models: from 23009 to 34010
maintenance and repair be performed at an All models: from A34011 to A47000
authorized Genie dealer service center. All models: from B101
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 Copyright © 2012 Terex Corporation
communications will be carefully considered for 219418 Rev C August 2013
future printings of this and all other manuals. Fourth Edition, Third Printing
"Genie" and "Z" are registered trademarks of

Contact Us: Terex South Dakota, Inc. in the USA and many
other countries.
http://www.genielift.com Printed on recycled paper
e-mail: awp.techpub@terex.com
Printed in U.S.A.
ii Z-45/25 • Z-45/25J Part No. 219418

August 2013
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 12/2012 New release
B 4/2013 6 - Schem 6-94, 6-95
C 8/2013 Added Deutz D 2.9 L4 Engine to all sections

Added Perkins 404F-22 Engine to all sections
2 - Specs Added Deutz D 2.9 L4

Added Perkins 404F-22
5 - Faults Added Deutz D 2.9 L4 Fault Codes
Added Perkins 404F-22 Fault Codes
6 - Schem Updated all schematics

Added Deutz D 2.9 L4
Added Perkins 404F-22
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Part No. 219418 Z-45/25 • Z-45/25J iii

August 2013
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
iv Z-45/25 • Z-45/25J Part No. 219418

August 2013
INTRODUCTION
Serial Number Legend
Model:
Serial number: Z452512-12345
Manufacture date: 1/2/12 Model year: 2012
Electrical schematic number:
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Z4525 12 - 12345
Maximum number of platform occupants: 2
Maximum allowable side force: 150 lb / 670 N Model Sequence
Maximum allowable inclination of the chassis: number
0 deg
Maximum wind speed: 28 mpg/ 12.5 m/s Model year
Maximum platform height: 45 ft 6 in/ 13.8 m
Maximum platform reach:
Gradeability:
Nominal Power:
Power Supply:
Country of Manufacture:
Manufacturer: European Representative:
Terex South Dakota Genie UK LTD Serial label
500 Oakwood Road The Maltings Sequence number
Watertown, SD 57201 Wharf Road, Grantham, Lin (located under cover)
USA NG31 6BH United Kingdom stamped on chassis
This machine complies with:
Part No. 219418 Z-45/25 • Z-45/25J v

Section 1 • Safety Rules August 2013
Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This

Danger manual and the decals on the machine use
signal words to identify the following:
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual Safety alert symbol—used to alert
on your machine will result in death or serious personnel to potential personal
injury. injury hazards. Obey all safety
messages that follow this symbol
Many of the hazards identified in the operator's to avoid possible injury or death.
manual are also safety hazards when maintenance
and repair procedures are performed. Indicates an imminently hazardous
situation which, if not avoided, will
Do Not Perform Maintenance result in death or serious injury.
Unless: Indicates a potentially hazardous
situation which, if not avoided,
You are trained and qualified to perform could result in death or serious
maintenance on this machine. injury.
You read, understand and obey: Indicates a potentially hazardous
- manufacturer’s instructions and safety rules situation which, if not avoided,
- employer’s safety rules and worksite may result in minor or moderate
regulations injury.
- applicable governmental regulations
Indicates a potentially hazardous
You have the appropriate tools, lifting situation which, if not avoided,
equipment and a suitable workshop. may result in property damage.
Be sure to wear protective eye
wear and other protective clothing
if the situation warrants it.
Be aware of potential crushing
hazards such as moving parts,
free swinging or unsecured
components when lifting or placing
loads. Always wear approved
steel-toed shoes.
vi Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 1 • Safety Rules
SAFETY RULES
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.
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. 219418 Z-45/25 • Z-45/25J vii

August 2013
Table of Contents
Introduction
Important Information ........................................................................................................... ii
Serial Number Information .................................................................................................... ii
Revision History .................................................................................................................. iii
Serial Number Legend ......................................................................................................... v
Section 1 Safety Rules

General Safety Rules .......................................................................................................... vi
Section 2 Specifications
Machine Specifications .................................................................................................. 2 - 1
Performance Specifications ........................................................................................... 2 - 2
Hydraulic Specifications ................................................................................................. 2 - 3
Manifold Component Specifications ............................................................................... 2 - 5
Ford MSG-425 EFI Engine Specifications ...................................................................... 2 - 6
Deutz D2011 L03i Engine Specifications ........................................................................ 2 - 8
Deutz D 2.9 L4 Engine Specifications .......................................................................... 2 - 10
Perkins 404D-22 Engine Specifications ....................................................................... 2 - 12
Perkins 404F-22 Engine Specifications ........................................................................ 2 - 14
Machine Torque Specifications .................................................................................... 2 - 16
Hydraulic Hose and Fitting Torque Specifications ........................................................ 2 - 18
SAE and Metric Fastener Torque Chart ....................................................................... 2 - 20
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August 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures

Introduction .................................................................................................................... 3 - 1
Pre-Delivery Preparation ................................................................................................ 3 - 2
Maintenance Inspection Report ...................................................................................... 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals ............................................................................ 3 - 7
A-2 Perform Pre-operation Inspection ........................................................................... 3 - 8
A-3 Perform Function Tests ......................................................................................... 3 - 8
A-4 Perform Engine Maintenance - Ford Models .......................................................... 3 - 9
A-5 Perform Engine Maintenance - Deutz Models ........................................................ 3 - 9
A-6 Perform Engine Maintenance - Perkins Models .................................................... 3 - 10
A-7 Check the High Pressure Hydraulic Filter Condition Indicator ............................... 3 - 10
A-8 Test the Oscillate Axle (if equipped) .................................................................... 3 - 11
A-9 Perform 30 Day Service ....................................................................................... 3 - 11
A-10 Perform Engine Maintenance - Ford Models ........................................................ 3 - 12
A-12 Inspect the Fuel Filter/Water Separator - Diesel Models ....................................... 3 - 13
A-13 Check and Adjust the Engine RPM - Perkins 404D-22 Models ............................. 3 - 14
A-14 Grease the Turntable Rotation Bearing and Rotate Gear ...................................... 3 - 15
A-15 Replace the Drive Hub Oil .................................................................................... 3 - 16
Part No. 219418 Z-45/25 • Z-45/25J ix

August 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures
B-1 Inspect the Battery .............................................................................................. 3 - 17
B-2 Inspect the Electrical Wiring ................................................................................ 3 - 18
B-3 Check the Exhaust System ................................................................................. 3 - 20
B-4 Perform Engine Maintenance - Perkins Models .................................................... 3 - 21
B-5 Check the Oil Cooler and Cooling Fins - Deutz D2011 L03i Models ...................... 3 - 21
B-6 Inspect the Tires, Wheels and Lug Nut Torque .................................................... 3 - 23
B-7 Confirm the Proper Brake Configuration ............................................................... 3 - 23
B-8 Check the Drive Hub Oil Level and Fastener Torque ............................................ 3 - 24
B-9 Check and Adjust the Engine RPM - Deutz D2011 L03i Models .......................... 3 - 25
B-10 Test the Ground Control Override ......................................................................... 3 - 26
B-11 Check the Directional Valve Linkage .................................................................... 3 - 27
B-12 Test the Platform Self-leveling ............................................................................. 3 - 27
B-13 Test the Engine Idle Select .................................................................................. 3 - 28
B-14 Test the Fuel Select Operation - Ford Models ...................................................... 3 - 29
B-15 Test the Drive Brakes .......................................................................................... 3 - 30
B-16 Test the Drive Speed - Stowed Position ............................................................... 3 - 31
B-17 Test the Drive Speed - Raised or Extended Position ............................................ 3 - 32
B-18 Test the Alarm Package (if equipped) .................................................................. 3 - 33
B-19 Perform Hydraulic Oil Analysis ............................................................................ 3 - 34
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ................................. 3 - 35
B-21 Perform Engine Maintenance - Ford Models ........................................................ 3 - 36
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August 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ...................................................... 3 - 37
C-2 Perform Engine Maintenance - Perkins Models .................................................... 3 - 37
C-3 Perform Engine Maintenance - Perkins Models .................................................... 3 - 38
C-4 Grease the Platform Overload Mechanism (if equipped) ....................................... 3 - 38
C-5 Test the Platform Overload System (if equipped) ................................................. 3 - 39
C-6 Replace the Fuel Filter/Water Separator - Perkins Models ................................... 3 - 42
C-7 Perform Engine Maintenance - Ford Models ........................................................ 3 - 44
Checklist D Procedures
D-1 Check the Boom Wear Pads ................................................................................ 3 - 45
D-2 Check the Turntable Rotation Bearing Bolts ......................................................... 3 - 46
D-3 Inspect for Turntable Bearing Wear ...................................................................... 3 - 47
D-4 Replace the Drive Hub Oil .................................................................................... 3 - 49
D-5 Check the Free-wheel Configuration ..................................................................... 3 - 50
D-6 Replace the Hydraulic Filters ............................................................................... 3 - 51
D-7 Perform Engine Maintenance - Deutz Models ...................................................... 3 - 53
D-8 Perform Engine Maintenance - Perkins Models .................................................... 3 - 53
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ......................................................................... 3 - 54
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models .......................................... 3 - 56
E-3 Perform Engine Maintenance - Perkins Models .................................................... 3 - 58
E-4 Perform Engine Maintenance - Deutz Models ...................................................... 3 - 58
Part No. 219418 Z-45/25 • Z-45/25J xi

August 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued ................................................................

E-5 Perform Engine Maintenance - Perkins 404D-22 Models ...................................... 3 - 59
E-6 Perform Engine Maintenance - Perkins 404F-22 Models ...................................... 3 - 59
E-8 Perform Engine Maintenance - Deutz D 2.9 L4 Models ....................................... 3 - 60
E-9 Perform Engine Maintenance - Perkins 404D-22 Models ...................................... 3 - 61
Section 4 Repair Procedures

Introduction .................................................................................................................... 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board ........................................................................................... 4 - 2
1-2 Joysticks ............................................................................................................... 4 - 3
Platform Components
2-1 Platform Leveling Slave Cylinder ........................................................................... 4 - 8
2-2 Platform Rotator ..................................................................................................... 4 - 9
2-3 Platform Overload System ................................................................................... 4 - 10
Section 4 Repair Procedures

Jib Boom Components, Z-45/25J
3-1 Jib Boom ............................................................................................................. 4 - 13
3-2 Jib Boom Lift Cylinder .......................................................................................... 4 - 15
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August 2013
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

Primary Boom Components
4-1 Cable Track ......................................................................................................... 4 - 16
4-2 Primary Boom ...................................................................................................... 4 - 20
4-3 Primary Boom Lift Cylinder .................................................................................. 4 - 23
4-4 Primary Boom Extension Cylinder ....................................................................... 4 - 25
4-5 Platform Leveling Master Cylinder ....................................................................... 4 - 26
Secondary Boom Components
5-1 Secondary Boom ................................................................................................. 4 - 29
5-2 Secondary Boom Lift Cylinders ............................................................................ 4 - 34
Engines
6-1 RPM Adjustment - Deutz D2011 L03i Models ...................................................... 4 - 36
6-2 RPM Adjustment - Perkins 404D-22 Models ........................................................ 4 - 36
6-3 Flex Plate ............................................................................................................ 4 - 36
6-4 Ford MSG-425 Engine Fault Codes ...................................................................... 4 - 40
6-5 Deutz D 2.9 L4 and Perkins 404F-22 Engine Fault Codes .................................... 4 - 40
Hydraulic Pumps
7-1 Lift/Steer Pump .................................................................................................... 4 - 41
7-2 Drive Pump .......................................................................................................... 4 - 42
Manifolds
8-1 Function Manifold Components ............................................................................ 4 - 46
8-2 Valve Adjustments - Function Manifold ................................................................ 4 - 50
8-3 Jib Boom / Platform Rotate Manifold Components ............................................... 4 - 51
Part No. 219418 Z-45/25 • Z-45/25J xiii

August 2013
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

8-4 Turntable Rotation Manifold Components ............................................................. 4 - 52
8-5 Directional Valve Manifold Components ............................................................... 4 - 53
8-6 Traction Manifold Components, 2WD ................................................................... 4 - 56
8-7 Valve Adjustments, 2WD Traction Manifold ......................................................... 4 - 58
8-8 Traction Manifold Components, 4WD ................................................................... 4 - 60
8-9 Valve Adjustments, 4WD Traction Manifold ......................................................... 4 - 62
8-10 Hydraulic Generator Manifold Components, 2.2kW .............................................. 4 - 63
8-11 Valve Coils .......................................................................................................... 4 - 64
Turntable Rotation Components
9-1 Turntable Rotation Assembly ............................................................................... 4 - 66
Axle Components
10-1 Hub and Bearings, 2WD Models .......................................................................... 4 - 68
10-2 Oscillate Axle Cylinders ....................................................................................... 4 - 69
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August 2013
TABLE OF CONTENTS
Section 5 Fault Codes

Introduction .................................................................................................................... 5 - 1
Control System Fault Codes .......................................................................................... 5 - 2
Deutz D 2.9 L4 and Perkins 404F-22 Fault code Display ................................................ 5 - 8
Deutz D 2.9 L4 Engine Fault Codes ............................................................................. 5 - 12
Perkins 404F-2 Engine Fault Codes ............................................................................. 5 - 27
Ford Engine Fault Codes ............................................................................................. 5 - 30
Section 6 Schematics
Introduction .................................................................................................................... 6 - 1
Electrical Symbols Legend ............................................................................................. 6 - 2
Hydraulic Symbols Legend ............................................................................................. 6 - 3
Electrical Abbreviations Legend ..................................................................................... 6 - 4
Ford Engine Relay Layout .............................................................................................. 6 - 7
Deutz D 2.9 L4 and Perkins 404F-22 Engine Relay Layout ............................................ 6 - 8
Ford MSG-425 EFI Engine Wire Harness ..................................................................... 6 - 10
Deutz D 2.9 L4 Engine Wire Harness ........................................................................... 6 - 11
Perkins 404F-22 Engine Wire Harness ......................................................................... 6 - 14
Electrical Schematic, Options (All Models) .................................................................. 6 - 15
Ground Control Box Terminal Strip Wiring Diagram, Options ........................................ 6 - 18
Platform Control Box Wiring Diagram, Options ............................................................. 6 - 19
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options ........................ 6 - 22
Wiring Diagram, 2.2kW Hydraulic Generator ................................................................. 6 - 23
Hydraulic Schematic, 2WD Models .............................................................................. 6 - 26
Hydraulic Schematic, 4WD Models .............................................................................. 6 - 27
Part No. 219418 Z-45/25 • Z-45/25J xv

August 2013
TABLE OF CONTENTS
Section 6 Schematics, continued

Electrical Schematics - ANSI/CSA
Electrical Schematic, Ford MSG-425 EFI Models (ANSI / CSA) .................................. 6 - 30
Ground Control Box Terminal Strip Wiring Diagram,
Ford MSG-425 EFI Models (ANSI / CSA) ................................................... 6 - 34
Ground Control Box Switch Panel Wiring Diagram,
Platform Control Box Wiring Diagram,
Ford MSG-425 EFI Models (ANSI/CSA) ..................................................... 6 - 38
Platform Control Box Switch Panel Wiring Diagram,
Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (ANSI / CSA) ......... 6 - 42
Deutz 2011 L03i / Perkins 404D-22 Modelss (ANSI / CSA) ........................ 6 - 46
Deutz 2011 L03i / Perkins 404D-22 Models (ANSI / CSA) .......................... 6 - 47
Deutz 2011 L03i / Perkins 404D-22 Models (ANSI / CSA) .......................... 6 - 50
Deutz 2011 L03i / Perkins 404D-22 Models (ANSI / CSA) ............................ 6 -51
xvi Z-45/25 • Z-45/25J Part No. 219418

August 2013
TABLE OF CONTENTS

Electrical Schematics - ANSI
Electrical Schematic, Deutz D 2.9 L4 Models (ANSI) ................................................... 6 - 54
Deutz D 2.9 L4 Models (ANSI) ................................................................... 6 - 58
Electrical Schematic, Perkins 404F-22 Models (ANSI) ................................................ 6 - 66
Perkins 404F-22 Models (ANSI) ................................................................. 6 - 70
Part No. 219418 Z-45/25 • Z-45/25J xvii

August 2013
TABLE OF CONTENTS

Electrical Schematics - AS
Electrical Schematic, Ford MSG-425 EFI Models (AS) ................................................ 6 - 78
Ford MSG-425 EFI Models (AS) ................................................................. 6 - 82
Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (AS) ....................... 6 - 90
Deutz 2011 L03i / Perkins 404D-22 Models (AS) ........................................ 6 - 94
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August 2013
TABLE OF CONTENTS

Electrical Schematics - CE
Electrical Schematic, Ford MSG-425 EFI Models (CE) ............................................... 6 - 102
Ford MSG-425 EFI Models (CE) ................................................................ 6 - 106
Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (CE) ...................... 6 - 114
Deutz 2011 L03i / Perkins 404D-22 Models (CE) ....................................... 6 - 118
Part No. 219418 Z-45/25 • Z-45/25J xix

August 2013
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xx Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 2 • Specifications
Specifications
Machine Specifications Tires and wheels Hi-flotation
(option)
Tires and wheels Rough terrain
Tire size 33/16LL500
Tire size 315/55 D20
Tire ply rating 10
Tire ply rating 12
Overall tire diameter 33 in
Tire and wheel weight, 84 cm
air filled 140 lbs
63.5 kg Wheel diameter 19.5 inches
foam filled (minimum) 290 lbs 49.5 cm
131.5 kg Wheel width 14 inches
Overall tire diameter 32.5 in 35.6 cm
82.5 cm Wheel lugs 9 @ 5/8 -18
Wheel diameter 20 inches Lug nut torque
50.8 cm (lubricated) 94 ft-lbs
Wheel width 11 inches 127.4 Nm
27.9 cm (dry) 125 ft-lbs
169.5 Nm
Wheel lugs 9 @ 5/8 -18
Tire pressure 38 psi
Lug nut torque 2.6 bar
(lubricated) 94 ft-lbs
127.4 Nm
(dry) 125 ft-lbs
169.5 Nm
Tire pressure (air-filled tires) 60 psi

4.1 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. 219418 Z-45/25 • Z-45/25J 2-1

Section 2 • Specifications August 2013
SPECIFICATIONS
Fluid capacities Performance Specifications

LPG tank 33.5 pounds
Drive speed, maximum
15.2 kg
Fuel tank 17 gallons Stowed position 4.5 mph
64.4 liters 7.2 km/h
40 ft / 6.1 sec
Hydraulic tank 22 gallons 12.2 m / 6.1 sec
83 liters
Raised or extended position 0.6 mph
Hydraulic system 30 gallons 0.98 km/h
(including tank) 113.6 liters 40 ft / 45 sec
Drive hubs 24 fl oz 12.2 m / 45 sec
0.7 liters Gradeability See Operator's Manual
Drive hub oil type:
Braking distance, maximum
SAE 90 multipurpose hypoid gear oil API service
classification GL5 High range on paved surface 3 to 6 ft
0.9 to 1.8 m
Joystick function speeds, maximum
from platform controls
Primary boom up 24 to 28 seconds
Primary boom down 24 to 28 seconds
Primary boom extend 18 to 22 seconds
Primary boom retract 18 to 22 seconds
Secondary boom up 24 to 28 seconds
Secondary boom down 24 to 28 seconds
Turntable rotate, 355° 62 to 68 seconds

Genie policy. Product specifications are subject
to change without notice.
2-2 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Hydraulic Specifications Note: Use Chevron Aviation A hydraulic oil when

ambient temperatures consistently below
Hydraulic Oil Specifications 0°F / -18°C.
Hydraulic oil type Chevron Rando HD MV equivalent Note: Use Shell Tellus S2 V46 hydraulic oil when
Approximate SAE grade 5W-20 oil temperatures consistently exceed 205°F / 96°C.
Viscosity index rating 200
Note: Genie specifications require additional
Cleanliness level, minimum 15/13 equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Water content, maximum 200 ppm
Service Department before use.
Chevron Rando HD 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 the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046

Quintolubric 822
Mineral based Shell Tellus S2 V 32

Shell Tellus S2 V 46
Chevron Aviation A
ARNICA 32
Continued use of Chevron Aviation

A hydraulic oil when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.

Part No. 219418 Z-45/25 • Z-45/25J 2-3

SPECIFICATIONS
Hydraulic Specifications, continued Auxiliary pump
Drive pump Type: gear, fixed displacement
Type: bi-directional, variable Displacement per revolution 0.067 cu in

displacement piston pump 1.1 cc
Flow rate @ 2500 rpm 32 gpm Auxiliary pump relief pressure 3200 psi
121 L/min 220.6 bar
Drive pressure, maximum 3500 psi Function manifold

241 bar
System relief valve pressure 3200 psi
Charge pump 220.6 bar
Type: gear Secondary boom down 2100 psi

relief valve pressure 145 bar
Displacement 0.84 cu in
13.76 cc Platform level relief valve pressure 2500 psi
172 bar
Flow rate @ 2500 rpm 9.1 gpm
34.4 L/min Steer flow regulator 2.0 gpm
7.6 L/min
Charge pressure @ 2500 rpm 315 psi
21.7 bar Boom extend flow regulator 2 gpm
7.6 L/min
Function pump
Jib boom / platform rotate flow regulator 0.4 gpm
Type: gear 1.5 L/min
Displacement 0.67 cu in Traction manifold
11 cc
Hot oil relief pressure 250 psi
Flow rate @ 2500 rpm 7.25 gpm 17.2 bar
27.4 L/min
Steer end drive motors (4WD models)
Displacement 0.54 to 1.53 cu in

per revolution, variable 8.77 to 25 cc

2-4 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Non-steer end drive motors Manifold Component

Displacement per revolution, variable 0.54 to 1.53 cu in Specifications
4WD (2 speed motor) 8.85 to 25.1 cc
Plug torque
Displacement per revolution, variable 0.99 to 1.83 cu in
2WD 16.2 to 30 cc SAE No. 2 36 in-lbs / 4 Nm
Hydraulic filters SAE No. 4 10 ft-lbs / 13 Nm
High pressure filter Beta 3 ≥ 200 SAE No. 6 14 ft-lbs / 19 Nm
High pressure filter 100 psi SAE No. 8 38 ft-lbs / 51 Nm

bypass pressure 6.89 bar
SAE No. 10 41 ft-lbs / 55 Nm
Medium pressure filter Beta 3 ≥ 200
SAE No. 12 56 ft-lbs / 76 Nm
Medium pressure filter 50 psi
bypass pressure 3.4 bar
Hydraulic return filter 10 micron with

25 psi / 1.7 bar bypass

Part No. 219418 Z-45/25 • Z-45/25J 2-5

SPECIFICATIONS
Ford MSG-425 EFI Engine Oil pressure switch
Displacement 153 cu in Oil pressure switch point 7.5 psi

2.5 liters 0.51 bar
Number of cylinders 4 Oil viscosity requirements
Bore & stroke 3.5 x 3.9 inches Extreme operating temperatures may require the use of
89 x 100 mm alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Horsepower 60 @ 2500 rpm
45 kW @ 2500 rpm Electronic fuel pump
Firing order 1-3-4-2 Fuel pressure, static 60 psi

4.1 bar
Low engine idle (computer controlled) 1000 rpm
33.3 Hz Fuel flow rate 0.58 gpm
2.2 L/min
Low function idle (computer controlled) 1600 rpm
53.3 Hz Fuel requirement
High function idle (computer controlled) 2500 rpm For fuel requirements, refer to the engine Operator's
83.3 Hz Manual on your machine.
Compression ratio 9.7:1 Ignition system
Compression pressure (approx.) Spark plug type Motorcraft AYFS-32Y-R

Pressure (psi or bar) of lowest cylinder must be Spark plug gap 0.049 to 0.053 inches
at least 75% of highest cylinder 1.25 to 1.35 mm
Lubrication system Engine coolant
Oil pressure 29 to 39 psi Capacity 11.5 quarts
(operating temperature @ 2000 rpm) 2.75 to 4.1 bar 10.9 liters
Oil capacity 6.7 quarts Coolant temperature switch
(including filter) 6.4 liters
Temperature switch point 230°F
110°C

2-6 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Ford MSG-425 EFI Engine, continued
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Current draw, maximum load 800A
Alternator
Output 95A, 13.8V DC
Battery
Type 12V DC, Group 34/78
Quantity 1
Cold cranking ampere @ 0°F 900A
Reserve capacity @ 25A rate 200 minutes

Part No. 219418 Z-45/25 • Z-45/25J 2-7

SPECIFICATIONS
Deutz D2011 L03i Engine Lubrication system
Displacement 142 cu in Oil pressure 20 to 44 psi

2.33 liters 1.4 to 3 bar
Number of cylinders 3 Oil capacity 9.5 quarts

(including filter) 9 liters
Bore and stroke 3.7 x 4.4 inches
94 x 112 mm Oil viscosity requirements
Horsepower 48 @ 2800 rpm -22° F to 86° F/ -30° C to 30° C 5W-30

36 kW @ 2800 rpm (synthetic)
Firing order 1-2-3 -4° F to 90° F / -20° C to 32° C 10W-40
Low idle 1500 rpm Above 23° F / -5° C 20W-50

313 Hz Units ship with 15W-40.
High idle 2500 rpm Extreme operating temperatures may require the use of
521.7 Hz alternative engine oils. For oil requirements, refer to the
Compression ratio 19:1
Oil temperature switch
Compression pressure 362 to 435 psi
25 to 30 bar Temperature switch point 300°F
149°C
Governor centrifugal mechanical
Oil pressure switch
Valve clearance, cold
Oil pressure switch point 22 psi
Intake 0.012 in 1.5 bar
0.3 mm
Exhaust 0.020 in
0.5 mm

2-8 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Deutz D2011 L03i Engine, continued
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
Quantity 1
Cold cranking ampere 900A
Alternator output 60A @ 14V DC
Fan belt deflection 3/8to 1/2 inch

9 to 12 mm

Part No. 219418 Z-45/25 • Z-45/25J 2-9

SPECIFICATIONS
Deutz D 2.9 L4 Engine Oil viscosity requirements
Displacement 177 cu in -22° F to 86° F/ -30° C to 30° C 5W-30

2.9 liters (synthetic)
Number of cylinders 4 -4° F to 90° F / -20° C to 32° C 10W-40
Bore and stroke 3.6 x 4.3 inches Above 23° F / -5° C 20W-50
92 x 110 mm Units ship with 15W-40.
Horsepower 48.8 @ 2600 rpm Extreme operating temperatures may require the use of
37 kW @ 2600 rpm alternative engine oils. For oil requirements, refer to the
Firing order 1-3-4-2
Low idle 1500 rpm
313 Hz Temperature switch point 257°F
125°C
High idle 2500 rpm
521.7 Hz Oil pressure switch
Compression ratio 18.4:1 Oil pressure switch point 20 psi

1.4 bar
Compression pressure 362 to 435 psi
Engine coolant
25 to 30 bar
Capacity 10 quarts
Governor electronic
9.4 liters
Fuel injection system

Lubrication system
Injection pump make Bosch
Oil pressure 40 to 60 psi
Injection pump pressure, maximum 15000 psi
(@ 2000 rpm) 1.4 to 3 bar
1034 bar
Oil capacity 9.4 quarts
Injector opening pressure 3046 psi
(including filter) 9 liters
210 bar
Fuel requirement

Manual on your machine.

2 - 10 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Deutz D 2.9 L4 Engine, continued
Starter motor
Cranking speed 150-250 RPM
Current draw, normal load 250A to 400A
Output 3.2kW
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Fan belt deflection 3/8 to 1/2 inch

9 to 12 mm

Part No. 219418 Z-45/25 • Z-45/25J 2 - 11

SPECIFICATIONS
Perkins 404D-22 Engine Lubrication system
Displacement 134 cu in Oil pressure, cold 60 psi

2.2 liters (at 2500 rpm) 4.1 bar
Number of cylinders 4 Oil capacity 9.3 quarts

(including filter) 8.8 liters
Horsepower 51 @ 2500 rpm Below 86°F / 30°C 5W-20

38 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Low idle 1300 rpm Units ship with 15W-40.
229.7 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
441.7 Hz Engine Operator Handbook on your machine.
Compression ratio 23.3:1 Oil pressure sending unit
Compression pressure 426 psi Oil pressure switch point 14.2 psi
29.4 bar 1 bar
Pressure (psi) of lowest cylinder must Fuel injection system
be within 50 psi / 3.45 bar of highest cylinder
Injection pump make Zexel
Governor centrifugal mechanical
Injection pressure 2133 psi
Valve clearance, cold 147 bar
Intake 0.008 in Fuel requirement
0.2 mm
Exhaust 0.008 in Manual on your machine.
0.2 mm

2 - 12 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Perkins 404D-22 Engine, continued
Fan belt deflection 3/8 in

10 mm
Starter motor
Current draw, no load 140-200A

19 mm

12.7 mm
Battery
Quantity 1
Engine coolant
Capacity 7.7 quarts

7.3 liters
Coolant temperature sending unit
Temperature switch point 221° F

105° C

Part No. 219418 Z-45/25 • Z-45/25J 2 - 13

SPECIFICATIONS
Perkins 404F-22 Engine Lubrication system
Displacement 134 cu in Oil pressure 40 to 60 psi

2.2 liters (@ 2000 rpm) 1.4 to 3 bar
Number of cylinders 4 Oil capacity 9.4 - 11.2 quarts

(including filter) 8.9 - 10.6 liters
Horsepower 48 @ 2800 rpm Below 86°F / 30°C 5W-20

38 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Low idle 1300 rpm Units ship with 15W-40.
229.7 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
441.7 Hz Engine Operator Handbook on your machine.
Compression ratio 23.3:1 Oil pressure sending unit
Compression pressure 426 psi Oil pressure switch point 14.2 psi
29.4 bar 1 bar
Pressure (psi) of lowest cylinder must Fuel injection system
be within 50 psi / 3.45 bar of highest cylinder
Injection pump make Zexel
Governor electronic
Injection pressure 2133 psi
Valve clearance, cold 147 bar
Intake 0.008 in Fuel requirement
0.2 mm
Exhaust 0.008 in Manual on your machine.
0.2 mm
Fan belt deflection 3/8 in

10 mm
Starter motor
Current draw, normal load 140A - 200A

19 mm

12.7 mm

2 - 14 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Perkins 404F-22 Engine, continued
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Engine coolant
Capacity 7.7 quarts

7.3 liters
Coolant temperature sending unit
Temperature switch point 221° F

105° C

Part No. 219418 Z-45/25 • Z-45/25J 2 - 15

SPECIFICATIONS
Machine Torque Specifications

Platform rotator
3 /4 -10 center bolt, GR 8 380 ft-lbs
515 Nm
3 /8 -16 bolts, GR 8 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 180 ft-lbs

244 Nm
Drive motor mounting bolts, lubricated 55 ft-lbs

75 Nm

2 - 16 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Part No. 219418 Z-45/25 • Z-45/25J 2 - 17

SPECIFICATIONS
Hydraulic Hose and Fitting SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
Torque Specifications (all types)
Your machine is equipped with Parker Seal-Lok™
SAE Dash size Torque
ORFS or 37° JIC fittings and hose ends.
Genie specifications require that fittings and hose -4 14 ft-lbs / 19 Nm
ends be torqued to specification when they are
-6 23 ft-lbs / 31.2 Nm
removed and installed or when new hoses or fittings
are installed. -8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings
(hose end - ORFS) -12 84 ft-lbs / 114 Nm
SAE Dash size Torque -16 125 ft-lbs / 169.5 Nm
-4 10 ft-lbs / 13.6 Nm -20 151 ft-lbs / 204.7 Nm
-6 30 ft-lbs / 40.7 Nm -24 184 ft-lbs / 249.5 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm Jamb nut Non-adjustable

-12 85 ft-lbs / 115 Nm fitting (Non-adj)
Adjustable
-16 110 ft-lbs / 150 Nm
fitting (Adj)
-20 140 ft-lbs / 190 Nm
SAE O-ring Boss Port
-24 180 ft-lbs / 245 Nm (tube fitting - installed into Steel)
SAE Dash size Torque
JIC 37° Fittings -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm

(swivel nut or hose connection) ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
SAE Dash size Thread Size Flats
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-4 7/16-20 2 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-6 9/16-18 1 1/4 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm

3/4-16
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-8 1
7/8-14
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-10 1
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 1 1/16-12 1
-12 (All types) 135 ft-lbs / 183 Nm
-16 1 5/16-12 1
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 1 5/8-12 1
-20 (All types) 250 ft-lbs / 339 Nm
-24 1 7/8-12 1
-24 (All types) 305 ft-lbs / 413.5 Nm
2 - 18 Z-45/25 • Z-45/25J Part No. 219418

SPECIFICATIONS
Torque Procedure
Seal-Lok™ fittings
a
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring c b
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok™
Figure 1
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are a hex nut
available in the O-ring field service kit (Genie part b reference mark
number 49612). c body hex fitting
2 Lubricate the O-ring before installation. 3 Working clockwise on the body hex fitting, make
a second mark with a permanent ink marker to
3 Be sure that the face seal O-ring is seated and indicate the proper tightening position. Refer to
retained properly. Figure 2.
4 Position the tube and nut squarely on the face Note: Use the JIC 37° Fittings table on the previous
seal end of the fitting and tighten the nut finger page to determine the correct number of flats for
tight. the proper tightening position.
5 Tighten the nut or fitting to the appropriate Note: The marks indicate that the correct tightening
torque per given size as shown in the table. positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
6 Operate all machine functions and inspect the
joint after it has been loosened.
hoses and fittings and related components to
confirm that there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of b

the fitting body (body hex fitting) and tighten the a
hex nut to the body hex fitting to hand-tight, c
b
approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of the
hex nut, and continue it on to the body hex Figure 2
fitting with a permanent ink marker. Refer to
Figure 1. a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex nut
is aligned with the second mark on the body hex
fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
Part No. 219418 Z-45/25 • Z-45/25J 2 - 19

SPECIFICATIONS
4.6 8.8 10.9 12.9
2 - 20 Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

information and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
and every 2 years as specified on the Indicates an imminently hazardous
Maintenance Inspection Report. The frequency situation which, if not avoided, will
and extent of periodical examinations and tests result in death or serious injury.
may also depend on national regulations. Indicates a potentially hazardous
Failure to perform each procedure situation which, if not avoided,
as presented and scheduled may could result in death or serious
cause death, serious injury or injury.
substantial damage.
Immediately tag and remove from service a situation which, if not avoided,
damaged or malfunctioning machine. may cause minor or moderate
Repair any machine damage or malfunction injury.
before operating machine. Indicates a potentially hazardous
Use only Genie Approved replacement parts. situation which, if not avoided,
may result in property damage.
Machines that have been out of service for a
period longer than 3 months must complete the Indicates that a specific result is expected after
quarterly inspection. performing a series of steps.
Unless otherwise specified, perform each Indicates that an incorrect result has occurred
maintenance procedure with the machine in the after performing a series of steps.
following configuration:
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Part No. 219418 Z-45/25 • Z-45/25J 3-1

Section 3 • Scheduled Maintenance Procedures August 2013
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. 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
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
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
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Table or Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Six months or every 500 hours A+B+C

Indicates that dealer service is required
to perform this procedure. Annual or every 1000 hours A+B+C+D
Two years or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental regulations
and requirements.
3-2 Z-45/25 • Z-45/25J Part No. 219418

Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to each the Pre-operation Inspection, the Maintenance items
delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it is
put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed N = no, unable to complete
by qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements Comments
listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
3-4 Z-45/25 • Z-45/25J Part No. 219418

Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals and Decals B-1 Battery
Serial number
A-2 Pre-operation B-2 Electrical wiring
Date inspection B-3 Exhaust system
A-3 Functions tests B-4 Engine maintenance
Hour meter A-4 Engine maintenance - Perkins Models
Ford Models B-5 Oil cooler and fins-
Machine owner A-5 Engine maintenance - Deutz D2011 L03i
Deutz Models B-6 Tires and wheels
Inspected by (print)
A-6 Engine maintenance - B-7 Brake configuration
Inspector signature Perkins Models
B-8 Drive hub oil level
A-7 Filter condition indicator
B-9 Engine RPM -
Inspector title A-8 Oscillate axle Deutz D2011 L03i
Perform after 50 hours: B-10 Ground control override
Inspector company
A-9 30 day service B-11 Directional valve
Instructions Perform every 100 hours: B-12 Platform leveling
• Make copies of both pages to use for A-10 Engine maintenance - B-13 Engine idle select
each inspection. Ford models
B-14 Fuel select -
• Select the appropriate checklist(s) for A-11 Engine maintenance - Ford models
the type of inspection to be Ford models
B-15 Drive brakes
performed. A-12 Fuel filter/separator -
B-16 Drive speed -
Diesel models
Daily or 8 hour stowed position
Inspection: A A-13 Engine RPM -
B-17 Drive speed -
Perkins 404D-22
Quarterly or 250 hour raised position
A-14 Rotation bearing
Inspection: A+B B-18 Alarm package
Perform every 150 hours:
Six Month or 500 hour B-19 Hydraulic oil analysis
Inspection: A+B+C A-15 Drive hub oil
B-20 Fuel and hydraulic
Annual or 1000 hours Perform every 200 hours: tank cap venting
Inspection: A+B+C+D A-16 Engine maintenance - Perform every 400 hours:
Ford models
2 Year or 2000 hour B-21 Engine maintenance -
Inspection: A+B+C+D+E Ford models
• Place a check in the appropriate box

after each inspection procedure is
completed.
• Use the step-by-step procedures in Comments
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. 219418 Z-45/25 • Z-45/25J 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C Y N R Checklist D Y N R

C-1 Engine maintenance - D-1 Boom wear pads
Serial number Deutz models D-2 Turntable bearing bolts
Date C-2 Engine maintenance - D-3 Turntable bearing wear
Perkins models
D-4 Drive hub oil
Hour meter C-3 Engine maintenance -
D-5 Free-wheel
Perkins models
configuration
Machine owner C-4 Grease platform
D-6 Hydraulic filters
overload (if equipped)
Inspected by (print) D-7 Engine maintenance -
C-5 Test platform overload
Deutz models
(if equipped)
Inspector signature D-8 Engine maintenance -
C-6 Fuel filter/separator -
Perkins models
Perkins models
Inspector title
Checklist E Y N R
Inspector company C-7 Engine maintenance -
Ford models E-1 Hydraulic oil
Instructions E-2 Grease steer axle
• Make copies of both pages to use for wheel bearings,
each inspection. 2WD models
• Select the appropriate checklist(s) for E-3 Engine maintenance -
the type of inspection to be Perkins models
performed. Perform every 3000 hours:
E-4 Engine maintenance -
Daily or 8 hour
Deutz models
Inspection: A
Quarterly or 250 hour
Perkins 404D-22
Inspection: A+B
Six Month or 500 hour
Perkins 404F-22
Inspection: A+B+C
Annual or 1000 hours Perkins Models
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
Deutz D 2.9 L4
• Place a check in the appropriate box E-9 Engine maintenance -
after each inspection procedure is Perkins 404D-22
completed. Perform every 12000 hours:
• Use the step-by-step procedures in E-10 Engine maintenance -
this section to learn how to perform Perkin Models
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from Comments
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. 219418

Checklist A Procedures
A-1 2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Inspect the Manuals and Decals
Result: The operator's manual is appropriate for
Genie specifications require that this procedure be the machine and all manuals are legible and in
performed daily or every 8 hours, whichever comes good condition.
first.
Result: The operator's manual is not appropriate
Maintaining the operator’s and safety manuals in for the machine or all manuals are not in good
good condition is essential to safe machine condition or are illegible. Remove the machine
operation. Manuals are included with each machine from service until the manual is replaced.
and should be stored in the container provided in
the platform. An illegible or missing manual will not 3 Open the operator's manual to the decals
provide safety and operational information inspection section. Carefully and thoroughly
necessary for a safe operating condition. inspect all decals on the machine for legibility
and damage.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Result: The machine is equipped with all
for safe machine operation. Decals alert operators required decals, and all decals are legible and in
and personnel to the many possible hazards good condition.
associated with using this machine. They also Result: The machine is not equipped with all
provide users with operation and maintenance required decals, or one or more decals are
information. An illegible decal will fail to alert illegible or in poor condition. Remove the
personnel of a procedure or hazard and could result machine from service until the decals are
in unsafe operating conditions. replaced.
1 Check to make sure that the operator's and 4 Always return the manuals to the storage
safety manuals are present and complete in the container after use.
storage container on the platform.
Note: Contact your authorized Genie distributor or
Genie if replacement manuals or decals are
needed.
Part No. 219418 Z-45/25 • Z-45/25J 3-7

CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a pre-operation inspection is essential machine operation. Function tests are designed to
to safe machine operation. The pre-operation discover any malfunctions before the machine is
inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The pre-operation inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the appropriate operator's manual. Refer
procedures are required. 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.
3-8 Z-45/25 • Z-45/25J Part No. 219418

A-4 A-5
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Deutz Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed daily or every 8 hours, whichever comes performed daily or every 8 hours, whichever comes
first. first.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
• Oil level All models:
• Coolant level
• Oil, fuel and coolant leaks • Oil level
• Coolant level
Required maintenance procedures and additional • Oil, fuel and coolant leaks
engine information are available in the • Air filter
Ford MSG-425 EFI Operator Handbook
(EDI part number 1020010) D 2.9 L4 Models:
• Fuel filter / separator
Ford MSG 425 EFI Operator Handbook • Exhaust system
Genie part number 215322 Required maintenance procedures and additional
engine information are available in the
Deutz 2011 Series Operation Manual
(Deutz part number 0312-3547) OR the
Deutz D 2.9 L4 Series Operation Manual
(Deutz part number 0312-3893)

Genie part number 139320

Part No. 219418 Z-45/25 • Z-45/25J 3-9

A-6 A-7
Perform Engine Maintenance - Check the High Pressure
Perkins Models Hydraulic Filter Condition
Indicator
Genie specifications require that this procedure be
Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes
performed daily or every 8 hours, whichever comes first.
first. Maintaining the high pressure hydraulic filter in
Proper engine maintenance, following the engine good condition is essential to good system
manufacturer's maintenance schedule, is essential performance and safe machine operation. The filter
to good engine performance and service life. Failure condition indicator will show when the hydraulic flow
to perform the maintenance procedures can lead to is bypassing a clogged filter. If the filter is not
poor engine performance and component damage. frequently checked and replaced, impurities will
remain in the hydraulic system and cause
• Oil level component damage.
• Coolant level
• Oil, fuel and coolant leaks 1 Open the engine side turntable cover.
• Air filter 2 Start the engine from the ground controls.
• Pre-cleaner (if equipped)
3 Change the engine idle to high rpm (rabbit
Perkins 400 Series Operation Manual symbol).
(Perkins part number TPD 1443S)OR the
Perkins 404F Series Operation Manual 4 Visually inspect the filter condition indicator.
(Perkins part number SEBU8609).
Result: The filter condition indicator should be
operating with the plunger in the green area.
Perkins 400 Series Operation Manual
Genie part number 94890 Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
Perkins 404F Series Operation Manual filter is being bypassed and the filter should be
Genie part number 1251562 replaced. See D-6, Replace the Hydraulic
Filters.
3 - 10 Z-45/25 • Z-45/25J Part No. 219418

A-8 A-9
Test the Oscillate Axle Perform 30 Day Service
(if equipped)
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
performed daily or every 8 hours, whichever comes
comes first. After this interval, refer to the
first.
maintenance checklist for continued scheduled
Proper axle oscillation is essential to safe machine maintenance.
operation. If the axle oscillation system is not
1 Perform the following maintenance procedures:
operating correctly, the stability of the machine is
compromised and it may tip over. All Models:
• A-14 Grease the Turntable Rotation Bearing
1 Start the engine from the platform controls. and Rotate Gear
2 Drive the right steer tire up onto a • B-6 Inspect the Tires, Wheels and
6 inch / 15 cm block or curb. Lug Nut Torque
Result: The three remaining tires should stay in • C-1 Perform Engine Maintenance -
firm contact with the ground and the chassis Deutz Models
should remain level at all times. • C-6 Perform Engine Maintenance -
Perkins Models
3 Drive the left steer tire up onto a
6 inch / 15 cm block or curb. • D-2 Check the Turnable Rotation Bearing
Bolts
Result: The three remaining tires should stay in
firm contact with the ground and the chassis • D-6 Replace the Hydraulic Filters
should remain level at all times. Ford Engine Models:
4 Drive both steer tires up onto a • Check exhaust and vacuum hoses/pipes for
6 inch / 15 cm block or curb. leaks, damage or deterioration.
Result: The non-steer tires should stay in firm

contact with the ground.
Note: If the chassis does not remain level during
test, refer to Repair Procedure 8-5, How to Set Up
the Directional Valve Linkage.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 11

A-10 A-11
Ford Models Ford Models
The 50 hour maintenance procedure is a one time Engine specifications require that this procedure be
sequence of procedures to be performed after the performed every 100 hours. Perform this procedure
first 30 days or 50 hours of usage, whichever more often if dusty conditions exist or the machine
comes first. After this interval, refer to the is subjected to extended low idle operation.
maintenance tables for continued scheduled
maintenance. • Oil level
• Coolant level
1 Perform the following maintenance procedures: • Oil, fuel and coolant leaks
• Hoses and pipes for leaks and damage
• Oil level
• Electrical wiring damage
• Coolant level
• Oil, fuel and coolant leaks Required maintenance procedures and additional
• Hoses and pipes for leaks and damage engine information are available in the
• Electrical wiring damage Ford MSG-425 EFI Operator Handbook
(EDI part number 1020010)
Required maintenance procedures and additional
Ford MSG-425 EFI Operator Handbook Ford MSG 425 EFI Operator Handbook
(EDI part number 1020010) Genie part number 215322
Ford MSG 425 EFI Operator Handbook

3 - 12 Z-45/25 • Z-45/25J Part No. 219418

A-12 4 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
Inspect the Fuel Filter/ Water machine.
Separator - Perkins Models 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 Result: If water is present in the filter bowl,
performed every 100 hours or monthly, whichever continue with steps 7 through 11.
comes first.
7 Loosen the vent plug located on the fuel filter/
Proper maintenance of the fuel filter/water separator water separator head.
is essential for good engine performance. Failure to
perform this procedure can lead to poor engine
performance and/or hard starting, and continued a
use may result in component damage. Extremely d
dirty conditions may require this procedure be
performed more often.
Explosion and fire hazard. Engine
c
fuels are combustible. Perform this
procedure in an open, well- b
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
Note: Perform this procedure with the engine off. a vent plug
b drain plug
c filter bowl
1 Put on protective clothing and eye wear.
d separator head
2 Open the engine side turntable cover.
8 Loosen the drain plug located at the bottom of
3 Remove the safety pin from the engine pivot the bowl. Allow the water to drain into a suitable
plate latch. container until fuel starts to come out.
Immediately tighten the drain plug.
Note: The engine pivot plate latch is located under
the engine turntable pivot plate at the counterweight
end of the machine.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 13

9 Tighten the vent plug. A-13

Note: If the fuel filter/water separator is completely Check and Adjust the Engine
drained, you must prime the fuel filter/water
separator before starting the engine.
RPM - Perkins 404D-22 Models
See C-4, Replace The Fuel Filter/Water Separator
Element - Perkins Models, for instructions on how
to prime the fuel filter/water separator.
Engine specifications require that this procedure be
10 Clean up any fuel that may have spilled. performed every 100 hours.
11 Start the engine from the ground controls and
Maintaining the engine rpm at the proper setting for
check the fuel filter/water separator and vent
both low and high idle is essential to good engine
plug for leaks.
performance and service life. The machine will not
Explosion and fire hazard. If a fuel operate properly if the rpm is incorrect and
leak is discovered, keep any continued use may cause component damage.
additional personnel from entering
the area and do not operate the Note: This procedure will require two people.
machine. Repair the leak 1 Connect a tachometer to the engine. Start the
immediately. engine from the ground controls and check the
12 Swing the engine back to its original position rpm. Refer to Section 2, Specifications.
and close the engine pivot plate latch. Skip to step 3 if the low idle rpm is correct.
13 Install the engine pivot plate safety pin.
2 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.
3 - 14 Z-45/25 • Z-45/25J Part No. 219418

A-14
Grease the Turntable Rotation
Bearing and Rotate Gear

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.
a b c d 1 Locate the grease fitting near the ground control

box.
a solenoid boot
b high idle adjustment nut
2 Pump grease into the turntable rotation bearing.
c yoke Rotate the turntable in increments of 4 to 5
d low idle lock nut and adjustment inches / 10 to 13 cm at a time and repeat this
screw step until the entire bearing has been greased.
3 Move the function enable toggle switch to the 3 Apply grease to each tooth of the drive gear,
high idle (rabbit symbol) position and note the located under the turntable.
rpm. Refer to Section 2, Specifications.
If high idle rpm is correct, disregard adjustment Grease Specification
step 4.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
4 Loosen the yoke lock nut, then turn the high idle or equivalent
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.
Note: Be sure the solenoid fully retracts when
activating high idle.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 15

A-15 A-16
Replace the Drive Hub Oil Perform Engine Maintenance -
Ford Models
Manufacturer drive hub specifications require that

this one-time procedure be performed after the first Engine specifications require that this procedure be
150 hours. performed every 200 hours.
Replacing the drive hub oil is essential for good • Oil level
machine performance and service life. Failure to • Coolant level
replace the drive hub oil after the first 150 hours of • Oil, fuel and coolant leaks
use may cause the machine to perform poorly and • Hoses and pipes for leaks and damage
continued use may cause component damage. • Electrical wiring damage
1 Select the drive hub to be serviced. Drive the • Engine belts
machine until one of the two plugs is at the • Fuel filters
lowest point. Required maintenance procedures and additional
2 Remove both plugs and drain the oil into a
suitable container.
(Ford part number 1020010)
3 Drive the machine until both plugs are
horizontal. Ford MSG-425 EFI Operator Handbook
a
To access the engine:

1 Remove the safety pin from the engine pivot
plate latch.
end of the machine.
2 Open the engine pivot plate latch and swing the

a drive hub plugs
4 Fill the hub until the oil level is even with the machine.
bottom of the plug hole. Refer to Section 2,
Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.
3 - 16 Z-45/25 • Z-45/25J Part No. 219418

Checklist B Procedures
B-1 3 Be sure that the battery retainers and cable
connections are tight.
Inspect the Battery
4 Fully charge the batteries. Allow the batteries to
rest 24 hours before performing this procedure
to allow the battery cells to equalize.
Genie specifications require that this procedure be 5 Put on protective clothing and eye wear.
performed every 250 hours or quarterly, whichever 6 Remove the battery vent caps and check the
comes first. specific gravity of each battery cell with a
Proper battery condition is essential to good engine hydrometer. Note the results.
performance and operational safety. Improper fluid 7 Check the ambient air temperature and adjust
levels or damaged cables and connections can the specific gravity reading for each cell as
result in engine component damage and hazardous follows:
conditions.
• Add 0.004 to the reading of each cell for
Electrocution/burn hazard. Contact every 10° / 5.5° C above 80° F / 26.7° C.
with hot or live circuits could result
in death or serious injury. Remove • Subtract 0.004 from the reading of each cell for
all rings, watches and other every 10° / 5.5° C below 80° F / 26.7° C.
jewelry. Result: All battery cells display an adjusted
Bodily injury hazard. Batteries specific gravity of 1.277 +/- 0.007. The battery
contain acid. Avoid spilling or is fully charged. Proceed to step 11.
contacting battery acid. Neutralize Result: One or more battery cells display a
battery acid spills with baking soda specific gravity of 1.269 or below. Proceed to
and water. step 8.
1 Open the side covers. 8 Perform an equalizing charge OR fully charge
2 Be sure that the battery cable connections are the batteries and allow the batteries to rest at
free of corrosion. least 6 hours.
Note: Adding terminal protectors and a corrosion 9 Remove the battery vent caps and check the
preventative sealant will help eliminate corrosion on specific gravity of each battery cell with a
the battery terminals and cables. hydrometer. Note the results.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 17

CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: 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. Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
Result: All battery cells display a specific comes first.
gravity of 1.277 +/- 0.007. The battery is fully
charged. Proceed to step 11. Maintaining electrical wiring in good condition is
essential to safe operation and good machine
Result: One or more battery cells display a performance. Failure to find and replace burnt,
specific gravity from 1.269 to 1.218. The battery chafed, corroded or pinched wires could result in
is still useable, but at a lower performance so unsafe operating conditions and may cause
will need to be recharged more often. Proceed component damage.
to step 11.
Electrocution/burn hazard. Contact
Result: One or more battery cells display a with hot or live circuits could result
specific gravity from 1.217 to 1.173. The battery in death or serious injury. Remove
is approaching the end of its life. Proceed to all rings, watches and other
step 11. jewelry.
Result: The difference in specific gravity 1 Open the engine side turntable cover.
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is 1.172 2 Remove the safety pin from the engine pivot
or less. Replace the battery. plate latch.
11 Check the battery acid level. If needed, Note: The engine pivot plate latch is located under
replenish with distilled water to 1/8 inch / 3 mm the engine turntable pivot plate at the counterweight
below the bottom of the battery fill tube. Do not end of the machine.
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.
3 - 18 Z-45/25 • Z-45/25J Part No. 219418

3 Open the engine pivot plate latch and swing the 10 Inspect the turntable area for burnt, chafed and
engine pivot plate out and away from the pinched cables.
machine.
11 Lower the boom to the stowed position and turn
4 Inspect the following areas for burnt, chafed, the engine off.
corroded and loose wires:
12 Inspect the following areas for burnt, chafed,
• Engine wiring harness corroded, pinched and loose wires:
• Hydraulic manifold wiring • Cable track on the primary boom
5 Open the ground controls side turntable cover. • Cables on the primary, and jib booms
6 Inspect the following areas for burnt, chafed, • Jib boom/Platform rotate manifold
corroded and loose wires: • Inside of the platform control box
• Ground control box wire harnesses 13 Inspect for a liberal coating of dielectric grease
• Inside of the ground control box at the following location:
• Hydraulic manifold wiring • All wire harnesses connectors to the
7 Inspect for a liberal coating of dielectric grease platform control box
at the following location: 14 Swing the engine back to its original position
• All wire harnesses connectors to the and close the engine pivot plate latch.
ground control box 15 Install the engine pivot plate safety pin.
8 Start the engine from the ground controls and 16 Install the center turntable cover and tighten the
raise the secondary boom above the turntable retaining fasteners.
covers.
9 Remove the center turntable cover retaining
fasteners. Remove the center turntable cover
from the machine.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 19

B-3 2 Open the engine pivot plate latch and swing the
Check the Exhaust System machine to access the exhaust system.
Engine specifications require that this procedure be All models:
comes first. 3 Be sure that all nuts and bolts are tight.
Maintaining the exhaust system is essential to 4 Inspect all welds for cracks.
good engine performance and service life. Running 5 Inspect for exhaust leaks; i.e., carbon buildup
the engine with a damaged or leaking exhaust around seams and joints.
system can cause component damage and unsafe
operating conditions. Ford models:
Bodily injury hazard. Do not 6 Swing the engine back to its original position
inspect while the engine is running. and close the engine pivot plate latch.
Remove the key to secure from 7 Install the engine pivot plate safety pin.
operation.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
Ford models:

plate latch.
end of the machine.
3 - 20 Z-45/25 • Z-45/25J Part No. 219418

B-4 B-5
Perform Engine Maintenance - Check the Oil Cooler and
Perkins Models Cooling Fins - Deutz D2011 L03i
Models

performed every 250 hours. Engine specifications require that this procedure be
Proper engine maintenance, following the engine performed every 250 hours or quarterly, whichever
manufacturer's maintenance schedule, is essential comes first.
to good engine performance and service life. Failure Maintaining the oil cooler in good condition is
to perform the maintenance procedures can lead to essential for good engine performance. Operating a
poor engine performance and component damage. machine with a damaged oil cooler may result in
• Engine belts engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
Required maintenance procedures and additional cooling system.
Perkins 400 Series Operation Manual Bodily injury hazard. Do not
(Perkins part number TPD 1443S)OR the inspect while the engine
Perkins 404F Series Operation Manual is running. Remove the key to
(Perkins part number SEBU8609). secure from operation.
Burn hazard. Beware of hot engine
Perkins 400 Series Operation Manual components. Contact with hot
Genie part number 94890 engine components may result in
severe burns.
Perkins 404F Series Operation Manual
Genie part number 1251562 Oil cooler:
plate latch.
end of the machine.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 21

2 Open the engine pivot plate latch and swing the Cooling and fan blower fins:
machine. 6 Inspect the fan blower fins for physical damage.
3 Remove the fasteners from the engine side 7 Clean the fan blower fins of debris and foreign
cover, then remove the cover. material.
4 Inspect the oil cooler for leaks and physical 8 Inspect the head cooling passages and fins for
damage. physical damage or foreign material, using a
flashlight.
a b c
9 Clean the cylinder head cooling passages of
debris and foreign material.
10 Install the engine side cover.
11 Swing the engine back to its original position
and close the engine pivot plate latch.
a oil cooler
b cylinder head cooling fins
c fan blower fins
5 Clean the oil cooler of debris and foreign

material.
3 - 22 Z-45/25 • Z-45/25J Part No. 219418

B-6 B-7
Inspect the Tires, Wheels and Confirm the Proper
Lug Nut Torque Brake Configuration
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the tires and wheels, including proper Proper brake configuration is essential to safe
wheel fastener torque, is essential to safe operation operation and good machine performance.
and good performance. Tire and/or wheel failure Hydrostatic brakes and hydraulically-released,
could result in a machine tip-over. Component spring-applied individual wheel brakes can appear
damage may also result if problems are not to operate normally when they are actually not fully
discovered and repaired in a timely fashion. operational.
Bodily injury hazard. An over- 1 Check each drive hub disconnect cap to be sure
inflated tire can explode and could it is in the engaged position.
cause death or serious injury.
Tip-over hazard. Do not use
brake disengaged position
temporary flat tire repair products.
Note: The tires on some machines are foam-filled
and do not need air added to them.
1 Check all tire treads and sidewalls for cuts, brake engaged position
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque.
Refer to Section 2, Specifications.
4 Check the pressure in each air-filled tire.
Refer to Section 2, Specifications.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 23

B-8 2 Remove the plug located at 90 degrees and

check the oil level.
Check the Drive Hub Oil Level
Result: The oil level should be even with the
and Fastener Torque 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
Genie specifications require that this procedure be side plug hole.
performed every 250 hours or quarterly, whichever 4 Install the plug(s) into the drive hub.
comes first.
5 Check the torque of the drive hub mounting
Failure to maintain proper drive hub oil levels may bolts. Refer to Section 2, Specifications.
cause the machine to perform poorly and continued
6 Repeat this procedure for each drive hub.
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.
a drive hub plugs
3 - 24 Z-45/25 • Z-45/25J Part No. 219418

B-9 4 Loosen the low idle lock nut, then turn the low
idle adjustment screw clockwise to increase the
Check and Adjust the rpm or counterclockwise to decrease the rpm.
Engine RPM - Tighten the low idle lock nut and recheck the
rpm.
Deutz D2011 L03i Models

f
comes first. e
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. a b c d
Note: This procedure will require two people. a solenoid boot

b high idle adjustment nut
1 Remove the safety pin from the engine pivot c yoke lock nut
plate latch. d yoke
e low idle adjustment screw
The engine pivot plate latch is f low idle lock nut
located under the engine turntable 5 Move the function enable/rpm select toggle
pivot plate at the counterweight switch to the high idle (rabbit symbol) position at
end of the machine. the ground controls and check the rpm. Refer to
2 Open the engine pivot plate latch and swing the Section 2, Specifications.
engine pivot plate out and away from the If high idle rpm is correct, disregard adjustment
machine. step 6.
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.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 25

6 Loosen the yoke lock nut, then turn the high idle B-10
adjustment nut and solenoid boot
counterclockwise to increase the rpm or Test the Ground Control
clockwise to decrease the rpm. Tighten the Override
yoke lock nut and recheck the rpm.
Be sure the solenoid fully retracts performed every 250 hours or quarterly, whichever
when activating high idle. comes first.
7 Swing the engine back to its original position A properly functioning ground control override is
and close the engine pivot plate latch. essential to safe machine operation. The ground
8 Install the engine pivot plate safety pin. 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 - 26 Z-45/25 • Z-45/25J Part No. 219418

B-11 B-12
Check the Oscillate Directional Test the Platform Self-leveling
Valve Linkage

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever
performed every 250 hours or quarterly, whichever comes first.
comes first. Automatic platform self-leveling throughout
Note: Perform this test only on models equipped the full cycle of boom raising and lowering is
with an oscillating axle. essential for safe machine operation. The
platform is maintained at level by the platform
Proper axle oscillation is essential to safe machine leveling slave cylinder which operates in a closed
operation. If the oscillate directional valve linkage is loop hydraulic circuit with the master cylinder
not operating correctly, the stability of the machine located at the base of the boom.
is compromised and it may tip over. A platform self-leveling failure creates an unsafe
working condition for platform and ground
1 Remove the drive chassis cover and the axle personnel.
covers from the non-steer end of the drive
chassis. 1 Start the engine from the ground controls and
lower the boom into the stowed position.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for 2 Hold the function enable toggle switch to either
the following: side and adjust the platform to a level position
using the platform level toggle switch.
• Lock nut is tight against yoke
3 Raise and lower the primary boom through
• Yoke clevis pins are installed
a full cycle.
• Cotter pins are installed through clevis pins
Result: The platform should remain level at
• Linkage is properly attached to all times to within ±5 degrees.
directional valve
Part No. 219418 Z-45/25 • Z-45/25J 3 - 27

B-13 4 Turn the key switch to platform controls.

Test the Engine Idle Select 5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
Genie specifications require that this procedure be symbol).
comes first. Result: The engine should not change to
high idle.
A properly operating engine idle select switch
is essential to good engine performance and safe 6 Press down the foot switch.
machine operation. There are two settings. Result: The engine should change to high idle.
Foot switch activated low idle (turtle symbol) 7 Move the engine idle control switch to foot
allows the operator to control individual boom switch activated low idle (turtle symbol).
functions. Drive functions will operate at low idle,
but at reduced performance. 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.
3 - 28 Z-45/25 • Z-45/25J Part No. 219418

B-14 3 Press down the foot switch to allow the engine

to run at high idle.
Test the Fuel Select Operation -
Result: The engine should start promptly and
Ford Models operate smoothly in low and high idle.
4 Release the foot switch and shut the engine off
by pushing in the red Emergency Stop button in
Genie specifications require that this procedure be to the off position.
performed every 250 hours or quarterly, whichever 5 Move the fuel select switch to LPG.
comes first.
6 Restart the engine and allow it to run at
The ability to select and switch between low idle.
gasoline and LPG fuels as needed is essential to
7 Press down the foot switch to allow the engine
safe machine operation. A fuel selection can be
to run at high idle.
made when the engine is running or not.
Switching malfunctions and/or the failure of the Result: The engine should start promptly and
engine to start and run properly in both fuel operate smoothly in low and high idle.
modes and through all idle speeds can indicate fuel
system problems that could develop into a Note: The engine may hesitate momentarily and
hazardous situation. then continue to run on the selected fuel if the fuel
source is switched while the engine is running.
Note: 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.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 29

B-15 4 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use
Test the Drive Brakes when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
comes first. 6 Measure the distance between the test line and
your machine reference point. Refer to
Proper brake action is essential to safe machine Section 2, Specifications.
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Note: The brakes must be able to hold the machine
noise. Hydrostatic brakes and hydraulically- on any slope it is able to climb.
released 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.
Note: Select a test area that is firm, level and free
of obstructions.
1 Mark a test line on the ground for reference.

2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and
foot switch symbol), then lower the boom into
the stowed position.
3 - 30 Z-45/25 • Z-45/25J Part No. 219418

B-16 5 Bring the machine to top drive speed before

reaching the start line. Begin timing when your
Test the Drive Speed - reference point on the machine crosses the
Stowed Position start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
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.

of obstructions.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
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
when crossing the start and finish lines.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 31

B-17 6 Bring the machine to top drive speed before

reaching the start line. Begin timing when your
Test the Drive Speed - reference point on the machine crosses the
Raised or Extended Position start line.
7 Continue at full speed and note the time when
line. Refer to Section 2, Specifications.
8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
comes first.
Proper drive function movement is essential to safe patch of a tire, as a visual reference for use
machine operation. The drive function should when crossing the start and finish lines.
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, 10 Bring the machine to top drive speed before
jerking and unusual noise over the entire reaching the start line. Begin timing when your
proportionally controlled speed range. reference point on the machine crosses the
start line.
of obstructions. 11 Continue at top speed and note the time when
1 Create start and finish lines by marking two lines line. Refer to Section 2, Specifications.
on the ground 40 feet / 12.2 m apart.
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.
when crossing the start and finish lines.
3 - 32 Z-45/25 • Z-45/25J Part No. 219418

B-18 3 Move the function enable switch to either side

and activate the secondary boom toggle switch
Test the Alarm Package in the down position, hold for a moment and
(if equipped) then release it.
Genie specifications require that this procedure be Result: The descent alarm should sound when
performed every 250 hours or quarterly, whichever the switch is held down.
comes first. 4 Z-45/25J: Move the function enable toggle
The alarm package includes: switch to either side and activate the jib boom
toggle switch in the down position, hold for a
• Travel alarm moment and then release it.
• Descent alarm Result: The descent alarm should sound when
• Flashing beacon the switch is held down.
Alarms and a beacon are installed to alert operators 5 Turn the key switch to platform control.
and ground personnel of machine proximity and
motion. The alarm package is installed on the Result: The flashing beacon should be on
turntable covers. and flashing.
6 Press down the foot switch. Move the primary
Note: The alarms and beacon will operate with the
boom control handle to the down position, hold
engine running or not running.
for a moment and then release it.
1 Turn the key switch to ground control and pull
Result: The descent alarm should sound when
out the red Emergency Stop button to the on
the control handle is held down.
position at both the ground and platform
controls. 7 Press down the foot switch. Move the
secondary boom control handle to the down
Result: The flashing beacon should be on and
position, hold for a moment and then release it.
flashing.
2 Move the function enable switch to either side
the control handle is held down.
and activate the primary boom toggle switch in
the down position, hold for a moment and then
release it.
the switch is held down.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 33

8 Z-45/25J: Press down the foot switch. Activate B-19

the jib boom toggle switch in the down position,
hold for a moment and then release it. Perform Hydraulic Oil Analysis
the switch is held down.
9 Press down the foot switch. Move the drive Genie specifications require that this procedure be
control handle off center, hold for a moment and performed every 250 hours or quarterly, whichever
then release it. Move the drive control handle off comes first.
center in the opposite direction, hold for a
Replacement or testing of the hydraulic oil is
moment and then release it.
essential for good machine performance and
Result: The travel alarm should sound when the service life. Dirty oil and a clogged suction strainer
drive control handle is moved off center in either may cause the machine to perform poorly and
direction. 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.
Note: 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.
3 - 34 Z-45/25 • Z-45/25J Part No. 219418

B-20 2 Check for proper venting.

Inspect the Fuel and Hydraulic Result: Air passes through the fuel tank cap.
Proceed to step 4.
Tank Cap Venting Systems
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank
Genie requires that this procedure be performed cap venting, air should pass freely
every 250 hours or quarterly, whichever comes through the cap.
first. Perform this procedure more often if dusty
conditions exist. 3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Free-breathing fuel and hydraulic tank caps are compressed air. Repeat this procedure
essential for good machine performance and beginning with step 2.
service life. A dirty or clogged tank cap may cause
4 Install the fuel tank cap onto the fuel tank.
the machine to perform poorly and continued use
may cause component damage. Extremely dirty 5 Remove the breather cap from the hydraulic
conditions may require that the caps be inspected tank.
more often.
6 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 8.
procedure in an open, well-
ventilated area away from heaters, Result: If air does not pass through the cap,
sparks, flames and lighted clean or replace the cap. Proceed to step 7.
fire extinguisher within easy reach. Note: When checking for positive tank cap venting,
air should pass freely through the cap.
Note: Perform this procedure with the engine off.
7 Using a mild solvent, carefully wash the cap
1 Remove the cap from the fuel tank. venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 35

B-21
Perform Engine Maintenance -
Ford Models

performed every 400 hours.
• Engine oil
• Oil filter
• Coolant level
• Oil, fuel and coolant leaks
• Engine belts
• Fuel filters
• Air filter
• Spark plugs
• Loose or missing fasteners

3 - 36 Z-45/25 • Z-45/25J Part No. 219418

Checklist C Procedures
C-1 C-2
Deutz Models Perkins Models
performed every 500 hours.. performed every 500 hours.
All models: All Models:

• Engine oil • Fuel filters
• Oil filter
404F-22 Models:
D 2.9 L4 Models: • Air filters
• Engine coolant • Fan clearance
• Air intake pipes
• V-belts
• Fuel filter / separator
D2011 L03i Models: (Perkins part number TPD 1443S)OR the
• Valve clearance Perkins 404F Series Operation Manual
Deutz 2011 Series Operation Manual Perkins 400 Series Operation Manual
(Deutz part number 0312-3547) OR the Genie part number 94890


Part No. 219418 Z-45/25 • Z-45/25J 3 - 37

CHECKLIST C PROCEDURES
C-3 C-4
Perform Engine Maintenance - Grease the Platform Overload
Perkins Models Mechanism (if equipped)
Engine specifications require that this procedure be Genie specifications require that this procedure be
performed every 500 hours or annually, whichever performed every 500 hours or 6 months, whichever
comes first.. comes first. Perform this procedure more often if
dusty conditions exist.
All Models:
• Engine colant Application of lubrication to the platform overload
• Engine oil mechanism is essential to safe machine operation.
• Oil filter Continued use of an improperly greased platform
• Hoses and clamps overload mechanism could result in the system not
• Radiator sensing an overloaded platform condition and will
result in component damage.
404D-22 Models:
• Air filter 1 Locate the grease fittings on each pivot pin of
Required maintenance procedures and additional the platform overload assembly.
engine information are available in the 2 Thoroughly pump grease into each grease
Perkins 400 Series Operation Manual fitting.
Perkins 404F Series Operation Manual Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
Perkins 400 Series Operation Manual or equivalent

3 - 38 Z-45/25 • Z-45/25J Part No. 219418

C-5 compressive load. A spring in the parallelogram link

supports this purely compressive load regardless of
Test the Platform Overload where the load is placed in the platform.
System (if equipped)
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
Genie specifications require that this procedure be correctly, the platform overload system will
performed every 500 hours or six months, deactivate normal boom operation at platform
whichever comes first. capacity.
Testing the platform overload system regularly is Note: Perform this procedure with the machine on a
essential to safe machine operation. Continued use firm, level surface.
of an improperly operating platform overload
system could result in the system not sensing an 1 Turn the key switch to platform control. Start the
overloaded platform condition. Machine stability engine and level the platform.
could be compromised resulting in the machine 2 Determine the maximum platform capacity.
tipping over. Refer to the machine serial plate.
The platform overload system is designed to detect 3 Remove all weight, tools and accessories from
an overloaded platform and prevent machine the platform.
operation anytime the machine is turned on. When
activated, the system halts all normal boom Note: Failure to remove all weight, tools and
operation, giving visual and audible warning to the accessories from the platform will result in an
operator. inaccurate test.
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.
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
Part No. 219418 Z-45/25 • Z-45/25J 3 - 39

4 Using a suitable lifting device, place a test 6 Using a suitable lifting device, place an
weight equal to that of the available capacity additional 50 lbs / 23 kg of weight onto the
one of the locations shown. platform.
Refer to Illustration 1.
Result: The alarm should sound.
Result: The platform overload indicator lights The platform overload indicator lights should be
should be off at both the ground and platform flashing at both the ground and platform
controls and the alarm should not sound. controls.
Result: The platform overload indicator lights are Result: The alarm does not sound and the
on and the alarm is sounding. Calibrate the platform overload indicator lights are not
platform overload system. Refer to Repair flashing. Calibrate the platform overload
Procedure 2-3, How to Calibrate the Platform system. Refer to Repair Procedure 2-3,
Overload System (if equipped). How to Calibrate the Platform Overload System
(if equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1. Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
Result: The platform overload indicator lights
sounds.
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
Procedure 2-3, How to Calibrate the Platform
Overload System (if equipped).
Illustration 1
3 - 40 Z-45/25 • Z-45/25J Part No. 219418

7 Carefully move the test weights to each 12 Using auxiliary power, test all machine functions
remaining location on the platform. from the ground controls.
Refer to Illustration 1.
Result: All ground control functions should
Result: The alarm should sound. operate.
The platform overload indicator lights should be
13 Using a suitable lifting device, lift the additional
flashing at both the ground and platform
test weight from the platform.
controls.
Result: The platform overload indicator lights
Result: The alarm does not sound and the
should turn off at both the ground and platform
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-3, Note: There may be an 2 second delay before the
How to Calibrate the Platform Overload overload indicator lights and alarm turn off.
System (if equipped).
14 Start the engine and test all machine functions
Note: There may be a 2 second delay before the from the ground controls.
overload indicator lights flash and the alarm
sounds. Result: All ground control functions should
operate normally.
8 Test all machine functions from the platform
controls. 15 Turn the key switch to platform control.
Result: All platform control functions should not 16 Test all machine functions from the platform
operate. controls.
9 Turn the key switch to ground control. Result: All platform control functions should
operate.
10 Test all machine functions from the ground
controls. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
Result: All ground control functions should not How to Calibrate the Platform Overload System (if
operate. equipped).
11 Activate the auxiliary power toggle switch. 17 Using a suitable lifting device, remove the
Note: The engine will turn off when the auxiliary remaining test weights from the platform.
power is activated.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 41

C-6 4 Open the engine pivot plate latch and swing the
Replace the Fuel Filter/Water machine.
Separator - Perkins Models 5 Locate the fuel filter/water separator mounted to
the rear engine mounting bracket.
6 Disconnect and plug the fuel supply hose from
Genie specifications require that this procedure be the fuel tank to the fuel filter/water separator.
performed every 500 hours or six months, 7 Loosen the vent plug located on the fuel filter/
whichever comes first. water separator head.
Regular replacement of the fuel filter/water
separator is essential for good engine performance. a
Failure to perform this procedure can lead to poor
engine performance and/or hard starting, and f
continued use may result in component damage.
e b
Extremely dirty conditions may require this
procedure be performed more often.
d
c
fire extinguisher within easy reach. a vent plug
b main fuel line
Note: Perform this procedure with the engine off. c drain plug
d filter bowl
1 Put on protective clothing and eye wear. e filter element
f separator head
2 Open the engine side turntable cover.
8 Place a suitable container under the filter bowl.
3 Remove the safety pin from the engine pivot Loosen the drain plug located at the bottom of
plate latch. the bowl. Completely drain the fuel.
Note: The engine pivot plate latch is located under 9 Rotate the filter bowl counterclockwise and
the engine turntable pivot plate at the counterweight remove it from the element.
end of the machine.
3 - 42 Z-45/25 • Z-45/25J Part No. 219418

10 Rotate the filter element counterclockwise and 17 Operate the priming lever or priming bulb (if
remove it from the filter head. equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
11 Install the bowl onto the new filter element.
vent plug.
12 Apply a thin layer of oil onto the element gasket.
18 Clean up any fuel that may have spilled during
Install the filter/bowl assembly onto the filter
this procedure.
head. Tighten the drain plug and vent plug.
19 Operate the starter motor for intervals of 15
Component damage hazard. The
seconds until the engine starts.
drain plug and vent plug can be
damaged if they are overtightened. Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
13 Clean up any diesel fuel that may have spilled
interval of operation.
during the installation procedure.
Note: If the engine runs correctly for a short time
14 Install the fuel supply hose from the fuel tank to
and then stops or runs roughly, check for air in the
the fuel filter/water separator. Tighten the
fuel system. If there is air in the fuel system, there
clamp.
is probably a leak in the low pressure side of the
15 Use a permanent ink marker to write the date system.
and number of hours from the hour meter on the
filter element housing. 20 Swing the engine back to its original position
and close the engine pivot plate latch.
Prime the fuel system:
16 Loosen the vent plug on top of the fuel injection
pump.
c b
a vent plug
b fuel injection pump
c fuel lift pump
Part No. 219418 Z-45/25 • Z-45/25J 3 - 43

C-7
Perform Engine Maintenance -
Ford Models

performed every 800 hours.
• Engine oil
• Oil filter
• Coolant level
• Oil, fuel and coolant leaks
• Engine belts
• Fuel filters
• Air filter
• Spark plugs
• Loose or missing fasteners
• PCV valve
• PCV hoses, tubes and fittings

3 - 44 Z-45/25 • Z-45/25J Part No. 219418

Checklist D Procedures
D-1 2 Extend and retract the primary boom through the
entire range of motion to check for tight spots
Check the Boom Wear Pads that may cause binding or scraping of the boom.
Note: Always maintain squareness between the
outer and inner boom tubes.

performed every 1000 hours or annually, whichever Primary boom wear
pad specifications Minimum
comes first.
Top, bottom and side wear pads 5/8 inch
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads (platform end of boom) 15.9 mm
are placed on boom tube surfaces to provide a low
Side and bottom wear pads 1 /2
inch
friction, replaceable wear pad between moving
(pivot end of boom) 12.7 mm
parts. Improperly shimmed wear pads or continued
use of worn wear pads may result in component 5/8 inch
Top wear pads
damage and unsafe operating conditions. (pivot end of boom) 15.9 mm
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.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 45

CHECKLIST D PROCEDURES
D-2 3 Remove the safety pin from the engine pivot

plate latch.
Check the Turntable Rotation
Bearing Bolts the engine turntable pivot plate at the counterweight
end of the machine.
4 Open the engine pivot plate latch and swing the

Genie specifications require that this procedure be engine pivot plate out and away from the
performed every 1000 hours or annually, whichever machine.
comes first. 5 Remove the center turntable cover retaining
fasteners. Remove the center turntable cover
Maintaining proper torque on the turntable bearing
from the machine.
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe 6 Be sure that each turntable mounting bolt is
operating condition and component damage. torqued in sequence to specification. Refer to
Section 2, Specifications.
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 18 6 13
3 10
away from the cylinder and all 11 1
moving parts when lowering the
boom. 8 15
Note: The lift cylinder safety chock is available 16 7

through the Genie. 2 12
2 Turn the engine off. 9 4
14 5 17
Bolt torque sequence
3 - 46 Z-45/25 • Z-45/25J Part No. 219418

7 Start the engine from the ground controls. D-3

8 Raise the secondary boom and remove the Inspect for Turntable Bearing
safety chocks.
Wear
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.
11 Remove the lower chassis cover mounting
performed every 1000 hours or annually, whichever
fasteners from inside of the drive chassis (if
comes first.
equipped).
Periodic inspection of turntable bearing wear is
12 Remove the lower chassis cover to access the
essential to safe machine operation, good machine
lower turntable bearing bolts under the drive
performance and service life. Continued use of a
chassis.
worn turntable bearing could create an unsafe
13 Check to ensure that each lower bearing operating condition, resulting in death or serious
mounting bolt under the drive chassis is torqued injury and component damage.
in sequence to specification. Refer to Section 2,
Specifications. Note: Perform this procedure with the machine on a
firm, level surface and the boom in the stowed
position.
1 Grease the turntable bearing. See A-10, Grease
1 the Turntable Bearing and Rotate Gear.
10 15
13 7 2 Torque the turntable bearing bolts to
specification. See D-2, Check the Turntable
6 4 Rotation Bearing Bolts.
11 12 3 Start the machine from the ground controls and
raise the primary and secondary booms to full
3 5 height. Do not extend the primary boom.
8 14
16 2 9
Part No. 219418 Z-45/25 • Z-45/25J 3 - 47

4 Place a dial indicator between the drive chassis 6 Lower the secondary boom to the stowed
and the turntable at a point that is directly position and lower the primary boom to a
under, or inline with, the boom and no more than horizontal position. Fully extend the primary
1 inch / 2.5 cm from the bearing. boom.
Note: To obtain an accurate measurement, place 7 Note the reading on the dial indicator.
the dial indicator no more than 1 inch /
Result: The measurement is less than
2.5 cm from the turntable rotation bearing.
0.055 inch / 1.4 mm. The bearing is good.
Result: The measurement is more than
a 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.
b
Visually inspect the dial indicator to be sure the
needle returns to the "zero" position.
c 9 Remove the dial indicator and rotate the

turntable 90°.
10 Repeat steps 4 through 9 until the rotation
d bearing has been checked in at least four
equally spaced areas 90° apart.
a turntable
b dial indicator 11 Lower the primary and secondary booms to the
c drive chassis stowed position and turn the machine off.
d turntable rotation bearing
12 Remove the dial indicator from the machine.
5 At the dial indicator, adjust it to "zero" the
indicator.
3 - 48 Z-45/25 • Z-45/25J Part No. 219418

D-4 4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Replace the Drive Hub Oil Install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
Genie specifications require that this procedure be 6 Check the torque of the drive hub mounting
performed every 1000 hours or annually, whichever bolts. Refer to Section 2, Specifications.
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.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a drive hub plugs
Part No. 219418 Z-45/25 • Z-45/25J 3 - 49

D-5 3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
Check the Free-wheel
4 Disengage the drive hubs by turning over the
Configuration drive hub disconnect caps on each
non-steer wheel hub.
disengaged position

performed every 1000 hours or annually, whichever
comes first.
engaged position
Proper use of the free-wheel configuration is
essential to safe machine operation. The 5 Manually rotate each non-steer wheel.
free-wheel configuration is used primarily for towing.
Result: Each non-steer wheel should rotate with
A machine configured to free-wheel without operator
minimum effort.
knowledge may cause death or serious injury and
property damage. 6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
Collision hazard. Select a work site check for engagement. Raise the machine,
that is firm and level. remove the jack stands and lower the machine.
Component damage hazard. If the Collision hazard. Failure to
machine must be towed, do not re-engage the drive hubs could
exceed 2 mph / 3.2 km/h. result in death or serious injury and
Non-steer wheels: All models property damage.
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 - 50 Z-45/25 • Z-45/25J Part No. 219418

Steer wheels: 4WD models D-6

7 Chock the non-steer wheels to prevent the Replace the Hydraulic Filters
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. Genie requires that this procedure be performed
yearly or every 1000 hours, whichever comes first.
9 Lift the wheels off the ground and then place Perform this procedure more often if dusty
jack stands under the drive chassis for support. conditions exist.
10 Disengage the drive hubs by turning over the
Replacement of the hydraulic filters is essential for
drive hub disconnect caps on each
good machine performance and service life. A dirty
steer wheel hub.
disengaged position 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.
engaged position Bodily injury hazard. Beware of hot

oil. Contact with hot oil may cause
severe burns.
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort. Hydraulic return filter
12 Re-engage the drive hubs by turning over 1 Open the ground controls side turntable cover
the hub disconnect caps. Rotate each wheel to and locate the hydraulic return filter housing on
check for engagement. Raise the machine, top of the hydraulic tank.
remove the jack stands and lower the machine.
2 Remove the cap from the filter housing.
Collision hazard. Failure to
re-engage the drive hubs could 3 Lift the handle on the filter element and rotate
result in death or serious injury and the element counterclockwise to release the
property damage. element from the housing.
4 Remove the filter element from the filter
housing.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 51

5 Install the new filter element into the filter 13 Remove the filter elements from the housings.
housing.
14 Inspect the housing seals and replace them if
6 Push the filter element down to be sure the necessary.
O-ring on the element is fully seated into the
15 Install the new filter elements into the housings
housing.
and tighten them securely.
7 Rotate the filter element clockwise to lock it in
Note: The medium and high pressure filters use the
place.
same elements.
8 Install the filter housing cap.
16 Clean up any oil that may have spilled during the
9 Use a permanent ink marker to write the date installation procedure.
oil filter housing. 17 Use a permanent ink marker to write the date
Medium and high pressure filters oil filter housings.
Note: The medium pressure filter is for the charge 18 Start the engine from the ground controls.
pump and the high pressure filter is for all machine
19 Inspect the filter housings and related
functions except the drive circuit and oscillating
components to be sure that there are no leaks.
axle circuit.
10 Open the engine side turntable cover and locate

the medium and high pressure filters located
near the pump.
11 Place a suitable container under each filter.
12 Remove the filter housings by using a wrench on
the nut provided on the bottom of the housings.
3 - 52 Z-45/25 • Z-45/25J Part No. 219418

D-7 D-8
Deutz Models Perkins Models
performed every 1,000 hours. performed every 1,000 hours.
All models: All models:

• Glow plugs • Alternator
• Engine mounts • Fan belts
• Hoses and clamps • Engine valve lash
• V-belts 404F-22 models:
• Fuel filter
• Fuel filter / separator • Air pump belt
• Air filter • Crankcase breather
• By-pass oil filter Required maintenance procedures and additional
D2011 L03i models: engine information are available in the
• Valve clearance (Perkins part number TPD 1443S)OR the
D 2.9 L4 models: Perkins 404F Series Operation Manual
• Charge air cooler
Required maintenance procedures and additional Perkins 400 Series Operation Manual
engine information are available in the Genie part number 94890
(Deutz part number 0312-3547) OR the Perkins 404F Series Operation Manual
Deutz D 2.9 L4 Series Operation Manual Genie part number 1251562


Part No. 219418 Z-45/25 • Z-45/25J 3 - 53

Checklist E Procedures
E-1 1 Ford models: Turn the valve on the LPG tank
clockwise to the off position (if equipped). Then
Test or Replace the Hydraulic Oil 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).
Genie requires that this procedure be performed
every 2000 hours or every two years, whichever 3 Locate the two hydraulic tank valves at the
comes first. Perform this procedure more often if hydraulic tank through the access hole
dusty conditions exist. underneath the turntable. Close the valves.
Replacement or testing of the hydraulic oil is Component damage hazard. The

essential for good machine performance and engine must not be started with the
service life. Dirty oil and suction strainers may hydraulic tank shut-off valves in
cause the machine to perform poorly and continued the closed position or component
use may cause component damage. Extremely damage will occur. If the tank
dirty conditions may require oil changes to be valves are closed, remove the key
performed more often. from the key switch and tag the
machine to inform personnel of the
Note: Before replacing the hydraulic oil, the oil may condition.
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.
Note: 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 open closed
to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the boom in the
stowed position.
3 - 54 Z-45/25 • Z-45/25J Part No. 219418

CHECKLIST E PROCEDURES
4 Remove the drain plug from the hydraulic tank 12 Remove the suction strainers from the tank and
and completely drain the tank into a container of clean them using a mild solvent.
suitable capacity. Refer to Section 2,
13 Rinse out the inside of the tank using a mild
Specifications.
solvent.
5 Tag, disconnect and plug the two suction hoses
14 Install the suction strainers using a thread
and supply hose for the auxiliary pump from the
sealant on the threads.
hydraulic tank. Cap the fittings on the tank.
15 Install the drain plug using a thread sealant on
Note: The hoses can be accessed through the
the threads.
access hole under the turntable.
16 Install the hydraulic return filter housing onto the
6 Disconnect and plug the return filter hydraulic hydraulic tank.
hose at the return filter. Cap the fitting on the
filter housing. 17 Install the hydraulic tank onto the machine.
7 Remove the ground controls side turntable 18 Install the two suction hoses to the suction
cover. strainers.
8 Support the hydraulic tank with an appropriate 19 Install the supply hose for the auxiliary power
lifting device. unit and the return filter hose.
9 Remove the hydraulic tank mounting fasteners. 20 Open the two hydraulic tank valves at the
hydraulic tank.
10 Remove the hydraulic tank from the machine.
21 Fill the tank with the proper hydraulic oil for your
Crushing hazard. The hydraulic
machine until the level is within the top
tank could become unbalanced
2 inches / 5 cm of the sight gauge. Do not
and fall if not properly supported
overfill. Refer to Section 2, Specifications.
when removed from the machine.
22 Clean up any oil that may have spilled.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic 23 Prime the pump. Refer to Repair Procedure 7-2,
return filter housing from the hydraulic tank. How to Prime the Pump.
Note: Always use pipe thread sealant when
installing the suction hose fittings and the drain
plug.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 55

E-2 4 Remove the lug nuts. Remove the tire and wheel
assembly.
Grease the Steer Axle
5 Check for wheel bearing wear by attempting to
Wheel Bearings, 2WD Models move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Genie requires that this procedure be performed
every 2000 hours or every two years, whichever Skip to step 10 if there is no movement.
comes first. Perform this procedure more often if
6 Remove the dust cap from the hub. Remove the
dusty conditions exist.
cotter pin from the castle nut.
Maintaining the steer axle wheel bearings is
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to
essential for safe machine operation and service
seat the bearings.
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating 8 Loosen the castle nut and re-tighten to
condition and continued use may result in 8 ft-lbs / 11 Nm.
component damage. Extremely wet or dirty
9 Check for wheel bearing wear by attempting to
conditions or regular steam cleaning and pressure
move the wheel hub side to side, then up and
washing of the machine may require that this
down.
procedure be performed more often.
Result: If there is no side to side or up and
1 Loosen the wheel lug nuts. Do not remove them. down movement, continue with step 11 and
2 Block the non-steer wheels, then center a lifting grease the wheel bearings.
jack under the steer axle.
Result: If there is side to side or up and down
3 Raise the machine 6 inches / 15 cm and place movement, continue to step 11 and replace the
blocks under the drive chassis for support. wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
3 - 56 Z-45/25 • Z-45/25J Part No. 219418

10 Remove the dust cap from the hub. Remove the 18 Place the outer bearing into the hub.
cotter pin from the castle nut.
19 Install the washer and castle nut.
11 Remove the castle nut.
20 Tighten the slotted nut to 35 ft-lbs / 47 Nm to
12 Pull the hub off of the spindle. The washer and seat the bearings.
outer bearing should fall loose from the hub.
21 Loosen the castle nut and re-tighten to
13 Place the hub on a flat surface and gently pry 8 ft-lbs / 11 Nm.
the bearing seal out of the hub. Remove the rear
22 Install a new cotter pin. Bend the cotter pin
bearing.
to lock it in.
14 Pack both bearings with clean, fresh grease.
Note: Always use a new cotter pin when installing a
15 Place the large inner bearing into the rear of the castle nut.
hub.
23 Install the dust cap, then the tire and wheel
16 Install a new bearing grease seal into the hub by assembly. Torque the wheel lug nuts to
pressing it evenly into the hub until it is flush. specification. Refer to Section 2, Specifications.
17 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
Part No. 219418 Z-45/25 • Z-45/25J 3 - 57

E-3 E-4
Perkins Models Deutz Models
performed every 2,000 hours. performed every 3,000 hours..
All models: D2011 L03i models:

• Alternator • Toothed belt
• Engine mounts • Fuel injectors
• Starter • Charge air cooler
404D-22 models: D 2.9 L4 Models:
• Engine crankcase breather • V-rib belt and tensioning pulley
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Perkins 400 Series Operation Manual Deutz 2011 Series Operation Manual
(Perkins part number TPD 1443S)OR the (Deutz part number 0312-3547) OR the
Perkins 404F Series Operation Manual Deutz D 2.9 L4 Series Operation Manual
(Perkins part number SEBU8609). (Deutz part number 0312-3893)
Perkins 400 Series Operation Manual Deutz 2011 Series Operation Manual
Genie part number 94890 Genie part number 139320
Perkins 404F Series Operation Manual Deutz D 2.9 L4 Series Operation Manual
Genie part number 1251562 Genie part number 1251561
3 - 58 Z-45/25 • Z-45/25J Part No. 219418

E-5 E-6
Perkins 404D-22 Models Perkins 404F-22 Models
performed every 3,000 hours. performed every 3,000 hours.
• Fuel injectors • Fuel injectors

• Water pump • Water pump
Required maintenance procedures and additional • Coolant temperature regulator
engine information are available in the • Particulate filter
Perkins 400 Series Operation Manual • Glow plugs
(Perkins part number TPD 1443S) • Radiator cap
Perkins 400 Series Operation Manual engine information are available in the
Genie part number 94890 Perkins 404F Series Operation Manual

Part No. 219418 Z-45/25 • Z-45/25J 3 - 59

E-7 E-8
Perkins Models Deutz D 2.9 L4 Models
performed every 3,000 hours or 2 years, whichever performed every 6,000 hours.
comes first.
• General overhaul
All models: Required maintenance procedures and additional
• Engine coolant engine information are available in the
Required maintenance procedures and additional (Deutz part number 3012-3893)
(Perkins part number TPD 1443S)OR the Deutz D 2.9 L4 Series Operation Manual


3 - 60 Z-45/25 • Z-45/25J Part No. 219418

E-9 E-10
Perkins 404D-22 Models Perkins Models
performed every 6,000 hours or 3 years, whichever performed every 12,000 hours or 6 years,
comes first. whichever comes first.
• Engine coolant extender All models:

Required maintenance procedures and additional • Engine coolant
Perkins 400 Series Operation Manual Required maintenance procedures and additional
(Perkins part number TPD 1443S) engine information are available in the
Perkins 400 Series Operation Manual Perkins 404F Series Operation Manual


Part No. 219418 Z-45/25 • Z-45/25J 3 - 61

3 - 62 Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
Repair procedures shall be completed by a
perform the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
injury hazards. Obey all safety
Repair any machine damage or malfunction
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Indicates an imminently hazardous
situation which, if not avoided, will
Read, understand and obey the safety rules and
result in death or serious injury.
operating instructions in the appropriate
Operator's Manual on your machine. Indicates a potentially hazardous
Be sure that all necessary tools and parts are could result in death or serious
available and ready for use. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous
Read each procedure completely and adhere
may cause minor or moderate
to the instructions. Attempting shortcuts may
injury.
produce hazardous conditions.
Unless otherwise specified, perform each
repair procedure with the machine in the may result in property damage.
following configuration:
• Machine parked on a firm, level surface Indicates that a specific result is expected after
performing a series of steps.
• Turntable rotated with the boom between Indicates that an incorrect result has occurred
the non-steer wheels after performing a series of steps.

rotation lock
key removed
• Wheels chocked
from the machine
Part No. 219418 Z-45/25 • Z-45/25J 4-1

Section 4 • Repair Procedures August 2013
Platform Controls
The platform control box contains one printed 1-1
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution/burn hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that Note: When the ALC-500 circuit board is replaced,
particular machine function will operate. See 1-2, the joystick controllers will need to be calibrated.
How to Calibrate a Joystick. See 1-2, How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its How to Remove the ALC-500
entire range of motion. Circuit Board
1 Push in the red Emergency Stop button to the
a
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.
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
d c b
a ALC-500 circuit board

b drive/steer joystick controller
c secondary boom up/down
joystick controller
d primary boom up/down and
turntable rotate left/right
joystick controller
4-2 Z-45/25 • Z-45/25J Part No. 219418

PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 1-2

screw inside the platform control box.
Joysticks
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
How to Calibrate a Joystick
components. Maintain firm contact The joysticks on this machine utilize digital Hall
with a metal part of the machine Effect technology for proportional control. If a
that is grounded at all times when joystick is disconnected or replaced, it must be
handling printed circuit boards OR calibrated before that particular machine function
use a grounded wrist strap. will operate.
5 Carefully disconnect the wire connectors from Note: The joystick must be calibrated before the
the circuit board. threshold, max-out or ramp rate can be set.
6 Remove the ALC-500 circuit board mounting
fasteners.
1 Open the platform control box.
7 Carefully remove the ALC-500 circuit board from
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.
Part No. 219418 Z-45/25 • Z-45/25J 4-3

PLATFORM CONTROLS
7 Return the joystick to the neutral position, pause 1 Pull out the red Emergency Stop button to the
for a moment, then move the joystick full stroke on position at both the ground and platform
in the opposite direction. Hold for 5 seconds and controls.
return the joystick to the neutral position.
Result: The alarm should sound indicating start the engine.
successful joystick calibration.
3 Push in the platform controls red Emergency
8 Repeat this procedure for each joystick Stop button to the off position.
controlled machine function including the thumb
4 Do not press down the foot switch.
rocker steer switch.
5 Move and hold the drive enable toggle switch in
Note: No machine function should operate while
the right position and pull out the red
performing the joystick calibration procedure.
Emergency Stop button to the on position.
How to Adjust the Joystick 6 When the alarm sounds, release the drive
Max-out Setting enable toggle switch.
The max-out setting of a joystick controls the 7 Momentarily activate the drive enable toggle
maximum speed of a joystick-controlled machine switch in the right direction 4 times.
function. Whenever a hydraulic cylinder, drive Result: There should be a pause and the alarm
motor or hydraulic pump is replaced, the max-out should sound 4 times indicating that the
setting should be adjusted to maintain optimum machine is in max-out calibration mode.
performance. The max-out settings on the joystick
can be changed to compensate for hydraulic pump 8 Start the engine from the platform controls and
wear to maintain peak performance from the press down the foot switch.
machine. 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
stowed position.
(ie; boom up).
4-4 Z-45/25 • Z-45/25J Part No. 219418

PLATFORM CONTROLS
10 Compare the machine function time with the How to Adjust the Joystick
function times listed in Section 2,
Specifications. Determine whether the function Ramp Rate Setting
time needs to increase or decrease. The ramp rate setting of a joystick controls the time
11 While the joystick is activated, adjust the max- at which it takes for the joystick to reach maximum
out setting to achieve the proper function cycle output, when moved out of the neutral position. The
time. Momentarily move the drive enable toggle ramp rate settings of a joystick can be changed to
switch in the right direction to increase the compensate for hydraulic pump wear to maintain
function speed or momentarily move the drive peak performance from the machine.
enable toggle switch in the left direction to
decrease the function speed.
stowed position.
Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change 1 Pull out the red Emergency Stop button to the
in 2% increments. on position at both the ground and platform
controls.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
start the engine.
13 Return the joystick to the neutral position and
3 Push in the platform controls red Emergency
wait for approximately 10 seconds to allow the
Stop button to the off position.
settings to be saved.
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
Note: Do not operate any machine function during
Emergency Stop button to the on position.
the 10 second waiting time.
6 When the alarm sounds, release the drive
enable toggle switch.
Part No. 219418 Z-45/25 • Z-45/25J 4-5

PLATFORM CONTROLS
7 Momentarily activate the drive enable toggle 13 Return the joystick to the neutral position and
switch in the right direction 6 times. wait for approximately 10 seconds to allow the
Result: There should be a pause and the alarm
should sound 6 times indicating that the Result: The alarm should sound indicating that
machine is in ramp rate calibration mode. the settings have been saved in memory.
8 Start the engine from the platform controls and Note: Do not operate any machine function during
press down the foot switch. the 10 second waiting time.
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how Ramp rate (factory settings)
long it takes the function to reach maximum Primary boom up/down
speed. This is the ramp rate. accelerate 2 seconds
10 Compare the function ramp rate time with the decelerate 0.5 second
table below and determine whether the ramp Secondary boom up/down
rate time needs to increase or decrease. accelerate 2 seconds
decelerate 0.5 second
11 While the joystick is activated, set the ramp
rate. Momentarily move the drive enable toggle Turntable rotate
switch in the right direction to increase the time accelerate 2 seconds
or momentarily move the drive enable toggle decelerate 0.5 second
switch in the left direction to decrease the time.
Drive
Note: Each time the drive enable toggle switch is accelerate 3.3 seconds
momentarily moved, the time will change in 10% decelerate to neutral 0.5 second
increments. decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
12 Repeat steps 9 through 11 for each joystick decelerate, braking 1 second
controlled machine function. decelerate, shift from low to high speed 1.25 seconds
decelerate, shift from high to low speed 3.75 seconds
4-6 Z-45/25 • Z-45/25J Part No. 219418

PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Threshold Setting
9 Select a boom function joystick to set the
The threshold setting of a joystick is the minimum threshold.
output at which a function proportional valve can
open and allow the function to operate. 10 Slowly move the joystick off center in either
direction just until the function begins to move.
stowed position. 11 Slowly move the joystick back towards the
neutral position. Just before the function stops
1 Pull out the red Emergency Stop button to the moving, move the drive enable toggle switch to
on position at both the ground and platform either side to set the threshold.
controls.
Result: The alarm should sound indicating a
2 Turn the key switch to platform control. Do not successful calibration.
start the engine.
Note: For each joystick axis, the threshold must be
3 Push in the platform controls red Emergency set for both directions.
Stop button to the off position.
12 Repeat steps 9 through 11 for each direction of
4 Do not press down the foot switch. boom joystick controlled machine function
(boom up/down, boom extend/retract and
5 Move and hold the drive enable toggle switch in
turntable rotate left/right).
Emergency Stop button to the on position. 13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
6 When the alarm sounds, release the drive
enable toggle switch.
Result: The alarm should sound indicating that
7 Momentarily activate the drive enable toggle
the settings have been saved in memory.
switch in the right direction 8 times.
Note: Do not operate any machine function during
Result: There should be a pause and the alarm
the 10 second waiting time.
should sound 8 times indicating that the
machine is in threshold calibration mode.
Part No. 219418 Z-45/25 • Z-45/25J 4-7

Platform Components
2-1 3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
Platform Leveling Slave Cylinder platform.
The slave cylinder and the rotator pivot are the Note: Do not rest the entire weight of the boom on
two primary supports for the platform. The slave the blocks.
cylinder keeps the platform level through the
4 Tag, disconnect and plug the hydraulic hoses
entire range of boom motion. It operates in a
from the slave cylinder at the unions and
closed-circuit hydraulic loop with the master
connect them together using a connector.
cylinder. The slave cylinder is equipped with
Connect the hoses from the cylinder together
counterbalance valves to prevent movement in
using a connector.
the event of a hydraulic line failure.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
Leveling Slave Cylinder burn skin. Loosen hydraulic
connections very slowly to allow
Note: Before cylinder removal is considered, bleed the oil pressure to dissipate
the slave cylinder to be sure there is no gradually. Do not allow oil to
air in the closed loop. squirt or spray.
Note: When removing a hose assembly or fitting, 5 Remove the pin retaining fastener from the slave
the O-ring (if equipped) on the fitting and/or the cylinder rod-end pivot pin. Do not remove the
hose end must be replaced. All connections must pin.
be torqued to specification during installation. Refer 6 Z-45/25J: Remove the external snap rings from
to the slave cylinder barrel-end pivot pin. Do not
Section 2, Hydraulic Hose and Fitting Torque remove the pin.
Specifications..
Z-45/25: Remove the pin retaining fastener from
1 Z-45/25J: Extend the primary boom until the the slave cylinder barrel-end pivot pin. Do not
slave cylinder barrel-end pivot pin is accessible. remove the pin.
2 Raise the primary boom slightly and place 7 Place a block under the slave cylinder for
blocks under the platform for support. support. Protect the cylinder rod from damage.
4-8 Z-45/25 • Z-45/25J Part No. 219418

PLATFORM COMPONENTS
8 Z-45/25: Support the platform rotator with a 2-2

suitable lifting device.
Platform Rotator
9 Use a soft metal drift to drive the rod-end pivot
pin out.
How to Bleed the Platform
Crushing hazard. The platform Rotator
could fall when the slave cylinder
rod-end pivot pin is removed if not Note: This procedure will require two people. Do not
properly supported. start the engine. Use auxiliary power for this
procedure.
slave cylinder rod may become 1 Move the function enable toggle switch to either
damaged if it is allowed to fall if side and activate the platform rotate toggle
not properly supported by the lifting switch to the right then the left through two
device. platform rotation cycles, then hold the switch to
10 Use a soft metal drift and drive the barrel-end the right position until the platform is fully
pin out. rotated to the right.
11 Carefully pull the cylinder out of the primary 2 Place a suitable container underneath the
boom. platform rotator.
3 Open the top bleed screw on the rotator, but do
How to Bleed the Slave Cylinder not remove it.
1 Simultaneously activate the boom up function Bodily injury hazard. Spraying
and the platform level up function until the boom hydraulic oil can penetrate and
is fully raised. burn skin. Loosen hydraulic
2 Simultaneously activate the boom down function connections very slowly to allow
and the platform level down function until the the oil pressure to dissipate
boom is fully lowered. gradually. Do not allow oil to
squirt or spray.
Part No. 219418 Z-45/25 • Z-45/25J 4-9

PLATFORM COMPONENTS
4 Move the function enable toggle switch to either 2-3

side and hold the platform rotate toggle switch
to the left position until the platform is fully Platform Overload System
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed How to Calibrate the Platform
screw. Close the bleed screw.
Overload System
Crushing hazard. Keep clear of the
Calibration of the platform overload system is
platform during rotation.
essential to safe machine operation. Continued use
5 Open the bottom bleed screw on the rotator, but of an improperly calibrated platform overload
do not remove it. system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic Note: Perform this procedure with the machine on a
connections very slowly to allow firm, level surface.
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray. 1 Turn the key switch to platform control. Start the
engine and level the platform.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch 2 Determine the maximum platform capacity.
to the right position until the platform is fully Refer to the machine serial plate.
rotated to the right. Continue holding the toggle 3 Remove all weight, tools and accessories from
switch until air stops coming out of the bleed the platform.
screw. Close the bleed screw.
Note: Failure to remove all weight, tools and
Crushing hazard. Keep clear of the accessories from the platform will result in an
platform during rotation. incorrect calibration.
7 Clean up any hydraulic oil that may have spilled.
4 Using a suitable lifting device, place a test
8 Rotate the platform fully in both directions and weight equal to the maximum platform capacity
inspect the bleed screws for leaks. at the center of the platform floor.
4 - 10 Z-45/25 • Z-45/25J Part No. 219418

PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it 6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off at
the alarm does not sound. Proceed to step 6. the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
Result: The overload indicator lights are flashing
adjustment nut in a counterclockwise direction
at the platform and ground controls, and the
in 10° increments until the overload indicator
alarm is sounding. Slowly tighten the load spring
light flashes at both the platform and ground
adjustment nut in a clockwise direction in 10°
controls, and the alarm sounds.
increments until the overload indicator light
Proceed to step 7.
turns off, and the alarm does not sound.
Proceed to step 8. Result: The overload indicator lights are flashing
Note: The platform will need to be moved up and
alarm is sounding. Repeat this procedure
down and allowed to settle between each
beginning with step 5.
adjustment.
Note: The platform will need to be moved up and
Note: There may be a 2 second delay before the down and allowed to settle between each
platform overload indicator light and alarm adjustment.
responds.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 11

PLATFORM COMPONENTS
7 Move the platform up and down by hand, so it 9 Test all machine functions from the platform
bounces approximately 2.5 to 5 cm / 1 to 2 controls.
inches. Allow the platform to settle.
Result: All platform control functions should not
Result: The overload indicator lights are off and operate.
the alarm does not sound. Proceed to step 8.
10 Turn the key switch to ground control.
Result: The overload indicator lights are flashing
11 Test all machine functions from the ground
controls.
alarm is sounding. Repeat this procedure
beginning with step 5. Result: All ground control functions should not
operate.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm 12 Using a suitable lifting device, lift the test weight
responds. off the platform floor.
8 Add an additional 10 lb / 4.5 kg test weight to Result: The platform overload indicator light
the platform. should be off at both the ground and platform
Result: The overload indicator light is flashing at
both the ground and platform controls, and the Note: There may be a 2 second delay before the
alarm is sounding. Proceed to step 9. overload indicator lights and alarm turn off.
Result: The overload indicator light is off at both 13 Test all machine functions from the ground
the ground and platform controls, and the alarm controls.
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure Result: All ground control functions should
beginning with step 6. operate normally.
Note: There may be a 2 second delay before the 14 Turn the key switch to platform control.
platform overload indicator light and alarm 15 Test all machine functions from the platform
responds. controls.
Result: All platform control functions should
operate normally.
4 - 12 Z-45/25 • Z-45/25J Part No. 219418

Jib Boom Components, Z-45/25J

3-1 4 Remove the platform mounting weldment.
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
Note: Perform this procedure with the boom in the remove the pin.
stowed position.
7 Remove the pin retaining fasteners from both
Note: When removing a hose assembly or fitting, platform rotator pivot pins. Do not remove the
the O-ring (if equipped) on the fitting and/or the pins.
be torqued to specification during installation. Refer 8 Use a soft metal drift to remove the leveling arm
to Section 2, Hydraulic Hose and Fitting Torque pivot pin and let the leveling arms hang down.
Specifications. 9 Use a soft metal drift to remove the platform
1 Remove the platform. rotator pivot pin and remove the platform rotator
from the machine.
2 Disconnect the electrical connector from the jib
boom/platform rotate select valve manifold 10 Slide both of the jib boom leveling arms off of
mounted to the platform support. the jib boom cylinder rod-end pivot pin.
3 Tag, disconnect and plug all of the hydraulic 11 Remove the hose and cable cover from the side
hoses from the jib boom/platform rotate select of the jib boom. Remove the hose and cable
valve manifold. Cap the fittings on the manifold separators.
and pull the hoses out through the platform 12 Attach a lifting strap from an overhead crane to
rotator. the jib boom.
burn skin. Loosen hydraulic
squirt or spray.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 13

JIB BOOM COMPONENTS, Z-45/25J
13 Support the barrel end of the jib boom lift 17 Remove the pin retaining fastener from the jib
cylinder with a suitable lifting device. boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
14 Tag, disconnect and plug the jib boom lift
bellcrank.
cylinder hydraulic hoses. Cap the fittings on the
cylinder. Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
the oil pressure to dissipate 18 Attach a lifting strap from an overhead crane to
gradually. Do not allow oil to the lug on the rod end of the jib boom lift
squirt or spray. cylinder.
15 Remove the pin retaining fastener from the jib 19 Use a soft metal drift to remove the jib boom lift
boom lift cylinder barrel-end pivot pin. cylinder rod-end pivot pin, then remove the jib
boom lift cylinder from the bellcrank.
16 Use a soft metal drift to remove the pin and let
the cylinder hang down. Crushing hazard. The jib boom lift
cylinder could become unbalanced
Crushing hazard. The jib boom
and fall when removed from the
could fall when the barrel-end pivot
machine if not properly attached to
pin is removed if not properly
the overhead crane.
supported by the overhead crane.
4 - 14 Z-45/25 • Z-45/25J Part No. 219418

JIB BOOM COMPONENTS, Z-45/25J
3-2 3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not
Jib Boom Lift Cylinder remove the pin.
4 Use a soft metal drift to tap the jib boom lift
How to Remove the Jib Boom cylinder rod-end pivot pin half way out. Then
Lift Cylinder 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.
stowed position.
5 Support the jib boom lift cylinder with a suitable
Note: When removing a hose assembly or fitting, lifting device.
hose end must be replaced. All connections must 6 Remove the pin retaining fastener from the jib
be torqued to specification during installation. Refer boom lift cylinder barrel-end pivot pin. Use a
to Section 2, Hydraulic Hose and Fitting Torque soft metal drift to remove the barrel-end pin and
Specifications. let the cylinder hang down.
1 Raise the jib boom slightly and place blocks Crushing hazard. The jib boom
under the platform mounting weldment. Then could fall when the barrel-end pivot
lower the jib boom until the platform is resting pin is removed if not properly
on the blocks just enough to support the supported by the overhead crane.
platform. 7 Attach a lifting strap from an overhead crane to
Note: Do not rest the entire weight of the boom on the lug on the rod end of the jib boom lift
the blocks. cylinder.
2 Tag, disconnect and plug the jib boom lift 8 Use a soft metal drift to remove the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the cylinder rod-end pin. Remove the jib boom lift
cylinder. cylinder from the machine.
Bodily injury hazard. Spraying Crushing hazard. The jib boom lift
hydraulic oil can penetrate and cylinder could become unbalanced
burn skin. Loosen hydraulic and fall when removed from the
connections very slowly to allow machine if not properly attached to
the oil pressure to dissipate the overhead crane.
squirt or spray.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 15

Primary Boom Components

4-1 5 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located above the
Cable Track primary boom lift cylinder. Cap the fittings on
the unions.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
Z-45/25 from the "PR1" and "PR2" ports on the
counterbalance valve manifold located on the
Note: When removing a hose assembly or fitting, platform rotator. Cap the fittings on the
the O-ring (if equipped) on the fitting and/or the manifold.
be torqued to specification during installation. Refer Bodily injury hazard. Spraying
to Section 2, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
1 Locate the cables from the primary boom cable the oil pressure to dissipate
track to the platform control box. Number each gradually. Do not allow oil to
cable and its entry location at the platform squirt or spray.
control box.
2 Disconnect the cables from the platform control from the platform leveling master cylinder. Cap
box. the fittings on the cylinder.
3 Pull all of the electrical cables out of the plastic Bodily injury hazard. Spraying
cable track. Do not pull out the hydraulic hoses. hydraulic oil can penetrate and
4 Raise the primary boom to a horizontal position. burn skin. Loosen hydraulic
squirt or spray.
4 - 16 Z-45/25 • Z-45/25J Part No. 219418

PRIMARY BOOM COMPONENTS
8 Tag and disconnect the hydraulic hoses from 14 Remove the cable track mounting fasteners that
the platform leveling slave cylinder and connect attach the lower cable track to the primary
them together using a connector. Cap the boom.
fittings on the cylinder.
15 Remove the cable track from the machine and
Bodily injury hazard. Spraying place it on a structure capable of supporting it.
Crushing hazard. The cable track
if not properly attached to the
overhead crane.
squirt or spray. Component damage hazard.
Cables and hoses can be damaged
9 Pull the four hydraulic hoses toward the platform
if they are kinked or pinched.
to clear the rod end of the primary boom lift
cylinder. How to Remove the Cable Track,
10 Place blocks in between the upper and lower Z-45/25J
cable tracks and secure the upper and lower
tracks together. Note: When removing a hose assembly or fitting,
Crushing hazard. If the upper and hose end must be replaced. All connections must
lower cable tracks are not properly be torqued to specification during installation. Refer
secured together, the cable track to Section 2, Hydraulic Hose and Fitting Torque
could become unbalanced and fall Specifications.
1 Locate the cables from the primary boom cable
11 Remove all hose and cable clamps from the
track to the platform control box. Number each
underside of the primary boom.
cable and its entry location at the platform
12 Attach a strap from an overhead crane to the control box.
cable track.
2 Disconnect the cables from the platform control
13 Remove the mounting fasteners from the upper box.
cable track at the platform end of the extension
boom.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 17

3 Remove the hose and cable cover from the side 8 Tag, disconnect and plug the hydraulic hoses
of the jib boom. Remove the hose and cable from the jib boom/platform rotate manifold. Cap
separators. the fittings on the manifold.
4 Remove the hose clamp on the primary boom Bodily injury hazard. Spraying
bellcrank. hydraulic oil can penetrate and
5 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
6 Tag, disconnect and plug the hydraulic hoses gradually. Do not allow oil to
from the "V1" and "V2" ports on the squirt or spray.
counterbalance valve manifold located on the
9 Tag, disconnect and plug the platform rotator
platform rotator. Cap the fittings on the
hydraulic hoses at the union located above the
manifold.
primary boom lift cylinder. Cap the fittings on
Bodily injury hazard. Spraying the unions.
squirt or spray.
7 Tag and disconnect the hydraulic hoses from squirt or spray.
the platform leveling slave cylinder at the union
and connect them together using a connector.
from the platform leveling master cylinder. Cap
Connect the hoses from the cylinder together
the fittings on the cylinder.
using a connector.
squirt or spray.
squirt or spray.
4 - 18 Z-45/25 • Z-45/25J Part No. 219418

11 Raise the boom to a horizontal position. 19 Lower the rod end of the primary boom lift
cylinder approximately 12 inches / 30 cm.
12 Place blocks between the upper and lower cable
tracks and secure the upper and lower tracks 20 Pull all of the hoses and cables out and away
together. from the mounting ears for the rod end of the
primary boom lift cylinder.
Crushing hazard. If the upper and
lower cable tracks are not properly 21 Raise the rod end of the primary boom lift
secured together, the cable track cylinder back into position and install the rod-
could become unbalanced and fall end pivot pin. Install the pin retaining fasteners.
22 Attach a strap from an overhead crane to the
13 Attach a lifting strap from an overhead 5 ton / cable track.
5,000 kg capacity crane to the platform end of
23 Remove the mounting fasteners from the upper
the primary boom for support. Do not lift it.
cable track at the platform end of the extension
14 Remove all hose and cable clamps from the boom.
underside of the primary boom.
24 Remove the cable track mounting fasteners that
15 Support the rod end of the primary boom lift attach the lower cable track to the primary
cylinder with a suitable lifting device. boom.
16 Remove the pin retaining fasteners from the 25 Remove the cable track from the machine and
primary boom lift cylinder rod-end pivot pin. Do place it on a structure capable of supporting it.
not remove the pin.
Crushing hazard. The cable track
17 Raise the primary boom slightly with the could become unbalanced and fall
overhead crane to relieve the pressure on the if not properly attached to the
primary boom lift cylinder rod-end pivot pin. overhead crane.
18 Use a soft metal drift to remove the primary Component damage hazard.
boom lift cylinder rod-end pivot pin. Cables and hoses can be damaged
if they are kinked or pinched.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the lifting device.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 19

How to Repair the Primary Boom 4-2

Cable Track Primary Boom
primary boom cable track can be How to Remove the Primary
damaged if it is twisted. Boom
Note: A 7 link repair section of cable track is Bodily injury hazard. This
available through the Genie Service Parts procedure requires specific repair
Department. skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
a component damage. Dealer
service is strongly recommended.
b Note: Perform this procedure with the boom in the
stowed position.
a link separation point the O-ring (if equipped) on the fitting and/or the
b lower clip
1 Use a slotted screwdriver to pry down on the be torqued to specification during installation. Refer
lower clip. to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to the 1 Remove the platform.
side.
2 Z-45/25: Remove the platform rotator and
3 Repeat steps 1 and 2 for each link. platform mounting weldment.
Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
4 - 20 Z-45/25 • Z-45/25J Part No. 219418

3 Remove the cable track. See 4-1, How to 11 Pull the limit switch and the wiring out of the
Remove the Cable Track. extension tube and move it out of the way.
4 Raise the primary boom to a horizontal position. 12 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
5 Remove the hose and cable cover from the
fittings on the cylinder.
upper pivot.
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.
Component damage hazard. gradually. Do not allow oil to
When lowering the master cylinder squirt or spray.
down, be sure not to damage the
13 Remove the hose clamp at the pivot end of the
master cylinder hoses or fittings.
boom.
7 Locate the primary boom drive speed limit
14 Attach a 5 ton / 5,000 kg overhead crane to the
switch inside of the upper pivot.
center point of the primary boom.
8 Remove the primary boom drive speed limit
15 Attach a similar lifting device to the primary
switch mounting fasteners. Do not disconnect
boom lift cylinder.
the wiring.
16 Place support blocks under the primary boom lift
9 Locate the primary extension boom drive speed
cylinder.
limit switch inside of the extension boom.
17 Remove the pin retaining fasteners from the
10 Remove the primary extension boom drive
primary boom lift cylinder rod-end pivot pin. Use
speed limit switch mounting fasteners. Do not
a soft metal drift to remove the pin.
disconnect the wiring.
Crushing hazard. The boom lift
cylinder and primary boom will fall
if not properly supported.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 21

18 Lower the rod end of the primary boom lift How to Disassemble the Primary
cylinder onto support blocks. Protect the
cylinder rod from damage. Boom
19 Remove the pin retaining fasteners from the Complete disassembly of the boom is only
primary boom pivot pin. necessary if the outer or inner boom tube must be
replaced. The extension cylinder can be removed
20 Remove the primary boom pivot pin with a soft without completely disassembling the boom.
metal drift, then carefully remove the primary See 4-4, How to Remove the Primary Boom
boom from the machine and place it on a Extension Cylinder.
structure capable of supporting it.
1 Remove the primary boom. See How to Remove
Crushing hazard. The primary the Primary Boom.
boom could become unbalanced
and fall when removed from the 2 Place blocks under the barrel end of the primary
machine if not properly attached to boom extension cylinder for support.
the overhead crane.
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.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
4 - 22 Z-45/25 • Z-45/25J Part No. 219418

5 Support and slide the extension tube and 4-3

extension cylinder assembly out of the boom
tube. Primary Boom Lift Cylinder
Crushing hazard. The primary The primary boom lift cylinder raises and lowers the
boom extension tube could primary boom. The primary boom lift cylinder is
become unbalanced and fall when equipped with a counterbalance valve to prevent
removed from the primary boom movement in the event of a hydraulic line failure.
tube if not properly supported.
Note: During removal, the overhead crane strap will How to Remove the Primary
need to be carefully adjusted for proper balancing. Boom Lift Cylinder
6 Remove the external snap rings from the Bodily injury hazard. This
extension cylinder rod-end pivot pin at the procedure requires specific repair
platform end of the extension tube. Use a soft skills, lifting equipment and a
metal drift to remove the pin. suitable workshop. Attempting this
7 Support and slide the extension cylinder out of
the base end of the extension tube. Place the
extension cylinder on blocks for support.
component damage. Dealer
Crushing hazard. The extension service is strongly recommended.
and fall when removed from
primary boom extension tube if not
properly supported.
be torqued to specification during installation. Refer
Note: During removal, the overhead crane strap will to Section 2, Hydraulic Hose and Fitting Torque
need to be carefully adjusted for proper balancing. 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.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 23

3 Attach a 5 ton / 5000 kg overhead crane to the 8 Place a support block across both turntable
primary boom for support. covers under the primary boom lift cylinder.
4 Raise the primary boom with the overhead crane 9 Lower the rod end of the lift cylinder onto the
slightly to take the pressure off the primary block. Protect the cylinder rod from damage.
boom lift cylinder pivot pins.
5 Support the rod end and the barrel end of the boom lift cylinder could fall if not
primary boom lift cylinder with a second properly supported.
overhead crane or similar lifting device.
10 Remove the primary boom lift cylinder barrel-end
6 Tag, disconnect and plug the primary boom lift pivot pin retaining fasteners. Do not remove the
cylinder hydraulic hoses. Cap the fittings on the pin.
cylinder.
11 Use a slide hammer to remove the barrel-end
Bodily injury hazard. Spraying pivot pin. Carefully remove the primary boom lift
hydraulic oil can penetrate and cylinder from the machine.
Crushing hazard. The lift cylinder
if not properly supported and
secured to the lifting device.
squirt or spray.
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
boom will fall if not properly
supported when the primary boom
rod-end pivot pin is removed.
4 - 24 Z-45/25 • Z-45/25J Part No. 219418

4-4 2 Extend the primary boom until the primary boom

extension cylinder rod-end pivot pin is
Primary Boom Extension accessible in the primary boom extension tube.
Cylinder 3 Remove the hose and cable guard from the
upper pivot.
The primary boom extension cylinder extends and
retracts the primary boom extension tube. The 4 Tag, disconnect and plug the primary boom
primary boom extension cylinder is equipped with extension cylinder hydraulic hoses. Cap the
counterbalance valves to prevent movement in the fittings on the cylinder.
event of a hydraulic line failure.
How to Remove the Primary burn skin. Loosen hydraulic
Boom Extension Cylinder connections very slowly to allow
Bodily injury hazard. This
procedure requires specific repair
squirt or spray.
skills, lifting equipment and a
suitable workshop. Attempting this 5 At the platform end of the boom, remove the
procedure without these skills and external snap rings from the extension cylinder
tools could result in death or rod-end pivot pin. Use a soft metal drift to
serious injury and significant 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.
Specifications.
1 Raise the primary boom to a horizontal position.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 25

8 Support and slide the extension cylinder out of 4-5

the upper pivot.
Platform Leveling
Crushing hazard. The extension
cylinder could fall when removed
Master Cylinder
from the extension boom if not
properly supported. The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop
Component damage hazard. Be that keeps the platform level through the entire
careful not to damage the range of boom motion. The master cylinder is
counterbalance valves on the located at the base of the primary boom.
primary boom extension cylinder
when removing the cylinder from How to Remove the Platform
the primary boom.
Leveling Master Cylinder
Component damage hazard. Hoses
and cables can be damaged if the
primary boom extension cylinder is
dragged across them.
Note: Note the length of the cylinder after removal. be torqued to specification during installation. Refer
The cylinder must be at the same length for to Section 2, Hydraulic Hose and Fitting Torque
installation. Specifications.
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.
squirt or spray.
4 - 26 Z-45/25 • Z-45/25J Part No. 219418

3 Attach overhead crane or similar lifting device to

the master cylinder.
master cylinder barrel-end pivot pin.
5 Place a rod through the barrel-end pivot pin and
6 Remove the pin retaining fastener from the rod-
end pivot pin.
7 Place a rod through the rod-end pivot pin and
8 Remove the master cylinder from the machine.
Crushing hazard. The master
and fall if not properly attached to
the overhead crane.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 27

Secondary Boom Components

a b c
h d
f
Secondary Boom components
a upper secondary boom

(number 1 arm)
b upper tension link
(number 2 arm)
c lower tension link
(number 3 arm)
d mid-pivot
e compression link
f secondary boom lift cylinder (2)
g lower secondary boom
(number 4 arm)
h turntable pivot
i boom rest
j upper pivot
4 - 28 Z-45/25 • Z-45/25J Part No. 219418

SECONDARY BOOM COMPONENTS
5-1 3 Remove the primary boom. See 4-2, How to

Remove the Primary Boom.
Secondary Boom
4 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder.
How to Disassemble the
Secondary Boom 5 Attach a lifting strap from an overhead crane to
the lug on the rod end of the primary boom lift
Bodily injury hazard. The cylinder. Then raise the primary boom lift
procedures in this section require cylinder with the crane, to a vertical position.
specific repair skills, lifting
6 Tag, disconnect and plug the hydraulic hoses at
equipment and a suitable
the primary boom lift cylinder. Cap the fittings
workshop. Attempting this
on the cylinder.
tools could result in death or Bodily injury hazard. Spraying
serious injury and significant hydraulic oil can penetrate and
component damage. Dealer burn skin. Loosen hydraulic
service is required. connections very slowly to allow
Follow the disassembly steps to the point required
gradually. Do not allow oil to squirt
to complete the repair. Then re-assemble the
or spray.
secondary boom by following the disassembly
steps in reverse order. 7 Remove the pin retaining fastener from the
primary boom lift cylinder barrel-end pivot pin.
the O-ring (if equipped) on the fitting and/or the 8 Use a slide hammer to remove the pin. Remove
hose end must be replaced. All connections must the primary boom lift cylinder from the machine.
boom lift cylinder could become
Specifications.
1 Remove the platform. supported by the overhead crane.
2 Z-45/25J: Remove the jib boom.

See 3-1, How to Remove the Jib Boom.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 29

9 Tag, disconnect and plug the hydraulic hoses 15 Repeat steps 11 through 14 for the other
on both of the secondary boom lift cylinders. secondary boom lift cylinder.
Cap the fittings on the cylinders.
Crushing hazard. The secondary
Bodily injury hazard. Spraying boom lift cylinder could become
hydraulic oil can penetrate and unbalanced and fall when removed
burn skin. Loosen hydraulic from the machine if not properly
connections very slowly to allow attached to the overhead crane.
Component damage hazard. When
removing a secondary boom lift
or spray.
cylinder from the machine, be
10 Remove the pin retaining fasteners from both careful not to damage the
sides of the secondary boom lift cylinder rod- counterbalance valve at the barrel
end pivot pin and barrel-end pivot pin. Do not end of the cylinder.
remove the pins.
16 Attach a lifting strap from an overhead crane to
11 Attach a strap from an overhead crane to the lug the upper pivot for support. Do not lift it.
on the rod end of one of the secondary boom lift
17 Attach a lifting strap from a second overhead
cylinders for support. Do not apply any lifting
crane to the number 1 arm at the mid-point
pressure.
between the upper pivot and mid-pivot.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
number 1 arm pivot pins at the mid-pivot and
the secondary boom lift cylinder and let it hang
the upper pivot. Do not remove the pins.
down.
19 Use a soft metal drift to drive both pins out.
pin half way out.
14 Remove the secondary boom lift cylinder from
the machine.
4 - 30 Z-45/25 • Z-45/25J Part No. 219418

20 Remove the number 1 arm from the machine. 25 Pull all of the hoses and cables out of the upper
pivot and out through the mid-pivot. Lay the
Crushing hazard. The number 1
hoses and cables on the ground.
arm could become unbalanced and
fall when removed from the Component damage hazard.
machine if not properly attached to Cables and hoses can be
the overhead crane. damaged if they are kinked or
pinched.
Crushing hazard. The upper pivot
could fall when the number 1 arm 26 Remove the pin retaining fastener from the
is removed from the machine if not number 2 arm pivot pin at the upper pivot. Use a
properly supported by the overhead soft metal drift to remove the pin.
crane.
27 Remove the upper pivot from the machine.
21 Using the overhead crane attached to the upper
Crushing hazard. The upper pivot
pivot, raise the secondary boom assembly
approximately 30 inches / 76 cm.
when removed from the machine if
22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block not properly attached to the
between the number 2 arm and the boom rest. overhead crane.
Then lower the secondary boom assembly onto
28 Attach the lifting strap from an overhead crane
the block.
to the number 2 arm at the upper pivot end.
Crushing hazard. The secondary
29 Raise the number 2 arm slightly and remove the
boom assembly could fall if not
4 x 4 x 11 inch / 10 x 10 x 28 cm block.
properly supported by the
4 x 4 x 11 inch / 10 x 10 x 30 Lower the number 2 arm onto the boom rest pad.
28 cm block.
31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
23 Pull all of the cables and hoses out through the block between the number 3 arm and the
upper pivot. number 4 arm at the mid-pivot end.
Component damage hazard. 32 Attach a lifting strap from the overhead crane to
Cables and hoses can be the mid-pivot for support. Do not lift it.
damaged if they are kinked or
pinched. 33 Remove the pin retaining fasteners from the
number 2, 3 and 4 arm pivot pins at the
24 Remove the hose and cable covers from the top mid-pivot. Do not remove the pins.
of the number 2 arm.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 31

34 Use a soft metal drift to drive each pin out. Then 40 Remove the number 2 arm from the machine.
remove the mid-pivot from the secondary boom
assembly.
Crushing hazard. The mid-pivot fall when removed from the
could become unbalanced and fall secondary boom assembly if not
when removed from the secondary properly supported by the overhead
boom assembly if not properly crane.
supported by the overhead crane.
41 Remove the upper and lower hose and cable
35 Attach the lifting strap from an overhead crane covers from the number 3 arm.
to the center point of the number 2 arm for
42 Pull all of the cables and hoses from the number
support. Do not lift it.
3 arm and lay them over the turntable
36 Remove the pin retaining fasteners from both counterweight.
compression link pivot pins. Do not remove the
pins.
Cables and hoses can be
37 Use a soft metal drift to remove the lower damaged if they are kinked or
compression link pivot pin at the number 3 arm. pinched.
38 Support the compression link with an appropriate 43 Open the ground controls side turntable cover.
lifting device.
44 Remove the fuel tank filler cap.
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.
arm could fall when the
compression link is disconnected
from the number 2 arm if not
properly supported by the overhead
crane.
Crushing hazard. The compression
link may fall if not properly
supported when removed from the
secondary boom assembly.
4 - 32 Z-45/25 • Z-45/25J Part No. 219418

45 Using an approved hand-operated pump, drain 48 Remove the retaining fastener from the ground
the fuel tank into a container of suitable control box and function manifold pivot plate.
capacity. Refer to Section 2, Specifications.
49 Lower the ground control box and function
Explosion and fire hazard. Engine manifold pivot plate to access the number 3 arm
fuels are combustible. Perform this 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.
fire extinguisher within easy reach. 51 Remove the mounting fasteners from the cover
located in the boom storage area to access the
Explosion and fire hazard. When
number 3 and number 4 arm pivot pin retaining
transferring fuel, connect a
fasteners at the turntable riser.
grounding wire between the
machine and pump or container. 52 Remove the pin retaining fasteners from the
number 3 arm at the turntable riser. Do not
Note: Be sure to only use a hand-operated pump
remove the pin.
suitable for use with gasoline and diesel fuel.
53 Use a slide hammer to remove the number 3
46 Tag, disconnect and plug the fuel hoses from
arm pivot pin from the turntable pivot through
the fuel tank. Clean up any fuel that may have
the access hole behind the ground control box.
spilled.
54 Remove the number 3 arm from the machine.
47 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the Crushing hazard. The number 3
machine. arm could become unbalanced and
fall when removed from the
machine if not properly supported
fuel tank is plastic and may
by the overhead crane.
become damaged if allowed to fall.
Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 33

55 Remove the upper and lower hose and cable 5-2

covers from the number 3 arm.
Secondary Boom Lift Cylinders
56 Remove the secondary boom drive speed limit
switch mounting fasteners from the number 4 There are two secondary boom lift cylinders
arm at the mid-pivot end. Do not disconnect the incorporated in the structure of the secondary boom
wiring. assembly. These cylinders operate in parallel and
57 Remove the pin retaining fasteners from the require hydraulic pressure to extend and retract.
number 4 arm at the turntable riser. Do not Each secondary boom lift cylinder is equipped with
remove the pin. a counterbalance valve to prevent movement in the
event of a hydraulic line failure.
58 Attach a lifting strap from the overhead crane to
the center point of the number 4 arm. Do not How to Remove a Secondary
lift it.
Boom Lift Cylinder
59 Use a slide hammer to remove the number 4
arm from the turntable riser through the ground Bodily injury hazard. This
controls side bulkhead. procedure requires specific repair
skills, lifting equipment and a
60 Remove the number 4 arm from the machine. suitable workshop. Attempting this
fall when removed from the
machine if not properly supported
by the overhead crane.
Specifications.
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 - 34 Z-45/25 • Z-45/25J Part No. 219418

3 Tag, disconnect and plug the hydraulic hoses 8 Remove the secondary boom lift cylinder from
on the secondary boom lift cylinder. the machine.
Bodily injury hazard. Spraying Crushing hazard. The secondary
hydraulic oil can penetrate and boom lift cylinder could become
burn skin. Loosen hydraulic unbalanced and fall when removed
connections very slowly to allow from the machine if not properly
the oil pressure to dissipate attached to the overhead crane.
or spray.
removing a secondary boom lift
4 Remove the pin retaining fasteners from the cylinder from the machine, be
secondary boom lift cylinder rod-end pivot pin careful not to damage the
and barrel-end pivot pin. Do not remove the counterbalance valve at the barrel
pins. end of the cylinder.
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.
pin half way out.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 35

Engines
6-1 6-3
RPM Adjustment - Deutz Flex Plate
D2011L03i Models
The flex plate acts as a coupler between the engine
Refer to Maintenance Procedure B-9, Check and and the pump. It is bolted to the engine flywheel
Adjust the Engine RPM - Deutz D2011L03i. and has a splined center to drive the pump.
How to Remove the Flex Plate

1 Disconnect the battery cables from the battery.
6-2
RPM Adjustment - with electrically charged circuits
Perkins 404D-22 Models could result in death or serious
Refer to Maintenance Procedure A-13, Check and and other jewelry.
Adjust the Engine RPM - Perkins 404D-22 Models. 2 Disconnect the electrical connectors at the
electrical proportional controller, located on the
drive pump.
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.
4 - 36 Z-45/25 • Z-45/25J Part No. 219418

ENGINES
5 Carefully pull the pump and bell housing away 9 Remove the muffler bracket mounting fasteners
from the engine and secure it from moving. from the bell housing. Carefully remove the
muffler and bracket assembly from the engine.
can be damaged if they are kinked 10 Support the engine with an overhead crane or
or pinched. other suitable lifting device. Do not lift it.
6 Remove the flex plate mounting fasteners, 11 Remove the engine mounting plate to bell
then remove the flex plate from the engine housing fasteners.
flywheel.
12 Raise the engine slightly using the overhead
Ford models: crane and place a block of wood under the oil
pan for support.
3 Support the drive pump assembly with an
overhead crane or other suitable lifting device. 13 Remove all of the engine bell housing retaining
Do not apply any lifting pressure. fasteners.
4 Remove the drive pump retaining fasteners. 14 Carefully remove the bell housing from the
engine.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate. 15 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
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.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 37

ENGINES
How to Install the Flex Plate 1

1 Install the flex plate onto the engine flywheel
with the rubber vibration isolators towards the 3
6
pump.
2 Apply Loctite® removable thread sealant to the
flex plate fasteners and loosely install the
fasteners.
3 Deutz models: Torque the flex plate mounting 4 5
bolts in sequence to 28 ft-lbs / 38 Nm.
Then torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm. 2
Ford and Perkins models: Torque the flex Ford models
plate mounting bolts in sequence to
6 1
14 ft-lbs / 19 Nm. Then torque the flex plate
mounting bolts in sequence to 20 ft-lbs / 27 Nm.
4 Apply a high viscosity coupling grease
(Genie part number 128025) to the splines of the
pump shaft and flex plate. 4 3
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
2 5
Deutz models
6 3
4 5
2
Perkins models
4 - 38 Z-45/25 • Z-45/25J Part No. 219418

ENGINES
How to install the Pump and Bell 6

1 B
Housing Assembly B
3
A
1 Install the pump and bell housing assembly.
Deutz models: Torque the bell housing
mounting bolts labeled "C" in sequence to 28 ft- A
4
lbs / 38 Nm. Then torque the bell housing
mounting bolts labeled "C" in sequence to 40 ft-
lbs / 54 Nm. C C
7 B 5
Ford models: Torque the bell housing mounting 2
bolts labeled "A" and "B" in sequence to 28 ft-
lbs / 38 Nm and the mounting bolts labeled "C" Ford models
to 49 ft-lbs / 66 Nm. Then torque the bell
housing mounting bolts labeled "A" and "B" in 6 1
sequence to 40 ft-lbs / 54 Nm and the mounting
10 C C 8
bolts labeled "C" to 70 ft-lbs / 95 Nm.
C C
Perkins models: Torque the bell housing
mounting bolts labeled "B" in sequence to 4
C
3
28 ft-lbs / 38 Nm and the mounting bolts labeled C
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
housing mounting bolts labeled "B" in sequence
C C
to 40 ft-lbs / 54 Nm and the mounting bolts 11 12
labeled "A" to 70 ft-lbs / 95 Nm.
C C
7 C C 5
installing the pump, do not force
the pump coupler into the flexplate
2 9
or damage to the pump shaft seal
may occur. Deutz models
Component damage hazard. Do

not force the drive pump during 6 1
installation or the flex plate teeth A A
may become damaged.
9
B
B
4 5
B
B B
8 B B 7
2 3
Perkins models
Part No. 219418 Z-45/25 • Z-45/25J 4 - 39

ENGINES
6-4 6-5
Ford MSG-425 Engine Engine Fault Codes -
Fault Codes Deutz D 2.9 L4 and
Perkins 404F-22 Models
How to Retrieve Engine Fault
Codes How to Retrieve Engine Fault
The ECM constantly monitors the engine by the Codes
use of sensors on the engine. The ECM also uses The ECM constantly monitors the engine by the
signals from the sensors to initiate sequential fuel use of sensors on the engine. The ECM also uses
injection and make constant and instantaneous signals from the sensors to initiate sequential fuel
changes to ignition timing, fuel delivery and throttle injection and make constant and instantaneous
position to maintain the engine's running condition changes to ignition timing, fuel delivery and throttle
at its highest efficiency while at the same time position to maintain the engine's running condition
keeping exhaust emissions to a minimum. When a at its highest efficiency while at the same time
sensor fails or returns signals that are outside of keeping exhaust emissions to a minimum. When a
set parameters, the ECM will store a fault code in sensor fails or returns signals that are outside of
memory that relates to the appropriate sensor and set parameters, the ECM will store a fault code in
will turn on the Check Engine Light. memory that relates to the appropriate sensor. One
Refer to Section 5, How to Retrieve Ford MSG-425 or more fault LED's will illuminate on the display
Engine Fault Codes for your specific model of located at the ground control box. The active fault
engine. Use the Fault Code Chart within Section 5 code will also be displayed on the LCD screen.
to aid in identifying the fault. If a fault occurs that does not result in an engine
shutdown, the engine rpm will go into limp home
mode resulting in the loss of high rpm.
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.
4 - 40 Z-45/25 • Z-45/25J Part No. 219418

Hydraulic Pumps
7-1 2 Tag, disconnect and plug the lift/steer pump
hydraulic hoses. Cap the fittings on the pump.
Lift/Steer Pump
How to Remove the burn skin. Loosen hydraulic
Lift/Steer Pump connections very slowly to allow
When removing a hose assembly or fitting, the O-
ring (if equipped) on the fitting and/or the hose end
squirt or spray.
must be replaced. All connections must be torqued
to specification during installation. Refer to 3 Remove the pump mounting bolts. Carefully
Section 2, Hydraulic Hose and Fitting Torque remove the pump.
Specifications.
Component damage hazard. Be
1 Locate the two hydraulic tank valves at the sure to open the two hydraulic tank
hydraulic tank through the access hole valves and prime the pump after
underneath the turntable. Close the valves. installing the pump.

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 closed
Part No. 219418 Z-45/25 • Z-45/25J 4 - 41

HYDRAULIC PUMPS
7-2 2 Locate the two hydraulic tank valves at the

hydraulic tank through the access hole
Drive Pump underneath the turntable. Close the valves.
The drive pump is a bi-directional variable Component damage hazard. The

displacement piston pump. The pump output is engine must not be started with the
controlled by the electro-proportional controller, hydraulic tank shut-off valves in
located on the pump. The only adjustment that can the closed position or component
be made to the pump is the neutral or null damage will occur. If the tank
adjustment. Any internal service to the pump valves are closed, remove the key
should only be performed at an authorized Eaton from the key switch and tag the
Hydraulics center. Call Genie Service Department machine to inform personnel of the
to locate your local authorized service center. condition.
How to Remove the Drive Pump

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 open closed
damage. Dealer service is
recommended. 3 Tag and disconnect and plug the hydraulic
hoses from the drive and lift/steer pumps. Cap
Note: When removing a hose assembly or fitting, the fittings on the pumps.
hose end must be replaced. All connections must Bodily injury hazard. Spraying
be torqued to specification during installation. Refer hydraulic oil can penetrate and
to Section 2, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Disconnect the electrical connectors at the gradually. Do not allow oil to
electrical proportional controller located on the squirt or spray.
drive pump.
4 - 42 Z-45/25 • Z-45/25J Part No. 219418

HYDRAULIC PUMPS
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.
hydraulic pump may become
supported.
installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 43

HYDRAULIC PUMPS
How to Prime the Pump 5 Have another person crank the engine with the
starter motor for 15 seconds, wait 15 seconds,
1 Connect a 0 to 600 psi / 0 to 41 bar pressure then crank the engine an additional 15 seconds
gauge to the test port on the drive pump. or until the pressure reaches 320 psi / 22 bar.
2 Remove the safety pin from the engine pivot 6 Ford models: Connect the LPG hose to the
plate latch. LPG tank and open the valve on the tank.
Note: The engine pivot plate latch is located under Perkins 404D-22 models: Connect the engine
the engine turntable pivot plate at the counterweight wiring harness to the fuel solenoid.
end of the machine.
Deutz D2011 L03i models: Release the manual
3 Open the engine pivot plate latch and swing the fuel shutoff valve.
7 Start the engine from the ground controls and
machine.
check for hydraulic leaks.
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 404D-22 models: Disconnect the
engine wiring harness from the fuel solenoid at
the injector pump.
Deutz D2011 L03i models: Hold the manual
fuel shutoff valve clockwise to the closed
position.
a manual fuel shutoff valve
4 - 44 Z-45/25 • Z-45/25J Part No. 219418

Part No. 219418 Z-45/25 • Z-45/25J 4 - 45

Manifolds
8-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque
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
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
solenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm
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, 5 psi / 0.3 bar ............... BT ......... Differential sensing circuit,
secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm
13 Check valve, 5 psi / 0.3 bar ............... BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm
14 Check valve, 5 psi / 0.3 bar ............... BS ......... Differential sensing circuit,
secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve,
2.0 gpm / 7.6 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm
16 Relief valve, 3200 psi / 221 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, 5 psi / 0.3 bar ............... BQ ........ Differential sensing circuit,
turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5 psi / 0.3 bar ............... CB ........ Differential sensing circuit,
primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5 psi / 0.3 bar ............... BC ........ Differential sensing circuit,
platform rotate left and
jib boom up .................................................. 25 ft-lbs / 34 Nm
4 - 46 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
1 2 3 4 5 6 7 8
BM CG BZ CA BY BG BP BU
BJ
33
BI
32
CC BF
31 9
BL BV
30 10
BK
29
CF
11
BH
28
BN
27
BE
26
CE
25
BT
BR 12
24
CD
23
BX
22
BW
13
BD BC CB BQ BO BA BB BS
21 20 19 18 17 16 15 14
Part No. 219418 Z-45/25 • Z-45/25J 4 - 47

MANIFOLDS
Function Manifold Components, continued

Index Schematic
21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit,
platform rotate right and
jib boom down ............................................. 25 ft-lbs / 34 Nm
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
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, 5 psi / 0.3 bar ............... BK ......... Differential sensing circuit,
platform level up ............................... 12-14 ft-lbs / 16-19 Nm
30 Check valve, 5 psi / 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 - 48 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
1 2 3 4 5 6 7 8
BM CG BZ CA BY BG BP BU
BJ
33
BI
32
CC BF
31 9
BL BV
30 10
BK
29
CF
11
BH
28
BN
27
BE
26
CE
25
BT
BR 12
24
CD
23
BX
22
BW
13
BD BC CB BQ BO BA BB BS
21 20 19 18 17 16 15 14
Part No. 219418 Z-45/25 • Z-45/25J 4 - 49

MANIFOLDS
8-2 How to Adjust the Secondary

Valve Adjustments - Boom Down Relief Valve
Function Manifold Note: Perform this procedure with the boom in the
stowed position.
How to Adjust the System 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
Relief Valve gauge to the TEST1 port on the function manifold.
Note: Perform this procedure with the boom in the 2 Start the engine from the ground controls.
stowed position.
3 Hold the function enable switch to the high rpm
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure position and activate and hold the secondary
gauge to the TEST1 port on the function manifold. 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
3 Hold the function enable switch to the high rpm gauge. Refer to Section 2, Specifications.
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. 6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
5 Turn the engine off. Use a wrench to hold the decrease the pressure. Install the relief valve
relief valve and remove the cap (item BA). cap.
6 Adjust the internal hex socket. Turn it clockwise Tip-over hazard. Do not adjust
to increase the pressure or counterclockwise to the relief valve higher than
decrease the pressure. Install the relief valve specified.
cap.
7 Repeat steps 2 through 5 and recheck relief
Tip-over hazard. Do not adjust valve pressure.
the relief valve higher than
specified. 8 Remove the pressure gauge.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
4 - 50 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
8-3
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
Part No. 219418 Z-45/25 • Z-45/25J 4 - 51

MANIFOLDS
8-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function
1 Counterbalance valve ...................... L ............ Turntable rotate right

2 Counterbalance valve ...................... J ............ Turntable rotate left
1 2
L J
4 - 52 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
8-5
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather .......................................... 20-25 ft-lbs / 27-33 Nm
2 Spool valve ....................................... CH ........ Directional control
CH 2
Part No. 219418 Z-45/25 • Z-45/25J 4 - 53

MANIFOLDS
How to Set Up the Directional 7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
Valve Linkage the machine is completely level.
Note: Adjustment of the oscillate directional valve 8 Verify that the ground and drive chassis are
linkage is only necessary when the linkage or valve completely level.
has been replaced.
9 Adjust the ball joint until the hole lines up with
1 Lower the boom to the stowed position. the retaining fastener hole in the bracket.
2 Use a "bubble type" level to be sure the floor is 10 Install the ball joint to the axle and tighten the
completely level. jam nut.
Tip-over hazard. Failure to perform 11 Check to be sure the drive chassis is
this procedure on a level floor completely level.
could compromise the stability of
the machine resulting in the 12 Measure the distance between the drive chassis
machine tipping over. and the non-steer axle on both sides (from the
inside of the drive chassis).
3 Check the tire pressure in all four tires and add
air if needed to meet specification. Note: If the distance is not equal and the
adjustment to the linkage was completed with the
Note: The tires on some machines are foam-filled ground and drive chassis level, repeat steps 6
and do not need air added to them. through 11 OR consult Genie Service Department.
4 Remove the drive chassis cover and the non-
steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 Remove the ball joint retaining fastener from the
bracket.
4 - 54 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
Part No. 219418 Z-45/25 • Z-45/25J 4 - 55

MANIFOLDS
8-6
Traction Manifold Components, 2WD
The traction manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index Schematic
1 Flow divider/combiner valve ............. AA ......... Controls flow to drive motors
in forward and reverse ..................... 25-30 ft-lbs / 34-41 Nm
2 Orifice, 0.067 in / 1.70 mm ................ AB ......... Drive circuit
3 Shuttle valve, 3 position 3 way ......... AC ........ 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
4 Check valve ....................................... AD ........ Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
5 Relief valve, 250 psi / 17.2 bar ......... AE ......... Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
6 Solenoid valve, 2 position 3 way ...... AF ......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
7 Solenoid valve, 2 position 3 way ...... AG ........ Braking ............................................. 10-12 ft-lbs / 14-16 Nm
8 Check valve ....................................... AH ........ Drive circuit ....................................... 25-30 ft-lbs / 34-41 Nm
9 Check valve ....................................... AI .......... 2-speed motor shift circuit ................ 25-30 ft-lbs / 34-41 Nm
10 Orifice, 0.030 in / 0.76 mm ................ AJ ......... Brake circuit
4 - 56 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
1 2 3
AA AB AC
AD 4
AE 5
10 AJ AF 6
9 AI
AG 7
8 AH
Part No. 219418 Z-45/25 • Z-45/25J 4 - 57

MANIFOLDS
8-7 8 Start the engine and move and hold the function
enable/rpm select toggle switch to the high rpm
Valve Adjustments, 2WD (rabbit symbol) position.
Traction Manifold 9 Adjust the internal hex socket until the pressure
reading on the gauge is 40 psi / 2.8 bar less
How to Adjust the Charge than the pressure reading on the pump. Turn it
Pressure Relief Valve clockwise to increase the pressure or
counterclockwise to decrease the pressure.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure Install the valve cap.
gauge to the test port on the drive pump.
10 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
remove the cap (item AE).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 Start the engine and move and hold the function
(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 AE).
4 - 58 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
Part No. 219418 Z-45/25 • Z-45/25J 4 - 59

MANIFOLDS
8-8
Traction Manifold Components, 4WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Flow divider/combiner valve ............. AA ......... Controls flow to flow
divider/combiner valves 2 and 4 ...... 25-30 ft-lbs / 34-41 Nm
2 Flow divider/combiner valve ............. AB ......... Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
3 Orifice, 0.047 in / 1.2 mm .................. AC ........ Drive circuit
4 Flow divider/combiner valve ............. AD ........ Controls flow to steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
5 Orifice, 0.040 in / 1.02 mm ................ AE ......... Drive circuit
6 Check valve ....................................... AF ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
7 Solenoid valve, 2 position 3 way ...... AG ........ Braking ............................................. 10-12 ft-lbs / 14-16 Nm
8 Relief valve, 250 psi / 17.2 bar ......... AH ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
9 Solenoid valve, 2 position 3 way ...... AI .......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
10 Check valve ....................................... AJ ......... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... AK ......... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
12 Check valve ....................................... AL ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
13 Check valve ....................................... AM ........ Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
14 Check valve ....................................... AN ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm
15 Orifice, 0.030 inch / 0.76 mm ............ AO ........ Brake circuit
16 Check valve ....................................... AP ......... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
17 Shuttle valve, 3 position 3 way ......... AQ ........ 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
18 Orifice, 0.040 in / 1.01 mm ................ AR ........ Drive circuit
4 - 60 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
1 2 3 4
AA AB AC AD
AR
18
AE 5
AF 6
17 AQ
16 AP
15 AO AG 7
14 AN AH 8
AI 9
AJ 10
AK 11
AL 12
AM
13
Part No. 219418 Z-45/25 • Z-45/25J 4 - 61

MANIFOLDS
8-9 8 Start the engine and move and hold the function
Valve Adjustments, 4WD (rabbit symbol) position.
Traction Manifold 9 Adjust the internal hex socket until the pressure
reading on the gauge is 40 psi / 2.8 bar less
How to Adjust the Charge than the pressure reading on the pump. Turn it
Pressure Relief Valve clockwise to increase the pressure or
counterclockwise to decrease the pressure.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure Install the valve cap.
gauge to the test port on the drive pump.
10 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
remove the cap (item AH).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 Start the engine and move and hold the function
(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 AH).
4 - 62 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
8-10
Hydraulic Generator Manifold Components, 2.2kW
The generator manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
1 Proportional solenoid valve ................. HH ........ Generator speed ........................... 33-37 ft-lbs / 45-50 Nm
2 Relief valve, 3000 psi / 207 bar ........... GG ........ Generator circuit ........................... 20-25 ft-lbs / 27-34 Nm
HH
1
GG
2
Part No. 219418 Z-45/25 • Z-45/25J 4 - 63

MANIFOLDS
8-11 How to Test a Coil Diode

Valve Coils Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
How to Test a Coil Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
A properly functioning coil provides an to a coil. Faulty diodes can fail to protect the
electromotive force which operates the solenoid electrical system, resulting in a tripped circuit
valve. Critical to normal operation is continuity breaker or component damage.
within the coil that provides this force field.
Electrocution/burn hazard. Contact with electrically charged circuits
with electrically charged circuits could result in death or serious
could result in death or serious injury. Remove all rings, watches
injury. Remove all rings, watches and other jewelry.
and other jewelry.
1 Test the coil for resistance. See, How to Test a
1 Tag and disconnect the wiring from the coil to be Coil.
tested.
2 Connect a 10Ω resistor to the negative terminal
2 Test the coil resistance. of a known good 9V DC battery. Connect the
Result: The resistance should be within other end of the resistor to a terminal on the
coil.
specification, plus or minus 30%.
Result: If the resistance is not within Ω
Resistor, 10Ω
specification, plus or minus 30%, replace the Genie part number 27287
coil.
Valve Coil Resistance Specification

Note: The battery should read 9V DC or more when
measured across the terminals.
Proportional directional solenoid valve, 10V DC 6 to 8Ω
(schematic items BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω

(schematic items BF, BM and CG)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω

(schematic items CA, CC, AF, AG and AI)
4 - 64 Z-45/25 • Z-45/25J Part No. 219418

MANIFOLDS
6 At the battery or coil terminals, reverse the

COIL connections. Note and record the current
a
d
MULTI reading.
METER
Result: Both current readings are greater than
c - 0 mA and are different by a minimum of 20%.
The coil is good.
+ b
10 W 9V Result: If one or both of the current readings are
RESISTOR BATTERY 0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
+
c - b internal diode are faulty and the coil should be

replaced.
a multimeter
b 9V DC battery
c 10Ω resistor
d coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6
3 Set a multimeter to read DC current.

Note: 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.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 65

Turntable Rotation Components

9-1 2 Secure the turntable from rotating with the
turntable rotation lock.
Turntable Rotation Assembly
Tip-over hazard. The machine
could tip over when the turntable
How to Remove the Turntable rotation assembly is removed if the
Rotation Assembly turntable rotation lock is not in the
locked position.
Specifications.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine
off.
Unlocked position
Locked position
4 - 66 Z-45/25 • Z-45/25J Part No. 219418

TURNTABLE ROTATION COMPONENTS
3 Remove the safety pin from the engine pivot 7 Attach a lifting strap from and overhead crane or
plate latch. other suitable lifting device to the turntable
rotator assembly.
the engine turntable pivot plate at the counterweight 8 Remove the turntable rotation assembly
end of the machine. mounting fasteners.
4 Remove the center turntable cover retaining 9 Carefully remove the turntable rotation assembly
fasteners. Remove the center turntable cover from the machine.
from the machine. Tip-over hazard. The machine
5 Open the engine pivot plate latch and swing the could tip over when the turntable
engine pivot plate out and away from the rotation assembly is removed if the
machine. turntable rotation lock is not in the
locked position.
from the turntable rotation motor manifold. Cap Crushing hazard. The turntable
the fittings on the manifold. rotation assembly could become
unbalanced and fall when removed
Bodily injury hazard. Spraying from the machine if not properly
hydraulic oil can penetrate and supported by the overhead crane.
or spray.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 67

Axle Components
10-1 How to Install the Hub and
Hub and Bearings, 2WD Models Bearings, 2WD Models
Note: When replacing a wheel bearing, both the
How to Remove the inner and outer bearings including the pressed-in
Hub and Bearings, 2WD Models races must be replaced.
1 Loosen the wheel lug nuts. Do not remove them. 1 Be sure that both bearings are packed
with clean, fresh grease.
2 Block the non-steer wheels and place a lifting
jack of ample capacity under the steer axle. 2 Place the large inner bearing into the rear
of the hub.
3 Raise the machine 6 inches / 15 cm and place
blocks under the chassis for support. 3 Press the bearing seal evenly into the hub
until it is flush.
Crushing hazard. The machine
may fall if not properly supported. 4 Slide the hub onto the yoke spindle.
4 Remove the lug nuts. Remove the tire and wheel Component damage. Do not
assembly. apply excessive force or damage
to the lip of the seal may occur.
5 Remove the dust cap, cotter pin and
castle nut. 5 Place the outer bearing into the hub.
Note: Always use a new cotter pin when installing a 6 Install the washer and castle nut.
castle nut.
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to
6 Pull the hub off the spindle. The washer and seat the bearing.
outer bearing should fall loose from the hub. 8 Fully loosen the castle nut, then re-tighten to
7 Place the hub on a flat surface and gently pry 8 ft-lbs / 11 Nm.
the bearing seal out of the hub. 9 Install a new cotter pin. Bend the cotter pin
8 Remove the rear bearing. to secure the castle nut.
Note: 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.
4 - 68 Z-45/25 • Z-45/25J Part No. 219418

AXLE COMPONENTS
10-2 1 Tag, disconnect and plug the oscillating axle

cylinder hydraulic hoses. Cap the fittings on the
Oscillating Axle Cylinders oscillate cylinder.
The oscillating axle cylinders extend and retract Bodily injury hazard. Spraying
between the drive chassis and the oscillating axle. hydraulic oil can penetrate and
The cylinders are equipped with counterbalance burn skin. Loosen hydraulic
valves to prevent movement in the event of a connections very slowly to allow
hydraulic line failure. The valves are not adjustable. the oil pressure to dissipate
How to Remove an Oscillating or spray.
Axle Cylinder 2 Remove the pin retaining fasteners from the
rod-end pivot pin. Use a soft metal drift to
Note: Perform this procedure on a firm, level remove the pin.
surface with the boom in the stowed position.
3 Attach a lifting strap from an overhead crane to
Note: When removing a hose assembly or fitting, the barrel end of the oscillating cylinder.
hose end must be replaced. All connections must 4 Remove the pin retaining fasteners from the
be torqued to specification during installation. Refer barrel-end pivot pin. Use a soft metal drift to
to Section 2, Hydraulic Hose and Fitting Torque remove the pin.
Specifications. Crushing hazard. The oscillate
cylinder may become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
5 Remove the oscillate cylinder from the machine.
Part No. 219418 Z-45/25 • Z-45/25J 4 - 69

4 - 70 Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Repair any machine damage or malfunction with electrically charged circuits
before operating the machine. could result in death or serious
Unless otherwise specified, perform each and other jewelry.
repair procedure with the machine in the
following configuration: Note: Two persons may be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Turntable rotated with the boom between
the non-steer wheels
rotation lock
key removed
• Wheels chocked
from the machine
Part No. 219418 Z-45/25 • Z-45/25J 5-1

Section 5 • Fault Codes August 2013
Control System Fault Codes
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once per
Fault Codes second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
At least one fault code is present when the alarm at
the platform controls produces two short beeps Note: When the red LED is flashing the code, the
every 30 seconds for 10 minutes. yellow LED will be on solid.
Perform this procedure with the engine off, the key 4 Determine the error type: The yellow LED
switch turned to platform controls and the red indidates the error type and will flash two
Emergency Stop button pulled out to the on separate codes. The first code will indicate the
position at both the ground and platform controls. first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
1 Open the platform control box lid. flash the second digit once per 0.5 second.
Electrocution/burn hazard. Contact Note: When the yellow LED is flashing the code,
with electrically charged circuits the red LED will be on solid.
could result in death or serious
injury. Remove all rings, watches 5 Use the fault code table on the following pages
and other jewelry. 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.
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. 219418

Error Source Error Type Condition Solution

ID Name ID Name
21 Primary Up / Down 11 Value at 5V Function is Cycle power off,
Joystick 12 Value too high inoperative. then on after
15 Value too low Alarm sounds problem has been
16 Value at 0V indicating a fault. corrected.
17 Not calibrated Calibrate joystick.

22 Primary 21 Fault Valve is operating Cycle power off,
Up / Down outside of limits. then on after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
23 Primary 12 Value too high Valve is operating Cycle power off,
Up / Down 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been
indicating a fault. corrected.
17 Not calibrated Normal function Calibrate valve

except threshold threshold.
for one or both
directions is zero.
24 Angle sensor 11 Value at 5V Reduced speed Cycle power off,
12 Value too high function. then on after
15 Value too low Alarm sounds problem has been
17 Not calibrated Calibrate angle sensor.
31 Invalid setup Initiate 1 -second Calibrate angle sensor.

beep of Alarm Buzzer
and required retract
into safe envelope
Part No. 219418 Z-45/25 • Z-45/25J 5-3


ID Name ID Name
26 Angle sensor 19 Out of range Reduced speed, Power up controller with
cross check required retract into problem corrected
safe envelope
31 Primary 11 Value at 5V Function is Cycle power off,
Ext. / Ret. 12 Value too high inoperative. then on after
Joystick 15 Value too low Alarm sounds problem has been

32 Primary 21 Fault Valve is operating Cycle power off,
Ext. / Ret. outside of limits. then on after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
33 Primary 12 Value too high Valve is operating Cycle power off,
Ext. / Ret. 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been

for one or both
directions is zero.
34 Ext. Ret. 31 Invalid setup Initiate 1-second beep Fully retract, then lower
Limit Switch of Alarm Buzzer boom
-1000lb. Mode: Check and service ext/

Required retract into ret and fully stowed
“FULLY RETRACTED” switches
state before lowering
-500lb. Mode:
Operates normally
5-4 Z-45/25 • Z-45/25J Part No. 219418


ID Name ID Name
41 Turntable 11 Value at 5V Limited speed Cycle power off,
Rotate 12 Value too high and direction then on after
Joystick 15 Value too low frozen at zero problem has been
16 Value at 0V and neutral. corrected.
Alarm sounds
indicating a fault.

42 Turntable 21 Fault Limited direction. Cycle power off,
Rotate Frozen at zero then on after
Directional and neutral. problem has been
Valves Alarm sounds corrected.
indicating a fault.
43 Turntable 12 Value too high Limited speed Cycle power off,
Rotate 15 Value too low and direction. then on after
Flow Valve Frozen at zero problem has been
and neutral. corrected.
Alarm sounds
indicating a fault.

for one or both
directions is zero.
44 Drive Enable 21 Fault Drive enable Cycle power off,
Override override direction then on after
Switch is frozen at problem has been
neutral. corrected.
Part No. 219418 Z-45/25 • Z-45/25J 5-5


ID Name ID Name
45 Platform Level Switch 21 Fault Platform level Power up controller with
frozen at neutral problem corrected
46 Primary Extend/Retract 21 Fault Platform Ext/Ret Power up controller with

Switch frozen at neutral problem corrected
51 Drive Joystick 11 Value at 5V Limited speed Cycle power off,

12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.

53 Drive Flow 12 Value too high Limited speed Cycle power off,
Valve (EDC) 15 Value too low and direction. then on after
Frozen at zero problem has been
Alarm sounds
indicating a fault.

for one or both
directions is zero.
5-6 Z-45/25 • Z-45/25J Part No. 219418


ID Name ID Name
54 Drive Brake 21 Fault Drive frozen Cycle power off,
Valve at zero and then on after
neutral. problem has been
Alarm sounds corrected.
indicating a fault.
55 High Drive 21 Fault Motor speed Cycle power off,
Motor Speed in the low state. then on after
Valve Alarm sounds problem has been
56 Platform Level Value 21 Fault Direction frozen at Power up controller with
zero and neutral, AB problem corrected
57 Foot switch/ECU 12 Value too high Direction frozen at Power up controller with
Power Crosscheck 15 Value too low zero and neutral, AB problem corrected
61 Steer Joystick 11 Value at 5V Limited speed Cycle power off,
12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.

62 Steer 21 Fault Limited speed Cycle power off,
Directional and direction. then on after
Valve Frozen at zero problem has been
Alarm sounds
indicating a fault.
Part No. 219418 Z-45/25 • Z-45/25J 5-7

Fault Code Display -

Deutz D 2.9 L4 and Perkins 404F-22 Models
How to Retrieve Active Engine With an active fault and the engine running:
(preferred method)
Fault Codes
1 At the ground controls, activate the auxiliary
The ECM constantly monitors the engine by the pump toggle switch to shut the engine off.
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel Note: Do not push in the red Emergency Stop
injection and make constant and instantaneous button or turn the key switch to the off position.
changes to ignition timing, fuel delivery and throttle
3 Press any soft key below the display.
position to maintain the engine's running condition
at its highest efficiency while at the same time 4 Use the scroll up / down keys to check for
keeping exhaust emissions to a minimum. When a multiple engine fault codes.
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in With the engine not running:
memory that relates to the appropriate sensor. One 1 At the ground controls, turn the key switch to
or more fault LED's will illuminate on the display ground controls and pull out the red Emergency
located at the ground control box. The active fault Stop button.
code will also be displayed on the LCD screen.
2 Navigate to the Active Fault Menu and use the
Note: The Perkins 404F-22 is equipped with an scroll up / down keys to check for multiple
engine fault LED located at the platform control engine fault codes.
box.
If an engine fault occurs that does not result in an Any Soft Key
engine shutdown, the engine rpm will go into limp
Next Menu Next Menu Main Menu
home mode resulting in the loss of high rpm.
When operating from the platform, if the red

Emergency Stop button is pushed in, the active Main Menu Note: Use the Scroll
Up/Down buttons to
fault code(s) will be erased from the display. Basic Setup move the Select icon.
Diagnostics Press the Select button
Start the engine from the ground control box and Screen Setup to enter that menu
operate various boom functions to verify that an System setup option.
active engine fault occurs and is shown on the
display. Diagnostics Fault Menu
Note: All faults are stored in the Previous Fault System Info Active Faults
history menu. These faults will not be erased when Fault Log Previous Faults
corrective action has been completed. Device List
Quick Data
Currently Active Faults

SPN: FMI: OC:
5-8 Z-45/25 • Z-45/25J Part No. 219418


Flashing and Solid LED's
1 4
2 5
3 6
1 Left green LED:

Flashing, engine fault detected. Contact service.
Solid, fault acknowledged. Contact service.
2 Left amber LED: (Perkins models)
Solid,
a) Regeneration is inhibited. No service required.
b) High exhaust temperature during regeneration mode. No service required.
3 Left red LED:
Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact
service.
4 Right green LED:
Solid, fault acknowledged. Contact service.
5 Right amber LED: (Perkins models)
Solid with left amber LED on solid, regeneration has been inhibited and engine soot level is between
80 - 100%. Regeneration is required.
Flashing with left amber LED on solid, regeneration has been inhibited and soot level is between
100 - 140%. Engine rpm is de-rated. Regeneration is required.
Flashing with left and right red LED's flashing, engine soot level over 140%. Engine shut down. Contact
service.
6 Right red LED:
Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact
service.
Part No. 219418 Z-45/25 • Z-45/25J 5-9


Soft Key Functions and Icons
1 2 3 4
1 Next menu • Exit / Back one screen • Decrease brightness (-)

2 Brightness / Contrast • Scroll up • Increase • Increase brightness (+)
3 Regeneration forced • Scroll down • Decrease • Decrease contrast (-)
4 Regeneration inhibited • Select / Next • Main menu • Increase contarst (+)
Next Menu Brightness/ Initiate Inhibit

Contrast Switch Switch
Exit / Back Scroll Scroll Select

One Screen Up Down
Main Hour Oil Coolant

Menu Meter Pressure Temp.
Soot V
Engine Soot Level Voltage Pin #

RPM Percent (%) Protected
5 - 10 Z-45/25 • Z-45/25J Part No. 219418


Main Menu Structure
Any Soft Key
Next Menu Brightness/Contrast Regeneration Regeneration

Forced Inhibit
Next Menu Scroll Up Scroll Down Main Menu
V Soot Main Menu Note: Use the Scroll

Hour Engine Soot Up/Down buttons to
Voltage move the Select icon.
Meter RPM Level (%) Basic Setup
Diagnostics Press the Select button
Screen Setup to enter that menu
Oil Coolant System setup option.
Pressure Temp.
Basic Setup Diagnostics Screen Setup System Setup

Note: The following
menu items should only
PIN Code PIN Code be accessed by a
Time / Date System Setup trained service
**** ****
technician.
Language Fault Log Screen Setup System Setup
Parameters Reset Defaults

Number of Screens CAN
Units Device List Select Screen Display
PIN Setup
Trip Reset
Quick Data
Part No. 219418 Z-45/25 • Z-45/25J 5 - 11

Deutz D 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number / FMI - Failure Mode Identifier / KWP = Keyword Protocol
SPN FMI KWP Description SPN FMI KWP Description
51 3 1019 EGR-Valve, short 51 6 1022 Actuator error EGR-Valve;
circuit to battery signal range check high
51 3 1024 Position sensor error of 51 6 1224 Actuator EGR-Valve;
actuator EGR-Valve; over current
signal range check high
51 6 1230 Actuator error EGR-Valve;
51 3 1226 EGR-Valve; short Overload by short-circuit
circuit to battery (A02)
51 7 1016 Actuator position for EGR-
51 3 1227 EGR-Valve; short circuit to Valve not plausible
battery (A67)
51 4 1020 EGR-Valve; short circuit Power stage over temp
to ground due to high current
51 4 1025 Position sensor error actuator 51 12 1018 Actuator EGR-Valve;
EGR-Valve; signal range powerstage over temperature
check low
51 12 1021 Mechanical actuator defect
51 4 1228 EGR-Valve; short circuit to EGR-Valve
ground (A02)
51 12 1225 Actuator EGR-Valve;
51 4 1229 EGR-Valve; short circuit to over temperature
ground (A67)
94 1 474 Low fuel pressure; warning
51 4 1232 Actuator error EGR-Valve; threshold exceeded
Voltage below threshold
94 1 475 Low fuel pressure; shut off
51 5 1015 Actuator error EGR-Valve; threshold exceeded
signal range check low
94 3 472 Sensor error low fuel pressure;
51 5 1017 Actuator EGR-Valve; open load signal range check high
51 5 1023 Actuator error EGR-Valve; 94 4 473 Sensor error low fuel pressure;
signal range check low signal range check low
51 5 1223 Actuator EGR-Valve; open load 97 3 464 Sensor error water in fuel;
signal range check high 97 4 465 Sensor error water in fuel;
97 12 1157 Water in fuel level prefilter;
maximum value exceeded
5 - 12 Z-45/25 • Z-45/25J Part No. 219418

100 0 734 High oil pressure; warning 108 3 412 Sensor error ambient air
threshold exceeded press.; signal range check high
100 0 735 High oil pressure; shut off 108 4 413 Sensor error ambient air
threshold exceeded press.; signal range check low
100 1 736 Low oil pressure; warning 110 0 98 High coolant temperature;
threshold exceeded warning threshold exceeded
100 1 737 Low oil pressure; shut off 110 0 99 High coolant temperature; shut
threshold exceeded off threshold exceeded
100 3 732 Sensor error oil pressure; signal 110 3 96 Sensor error coolant
range check high temp.; signal range check high
100 4 733 Sensor error oil pressure 110 4 97 Sensor error coolant
sensor; signal range check low temp.; signal range check low
102 2 88 Charged air pressure above 111 1 101 Coolant level too low
warning threshold
132 11 1 Air flow sensor load correction
102 2 89 Charged air pressure above factor exceeding the maximum
shut off threshold drift limit; plausibility error
102 4 777 Sensor error charged air 132 11 2 Air flow sensor load correction
press.; signal range check low factor exceeding drift limit;
plausibility error
105 0 996 High charged air cooler
temperature; warning 132 11 3 Air flow sensor low idle
threshold exceeded correction factor exceeding the
maximum drift limit
105 0 997 High charged air cooler
temperature; shut off 132 11 4 Air flow sensor load correction
threshold exceeded factor exceeding the maximum
drift limit
105 3 994 Sensor error charged air
temperature; signal range 157 3 877 Sesnor error rail pressure;
check high signal range check high
105 4 995 Sensor error charged air 157 4 878 Sensor error rail pressure;
temperature; signal range signal range check low
check low
Part No. 219418 Z-45/25 • Z-45/25J 5 - 13

168 0 1180 Physical range check high for 174 0 481 High low fuel temperature;
battery voltage warning threshold exceeded
168 1 1181 Physical range check low for 174 0 482 High Low fuel temperature; shut
battery voltage off threshold exceeded
168 2 47 High battery voltage; warning 175 0 740 Physical range check high for
threshold exceeded oil temperature
168 2 48 Low battery voltage; warning 175 0 745 High oil temperature; warning
threshold exceeded threshold exceeded
168 3 45 Sensor error battery voltage; 175 0 746 High oil temperature; shut off
signal range check high threshold exceeded
168 4 46 Sensor error battery voltage; 175 1 741 Physical range check low for oil
signal range check low temperature
171 3 417 Sensor error environment 175 2 738 Sensor oil temperature;
temperature; signal range plausibility error
check high
175 2 739 Sensor oil temperature;
171 4 418 Sensor error environment plausibility error
temperature; signal range oil temperature too high
check low
175 3 743 Sensor error oil temperature;
172 0 1182 Physical range check high for signal range check high
intake air temperature
175 4 744 Sensor error oil temperature;
172 1 1183 Physical range check low for signal range check low
intake air temperature
190 0 389 Engine speed above warning
172 2 9 Sensor ambient air threshold (FOC-Level 1)
temperature; plausibility error
190 2 421 Offset angle between crank-
172 2 983 Intake air sensor; plausibility and camshaft sensor is
error too large
172 3 981 Sensor error intake air; signal 190 8 419 Sensor camshaft speed;
range check high disturbed signal
172 4 982 Sensor error intake air sensor;
5 - 14 Z-45/25 • Z-45/25J Part No. 219418

190 8 422 Sensor crankshaft speed; 412 3 1007 Sensor error EGR cooler
disturbed signal downstream temperature;
190 11 390 Engine speed above warning
threshold (FOC-Level 2) 412 4 1008 Sensor error EGR cooler
downstream temperature;
190 12 420 Sensor camshaft speed; no signal range check low
signal
520 9 306 Timeout Error of CAN-Receive-
190 12 423 Sensor crankshaft speed; no Frame TSC1TR; Setpoint
signal
597 2 49 Break lever mainswitch and
190 14 391 Engine speed above warning break lever redundancyswitch
threshold (Overrun Mode) status not plausible
190 14 1222 Camshaft- and Crankshaft 624 3 971 SVS lamp; short circuit to batt.
speed sensor signal not
available on CAN 624 4 972 SVS lamp; short circuit to grd.
411 0 791 Physical range check high for 624 5 969 SVS lamp; open load
differential pressure
Venturiunit (EGR) 624 12 970 SVS lamp; powerstage
over temperature
411 1 792 Physical range check low for
differential pressure 630 12 376 Access error EEPROM
Venturiunit (EGR) memory (delete)
411 3 795 Sensor error differential 630 12 377 Access error EEPROM
pressure Venturiunit (EGR); memory (read)
630 12 378 Access error EEPROM
411 4 381 Physical range check low for memory (write)
EGR differential pressure
639 14 84 CAN-Bus 0 "BusOff-Status"
411 4 796 Sensor error differential
651 3 580 Injector 1 (in firing order);
pressure Venturiunit (EGR);
short circuit
651 4 586 High side to low side short
circuit in the injector 1
(in firing order)
Part No. 219418 Z-45/25 • Z-45/25J 5 - 15

651 5 568 Injector 1 (in firing order); 677 3 956 Starter relay high side;
interruption of electric short circuit to battery
connection
677 3 960 Starter relay low side; short
652 3 581 Injector 2 (in firing order); circuit to battery
short circuit
677 4 957 Starter relay high side; short
652 4 587 High side to low side short circuit to ground
(in firing order) 677 4 961 Starter relay low side; short
circuit to ground
interruption of 677 5 958 Starter relay; no load error
electric connection
677 12 959 Starter relay; powerstage over
653 3 582 Injector 3 (in firing order); temperature
short circuit
703 3 426 Engine running lamp; short
653 4 588 High side to low side short circuit to battery
703 4 427 Engine running lamp; short
(in firing order)
circuit to ground
703 5 424 Engine running lamp; open load
interruption of
electric connection 703 12 425 Engine running lamp;
powerstage over temperature
short circuit 729 5 545 Cold start aid relay open load
654 4 589 High side to low side short 729 12 547 Cold start aid relay; over
circuit in the injector 4 temperature error
(in firing order)
654 5 571 Injector 4 (in firing order); Frame TSC1TE; Setpoint
interruption of
electric connection 1079 13 946 Sensor supply voltage monitor
1 error (ECU)
676 11 543 Cold start aid relay error.
1080 13 947 Sensor supply voltage monitor
676 11 544 Cold start aid relay open load 2 error (ECU)
5 - 16 Z-45/25 • Z-45/25J Part No. 219418

1109 2 121 Engine shut off demand ignored 1180 1 1463 Exhaust gas temperature
upstream turbine; shut off
1136 0 1398 Physikal range check high for threshold exceeded
ECU temperature
1180 3 1067 Sensor error exhaust gas
1136 1 1399 Physikal range check low for temperature upstream turbine;
ECU temperature signal range check high
1136 3 1400 Sensor error ECU temperature; 1180 11 1066 Sensor exhaust gas
signal range check high temperature upstream turbine;
plausibility error
1136 4 1401 Sensor error ECU temperature;
signal range check low 1188 2 1414 Wastegate; status message
from ECU missing
1176 3 849 Sensor error pressure sensor
upstream turbine; signal 1188 7 1415 Wastegate actuator; blocked
range check high
1188 11 1411 Wastegate actuator;
1176 4 850 Sensor error pressure sensor internal error
downstream turbine; signal
range check high 1188 11 1412 Wastegate actuator; EOL
calibration not
1180 0 1193 Physical range check high for performed correctly
exhaust gas temperature
upstream turbine 1188 11 1416 Wastegate actuator; over
temperature (> 145°C)
1180 0 1460 Turbocharger Wastegate CAN
feedback; warning threshold 1188 11 1417 Wastegate actuator; over
exceeded temperature (> 135°C)
1180 0 1462 Exhaust gas temperature 1188 11 1418 Wastegate actuator; operating
upstream turbine; warning voltage error
threshold exceeded
1188 13 1413 Wastegate actuator calibration
1180 1 1194 Physical range check low for deviation too large,
exhaust gas temperature recalibration required
upstream turbine
1231 14 85 CAN-Bus 1 "BusOff-Status"
1180 1 1461 Turbocharger Wastegate CAN
feedback; shut off threshold 1235 14 86 CAN-Bus 2 "BusOff-Status"
exceeded
Part No. 219418 Z-45/25 • Z-45/25J 5 - 17

1237 2 747 Override switch; 2798 4 1338 Injector diagnostics; timeout
plausibility error error of short circuit to ground
measurement cyl. Bank 1
1322 12 610 Too many recognized misfires
in more than one cylinder 2798 4 1339 Injector diagnostics; short
circuit to ground monitoring
1323 12 604 Too many recognized misfires Test in Cyl. Bank 0
in cylinder 1 (in firing order)
2798 4 1340 Injector diagnostics; short
1324 12 605 Too many recognized misfires circuit to ground monitoring
in cylinder 2 (in firing order) Test in Cyl. Bank 1
1325 12 606 Too many recognized misfires 3224 2 127 DLC Error of CAN-Receive-
in cylinder 3 (in firing order) Frame AT1IG1 NOX Sensor
(SCR-system upstream cat;
1326 12 607 Too many recognized misfires
DPF-system downstream cat);
in cylinder 4 (in firing order)
length of frame incorrect
2659 0 1524 Physical range check high for
EGR exhaust gas mass flow
Frame AT1IG1;
2659 1 1525 Physical range check low for NOX sensor upstream
EGR exhaust gas mass flow
3248 4 1047 Sensor error particle filter
2659 2 1523 Exhaust gas recirculation AGS downstream temperature;
sensor; plausibility error signal range check low
2659 2 1527 AGS sensor temperature 3699 2 1616 DPF differential pressure
exhaust gas mass flow; sensor and a further sensor or
plausibility error actuator CRT system defective
2659 12 1526 Exhaust gas recirculation; AGS 3699 2 1617 Temperature sensor us. and
sensor has "burn off" ds. DOC simultaneously defect
not performed
3699 14 1615 Maximum stand-still-duration
2797 4 1337 Injector diagnostics; timeout reached; oil exchange required
error of short circuit to ground
4765 0 1039 Physical range check high for
measurement cyl. Bank 0
upstream (DOC)
4765 1 1042 Physical range check low for
upstream (DOC)
5 - 18 Z-45/25 • Z-45/25J Part No. 219418

4766 0 1029 Physical range check high for 523008 2 649 Timeout error in Manipulation
exhaust gas temperature control
downstream (DOC)
523009 9 825 Pressure Relief Valve (PRV)
4766 1 1032 Physical range check low for reached maximun allowed
exhaust gas temperature opening count
downstream (DOC)
523009 10 833 Pressure relief valve (PRV)
4768 2 1036 Sensor exhaust gas reached maximun allowed
temperature upstream (DOC); open time
plausibility error
4768 3 1044 Sensor error exhaust gas Frame ComEngPrt;
temperature upstream (DOC); Engine Protection
4768 4 1045 Sensor error exhaust gas Frame PrHtEnCmd; pre-heat
temperature upstream (DOC); command, engine command
523240 9 179 Timeout CAN-message
4769 2 1026 Sensor exhaust gas FunModCtl;
temperature downstream Function Mode Control
(DOC); plausibility error
523350 4 565 Injector cylinder-bank 1;
4769 3 1034 Sensor error exhaust gas short circuit
temperature downstream
(DOC); signal range check high 523352 4 566 Injector cylinder-bank 2;
short circuit
4769 4 1035 Sensor error exhaust gas
temperature downstream 523354 12 567 Injector powerstage output
(DOC); signal range check low defect
523006 3 34 Controller mode switch; short 523470 2 826 Pressure Relief Valve (PRV)
circuit to battery forced to open; performed by
pressure increase
523006 4 35 Controller mode switch; short
circuit to ground 523470 2 827 Pressure Relief Valve (PRV)
forced to open; performed by
523008 1 648 Manipulation control was pressure shock
triggered
Part No. 219418 Z-45/25 • Z-45/25J 5 - 19

523470 7 876 Maximum rail pressure in limp 523612 12 613 Internal ECU monitoring
home mode exceeded (PRV) detection reported error
523470 11 831 The PRV can not be opened at 523612 12 614 Internal ECU monitoring
this operating point with a detection reported error
pressure shock
523612 12 615 Internal ECU monitoring
523470 11 832 Rail pressure out of tolerance detection reported error
range
523470 12 828 Open Pressure Relief Valve detection reported error
(PRV); shut off condition
523470 12 829 Open Pressure Relief Valve detection reported error
(PRV); warning condition
523470 14 830 Pressure Relief Valve (PRV) is detection reported error
open
523550 12 980 T50 start switch active for detection reported error
too long
523601 13 948 Sensor supply voltage monitor detection reported error
3 error (ECU)
523603 9 126 Timeout Error of CAN-Receive- detection reported error
Frame AMB; Ambient
Temperature Sensor 523612 12 623 Internal ECU monitoring
detection reported error
Frame TSC1AE; 523612 12 624 Internal ECU monitoring
Traction Control detection reported error
523606 9 301 Timeout Error of CAN-Receive- 523612 12 625 Internal ECU monitoring
Frame TSC1AR; Retarder detection reported error
523612 12 387 Internal software error ECU; 523612 12 627 Internal ECU monitoring
injection cut off detection reported error
523612 12 612 Internal ECU monitoring 523612 12 628 Internal ECU monitoring
detection reported error detection reported error
5 - 20 Z-45/25 • Z-45/25J Part No. 219418

523612 12 637 Internal ECU monitoring 523615 3 596 Metering unit (Fuel-System);
detection reported error short circuit to battery low side
523612 12 1170 Internal software error ECU 523615 4 595 Metering unit (Fuel-System);
short circuit to ground high side
523612 14 973 Softwarereset CPU SWReset_0
523615 4 597 Metering Unit (Fuel-System);
523612 14 974 Softwarereset CPU SWReset_1 short circuit to ground low side
523612 14 975 Softwarereset CPU SWReset_2 523615 5 592 Metering unit (Fuel-System);
open load
523613 0 856 Maximum positive deviation of
rail pressure exceeded 523615 12 593 Metering unit (Fuel-System);
(RailMeUn0) powerstage over temperature
523613 0 857 Maximum positive deviation of 523619 2 488 Physical range check high for
rail pressure in metering unit exhaust gas temperature
exceeded (RailMeUn1) upstrem (SCR-CAT)
523613 0 858 Railsystem leakage detected 523698 11 122 Shut off request from
(RailMeUn10) supervisory monitoring function
523613 0 859 Maximum negative deviation of 523717 12 125 Timeout Error of CAN-Transmit-
rail pressure in metering unit Frame AmbCon;
exceeded (RailMeUn2) Weather environments
523613 0 860 Negative deviation of rail 523718 3 1488 SCR mainrelay; short circuit to
pressure second stage battery (only CV56B)
(RailMeUn22)
523718 4 1489 SCR mainrelay; short circuit to
523613 0 862 Maximum rail pressure ground (only CV56B)
exceeded (RailMeUn4)
523718 5 1486 SCR mainrelay; open load
523613 1 861 Minimum rail pressure (only CV56B)
exceeded (RailMeUn3)
523718 12 1487 SCR mainrelay; powerstage
523613 2 864 Setpoint of metering unit in over temperature (only CV56B)
overrun mode not plausible
523615 3 594 Metering unit (Fuel-System); Frame Active TSC1AE
short circuit to battery highside
Frame Passive TSC1AE
Part No. 219418 Z-45/25 • Z-45/25J 5 - 21

523768 9 283 Timeout Error of CAN-Receive- 523897 13 561 check of missing injector
Frame Active TSC1AR adjustment value programming
(IMA) injector 3 (in firing order)
Frame Passive TSC1AR 523898 13 562 check of missing injector
adjustment value programming
523770 9 285 Timeout Error of CAN-Receive- (IMA) injector 4 (in firing order)
Frame Passive TSC1DE
523910 6 1261 Air Pump; over current
Frame TSC1TE - active 523913 3 74 Sensor error glow plug control
diagnostic line voltage; signal
523777 9 292 Passive Timeout Error of CAN- range check high
Receive-Frame TSC1TE;
Setpoint 523913 4 75 Sensor error glow plug control
diagnostic line voltage; signal
523778 9 293 Active Timeout Errorof CAN- range check low
Receive-Frame TSC1TR
523914 3 78 Glow plug control; short circuit
523779 9 294 Passive Timeout Error of CAN- to battery
Receive-Frame TSC1TR
523914 4 79 Glow plug control; short circuit
523788 12 299 Timeout Error of CAN-Transmit- to ground
Frame TrbCH; Status
Wastegate 523914 5 76 Glow plug control; open load
523793 9 202 Timeout Error of CAN-Receive- 523914 5 1216 Glow plug control release line;
Frame UAA10; AGS sensor short circuit error
service message
523914 11 1217 Glow plug control; internal error
Frame UAA11; 523914 12 77 Glow plug control; powerstage
AGS sensor data over temperature
523895 13 559 Check of missing injector 523919 2 1378 Sensor air pump airpressure;
adjustment value programming plausibility error
523920 2 1379 Sensor exhaust gas back
523896 13 560 check of missing injector pressure burner;
adjustment value programming plausibility error
5 - 22 Z-45/25 • Z-45/25J Part No. 219418

523922 7 1262 Burner Shut Off Valve; 523936 12 169 Timeout Error of CAN-Transmit-
blocked closed Frame EEC3VOL2; Engine
send messages
523922 7 1264 Burner Shut Off Valve;
blocked open 523946 0 1158 Zerofuel calibration injector 1
(in firing order);
523929 0 109 Fuel Balance Control integrator maximum value exceeded
injector 1 (in firing order);
maximum value exceeded 523946 1 1164 Zerofuel calibration injector 1
(in firing order);
523929 1 115 Fuel Balance Control integrator minimum value exceeded
minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2
(in firing order);
(in firing order);
(in firing order);
(in firing order);
(in firing order);
(in firing order);
minimum value exceeded 523960 0 1011 Physical range check high for
EGR cooler downstream temp.
523935 12 168 Timeout Error of CAN-Transmit-
Frame EEC3VOL1; Engine
send messages
Part No. 219418 Z-45/25 • Z-45/25J 5 - 23

523960 0 1458 High exhaust gas temperature 524016 2 1259 Amount of air is not plausible to
EGR cooler downstream; pump speed
warning threshold exceeded
524016 2 1260 Calculated amount of air is not
523960 1 1012 Physical range check low for plausible to HFM reading
EGR cooler downstream temp.
524016 11 1258 HFM sensor; electrical fault
523960 1 1459 High exhaust gas temperature
EGR cooler downstream; shut 524021 11 1263 Burner fuel line pipe leak
off threshold exceeded behind Shut Off Valve
523980 14 1187 Bad quality of reduction 524024 11 1302 Deviation of the exhaust gas
agent detected temp. setpoint to actual value
downstream (DOC) too high
523981 11 918 Urea-tank without heating
function (heating phase) 524028 2 1431 CAN message PROEGRActr;
plausibility error
523982 0 360 Powerstage diagnosis disabled;
high battery voltage 524029 2 1432 Timeout Error of CAN-Receive-
Frame ComEGRActr - exhaust
523982 1 361 Powerstage diagnosis disabled; gas recirculation positioner
low battery voltage
524030 7 1440 EGR actuator; internal error
523988 3 1245 Charging lamp;
short circuit to battery 524031 13 1441 EGR actuator; calibration error
523988 4 1246 Charging lamp; 524032 2 1442 EGR actuator; status message
short circuit to ground "EGRCust" is missing
523988 5 1243 Charging lamp; open load 524033 7 1443 EGR actuator; due to overload
in Save Mode
523988 12 1244 Charging lamp; over temp.
524034 3 1438 Disc separator;
523998 4 1327 Injector cylinder bank 2 slave; short circuit to battery
short circuit
524034 4 1439 Disc separator;
523999 12 1328 Injector powerstage output short circuit to ground
Slave defect
524034 5 1436 Disc Separator; open load
524014 1 1254 Air pressure glow plug flush
line; below limit 524034 12 1437 Disc Separator;
powerstage over temperature
5 - 24 Z-45/25 • Z-45/25J Part No. 219418

524035 12 1341 Injector diagnostics; time out 524108 9 1669 Timeout error of CAN-
error in the SPI communication Transmit-Frame
ComEGRTVActr
524057 2 1505 Electric fuel pump; fuel
pressure build up error 524109 9 1679 Timeout error of CAN-
Receive-Frame
524097 9 1663 Timeout error of CAN-Transmit- ComRxEGRTVActr
Frame DPFBrnAirPmpCtl
524110 9 1670 Timeout error of CAN-
524098 9 1664 Timeout error of CAN-Transmit- Transmit-Frame
Frame ComDPFBrnPT ComETVActr
524099 9 1665 Timeout error of CAN-Transmit- 524111 9 1680 Timeout error of CAN-
Frame ComDPFC1 Receive-Frame
ComRxETVActr
524100 9 1666 Timeout error of CAN-Transmit-
Frame ComDPFHisDat 524112 9 1671 Timeout ComITVActr
Frame ComDPFTstMon Receive-Frame
ComRxITVActr
Receive-Frame 524114 9 1659 Timeout error of CAN-
ComRxDPFBrnAirPmpCtl Transmit-Frame A1DOC
524103 9 1675 Timeout error of CAN-Receive- 524115 9 1660 Timeout error of CAN-
Frame ComRxDPFBrnAirPmp Transmit-Frame AT1S
524104 9 1676 Timeout error of CAN-Receive- 524116 9 1661 Timeout error of CAN-
Frame ComRxDPFCtl Transmit-Frame SCR2
Frame ComEGRMsFlw Transmit-Frame SCR3
524106 9 1677 Timeout error of CAN- 524118 9 1672 Timeout error of CAN-
Receive-Frame Receive-Frame ComRxCM1
ComRxEGRMsFlw1
524107 9 1678 Timeout error of CAN- Receive-Frame
Receive-Frame ComRxCustSCR3
ComRxEGRMsFlw2
Part No. 219418 Z-45/25 • Z-45/25J 5 - 25

SPN FMI KWP Description
Receive-Frame
ComRxSCRHtDiag
Receive-Frame
ComRxTrbChActr
Receive-Frame
ComRxUQSens
Receive-Frame
ComSCRHtCtl
Receive-Frame
ComTxAT1IMG
Receive-Frame
ComTxTrbChActr
5 - 26 Z-45/25 • Z-45/25J Part No. 219418

Perkins 404F-22 Engine Fault Codes
SPN = Suspect Parameter Number / FMI - Failure Mode Identifier

SPN FMI Description SPN FMI Description
29 3 Accelerator Pedal Position 2: 172 3 Engine Air Inlet Temperature:
Voltage Above Normal Voltage Above Normal
29 4 Accelerator Pedal Position 2: 172 4 Engine Air Inlet Temperature:
Voltage Below Normal Voltage Below Normal
91 3 Accelerator Pedal Position 1: 190 0 Engine Speed : High- most severe (3)
Voltage Above Normal
190 8 Engine Speed : Abnormal Frequency,
91 4 Accelerator Pedal Position 1: Pulse Width or Period
Voltage Below Normal
558 3 Accelerator Pedal1 Low Idle Switch:
100 1 Engine Oil Pressure :Low- most Voltage Above Normal
severe (3)
558 4 Accelerator Pedal1 Low Idle Switch:
108 3 Barometric Pressure : Voltage Below Normal
638 6 Engine Fuel Rack Actuator:
108 4 Barometric Pressure : Current Above Normal
639 14 J1939 Network#1: Special Instruction
110 3 Engine Coolant Temperature :
Voltage Above Normal 723 3 Engine Speed Sensor #2:
Voltage Below Normal 723 4 Engine Speed Sensor #2:
High -least severe (1) 723 8 "Engine Speed Sensor#2:
Abnormal Frequency,
168 0 Battery Potential/ Power Input 1 : Pulse Width or “Period"
High- most severe (3)
723 10 Engine Speed Sensor #2:
168 3 Battery Potential/ Power Input 1: Abnormal Rate of Change
733 3 Engine Rack Position Sensor:
168 4 Battery Potential/ Power Input 1: Voltage Above Normal
733 4 Engine Rack Position Sensor:
Part No. 219418 Z-45/25 • Z-45/25J 5 - 27


1485 7 ECU Main Relay : 3242 15 "Particulate Trap Intake Gas Temp:
Not Responding Property High - least severe“(1)"
2840 11 ECU Instance: Other Failure Mode 3242 16 Particulate Trap Intake Gas Temp:
High-moderate severity (2)
2840 12 ECU Instance: Failure
3251 3 Particulate Trap Differential Pressure
2840 13 ECU Instance: Out of Calibration :Voltage Above Normal
2970 3 Accelerator Pedal 2 Low Idle Switch: 3251 4 Particulate Trap Differential Pressure
Voltage Above Normal :Voltage Below Normal
2970 4 Accelerator Pedal 2 Low Idle Switch: 3473 7 Aftertreatmert #1 Failed to Ignite:
Voltage Below Normal Not Responding Properly
3241 1 Exhaust Gas Temperature 1: 3473 11 Aftertreatmert #1 Failed to Ignite :
Low- most severe (3) Other Failure Mode
3241 3 Exhaust Gas Temperature 1: 3484 0 Aftertreatmert #1 Ignition :
Voltage Above Normal High-most severe (3)
Voltage Below Normal Voltage Above Normal
High- least severe (1) Voltage Below Normal
3241 16 Exhaust Gas Temperature 1: 3556 6 Aftertreatmert 1 Hydrocarbon
High- moderate severity (2) Doser 1: Current Above Normal
3242 1 "Particulate Trap Intake Gas Temp: 3610 3 "Diesel Particulate Filter Outlet
Low- most severe“(3)" Pressure Sensor 1:
Voltage “Above Normal"
3242 3 "Particulate Trap Intake Gas Temp:
Voltage Above “Normal" 3610 4 DieselParticulate Filter Outlet
Pressure Sensor 1:
3242 4 "Particulate Trap Intake Gas Temp:
Voltage Below “Normal"
5 - 28 Z-45/25 • Z-45/25J Part No. 219418


3713 7 DPF Active Regeneration Inhibited 4765 4 Aftertreatmert #1 Diesel Oxidation
Due to System Timeout: Catalyst Intake Gas Temperature:
Not Responding Properly Voltage Below Normal
3713 31 DPF Active Regeneration Inhibited 4765 15 Aftertreatmert #1Diesel Oxidation
Due to System Timeout Catalyst Intake Gas Temperature:
High-least severe (1)
3719 0 Particulate Trap #1 Soot Load
Percent: High- most severe (3) 4765 16 Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
3719 16 Particulate Trap #1 Soot Load High-moderate severity (2)
Percent: High-moderate severity (2)
5487 3 Aftertreatmert 1 Burner Unit
4016 6 High Current Auxiliary Power Relay Combustion Chamber Temperature:
1: Current Above Normal Voltage Above Normal
4201 3 Engine Speed Sensor #1: 5487 4 Aftertreatmert 1 Burner Unit
Voltage Above Normal Combustion Chamber Temperature:
Voltage Below Normal 6581 6 Aftertreatmert 1 Hydrocarbon
Doser 2 : Current Above Normal
4201 8 "Engine Speed Sensor #1:
Abnormal Frequency,
Pulse \Nidth, or “Period"
Abnormal Rate of Change
4765 1 Aftertreatmert #1 Diesel Oxidation
Low-most severe (3)
4765 3 Aftertreatmert #1 Diesel Oxidation
Part No. 219418 Z-45/25 • Z-45/25J 5 - 29

Ford MSG-425 Engine Fault Codes
Ford MSG-425 Engine Fault 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
Codes
Note: Before the fault codes are displayed, the
check engine light will blink a code 1-6-5-4 three
How to Retrieve Ford Engine times. After the fault codes, the check engine light
Fault Codes will blink a code 1-6-5-4 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 Note: If any fault codes are present, the ECM will
signals from the sensors to initiate sequential fuel blink a three digit code three times for each code
injection and make constant and instantaneous stored in memory. It will blink the first digit of a
changes to ignition timing, fuel delivery and throttle three digit code, pause, blink the second digit,
position to maintain the engine's running condition pause, and then blink the third digit. For example:
at its highest efficiency while at the same time the check engine light blinks 5 consecutive times,
keeping exhaust emissions to a minimum. When a blinks 3 times and then 1 time. That would indicate
sensor fails or returns signals that are outside of code 531.
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and Note: Once a fault code has been retrieved and the
will turn on the Check Engine Light. repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
Note: Perform this procedure with the key switch in How to Clear Engine Fault Codes from the ECM.
the off position.
How to Clear Engine Fault
1 Locate the run/test toggle switch on the side of
the ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
1 Open the engine side turntable cover and locate
3 Quickly activate and release the start toggle the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from the
4 Move and hold the run/test toggle switch to the battery for a minimum of 5 minutes.
test position.
Result: The check engine light should turn on. with electrically charged circuits
The check engine light should begin to blink. could result in death or serious
and other jewelry.
3 Connect the negative battery cable to the
battery.
5 - 30 Z-45/25 • Z-45/25J Part No. 219418

Code Description Code Description

16 Never crank synced at start 174 AL high gasoline bank2
91 FP low voltage 175 AL low gasoline bank2
92 FP high voltage 182 FT Gasoline Low Voltage
107 MAP Low Voltage 183 FT Gasoline High Voltage
108 MAP High Pressure 187 FT Gaseaous fuel low voltage
111 IAT higher than expected 1 188 FT Gaseaous fuel high voltage
112 IAT low voltage 217 ECT higher than expected 2
113 IAT high voltage 219 Max govern speed override
116 ECT higher than expected 1 221 TPS1 higher than TPS2
117 ECT/CHT Low Voltage 222 TPS2 low voltage
118 ECT/CHT High Voltage 223 TPS2 high voltage
121 TPS1 lower than TPS2 236 TIP Active
122 TPS1 low voltage 237 TIP Low Voltage
123 TPS1 high voltage 238 TIP High Voltage
127 IAT higher than expected 2 261 Injector Loop Open or Low-side
short to Ground
129 BP low pressure
262 Injector Coil Shorted
134 EGO open/lazy pre-cat 1
264 Injector Loop Open or Low-side
140 EGO open/lazy post-cat 1
short to Ground
154 EGO open/lazy pre-cat 2/post-cat 1 265 Injector Coil Shorted
160 EGO open/lazy post-cat 2 267 Injector Loop Open or Low-side
171 AL high gasoline bank1 short to Ground
172 AL low gasoline bank1
For further engine fault code troubleshooting and

diagnostic information, refer to the Ford MSG-425/
Ford DSG-423 EFI Diagnostic Manual (EDI part
number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic Manual

Part No. 219418 Z-45/25 • Z-45/25J 5 - 31


268 Injector Coil Shorted 301 Emissions/catalyst damaging misfire
270 Injector Loop Open or Low-side 302 Emissions/catalyst damaging misfire
short to Ground
303 Emissions/catalyst damaging misfire
273 Injector Loop Open or Low-side
short to Ground
274 Injector Coil Shorted 306 Emissions/catalyst damaging misfire
276 Injector Loop Open or Low-side 307 Emissions/catalyst damaging misfire

short to Ground 308 Emissions/catalyst damaging misfire
277 Injector Coil Shorted 326 Knock 1 Excessive Signal
279 Injector Loop Open or Low-side 327 Knock 1 sensor Open
short to Ground
331 Knock 2 Excessive Signal
332 Knock 2 sensor Open
282 Injector Loop Open or Low-
side short to Ground 336 Crank sync noise
283 Injector Coil Shorted 337 Crank loss
285 Injector Loop Open or Low-side 341 Cam sync noise

short to Ground 342 Cam loss
286 Injector Coil Shorted 420 Gasoline cat monitor
288 Injector Loop Open or Low-side 430 Gasoline cat monitor
short to Ground
524 Oil pressure low
562 Battery Voltage Low
563 Battery Voltage High

number 1080030).

5 - 32 Z-45/25 • Z-45/25J Part No. 219418


601 Flash checksum invalid 1122 FPP1/2 do not match each other or the IVS
604 RAM failure 1151 CL high LPG
606 COP failure 1152 CL low LPG
615 Start relay coil open 1153 CL high NG
616 Start relay control ground short 1154 CL low NG
617 Start relay coil short to power 1155 CL high gasoline bank1
627 Fpump relay coil open 1156 CL low gasoline bank1
628 FPump motor loop open or high-side 1157 CL high gasoline bank2
shorted to ground
1158 CL low gasoline bank2
628 Fpump relay control ground short
1161 AL high LPG
629 FPump motor high-side shorted to power
1162 AL low LPG
629 Fpump relay coil short to power
1163 AL high NG
642 5VE1 low voltage
1164 AL low NG
643 5VE1 high voltage
1165 LPG cat monitor
650 MIL open
1166 NG cat monitor
652 5VE2 low voltage
1171 Megajector delivery pressure
653 5VE2 high voltage higher than expected
685 Relay Coil Open 1172 Megajector delivery pressure
lower than expected
686 Relay Control ground short
1173 Megajector comm lost
687 Relay coil short to power
1174 Megajector voltage supply high
1111 Fuel rev limit
1175 Megajector voltage supply low
1112 Spark rev limit
1176 Megajector internal actuator fault detection
1121 FPP1/2 simultaneous voltages out of range

number 1080030).

Part No. 219418 Z-45/25 • Z-45/25J 5 - 33


1177 Megajector internal circuitry fault detection 1541 AUX analog PUD1 high
1178 Megajector internal comm fault detection 1542 AUX analog PUD1 low
1311 Misfire detected 1543 AUX analog PUD2 high
1312 Misfire detected 1544 AUX analog PUD2 low
1313 Misfire detected 1545 AUX analog PUD3 high
1314 Misfire detected 1551 AUX DIG1 high
1315 Misfire detected 1552 AUX DIG1 low
1317 Misfire detected 1554 AUX DIG2 low
1511 AUX analog PU1 high 1556 AUX DIG3 low
1512 AUX analog PU1 low 1561 AUX analog PD2 high
1513 AUX analog PU2 high 1562 AUX analog PD2 low
1514 AUX analog PU2 low 1563 AUX analog PD3 high
1515 AUX analog PD1 high 1564 AUX analog PD3 low
1516 AUX analog PD1 low 1611 5VE 1/2 simultaneous out of range
1517 AUX analog PU3 high 1612 RTI 1 loss
1518 AUX analog PU3 low 1613 RTI 2 loss
1521 CHT higher than expected 1 1614 RTI 3 loss
1522 CHT higher than expected 2 1615 A/D loss
1531 IVS/Brake/Trans-Park interlock failure 1616 Invalid interrupt
1621 Rx Inactive
1622 Rx Noise

number 1080030).

5 - 34 Z-45/25 • Z-45/25J Part No. 219418

August 2013 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
with electrically charged circuits
Observe and Obey: could result in death or serious
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules and General Repair Process
Operator's Manual on your machine.
Malfunction Identify Troubleshoot
Be sure that all necessary tools and test discovered symptoms
equipment are available and ready for use.
problem
still exists
Return to Inspect Perform

service and test repair
problem
solved
Part No. 219418 Z-45/25 • Z-45/25J 6-1

Section 6 • Schematics August 2013
Electrical Symbols Legend
FS1
BK BK
LS3
N.O.H.C. N.C.H.O. P3
WH Foot switch
Quick disconnect Limit switch
Horn button P1
terminal Coil, soleniod normally open
or relay PLATFORM
TB21 GROUND
KS1 SW3
N.O. Emergancy Stop button
T-circuits connect H1 normally closed
at terminal
Horn or alarm Key switch normally open
FAN
T-circuits connect SW1

N.O.
PR1 Hydraulic oil
FB
Coolant temperature cooling fan
Power relay switch, normally open
Flashing beacon
M2
Connection SW2
N.C.
no terminal TS2
Auxiliary pump
Oil pressure switch
START
ENGINE
G1
normally closed
510W
Gauge
Circuits crossing Resistor with
no connection ohm value
Toggle switch SPDT
HM Gauge sending unit
Diode Hour meter TS6 A B C

PULL IN
HOLD
Tilt sensor
DOWN LEVEL
UP
+
L3
PLATFORM
- Fuel or RPM soleniod

KS1
LED
Battery F1
Toggle switch DPDT
Key switch
25A
CB1 Coil with suppresion
Fuse with amperage
15A CR4
Circuit breaker N.O.
with amperage
Control relay contact
DiodeStarting aid: normally open (NO)
glow plug or
flame ignitor
6-2 Z-45/25 • Z-45/25J Part No. 219418

Hydraulic Symbols Legend
.035
Orifice with size Solenoid operated 3 position,
Solenoid operated 3 position, 4 way, proportional
Filter with bypass 4 way, directional valve directional valve
relief valve
Check valve
2 position, 3 way, shuttle valve
200 psi
Pump, fixed displacement 13.8 bar Priority flow regulator valve
Reilief valve with
pressure setting
o Brake
Solenoid operated 2 position,

Pump, bi-directional Directional valve 3 way, directional valve
variable displacement (mechanically activated) Shut off valve
3000 psi
206.8 bar
3:1
50% 50%
Flow divider/combiner valve

Motor, bi-directional
Counterbalance valve with
pressure and pilot ratio
Pilot operated 3 position,

3 way, shuttle valve
Motor 2 speed
bi-directional 2 position, 2 way,
solenoid valve
E
Pump, prime mover
(engine or motor) Differential sensing valve
Pilot operated 2 position,

Double acting cylinder
2 way, directional valve
Solenoid operated
proportional valve
Part No. 219418 Z-45/25 • Z-45/25J 6-3

Electrical Abbreviations Legend
Item Description Item Description

B Battery H Horn or Alarm
B1 Engine Start - 12V DC H1 Tilt/load sense alarm
C Connector H4 Descent (ground)
C7 Power to platform, 12v cable H6 Load sense (ground)
connector JC Joystick
C9 Footswitch input connector JC1 Boom proportional joystick:
C54 Options connector secondary boom up/down
CB Circuit Breaker JC2 Boom proportional joystick:
primary up/down, turntable rotate
CB1 Circuit breaker, engine, 15a
JC3 Drive proportional joystick
CB2 Circuit breaker, controls, 15a
CB7 Circuit breaker, controls, 10a KS Keyswitch
Engine throttle solenoid KS1 Key switch
CR Control Relay L LED or Light
CR1 Start relay L1 Drive enable led
CR2 Ingition power relay L2 Check engine led
CR4 High idle relay L4 Platform overload led (ce only)
CR5 Horn relay L29 Drive lights
CR13 Jib relay (jib option) L48 Tilt alarm led (ansi/csa only)
CR14 Jib relay (jib option) LS Limit Switch
CR17 Hydraulic oil cooling fan (option) LS1 Primary boom extend
CR23 Drive light enable LS2 Primary boom up
CR27 Brake circuit relay (lift/drive option) LS3 Drive enable
CR30 Limit switch relay (lift/drive option) LS4 Secondary boom up
CR76 Load sense aux recovery (AS models) LS18 CE limit switch
CR51 Aircraft package (option)
G Gauge
G1 Battery Charge Indicator
G2 Engine oil pressure
G3 Engine coolant temp.
G4 Engine oil temp.
G6 Hour meter
6-4 Z-45/25 • Z-45/25J Part No. 219418

Item Description Item Description

M Motor TS Toggle Switch
M2 Auxiliary pump TS1 Auxiliary pump switch
M3 Engine starter TS2 Start engine switch
M4 Fuel pump TS3 Fuel select switch (ford efi only)
P Button TS4 Hi/low rpm switch
P1 Red emergency stop button TS6 Glow plug switch
P2 Emergency stop button TS7 Platform rotate switch
P3 Horn Button TS8 Jib rotate switch (jib option)
P4 Function enable button TS9 Platform level switch
TS13 Primary boom extend/retract switch
PR Power Relay TS14 Drive speed switch
PR1 Auxiliary pump (m2) TS15 Drive enable switch
PR2 Engine starter (m3) TS43 Heater switch (option)
PR3 Starting aid / glow plugs TS46 Proximity kill switch (option)
PR4 Function pump (m5) TS47 Generator switch (option)
R Resistor TS51 Auxiliary pump toggle switch
R4 Speed limiting variable resistor 20 ohms TS52 Engine start toggle switch
R14 Up/down speed resister 7.5 ohms TS53 Fuel select toggle switch
TS54 Rpm select toggle switch
SW Switch
TS56 Glow plug toggle switch
SW2 Engine oil pressure
TS57 Platform rotate toggle switch
SW3 Engine oil tempurature
TS58 Jib boom up/down toggle switch (option)
TS59 Platform level up/down toggle switch
TS60 Secondary boom up/down toggle switch
TS61 Primary boom up/down toggle switch
TS62 Turntable rotate toggle switch
TS63 Primary boom extend/retract toggle switch
TS64 Run/test toggle switch (Ford)
TS74 Run/test toggle switch (Deutz)
Part No. 219418 Z-45/25 • Z-45/25J 6-5

Item Description Wire Color Legend

U Module Item ................................ Description
U1 Ignition start module BL ........................................... Blue
U4 EDC - drive pump BK .......................................... Black
U13 Alc 500 joystick controller card BR .......................................... Brown
U18 Control module GN .......................................... Green
U33 Load sense module OR .......................................... Orange
U34 Time delay relay - 2 seconds, 10A PP .......................................... Purple
U35 Time delay relay RD .......................................... Red
U38 Time delay relay WH .......................................... White
U39 J1939 Ground Control Box Display YL ........................................... Yellow
X ALC500 connectors BL/RD ..................................... Blue/Red
X101 ALC500 power connector BL/WH .................................... Blue/White
X101 ALC500 input/out connectors BK/RD .................................... Black/Red
X102 ALC500 input/out connectors OR/WH ................................... Orange/White
X103 ALC500 input/out connectors RD/BK .................................... Red/Black
X104 ALC500 input/out connectors RD/WH .................................... Red/White
X105 ALC500 input/out connectors WH/BL .................................... White/Blue
X106 ALC500 input/out connectors WH/BK .................................... White/Black
X107 ALC500 input/out connectors WH/RD .................................... White/Red
X108 ALC500 input/out connectors WH/YL .................................... White/Yellow
X109 ALC500 input/out connectors YL/BK ..................................... Yellow/Black
X1-4 Circuit splice
6-6 Z-45/25 • Z-45/25J Part No. 219418

Ford Engine Relay Layout
Ford MSG-425 EFI
Power Fuel
Empty
Relay Pump
Relay
Starter
20A F1-10A F2-5A
Empty F3-10A F4-15A
Empty F5-15A F6-10A
F1 Battery voltage to EPR
F2 Ignition voltage to GCP and relays
F3 Battery voltage to GCP
F4 Fuel pump
F5 Battery voltage out of Power Relay
F6 Alternator
Part No. 219418 Z-45/25 • Z-45/25J 6-7

Engine Relay Layout -

Deutz D 2.9 L4 and Perkins 404F-22
C5 (GREY) Deutz D 2.9 L4

5A 5C
NOT USED
Fuses
F7 20A, Horn, Hydraulic oil cooler

F8 30A, ECU power
F17 15A, Ignition
F19 10A, Engine accessory
F17 F7 F8 F19 F20
F20 20A, Fuel pump
CR2B CR39B CR6 Relays

CR2B Ignition on
CR5B Horn
CR5B CR17B CR23B
CR6 Fuel pump
CR17B Hydraulic oil cooler (option)
D22 CR23B Engine accessory
CR39B Auxiliary pump
Diode
1D 1C 1B 1A 2D 2C 2B 2A
D22 6A, Alternator Ext.

1E 1F 1G 1H 2E 2F 2G 2H
C1 (BLUE) C2 (GREEN)
Perkins 404F-22
C6 (BLACK) C5 (GREY) Fuses
6A 6C 5A
F10 15A, Relay power

F11A 15A, ARD Injector 1
F11B 15A, ARD Injector 2
F11C 5A, Linear solenoid
F22C
F11C
F11A
F11B
F17
F12
F26
F10
F12 7.5A, Engine start

F17 10A, Fuel, Alternator Ext.
F22A 15A, Glow plug 1
F22B 20A, Glow plug 2
D22
F22A F22B CR15C CR1B

F22C 20A, ARD Glow plug
Relays
CR15A CR15B CR79 CR6
CR1B Engine start
CR6 Fuel, Alternator Ext.
CR15A Glow plug 1
CR15B Glow plug 2
CR15C ARD Glow plug
1D 1C 1B 1A 2D 2C 2B 2A CR79 Burner air pump
1E 1F 1G 1H 2E 2F 2G 2H
Diode
C1 (BLACK) C2 (GREY) D22 6A, Alternator Ext.
6-8 Z-45/25 • Z-45/25J Part No. 219418

Ford MSG-425 EFI Engine Wire Harness
6-9 6 - 10
Ford MSG-425 EFI Engine Wire Harness
A B C D E F G H I J K L M N
SPK_COIL1A 1 YELLOW/BLACK 18 YELLOW/BLACK 18

DK BLUE/ORANGE 18 GRAY/RED 18
SHD
A
SPK_COIL1B 2 WHITE/PINK 18 GRAY/RED 18 GRAY/LT BLUE 18
B HO2S #1
YELLOW/RED 18 BROWN/WHITE 18 RED 16
SPARK_COIL2A 3 YELLOW/RED 18
1 SPK_GND 4 BLACK/WHITE 16
DK GREEN/PURPLE 18
BLACK/LT GREEN 18
C
D GRAY/RED 18
SHD
A
SPK_COIL2B 5 DK GREEN/PURPLE 18 RED 16 RED 16 3 2 1
GRAY/YELLOW 18 B HO2S #2
RED 16
SPK_COIL3A 6 BLACK/LT BLUE 18
C
SPK_COIL3B 7 CAMSHAFT POSITION SENSOR D
TWR
UEGOS 8 GRAY/RED 18
LT GREEN/WHITE 18
A GASOLINE
UEGOC 9 2 1 BROWN/WHITE 18
B SENSOR
UEGOP 10 C INTERFACE
IGNITION COIL CYL #4 2 1 2 1 2 1 WHITE/LT GREEN 18 D
UEGPR 11 IGNITION COIL CYL #3 IGNITION COIL CYL #2 IGNITION COIL CYL #1
DK GREEN/ORANGE 18 MTRTWR4
AUX ANA PD1 12 DK GREEN/ORANGE 18
WHITE/LT GREEN 18
(FRP) AUX ANA PD2 13 WHITE/LT GREEN 18 DK GREEN/PURPLE 18
CAN1 + 14 DK GREEN/PURPLE 18 ORANGE/LT GREEN 18
CAN1 - 15 ORANGE/LT GREEN 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH GRAY/LT BLUE 18
CAN2 - 16
2 CAN2 +
AUX ANA PD3
17
18
GRAY/YELLOW 18
LT GREEN/RED 18
BROWN/WHITE 18
5V EXT 1 19 BROWN/WHITE 18
GRAY/RED 18 GRAY/RED 18
5V RTN 20 GRAY/RED 18
EGO1 21 GRAY/LT BLUE 18
EGO2 22 GRAY/YELLOW 18
MAP 23 LT GREEN/BLACK 18 CHT
BLACK/LT BLUE 18
AUX ANA PUD3 24 1 2
CRANK + 25 GRAY 18 BLACK/WHITE 16 GROUND
CRANK - 26 DK BLUE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH BLACK/WHITE 16 BLACK/WHITE 12 10MM
CAM + 27 GRAY/RED 18 BLACK/WHITE 16 RING
CAM - 28 DK BLUE/ORANGE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
SPEED + 29 DK GREEN/BLACK 18 TMAP SENSOR
SPEED - 30 LT BLUE/RED 18 F2
3 5V EXT 2
5V RTN 2
31
32
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
LT GREEN/BLACK 18
BROWN/WHITE 18
4 MAP
3 5V
RED/LT GREEN 18
5A
RED/LT GREEN 18
LT BLUE/RED 18 36 ROADSPEED -
GRAY 18 2 IAT F3
PULSE IN 33 GRAY/RED 18 1 5V RTN
VSW RED/TAN 14 RED 12 RED 14 DK GREEN/BLACK 18 35 ROADSPEED +
GOV 1 34 TAN/LT BLUE 18 10A
TAN/LT BLUE 18 24 GOV SELECT 1 C128RPM 24 OR/BK - LOW IDLE INPUT(12V)
OIL PRESS 35 DK GREEN/WHITE 18 ECM LT BLUE/BLACK 18 14 FPP1
IAT 36 GRAY 18 RED/LT GREEN 18 1 VSW R23BAT 1 WH - KEYSWITCH POWER(12V)
BLACK/YELLOW 18
ECT 37 LT GREEN/RED 18 BLACK/YELLOW 18 23 GOV SELECT 2 C35RPM 23 BK/RD - HIGH IDLE SWITCH INPUT(12V)
(FRT) AUX ANA PU1 38 LT GREEN/WHITE 18 DK BLUE/WHITE 18
DK GREEN/ORANGE 18 32 ANA AUX PD1
(LPTEMP) AUX ANA PU2 39 LT BLUE/YELLOW 18
DK BLUE/WHITE 18 37 AUX ANA PU2B
(IVS) AUX ANA PU3 40 BLACK/ORANGE 18 RED 14
LT BLUE/YELLOW 18 12 FPP2
(BRAKE) AUX DIG 3 41 WHITE/LT BLUE 18 BLACK/YELLOW 18
GRAY/RED 18 33 ANA RTN
(GOV2) AUX DIG 4 42 BLACK/YELLOW 18 RED 16
3 ALTERNATOR BROWN/WHITE 18 31 VREF
TACH 43 TAN/YELLOW 18 RED/LT GREEN 18
BLACK/ORANGE 18 25 IVS
WHITE 18
VSW 44 RED/LT GREEN 18 2 DK GREEN/WHITE 18 26 OIL PRES
4 AUX ANA PUD2 45 DK BLUE/WHITE 18 BATT+ RED 12
RED/TAN 18
1
TAN/YELLOW 18 2 TACH C41RPM 2 OR/BK - ENGINE SPEED (2 PULSES/REV)
AUX ANA PUD1 46 PURPLE/LT BLUE 18 1 2 PINK/LT GREEN 18 6 MIL C108ESL 6 BL/WH - DIAGNOSTIC LAMP OUTPUT(GND)
8MM
TPS 1 47 GRAY/WHITE 18 CRANK SENSOR
RING 500OHM, 3 WATT ORANGE/LT GREEN 18 39 AUX OUT1 C26TSR 39 WH/RD - COOLANT TEMP SENDER OUTPUT
TPS 2 48 YELLOW/WHITE 18 RED/TAN 18 YELLOW/DK BLUE 18 7 FUEL SELECT C39LP 7 BL/RD - FUEL SELECT SWITCH INPUT(12V)
(FUELSELECT)AUX DIG1 49 YELLOW/DK BLUE 18 BLACK/LT GREEN 18
PURPLE/LT BLUE 18 10 AUX ANA PD1B
AUX DIG 2 50 TTI - RS2B 500 1
TAN/GREEN 18 27 AUX OUT 2
(or Equivalent)
KNOCK + 51 YELLOW/RED 18 WHITE/LT BLUE 18 4 BRAKE
KNOCK - 52 DK GREEN/PURPLE 18 LT BLUE/BLACK 18 ALTERNATOR S TERMINAL
RED/BLACK 18 16 AUX PWM 5 C21IGN 16 WH - ENGINE RUNNING OUTPUT(GND)
FPP1 53 LT BLUE/BLACK 18 ORANGE/LT GREEN 18 29 CAN - CAN - 29 GR
(FPP2) FPP2-IVS 54 LT BLUE/YELLOW 18 DK GREEN/PURPLE 18 28 CAN + CAN + 28 YL
PC TX 55 DK GREEN 18 DK GREEN 18
DK GREEN 18 11 RS 232+ TWIST WIRES 10 TURNS(360 DEG)/FOOT
ORANGE 18
PC RX 56 ORANGE 18 BLACK/ORANGE 18
ORANGE 18 3 RS 232- C127TSW 3 GR - DIAGNOSTIC SWITCH INPUT(GND)
KNOCK 2+ 57 DK GREEN/WHITE 18 LT BLUE/PINK 18 15 START COMMAND R33STR 15 BK - ENGINE START INPUT(12V)
5 KNOCK 2-
VBAT PROT
58
59
TAN/YELLOW 18
PINK/LT GREEN 18
PINK/BLACK 16
BLACK/RED 16
5 FUEL PUMP +
18 FUEL PUMP -
C135FP 5
C135RET 18
BL/WH - FUEL PUMP (12V)
BL - FUEL PUMP (GND)
VBAT 60 RED/TAN 16 YELLOW/DK BLUE 18
EGOH 2 61 BLACK/LT BLUE 18 PURPLE/LT BLUE 18
WHITE/LT BLUE 18
EGOH 1 62 BLACK/LT GREEN 18 BLACK/WHITE 16 DK GREEN/WHITE 18
INJ HS 63 BOSCH THROTTLE
INJ1 LS 64 TAN 16
DK GREEN/PURPLE 18
INJ2 LS 65 BROWN/YELLOW 16 GRAY/WHITE 18

OIL PRESSURE
INJ3 LS 66 BROWN/LT BLUE 16 6
YELLOW/RED 18
YELLOW/WHITE 18 5
INJ4 LS 67 WHITE 16 LT BLUE/DK GREEN 18 4
INJ5 LS 68 BROWN/WHITE 18
3
GROUND 69 BLACK/WHITE 16 GRAY/RED 18 2 DIAGNOSTIC CONNECTOR
INJ6 LS 70 TWR LPG LOCKOFF
GRAY/ORANGE 18 1
AUX PWM8 71 BROWN/WHITE 18 2 3 DK GREEN 18
6 STARTER
RELAY
72
73
LT GREEN/PURPLE 18
RED/YELLOW 18
WHITE/BLACK 18
RED/LT GREEN 18
A
B
GRAY/RED 18 1 4 ORANGE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
5 8 ORANGE/LT GREEN 18
MIL 74 PINK/LT GREEN 18 6 7 DK GREEN/PURPLE 18
UEGO H 75 BLACK/RED 16 KNOCK SENSOR
RED/BLACK 18
AUX PWM7 76 RED/LT GREEN 18
LOCKOFF 77 WHITE/BLACK 18 ORANGE/LT GREEN 18
(FUEL PUMP) AUX PWM6 78 LT BLUE/ORANGE 18 TAN/GREEN 18
VBAT 79 RED/TAN 16 PINK/BLACK 16 CAN TERMINATION CONNECTOR
DBW + 80 LT BLUE/DK GREEN 18 BLACK/RED 16 SHD TWR
GRAY/ORANGE 18
GROUND 81 BLACK/WHITE 16 LT BLUE/PINK 18 WHITE 18 DEPR
DBW - 82 GRAY/ORANGE 18 RED/LT BLUE 16 V-RELAY
AUX PWM5 REC 83 STARTER SOLENOID DK GREEN/PURPLE 18 CAN +
AUX PWM5 84 RED/BLACK 18 WHITE 18 CAN TERM
1 2 3
AUX PWM1 85 ORANGE/LT GREEN 18 6MM BLACK/WHITE 18 GROUND
7 AUX PWM4 86 RED/WHITE 18 RING
RED/TAN 18
ORANGE/LT GREEN 18
RED/TAN 18
CAN -
VBAT
4 5 6
AUX PWM2 87 TAN/GREEN 18

AUX PWM4 REC 88 RED 18 STARTER RELAY
FP REC AUX PWM3 REC 89 PINK/BLACK 16 87A
FUEL PUMP AUX PWM3 90 BLACK/RED 16 LT BLUE/PINK 16 30
M1
87 RED/TAN 16 RED 16
LT BLUE/PINK 18 86 20A F4
PINK/BLACK 16 PINK/BLACK 16
STARTER
15A
85
LT GREEN/PURPLE 18 85 FUEL PUMP
RED 16 30
RELAY_OMRON_FPP PINK/BLACK 16 87
LT BLUE/ORANGE 18 F6
RED/LT GREEN 18 86 RED 18 RED/TAN 18
TAN 16
WHITE 16 87A FUELPUMPRELAY
10A
8
RED/WHITE 18
RED/YELLOW 18 85
ALTERNATOR
BROWN/YELLOW 16 RED 16 30
BROWN/LT BLUE 16 RED 14 87 F1
RED 16 RED/LT BLUE 16
RED/TAN 14 RED/TAN 14 86
RED 18 RED 16 87A POWERRELAY 10A
EPR
- + INJ CYL #4 INJ CYL #3 INJ CYL #2 INJ CYL #1
VVT SOLENOID F5
RED 16
15A
2 1 2 1 2 1 2 1 RELAYED POWER
RED 16
6-10 Z-45/25 • Z-45/25J Part No. 219418

Deutz D 2.9 L4 Engine Wire Harness
N M L K J I H G F E D C B A
C2-W
C2-M
C2-S
C2-A
C2-B
C2-H
C2-X
C2-J
1
R27AUX GN
P110RET BK-16
P23PWR WH-14
C33STR BK-16
D82CAN+ YL
D81CAN- GN
C34WTS BK/WH
C41RPM OR/BK
BIBAT RD
D2.2 (ECU)
FUSE/RELAY MODULE P20PWR RD-14 K1
02GRD BR-14
K2
P20PWR RD-14
F8 K3
02GND BR-14 K4
30A 1BLUE-B P20PWR RD P20PWR RD-10 P20PWR RD-14
K5
CR6 02GND BR-14 K6
C26LVL WH/RD C26LVL WH/RD
F20 FUEL 30
PUMP
87A
87 2GREEN-B R135PWR WH CLSWJPR BK/WH
K13
K15
2
20A 2GREEN-H C135RET BK C135RET BK C135RET BK
86 85 K26
P33RET BK K28
2GREEN-G C135FP BL/WH C135FP BL/WH UBATT WH UBATT WH
K29
CR39B R27AUX GN
K31
C33STR BK
30
87A K35
AUX 87 2GREEN-F EGRPOSPWR WH/BK
PUMP R27AUX K44
C34WTS BK/WH
86 85 K48
C41RPM OR/BK K49
1BLUE-A C27AUX
D104CAN- WH D104CAN- WH K53
F19 CR23B D82CAN+ YL D82CAN+ YL
10A K54
87A
C135WIF BL/WH C135WIF BL/WH K57
30
2GREEN-A FUELPRES BL
ACC. 87
ACC. PWR K61
3
F1
P135SEN GR/WH P135SEN GR/WH K64
86 85
CLSWJPR BK/WH K68
C21IGN2 WH C21IGN2 WH K71
F7 CR5B P33PWR BK/RD
20A K73
87A
D105CAN+ RD D105CAN+ RD K75
30
SERV 87 1BLUE-F R46HRN D81CAN- GR D81CAN+ GR
HORN K76
1BLUE-G 01GND BR EGRPOSGND BR K82
86 85 EGRPOSSIG WH/RD K85
1BLUE-E P110RET BK K87
C46HRN
CR17B P23PWR WH P23PWR WH K88
C135FP BL/WH
87A K90
HYD OIL 30
87 2GREEN-D TR1 B TR1 B
COOL. R116HYD
2GREEN-E 120 120 D2.1 (ECU)
86 85
C116TS
2GREEN-C C107AF WH
A A 4
INJ3 A02 BK-16
A2
F17 CR2B D22 INJ2 A03 OR-16
15A A3
87A
MPROP A04 WH-16 A4
30
IGNITION 87 1BLUE-H C21IGN MPROP A05 WH/BK-16
ON A5
1BLUE-C C21IGN WH RAILP A07 RD
VEC5-C
VEC5-A
86 85
A7
INJ1 A16 GR-16 A16
1BLUE-D P23PWR WH INJ4 A18 BL-16 A18
EGRSOLPWR OR/RD-16
C135SEN GR/WH
A19
C135WIF BL/WH
EGRSOLGND BR-16
C26LVL WH/RD
B A20
R34SA RD
P110RET BK
A23
BIBAT RD
BIBAT RD
120
UBATT WH
MSENSPWR GR/WH A24
A RAILP A25 RD/WH
RAILPSIG A26 RD/BK
A25
5
D105CAN+ RD
D104CAN- WH
A26
P23PWR WH
D81CAN- GN
D82CAN+ YL
BSTSIG A27 GR/WH A27
01GND BR
C26SEN A28 WH/RD A28
1 L3 1 MSENSGND BK
L A29
2 2 INJ3 A32 BK/WH-16 A32
COOLANT INJ1 A33 GR/WH-16 A33
LEVEL WATER IN C34RET BK
FUEL LEVEL A35
CAMSPD A37 WH/BK A37
H
G
M
B
F
A
CRNKSPD SHD WH
DIAGNOSTIC A38
CRNKSPD A39 BL/WH A39
BSTSIG A40 YL A40
C107AF WH
BSTPT A43 RD/WH A43
P25SEN A44 WH/BK A44
6
GND BR
INJ2 A46 OR/BK A46
INJ4 A48 BL/WH A48
CAMSPD A52 BK/WH A52
CAMSPD SHD WH A53
CRNKSPD A54 BL/RD A54
BIBAT RD PRM 86 85 C34RET BK
EGRSOL PWR OR/RD-16

60A
CRNKSPD A39 BL/WH
CRNKSPD A54 BL/RD
EGRPOSPWR WH/BK
RAILPSIG A26 RD/BK
R34SA RD
CAMSPD A52 BK/WH

CAMSPD A37 WH/BK
D+
EGRSOL GRD BR-16

EGRPOSSIG WH/RD
C26SEN A28 WH/RD
MSENSPWR GR/WH
R135PWR WH
P25SEN A44 WH/BK
INJ1 A33 GR/WH-16

MPROP A05 WH/BK
CRNKSPD SHD WH
ALTERNATOR
BSTSIG A27 GR/BK
INJ3 A32 BK/WH-16

MPROP A04 WH-16
INJ4 A48 BL/WH-16

INJ2 A46 OR/BK-16
87
BATPT A43 RD/WH

CAMSPD SHD WH
RAILP A25 RD/WH
EGRPOSGND BR
30 60A 87A
FUELPRESS BL
P33PWR BK/RD
INJ1 A16 GR-16
INJ2 A03 OR-16

BSTSIG A40 YL
INJ3 A02 BK-16

EXCT.
INJ4 A18 BL-16

MSENGND BK
RAILP A07 RD
B+
01GND BR-14
7
P33RET BK
BAT. BAT.
+ -
X18.1
X18.2
STA. W
GLOW PLUG
GLOW PLUG
M4 FUEL
01GND BR
02GND BR
STARTER
REGULATOR
PUMP
IND.
J3-1
J3-21
J3-31
J3-41
J3-51
J3-61
J3-2
J3-22
J3-32
J3-42
J3-62
J3-9
J3-15
J3-19
J3-25
J3-29
J3-35
J3-3
J3-13
J3-20
J3-23
J3-26
J3-28
J3-38
J3-40
J3-46
J3-48
J3-50
J3-60
J3-14
J3-17
J3-24
J3-27
J3-37
J3-47
P33PWR
P33RET
Part No. 219418 Z-45/25 • Z-45/25J 6-11

Deutz D 2.9 L4 Engine Wire Harness
6 - 11 6 - 12
Perkins 404F-22 Engine Wire Harness
6 - 13 6 - 14
Perkins 404F-22 Engine Wire Harness
AUX SHUTDOWN
D81CAN- GN K76
D82CAN+ YL K54
1
HIGH RPM
LOW RPM
KEY PWR
BATT + TO STARTER
STOPLP
WTSLP
START
TACH
BATT - TO ENG BLK 30 PRM
C2-S
C2-M
C2-K
C2-T
C2-W
C2-X D81CAN- GN
C2-C
C2-J C25ESL WH/BK
C2-H C34WTS BK/WH
C2-B C33STR BK
60A 60A
86
D82CAN+ YL
P23PWR WH
2
85
87A 87
FUSE/RELAY MODULE J1-13

KEY PWR
F11A 15A J1-33
1D KEY PWR
J1-12 START
6A PR1+ A1 B1
J1-07 WTSLP
F11B 15A 1C J1-73 STOPLP
A2 B2 C128RPM OR/RD J1-14 LOW RPM
3 F11C 5A 1B C35RPM BK/RD J1-15 HIGH RPM
A4 B4 C41RPM OR/BK J1-34 TACH
F10 15A R27AUX GN J1-32
1G AUX SHUTDOWN
A3 B3
D22
PR1- WH J1-03 MAIN RELAY -
2C PR1- WH J1-23 MAIN RELAY -
CR3
C6 D6 PR1+ RD J1-04
F17 10A MAIN RELAY +
5C B+ F8 87A B2+ RD/BK J1-18
30 B2 +
A8 B8 FUEL 87 H8 2H B2+ RD/BK J1-38
PUMP B2 +
2G
4 F7 85R6 86 H7 B3+ RD/BK J1-58 B3 +
B3+ RD/BK J1-78 B3 +
CR79
F26 7.5A B1+ RD/BK J1-01
F6 87A B1 +
30
A6 B6 BURNER 87 2F B1+ RD/BK J1-21 B1 +
AIR P. F5 85 2E B4+ RD J1-19
86
B4 +
R5
C135RET BL/WH J1-53 FUEL PUMP

CR1B BRNPMP BL/RD J1-54
F12 7.5A BURNER AIR PUMP
C8 87A
30 C33RET BK J1-05
A7 B7 START 87 E8 2A START
ENGINE ARDGP1 BK/RD J1-74
5 C7 85 86 E7 2B
C34SA BK/WH J1-24
ARD GLOW PLUG
R2
GLOW PLUG
D105CAN+ YL J1-37 CAN1 HIGH
CR15C
15A D104CAN- GR J1-17
C5
30
87A CAN1 LOW
A5 B5 ARD 87 E5 2D D81CAN- GR J1-16 CAN0 LOW
GP C4 85 86 E4 1A D82CAN+ YL J1-36 CAN0 HIGH
R1
J1-20
B-
CR15B J1-39
20A B-
6C B+ F4 87A
J1-40
B-
6 D2 E2 GLOW
30
87 H4 1H J1-59 B-
PLUG2 F3 85 86 H3
J1-60 B-
R4
20A CR15A J1-79 B-

F2
D1 E1 87A J1-80 B-
GLOW 30
87 H2 1F
PLUG1
F1 85 86 H1 1E
R3
DIAGNOSTIC
D82CAN+ YL DIAG-G
CAN0 HIGH
D+ D81CAN- GR
7 D104CAN- GR
DIAG-F
CAN0 LOW
ALTERNATOR DIAG-H CAN1 LOW
D105CAN+ YL DIAG-J
EXCT. CAN1 HIGH
B+ DIAG-B B-
BAT. BAT. B4+ RD DIAG-A
+ - RELAY PWR
STA. W EIC2-1
SPARE
R135PWR BL/WH EIC2-2
FUEL PUMP
8 M3 STARTER ARDPMP BL/RD EIC2-3
ARD AIR PUMP
REGULATOR
R34SA2 BK/WH EIC2-4 GLOW PLUG 2
IND.
R34SA1 BK/WH EIC2-5
GLOW PLUG 1
ARDGP2 BK/RD EIC2-6
ARD GLOW PLUG
BATT - (NEG) TO ENG BLK
6-14 Z-45/25 • Z-45/25J Part No. 219418

Electrical Schematic, Options (All Models)
P2 FS1
RD
C9P-1 BK BK (FS) RD (FS)
WH (FS)
C9P-3
C9P-2
P25FS RD
P24FS WH
1
C7P-1
P22BAT BK R26FS WH TO ALC500 - X103-3 AND TS15
WH
P26FS WH
LIFT/DRIVE OPTION BRN TS47
R22BAT BK
TS43 C90PXS RD/BK
U13, X103 #1 TS46 CR78 D106
SW19 WH
NO
BYPASS
WH - CR13
P24FS WH U13, X103 #4
HC
PROXIMITY SENSOR 2
C7B-1
CR27
NC D107 L30 L30
P22BAT
C54-11
C2P-7
1 3 C40LSS OR
P1 TB22
CB2 CR30
RD PLAT 4 5
KS1 NO AIRCRAFT PROTECTION OPTION
BR
BR
SW20
15AMP. GRND NC
6
C45GEN GR/WH
PLAT C32 7 RD OPT. CABLE (4/16)
KS1 PLUG
3
BR
BK
RD
WH
GRND
P20BAT RD
12 8 U13, X102 #4 R21 R22

U13, X102 #19 10 10
C32-8
TB134 GND BR
CB1
RD TB24
C2B-7
15AMP.
CB4
P20BAT RD P20LPS RD 1
CR23 4
C49LPS WH/RD
15A D15
R49LPS WH
CB3 CB8
15A 15A
TB45 TB34
TB20 P20BAT RD
2 C6-28
TB21 TB21 C6-17

C21IGN WH
R49LPS WH
P116HYD RD
WH/BK
CR6
30 86
J196
CONTROL MODULE GP#1 G1 5
U18
C6-22
87A 87 85 FUSE G3 G2
C6-29
C225PAS WH J196-7
R34SA RD
C5-21
C5-19
PULL IN RELAY
C225RET BK J196-12 PULL RELAY -GND
C224PAS RD J196-11
C5-2
HOLD COIL
GND BR J196-1
R225PAS WH
30 86
C26TS WH/RD
C25PSR WH/BK
CR17 -GND 70A
C45GEN GR/WH
85 J196-2 +12V
P134FB WH
87A 87
J196-10 RPM SIGNAL
P116HYD OR
C116TS WH
J196-9 PR4
TEST SWITCH
C1B-A
C1B-Q
PLUS+1 NO
12V GR C1B-W
DC 3 2 1
J57 6
+ FB1 L29 L29
WH
BR
BK
RD
TS74
C5-5
C5-27
C2-O
C2-N
OR/BK TB41
PULL IN
Y29
HOLD
RD
- TB134
C5-1
SW3
M1 NO
B1 BRN
LIGHTS RELAY
DRIVE/WORK
PLUG OPTION
DRIVE LIGHTS
OPTION
OPTION
GENERATOR
PLAT BOX PCB
SECOND GLOW
OPTION
HEATER
DOWN SOLENOID
SENDER
SENDER
WORK LIGHTS
VALVE SHUT
TEST SWITCH
WATER TEMP
VOLTMETER
OIL PRESSURE
COOLONG FAN
TEMP SWITCH
BEACONS
HYD. OIL
FLASHING
ES0548E
1 DEUTZ D 2.9 L4 AND PERKINS 404F-22 ENGINES
DIODE INSTALLED FOR FOOTSWITCH LOW IDLE (1500 RPM) POSITIVE AIR SHUTDOWN VALVE PLAT BOX HEATER GLOW PLUG ENGINE LIGHTS LIGHTS GENERATOR
2 DEUTZ D 2.9 L4 AND PERKINS 404F-22 ENGINES
TB21 SUPPLIED FROM TB25
8
Part No. 219418 Z-45/25 • Z-45/25J 6-15

Electrical Schematic, Options (All Models)
6 - 15 6 - 16
Ground Control Box Terminal Strip Wiring Diagram, Options
6 - 17 6 - 18
8
7
6
5
4
3
2
1
6-18
Genie
1 TO REMOVE: 1 START RELAY
2 Push gently 2 TACHOMETER
3 and lift 3 START INPUT
4 4 AUX PWR UNIT
5 5 GROUND
A
U1 (ISM)
6 6 BATTERY
7 7 TO KEY SW (DIESEL ONLY)
WH U34-8 8 8 JUMP TO 7 (GAS ONLY)
C6
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
PIN
10 10 TEMP OR PRESS FAULT
Section 6 • Schematics
HARNESS
FUNCTION
12/24 Volt IGNITON/START MODULE P/N 56057
D C TERMINAL BASE (TB) B A

B
1 PRIMARY BOOM UP 1
2 2
C6-25 BL C36SCC C1B-L

PRIMARY BOOM DOWN
4 TURNTABLE ROTATE LEFT 4

C6-26 BL/BK C37SCW C1B-M
5 TURNTABLE ROTATE RIGHT 5
7 PRIMARY BOOM EXTEND 7
8 PRIMARY BOOM RETRACT 8

C
10 SECONDARY BOOM UP 10
OIL PRESSURE
11 SECONDARY BOOM DOWN 11
G2
14 PLATFORM LEVEL UP 14
Z-45/25 • Z-45/25J
WH/BK C5-19
15 PLATFORM LEVEL DOWN 15
C1B-C C28TTA RD/BK C5-10
17 PLATFORM ROTATE LEFT/JIB UP 17

C5
SOC
18 PLATFORM ROTATE RIGHT/JIB DOWN 18

ENGINE
RD CB3
HARNESS
BR
WH
D
RD CB2
20 +12 VOLT BATTERY POWER 20
WH CR17
21 +12 VOLT IGN. POWER 21
WH C5-3 BR GND U34-3 12
WH CR17 GR/BK H6 8
WH FUSE WH C5-25 RD TS52 7
RD TS51 6
WH CR2 BK C7B-1 5
C32
U33

BK C32-4 BK 22B 4
TEMP
G3
BK C6-19 BL/WH C1B-N
WATER
22 +12 VOLT TO PLATFORM 22 3
RD U34-2+
1
22 +12 VOLT TO PLATFORM 22
BK C5-6
WH/RD C5-21
WH C7-2
E
WH U1-7
23 KEYSWITCH POWER 23
RD CR2
24 CB1 POWER 24
RD CB1
WH /BK L2 WH/RD C5-9
WH/BK U1-10 WH/BK C5-8
25 OIL PRESSURE ANDTEMP SW 25
RD TS51
BR
WH
27 AUXILIARY PUMP 27
29 MOTOR STROKE 29
Part No. 219418

Ground Control Box Terminal Strip Wiring Diagram, Options
August 2013
30 DRIVE FORWARD 30
F
31 DRIVE REVERSE 31
G1
32 BRAKE 32
BATTERY
INDICATOR
33 START ENGINE 33
34 GLOW PLUG OR LP 34
35 HIGH RPM 35
BK/RD TS54
BR TB GND
WH/BK U1-10
41 ALTERNATOR PULSE PICKUP 41
OR/BK C5-22
G
45 GENERATOR OPT. 45
GR/BK C3-N
129 ALARMS OPT. 129
D27
PIN
C3B
134 KS POWER 134

RD U34-2
RD H6+
134A KS POWER 134A
19/18 CABLES
GND MAIN GROUND GND

RD U34-3
BR TB21-D
GND MAIN GROUND GND
H
GND MAIN GROUND GND

RD 134C
+
WH TB21-D WH ISM-9
WH CR2 8 RELAY
9
H6
RD C32-1
RD TB134-B 2
GR/BK C32-8
BR C32-12
-
BL/RD C3-O BR GND

GR/BK L45(-) 3 5
U34
START RELAY IDLE RELAY HORN RELAY WH/RD C3B-G
C1-P9 GR TEST
IGNITION
I
C1-P2 RD P134BAT
TB134 RD P134BAT
CR1
CR4
CR5
CR2
TS74
1
TEST SWITCH
WH C5-27
WH ISM 9 (CE SEE U34) OR C5-5
WH/RD R46LPS C5-2
BR GND
WH/BK R49LPS C6-17
WH TB21-C
TB20C RD
PIN
C1B
J
C46LPS WH/RD TB21

BAT
AUX
15A
OIL
CB3
19/18 CABLES
CR23
CR17
OIL COOLER
RD
COOLER
LIGHT
BAT
F19
15A
AUX
ES0549E
DRIVE/WORK
LIGHT
DRIVE
WORK
K
GROUND CONTROL
HARNESS
L
M
N
Platform Control Box Wiring Diagram, Options
P2C-2 P26FS BK C54-6

SP4 C19JSV GR/WH C54-12
SP3 C40LSS 0R C54-11
SP1 P24FS WH C54-3

SP2 C32BRK WH/RD C54-2
CR76#85 C171LS WH/BK C54-9
CR76#87 P26BAT BK C54-8
C9-1 P26BAT BK C54-7
CR13#86 C19JIB RD C54-1

TS7-5 P24FS WH C54-10
TS46-3 P24FS WH C54-5

TS46-2 P24FS WH C54-4
PLATFORM CONTROL HARNESS P22PWR RD
(TO SWITCH PANEL)
C54-7 P26BAT BK
C54-6 P26FS BK
C54-10 WH
C54-3 P24FS WH
SW20 2
TO C54A TO C54B
R21
C54A
DALE RH-25 25W

4.7k ohm 1%
C54B
PLATFORM BOX PCB R22
DALE RH-25 25W

4.7k ohm 1%
OPTION WIRING HEATER OPTION 3
CONNECTOR
BATGND
BR
C54-10 P24FS WH
C54-4 P24FS WH
C54-7 P26BAT BK
C54-3 P24FS WH
C54-6 P26FS BK
C54-10 WH
C54-2 C32BRK WH/RD
C54-5 P25FS WH 5
TO C54B C54-3 P24FS WH
CR30 CR27 C54-11 C40LSS OR
C54-11 C40LSS OR CR51
R
R
C54A TO C54B OR
R
R
CUT AND INSTALL BLUE MALE TERM.

BR
C54A
WH
BR
R INSTALL PIN TERMINAL INTO TH C9-2
BK 6
LIFT/DRIVE CUTOUT OPTION
STANDARD ON CE MODELS AIRCRAFT PROTECTION OPTION Y
WH
7
BATGND BATGND
WH B
ES0549E
PROX. KILL PLAT_OPTIONS_WIRE_DIAGRAM 8
Part No. 219418 Z-45/25 • Z-45/25J 6-19

Platform Control Box Wiring Diagram, Options
6 - 19 6 - 20
Wiring Diagram - Battery, Hydraulic Oil

and Engine Oil Heater Options
6 - 21 6 - 22
Wiring Diagram - Battery, Hydraulic Oil

and Engine Oil Heater Options
2 BK J3-1 LINE PWR

BK
HEATER 3 JUNCTION BOX
BATTERY HEATER
CB20
3 BK J3-2 NEUTRAL
WH TB4H
BK J2-A LINE PWR LINE

TB3H
POWER SUPPLY
GR J2-B NEUTRAL BK BK
4 HEATER 2
WH WH
HYDRAULIC TANK HEATER
TB2H
BK J2-C CHASSIS
NEUTRAL
BK J1-A LINE PWR
5 TB1H
BK
GR J1 -B NEUTRAL
HEATER 1 WH
TERMINAL
ENGINE OIL HEATER
BK J1-C CHASSIS
6
GR
GR
GR
6-22 Z-45/25 • Z-45/25J Part No. 219418

Wiring Diagram, 2.2kW Hydraulic Generator
1
120V AC 60HZ 120V AC 50HZ
CB CB
BLACK BLACK
BLACK BLACK BLACK RED BLACK BLACK
L1 L1
T1 T1 2
T2 WHITE T2 WHITE
WHITE WHITE GREEN YELLOW WHITE
BLACK BLACK GREEN
RED RED
GREEN BLACK GREEN BLACK

GROUND GROUND
BLUE BLUE
T3 WHITE WHITE YELLOW T3 WHITE BLACK YELLOW
WHITE L2 WHITE L2 3
T4 T4
BLACK BLACK GND 1 2 3 4 GREEN WHITE GND 1 2 3 4
DTP04-4P DTP04-4P
5 RED 5 BLACK
DTP06-4S DTP06-4S
CAPACITOR CAPACITOR
8 RED
1 2 3 4
YELLOW 8 BLACK
1 2 3 4
YELLOW 4
DIAGNOSTIC DIAGNOSTIC
BLUE BLUE
+12VDC (PURGE) +12VDC (PURGE)
BLACK BLACK
-12VDC -12VDC
RED +12VDC GEN OFF/ON RED +12VDC GEN OFF/ON
5
240VAC 50HZ
CB
BLACK
RED BLACK WHITE L2
T1
WHITE
T2 6
YELLOW WHITE GREEN
GREEN GROUND
RED
T3 WHITE WHITE
BLACK
GND BLUE
T4 CB YELLOW
GREEN BLACK
BLACK L1
BLACK 1 2 3 4 7
DTP04-4P
5 BLACK
DTP06-4S
CAPACITOR
1 2 3 4
8 BLACK YELLOW
DIAGNOSTIC
BLUE
+12VDC (PURGE) 8
BLACK
-12VDC
RED +12VDC GEN OFF/ON
Part No. 219418 Z-45/25 • Z-45/25J 6-23

Wiring Diagram, 2.2kW Hydraulic Generator
6 - 23 6 - 24
Hydraulic Schematic, 2WD Models
6 - 25 6 - 26
JIB BOOM
1 0.4 GPM PLATFORM ROTATE
0.4 GPM
MEDIUM HIGH GENERATOR 1.5 L/min
1.5 L/min
PRESSURE PRESSURE GG
FILTER FILTER OPTION
3000 psi L R SECONDARY BOOM
207 bar ELEVATE CYLINDERS
C D E F
51 psi 102 psi P PLATFORM LEVEL
1.0 GPM TURNTABLE ROTATE
3.5 bar 7 bar 3.8 L/min 0.6 GPM M
2.8 L/min
HH
2 A
E R PR2 PR1
SLAVE
TEST PRIMARY BOOM
3750 psi PRIMARY BOOM
259 bar LIFT CYLINDER EXTENSION CYLINDER
J1 J2 PR2 PR1 H I E R 3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM
12.1 / 9.1 L/min 15.5 / 8 L/min
J L
B
JIB SELECT
3200 psi MANIFOLD G O P Q
310 psi 221 bar E R
3 21.4 bar V2 V1 K
N
FUNCTION
0.030 inch
PUMP MASTER 0.080 mm
M
APU
E B A E R E R E R
9 7
AUX
PR1 PR2 PL1 PL2 SW1 SW2 S1 S2 P1 P2 EXT RET
DRIVE PUMP BI
25 psi TEST1 CD
1.7 bar BV
4 0.046 inch
1.2 mm
CF
OIL 2500 psi/ 173 bar

SET @ 0.6 GPM 2100 psi/145 bar
BC
COOLER BD 2.3 L/min @ TEST2 BO BS BT SET @ 2.5 GPM
TANK OPT. PRESS 3200 psi/221 bar BJ 9.5 L/min
@ TEST2 CE
SET @ 7 GPM BH
26.5 L/min CC
@ TEST1
BA
CG
BU BY CB
BP
BK BL
GEN 0.4 GPM
5 TEST A B BB 1.5 L/min BW
T BE
2.0 gpm 0.1 GPM
BM 0.4 L/min
7.6 L/mn CA
RA BX
BF
RIGHT AD
BR 2.0 GPM
REAR T1 BN BQ 7.6 L/min
A BZ
AC
B AE BG
RB T1
6 50% FUNCTION MANIFOLD
ST1 ST2 TEST2
0.067 inch
AA 250 psi
1.7 mm 17.2 bar
AB
COUNTERBALANCE VALVES
RATIO PRESSURE
50%
A B
STEERING 5.0:1 1000 psi / 69 bar
LB P CD 3:1 1000 psi / 69 bar
0.030 inch
0.76 mm AJ Q 3:1 1500 psi / 103 bar
7 B
E F 3:1 3300 psi / 228 bar
A H I 3:1 3500 psi / 241 bar
LEFT AI
REAR M N 4.5:1 3500 psi / 241 bar
AH AF AG
J L 4.25:1 3626 psi / 250 bar
LA
C D 1.5:1 3800 psi / 262 bar
T3
O 3:1 3800 psi / 262 bar
2SP
BK HS0089B
8 TRACTION MANIFOLD
6-26 Z-45/25 • Z-45/25J Part No. 219418

JIB BOOM
1
0.4 GPM
PLATFORM ROTATE
MEDIUM HIGH GENERATOR 1.5 L/min 0.4 GPM
PRESSURE PRESSURE 1.5 L/min
GG
FILTER FILTER OPTION
3000 psi L R SECONDARY BOOM
207 bar ELEVATE CYLINDERS
C D E F
51 psi 102 psi P PLATFORM LEVEL TURNTABLE ROTATE
3.5 bar 7 bar 1.0 GPM
3.8 L/min 0.6 GPM M
2.8 L/min
HH
E R PR2 PR1 2
A
SLAVE
TEST
3750 psi PRIMARY BOOM PRIMARY BOOM
259 bar I LIFT CYLINDER EXTENSION CYLINDER
J1 J2 PR2 PR1 H E R 3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM
J L 12.1 / 9.1 L/min 15.5 / 8 L/min
B
JIB SELECT
MANIFOLD O P Q
310 psi
3200 psi
221 bar
G
E R 3
21.4 bar V2 V1 K
FUNCTION N
0.030 inch
PUMP MASTER 0.080 mm
M
APU
E B A E R E R E R
9 7
AUX
PR1 PR2 PL1 PL2 SW1 SW2 S1 S2 P1 P2 EXT RET
DRIVE PUMP BI
25 psi
1.7 bar
TEST1
BV
CD 4
0.046 inch CF
1.2 mm
OIL 2500 psi/ 173 bar

SET @ 0.6 GPM 2100 psi/145 bar
BC
COOLER BD 2.3 L/min @ TEST2 BO BS BT SET @ 2.5 GPM
TANK OPT. PRESS 3200 psi/221 bar
BJ 9.5 L/min
@ TEST2 CE
SET @ 7 GPM BH
26.5 L/min CC
@ TEST1
BA
CG
BU BY CB
BP
TEST A B BL
GEN 0.4 GPM
BK
5
AM AK BB 1.5 L/min BW
RRA RFA RIGHT T BE
2.0 gpm 0.1 GPM
FRONT BM 0.4 L/min
RIGHT OSC 7.6 L/mn CA
BX
REAR A
A BF
BR 2.0 GPM
AQ BN 7.6 L/min
B BQ BZ
B AH RFB
RRB
BG
AB
50% 50% 6
T1 FUNCTION MANIFOLD
0.040 inch 250 psi AE
1.02 mm 17.2 bar 0.040 inch
1.02 mm
ST1 ST2 TEST2
AA
AR 50% 50%
50% 50% COUNTERBALANCE VALVES
AD
0.047 inch
1.2 mm RATIO PRESSURE
AL AJ AC
A B
LRB LFB STEERING 5.0:1 1000 psi / 69 bar
0.030 inch AO LEFT RIGHT P CD 3:1 1000 psi / 69 bar
B 0.080 mm
B
Q 3:1 1500 psi / 103 bar 7
E F 3:1 3300 psi / 228 bar
A A
LEFT AN A B H I 3:1 3500 psi / 241 bar
REAR
AF AP
AI AG LEFT M N 4.5:1 3500 psi / 241 bar
LRA LFA FRONT J L 4.25:1 3626 psi / 250 bar
CH
C D 1.5:1 3800 psi / 262 bar
T1
P A E R E R O 3:1 3800 psi / 262 bar
T3 T2 HS0089B
TF2SP
T B
OSCILLATE 8
R2SP
RBK FBK
TRACTION MANIFOLD
Part No. 219418 Z-45/25 • Z-45/25J 6-27

6 - 27 6 - 28
Electrical Schematic, Ford MSG-425 EFI Models

(ANSI/CSA)
6 - 29 6 - 30
N
P24FS WH
P134PWR RD
P47FE RD
P174AUX RD
C28TTA RD/BK
C41RPM OR/BK
P26EST OR/BK
P22BAT BK
BRN
1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

ES0548E
C1P-K C35RPM BK/RD C1B-K

HIGH
D12
IN THE STOWED POSITION AND THE KEY SWITCH OFF.
LOW
TS4
D4
ENGINE
TB35
M
D13
SPEED
ENGINE SPEED
TS54
2. DASHED LINES INDICATE OPTION WIRES.

P4
FUNCTION ENABLE
L
NOTES:
K
C21IGN WH
HOUR METER
G6
+
-
GY/RD
C21IGN WH
A
B GY/YL GASOLINE SENSOR
FORD ENGINE
P174AUX RD
RD
HARNESS
C
J
D BK/BL
RD/GN
WH/BK
LPG LOCKOUT
C25ELS CHECK ENGINE
L2
C5-8 WH/BK TB25
BR TEST SWITCH
CR39
C35RPM BK/RD
C5-24 GR
I
RD
TS64
TS3
CR39
C1P-J BK/WH
NC
C1B-J
(C34SA/C39LP) C5-7 R23BAT WH C2-B FEH (16) PIN 1
TB39
REFER TO FORD MSG-425 ENGINE WIRE HARNESS

D10
TS53
CR2
C5-3 C21IGN WH C2-A FEH (71) PIN 16

TB21
D11
C5-26 C128RPM OR/RD C2-T FEH (306) PIN 24

C1P-Q C41RPM OR/BK C1B-Q
H
FORD 42 PIN CONNECTOR

C25ESL WH/BK C2-Q FEH (658) PIN 6 BL/WH
CR2
NO
C127TSW GR C2-S FEH (458) PIN 3

BL/RD
C5-16 C34SA BK/WH C2-J (L) FEH (72) PIN 7

C28TTA RD/BK
TB41
C5-17 C35RPM BK/RD C2-K FEH (307A) PIN 23

TS2
C1P-H C33STR BK C1B-H

C5-22 C41RPM OR/BK C2-M FEH (11) PIN 2
START ENGINE
TS52
TB33
G
IGN./START RELAY
ENGINE C5-15 R33STR BK C2-H FEH (32) PIN 15
START C2-V
CR1
TB24
NO
C135FP BL/WH FEH (787A) PIN5

C2-R
M4
BK PIN 18
C5-25 C107AF WH C2-P
P26EST BK
C2-W
P24FS WH
P25FS RD
P24BAT RD
P22BAT BK
F
START (FEH)
August 2013
Part No. 219418

C9P-3
C9P-2
M3
STARTER MOTOR
CR19
TS51
C27AUX RD
TB27
AUXILIARY
TS1
C6-21
WH(FS)
PUMP AUXILIARY POWER

RD(FS)
AUX. PUMP C27AUX RD

RELAY
PR1
NO
C1P-B C27AUX RD C1P-B
E
M2
AUXILIARY PUMP
FS1
C28TTA RD/BK
TB23
C9P-1 BK BK(FS)
WH C7P-2 P23BAT WH C7B-2
B
RD/BK
RD/BK C5-10 WH
TILT ALARM
D2
P174BAT WH P134TTS RD C5-28 RD BK BRN

LEVEL SENSOR
C
H1
TB134
B
C28TTA
S8
D40
RD
D
P2
L48
C1P-C C28TTA RD/BK C1P-C

BK/RD C3P-K C46HRN BK/RD C3B-K C46HRN BK/RD SERVICE HORN
RD RELAY
P3
CR5
Z-45/25 • Z-45/25J
NO
H2
C7P-1 R22BAT BK C7B-1 GR/BK P22HRN BK R46HRN BK C6-23
SERVICE HORN
8
5
C
C32
C134PWR GR
1
C1P-S C1B-S
12
4
6
TB134
P134PWR RD
TB22
KS1
GRND
PLAT
B
P1
RD
STA.
S
A
I
ALTERNATOR
REGULATOR
15AMP. RD
TB20 15AMP.
FLD.
(ANSI/CSA)
CB1
A
GND.
BAT.
CB2
FUSE
LINK
12V
DC
B1
+
-
P20BAT RD C6-1
6-30
1
8
6-31

(ANSI/CSA)
GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A
C30FWD WH C1B-E C5-12 BK RD

15
C1P-E C30FWD WH C2-F BRN DRIVE EDC FORWARD
ROCKER OPTION
C160JPL WH/RD
4 C1B-F BRN DRIVE EDC REVERSE

C1P-F C31REV WH/BK C31REV WH/BK
C159STC BL/WH
C5-13
X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3
C1P-G C32BRK WH/RD C1B-G C5-14 C32BRK WH/RD J87-2

19 BRAKE RELEASE VALVE
B
X102
C1P-D C29MS RD/WH C1B-D C5-11 C29MS RD/WH J87-1

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK

Y OUT 4 C164PES RD/WH
2 C1P-M C37SCW BL/BK C6-26

X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR
C1P-L C36SCC BL C1B-L C6-25 C36SCC BL STEER LEFT

11 17
C
12
GND 1 BR
C3P-P C14PLU OR C3B-P

PRIMARY UP/DOWN
6
X102
TB14
C3P-Q C15PLD OR/BK C3B-Q

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59
C6-13 C14PLU OR PLAT LEVEL UP

UP PLATFORM LEVEL
DOWN C6-14 C15PLD OR/BK
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
C3P-J C8PBR BK/WH C3B-J
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
RETRACT C6-10 C8PBR BK/WH
PRIMARY RETRACT
6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
JC1
E
TB4
August 2013
C3P-E C4TRL WH C3B-E C14-1 C14-2

9 C6-7 C4TRL WH
X102
TURNTABLE ROTATE LEFT

C3P-F C5TRR WH/BK C3B-F
PRIMARY
10
C6-8 C5TRR WH/BK
BOOM
TURNTABLE ROTATE RIGHT

U13 JOYSTICK CONTROL CARD
TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
LEFT TURNTABLE ROTATE
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9
PLATFORM LEVEL C6-5 C1PBU RD

8 UP PRIMARY UP
C15PLD OR/BK PRIMARY BOOM
DOWN C6-6 C2PBD RD/BK
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30
C3P-C C2PBD RD/BK C3B-C

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108
C3P-M C11SBD BL/BK C3B-M

C29MS 9
8
C3P-L C10SBU BL C3B-L
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1
UP BOOM SECONDARY C6-11

D9
DOWN C11SBD BL/BK

TS60
C143DEL BL/RD SECONDARY DOWN

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
C3P-R C16DRE OR/RD C3B-R C5-18 BK-6 WH-6 C5-6
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
BK LS1-PRIMARY EXTEND
LS1
C1P-P
J2 BK
4 C11-2 WH-6 DRIVE LIMIT SWITCH

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

I
LS2- PRIMARY UP
X103
BR 22
1
LS4
DRIVE LIMIT SWITCH

C1B-P C6-27 OR C10-2 BK-4 WH-4 C10-1 J1-BK C10-2 WH-5
LS4- SECONDARY UP
21
22
P22LS RD DRIVE LIMIT SWITCH
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
C3P-N C3B-N C129DA RD/BK ALARM OPTIONS
X101
H4
15 10 TB129 DESCENT ALARM
J
TRAVEL ALARM
D29
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13
C3P-T C18PRR GR/BK C3P-T

NC
DOWN
UP C3P-S C17PRL GR C3P-S
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
PLATFORM ROTATE RIGHT - JIB DOWN
WH
DOWN
BR
ROTATE
UP JIB BOOM C6-16 C17PRL GR

PLATFORM ROTATE LEFT - JIB UP
PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT
L
C6-3
LEFT RIGHT PLAT ROTATE
LEFT
C3P-U C19JSV GR/WH C3P-U
GR/WH
CR13
M
RD
C1
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
JIB TIME DELAY CIRCUIT
N

(ANSI/CSA)
6 - 31 6 - 32
Ground Control Box Terminal Strip Wiring Diagram

Ford MSG-425 EFI Models (ANSI/CSA)
6 - 33 6 - 34
8
7
6
5
4
3
2
1
6-34
A
C6
PIN
C6
B
RD C3B-B
NOTES:
HARNESS
FUNCTION
RD TS61-1 RD-C6-5
1 PRIMARY BOOM UP 1
C3
RD/BK C3B-C
RD/BK TS61-3 RD C6-6
2 PRIMARY BOOM DOWN 2
WH C3B-E
D30
WH TS62-3 WH C6-7
WH/BK C3B-F

WH/BK TS62-1 WH/BK C6-8
BK C3B-H
BK TS63-3 BK C6-9
BK/WH C3B-J
C
BK/WH TS63-1 BK/WH C6-10
RD/BK TB129
BL C3B-L
C1
BL TS60-1 BL C6-11
BL/BK C3B-M
BL/BK TS60-3 BL/BK C6-12
Z-45/25 • Z-45/25J
D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q

OR/BK TS59-3 OR/BK C6-14
GR C3B-S
GR TS57-1 GR C6-16

D
GR/BK C3B-T
GR/BK TS57-3 GR/BK C6-15
RD/BK TB129
RD CB3 RD CB1
C5

C5
RD CB2 RD C6-1
SOC

WH CR17
ENGINE
HARNESS
WH C5-3
WH CR2

WH FUSE WH C5-25
D52
OR/BK C5-26
BK CR5 BK C32-4
E
BK KS1-4 BK C6-19
C7
BK C5-6
WH D2-KS1 WH C7-2
BR TBGND-D
RD CR2 WH TB23-A
RD CB1 BK C32-5
24 CB1 POWER 24
WH/RD C5-9
Part No. 219418

August 2013
BR GND
C7B
WH/BK C5-8
RD TS51 RD C1B-B
12V DC
F
RD C6-21
RD/WH C1-D
RD/WH C5-11
29 MOTOR STROKE 29
WH C1-E
WH C5-12
30 DRIVE FORWARD 30
POWER TO PLATFORM
WH/BK C1-F
WH/BK C5-13
31 DRIVE REVERSE 31
WH/RD C1-G
R35RPM BK/RD CR4-87
WH/RD C5-14 BAT
32 BRAKE 32
BK TS52-1 BK C1-H
10A
CB7
R35RPM BK/RD C5-17

AUX
G
33 START ENGINE 33
BK/WH C1-J
BK/WH TS56 BK/WH C5-16
BK/RD CR4 BK/RD C1-K
BK/RD TS54
35 HIGH RPM 35
OR/BK C1-Q
OR/BK C5-22
GR/WH C6-22
RD/BK H4(+) GR/BK C3-N
+
RD/BK D29/TS58 RD/BK D91&D30
129 ALARMS OPT. 129
D27
H
GR C1-S
PIN
C3B
RD KS1-4 RD C6-29
134 KS POWER 134
RD U34-2
H4
RD H6+ RD C5-28
- 134A KS POWER 134A
19/18 CABLES
BR C5-1
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR CR1 BR C6-28
GND MAIN GROUND GND
I
BK TB22-C
WH TB23-C
BK/RD TB27-C
RD TB24-C
BK/RD C3-K
WH TB21-2-C
J
BR GDN
CR1
CR2
CR5
CR39
TS64
1 GR C5-24 BK TB33-C
BK C5-15 BK C6-23
BR TB-GND BR
BR
PIN
C1B
WH C5-7
WH C5-3
K
19/18 CABLES
GROUND CONTROL HARNESS

TO SWITCH PANEL
L
ES0549E
M
N
Ground Control Box Switch Panel Wiring Diagram

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
C19JSV GR/WH C3-U D9
TS57 TS51
P4 COMPONENT INDEX
TS59 D3
NO
3
6 3
CB1 CIRCUIT BREAKER, ENGINE, 15A
6 3
+
2
NO
CB2
4
L2 - CIRCUIT BREAKER, CONTROLS, 15A
CR1 START RELAY
C14PLU OR D28 CR2 INGITION POWER RELAY
C15PLD OR/BK C18JD GR/BK
CR4 HIGH IDLE RELAY
C18JD GR/BK CR5 HORN RELAY
C17JU GR G6 HOUR METER
C27AUX RD-27C
KS1 KEY SWITCH
D29 L2 CHECK ENGINE LED 3
CB1 CB2 P1 RED EMERGENCY STOP BUTTON
TS58
RD/BK TB129D P4 FUNCTION ENABLE BUTTON
R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS
BK/WH C8PBR-8A
R14 UP/DOWN SPEED RESISTER 7.5 OHMS
DALE RH-25 25W

TS51 AUXILIARY PUMP TOGGLE SWITCH
TS63 TS62
14
1
TS52 ENGINE START TOGGLE SWITCH
1
R14 TS53 FUEL SELECT TOGGLE SWITCH 4
7.5 ohm
TS54 RPM SELECT TOGGLE SWITCH
6
C7PBE BK-7A TS56 GLOW PLUG TOGGLE SWITCH
+ - R4
TS57
TS58
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH (OPTION)
G6 TS59 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH

C5TRR WH/BK
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
C4TRL WH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH 5
TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
TS64 RUN/TEST TOGGLE SWITCH
1
TS61 ES0549E
NOTE: DASHED LINES INDICATE OPTIONS.
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
1 2
C21IGN WH
1
KS1
GND BR
BK-22D
B B1 C11SBD BL/BK-11A
WH
WH
RD
RD
RD
RD
C10SBU BL-10A
3 4
RD TB134C C33STR BK-33A

D2 C35RPM BK/RD-35A RD U33-7 7
RD
RD
RD
WH TB23C
RD RD
D13
TS53
1
NC
1
1
C39LP BK/WH-34A
1
P1 8
NC
1
TS52
TS54
D11
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-35


6 - 35 6 - 36
Platform Control Box Wiring Diagram

6 - 37 6 - 38
N
JUMPER WIRES BETWEEN C54-7 TO C54-6 AND C54-10 TO C54-3
PLATFORM CONTROL HARNESS TO SWITCH PANEL

MUST BE INSTALLED WITH NO OPTION INSTALLED ON UNIT
ES0549E
JC1, JC2, JC3 BATGND BR

X103-1 BATGND BR
CR13#86 C19JIB RD C54-1

FOR OTHER OPTIONS
JIB OPTION SHOWN
SEE OPTION SHEET

M
SP1 P24FS WH C54-3

1
TS46-2 P24FS WH C54-4 C54-7 BK

TS46-3 P24FS WH C54-5 C54-6 BK
P2C-2 P26FS BK C54-6 C54-10 WH
C54
C54
BATGND
C9-1 P26FS BK C54-7 C54-3 WH

CR76#87 P26BAT BK C54-8 C54-12 GR/WH (C1)
CR76#85 C171LS WH/BK C54-9 C54-1 C19JIB RD (CR14)
TS7-5 P24FS WH C54-10
L
GR/WH
BR
GR/WH
R
RD
BR
1
B
R
C1
SP1
R R
X103-2
RD OUTPUT
X103-4
CR14
GR/WH +
C9-2
OPT
GNDBAT BR C7P-3
K
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
B
P23BAT WH C7P-2
P22BAT BK C7P-1
J
TS7-4 C19JSV GR/WH C3P-U

TS7-1 C18JD GR/BK C3P-T
OPT
TS7-3 C17JU GR C3P-S

C15PLD OR/BK C3P-Q
C14PLU OR C3P-P
C133PLA GR/BK C3P-O
C46HRN BK/RD C3P-K
C8PBR BK/WH C3P-J
C7PBE BK C3P-H
P25FS RD C9-3
I
SP1 P24FS WH C9-2

J1-14 C129DA RD/BK C3P-N
SP2 SP4
TS7-4
C45-12 C19JSV GR/WH C19JSV GR/WH C3P-U
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
H
TS47-1 C45GEN GR/WH C1P-U

C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X103
X102
11
1
3
P26ESTP BK
C9
C1PBU RD C3P-B
SP1 P24FS WH
G
C7PBE BK C3P-H
SP1 P24FS WH C16DRE OR/RD C3P-R
C8PBR BK/WH C3P-J
BATGND BR C40LSS OR SP3
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
C15PLD OR/BK C3P-Q
C36SCC BL C1P-L
C7P
F
C7P
C2PBD RD/BK C3P-C
ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
August 2013
Part No. 219418

C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
JC1 GND BR
D
JC2 C164PES RD/WH

JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
JC3 C159STC BL/WH
C1P
Z-45/25 • Z-45/25J
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
TS15-3 C143DEL BL/RD C28TTA RD/BK H1
TS15-1 C144DER BL/WH
C
L1(-) C13DE BL/RD

TS14- 1 C29MS RD/WH
X109
7
P134BAT RD (TILT) C1P-S

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK
L48 (-) C28TTA RD/BK

L48(-) C28TTA RD/BK (TILT) D40 J1-15 C28TTA RD/BK
(-)
C3-O C133PLA BL/RD D39 C3-O C133PLA BL/RD
H1
D39
L4(+) C133PLA RD D39 L4(+) C133PLA RD
A
(+)
C1P-S P134BAT RD (TILT)
P2B-1 P134BAT RD P2B-1 P134BAT RD
6-38
1
8
Platform Control Box Switch Panel Wiring Diagram

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
TS3 TS4 TS15

JC2 JC3
1
1
JC1
D10
CR13 3 4 WH 3 4
BK
RD
3 4
2 5 2
2 5
2 5
1 6 1
TS13 1 6
6
1 TS2
ROCKER OPT.
1
1
CR76 TS6 L1
C164PES RD/WH X101-2
C144DER BL/WH X101-6

C165TRS WH/RD X101-1
C159STC BL/WH X101-5
C160JPL WH/RD X101-4

C143DEL BL/RD X101-7
3
C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C39LP BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P22PWR RD SW20
BK
C54-5 P24FS WH
C27AUX RD C1P-B
P24FS WH
H1(D40) C28TTA RD/BK
C45GEN GR/WH C1P-U
LS18 P134BAT RD
C3P-S C17PRL GR
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
X103-3 P24FS WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C3P-T C18PRR GR/BK
C7P-2 P23BAT WH
C7P-1 R22BAT BK
X109-8 C15PLD OR/BK
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
P25FS RD
P24FS WH
TS9
WH WH
TS43 TS47 TS46
5
1 GR 1 4 1 4
4
1 1 1
4
3
NO
C
1
P3 +
B
+
RD
A
2
1
1
L4 L48 TS14
TS7 TS8 TS1 P2
GR/BK
WH
RD RD
COMPONENT INDEX
6
C1 JIB TIMER CAPACITOR TS1 AUXILIARY SWITCH
C1,C2 BOOM CONTROL CABLE CONNECTORS TS2 START ENGINE SWITCH
C7 POWER TO PLATFORM, 12V CABLE CONNECTOR TS3 FUEL SELECT SWITCH (FORD EFI ONLY)
C9 FOOTSWITCH INPUT CONNECTOR TS4 HI/LOW RPM SWITCH
C54 OPTIONS CONNECTOR TS6 GLOW PLUG SWITCH
CR13 JIB RELAY (JIB OPTION) TS7 PLATFORM ROTATE SWITCH
CR14 JIB RELAY (JIB OPTION) TS8 JIB ROTATE SWITCH (JIB OPTION)
CR27 BRAKE CIRCUIT RELAY (LIFT/DRIVE OPTION) TS9 PLATFORM LEVEL SWITCH
CR30 TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
CR76
LIMIT SWITCH RELAY (LIFT/DRIVE OPTION)
LOAD SENSE AUX RECOVERY TS14 DRIVE SPEED SWITCH
7
H1 TILT/LOAD SENSE ALARM TS15 DRIVE ENABLE SWITCH
BOOM PROPORTIONAL JOYSTICK: TS43 HEATER SWITCH (OPTION)
JC1 SECONDARY BOOM UP/DOWN
BOOM PROPORTIONAL JOYSTICK: TS46 PROXIMITY KILL SWITCH (OPTION)
JC2 PRIMARY UP/DOWN, TURNTABLE ROTATE TS47 GENERATOR SWITCH (OPTION)
JC3 DRIVE PROPORTIONAL JOYSTICK U13 ALC 500 JOYSTICK CONTROLLER CARD
L1 DRIVE ENABLE LED U35 TIME DELAY RELAY
L4 PLATFORM OVERLOAD LED (CE ONLY) X1-4 CIRCUIT SPLICE
L48 TILT ALARM LED (ANSI/CSA ONLY) X101 ALC500 POWER CONNECTOR
X101-
LS18 CE LIMIT SWITCH
X109 ALC500 INPUT/OUT CONNECTORS 8
P2 EMERGENCY STOP BUTTON
ES0549E
P3 HORN BUTTON
Part No. 219418 Z-45/25 • Z-45/25J 6-39


6 - 39 6 - 40
Electrical Schematic, Deutz D2011 L03i / Perkins 404D-22

Models (ANSI/CSA)
6 - 41 6 - 42
Electrical Schematic,
Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)
P134BAT RD
1 C41RPM OR/BK C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
RD P2 FS1
BK-(FS) RD-(FS) C9P-3
BK
WH-(FS) C9P-2 P24FS WH
RD TS2 TS6 TS4
ENGINE GLOW ENGINE
RD
2
C1B-Q
C1P-S P134BAT GR
START PLUG
C7P-1 R22BAT BK
RPM
C1P-N C132PLI1 BL/WH
FS HIGH RPM
RD
C9P-1 P26BAT BK
TS1
H1 L48 AUXILIARY
D12
P3 PUMP
C1P-K
C1P-H
C1P-B
C7P-2
C1P-J
D40
P4
CB2 FUNCTION
3
C3P-K
C3P-O
C1P-C
15 AMP TB134 RD
C7B-1
C1B-S
C1B-N
P1 ENABLE
RD RD P47FE RD
D4
C41RPM OR/BK
P174AUX RD
C46HRN BK/RD
C133PLA BL/RD
C28TTA RD/BK
KS1
TB22 1 3 TS52 TS56
P174BAT WH
P23BAT WH
C33STR BK
C27AUX RD
C35RPM RD/BK
C34SA BK/WH
TS54 P22BAT BK
4 5 ENGINE GLOW ENGINE
PLAT C32 START PLUG
HIGH RPM
GND RPM
6 7 D64
TS51
4 12 8
RD
AUXILIARY
PUMP C1B-H
C1B-B
TB33
C3B-O
C3B-K
C1B-C
C7B-2
C1B-Q
BR
TB27
C1B-K
BK
GR/BK D2
C1B-J
TB41 TB23 1 START RELAY
CB1 2 TACHOMETER
15 AMP P134BAT RD 3 START INPUT
4 AUX. ON U1 D13
TB20 RD TB24 5 GROUND IGN/START TB34
6 BATTERY
5 MODULE
P22BAT BK
+ 7 KEY PWR
C3 TB35
C34SA
8 KEY BYPASS
C5-10
C5-28
L2
RD
9 IGN/FUEL ON
C5-22
3Mf CR1 CR2 10 ENG. FAULT

NO NO
C35RPM BK/RD
C6-1
D108 C25ESL WH/BK

C2-P 1 D22 TB22 TB25
C5-25 C21ING WH TB21
CR4
NO
P22BAT BK
C41RPM OR/BK
C46HRN BK/RD
C27AUX RD C6-21
C21ING WH
P20BAT RD
C107AF WH
C5-16
BK/RD
C25ESL WH/BK
C5-8
P134TTS RD
C2-E RD/BK
C2-U
C5-15
C5-3
R33STR BK
F22 CR4
6 70A
BK/WH
C21ING2 WH
CB7
C25ESL WH/BK
C2-H
D52 10A
ALTERNATOR CR5
D1 A C
C2-M
NO
WH
RD
EXCT
C2-J
C2-K
C6-23
BAT+ BAT- PR1 PR2
C5-17
C2-C
12 VDC NO NO
PR3
C2-A
+ S8 NO
STA
7 + SW2
M3
HM M2 NC
_
BK
REG H2 Q3
SW3
BRN
IND B NO
B1 -
BR
BR
SOLENOID
HIGH RPM
HOUR METER
RELAY
HIGH RPM
IGN/START RELAY
FUEL SOLENOID
POWER RELAY
POWER RELAY
AUXILIARY PUMP
GLOW PLUG
HORN RELAY
LEVEL SENSOR
SUPRESSION DIODE
SERVICE HORN
STARTER MOTOR
SWITCH
OIL PRSSURE
SWITCH
OIL TEMPERATURE
CHECK ENGINE LED

TILT ALARM
AUXILIARY PUMP
ES0548E
NOTES:
8 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
1 DEUTZ 2011 L03i ENGINE ONLY.
6-42 Z-45/25 • Z-45/25J Part No. 219418

6-43

GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A

15
ROCKER OPTION
C160JPL WH/RD

C1P-F C31REV WH/BK
C159STC BL/WH
C5-13 C31REV WH/BK

X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B
X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4
C3P-E C4TRL WH C3B-E

August 2013
9 C6-7 C14-1 C14-2

C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9

8 UP PRIMARY UP
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

LS2- PRIMARY UP
I
X103
BR
22
1
LS4
DRIVE LIMIT SWITCH

LS4- SECONDARY UP
21
22
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
TB129
15 10 DESCENT ALARM
TRAVEL ALARM
J
D29
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13

NC
DOWN
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
L
LEFT
GR/WH
CR13 RD
C1
M
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
Electrical Schematic, Deutz D2011 L03i / Perkins 404D-22

Models (ANSI/CSA)
6 - 43 6 - 44

6 - 45 6 - 46
8
7
6
5
4
3
2
1
6-46
Genie
BK-CR1 TO REMOVE: 1 START RELAY
1
1
OR/BK TB41-C Push gently 2 TACHOMETER
2
BK TB33D and lift 3 START INPUT
3
RD TB27D 4 AUX PWR UNIT
A
NOTES:
4
BR TBGND-D 5 GROUND
5 U1 (ISM)
WH TB24D 6 BATTERY
6
WH TB23-D 7 TO KEY SW (DIESEL ONLY)
7
8 8 JUMP TO 7 (GAS ONLY)
WH CR2 9 IGN OR FUEL ON

9 1 3 4 7 10 9 2
WH/BK TB25-D 10 TEMP OR PRESS FAULT
10

B
C6
PIN
RD C3B-B
HARNESS
FUNCTION
RD TS61-1 RD-C6-5
DEUTZ ENGINE MODELS ONLY.

1 PRIMARY BOOM UP 1
RD/BK C3B-C
WH C3B-E
D30
WH TS62-3 WH C6-7

WH/BK C3B-F C6-25 BL C36SCC C1B-L
BK C3B-H
C
BK TS63-3 BK C6-9
BK/WH C3B-J
RD/BK TB129
8 8

PRIMARY BOOM RETRACT
BL C3B-L
BL TS60-1 BL C6-11
Z-45/25 • Z-45/25J
BL/BK C3B-M

D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q
D
GR C3B-S
GR TS57-4 GR C6-16

GR/BK C3B-T
RD/BK TB129
RD CB3 RD CB1
C5
RD CB2 RD C6-1
SOC

ENGINE
WH CR17
HARNESS
WH C5-3

WH CR17
WH FUSE WH C5-25
D52
E
WH CR2
BK CR5 BK C32-4
BK KS1-4 BK C6-19
BK C5-6
WH D2-KS1 WH C7-2
BR TBGND-D
WH U1-7
RD CR2 WH TB23-A
WH ISM-7 RD CB1
Part No. 219418

August 2013
24 CB1 POWER 24 BK C32-5

WH /BK L2 WH/RD C5-9 BR GND
C7B

F
12V DC
RD TS51 RD C1B-B
RD ISM-4 RD C6-21
RD/WH C1-D
RD/WH C5-11
29 MOTOR STROKE 29
WH C1-E
WH C5-12
30 DRIVE FORWARD 30
POWER TO PLATFORM
WH/BK C1-F
WH/BK C5-13
31 DRIVE REVERSE 31
WH/RD C1-G
R35RPM BK/RD CR4-87
WH/RD C5-14 BAT
32 BRAKE 32
BK TS52-1 BK C1-H
10A
CB7
R35RPM BK/RD C5-17

G
BK ISM-3 AUX
33 START ENGINE 33
BK/WH C1-J
BK/RD TS54
35 HIGH RPM 35
1
OR/BK ISM-2 OR/BK C1-Q

// OR/BK C5-22
+
GR/WH C2P-7 GR/WH C6-22

C3
+
129 ALARMS OPT. 129
H
D27
GR C1-S
PIN
C3B
RD KS1-4 RD C6-29
134 KS POWER 134
RD U34-2
H4 RD H6+
134A KS POWER 134A
RD C5-28
-
19/18 CABLES
BR C5-1
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR ISM-5
BR CR1 BR C6-28 (WL)
GND MAIN GROUND GND
I
BK TB22-C
BK/RD TB35-C
RD TB24-C
WH ISM 9 (CE SEE U34)
BK/RD C3-K
WH TB21-D
J
CR1
CR2
CR4
CR5
BK ISM 1
WH
BK C5-15 BK C6-23
BR TB-GND BR BR BR
BK/RD CB7
PIN
C1B
K
19/18 CABLES

TO SWITCH PANEL
L
ES0549E
M
N

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
C19JSV GR/WH C3-U D9 COMPONENT INDEX
TS57 TS51 CB1 CIRCUIT BREAKER, ENGINE, 15A
P4 TS59 D3
NO
3
6 3
CB2 CIRCUIT BREAKER, CONTROLS, 15A
6 3
+
2
NO
CR1 START RELAY
4
L2 -
CR2 INGITION POWER RELAY
C14PLU OR D28 CR4 HIGH IDLE RELAY
CR5 HORN RELAY
C18JD GR/BK G6 HOUR METER
C17JU GR KS1 KEY SWITCH
C27AUX RD-27C L2 CHECK ENGINE LED
D29 P1 RED EMERGENCY STOP BUTTON 3
CB1 CB2 P4 FUNCTION ENABLE SWITCH
TS58
RD/BK TB129D R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS
BK/WH C8PBR-8A
DALE RH-25 25W

TS63 TS62
14
1
TS53 FUEL SELECT TOGGLE SWITCH
1
R14 TS54 RPM SELECT TOGGLE SWITCH 4
7.5 ohm
TS56 GLOW PLUG TOGGLE SWITCH
6
C7PBE BK-7A TS57 PLATFORM ROTATE TOGGLE SWITCH
+ - R4
TS58
TS59
JIB BOOM UP/DOWN TOGGLE SWITCH (OPTION)
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
G6 TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

C5TRR WH/BK
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
C4TRL WH TS62 TURNTABLE ROTATE TOGGLE SWITCH 5
ES0549E
1
TS61
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
1 2
C21IGN WH
1
KS1
GND BR
BK-22D
WH
WH
RD
RD
RD
C10SBU BL-10A
3 4

D2 RD U33-7 7
RD
RD
RD
WH TB23C C34SA BK/WH-34D
1
NC
TS56
1
1
1
P1 8
NC
1
D64 TS52
TS53 TS54
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-47


6 - 47 6 - 48

6 - 49 6 - 50
N

ES0549E

X103-1 BATGND BR
M
CR13#86 C19JIB RD C54-1

FOR OTHER OPTIONS
JIB OPTION SHOWN
SEE OPTION SHEET

SP1 P24FS WH C54-3
1
TS46-2 P24FS WH C54-4 C54-7 BK

TS46-3 P24FS WH C54-5 C54-6 BK
P2C-2 P26FS BK C54-6 C54-10 WH
C54
C54
BATGND
C9-1 P26FS BK C54-7 C54-3 WH

L
TS7-5 P24FS WH C54-10

GR/WH
BR
GR/WH
R
RD
BR
1
B
R
C1
SP1
K
R R
X103-2
RD OUTPUT
X103-4
CR14
GR/WH +
C9-2
OPT
GNDBAT BR C7P-3
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
B
R
J
P23BAT WH C7P-2
P22BAT BK C7P-1
OPT

C15PLD OR/BK C3P-Q
C14PLU OR C3P-P
C133PLA GR/BK C3P-O
C46HRN BK/RD C3P-K
C8PBR BK/WH C3P-J
I
C7PBE BK C3P-H
P25FS RD C9-3
SP1 P24FS WH C9-2
SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X103
X102
11
1
3
P26ESTP BK
G
C9
C1PBU RD C3P-B
SP1 P24FS WH
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C7P
C2PBD RD/BK C3P-C
August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-50
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
TS3 TS4 TS15

JC2
1
1
JC3
1
JC1
CR13 3 4 WH 3 4
BK
3 4
2 5 2
2 5
2 5
1 6 1
TS13 1 6
6
1
ROCKER OPT.
1
1
CR76 TS2 TS6 L1


3

C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C34SA BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P22PWR RD SW20
C54-5 P24FS WH
C45GEN GR/WH C1P-U
X103-3 P24FS WH
BK
P24FS WH
C27AUX RD C1P-B
LS18 P134BAT RD
C3P-S C17PRL GR
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C3P-T C18PRR GR/BK
C7P-2 P23BAT WH
C7P-1 R22BAT BK
X109-8 C15PLD OR/BK
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
P25FS RD
TS9
WH P24FS WH WH 5
GR 1 4 1 1 1
4
1 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
2
1
TS14
1
L4 L48
TS7 TS8 TS1 TS43 TS47 TS46 P2
GR/BK
WH
RD RD
COMPONENT INDEX
6
C1 JIB TIMER CAPACITOR NOTE: DASHED LINES INDICATE OPTIONS.
TS1 AUXILIARY SWITCH
CR30 LIMIT SWITCH RELAY (LIFT/DRIVE OPTION) TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
7
CR76 LOAD SENSE AUX RECOVERY TS14 DRIVE SPEED SWITCH
X101 ALC500 POWER CONNECTOR
L48 TILT ALARM LED (ANSI/CSA ONLY)
X101-
8
X109 ALC500 INPUT/OUT CONNECTORS
ES0549E
P3 HORN BUTTON
Part No. 219418 Z-45/25 • Z-45/25J 6-51


6 - 51 6 - 52
Electrical Schematic, Deutz D 2.9 L4 Models (ANSI)
6 - 53 6 - 54
BRN
ES0548E
P47FE RD
P174AUX RD
N
P24FS WH
P134BAT RD
P22BAT BK
C41RPM OR/BK
C28TTA RD/BK
P26EST BK
D12
FS HIGH RPM C1P-K C35RPM BK/RD C1B-K

C128RPM OR/RD C1B-R
M
FS LOW RPM C1P-R

TB34
TS54
D10
D13 D11
ENGINE
SPEED
D4
TB35
TS4
C1B-Q C41RPM OR/BK C1B-Q C41RPM OR/BK C5-22

C2-M
TB41
L
P4
FUNC. ENABLE
L2
C1P-J C34WTS BK/WH C1B-J C34WTS BK/WH C5-16

C2-J
K
D14
GR C5-20 GR D81CAN- GN
C2-W
C2-X
YL C5-23 YL D82CAN+ YL
C28TTA RD/BK
10
12
11
4
3
P174AUX RD
P134BAT RD
DISPLAY HIGH RPM

J1939 LOW RPM
ECU PWR
A
P26EST BK
P24FS WH
1 GND CAN +
2 PWR CAN -
U39
120
J
C21RET WH/BK
R164PWR WH

P25FS RD
ENGINE
START
BK C33STR BK C5-15 C33STR BK

I
C2-H
TS2
ENGINE
CR1
TB33
START
TS52
CR2A
GND BR
START RELAY
GND BR
NO
POWER RELAY
TB25
P23PWR WH C5-7 P23PWR WH

C2-B
TB21
NO
H
TB26
8
9
+
10A
NO
C9P-3
C9P-2
2
AUXILIARY
2 SEC
-
PUMP
TS1
U38 3
P164BAT RD
C27AUX RD C1B-B
WH-(FS)
C1P-B
RD-(FS)
P110RET BK C5-3 P110RET WH

C2-A
G
NO
C5-24 R27AUX GN
C2-S
FS1
GND BR
CR39A
PR1
RD C27AUX RD C6-21 AUXILIARY POWER
RELAY
AUXILIARY
TB27
BK-(FS) C9P-1 P26BAT BK

PUMP
TS51
M2
F
AUXILIARY PUMP
PR1
NO
August 2013
Part No. 219418

BK
C7B-2
TB23
C7P-2 P23BAT WH
P2
E
D2
L48
P174BAT WH
D40
C
RD C1P-C C28TTA RD/BK C1B-C C5-10 C28TTA RD/BK TILT ALARM
H1
C2-E WH
S8
C5-28 C2-U RD BK BRN
LEVEL SENSOR
P134TTS RD
B
A
D
C3P-O C133PLA BL/RD C3B-O
CR5A
NO
RD
P3
RD C3P-K C46HRN BK/RD C3B-K C46HRN BK/RD SERVICE HORN

RELAY
Z-45/25 • Z-45/25J
C7P-1 P22BAT BK C7B-1 P22BAT BK C6-23 BK
P134TTS RD
GR/BK
SERVICE HORN
H2
RD
7
8
C1P-N C132PLI1 BL/WH C1B-N
C32
3
C1P-S P134BAT GR C1B-S
C
12
RD
6
TB134
BRN
P22BAT BK
P164BAT RD
TB22
PLAT
GND
KS1
KS1
B
RD
P1
RD
BIBAT RD
15AMP.
STARTER B+
A
CB2
TB20
-
+
RD C6-1 P20BAT RD
12V DC
B1
6-54
1
8
6-55
GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A

15
ROCKER OPTION
C160JPL WH/RD

C1P-F C31REV WH/BK
C159STC BL/WH
C5-13 C31REV WH/BK

X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B
X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4

August 2013
9 C6-7 C14-1 C14-2

C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9

8 UP PRIMARY UP
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

LS2- PRIMARY UP
X103
BR
I
22
1
LS4
DRIVE LIMIT SWITCH

LS4- SECONDARY UP
21
22
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
TB129
15 10 DESCENT ALARM
TRAVEL ALARM
D29
J
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13

NC
DOWN
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
L
LEFT
GR/WH
CR13 RD
C1
M
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 55 6 - 56

Deutz D 2.9 L4 Models (ANSI)
6 - 57 6 - 58
8
7
6
5
4
3
2
1
6-58
C6
PIN
HARNESS
FUNCTION
A
NOTES:
RD C3B-B
C6-27 OR C40LS C1B-P

RD TS61-1 1 PRIMARY BOOM UP 1 RD-C6-5
RD/BK C3B-C

B
D30
2 PRIMARY BOOM DOWN WH C3B-E
WH TS62-3 4 TURNTABLE ROTATE LEFT 4 WH C6-7
WH/BK C3B-F
WH/BK TS62-1 5 TURNTABLE ROTATE RIGHT 5 WH/BK C6-8
BK C3B-H
BK TS63-3 7 PRIMARY BOOM EXTEND 7 BK C6-9
BK/WH C3B-J
BK/WH TS63-1 8 PRIMARY BOOM RETRACT 8 BK/WH C6-10
BL C3B-L
BL TS60-1 10 SECONDARY BOOM UP 10 BL C6-11
BL/BK C3B-M
C

RD/BK TB129A D91

OR C3B-P
OR TS59-1 14 PLATFORM LEVEL UP 14 OR C6-13
OR/BK C3B-Q
OR/BK TS59-3 15 PLAT LEVEL DOWN 15 OR/BK C6-14
GR C3B-S
Z-45/25 • Z-45/25J
C1B-J C34WTS BK/WH C5-16
C5-18 C16DRE OR/RD C3-R
GR TS57-1 17 PLAT ROTATE LEFT/JIB UP 17 GR C6-15

GR/BK C3B-T

C5
SOC
GR/BK TS57-3 18 PLAT ROTATE RIGHT/JIB DOWN GR/BK C6-16

18
ENGINE
GR/WH C3B-U
HARNESS
RD/BK TB129A
GR/WH TS57 19 PLAT ROTATE/JIB SEQ 19

RD CB2
D
RD CB1 20 +12 VOLT BATTERY POWER 20 RD C6-1

WH CR2-87 WH C5-7
BK CR5-30 21 +12 VOLT IGN. POWER 21 BK C5-6

BK KS1-1 BK C6-19
C5-23 D82CAN+ YL U39-3
C5-20 D81CAN- GR U39-4
BK CR5-30
BK C7-1
WH U38-5 22 +12 VOLT TO PLATFORM 22 WH U38-5
WH KS1-3 WH C7-2
23 KEYSWITCH POWER 23 BL/RD C1B-O
E
RD CB1 RD CB1
24 CB1 POWER 24 RD U38-8
WH CR2-86
WH U39-2
25 KS TRANSITION POWER 25 BK TB22-2-A
25 KS TRANSITION POWER 25 WH TB23-A
C7B
RD KS1-B RD U38-2 BR TBGND-1-B

1 2 3
26 P1 E-STOP POWER 26 RD C1B-B

RD CR39-86
12V DC
Part No. 219418

RD C6-21
August 2013
RD TS51 27 AUXILIARY PUMP 27 RD/WH C1B-D

RD/WH C5-11
29 MOTOR STROKE 29
F
WH C1B-E
WH C5-12
30 DRIVE FORWARD 30
POWER TO PLATFORM
WH/BK C1B-F
WH/BK C5-13
31 DRIVE REVERSE 31 WH/RD C1B-G
WH/RD C5-14
BK CR1A-86 32 BRAKE 32 BK C1B-H
BK TS52 BK C5-15
33 START ENGINE 33 OR/RD C1B-R
OR/RD U39-10
OR/RD TS54 34 LOW RPM 34
BK/RD U39-11 BK/RD C1B-K
BK/RD TS54 BK/RD TS54
G
35 HIGH RPM 35 OR/BK C1B-Q
+
OR/BK C5-22
41 ALT PULSE PICKUP 41 OR/BK C1B-U
GR/WH C6-22
PIN
C3B
RD/BK h4(+) 45 GENERATOR OPT. 45 GR/BK C3-N
H4
RD/BK TS58 RD/BK D91&D30
129 ALARMS OPT. 129
D27
GR C1B-S
-
19/18 CABLES
RD KS1-4 RD C6-29
134 KS POWER 134 RD TB25B
RD H6+ RD C5-28 RD TB26A
134A KS POWER 134A BR C7-3 BR TBGND-3-B
H
52 MAIN GROUND 52 BR C6-2

BR C5-1
3
2
BR CR1A-87 BR C6-3
9
52 MAIN GROUND 52 BR U38-3

BR U39-1 WH TB23B
5

8 RELAY
U38
BK TB22-C
RD TB27-C
BK C5-3
I
WH TB25-1-C
WH TB21-1-C BK/RD C3-K
WH/BK U39-12
CR39
CR5
CR2
CR1A
BK TB33-C
PIN
C1B
J
BR TBGND-2-D
BR BK C6-23
19/18 CABLES
BR
ES0549E
GROUND CONTROL GR C5-24

HARNESS
(TO SWITCH
K
PANEL)
L
M
N

(TO TERMINAL STRIP)

BASE BOX HARNESS
1
RD U33-6
COMPONENT INDEX
C17JU GR D4
C19JSV GR/WH TB19D D9 CB2 CIRCUIT BREAKER, CONTROLS, 15A
P4 +
CR1 START RELAY
D3
L45
NO
3
4
C14PLU OR 2
63
63
-
TS59 TS57 TS51
C15PLD OR/BK
NO
3
4
CR4 HIGH IDLE RELAY
RD P134BAT
CR5 HORN RELAY
GR/BK H6(-)
D28 G6 HOUR METER
C18JD GR/BK
D13 KS1 KEY SWITCH
C18JD GR/BK
1
L2 CHECK ENGINE LED
C17JU GR
C27AUX RD-27C
TS54 P1 RED EMERGENCY STOP BUTTON
C35RPM BK/RD-35A
D11
P4 FUNCTION ENABLE SWITCH 3
TS58 RD/BK TB129D R14 UP/DOWN SPEED RESISTER 7.5 OHMS
BK/WH C8PBR-8A
R14
1
TS62
DALE RH-25 25W TS52
14
1
7.5 ohm
TS63 TS56 GLOW PLUG TOGGLE SWITCH
RD 4
TS57 PLATFORM ROTATE TOGGLE SWITCH
6
C7PBE BK-7A TS58 JIB BOOM UP/DOWN TOGGLE SWITCH (OPTION)
TS59 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
R4
C128RPM OR/RD TB128A
C5TRR WH/BK
C4TRL WH
RD U33-7
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH 5
C33STR BK-33A
ES0549E
TS61 NOTE: DASHED LINES INDICATE OPTIONS.
1
C1PBU RD-1A
RD TB26D
BK TB22D
C2PBD RD/BK-2A
KS1
1
TS60 6
1
P-BOX
C11SBD BL/BK-11A
B1
B
C10SBU BL-10A
G-BOX
3
RD TB134C
B A
C
RD
RD
D81CAN- GR C5-20 120
12
P20BAT RD TB20B
P24BAT RD TB24A
RD P20BAT TB20D
1
RESISTOR
WH TB23C D82CAN+ YL C5-23 7
TB25-1-C WH
GND BR
RD
C21RET WH CR2-86
C35RPM BK/RD (D2.9-TB35C) (404F-TB25-2-C)
C128RPM OR/RD (D2.9-TB34C) (404F-TB25-2-D)
7
6
NC
2
1
P1 U39
NC
CB1 CB2
1
Part No. 219418 Z-45/25 • Z-45/25J 6-59


6 - 59 6 - 60

6 - 61 6 - 62
N

ES0549E

X103-1 BATGND BR
M
CR13#86 C19JIB RD C54-1

FOR OTHER OPTIONS
JIB OPTION SHOWN
SEE OPTION SHEET

SP1 P24FS WH C54-3
1
TS46-2 P24FS WH C54-4 C54-7 BK

TS46-3 P24FS WH C54-5 C54-6 BK
P2C-2 P26FS BK C54-6 C54-10 WH
C54
C54
BATGND
C9-1 P26FS BK C54-7 C54-3 WH

L
TS7-5 P24FS WH C54-10

GR/WH
BR
GR/WH
R
RD
BR
1
B
R
C1
SP1
K
R R
X103-2
RD OUTPUT
X103-4
CR14
GR/WH +
C9-2
OPT
GNDBAT BR C7P-3
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
B
R
J
P23BAT WH C7P-2
P22BAT BK C7P-1
OPT

C15PLD OR/BK C3P-Q
C14PLU OR C3P-P
C133PLA GR/BK C3P-O
C46HRN BK/RD C3P-K
C8PBR BK/WH C3P-J
I
C7PBE BK C3P-H
P25FS RD C9-3
SP1 P24FS WH C9-2
SP3 SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C25ESL GR/BK C1P-T
C34WTS BK/WH C1P-J
C128RPM OR/RD C1P-R
C35RPM BK/RD C1P-K
C9 (FS)
C33STR BK C1P-H
C3P
C27AUX RD C1P-B
X103
11
X102
1
G
C9
C1PBU RD C3P-B
3
P26ESTP BK
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
SP1 P24FS WH C40LSS OR SP3
C129DA RD/BK C3P-N
BATGND BR C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C7P
C2PBD RD/BK C3P-C
August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-62
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12 D10
TS4 TS15
JC2
1
1
JC1 JC3
CR13 3 4 WH 3 4
BK
3 4
2 5 2
2 5
2 5
1 6 1
TS13 1 6
6 L2
1
ROCKER OPT.
1
CR76 TS2 L1
D14

C128RPM OR/RD C1P-R

3

C161SB WH/BK X101-3
C35RPM BK/RD C1P-K

C34WTS BK/WH C1P-J
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P23BAT WH
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P22PWR RD SW20
C54-5 P24FS WH
C45GEN GR/WH C1P-U
X103-3 P24FS WH
BK
P24FS WH
C27AUX RD C1P-B
LS18 P134BAT RD
C3P-S C17PRL GR
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C3P-T C18PRR GR/BK
C7P-2 P23BAT WH
X109-8 C15PLD OR/BK
C7P-1 R22BAT BK
X103-3 P26ESTP BK
X109-9 C14PLU OR
X101-8 C29MS RD/WH

P25FS RD
TS9
WH P24FS WH WH 5
GR 1 4 1 1 1
4
1 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
2
1
TS14
1
L4 L48
GR/BK
WH
RD RD
COMPONENT INDEX
6
C1 JIB TIMER CAPACITOR P2 EMERGENCY STOP BUTTON NOTE: DASHED LINES INDICATE OPTIONS.
C1,C2 BOOM CONTROL CABLE CONNECTORS P3 HORN BUTTON
C7 POWER TO PLATFORM, 12V CABLE CONNECTOR TS1 AUXILIARY SWITCH
C9 FOOTSWITCH INPUT CONNECTOR TS2 START ENGINE SWITCH
C54 OPTIONS CONNECTOR TS3 FUEL SELECT SWITCH (FORD EFI ONLY)
CR13 JIB RELAY (JIB OPTION) TS4 HI/LOW RPM SWITCH
CR14 JIB RELAY (JIB OPTION) TS6 GLOW PLUG SWITCH
CR27 BRAKE CIRCUIT RELAY (LIFT/DRIVE OPTION) TS7 PLATFORM ROTATE SWITCH
CR30 LIMIT SWITCH RELAY (LIFT/DRIVE OPTION) TS8 JIB ROTATE SWITCH (JIB OPTION)
7
CR76 LOAD SENSE AUX RECOVERY TS9 PLATFORM LEVEL SWITCH
H1 TILT/LOAD SENSE ALARM TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
BOOM PROPORTIONAL JOYSTICK: TS14 DRIVE SPEED SWITCH
TS15 DRIVE ENABLE SWITCH
BOOM PROPORTIONAL JOYSTICK:
JC2 PRIMARY UP/DOWN, TURNTABLE ROTATE TS43 HEATER SWITCH (OPTION)
JC3 DRIVE PROPORTIONAL JOYSTICK TS46 PROXIMITY KILL SWITCH (OPTION)
L1 DRIVE ENABLE LED TS47 GENERATOR SWITCH (OPTION)
L2 WAIT TO START LED U13 ALC 500 JOYSTICK CONTROLLER CARD
U35 TIME DELAY RELAY
L4
L28
PLATFORM OVERLOAD LED (CE ONLY)
ENGINE SHUTDOWN LED - PERKINS 404F-22 X1-4 CIRCUIT SPLICE
8

X101-
ES0549E
Part No. 219418 Z-45/25 • Z-45/25J 6-63


6 - 63 6 - 64
Electrical Schematic, Perkins 404F-22 Models (ANSI)
6 - 65 6 - 66
N
BRN
P24FS WH
P47FE RD
P174AUX RD
P134BAT RD
P22BAT BK
C41RPM OR/BK
C28TTA RD/BK
P26EST BK
ES0548E
D12
FS HIGH RPM C1P-K C35RPM BK/RD C1B-K GND BR

CR4B
M
NO
C1P-R C128RPM OR/RD C1B-R

TB34
FS LOW RPM C5-26 C128RPM OR/RD C2-T

D11
D10
TS54
ENGINE
D4
SPEED
GND BR
TS4
LRPM RELAY
HRPM RELAY
D13
TB35
C5-17 C35RPM BK/RD

C2-K
P4
CR4A
FUNC. ENABLE
NO
L
C1B-Q
C1B-Q C41RPM OR/BK C41RPM OR/BK C5-22
C2-M
TB41
C1P-T C25ESL GN/BK C1B-T C25ESL GN/BK C5-8 C2-C

L28
C1P-J C34WTS BK/WH C1B-J C34WTS BK/WH C5-16

K
C2-J
L2
D14
GR C5-20 GR D81CAN- GN C2-W

C28TTA RD/BK
C2-X
YL C5-23 YL D82CAN+ YL
P174AUX RD
10
12
11
P134BAT RD
4
3
P26EST BK
P24FS WH
DISPLAY HIGH RPM

J1939 LOW RPM
ECU PWR
A
1 GND CAN +
2 PWR CAN -
U39
J
120
ENGINE
C21RET WH/BK
START
TS2
C33STR BK
C1P-H C1B-H
P25FS RD
I
C33STR BK C5-15 C33STR BK

BK C2-H
CR1A
R164PWR WH
ENGINE
TB33
START
TS52
CR2A
GND BR
STARTER RELAY
GND BR
NO
POWER RELAY
P23PWR WH C5-7 P23PWR WH
C2-B
TB25
TB21
NO
H
TB26
8
+
10A
C9P-3
C9P-2
AUXILIARY
NO
2
PUMP
2 SEC
-
TS1
U38 3
5
P164BAT RD
C27AUX RD C1B-B
C1P-B
WH-(FS)
RD-(FS)
P164PWR WH
G
NC
C5-24 R27AUX GN
FS1
C2-S
GND BR
CR39A
PR1
RD C27AUX RD C6-21 AUXILIARY POWER
AUXILIARY
RELAY
TB27
BK-(FS)
PUMP
C9P-1 P26BAT BK
TS51
F
M2
AUXILIARY PUMP
PR1
NO
August 2013
Part No. 219418

BK
TB23
C7P-2 P23BAT WH C7B-2

P2
E
D2
L48
P174BAT WH
D40
C
RD C1P-C C28TTA RD/BK C1B-C C5-10 C28TTA RD/BK TILT ALARM
WH
H1
C2-E
S8
C5-28 C2-U RD BK BRN
LEVEL SENSOR
P134TTS RD
B
A
D
C3P-O C133PLA BL/RD C3B-O
CR5
RD
P3
RD C3P-K C46HRN BK/RD C3B-K C46HRN BK/RD SERVICE HORN

RELAY
Z-45/25 • Z-45/25J
C7P-1 P22BAT BK C7B-1 P22BAT BK C6-23 BK
GR/BK
P134TTS RD
SERVICE HORN
NO
H2
RD
7
8
5
C1P-N C132PLI1 BL/WH C1B-N
C32
C1P-S P134BAT GR C1B-S
C
1
RD
12
4
6
TB134
BRN
TB22
P22BAT BK
P164BAT RD
PLAT
KS1 GND
KS1
B
RD
P1
RD
BIBAT RD STARTER B+
15AMP.
A
CB2
TB20
_
RD C6-1 P20BAT RD
12V DC
B1
6-66
1
8
6-67
GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A

15
ROCKER OPTION
C160JPL WH/RD

C1P-F C31REV WH/BK
C159STC BL/WH
C5-13 C31REV WH/BK

X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B
X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4

August 2013
9 C6-7 C14-1 C14-2

C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9

8 UP PRIMARY UP
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

LS2- PRIMARY UP
X103
BR
I
22
1
LS4
DRIVE LIMIT SWITCH

LS4- SECONDARY UP
21
22
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
TB129
15 10 DESCENT ALARM
TRAVEL ALARM
D29
J
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13

NC
DOWN
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
L
LEFT
GR/WH
CR13 RD
C1
M
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 67 6 - 68

Perkins 404F-22 Models (ANSI)
6 - 69 6 - 70
8
7
6
5
4
3
2
1
6-70
C6
PIN
A
HARNESS
NOTES:
FUNCTION

RD C3B-B
RD TS61-1 1 RD-C6-5
1 PRIMARY BOOM UP
RD/BK C3B-C
C6-27 OR C40LS C1B-P


2
D30
2 PRIMARY BOOM DOWN
B
WH C3B-E
WH TS62-3 WH C6-7

WH/BK C3B-F
BK C3B-H
BK TS63-3 7 BK C6-9
7 PRIMARY BOOM EXTEND
BK/WH C3B-J
BK/WH TS63-1 8 BK/WH C6-10
8 PRIMARY BOOM RETRACT
RD/BK TB129A
BL C3B-L

BL TS60-1 BL C6-11
BL/BK C3B-M
C

D91
OR C3B-P
OR TS59-1 OR C6-13
14 PLAT LEVEL UP 14
OR/BK C3B-Q

Z-45/25 • Z-45/25J
15 PLAT LEVEL DOWN 15
GR C3B-S
C1B-J C34WTS BK/WH C5-16
C1-T C108ESL GR/BK C5-8
C5-18 C16DRE OR/RD C3-R
GR TS57-1 GR C6-15
17 PLAT ROTATE LEFT/JIB UP 17
GR/BK C3B-T
C5

SOC
18 PLAT ROTATE RIGHT/JIB DOWN 18

GR/WH C3B-U
ENGINE
RD/BK TB129A
HARNESS
GR/WH TS57
D
RD CB2 19 PLAT ROTATE/JIB SEQUENCE 19

RD CB1 20 +12 VOLT BATTERY POWER 20 RD C6-1
WH CR2-87 WH C5-7
BK CR5-30 BK C5-6
BK KS1-1 22 +12 VOLT TO PLATFORM 22 BK C6-19
C5-23 D82CAN+ YL U39-3
C5-20 D81CAN- GR U39-4
BK CR5-30
BK C7-1
E
WH U38-5 22 +12 VOLT TO PLATFORM 22

WH U38-5
WH KS1-3 23 KEYSWITCH POWER 23 WH C7-2
BL/RD C1B-O
RD CB1 RD CB1
24 CB1 POWER 24
WH U39-2 RD U38-8
WH CR2-86 25 KS TRANSITION POWER 25
BK/RD U39-11 BK TB22-2-A
1
OR/RD U39-10
Part No. 219418

August 2013
25 KS TRANSITION POWER 25 WH TB23-A

2
BR TBGND-1-B
C7B
RD KS1-B RD U38-2
3
26 P1 E-STOP POWER 26
F
12V DC
RD CR39-86 RD C1B-B
RD TS51 27 AUXILIARY PUMP 27 RD C6-21
RD/WH C1B-D
29 MOTOR STROKE 29 RD/WH C5-11
WH C1B-E
30 DRIVE FORWARD 30 WH C5-12
POWER TO PLATFORM
WH/BK C1B-F
31 DRIVE REVERSE 31 WH/BK C5-13
WH/RD C1B-G
32 BRAKE 32 WH/RD C5-14
BK CR1A-86 BK C1B-H
G
BK TS52 33 START ENGINE 33 BK C5-15

BK CR4B-86 OR/RD C1B-R
OR/RD TS54 34 LOW RPM 34
BK CR4A-86 BK/RD C1B-K
BK/RD TS54 35 HIGH RPM 35 BK/RD TS54
OR/BK C1B-Q
+
41 ALT PULSE PICKUP 41 OR/BK C5-22
OR/BK C1B-U
PIN
GR/WH C6-22
C3B
RD/BK h4(+) 45 GENERATOR OPT. 45

GR/BK C3-N
H4
H
RD/BK TS58 RD/BK D91&D30

D27
129 ALARMS OPT. 129

GR C1B-S
19/18 CABLES
-
RD KS1-4 RD C6-29
134 KS POWER 134 RD TB25B
RD H6+ RD C5-28 RD TB26A
134A KS POWER 134A
BR C7-3 BR TBGND-3-B
BR C5-1
3
2
BR CR1A-87 BR C6-3
9
52 MAIN GROUND 52
BR U39-1 BR U38-3 WH TB23B
5
I
BR CR4A-85 52 MAIN GROUND 52 BR C6-28

8 RELAY
U38
RD TB27-C
WH/BK U39-12 BK/RD C3-K
WH TB25-1-D
BK TB22-C
WH TB21-1-C
J
CR5
CR39
CR2
CR1A
BK TB33-C
BR TB52-2-D BK C6-23
PIN
C1B
GR C5-24
K
BK/RD TB35-C
BK/RD C5-17
19/18 CABLES
OR/RD C5-26
CR4B
CR4A
BR TB52-3-D
CR23
CR17
L
OR/RD TB34-C
GROUND CONTROL
HARNESS
(TO SWITCH
PANEL)
M
ES0549E
N

(TO TERMINAL STRIP)

BASE BOX HARNESS
1
RD U33-6
COMPONENT INDEX
C17JU GR D4
C19JSV GR/WH TB19D D9 CB2 CIRCUIT BREAKER, CONTROLS, 15A
P4 +
CR1 START RELAY
D3
L45
NO
3
4
C14PLU OR 2
63
63
-
TS59 TS57 TS51
C15PLD OR/BK
NO
3
4
CR4 HIGH IDLE RELAY
RD P134BAT
CR5 HORN RELAY
GR/BK H6(-)
D28 G6 HOUR METER
C18JD GR/BK
D13 KS1 KEY SWITCH
C18JD GR/BK
1
L2 CHECK ENGINE LED
C17JU GR
C27AUX RD-27C
TS54 P1 RED EMERGENCY STOP BUTTON
C35RPM BK/RD-35A
D11
P4 FUNCTION ENABLE SWITCH 3
TS58 RD/BK TB129D R14 UP/DOWN SPEED RESISTER 7.5 OHMS
BK/WH C8PBR-8A
R14
1
TS62
DALE RH-25 25W TS52
14
1
7.5 ohm
TS63 TS56 GLOW PLUG TOGGLE SWITCH
RD 4
6
C7PBE BK-7A TS58 JIB BOOM UP/DOWN TOGGLE SWITCH (OPTION)
R4
C128RPM OR/RD TB128A
C5TRR WH/BK
C4TRL WH
RD U33-7
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH 5
C33STR BK-33A
ES0549E
1
C1PBU RD-1A
RD TB26D
BK TB22D
C2PBD RD/BK-2A
KS1
1
TS60 6
1
P-BOX
C11SBD BL/BK-11A
B1
B
C10SBU BL-10A
G-BOX
3
RD TB134C
B A
C
RD
RD
D81CAN- GR C5-20 120
12
P20BAT RD TB20B
P24BAT RD TB24A
RD P20BAT TB20D
1
RESISTOR
WH TB23C D82CAN+ YL C5-23 7
TB25-1-C WH
GND BR
RD
C21RET WH CR2-86
C35RPM BK/RD (D2.9-TB35C) (404F-TB25-2-C)
C128RPM OR/RD (D2.9-TB34C) (404F-TB25-2-D)
7
6
NC
2
1
P1 U39
NC
CB1 CB2
1
Part No. 219418 Z-45/25 • Z-45/25J 6-71


6 - 71 6 - 72

6 - 73 6 - 74
N

ES0549E

X103-1 BATGND BR
M
CR13#86 C19JIB RD C54-1

FOR OTHER OPTIONS
JIB OPTION SHOWN
SEE OPTION SHEET

SP1 P24FS WH C54-3
1
TS46-2 P24FS WH C54-4 C54-7 BK

TS46-3 P24FS WH C54-5 C54-6 BK
P2C-2 P26FS BK C54-6 C54-10 WH
C54
C54
BATGND
C9-1 P26FS BK C54-7 C54-3 WH

L
TS7-5 P24FS WH C54-10

GR/WH
BR
GR/WH
R
RD
BR
1
B
R
C1
SP1
K
R R
X103-2
RD OUTPUT
X103-4
CR14
GR/WH +
C9-2
OPT
GNDBAT BR C7P-3
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
B
R
J
P23BAT WH C7P-2
P22BAT BK C7P-1
OPT

C15PLD OR/BK C3P-Q
C14PLU OR C3P-P
C133PLA GR/BK C3P-O
C46HRN BK/RD C3P-K
C8PBR BK/WH C3P-J
I
C7PBE BK C3P-H
P25FS RD C9-3
SP1 P24FS WH C9-2
SP3 SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C25ESL GR/BK C1P-T
C34WTS BK/WH C1P-J
C128RPM OR/RD C1P-R
C35RPM BK/RD C1P-K
C9 (FS)
C33STR BK C1P-H
C3P
C27AUX RD C1P-B
X103
11
X102
1
G
C9
C1PBU RD C3P-B
3
P26ESTP BK
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
SP1 P24FS WH C40LSS OR SP3
C129DA RD/BK C3P-N
BATGND BR C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C7P
C2PBD RD/BK C3P-C
August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD

TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-74
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
L28 D12 D10

TS4 TS15
JC2
1
1
JC1 JC3
CR13 3 4 WH 3 4
BK
3 4
2 5 2
2 5
2 5
1 6 1
TS13 1 6
6 L2
1
ROCKER OPT.
1
CR76 TS2 L1
D14

C128RPM OR/RD C1P-R

3

C161SB WH/BK X101-3
C35RPM BK/RD C1P-K

C34WTS BK/WH C1P-J
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
C25ESL GR/BK C1P-T
P162JPW OR X101-11
P162JPW OR X101-9
C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P23BAT WH
P23BAT WH
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P22PWR RD SW20
C54-5 P24FS WH
C45GEN GR/WH C1P-U
X103-3 P24FS WH
BK
P24FS WH
C27AUX RD C1P-B
LS18 P134BAT RD
C3P-S C17PRL GR
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C3P-T C18PRR GR/BK
C7P-2 P23BAT WH
X109-8 C15PLD OR/BK
C7P-1 R22BAT BK
X103-3 P26ESTP BK
X109-9 C14PLU OR
X101-8 C29MS RD/WH

P25FS RD
TS9
WH P24FS WH WH 5
GR 1 4 1 1 1
4
1 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
2
1
TS14
1
L4 L48
GR/BK
WH
RD RD
COMPONENT INDEX
6
C1 JIB TIMER CAPACITOR P2 EMERGENCY STOP BUTTON NOTE: DASHED LINES INDICATE OPTIONS.
C1,C2 BOOM CONTROL CABLE CONNECTORS P3 HORN BUTTON
C7 POWER TO PLATFORM, 12V CABLE CONNECTOR TS1 AUXILIARY SWITCH
C9 FOOTSWITCH INPUT CONNECTOR TS2 START ENGINE SWITCH
C54 OPTIONS CONNECTOR TS3 FUEL SELECT SWITCH (FORD EFI ONLY)
CR13 JIB RELAY (JIB OPTION) TS4 HI/LOW RPM SWITCH
CR14 JIB RELAY (JIB OPTION) TS6 GLOW PLUG SWITCH
CR27 BRAKE CIRCUIT RELAY (LIFT/DRIVE OPTION) TS7 PLATFORM ROTATE SWITCH
CR30 LIMIT SWITCH RELAY (LIFT/DRIVE OPTION) TS8 JIB ROTATE SWITCH (JIB OPTION)
7
CR76 LOAD SENSE AUX RECOVERY TS9 PLATFORM LEVEL SWITCH
H1 TILT/LOAD SENSE ALARM TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
BOOM PROPORTIONAL JOYSTICK: TS14 DRIVE SPEED SWITCH
TS15 DRIVE ENABLE SWITCH
BOOM PROPORTIONAL JOYSTICK:
JC2 PRIMARY UP/DOWN, TURNTABLE ROTATE TS43 HEATER SWITCH (OPTION)
JC3 DRIVE PROPORTIONAL JOYSTICK TS46 PROXIMITY KILL SWITCH (OPTION)
L1 DRIVE ENABLE LED TS47 GENERATOR SWITCH (OPTION)
L2 WAIT TO START LED U13 ALC 500 JOYSTICK CONTROLLER CARD
U35 TIME DELAY RELAY
L4
L28
PLATFORM OVERLOAD LED (CE ONLY)
ENGINE SHUTDOWN LED - PERKINS 404F-22 X1-4 CIRCUIT SPLICE
8

X101-
ES0549E
Part No. 219418 Z-45/25 • Z-45/25J 6-75


6 - 75 6 - 76
Electrical Schematic, Ford MSG-425 EFI Models (AS)
6 - 77 6 - 78
N
P134PWR RD
BRN
P174AUX RD
P24FS WH
P47FE RD
C28TTA RD/BK
P26ESTP BK
C41RPM OR/BK
P22BAT BK

ES0548E

M

HIGH
D12
LOW
TS4
ENGINE
SPEED
D4
TB35
D13
LOW
HIGH
ENGINE SPEED
TS54
L
P4
FUNC. ENABLE
K
NOTES:
+
-
C21IGN WH
G6
HOUR METER
P174AUX RD
A GY/RD
GY/YL
B
C21IGN WH
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
J
BK/BL
WH D
RD/GN
WH/BK LPG LOCKOUT
9
8
NO
+
C25ESL CHECK ENGINE

TB25
L2
2
2 SEC
C132PLI WH/RD C3P-G

-
BR
U35 3
TEST SWITCH
5
10A
C5-8 WH/BK
C35RPM BK/RD
RD
C5-24 GR
TS64
CR39
NO
I
TS3
C1P-J BK/WH C1B-J

(C34SA/C39LP) C5-7 C2-B
TB39
R23BAT WH FEH (16) PIN 1

C28TTA RD/BK
TS53
D10

D11
CR2
NO
C5-26 C2-T FEH (306) PIN 24

C41RPM OR/BK C1B-Q

C1B-Q
C25ESL WH/BK C2-Q
TB21
FEH (658) PIN 6 BL/WH

C28TTA RD/BK
BL/RD

H
P24FS WH
P26EST BK

TB41

TS2

ENGINE
TS52
START
P25FS RD
TB33
IGN./START RELAY
C5-15 R33STR BK C2-H FEH (32) PIN 15
START ENGINE
TB24
CR1
G
TS1
NO
C135FP BL/WH C2-V FEH (787A) PIN5

AUX. PUMP
C2-R
M4
BK PIN 18
C2-W
P24BAT RD
P22BAT RD
C170LS WH/RD
C9P-3
C9P-2
85
87 86
F
30
CR76
87A
NO
C171LS WH/BK
RD(FS)
WH(FS)
August 2013
Part No. 219418

START (FEH)
PR8
FS1
NO
BK-(FS) C9P-1
M3
STARTER MOTOR
CR19
TS51
2 9
COM
NO
C27AUX RD
TB27
+
BK(FS)
AUXILIARY
2 SEC
PUMP
E
C27AUX RD C6-21
U34 3
AUXILIARY POWER
5
10A
PR1
NO
C9P-1 BK
M2
AUXILIARY PUMP
TB23
C5-10 C2-E
D2
P2
P174 BAT WH
B
C28TTA RD/BK WH TILT ALARM
4.7K
R20
D
BK BRN
WH/BK
H1
P134TTS RD RD
LEVEL SENSOR
C
A
D89
RD
TB134
S8
D40
D39
L4
NC RD
NO BK
C3P-O C133PLA BL/WH C3B-O C5-28 C2-U

LS18
C3B-K SERVICE HORN
Z-45/25 • Z-45/25J
BK/RD C3P-K
LS18A
C46HRN BK/RD C46HRN BK/RD

RELAY
P3
H2
CR5
NO
WH
OR

WH
SERVICE HORN
H6
C
8
D88
C132PLI BL/WH C1B-N
U33
3
C1P-N
C1B-S
1
C134PWR GR/BK
BN
C1P-S
L45
12
4
C32
C1B-O
TB22
C1P-O
P22BAT BL/RD
TB134
P134PWR ED
B
GRND
PLAT
ALTERNATOR FIELD (FEH)
KS1
RD
ALTERNATOR
STA.
S
REGULATOR A
I
P1
RD
CB1
FLD.
A
GND.
BAT.
15AMP.
CB2
FUSE
LINK
TB20
12V
DC
B1
+
-
P20BAT RD C61-1
6-78
1
8
6-79
GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A

15
ROCKER OPTION
C160JPL WH/RD

C1P-F C31REV WH/BK
C159STC BL/WH
C5-13 C31REV WH/BK

X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B
X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4

August 2013
9 C6-7 C14-1 C14-2

C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9

8 UP PRIMARY UP
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

LS2- PRIMARY UP
X103
BR
I
22
1
LS4
DRIVE LIMIT SWITCH

LS4- SECONDARY UP
21
22
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
TB129
15 10 DESCENT ALARM
TRAVEL ALARM
J
D29
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13

NC
DOWN
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
RIGHT PLAT ROTATE
L
LEFT
LEFT
GR/WH
CR13 RD
C1
M
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 79 6 - 80

Ford MSG-425 EFI Models (AS)
6 - 81 6 - 82
8
7
6
5
4
3
2
1
6-82
A
C6
PIN
C6
RD C3B-B
NOTES:
HARNESS
FUNCTION
RD TS61-1 RD-C6-5
B
1 PRIMARY BOOM UP 1
C3
RD/BK C3B-C
WH C3B-E
D30
WH TS62-3 WH C6-7
WH/BK C3B-F

BK C3B-H
BK TS63-3 BK C6-9
BK/WH C3B-J
C1
RD/BK TB129
BL C3B-L
C
BL TS60-1 BL C6-11
BL/BK C3B-M
D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q
Z-45/25 • Z-45/25J

GR C3B-S
GR TS57-1 GR C6-16
C5
GR/BK C3B-T
C5
SOC
RD/BK TB129
ENGINE

RD CB3 RD CB1
HARNESS

D
RD CB2 RD C6-1
WH CR17
WH C5-3 BR GND U34-3 12
WH CR2

GR/BK H6 8
D52
OR/BK C5-26 RD TS51 6
BK C7B-1 5
C32
U33

BK CR5 BK C32-4 BK 22B 4
BK KS1-4 BK C6-19 BL/WH C1B-N

RD U34-2+
1
BK C5-6
E
WH D2-KS1 WH C7-2
BR TBGND-D
RD CR2
C7
RD CB1
24 CB1 POWER 24
WH/RD C5-9
WH/BK C5-8
RD TS51 RD C1B-B
RD C6-21 WH TB23-A
RD/WH C1-D BK C32-5
Part No. 219418

August 2013
RD/WH C5-11 BR GND

29 MOTOR STROKE 29
C7B
WH C1-E
12V DC
WH C5-12
F
30 DRIVE FORWARD 30
WH/BK C1-F
WH/BK C5-13
31 DRIVE REVERSE 31
WH/RD C1-G
POWER TO PLATFORM
WH/RD C5-14
32 BRAKE 32
BK TS52-1 BK C1-H
33 START ENGINE 33
BK/WH C1-J R35RPM BK/RD CR4-87
BK/WH TS56 BK/WH C5-16 BAT
10A
CB7
R35RPM BK/RD C5-17

BK/RD TS54 AUX
35 HIGH RPM 35
OR/BK C1-Q
G
OR/BK C5-22
GR/WH C6-22
+
129 ALARMS OPT. 129
D27
GR C1-S
PIN
RD KS1-4 RD C6-29
C3B
134 KS POWER 134

RD U34-2
H4
RD H6+ RD C5-28
134A KS POWER 134A
-
BR C5-1
19/18 CABLES
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
H
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR CR1 BR C6-28
GND MAIN GROUND GND
WH ISM-9
RD 134C
WH CR2 8 RELAY
+
9
BK TB22-C RD C32-1
RD TB134-B 2
H6
GR/BK C32-8 WH TB23-C BR C32-12

I
BL/RD C3-O BK/RD TB27-C BR GND 5

3
-
GR/BK L45(-) RD TB24-C

BK/RD C3-K U34
WH TB21-2-C WH/RD C3B-G
BR GDN
CR1
CR2
CR5
CR39
TS64
BK C5-15 BK C6-23
BR TB-GND BR
BR
J
PIN
C1B
WH C5-7
WH C5-3
19/18 CABLES
K

TO SWITCH PANEL
ES0549E
L
M
N

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
TS57 TS51
P4 CB1 CIRCUIT BREAKER, ENGINE, 15A
TS59 D3
NO
3
6 3
6 3
+ +
2
NO
CR1 START RELAY
4
L2 - L45 -
CR5 HORN RELAY
D29 L45 PLATFORM OVERLOAD LED 3
TS58
BK/WH C8PBR-8A
DALE RH-25 25W

TS63 TS62
14
1
1
R14 TS53 FUEL SELECT TOGGLE SWITCH
4
7.5 ohm
6
C7PBE BK-7A
+ - R4 TS58 JIB BOOM UP/DOWN TOGGLE SWITCH (OPTION)
G6
C5TRR WH/BK TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
C4TRL WH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
5
ES0549E
1
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
RD P134BAT
1 2
C21IGN WH
1
KS1
BR GND
GND BR
BK-22D
WH
WH
RD
RD
RD
RD
C10SBU BL-10A
3 4

RD
RD
RD
WH TB23C
RD RD
D13
TS56
TS53
1
NC
1
1
C39LP BK/WH-34A
1
P1 8
NC
1
TS52
TS54
D11
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-83


6 - 83 6 - 84

6 - 85 6 - 86
N
PLATFORM CONTROL HARNESS (TO SWITCH PANEL)

X103-1 BATGND BR
C54-9 C171LS WH/BK
M
C54-3 P24FS WH
C54-10 WH
WH/BK
CR13#86 C19JIB RD C54-1 C54-8 P26BAT BK U35-NO
R
SP2 C32BRK WH/RD C54-2 C54-7 P26BAT BK U35-NO
COM
4.7k ohm 1%
C54-6 P26FS BK U35-COM
5
SP1 P24FS WH C54-3

DALE RH-25 25W
WH/BK
U35
R20
TS46-2 P24FS WH C54-4 C54-7 BK R

TS46-3 P24FS WH C54-5 C54-6 BK
2+
RD
3-
P2C-2 P26FS BK C54-6 C54-10 WH

C54
C54
C9-1 P26FS BK C54-7 C54-3 WH BR

CR76#87 P26BAT BK C54-8 C54-12 GR/WH (C1) C134PWR RD LS18
BR

L
TS7-5 P24FS WH C54-10

R

BR
GR/WH
R
BATGND
GR/WH
R R
R
BR
RD
R
R R
C1
SP1
R R
K
X103-2
X103-4
RD OUTPUT

CR14
C9-2
GR/WH +
OPT
GNDBAT BR C7P-3
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
C134PWR RD U35-3
B
BK R20/U35-5
GND OR R20
P23BAT WH C7P-2
J
P22BAT BK C7P-1
ES0549E

LS18

C15PLD OR/BK C3P-Q
WH
C14PLU OR C3P-P
C133PLA GR/BK C3P-O R
C46HRN BK/RD C3P-K
C8PBR BK/WH C3P-J BL/WH C1-N
C7PBE BK C3P-H WH/RD C3-G
I
C54-7 P26BAT BK C9-1 B

P25FS RD C9-3
SP1 P24FS WH C9-2
SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X102
11
1
X103
3
P26ESTP BK
G
C1PBU RD C3P-B
SP1 P24FS WH
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
C9
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C2PBD RD/BK C3P-C

ALC-500
August 2013
Part No. 219418

C37SCW BL/BK C1P-M
U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C7P
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
JC3 C159STC BL/WH
Z-45/25 • Z-45/25J
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-86
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
1
TS3 TS4 TS15
JC2 JC3
1
JC1
D10
CR13 3 4 WH 3 4
BK
RD
3 4
2 5
2
2 5
2 5
1 6 1
TS13 1 6
6
ROCKER OPT.
1
1
CR76 TS2 TS6 L1


3

C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C39LP BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
C171LS WH/BK C54-9
C170LS WH/RD TS1-1
P26BAT BK C54-8
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P22PWR RD SW20
C54-5 P24FS WH
C45GEN GR/WH C1P-U
BK
P24FS WH
C27AUX RD C1P-B
X103-3 P24FS WH
LS18 P134BAT RD
C3P-S C17PRL GR
GR/BK H1 (D39)
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C1P-0 P22BAT BL/RD

C3P-T C18PRR GR/BK
CR76#30 C170LS WH/RD
C7P-2 P23BAT WH
C7P-1 R22BAT BK
X109-8 C15PLD OR/BK
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
P25FS RD
WH P24FS WH WH 5
D
2
1
TS9
1 1 1
4
1 GR 1 4 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
1
1
TS14
RD
L4 L48
GR/BK
WH P22ESTP BK
RD RD
6
COMPONENT INDEX
CR27 BRAKE CIRCUIT RELAY (LIFT/DRIVE OPTION) TS9 PLATFORM LEVEL SWITCH 7
L48 TILT ALARM LED (ANSI/CSA ONLY) X101 ALC500 POWER CONNECTOR 8
LS18 CE LIMIT SWITCH X101-
P3 HORN BUTTON ES0549E
Part No. 219418 Z-45/25 • Z-45/25J 6-87


6 - 87 6 - 88
Deutz 2011 L03i / Perkins 404D-22 Models (AS)
6 - 89 6 - 90
P22BAT BL/RD
P134BAT RD P134BAT RD
1 C41RPM OR/BK C41RPM OR/BK C41RPM OR/BK
C28TTA RD/BK C28TTA RD/BK
D89 C132PLI GR
BR OR LS18 BK WH/BK P26EST BK P26EST BK
WH (A) RD RD P2
P26BAT BK RD-(FS) C9P-3 P25FS RD
D88 WH-(FS) C9P-2 P24FS WH P24FS WH
BK (FS)
RD FS1 TS4
TS2 TS6
BK P22ESTP
2
RD
C1B-Q
P22BAT BL/RD
C1P-O
C1P-S
C1P-N C132PLI BL/WH
RD
C7P-1
LOW
HIGH
ENGINE
START
ON
COM
TS1
C9P-1 BK P26 BAT

L4 SPEED
C170LS WH/RD
WH/BK
GLOW PLUG
ENGINE
P134BAT GR R20
PUMP
AUXILIARY
4.7K 5 2 9
P22BAT BK
C7P-2
P3 H1 2 SEC + D12
C1P-H
C1P-J
CR76
C1B-O
C1P-K
HORN L48 NO 30 86
NO
C3B-G GR
D39 D40 U35 87A
87 85
C1P-B
10A -
C3P-K
C3P-O
3 8
C1P-C
TB134 P4
C7B-1
CB2 RD
3 P1 KS1
C1B-S
C1B-N
RD RD C171LS WH/BK P47FE RD

15AMP. D4
C41ROM OR/BK
P174AUX RD P174AUX RD
C46HRN BK/RD
C133 PLA BL/RD
C28TTA RD/BK
C33STR BK C1B-H
C27AUX RD C1B-B
P174BAT WH
P23BAT WH
1 3
C34SA BK/WH
FUNCTION ENABLE
PLAT TB22 TS51 TS52 TS56
C35RPM BK/RD
4 5 TS54 P22BAT RD
ENGINE BK
START
5 2 9
+
PUMP
ON
HIGH RPM
LOW RPM
KS1 U33 2 SEC
ENGINE SPEED
6 7 D64
AUXILIARY
GND NO
12 8
WH
RD
-
4
GLOW PLUG
C3B-K
C1B-C
BRN
C3B-O
U34 3 8
C1B-Q
C7B-2
10A TB33
H6 L45
C1B-K
TB27
GR/BK D2
C1B-J
RD
TB23
TB41 1
2
START RELAY
TACHOMETER
CB1 P134TTS RD P134BAT RD 3 START INPUT U1
TB20
4 AUX. ON
IGN/START D13
RD TB24 5 GROUND
TB34
6 BATTERY MODULE
P22BAT BK
15AMP. + C3 7 KEY POWER TB35
C34SA
8 KEY BYPASS
3MF
C5-28
C5-10
C5-22
CR1 CR1 CR2

9 IGN/FUEL ON L2
5 CR2 10 ENG. FAULT
C6-1
C35RPM BK/RD
NO NO C108ESL WH/BK
C2-P C5-25 D22 TB21 C21IGN WH TB21 TB25 D108
CR4
C5-16 BK/WH C2-J

C41RPM OR/BK
C107AF WH
NO
C27AUX RD
P22BAT BK
C46HRN BK/RD
C21IGN WH
P20BAT RD
BK/RD
C2-U
C2-E
P134TTS RD
C28TTA RD/BK
C5-8
C108ESL WH/BK
C5-3
C5-15
FUSE 70A
R33STR BK
CR4
C21IGN2 WH
C108ESL WH/BK
C6-21
C2-H
6 ALTERNATOR CR5 D52 CB7
C2-M
D1 A C
NO 10A
WH
RD
EXCT. PR3
C2-K
NO
R34SA RD
C6-23
PR2
C5-17
BAT+ BAT- PR1
C2-C
12V DC S8 NO NO
C2-A
+
STA.
+ SW2
M3
HM M1
BK BRN LEVEL SENSOR
H2 - NC
REGULATOR
SW3
BRN
IND. B
7 B1 - NO
BRN
LOAD SENSE MODULE
SERVICE HORN
SERVICE HORN RELAY
TILT ALARM
HOUR METER
AUXILIARY PUMP
AUXILIARY POWER RELAY
STARTER MOTOR
IGN/START RELAY
SUPRESSION DIODE
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
CHECK ENGINE LED
GLOW PLUG
SOLENOID
HIGH RPM
RELAY
HIGH IDLE
ES0548E
8 NOTES:
6-90 Z-45/25 • Z-45/25J Part No. 219418

6-91

GROUND
C7P-3 BAT GND C7B-3
X109
LOAD S1 INPUT
U4
LOAD S2 INPUT 5 1
TB30
X102
A

15
ROCKER OPTION
C160JPL WH/RD

C1P-F C31REV WH/BK
C159STC BL/WH
C5-13 C31REV WH/BK

X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B
X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
PLAT LEVEL DOWN
TB15
C21-2
C21-1
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4

August 2013
9 C6-7 C14-1 C14-2

C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND
R4 20
RETRACT 2
C8PBR BK/WH
14
F
X109 X109
C14PLU OR
TB1
R14
TS61
9 C12-1 C12-2
7.5
TS9

8 UP PRIMARY UP
PRIMARY DOWN
TB2
C3P-B C13-1 C13-2

C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
P24FS WH
H
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
14
13
C11-3 BK-7 WH-7 C11-4

LS2- PRIMARY UP
X103
BR
I
22
1
LS4
DRIVE LIMIT SWITCH

LS4- SECONDARY UP
21
22
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
TB129
15 10 DESCENT ALARM
TRAVEL ALARM
J
D29
MOTION ALARM
C44JD GR/BK
C129DA RD/BK
JIB BOOM
TS8
K
CR13

NC
DOWN
TB18
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
RIGHT PLAT ROTATE
L
LEFT
LEFT
GR/WH
CR13 RD
C1
M
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 91 6 - 92

6 - 93 6 - 94
8
7
6
5
4
3
2
1
6-94
Genie
1
1
2
NOTES:
3
4
A
BR TBGND-D 5 GROUND
5 U1 (ISM)
WH TB24D 6 BATTERY
6
7
WH CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
10

C6
B
PIN
C6
RD C3B-B

HARNESS
FUNCTION
RD TS61-1 RD-C6-5
1 PRIMARY BOOM UP 1
C3
RD/BK C3B-C

WH C3B-E
D30
WH TS62-3 WH C6-7
WH/BK C3B-F

BK C3B-H
BK TS63-3 BK C6-9
C
BK/WH C3B-J

RD/BK TB129
BL C3B-L
C1
BL TS60-1 BL C6-11
BL/BK C3B-M

Z-45/25 • Z-45/25J
D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q
GR C3B-S
GR TS57-4 GR C6-16

D
GR/BK C3B-T
C5

SOC
RD/BK TB129
C5
RD CB3 RD CB1
ENGINE
HARNESS
RD CB2 RD C6-1
WH CR17
WH C5-3 BR GND U34-3 12

WH CR17 GR/BK H6 8
D52
RD TS51 6
WH CR2 BK C7B-1 5
C32
U33

E

RD U34-2+
1
BK C5-6
WH D2-KS1 WH C7-2
BR TBGND-D
WH U1-7
RD CR2
C7
WH ISM-7 RD CB1
24 CB1 POWER 24
Part No. 219418

25 25
August 2013
OIL PRESSURE ANDTEMP SW WH TB23-A

RD TS51 RD C1B-B
BK C32-5
RD ISM-4 RD C6-21
27 AUXILIARY PUMP 27 BR GND
RD/WH C1-D
C7B
F
12V DC
RD/WH C5-11
29 MOTOR STROKE 29
WH C1-E
WH C5-12
30 DRIVE FORWARD 30
WH/BK C1-F
WH/BK C5-13
POWER TO PLATFORM
31 DRIVE REVERSE 31
WH/RD C1-G
WH/RD C5-14
32 BRAKE 32
BK TS52-1 BK C1-H
BK ISM-3
33 START ENGINE 33
BAT
G
10A
CB7
BK/RD CR4 BK/RD C1-K R35RPM BK/RD C5-17

AUX
BK/RD TS54
1 35 HIGH RPM 35
// OR/BK C5-22
+

C3
+
129 ALARMS OPT. 129
D27
GR C1-S
PIN
C3B
RD KS1-4 RD C6-29
134 KS POWER 134
RD U34-2
H4
RD H6+ RD C5-28
H
134A KS POWER 134A

-
BR C5-1
19/18 CABLES
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR ISM-5
GND MAIN GROUND GND
RD 134C WH ISM-9
+
WH CR2 8 RELAY
I
9
BK TB22-C RD C32-1
H6
GR/BK C32-8 BK/RD TB35-C RD TB134-B 2

BL/RD C3-O RD TB24-C BR C32-12
-
GR/BK L45(-) WH ISM 9 (CE SEE U34) BR GND 3 5

BK/RD C3-K U34
WH TB21-D
WH/RD C3B-G
CR1
CR2
CR4
CR5
BK ISM 1
J
WH
BK C5-15 BK C6-23
BR TB-GND BR BR BR
BK/RD CB7
PIN
C1B
19/18 CABLES
ES0549E
K

TO SWITCH PANEL
L
M
N

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
P4 TS59 D3
NO
3
6 3
6 3
+ +
2
NO
CR1 START RELAY
4
L2 - L45 -
CR5 HORN RELAY
TS58
BK/WH C8PBR-8A
DALE RH-25 25W

TS63 TS62
14
1
1
4
7.5 ohm
6
G6
5
ES0549E
1
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
RD P134BAT
1 2
C21IGN WH
1
KS1
BR GND
GND BR
BK-22D
WH
WH
RD
RD
C10SBU BL-10A
3 4

RD
RD
RD
WH TB23C
C34SA BK/WH-34D
TS56
1
NC
1
1
P1 8
NC
1
D64 TS52
TS53 TS54
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-95


6 - 95 6 - 96

6 - 97 6 - 98
N

X103-1 BATGND BR
M
C54-9 C171LS WH/BK

C54-3 P24FS WH
C54-10 WH
WH/BK
R
SP2 C32BRK WH/RD C54-2 C54-7 P26BAT BK U35-NO
COM
4.7k ohm 1%
C54-6 P26FS BK U35-COM
5
SP1 P24FS WH C54-3

DALE RH-25 25W
WH/BK
U35
R20
TS46-2 P24FS WH C54-4 C54-7 BK R

TS46-3 P24FS WH C54-5 C54-6 BK
2+
RD
3-
P2C-2 P26FS BK C54-6 C54-10 WH

C54
C54
C9-1 P26FS BK C54-7 C54-3 WH BR

CR76#87 P26BAT BK C54-8 C54-12 GR/WH (C1) C134PWR RD LS18
BR

L
TS7-5 P24FS WH C54-10

R

BR
GR/WH
R
BATGND
GR/WH
R R
R
BR
RD
R
R R
C1
K
SP1
R R
X103-2
X103-4
RD OUTPUT

CR14
C9-2
GR/WH +
OPT
GNDBAT BR C7P-3
R R
TS4-2 C134PWR RD
C134PWR RD
BRN -
C54-3 P24FS WH
GR/WH
RD
C134PWR RD U35-3
B
BK R20/U35-5
J
GND OR R20
P23BAT WH C7P-2
P22BAT BK C7P-1
ES0549E

LS18

C15PLD OR/BK C3P-Q
WH
C14PLU OR C3P-P
C46HRN BK/RD C3P-K
I

P25FS RD C9-3
SP1 P24FS WH C9-2
SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X102
11
1
X103
3
1
G
P26ESTP BK
C1PBU RD C3P-B
SP1 P24FS WH
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
C9
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C2PBD RD/BK C3P-C

August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C7P
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-98
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
TS3 TS4 TS15

JC2 JC3
1
1
JC1
CR13 3 4 WH 3 4
BK
5
3 4 2
2 2 5
2 5
1 6 1
TS13 1 6
6
1
ROCKER OPT.
1
1
CR76 TS2 TS6 L1


C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C34SA BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
C171LS WH/BK C54-9
C170LS WH/RD TS1-1
P26BAT BK C54-8
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
BK
P24FS WH
C27AUX RD C1P-B
LS18 P134BAT RD
C3P-S C17PRL GR
GR/BK H1 (D39)
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C1P-0 P22BAT BL/RD

C3P-T C18PRR GR/BK
CR76#30 C170LS WH/RD
C7P-2 P23BAT WH
C7P-1 R22BAT BK
X109-8 C15PLD OR/BK
C54-5 P24FS WH
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
C45GEN GR/WH C1P-U
X103-3 P24FS WH
P25FS RD
P22BAT BK P2
P22PWR RD SW20
5
WH P24FS WH WH
D
2
1
TS9
1 1 1
4
1 GR 1 4 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
1
1
TS14
RD
L4 L48
GR/BK
WH P22ESTP BK
RD RD 6
COMPONENT INDEX
CR27 BRAKE CIRCUIT RELAY (LIFT/DRIVE OPTION) TS9 PLATFORM LEVEL SWITCH 7
L48 TILT ALARM LED (ANSI/CSA ONLY) X101 ALC500 POWER CONNECTOR 8
ES0549E
P3 HORN BUTTON
Part No. 219418 Z-45/25 • Z-45/25J 6-99


6 - 99 6 - 100
Electrical Schematic, Ford MSG-425 EFI Models (CE)
6 - 101 6 - 102
N
P134PWR RD
BRN
P174AUX RD
P24FS WH
P47FE RD
C28TTA RD/BK
P26ESTP BK
C41RPM OR/BK
P22BAT BK

ES0548E
M

HIGH
D12
LOW
TS4
ENGINE
SPEED
D4

TB35
D13
LOW
HIGH
ENGINE SPEED
TS54
L
P4
FUNC. ENABLE
K
NOTES:
+
-
C21IGN WH
G6
HOUR METER
P174AUX RD
A GY/RD
GY/YL
B
J
C21IGN WH
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
BK/BL
WH D
RD/GN
WH/BK LPG LOCKOUT
9
8
NO
+
C25ESL CHECK ENGINE

TB25
L2
2
2 SEC
C132PLI WH/RD C3P-G

-
BR
U35 3
TEST SWITCH
5
10A
C5-8 WH/BK
TEST
C35RPM BK/RD
RD
I
C5-24 GR
RUN
TS64
CR39
NO
TS3
C1P-J BK/WH C1B-J

(C34SA/C39LP) C5-7 C2-B
TB39
R23BAT WH FEH (16) PIN 1

C28TTA RD/BK
TS53

D10

D11
CR2
NO
C5-26 C2-T FEH (306) PIN 24

C1B-Q C41RPM OR/BK C1B-Q

H
C25ESL WH/BK C2-Q

TB21
FEH (658) PIN 6 BL/WH

C28TTA RD/BK
BL/RD

P24FS WH
P26EST BK

TB41

TS2

ENGINE
TS52
START
P25FS RD
TB33
IGN./START RELAY
C5-15 R33STR BK C2-H FEH (32) PIN 15
G
START ENGINE
TB24
CR1
TS1
NO
C135FP BL/WH C2-V FEH (787A) PIN5

AUX. PUMP
C2-R
M4
BK PIN 18
C2-W
P24BAT RD
P22BAT RD
C9P-3
C9P-2
F
August 2013
Part No. 219418

RD(FS)
WH(FS)
START (FEH)
FS1
BK-(FS) C9P-1
M3
STARTER MOTOR
CR19
TS51
2 9
COM
NO
C27AUX RD
TB27
+
BK(FS)
AUXILIARY
E
2 SEC
PUMP C27AUX RD C6-21

U34 3
AUXILIARY POWER
5
10A
PR1
NO
C9P-1 BK
M2
AUXILIARY PUMP
TB23
D2
P2
P174 BAT WH
B
C5-10 TILT ALARM
D
RD/BK WH
4.7K
R20
BK BRN
WH/BK
H1
P134TTS RD RD
C5-28 LEVEL SENSOR
C
D89
RD
A
TB134
S8
D40
D39
L4
NC RD
NO BK
C3P-O C133PLA BL/WH C3B-O

LS18
Z-45/25 • Z-45/25J
BK/RD C3P-K C3B-K SERVICE HORN
LS18A
C46HRN BK/RD C46HRN BK/RD

RELAY
P3
H2
CR5
NO
WH
OR

WH
SERVICE HORN
H6
C
8
LOAD SENSE
D88
C132PLI BL/WH C1B-N
U33
3
C1P-N MODULE
C1B-S
1
C134PWR GR/BK
BN
C1P-S
L45
12
4
C32
TB22
TB134
P134PWR ED
B
GRND
PLAT
KS1
P20BAT RD
RD
ALTERNATOR
STA.
S
REGULATOR A
I
P1
RD
A
CB1
FLD.
GND.
BAT.
15AMP.
CB2
FUSE
LINK
TB20
12V
DC
B1
+
-
P20BAT RD C61-1
6-102
1
8
6-103
GROUND
C7P-3 BAT GND C7B-3
LOAD S2 INPUT
X109
LOAD S1 INPUT
U4
5 1
TB30
A
X102

15
ROCKER OPTION
C160JPL WH/RD

C159STC BL/WH
C5-13
X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B

X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
DOWN C6-14 C15PLD OR/BK PLAT LEVEL DOWN
TB15
C21-1 C21-2
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4
August 2013

9 C6-7 C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND TURNTABLE ROTATE
R4 20
LEFT
RETRACT 2
C8PBR BK/WH
14
F
TB1
X109 X109
C14PLU OR
R14
TS61
9 C12-1 C12-2
7.5
TS9

TB2
8 UP PRIMARY UP
C15PLD OR/BK PRIMARY BOOM C2PBD RD/BK
DOWN C6-6
C13-1 C13-2 PRIMARY DOWN
C3P-B C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
H
P24FS WH
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
13
LS2- PRIMARY UP
14
C11-3 BK-7 WH-7 C11-4

I
DRIVE LIMIT SWITCH

X103
BR
1 22
LS4
C1B-P C6-27 OR C10-2 BK-4 WH-4 C10-1 J1-BK C10-2 WH-5 LS4- SECONDARY UP
DRIVE LIMIT SWITCH
21
22
P22LS RD
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
J
TRAVEL ALARM
D29
MOTION ALARM
CR27
CR30
C44JD GR/BK
OPTION
NC
NO
DRIVE
C129DA RD/BK
LIFT/
JIB BOOM
TS8
K
CR13

NC
DOWN
C3P-S
TB18
UP C3P-S C17PRL GR
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
L

LEFT
GR/WH
CR13
RD
M
C1
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 103 6 - 104

Ford MSG-425 EFI Models (CE)
6 - 105 6 - 106
8
7
6
5
4
3
2
1
6-106
A
C6
PIN
C6
RD C3B-B
NOTES:
HARNESS
FUNCTION
RD TS61-1 RD-C6-5
B
1 PRIMARY BOOM UP 1
C3
RD/BK C3B-C
WH C3B-E
D30
WH TS62-3 WH C6-7
WH/BK C3B-F

BK C3B-H
BK TS63-3 BK C6-9
BK/WH C3B-J
C1
RD/BK TB129
BL C3B-L
C
BL TS60-1 BL C6-11
BL/BK C3B-M
D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q
Z-45/25 • Z-45/25J

GR C3B-S
GR TS57-1 GR C6-16
C5
GR/BK C3B-T
C5
SOC
RD/BK TB129
ENGINE

RD CB3 RD CB1
HARNESS

D
RD CB2 RD C6-1
WH CR17
WH C5-3 BR GND U34-3 12
WH CR2

GR/BK H6 8
D52
OR/BK C5-26 RD TS51 6
BK C7B-1 5
C32
U33


RD U34-2+
1
BK C5-6
E
WH D2-KS1 WH C7-2
BR TBGND-D
RD CR2
C7
RD CB1
24 CB1 POWER 24
WH/RD C5-9
WH/BK C5-8
RD TS51 RD C1B-B
RD C6-21 WH TB23-A
RD/WH C1-D BK C32-5
Part No. 219418

August 2013
RD/WH C5-11 BR GND

29 MOTOR STROKE 29
C7B
WH C1-E
12V DC
WH C5-12
F
30 DRIVE FORWARD 30
WH/BK C1-F
WH/BK C5-13
31 DRIVE REVERSE 31
WH/RD C1-G
POWER TO PLATFORM
WH/RD C5-14
32 BRAKE 32
BK TS52-1 BK C1-H
33 START ENGINE 33
BK/WH TS56 BK/WH C5-16 BAT
10A
CB7
R35RPM BK/RD C5-17

BK/RD TS54 AUX
35 HIGH RPM 35
OR/BK C1-Q
G
OR/BK C5-22
GR/WH C6-22
+
129 ALARMS OPT. 129
D27
GR C1-S
PIN
RD KS1-4 RD C6-29
C3B
134 KS POWER 134

RD U34-2
H4
RD H6+ RD C5-28
134A KS POWER 134A
-
BR C5-1
19/18 CABLES
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
H
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR CR1 BR C6-28
GND MAIN GROUND GND
WH ISM-9
RD 134C
WH CR2 8 RELAY
+
9
BK TB22-C RD C32-1
RD TB134-B 2
H6
GR/BK C32-8 WH TB23-C BR C32-12

I
BL/RD C3-O BK/RD TB27-C BR GND 5

3
-
GR/BK L45(-) RD TB24-C

BK/RD C3-K U34
WH TB21-2-C WH/RD C3B-G
BR GDN
CR1
CR2
CR5
CR39
TS64
BK C5-15 BK C6-23
BR TB-GND BR
BR
J
PIN
C1B
WH C5-7
WH C5-3
19/18 CABLES
K

TO SWITCH PANEL
ES0549E
L
M
N

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
TS57 TS51
P4 CB1 CIRCUIT BREAKER, ENGINE, 15A
TS59 D3
NO
3
6 3
6 3
+ +
2
NO
CR1 START RELAY
4
L2 - L45 -
CR5 HORN RELAY
TS58
BK/WH C8PBR-8A
DALE RH-25 25W

TS63 TS62
14
1
1
4
7.5 ohm
6
C7PBE BK-7A
G6
5
ES0549E
1
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
RD P134BAT
1 2
C21IGN WH
1
KS1
BR GND
GND BR
BK-22D
WH
WH
RD
RD
RD
RD
C10SBU BL-10A
3 4

RD
RD
RD
WH TB23C
RD RD
D13
TS56
TS53
1
NC
1
1
C39LP BK/WH-34A
1
P1 8
NC
1
TS52
TS54
D11
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-107


6 - 107 6 - 108

6 - 109 6 - 110
N

X103-1 BATGND BR
BR
M
CR27
CR30
WH/BK
C54-10 WH
R
C54-2 C32BRK WH/RD

COM
4.7k ohm 1%
5
C54-11 C40LSS OR WH/BK

DALE RH-25 25W
U35
R20
C54-3 P24FS WH
2+
3-
C54-7 P26BAT BK U35-NO RD

L

C54-6 P26FS BK U35-COM BR
SP1 P24FS WH C54-3
BR
TS46-2 P24FS WH C54-4 C54-7 BK C134PWR RD LS18

C54
C54
TS46-3 P24FS WH C54-5 C54-6 BK

R
P2C-2 P26FS BK C54-6 C54-10 WH BR

C9-1 P26FS BK C54-7 C54-3 WH
CR76#87 P26BAT BK C54-8 C54-12 GR/WH R
BATGND
R R
CR76#85 C171LS WH/BK C54-9 C54-1 C19JIB RD
TS7-5 P24FS WH C54-10
SP3 C40LSS 0R C54-11 R R
R
R

GR/WH
K
R
C1
BR
R
RD
R
SP1
B
RD OUTPUT
OPT
GNDBAT BR C7P-3
X103-2
C134PWR RD
GR/WH +
X103-4 R
CR14
BRN -
C9-2 R
GR/WH
TS4-2 C134PWR RD
C54-3 P24FS WH
R
C134PWR RD U35-3
RD
B
BK R20/U35-5
J
GND OR R20
P23BAT WH C7P-2
P22BAT BK C7P-1
ES0549E

LS18

C15PLD OR/BK C3P-Q
WH
C14PLU OR C3P-P
C46HRN BK/RD C3P-K
I

P25FS RD C9-3
SP1 P24FS WH C9-2
SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X102
11
1
X103
3
1
G
P26ESTP BK
C1PBU RD C3P-B
SP1 P24FS WH
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
C9
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C2PBD RD/BK C3P-C

August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C7P
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-110
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
1
1
TS3 TS4 TS15
JC2 JC3
1
JC1
D10
CR13 3 4 WH 3 4 2
BK
RD
3 4
2 5 5
5 2
2
1 6 1
TS13 1 6
6
1
ROCKER OPT.
1
1
CR76 TS2 TS6 L1


C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C39LP BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
BK
P24FS WH
C27AUX RD C1P-B
P22PWR RD SW20
C54-5 P24FS WH
LS18 P134BAT RD
C3P-S C17PRL GR
GR/BK H1 (D39)
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
P25FS RD
C9HRN BK/RD C3P-K
C45GEN GR/WH C1P-U
X103-3 P24FS WH
C3P-T C18PRR GR/BK
C7P-2 P23BAT WH
C7P-1 R22BAT BK
X109-8 C15PLD OR/BK
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
5
WH P24FS WH WH
TS9
1 1 1
4
1 GR 1 4 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
1
1
TS14
RD
L4 L48
GR/BK
WH 6
RD RD
COMPONENT INDEX
CR13 JIB RELAY (JIB OPTION) TS7 PLATFORM ROTATE SWITCH 7
L1 DRIVE ENABLE LED U35 TIME DELAY RELAY 8

Part No. 219418 Z-45/25 • Z-45/25J 6-111


6 - 111 6 - 112
Deutz 2011 L03i / Perkins 404D-22 Models (CE)
6 - 113 6 - 114
P134BAT RD P134BAT RD
1 C41RPM OR/BK C41RPM OR/BK C41RPM OR/BK
C28TTA RD/BK C28TTA RD/BK
D89 C132PLI WH/RD
BR OR LS18 BK WH/BK P26EST BK P26EST BK
WH (A) RD RD P2
P26BAT BK RD-(FS) C9P-3 P25FS RD
D88 WH-(FS) C9P-2 P24FS WH P24FS WH
BK (FS)
RD FS1 TS4
TS2 TS6
RD
C3P-G WH
C1B-Q
C1P-S
C1P-N C132PLI BL/WH
RD
C7P-1
LOW
HIGH
2 ENGINE
START
ON
COM
TS1
C9P-1 BK P26 BAT

L4 SPEED
WH/BK
GLOW PLUG
ENGINE
R20
P134BAT GR
PUMP
AUXILIARY
4.7K 5 2 9
P22BAT BK
C7P-2
P3 H1 2 SEC + D12
C1P-H
C1P-J
C1P-K
HORN L48 NO
C3B-G WH/RD
D39 D40 U35
C1P-B
10A -
C3P-K
C3P-O
3 8
C1P-C
TB134 P4
C7B-1
CB2 P1 RD
KS1
C1B-S
C1B-N
3 RD RD P47FE RD
15AMP. D4
C41ROM OR/BK
P174AUX RD P174AUX RD
C46HRN BK/RD
C133 PLA BL/RD
C28TTA RD/BK
C33STR BK C1B-H
C27AUX RD C1B-B
P174BAT WH
P23BAT WH
1 3
C34SA BK/WH
FUNCTION ENABLE
PLAT TB22 TS51 TS52 TS56
C35RPM BK/RD
4 5 TS54 P22BAT RD
ENGINE BK
START
5 2 9
+
PUMP
ON
HIGH RPM
LOW RPM
KS1 U33 2 SEC
ENGINE SPEED
6 7 D64
AUXILIARY
GND NO
12 8
WH
RD
-
GLOW PLUG
C3B-K
C1B-C
BRN
C3B-O
U34 3 8
C1B-Q
C7B-2
10A TB33
H6 L45
C1B-K
TB27
GR/BK D2
C1B-J
RD
TB23
TB41 1
2
START RELAY
TACHOMETER
CB1 P134TTS RD P134BAT RD 3 START INPUT U1
TB20
4 AUX. ON
IGN/START D13
RD TB24 5 GROUND
TB34
6 BATTERY MODULE
P22BAT BK
15AMP. + C3 7 KEY POWER TB35
C34SA
8 KEY BYPASS
3MF
C5-28
C5-10
C5-22
CR1 CR1 CR2

9 IGN/FUEL ON L2
10 ENG. FAULT
CR2
C6-1
C35RPM BK/RD
NO NO C25ESL WH/BK
5 C2-P C5-25 D22 TB21 C21IGN WH TB21 TB25 D108
CR4
C5-16 BK/WH C2-J

C41RPM OR/BK
C107AF WH
NO
C27AUX RD
P22BAT BK
C46HRN BK/RD
C21IGN WH
P20BAT RD
BK/RD
C2-U
C2-E
P134TTS RD
C28TTA RD/BK
C5-8
C25ESL WH/BK
C5-3
C5-15
FUSE 70A
R33STR BK
CR4
C21IGN2 WH
C25ESL WH/BK
C6-21
C2-H
ALTERNATOR CR5 D52 CB7
C2-M
A C
6 D1
NO 10A
WH
RD
EXCT. PR3
C2-K
NO
R34SA RD
C6-23
PR2
C5-17
BAT+ BAT- PR1
C2-C
12V DC S8 NO NO
C2-A
+
STA.
+ SW2
M3
G6 M1
BK BRN LEVEL SENSOR
H2 - NC Q3
REGULATOR
SW3
BRN
IND. B
B1 - NO
BRN
7
LOAD SENSE MODULE
SERVICE HORN
SERVICE HORN RELAY
TILT ALARM
HOUR METER
AUXILIARY PUMP
AUXILIARY POWER RELAY
STARTER MOTOR
IGN/START RELAY
SUPRESSION DIODE
FUEL SOLENOID
POWER RELAY
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
CHECK ENGINE LED
GLOW PLUG
SOLENOID
HIGH RPM
RELAY
HIGH IDLE
ES0548E
NOTES:
8 2. DASHED LINES INDICATE OPTION WIRES.
6-114 Z-45/25 • Z-45/25J Part No. 219418

6-115
GROUND
C7P-3 BAT GND C7B-3
LOAD S2 INPUT
X109
LOAD S1 INPUT
U4
5 1
TB30
A
X102

15
ROCKER OPTION
C160JPL WH/RD

C159STC BL/WH
C5-13
X101
5 16
TB31
C2-G
PWR 2 P162JPW OR
13 RD BK
14
GND 1 BR
DRIVE FWD/REV
TB29 TB32
STEER R/L
J87-4
JC3 6
R OUT 5
Y OUT 4
X OUT 3

B

X102

20 MOTOR STROKE
Z-45/25 • Z-45/25J
C1B-M C37SCW BL/BK


X101
X102
STEER RIGHT
C165TRS WH/RD
18
1
PWR 2 P162JPW OR

11 17
C
12
GND 1 BR

PRIMARY UP/DOWN
6
X102
TB14

TT ROTATE
JC2 6
5
X OUT 3
7 C20-1 C20-2
TS59

UP PLATFORM LEVEL
DOWN C6-14 C15PLD OR/BK PLAT LEVEL DOWN
TB15
C21-1 C21-2
D
C161SB WH/BK
3
C3P-H C7PBE BK
PWR 2 P162JPW OR
C3B-H
X101
X102
9 12
TB7
13 C16-1 C16-2
TS63
10
C6-9 C7PBE BK
GND 1 BR
PRIMARY EXTEND
SECONDARY UP/DN
EXTEND BOOM
PRIMARY RETRACT
JC1 6
5
Y OUT 4
3
TB8
C17-1 C17-2
Part No. 219418
E
TB4
August 2013

9 C6-7 C4TRL WH
X102

PRIMARY
10
C6-8 C5TRR WH/BK
BOOM

TS62
TB5
C15-1 C15-2
T13
X109 X109
C7PBE BK
6
3 RIGHT
EXTEND TURNTABLE ROTATE
R4 20
LEFT
RETRACT 2
C8PBR BK/WH
14
F
TB1
X109 X109
C14PLU OR
R14
TS61
9 C12-1 C12-2
7.5
TS9

TB2
8 UP PRIMARY UP
C15PLD OR/BK PRIMARY BOOM C2PBD RD/BK
DOWN C6-6
C13-1 C13-2 PRIMARY DOWN
C3P-B C1PBU RD C3B-B
X109
GNDRTN BR 11
X102
6
D30

8
C129DA RD/BK
DRIVE
HIGH
TS14
G
X108 X108

C29MS 9
8
TB10
RD/WH 4
C13DE BL/RD C18-1 C18-2
X101
16 C10SBU BL
SECONDARY UP
L1

D9
DOWN C11SBD BL/BK

TS60

TB11
6 C6-12 C19-1 C19-2

LEFT
RIGHT
D3
D91
7
P26ESTP BK
TS15
DRIVE
ENABLE
C144DER BL/WH
H
P24FS WH
P24FS WH
2
X103
LS3
P24FS WH
4 LS3- DRIVE ENABLE
3 LIMIT SWITCH
P26ESTP
14
13
X102
3
LS1
C1P-P
J2 BK

BK-6 C11-1 BK-5 C10-1 BK C6-19
C40LSS OR
21 LS2
13
LS2- PRIMARY UP
14
C11-3 BK-7 WH-7 C11-4

I
DRIVE LIMIT SWITCH

X103
BR
1 22
LS4
C1B-P C6-27 OR C10-2 BK-4 WH-4 C10-1 J1-BK C10-2 WH-5 LS4- SECONDARY UP
DRIVE LIMIT SWITCH
21
22
P22LS RD
TB22
X102
5
D27
X109 X102
14 C129DA BL/WH
X101
H4
J
TRAVEL ALARM
D29
MOTION ALARM
CR27
CR30
C44JD GR/BK
OPTION
NC
NO
DRIVE
C129DA RD/BK
LIFT/
JIB BOOM
TS8
K
CR13

NC
DOWN
C3P-S
TB18
UP C3P-S C17PRL GR
C23-1 C23-2
D28
TS58
C6-15 C18PRR GR/BK
WH
DOWN
BR
ROTATE

PLAT
TB17
C22-1 C22-2
TS7
TS57
RIGHT C6-3
L

LEFT
GR/WH
CR13
RD
M
C1
R19JIB
JIB VALVES
VALVE
GR/WH
_
+
P24FS WH
C19JV RD
C41RPM OR/BK
C28TTA RD/BK
JIB
ES0548E
P174AUX RD
P134BAT RD
CR14
P26STP BK
P22BAT BK
NO
P47FE RD
BRN
N
6 - 115 6 - 116

6 - 117 6 - 118
8
7
6
5
4
3
2
1
6-118
Genie
1
1
2
NOTES:
3
4
A
BR TBGND-D 5 GROUND
5 U1 (ISM)
WH TB24D 6 BATTERY
6
7
WH CR2 9 IGN OR FUEL ON
9 1 3 4 7 10 9 2

10

C6
B
PIN
C6
RD C3B-B

HARNESS
FUNCTION
RD TS61-1 RD-C6-5
1 PRIMARY BOOM UP 1
C3
RD/BK C3B-C

WH C3B-E
D30
WH TS62-3 WH C6-7
WH/BK C3B-F

BK C3B-H
BK TS63-3 BK C6-9
BK/WH C3B-J
C

RD/BK TB129
BL C3B-L
C1
BL TS60-1 BL C6-11
BL/BK C3B-M

Z-45/25 • Z-45/25J
D91
OR C3B-P
OR TS59-1 OR C6-13
OR/BK C3B-Q
GR C3B-S
GR TS57-4 GR C6-16

GR/BK C3B-T
C5
D

SOC
RD/BK TB129
C5
RD CB3 RD CB1
ENGINE
HARNESS
RD CB2 RD C6-1
WH CR17
WH C5-3 BR GND U34-3 12

WH CR17 GR/BK H6 8
D52
RD TS51 6
WH CR2
BK C7B-1 5
C32
U33

E
RD U34-2+
1
BK C5-6
WH D2-KS1 WH C7-2
BR TBGND-D
WH U1-7
RD CR2
C7
WH ISM-7 RD CB1
24 CB1 POWER 24
25 OIL PRESSURE ANDTEMP SW 25 WH TB23-A
RD TS51 RD C1B-B
Part No. 219418

BK C32-5
August 2013
RD ISM-4 RD C6-21
27 AUXILIARY PUMP 27 BR GND
RD/WH C1-D
C7B
12V DC
RD/WH C5-11
F
29 MOTOR STROKE 29
WH C1-E
WH C5-12
30 DRIVE FORWARD 30
WH/BK C1-F
WH/BK C5-13
POWER TO PLATFORM
31 DRIVE REVERSE 31
WH/RD C1-G
WH/RD C5-14
32 BRAKE 32
BK TS52-1 BK C1-H
BK ISM-3
33 START ENGINE 33
BAT
10A
CB7
BK/RD CR4 BK/RD C1-K R35RPM BK/RD C5-17

AUX
G
BK/RD TS54
1 35 HIGH RPM 35
// OR/BK C5-22
+

C3
+
129 ALARMS OPT. 129
D27
GR C1-S
PIN
C3B
RD KS1-4 RD C6-29
134 KS POWER 134
RD U34-2
H4
RD H6+ RD C5-28
134A KS POWER 134A
-
BR C5-1
19/18 CABLES
H
BR TB41-D BR C6-2
GND MAIN GROUND GND
RD U43-3-
BR TB21-D BR C6-3
GND MAIN GROUND GND
BR ISM-5
GND MAIN GROUND GND
RD 134C WH ISM-9
+
WH CR2 8 RELAY
9
BK TB22-C RD C32-1
I
H6
GR/BK C32-8 BK/RD TB35-C RD TB134-B 2

BL/RD C3-O RD TB24-C BR C32-12
-
GR/BK L45(-) WH ISM 9 (CE SEE U34) BR GND 3 5

BK/RD C3-K U34
WH TB21-D
WH/RD C3B-G
CR1
CR2
CR4
CR5
BK ISM 1
WH
BK C5-15 BK C6-23
J
BR TB-GND BR BR BR
BK/RD CB7
PIN
C1B
19/18 CABLES
ES0549E
K

TO SWITCH PANEL
L
M
N

(TO TERMINAL STRIP)

RD U33-6
BASE BOX HARNESS

C17JU GR
D4
P4 TS59 D3
NO
3
6 3
6 3
+ +
2
NO
CR1 START RELAY
4
L2 - L45 -
CR5 HORN RELAY
TS58
BK/WH C8PBR-8A
DALE RH-25 25W

TS63 TS62
14
1
1
4
7.5 ohm
6
G6
5
ES0549E
1
C1PBU RD-1A
RD P20BAT TB20D
P20BAT RD TB20B
P24BAT RD TB24A
C2PBD RD/BK-2A
6
C25TSR TB25D
TS60
RD P134BAT
1 2
C21IGN WH
1
KS1
BR GND
GND BR
BK-22D
WH
WH
RD
RD
C10SBU BL-10A
3 4

RD
RD
RD
WH TB23C
C34SA BK/WH-34D
TS56
1
NC
1
1
P1 8
NC
1
D64 TS52
TS53 TS54
WH
Part No. 219418 Z-45/25 • Z-45/25J 6-119


6 - 119 6 - 120

6 - 121 6 - 122
N

X103-1 BATGND BR
BR
M
CR27
CR30
WH/BK
C54-10 WH
R
C54-2 C32BRK WH/RD

COM
4.7k ohm 1%
5
C54-11 C40LSS OR WH/BK

DALE RH-25 25W
U35
R20
C54-3 P24FS WH
2+
3-
C54-7 P26BAT BK U35-NO RD

L

C54-6 P26FS BK U35-COM BR
SP1 P24FS WH C54-3
BR
TS46-2 P24FS WH C54-4 C54-7 BK C134PWR RD LS18

C54
C54
TS46-3 P24FS WH C54-5 C54-6 BK

R
P2C-2 P26FS BK C54-6 C54-10 WH BR

C9-1 P26FS BK C54-7 C54-3 WH
CR76#87 P26BAT BK C54-8 C54-12 GR/WH R
BATGND
R R
CR76#85 C171LS WH/BK C54-9 C54-1 C19JIB RD
TS7-5 P24FS WH C54-10
SP3 C40LSS 0R C54-11 R R
R
R

GR/WH
K
R
C1
BR
R
RD
R
SP1
B
RD OUTPUT
OPT
GNDBAT BR C7P-3
X103-2
C134PWR RD
GR/WH +
X103-4 R
CR14
BRN -
C9-2 R
GR/WH
TS4-2 C134PWR RD
C54-3 P24FS WH
R
C134PWR RD U35-3
RD
B
BK R20/U35-5
J
GND OR R20
P23BAT WH C7P-2
P22BAT BK C7P-1
ES0549E

LS18

C15PLD OR/BK C3P-Q
WH
C14PLU OR C3P-P
C46HRN BK/RD C3P-K
I

P25FS RD C9-3
SP1 P24FS WH C9-2
SP2 SP4
TS7-4
JIB
X102-19
C32BRK WH/RD C1P-G
C54-2 C32BRK WH/RD
SP3
H
X102-4
C40LSS OR C1P-P
C54-11 C40LSS OR
C35RPM BK/RD C1P-K
C33STR BK C1P-H
C9 (FS)
C27AUX RD C1P-B
C3P
X102
11
1
X103
3
1
G
P26ESTP BK
C1PBU RD C3P-B
SP1 P24FS WH
C7PBE BK C3P-H
C8PBR BK/WH C3P-J
C9
C129DA RD/BK C3P-N
C41RPM OR/BK C1P-Q
C30FWD WH C1P-E
C14PLU OR C3P-P
C31REV WH/BK C1P-F
F
C15PLD OR/BK C3P-Q

C36SCC BL C1P-L
C7P
C2PBD RD/BK C3P-C

August 2013
Part No. 219418

ALC-500
C37SCW BL/BK C1P-M

U13
C4TRL WH C3P-E
C32BRK WH/RD SP2
C5TRR WH/BK C3P-F
C7P
C29MS RD/WH C1P-D
X108
6
1
E
C3P-M C11SBD BL/BK

C3P-L C10SBU BL
C3P
C3P
X101
9
JC1 P162JPW OR
JC2 C165TRS WH/RD
D
JC1 GND BR
JC2 C164PES RD/WH
JC2 P162JPW OR
JC1 C161SB WH/BK
JC2 GND BR
JC3 C160JPL WH/RD
Z-45/25 • Z-45/25J
JC3 C159STC BL/WH
C1P
JC3 P162JPW OR
C1P
JC3 C159STC BL/WH
C3P-N C129DA RD/BK
C

L1(-) C13DE BL/RD
TS14- 1 C29MS RD/WH
X109
7

TS9-1 C15PLD OR/BK
C28TTA RD/BK C1P-C

TS13-1 C8PBR BK/WH
TS9-3 C14PLU OR
TS13-3 C7PBE BK
TS8-6 C44JD GR/BK
B
TS13-2 GNDRTN BR
D40
C1P-C C28TTA RD/BK

(-)
H1
D39
A
(+)
6-122
1
8

PLATFORM CONTROL
HARNESS 1
(TO CONTROL BOX)
D12
1
TS3 TS4 TS15
JC2 JC3
1
1
JC1
CR13 3 4 WH 3 4 2
BK
3 4
2 5 5
5 2
2
1 6 1
TS13 1 6
6
1
ROCKER OPT.
1
1
CR76 TS2 TS6 L1


C161SB WH/BK X101-3
C35RPM BK/RD C1P-K
C13DE BL/RD X101-16

C8PBR BK/WH X109-2
P162JPW OR X101-13
P162JPW OR X101-11
P162JPW OR X101-9
C34SA BK/WH C1P-J

C19JV RD CR14-#86
GNDRTN BR X109-6
C33STR BK C1P-H
C7PBE BK X109-3
GND BR X101-10
GND BR X101-14
GND BR X101-12
BATGND BR JC2
BATGND BR JC1
BATGND BR JC1
P25FS RD C9-3
P24FS WH SP1
GND BR SP5
P26ESTP BK
GNDRTN BR
P24FS WH
GND BR
BR JC3
WH-JIB
P22BAT BK P2
P25FS RD
BK
P24FS WH
C27AUX RD C1P-B
LS18 P134BAT RD
P22PWR RD SW20
C3P-S C17PRL GR
GR/BK H1 (D39)
C54-6 P26ESTP BK
SP1 C19JSV GR/WH
GR/BK X109-10
C9HRN BK/RD C3P-K
C45GEN GR/WH C1P-U

C3P-T C18PRR GR/BK
C54-5 P24FS WH
C7P-2 P23BAT WH
X109-8 C15PLD OR/BK
X103-3 P24FS WH
C7P-1 R22BAT BK
X103-3 P26ESTP BK
X101-8 C29MS RD/WH
X109-9 C14PLU OR
5
WH P24FS WH WH
TS9
1 1 1
4
1 GR 1 4 1 4
4
3
NO
C
1
P3 +
B
+
RD
A
1
1
TS14
RD
L4 L48
GR/BK
WH 6
RD RD
COMPONENT INDEX
CR13 JIB RELAY (JIB OPTION) TS7 PLATFORM ROTATE SWITCH 7
L1 DRIVE ENABLE LED U35 TIME DELAY RELAY 8

Part No. 219418 Z-45/25 • Z-45/25J 6-123


6 - 123 6 - 124

Genie Z45.25 J Internal Combustion - Service Manual - Part No. 219418

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Genie Z45.25 J Internal Combustion - Service Manual - Part No. 219418

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Service Manual

Serial Number Range

Part No. 219418

Important Serial Number Information

Machine Design Life

"Genie" and "Z" are registered trademarks of

ii Z-45/25 • Z-45/25J Part No. 219418

C 8/2013 Added Deutz D 2.9 L4 Engine to all sections

2 - Specs Added Deutz D 2.9 L4

6 - Schem Updated all schematics

Kubota Engine_Section 2_Specifications. Electronic Version

Part No. 219418 Z-45/25 • Z-45/25J iii

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

Kubota Engine_Section 2_Specifications. Electronic Version

iv Z-45/25 • Z-45/25J Part No. 219418

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

This machine complies with:

Part No. 219418 Z-45/25 • Z-45/25J v

Read each procedure thoroughly. This

vi Z-45/25 • Z-45/25J Part No. 219418

Be sure that all tools and working areas

Be sure that fasteners intended for one

Be sure that your workshop or work area

Part No. 219418 Z-45/25 • Z-45/25J vii

Section 1 Safety Rules

viii Z-45/25 • Z-45/25J Part No. 219418

Section 3 Scheduled Maintenance Procedures

Part No. 219418 Z-45/25 • Z-45/25J ix

Section 3 Scheduled Maintenance Procedures, continued

x Z-45/25 • Z-45/25J Part No. 219418

Section 3 Scheduled Maintenance Procedures, continued

Part No. 219418 Z-45/25 • Z-45/25J xi

Section 3 Scheduled Maintenance Procedures, continued ................................................................

Section 4 Repair Procedures

Section 4 Repair Procedures

xii Z-45/25 • Z-45/25J Part No. 219418

Section 4 Repair Procedures, continued

Part No. 219418 Z-45/25 • Z-45/25J xiii

Section 4 Repair Procedures, continued

xiv Z-45/25 • Z-45/25J Part No. 219418

Section 5 Fault Codes

Part No. 219418 Z-45/25 • Z-45/25J xv

Section 6 Schematics, continued

xvi Z-45/25 • Z-45/25J Part No. 219418

Section 6 Schematics, continued

Part No. 219418 Z-45/25 • Z-45/25J xvii

Section 6 Schematics, continued

xviii Z-45/25 • Z-45/25J Part No. 219418

Section 6 Schematics, continued

Part No. 219418 Z-45/25 • Z-45/25J xix

This page intentionally left blank.

xx Z-45/25 • Z-45/25J Part No. 219418

Tire pressure (air-filled tires) 60 psi

For operational specifications, refer to the

Continuous improvement of our products is a

Part No. 219418 Z-45/25 • Z-45/25J 2-1

Fluid capacities Performance Specifications

Primary boom up 24 to 28 seconds

Primary boom down 24 to 28 seconds

Primary boom extend 18 to 22 seconds

Primary boom retract 18 to 22 seconds

Secondary boom up 24 to 28 seconds