Genie Z-45/25 Service Manual
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Genie Z-45/25 Service Manual

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Service Manual
Z-45/25
Z-45/25J
IC Power
Serial Number Range
Deutz models: from 21180 to 23040
Ford models: from 21180 to 23189
Perkins models: from 21180 to 23008
Part No. 77809
Rev C2
August 2005

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Summary of Contents for Genie Z-45/25

  • Page 1 Service Manual Serial Number Range Z-45/25 Deutz models: from 21180 to 23040 Ford models: from 21180 to 23189 Perkins models: from 21180 to 23008 Z-45/25J IC Power Part No. 77809 Rev C2 August 2005...
  • Page 2 Important Serial Number Information Read, understand and obey the safety rules and Genie Industries offers the following Service operating instructions in the Genie Z-45/25 and Manuals for these models: Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure.
  • Page 3 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie Z-45/25 and Genie Z-45/25J Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 4 Please be environmentally safe. which, if not avoided, may result in property damage. Be sure that your workshop or work area Used to indicate operation or is properly ventilated and well lit. maintenance information. Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 5: Table Of Contents

    Perform Function Tests ................3 - 7 Perform Engine Maintenance - Deutz Models ..........3 - 8 Perform Engine Maintenance - Ford Models ..........3 - 8 Perform Engine Maintenance - Perkins Models ........... 3 - 9 Part No. 77809 Z-45/25 • Z-45/25J...
  • Page 6 Check the Oil Level in the Drive Hubs ............3 - 23 B-10 Check and Adjust the Engine RPM - Ford and Deutz Models ....3 - 23 B-11 Test the Ground Control Override .............. 3 - 24 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 7 Grease the Platform Overload Mechanism (if equipped) ......3 - 36 Test the Platform Overload Mechanism (if equipped) ........ 3 - 37 Perform Engine Maintenance - Perkins Models ......... 3 - 39 Perform Engine Maintenance - Ford Models ..........3 - 39 Part No. 77809 Z-45/25 • Z-45/25J...
  • Page 8 Introduction ......................4 - 1 Platform Controls ALC-500 Circuit Board ................. 4 - 2 Joysticks ...................... 4 - 3 Platform Components Platform Leveling Slave Cylinder ..............4 - 7 Platform Rotator ................... 4 - 8 viii Z-45/25 • Z-45/25J Part No. 77809...
  • Page 9 RPM Adjustment - Perkins Models ............4 - 28 Flex Plate ....................4 - 28 Engine Fault Codes - Ford Models ............4 - 29 Hydraulic Pumps Lift/Steer Pump ..................4 - 31 Drive Pump ....................4 - 32 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J...
  • Page 10 10-2 Oscillate Lock-out Cylinders ..............4 - 59 Section 5 Fault Codes Introduction ......................5 - 1 Fault Codes - Control System ................5 - 2 Fault Codes - Ford Models ..................5 - 6 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 11 Engine Harness (before serial number 22050) ............6 - 5 Engine Harness (after serial number 22049) ............6 - 6 Electrical Schematic, Z-45/25 (before serial number 22050) ......... 6 - 7 Electrical Schematic, Z-45/25 (after serial number 22049) ........6 - 9 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 22050) ................
  • Page 12 Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J (after serial number 22049) ................. 6 - 29 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J (after serial number 22049) ................. 6 - 30 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 13 Section 6 Schematics, continued Deutz F3L-1011F models Electrical Schematic, Z-45/25 (before serial number 22050) ....... 6 - 31 Electrical Schematic, Z-45/25 (after serial number 22049) ........6 - 33 Electrical Schematic, Z-45/25 (after serial number 22049) CE models ......................6 - 35 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 22050) ................
  • Page 14 Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J (after serial number 22049) ................. 6 - 61 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J (after serial number 22049) ................. 6 - 62 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 15 Section 6 Schematics, continued Perkins 104-22 models Electrical Schematic, Z-45/25 (before serial number 22050) ....... 6 - 63 Electrical Schematic, Z-45/25 (after serial number 22049) ........6 - 65 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 22050) ................6 - 67 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (before serial number 22050) ................
  • Page 16 Hydraulic Schematic, 2WD Models (after serial number 22049) ......6 - 88 Hydraulic Schematic, 4WD Models (before serial number 22050) ....... 6 - 89 Hydraulic Schematic, 4WD Models (after serial number 22049) ......6 - 90 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 17: A Machine Specifications

    For operational specifications, refer to the Operator's Manual. Platform rotate, 160° 5 to 7 seconds Z-45/25J Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 1...

  • Page 18: Hydraulic Specifications

    Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Drive pressure, maximum 3750 psi Genie specifications require hydraulic oils which are (after serial number 22049) 259 bar designed to give maximum protection to hydraulic...
  • Page 19 Displacement per revolution, variable 0.16 to 2.8 cu in 4WD (2 speed motor) 2.62 to 45.9 cc Displacement per revolution, variable 1.1 to 2.8 cu in 18.4 to 45.9 cc Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 3...

  • Page 20: Manifold Component Specifications

    6 to 8Ω (schematic items B, F, H) 2 position 3 way solenoid valve, 10V DC 6 to 8Ω (schematic items E, G, AD, OO, XX, AI and AK) 2 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 21: A Ford Lrg-425 Efi Engine Specifications

    45 to 84 in-lbs through brush 5.08 to 9.5 Nm Brush mounting 15 to 20 ft-lbs bolt torque 20 to 27 Nm Maximum commutator 0.005 in run-out 0.127 mm Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 5...
  • Page 22 7 to 14 Nm Engine coolant Capacity quarts 10.9 liters Coolant temperature switch Torque 8-18 ft-lbs 11-24 Nm Temperature switch point 230° F 112° C Alternator Output 95A, 14.5V DC 2 - 6 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 23: A Deutz F3L-1011F Engine Specifications

    -10°F to 90°F / -23°C to 32°C 10W-40 9 to 12 mm Above -4°F / -34°C 15W-40 Engine oil should have minimum properties of API classification CC/SG or CD/SG grades. Units ship with 10W-40 CH-4 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 7...

  • Page 24: A Perkins 104-22 Engine Specifications

    55A @ 13.8V DC Exhaust 0.008 in 0.2 mm Starter motor Current draw, no load Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm 2 - 8 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 25 200 minutes Fan belt deflection 10 mm Engine coolant Capacity 7.7 quarts 7.3 liters Coolant temperature sending unit Torque 8-18 ft-lbs 11-24 Nm Temperature switch point 221° F 105° C Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 2 - 9...

  • Page 26: Machine Torque Specifications

    271 Nm Drive hub mounting bolts, lubricated 150 ft-lbs 203 Nm Drive motor mounting bolts, dry 75 ft-lbs 102 Nm Drive motor mounting bolts, lubricated 56 ft-lbs 76 Nm 2 - 10 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
  • Page 28 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 2 - 12 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 29 · Key switch in the off position with the Indicates that an incorrect result has occurred key removed after performing a series of steps. · Wheels chocked · All external AC power supply disconnected from the machine Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 3 - 1...
  • Page 30 The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 31: Pre-Delivery Preparation

    Genie UK 18340 NE 76th Street The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 32 Section 3 • Scheduled Maintenance Procedures March 2005 This page intentionally left blank. 3 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 33: Maintenance Inspection Report

    After B-25 Engine maintenance - repair, place a check in the “R” box. Perkins models Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 77809 Z-45/25 • Z-45/25J 3 - 5...
  • Page 34 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 35: Checklist A Procedures

    The pre-operation inspection also Complete information to perform this procedure is serves to determine if routine maintenance available in the Genie Z-45/25 and Genie Z-45/25J procedures are required. Operator's Manual on your machine. Complete information to perform this procedure is available in the Genie Z-45/25 and Genie Z-45/25J Operator's Manual on your machine.

  • Page 36: Perform Engine Maintenance - Deutz Models

    Section 3 • Scheduled Maintenance Procedures August 2005 CHECKLIST A PROCEDURES REV E Perform Engine Maintenance - Deutz Models 3 - 8 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 37: Perform Engine Maintenance - Perkins Models

    August 2005 Section 3 • Scheduled Maintenance Procedures REV E CHECKLIST A PROCEDURES Perform Engine Maintenance - Perkins Models Part No. 77809 Z-45/25 • Z-45/25J 3 - 9...

  • Page 38: Test The Oscillate Axle (If Equipped)

    Result: The non-steer tires should stay in firm contact with the ground. If the chassis does not remain level during test, refer to Repair Procedure 8-8, How to Set Up the Directional Valve Linkage. 3 - 10 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 39: Perform Engine Maintenance - Ford And Perkins Models

    August 2005 Section 3 • Scheduled Maintenance Procedures REV E Perform Engine Maintenance - Ford and Perkins Models Part No. 77809 Z-45/25 • Z-45/25J 3 - 11...
  • Page 40 Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them. 3 - 12 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 41: Inspect The Fuel Filter/Water Separator - Diesel Models

    3 Visually inspect the filter bowl for water buildup. fuel filter/water separator. Result: If water is present in the filter bowl, 7 Clean up any fuel that may have spilled. continue with steps 3 through 7. Part No. 77809 Z-45/25 • Z-45/25J 3 - 13...
  • Page 42 Repair the leak immediately. 8 Swing the engine back to its original position and close the engine pivot plate latch. 9 Install the engine pivot plate safety pin. 3 - 14 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 43: Check And Adjust The Engine Rpm - Perkins Models

    Tighten the yoke lock nut and recheck the rpm. Be sure the solenoid fully retracts when activating high idle. Part No. 77809 Z-45/25 • Z-45/25J 3 - 15...

  • Page 44: Grease The Turntable Rotation Bearing And Rotate Gear

    A-14 Grease the Turntable Rotation Perform Engine Maintenance - Bearing and Rotate Gear Ford Models Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life.

  • Page 45: Perform Engine Maintenance - Perkins Models

    August 2005 Section 3 • Scheduled Maintenance Procedures REV E A-15 Perform Engine Maintenance - Perkins Models Part No. 77809 Z-45/25 • Z-45/25J 3 - 17...

  • Page 46: Checklist B Procedures

    Adding terminal protectors and a · Engine wiring harness corrosion preventative sealant will · Hydraulic manifold wiring help eliminate corrosion on the battery terminals and cables. 3 - 18 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 47: Test The Key Switch

    12 Install the engine pivot plate safety pin. controls. Result: All machine functions should not operate. 6 Turn the key switch to the off position. Result: The engine should stop and no functions should operate. Part No. 77809 Z-45/25 • Z-45/25J 3 - 19...

  • Page 48: Perform Engine Maintenance - Ford Models

    Ford models: 6 Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin. 3 - 20 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 49: Check The Oil Cooler And Cooling Fins - Deutz Models

    11 Swing the engine back to its original position and close the engine pivot plate latch. 3 Remove the fasteners from the engine side cover, then remove the cover. 12 Install the engine pivot plate safety pin. Part No. 77809 Z-45/25 • Z-45/25J 3 - 21...

  • Page 50: Check The Lug Nut Torque (Including The Tires And Wheels)

    Section 2, Specifications . drive pump free-wheel valve lift pump screwdriver The free-wheel valve is located on the side of the drive pump. The free-wheel valve should always remain closed. 3 - 22 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 51: Check The Oil Level In The Drive Hubs

    The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact Genie Industries Service Department OR your local Ford dealer. Deutz models: This procedure will require two drive hub plugs people.

  • Page 52: Test The Ground Control Override

    (rabbit symbol) position at the ground Result: All boom functions should operate. controls. Result: High idle should be 2500 rpm. If high idle rpm is correct, disregard adjustment step 6. 3 - 24 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 53: Check The Directional Valve Linkage

    · 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. 77809 Z-45/25 • Z-45/25J 3 - 25...

  • Page 54: Test The Engine Idle Select

    Result: The engine should change to high idle. 6 Move the engine idle control switch to foot switch activated low idle (turtle symbol). Result: The engine should change to low idle. 3 - 26 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 55: Test The Drive Brakes

    6 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb. Part No. 77809 Z-45/25 • Z-45/25J 3 - 27...

  • Page 56: Test The Drive Speed - Stowed Position

    6 Continue at full speed and note the time when the machine reference point crosses the finish the machine reference point crosses the finish line. Refer to Section 2, Specifications. line. 3 - 28 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 57: Test The Alarm Package (If Equipped)

    Result: The descent alarm should sound when the switch is held down. Part No. 77809 Z-45/25 • Z-45/25J 3 - 29...

  • Page 58: Perform Hydraulic Oil Analysis

    Result: The travel alarm should sound when the drive control handle is moved off center in either direction. 3 - 30 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 59: Replace The Fuel Filter/Water Separator Element - Perkins Models

    Install the filter/bowl assembly onto the filter head. Tighten the drain plug and vent plug. Component damage hazard. The drain plug and vent plug can be damaged if they are overtightened. Part No. 77809 Z-45/25 • Z-45/25J 3 - 31...
  • Page 60 14 Loosen the vent plug on top of the fuel injection and close the engine pivot plate latch. pump. 18 Install the engine pivot plate safety pin. vent plug fuel injection pump fuel lift pump 3 - 32 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 61: Replace The Fuel Filter Element - Perkins Models

    2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Thoroughly clean the outside surfaces of the fuel filter assembly. 4 Place a suitable container under the fuel filter element. Part No. 77809 Z-45/25 • Z-45/25J 3 - 33...

  • Page 62: Perform Engine Maintenance - Deutz Models

    If there is air in the fuel system, there is probably a leak in the low pressure side of the system. 3 - 34 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 63: Perform Engine Maintenance - Ford Models

    2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the engine pivot plate out and away from the machine. machine. Part No. 77809 Z-45/25 • Z-45/25J 3 - 35...

  • Page 64: Checklist C Procedures

    2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 - 36 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 65 Test the Platform Overload maximum platform capacity in one of the System (if equipped) locations shown. Genie specifications require that this procedure be performed every 500 hours or six months. Testing the platform overload system regularly is essential to safe machine operation. Continued use...
  • Page 66 Calibrate the Platform Overload System. 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls. 3 - 38 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 67 2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the engine pivot plate out and away from the machine. machine. Part No. 77809 Z-45/25 • Z-45/25J 3 - 39...

  • Page 68: Checklist D Procedures

    1 foot / 30 cm. The lift cylinder safety chock is 3 Measure each wear pad. Replace the wear pad if available through Genie Service it is less than inch / 14.3 mm. If the wear Parts.
  • Page 69 8 Lower the boom to the stowed position. Bolt torque sequence 9 Remove drive chassis covers from both the (after serial number 23331) steer end and the non-steer end of the machine. Part No. 77809 Z-45/25 • Z-45/25J 3 - 41...

  • Page 70: Check The Free-Wheel Configuration

    4 Disengage the drive hubs by turning over the engaged position drive hub disconnect caps on each non-steer wheel hub. disengaged position engaged position 3 - 42 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 71: Replace The Drive Hub Oil

    Apply pipe thread sealant to the plugs, and then The free-wheel valve should install the plugs. always remain closed. 5 Repeat steps 1 through 4 for all the other drive hubs. Part No. 77809 Z-45/25 • Z-45/25J 3 - 43...

  • Page 72: Check And Adjust The Air/Lpg Mixture - Ford Models

    3 Loosen the lock nut on the high idle mixture adjustment screw. 4 Load the system by activating the primary boom retract function and moving the function enable toggle switch to the high idle (rabbit symbol) position. 3 - 44 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 73: Perform Engine Maintenance - Deutz Models

    2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 77809 Z-45/25 • Z-45/25J 3 - 45...
  • Page 74 5 At the dial indicator, adjust it to "zero" the indicator. 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom. 3 - 46 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 75: Calibrate The Platform Overload System (If Equipped)

    Result: The overload indicator light and the alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until Genie specifications require that the overload indicator light and alarm turns off. this procedure be performed every 1000 hours of operation or yearly.

  • Page 76: Replace The Hydraulic Filters

    6 Lift the test weight off the platform floor using a suitable lifting device. Genie requires that this procedure 7 Place the test weight back onto the center of the be performed quarterly or every platform floor using a suitable lifting device.
  • Page 77 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings. 13 Remove the filter elements from the housings. 14 Inspect the housing seals and replace them if necessary. Part No. 77809 Z-45/25 • Z-45/25J 3 - 49...

  • Page 78: Checklist E Procedures

    The hoses can be accessed through the access hole under the turntable. 7 Disconnect and plug the return filter hydraulic hose at the return filter. Cap the fitting on the filter housing. 3 - 50 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 79 18 Install the hydraulic tank onto the machine. 19 Install the two suction hoses to the suction strainers. 20 Install the supply hose for the auxiliary power unit and the return filter hose. Part No. 77809 Z-45/25 • Z-45/25J 3 - 51...

  • Page 80: Change The Fuel Hoses - Ford Models

    4 At the pre-filter, disconnect and drain the fuel additional personnel from entering tank into a suitable container. See capacity the area and do not operate the specifications. machine. Repair the leak immediately. 3 - 52 Z-45/25 • Z-45/25J Part No. 77809...

  • Page 81: Perform Engine Maintenance - Deutz Models

    Skip to step 10 if there is no movement. end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 77809 Z-45/25 • Z-45/25J 3 - 53...
  • Page 82 Refer to Section 2, Specifications. 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing. 3 - 54 Z-45/25 • Z-45/25J Part No. 77809...
  • Page 83 Read, understand and obey the safety rules which, if not avoided, will result in and operating instructions in the Genie Z-45/25 death or serious injury. and Genie Z-45/25J Operator’s Manual on your Used to indicate the presence of a machine.

  • Page 84: Platform Controls

    Remove all rings, watches and other jewelry. ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 85: Joysticks

    6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 3...
  • Page 86 10 second Result: There should be a pause and the alarm waiting time. should sound 4 times indicating that the machine is in max-out calibration mode. 4 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 87 0.5 second decelerate, coasting 0.75 second decelerate, braking 1 second decelerate, shift from low to high speed 1 second decelerate, shift from high to low speed 2 seconds Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 5...
  • Page 88 8 Start the engine from the platform controls and press down the foot switch. 9 Select a boom function joystick to set the threshold. 4 - 6 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 89: Platform Components

    Z-45/25: Tag, disconnect and plug the hydraulic When removing a hose assembly hoses from the slave cylinder and connect the or fitting, the O-ring on the fitting hoses together using a connector.

  • Page 90: Platform Rotator

    REV A 6 Z-45/25J: Remove the external snap rings from the barrel-end pivot pin. Platform Rotator Z-45/25: Remove the pin retaining fastener from the slave cylinder barrel-end pivot pin. Do not How to Bleed the Platform remove the pin. Rotator 7 Support the slave cylinder with a lifting device.
  • Page 91 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 9...

  • Page 92: Jib Boom Components, Z-45/25J

    Do not allow oil to and fall when removed from the squirt or spray. machine if not properly attached to the overhead crane. 4 - 10 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 93: Jib Boom Lift Cylinder

    Do not allow oil to squirt or spray. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 11...

  • Page 94: Primary Boom Components

    Loosen hydraulic connections very slowly to allow 4 Raise the primary boom to a horizontal position. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 12 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 95 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 14 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 13...
  • Page 96 Do not allow oil to secured together, the cable track squirt or spray. could become unbalanced and fall when removed from the machine. 4 - 14 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 97 2 To remove a single link, open the lower clip and then use a screw driver to pry the link to the side. 3 Repeat steps 1 and 2 for each link. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 15...

  • Page 98: Primary Boom

    13 Tag, disconnect and plug the primary boom 3 Z-45/25: Remove the platform leveling slave extension cylinder hydraulic hoses. Cap the cylinder. See 2-1, How to Remove the Platform fittings on the cylinder.
  • Page 99 During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 17...

  • Page 100: Primary Boom Lift Cylinder

    3 Attach a 5 ton / 5000 kg overhead crane to the primary boom for support. Do not lift the boom. 4 - 18 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 101: Primary Boom Extension Cylinder

    3 Remove the hose and cable guard from the cylinder from the machine. upper pivot. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 19...

  • Page 102: Platform Leveling Master Cylinder

    3 Attach overhead crane or similar lifting device to dragged across them. the master cylinder. Note the length of the cylinder after removal. The cylinder must be at the same length for installation. 4 - 20 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 103 8 Remove the master cylinder from the machine. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 21...

  • Page 104: Secondary Boom Components

    Follow the disassembly steps to the point required boom rest upper pivot to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order. 4 - 22 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 105 7 Remove the pin retaining fastener from the pin half way out. primary boom lift cylinder barrel-end pivot pin. 14 Remove the secondary boom lift cylinder from the machine. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 23...
  • Page 106 Crushing hazard. The upper pivot soft metal drift to remove the pin. could fall when the number 1 arm is removed from the machine if not properly supported by the overhead crane. 4 - 24 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 107 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 support. Do not lift it. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 25...
  • Page 108 49 Remove the pin retaining fasteners from the number 3 arm at the turntable pivot. Do not remove the pin. 4 - 26 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 109: Secondary Boom Lift Cylinders

    Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 27...

  • Page 110: Engines

    / 1.5 mm gap - Perkins Models not force the drive pump during inch / 1.5 mm gap - Ford Models installation or the flex plate teeth may become damaged. 4 - 28 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 111: Engine Fault Codes - Ford Models

    Engine Fault Codes. The check engine light should begin to blink. The check engine light will blink a "123" code three times before blinking a fault code if one is present. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 29...
  • Page 112 Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 4 - 30 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 113: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 31...

  • Page 114: Drive Pump

    (EDC) located burn skin. Loosen hydraulic on the drive pump. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 32 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 115 7 Start the engine from the ground controls and end of the machine. check for hydraulic leaks. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 33...

  • Page 116: Manifolds

    Counterbalance valve ....... P ... Platform level down ......35-40 ft-lbs / 47-54 Nm Counterbalance valve ....... Q ... Platform level up ....... 35-40 ft-lbs / 47-54 Nm This list continues. Please turn the page 4 - 34 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 117 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 35...
  • Page 118 Check valve ........II .... Secondary boom circuit ....10-12 ft-lbs / 14-16 Nm Diagnostic nipple ......JJ ..Testing Proportional solenoid valve ....KK ..Primary boom up/down ....10-12 ft-lbs / 14-16 Nm 4 - 36 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 119 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 37...

  • Page 120: Valve Adjustments - Function Manifold (Before Serial Number 22050)

    Tip-over hazard. Do not adjust 8 Remove the pressure gauge. the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 38 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 121 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS This page intentionally left blank. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 39...

  • Page 122: Function Manifold Components (After Serial Number 22049)

    Flow regulator valve, 0.4 gpm / 1.5 L/min ......T ... Jib boom and platform rotate circuit ..........20 ft-lbs / 27 Nm This list continues. Please turn the page. 4 - 40 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 123 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 41...
  • Page 124 Check valve ........AB ..Differential sensing circuit, turntable rotate left ......12-14 ft-lbs / 16-19 Nm Relief valve, 2100 psi / 145 bar ..AC ..Secondary boom down ....... 25 ft-lbs / 34 Nm 4 - 42 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 125 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 43...

  • Page 126: Valve Adjustments - Function Manifold (After Serial Number 22049)

    Tip-over hazard. Do not adjust 8 Remove the pressure gauge. the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 44 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 127: Jib Boom / Platform Rotate Manifold Components (Before Serial Number 22050)

    Solenoid valve, 2 position 3 way ..AU ..Platform rotate/jib boom select ... 8-10 ft-lbs / 11-14 Nm Solenoid valve, 2 position 3 way ..AV ..Platform rotate/jib boom select ... 8-10 ft-lbs / 11-14 Nm Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 45...

  • Page 128: Jib Boom / Platform Rotate Manifold Components (After Serial Number 22049)

    (after serial number 22049) Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..AD ..Platform rotate/jib boom select ... 8-10 ft-lbs / 11-14 Nm 4 - 46 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 129: Turntable Rotation Manifold Components

    Shuttle valve, 2 position 3 way ..LL ... Turntable rotation brake release ..10-13 ft-lbs / 14-18 Nm Counterbalance valve ....MM ..Turntable rotate right ....... 35-40 ft-lbs / 47-54 Nm Counterbalance valve ....NN ... Turntable rotate left ......35-40 ft-lbs / 47-54 Nm Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 47...

  • Page 130: Directional Valve Manifold Components

    The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control 4 - 48 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 131 6 To level the drive chassis, start the engine and loosen the lock nuts on both sides of the urethane cushions. 7 Push up or pull down on the threaded rod until the machine is completely level. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 49...

  • Page 132: Drive Manifold Components, 2Wd

    Orifice, 0.030 in / 0.76 mm ....WW ..Brake circuit Solenoid valve, 2 position 3 way ..XX ..2-speed motor shift ......10-12 ft-lbs / 14-16 Nm 4 - 50 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 133 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 51...

  • Page 134: Valve Adjustments, 2Wd Drive Manifold

    Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 52 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 135 March 2005 Section 4 • Repair Procedures REV B MANIFOLDS This page intentionally left blank. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 53...

  • Page 136: Drive Manifold Components, 4Wd

    Check valve ........AS ..Non-steer end drive motor circuit ..10-12 ft-lbs / 14-16 Nm Check valve ........AT ..Non-steer end drive motor circuit ..10-12 ft-lbs / 14-16 Nm 4 - 54 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 137 March 2005 Section 4 • Repair Procedures REV B Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 55...

  • Page 138: Valve Adjustments, 4Wd Drive Manifold

    Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 56 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...

  • Page 139: Turntable Rotation Components

    Crushing hazard. The turntable rotation assembly could become unbalanced and fall when removed Unlocked position from the machine if not properly supported by the overhead crane. Locked position Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 57...

  • Page 140: Axle Components

    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 - 58 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 141 Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 4 - 59...
  • Page 142 Section 4 • Repair Procedures March 2005 REV A This page intentionally left blank. 4 - 60 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 143 Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 and Genie Z-45/25J Operator’s Manual on your machine. Observe and Obey: Be sure that all necessary tools and test Troubleshooting and repair procedures shall be equipment are available and ready for use.

  • Page 144: Fault Codes - Control System

    OR use a grounded wrist strap. 5 - 2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 145 (transient) Boom 2 directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 3...
  • Page 146 Self-clearing. Just calibrated is zero. (transient) Drive enable Enable override Power up override switches Fault direction is frozen at controller with neutral. problem corrected. 5 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 147 Self-clearing. Just calibrated of alarm. (transient) Steer directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 5...

  • Page 148: Fault Codes - Ford Models

    Check Engine Light. Refer to Repair Procedure 6-4, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5 - 6 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 149 OR replace fuel OR Low (LPG) OR fuel quality is poor OR test and repair the fuel fuel system components may system components. be faulty. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 7...
  • Page 150 ECM is open supply wiring to ECM. or shorted. Alternator is overcharging the Repair or replace the System Voltage High battery when engine RPM is alternator. greater than 1500 rpm. 5 - 8 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 151 Voltage sensor OR replace sensor connections open or shorted OR fill engine coolant level to OR sensor is faulty OR specification. coolant level is low. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 9...
  • Page 152 Never Crank Synced open or shorted OR there is a secure OR repair wiring At Start poor system ground and/or connections to sensor connection OR sensor is OR replace sensor. faulty. 5 - 10 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 153 #2 Injector Driver #2 Open OR replace fuel injector #2 OR fuel injector #2 is faulty OR ECM is faulty. OR replace the ECM. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 11...
  • Page 154 Wiring and/or connections to Repair wiring and/or Coil Driver #1 Shorted ignition coil #1 shorted OR connections to ignition coil #1 ignition coil #1 is faulty. OR replace ignition coil #1. 5 - 12 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 155 FPP2 High Voltage Not used. Industries Service Department. If this fault appears on your machine, contact Genie FPP2 Low Voltage Not used. Industries Service Department. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 13...
  • Page 156 OR there is a poor TPS2 and/or connections to one or system ground connection OR both TPS sensors OR replace one or both throttle position one or both TPS sensors. sensors are faulty. 5 - 14 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 157 OR there are air repair any air leaks between leaks between the throttle body the throttle body and cylinder and cylinder head. head. Continued on next page Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 15...
  • Page 158 External 5V DC Ref shorts OR locate and ground OR there is a faulty Lower than Expected troubleshoot or repair faulty engine sensor OR ECM is engine sensor OR replace faulty. ECM. 5 - 16 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 159 Locate and repair any engine Loose wire connections to harness wiring damage or RTI 3 Loss shorts to ECM to be sure they ECM OR ECM is faulty. are secure OR replace ECM. Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 5 - 17...
  • Page 160 Section 5 • Fault Codes March 2005 REV B This page intentionally left blank. 5 - 18 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 161 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie Z-45/25 and Genie Z-45/25J General Repair Process Operator's Manual on your machine. Be sure that all necessary tools and test...
  • Page 162 Key switch N.O. (after serial number 22050) Circuit breaker with amperage Fuel or RPM Control relay contact solenoid normally open Starting aid: glow plug or flame ignitor Coil 6 - 2 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 163 2 position, 2 way solenoid valve Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 3...
  • Page 164 Section 6 • Schematics March 2005 6 - 4 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 165 1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE RELAY 15 R-Y 18 EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE 2. INTERNAL SPLICES ARE NOT SHOWN Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 5...
  • Page 166 March 2005 Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness (before serial number 22050)
  • Page 167 1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GAUGE 16 R-LG 18 (EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GRAY WIRE WITH LIGHT BLUE STRIPE, 18 GAUGE WIRE) POWER RELAY 15 R-Y 18 2. INTERNAL SPLICES ARE NOT SHOWN Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 6...
  • Page 168 March 2005 Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness (after serial number 22049)
  • Page 170 FUSE ENGINE BAT. LINK TB25 GND. C127TSW C5-8 TB38 C108ESL C5-13 STA. C5-9 FLD. REGULATOR FUEL 12V DC PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 6 - 7 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 171 TS13 STEER ROCKER SWITCH OPTION CR30 U13 JOYSTICK CONTROL CARD LIFT/ DRIVE OPTION C40LSS OR TS59 TS60 TS63 TS61 TS62 TS57 TB15 TB17 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 8...
  • Page 172 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050)
  • Page 174 1) All switches and contacts are shown with the FORD 42 PIN QUICK DISCONNECT C3B & C3P - GREEN ENGINE HARNESS #2 boom in the stowed position and the keyswitch off. C4B & C4P - BROWN 6 - 9 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 175 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 10...
  • Page 176 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049)
  • Page 177 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050)
  • Page 178 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Ford LRG-425 EFI Models (before serial number 22050) BK-ALARM BK-ALARM GROUND (TO SWITCH CONTROL WH/RD-ALARM PANEL) HARNESS GROUND CONTROL HARNESS GROUND CONTROL HARNESS FUSE...
  • Page 179 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050) BK/WH-8 BK-7 WH-23 WH-CR2 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 12...
  • Page 180 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050)
  • Page 181 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049)
  • Page 182 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Ford LRG-425 EFI Models (after serial number 22049) BK-ALARM BK-ALARM WH/RD-ALARM GROUND CONTROL HARNESS 10A FUSE CR37 SECONDARY BOOM RELAY CR23 DRIVE LIGHT OPTION RELAY...
  • Page 183 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049) LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY INGITION POWER RELAY...
  • Page 184 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049)
  • Page 185 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050)
  • Page 186 Section 6 • Schematics March 2005 Platform Box Wiring Diagram, Z-45/25 REV A Ford LRG-425 EFI Models (before serial number 22050) CR30 CR27 ALC-500 PLATFORM CONTROL HARNESS CE LIFT/DRIVE OPTION (TO SWITCH PANEL) WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
  • Page 187 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050) PLATFORM CONTROL HARNESS (TO CONTROL BOX) TS47 GENERATOR (OPTION) TS15 DRIVE GR/WH FORWARD/REVERSE DRIVE PRIMARY BOOM UP/DOWN &...
  • Page 188 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (before serial number 22050)
  • Page 189 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049)
  • Page 190 Section 6 • Schematics March 2005 Platform Box Wiring Diagram, Z-45/25 REV A Ford LRG-425 EFI Models (after serial number 22049) CR30 CR27 P24FS WH ALC-500 PLATFORM CONTROL CE LIFT/DRIVE OPTION HARNESS (TO SWITCH PANEL) C28TTA RD/BK C1P-2 WLITE BRN C2P-9...
  • Page 191 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049) PLATFORM CONTROL TS47 HARNESS GENERATOR (TO CONTROL BOX) (OPTION) GR/WH DRIVE PRIMARY BOOM FORWARD/REVERSE UP/DOWN & STEER LEFT/RIGHT SECONDARY BOOM &...
  • Page 192 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Ford LRG-425 EFI Models (after serial number 22049)
  • Page 194 FUSE ENGINE BAT. LINK TB25 GND. C127TSW C5-8 TB38 C108ESL C5-13 STA. C5-9 FLD. REGULATOR FUEL 12V DC PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 6 - 19 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 195 SWITCH OPTION CR30 JOYSTICK CONTROL CARD C19JSV GR/WH LIFT/ DRIVE OPTION C40LSS OR TS59 TS63 TS60 TS61 TS62 TS57 TS58 TB44 TB17 TB15 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 20...
  • Page 196 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050)
  • Page 198 1) All switches and contacts are shown with the FORD 42 PIN QUICK DISCONNECT C3B & C3P - GREEN ENGINE HARNESS #2 boom in the stowed position and the keyswitch off. C4B & C4P - BROWN 6 - 21 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 199 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 22...
  • Page 200 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Ford LRG-425 EFI Models (after serial number 22049)
  • Page 201 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050)
  • Page 202 C5-20 SWITCH C6-40 C40LS1 OR C2B-2 C6-16 C16DRE OR/RD C4B-4 BRN-TS C2B C1B NOTE: GROUND BOLT DASHED LINES INDICATE 12V DC TO OPTION WIRES FUNCTIONS 19/18 CABLES ENGINE PLATFORM 6 - 23 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 203 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050) GR/BK BK/WH-8 BK-7 GR/BK GR/BK WH-23 WH-CR2 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 24...
  • Page 204 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050)
  • Page 205 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (after serial number 22049)
  • Page 206 30 = COMMON (12V DC IN) 87A = NC 12V DC TO FUNCTIONS ENGINE 19/18 CABLES 87 = NO 85 = COIL NEGATIVE PLATFORM 86 = COIL POSITIVE NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 25 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 207 TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH TS64 RUN/TEST TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES BK-22A WH-23 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 26...
  • Page 208 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (after serial number 22049)
  • Page 209 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050)
  • Page 210 C28TTA RD/BK C1P-2 WH/RD C1P-6 WLITE BRN C2P-9 WLITE BRN C2P-10 BATGRN C7P-3 F.S. NOTE: DASHED LINES INDICATE OPTION WIRING OPT. FOOT TILT SWITCH 19/18 CONTROL CABLE 12V DC BATTERY ALALRM 6 - 27 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 211 DASHED LINES CR13 INDICATE OPTION WIRING FUSE 10A BOOM DRIVE SPEED EMERGENCY STOP TS14 HIGH/LOW HIGH/LOW FUEL ENGINE SELECT HORN GR/BK (2WD/4WD) START PLATFORM AUXILIARY LEVEL PUMP PLATFORM ROTATE WH-24 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 28...
  • Page 212 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (before serial number 22050)
  • Page 213 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (after serial number 22049)
  • Page 214 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CR27 CONTROL RELAY (CE OPTION) CR30 CONTROL RELAY (CE OPTION) LS18 LOAD SENSE LIMIT SWITCH 6 - 29 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 215 FUSE 10A FUEL SELECT DRIVE EMERGENCY SPEED STOP TS14 ENGINE HIGH/LOW PLATFORM HIGH/LOW HORN START (2WD/4WD) ROTATE BOOM PLATFORM AUXILIARY PUMP GR/BK LEVEL WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 30...
  • Page 216 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Ford LRG-425 EFI Models (after serial number 22049)
  • Page 218 KEY BYPASS IGN./FUEL ON ENG. FAULT TEMP. P20BAT RD C21IGN WH C5-3 TB21 FUSE 10A TB25 CR23 TB26 ALTERNATOR EXCT. BAT. BAT. 12 V STA. STARTER PUMP REGULATOR IND. 6 - 31 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 219 TS13 STEER ROCKER SWITCH OPTION CR30 U13 JOYSTICK CONTROL CARD LIFT/ DRIVE OPTION C40LSS OR TS59 TS60 TS63 TS61 TS62 TS57 TB15 TB17 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 32...
  • Page 220 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Deutz F3L-1011F Models (before serial number 22050)
  • Page 222 C2B & C2P = BLACK Add D40 only if unit has L4 and L48. C3B & C3P = GREEN ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN 6 - 33 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 223 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 34...
  • Page 224 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Deutz F3L-1011F Models (after serial number 22049)
  • Page 226 Section 6 • Schematics March 2005 Electrical Schematic, Z-45/25, CE Models REV A Deutz F3L-1011F Models (after serial number 22049) C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
  • Page 227 March 2005 Section 6 • Schematics REV A Electrical Schematic, Z-45/25, CE Models Deutz F3L-1011F Models (after serial number 22049) C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH TS14 SECONDARY BOOM PRIMARY BOOM UP/DOWN DRIVE &...
  • Page 228 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 229 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050)
  • Page 230 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Deutz F3L-1011F Models (before serial number 22050) GROUND (TO SWITCH CONTROL PANEL) HARNESS BK-ALARM BK-ALARM WH/RD-ALARM GROUNDCONTROL HARNESS GROUND CONTROL HARNESS HIGH RPM SOLENOID...
  • Page 231 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050) BK/WH-8 BK-7 WH-23 WH-23 WH-23 WH-CR4 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J...
  • Page 232 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050)
  • Page 233 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049)
  • Page 234 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Deutz F3L-1011F Models (after serial number 22049) GROUND BRN GND CONTROL GR/BK H6 HARNESS RD TS52 (TO SWITCH PANEL) RD TS51 BK C7-1 BK-ALARM...
  • Page 235 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049) LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY BK/WH-8 IG ITION POWER RELAY...
  • Page 236 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049)
  • Page 237 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 238 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models REV A Deutz F3L-1011F Models (after serial number 22049) GROUND BRN GND CONTROL GR/BK H6 HARNESS RD TS52 (TO SWITCH PANEL) RD TS51 BK C7-1...
  • Page 239 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models Deutz F3L-1011F Models (after serial number 22049) LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY BK/WH-8...
  • Page 240 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 241 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050)
  • Page 242 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 REV A Deutz F3L-1011F Models (before serial number 22050) CE LIFT/DRIVE OPTION CR30 CR27 ALC-500 PLATFORM CONTROL HARNESS (TO SWITCH PANEL) NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
  • Page 243 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050) PLATFORM CONTROL GR/WH DRIVE HARNESS TS15 FORWARD/REVERSE PRIMARY BOOM UP/DOWN (TO CONTROL BOX) DRIVE ENABLE SECONDARY BOOM &...
  • Page 244 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (before serial number 22050)
  • Page 245 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049)
  • Page 246 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 REV A Deutz F3L-1011F Models (after serial number 22049) CR30 CR27 P24FS WH ALC-500 PLATFORM CONTROL HARNESS (TO SWITCH PANEL) CE LIFT/DRIVE OPTION C28TTA RD/BK C1P-2 WLITE BRN C2P-9...
  • Page 247 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049) TS47 GENERATOR (OPTION) PLATFORM CONTROL TS15 DRIVE HARNESS GR/WH DRIVE (TO CONTROL BOX) ENABLE PRIMARY BOOM UP/DOWN FORWARD/REVERSE &...
  • Page 248 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Deutz F3L-1011F Models (after serial number 22049)
  • Page 250 KEY BYPASS IGN./FUEL ON ENG. FAULT TEMP. P20BAT RD TB21 C21IGN WH C5-3 FUSE 10A TB25 CR23 TB26 ALTERNATOR EXCT. 12 V BAT. BAT. STA. STARTER PUMP REGULATOR IND. 6 - 47 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 251 SWITCH OPTION CR30 JOYSTICK CONTROL CARD C19JSV GR/WH LIFT/ DRIVE OPTION C40LSS OR TS59 TS63 TS60 TS61 TS62 TS57 TS58 TB44 TB17 TB15 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 48...
  • Page 252 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Deutz F3L-1011F Models (before serial number 22050)
  • Page 254 C2B & C2P = BLACK Add D40 only if unit has L4 and L48. C3B & C3P = GREEN ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN 6 - 49 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 255 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 50...
  • Page 256 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Deutz F3L-1011F Models (after serial number 22049)
  • Page 258 CE and Platform Overload Option C2B & C2P = BLACK C3B & C3P = GREEN Add D40 only if unit has L4 and L48. C4B & C4P = BROWN 6 - 51 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 259 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 52...
  • Page 260 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 261 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (before serial number 22050)
  • Page 262 C31REV WH/BK C5-20 C6-40 C40LS1 OR C2B-2 C6-16 C16DRE OR/RD C4B-4 C2B C1B GROUND BOLT 12V DC TO NOTE: FUNCTIONS 19/18 CABLES ENGINE DASHED LINES INDICATE OPTION WIRING PLATFORM 6 - 53 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 263 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (before serial number 22050) GR/BK BK/WH-8 BK-7 GR/BK WH-23 WH-23 WH-23 WH-CR4 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 54...
  • Page 264 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (before serial number 22050)
  • Page 265 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (after serial number 22049)
  • Page 266 30 = COMMON (12V DC IN) 87A = NC 12V DC TO FUNCTIONS ENGINE 19/18 CABLES 87 = NO 85 = COIL NEGATIVE PLATFORM NOTE: DASHED LINES INDICATE OPTION WIRES 86 = COIL POSITIVE 6 - 55 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 267 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH BK-22A TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH WH-23 WH-23 WH-23 WH-CR4 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 56...
  • Page 268 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (after serial number 22049)
  • Page 269 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 270 30 = COMMON (12V DC IN) 87A = NC 12V DC TO FUNCTIONS ENGINE 19/18 CABLES 87 = NO 85 = COIL NEGATIVE PLATFORM NOTE: DASHED LINES INDICATE OPTION WIRES 86 = COIL POSITIVE 6 - 57 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 271 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH BK-22A TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH WH-23 WH-23 WH-23 WH-CR4 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 58...
  • Page 272 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models Deutz F3L-1011F Models (after serial number 22049)
  • Page 273 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (before serial number 22050)
  • Page 274 JC3-6 FOR STEER ROCKER SWITCH OPTION. C28TTA RD/BK C1P-2 WH/RD C1P-6 WLITE BRN C2P-9 WLITE BRN C2P-10 BATGRN C7P-3 F.S. OPT. TILT 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH ALARM 6 - 59 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 275 CR13 FUSE 10A TS14 HIGH/LOW START PLATFORM HIGH/LOW GLOW PLUG HORN ROTATE GR/BK AUXILIARY (2WD/4WD) (OPTION) EMERGENCY PLATFORM POWER STOP LEVEL BOOM WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 60...
  • Page 276 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (before serial number 22050)
  • Page 277 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (after serial number 22049)
  • Page 278 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CR27 CONTROL RELAY (CE OPTION) CR30 CONTROL RELAY (CE OPTION) LS18 LOAD SENSE LIMIT SWITCH 6 - 61 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 279 SPEED EMERGENCY STOP TS14 HIGH/LOW GLOW HIGH/LOW ENGINE HORN JIB BOOM PLUG (2WD/4WD) START AUXILIARY GR/BK PLATFORM (OPTION) PUMP LEVEL WH-24 PLATFORM ROTATE NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 62...
  • Page 280 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Deutz F3L-1011F Models (after serial number 22049)
  • Page 282 KEY BYPASS IGN./FUEL ON ENG. FAULT TEMP. P20BAT RD TB21 C21IGN WH C5-3 FUSE 10A TB25 CR23 TB26 ALTERNATOR EXCT. BAT. BAT. 12 V STA. STARTER PUMP REGULATOR IND. 6 - 63 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 283 CR27 TS13 STEER ROCKER SWITCH OPTION CR30 JOYSTICK CONTROL CARD LIFT/ DRIVE OPTION C40LSS OR TS59 TS63 TS60 TS61 TS62 TS57 TB17 TB15 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 64...
  • Page 284 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Perkins 104-22 Models (before serial number 22050)
  • Page 286 C2B & C2P = BLACK Add D40 only if unit has L4 and L48. C3B & C3P = GREEN ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN 6 - 65 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 287 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 66...
  • Page 288 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25 Perkins 104-22 Models (after serial number 22049)
  • Page 289 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050)
  • Page 290 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Perkins 104-22 Models (before serial number 22050) GROUND (TO SWITCH CONTROL PANEL) HARNESS BK-ALARM BK-ALARM WH/RD-ALARM GROUNDCONTROL HARNESS GROUND CONTROL HARNESS HIGH RPM SOLENOID...
  • Page 291 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050) BK/WH-8 BK-7 WH-23 WH-23 WH-23 WH-CR4 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J...
  • Page 292 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050)
  • Page 293 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049)
  • Page 294 Section 6 • Schematics March 2005 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 REV A Perkins 104-22 Models (after serial number 22049) GROUND BRN GND CONTROL GR/BK H6 HARNESS RD TS52 (TO SWITCH PANEL) RD TS51 BK C7-1 BK-ALARM...
  • Page 295 March 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049) LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A IGNITION / START RELAY BK/WH-8 IG ITION POWER RELAY...
  • Page 296 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049)
  • Page 297 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050)
  • Page 298 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 REV A Perkins 104-22 Models (before serial number 22050) CE LIFT/DRIVE OPTION CR30 CR27 ALC-500 PLATFORM CONTROL HARNESS (TO SWITCH PANEL) NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
  • Page 299 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050) PLATFORM CONTROL GR/WH DRIVE HARNESS TS15 PRIMARY BOOM UP/DOWN FORWARD/REVERSE (TO CONTROL BOX) DRIVE ENABLE SECONDARY BOOM &...
  • Page 300 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (before serial number 22050)
  • Page 301 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049)
  • Page 302 Section 6 • Schematics March 2005 Platform Control Box Wiring Diagram, Z-45/25 REV A Perkins 104-22 Models (after serial number 22049) P24FS WH ALC-500 PLATFORM CONTROL HARNESS (TO SWITCH PANEL) C28TTA RD/BK C1P-2 WLITE BRN C2P-9 WLITE BRN C2P-10 BATGRN C7P-3 F.S.
  • Page 303 March 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049) TS47 GENERATOR (OPTION) PLATFORM CONTROL TS15 DRIVE HARNESS GR/WH DRIVE (TO CONTROL BOX) ENABLE PRIMARY BOOM UP/DOWN FORWARD/REVERSE &...
  • Page 304 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25 Perkins 104-22 Models (after serial number 22049)
  • Page 306 KEY BYPASS IGN./FUEL ON ENG. FAULT TEMP. P20BAT RD TB21 C21IGN WH C5-3 FUSE 10A TB25 CR23 TB26 ALTERNATOR EXCT. 12 V BAT. BAT. STA. STARTER PUMP REGULATOR IND. 6 - 75 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 307 SWITCH OPTION CR30 JOYSTICK CONTROL CARD C19JSV GR/WH LIFT/ DRIVE OPTION C40LSS OR TS59 TS63 TS60 TS61 TS62 TS57 TS58 TB44 TB17 TB15 TB10 TB14 TB11 TB32 TB18 TB12 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 76...
  • Page 308 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Perkins 104-22 Models (before serial number 22050)
  • Page 310 C2B & C2P = BLACK Add D40 only if unit has L4 and L48. C3B & C3P = GREEN ANSI/CSA (Domestic machine) add L48. C4B & C4P = BROWN 6 - 77 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 311 C1B & C1P - GRAY C2B & C2P - BLACK CR33 C3B & C3P - GREEN 87a 87 C4B & C4P - BROWN CR37 CR32 87a 87 87a 87 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 78...
  • Page 312 March 2005 Section 6 • Schematics Electrical Schematic, Z-45/25J Perkins 104-22 Models (after serial number 22049)
  • Page 313 March 2005 Section 6 • Schematics Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Perkins 104-22 Models (before serial number 22050)
  • Page 314 C31REV WH/BK C5-20 C6-40 C40LS1 OR C2B-2 C6-16 C16DRE OR/RD C4B-4 C2B C1B GROUND BOLT 12V DC TO NOTE: FUNCTIONS 19/18 CABLES ENGINE DASHED LINES INDICATE OPTION WIRING PLATFORM 6 - 79 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 315 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 104-22 Models (before serial number 22050) GR/BK BK/WH-8 BK-7 GR/BK WH-23 WH-23 WH-23 WH-CR4 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 80...
  • Page 316 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 104-22 Models (before serial number 22050)
  • Page 317 March 2005 Section 6 • Schematics Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J Perkins 104-22 Models (after serial number 22049)
  • Page 318 30 = COMMON (12V DC IN) 87A = NC 12V DC TO FUNCTIONS ENGINE 19/18 CABLES 87 = NO 85 = COIL NEGATIVE PLATFORM NOTE: DASHED LINES INDICATE OPTION WIRES 86 = COIL POSITIVE 6 - 81 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 319 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH BK-22A TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH WH-23 WH-23 WH-23 WH-CR4 Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 82...
  • Page 320 March 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 104-22 Models (after serial number 22049)
  • Page 321 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J Perkins 104-22 Models (before serial number 22050)
  • Page 322 JC3-6 FOR STEER ROCKER SWITCH OPTION. C28TTA RD/BK C1P-2 WH/RD C1P-6 WLITE BRN C2P-9 WLITE BRN C2P-10 BATGRN C7P-3 F.S. OPT. TILT 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH ALARM 6 - 83 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 323 (OPTION) CR13 FUSE 10A HIGH/LOW TS14 START PLATFORM HIGH/LOW GLOW PLUG HORN ROTATE (2WD/4WD) EMERGENCY GR/BK AUXILIARY PLATFORM STOP BOOM POWER LEVEL WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 84...
  • Page 324 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 104-22 Models (before serial number 22050)
  • Page 325 March 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J Perkins 104-22 Models (after serial number 22049)
  • Page 326 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR C1P - C4P 48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR 6 - 85 Genie Z-45/25 and Genie Z-45/25J Part No. 77809...
  • Page 327 DRIVE SPEED EMERGENCY STOP TS14 HIGH/LOW GLOW HIGH/LOW ENGINE JIB BOOM HORN PLUG (2WD/4WD) START AUXILIARY GR/BK PLATFORM PUMP LEVEL WH-24 PLATFORM ROTATE NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 86...
  • Page 328 March 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, Z-45/25J Perkins 104-22 Models (after serial number 22049)
  • Page 329 220.6 bar 17.2 bar 25 psi OSCILLATE 1.72 bar CYLINDERS 0.030 in 0.76 mm 2SPD AUXILIARY TANK POWER UNIT STEER CYLINDERS ATMOS 1000 psi 69 bar OPTIONAL OSCILLATE DIRECTIONAL VALVE Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 87...
  • Page 330 March 2005 Section 6 • Schematics Hydraulic Schematic, 2WD Models (before serial number 22051)
  • Page 331 REAR 1.7 bar LEFT TANK AUXILIARY 250 psi POWER UNIT 17.2 bar ATMOS 1000 psi / 69 bar STEER CYLINDERS 0.030 inch OPTIONAL OSCILLATE 0.76 mm 2SPD DIRECTIONAL VALVE Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 88...
  • Page 332 March 2005 Section 6 • Schematics Hydraulic Schematic, 2WD Models (after serial number 22050)
  • Page 333 OPTIONAL OSCILLATE LEFT DIRECTIONAL VALVE 0.052 in 1.32 mm REAR 0.025 in LEFT TEST 2 gpm 0.64 mm 250 psi 7.6 L/min 17.2 bar TANK 0.030 in 0.76 mm 2SPD Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 89...
  • Page 334 March 2005 Section 6 • Schematics Hydraulic Schematic, 4WD Models (before serial number 22340)
  • Page 335 1 gpm LEFT 3.8 L/min REAR 0.052 inch LEFT 1.3 mm 0.025 inch TEST 0.64 mm 2 gpm 250 psi 7.6 L/min 17.2 bar TANK 0.030 inch 0.76 mm 2SPD Part No. 77809 Genie Z-45/25 and Genie Z-45/25J 6 - 90...
  • Page 336 March 2005 Section 6 • Schematics Hydraulic Schematic, 4WD Models (after serial number 22339)
  • Page 337 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570...

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