75861

Introduction June 2015
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the Genie Z-60/34 these models:
Operator's Manual before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled
Z-60/34 Service Manual
maintenance information for the machine owner and
(before serial number 1090) ................................. 30105
user. It also provides troubleshooting fault codes
and repair procedures for qualified service Z-60/34 Service Manual
professionals. (from serial number 1090 to 4000) ....................... 52856
Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, 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 © 2011 by Terex Corporation
communications will be carefully considered for 75861 Rev E September 2013
future printings of this and all other manuals. Third Edition, Fifth Printing
Genie and "Z" are registered trademarks of

Terex South Dakota, Inc. in the USA and many
other countries.
Contact Us:
Printed on recycled paper
http://www.genielift.com
Printed in U.S.A.
e-mail: awp.techpub@terex.com
ii Z-60/34 Part No. 75861

June 2015
Revision History
Revision Date Section Procedure / Schematic Page / Description
E 9/2013 New Printing
E1 6/2015 Introduction TOC, Checklist B Procedures
Maintenance Inspection Report

E2 6/2015 Maintenance Inspection Report
C-6 and C-7
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Section 5_Fault Codes. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
Part No. 75861 Z-60/34 iii

June 2015
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
iv Z-60/34 Part No. 75861

June 2015 Section 1 • Serial Number Legend
INTRODUCTION
Serial Number Legend
Model: Z-60/34
Serial number: Z6006-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0423
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg Z60 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 4 in/ 18.3 m
Model Sequence
Maximum platform reach : 34 ft / 10.4 m number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5-
CAN B.354.4-
Terex South Dakota, Inc.

18340 NE 76th Street
Redmond, WA 98052 Serial label
(located on back
USA of tank side
bulkhead)
Serial number OR
(stamped on chassis)
(located on ground
control box)
PN - 77055
Part No. 75861 Z-60/34 v

Section 1 • Safety Rules June 2015
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-60/34
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
vi Z-60/34 Part No. 75861

June 2015 Section 1 • Safety Rules
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Workplace Safety
Be sure to keep sparks, flames and
Safety alert symbol—used to alert
lighted tobacco away from flammable and
personnel to potential personal
combustible materials like battery gases
injury hazards. Obey all safety
and engine fuels. Always have an approved fire
messages that follow this symbol
extinguisher within easy reach.
to avoid possible injury or death.
Be sure that all tools and working areas
Used to indicate the presence of
are properly maintained and ready for
an imminently hazardous situation
use. Keep work surfaces clean and free of
which, if not avoided, will result in
death or serious injury. debris that could get into machine components and
cause damage.
Used to indicate the presence of a
potentially hazardous situation Be sure any forklift, overhead crane or
which, if not avoided, could result other lifting or supporting device is fully
in death or serious injury. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Used to indicate the presence of a are in good condition and of ample capacity.
potentially hazardous situation
which, if not avoided, may result in Be sure that fasteners intended for one
minor or moderate injury. time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
Used to indicate the presence of a may fail if they are used a second time.
which, if not avoided, may result in Be sure to properly dispose of old oil or
property damage. 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. 75861 Z-60/34 vii

June 2015
Table of Contents
Introduction
Important 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 Oil Specifications ................................................................................... 2 - 3
Hydraulic Component Specifications ...................................................................... 2 - 4
Manifold Component Specifications ....................................................................... 2 - 6
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 7
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 9
Ford MSG-425 EFI Engine Specifications ............................................................ 2 - 10
Deutz F4L-1011F Engine Specifications .............................................................. 2 - 12
Deutz F3L-1011F Engine Specifications .............................................................. 2 - 13
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ..................................... 2 - 14
Perkins 404C-22 Engine Specifications ............................................................... 2 - 16
Machine Torque Specifications ............................................................................ 2 - 17
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 18
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 10
viii Z-60/34 Part No. 75861

June 2015
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
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 - All Models .................................................... 3 - 9
A-5 Perform 30 Day Service ............................................................................. 3 - 10
A-6 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10
A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 11
A-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12
A-9 Inspect the Fuel Filter/Water Separator - Deutz Models ............................. 3 - 12
A-10 Perform Engine Maintenance - Ford Models ............................................... 3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-12 Perform Engine Maintenance - Deutz 1011 F Models ................................. 3 - 14
A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15
A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 16
Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 17
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3 Inspect the Air Filter ................................................................................... 3 - 19
B-4 Test the Key Switch ................................................................................... 3 - 20
B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 20
B-6 Check the Exhaust System ....................................................................... 3 - 21
Part No. 75861 Z-60/34 ix

June 2015
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

B-7 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 21
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 24
B-11 Test the Engine Idle Select ........................................................................ 3 - 25
B-12 Test the Fuel Select Operation - Ford Models ............................................ 3 - 25
B-13 Test the Ground Control Override ............................................................... 3 - 26
B-14 Check the Directional Valve Linkage .......................................................... 3 - 27
B-15 Test the Platform Self-leveling ................................................................... 3 - 27
B-16 Test the Drive Brakes ................................................................................ 3 - 28
B-17 Test the Drive Speed - Stowed Position ..................................................... 3 - 28
B-18 Test the Drive Speed - Raised or Extended Position .................................. 3 - 29
B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 30
B-20 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 30
B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 31
B-22 Perform Engine Maintenance - Ford Models ............................................... 3 - 32
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 33
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 34
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 34
C-4 Replace the Air Filter Element - Deutz and Perkins Models ........................ 3 - 37
C-5 Replace the Fuel Inline Strainer- Deutz Models .......................................... 3 - 37
C-6 Check and Adjust the Engine RPM ............................................................ 3 - 38
C-7 Perform Engine Maintenance - Ford Models ............................................... 3 - 39
x Z-60/34 Part No. 75861

June 2015
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 41
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42
D-3 Check the Free-wheel Configuration ........................................................... 3 - 43
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 44
D-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 46
D-6 Replace the Hydraulic Filter Elements ........................................................ 3 - 47
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 48
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52
E-3 Perform Engine Maintenance - Deutz 1011F and Perkins Models .............. 3 - 53
E-4 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 54
E-5 Perform Engine Maintenance - Ford Models ............................................... 3 - 55
E-6 Perform Engine Maintenance - Deutz 2011 Models .................................... 3 - 55
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 How to Remove the Platform ........................................................................ 4 - 7
2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-3 Platform Rotator ........................................................................................... 4 - 9
2-4 Platform Overload System ......................................................................... 4 - 10
Part No. 75861 Z-60/34 xi

June 2015
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

Jib Boom Components
3-1 Jib Boom .................................................................................................... 4 - 14
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 15
Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 17
4-2 Primary Boom ............................................................................................ 4 - 19
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 21
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 22
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 25
Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 26
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 30
Engines
6-1 RPM Adjustment ........................................................................................ 4 - 31
6-2 Flex Plate ................................................................................................... 4 - 31
6-3 Engine Fault Codes - Ford Models ............................................................. 4 - 35
Hydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 36
7-2 Drive Pump ................................................................................................ 4 - 37
Manifolds
8-1 Function Manifold Components - View 1
(before serial number 4461) ....................................................................... 4 - 42
8-2 Function Manifold Components - View 2
(before serial number 4461) ....................................................................... 4 - 44
8-3 Function Manifold Components (from serial number 4461) ......................... 4 - 46
8-4 Valve Adjustments - Function Manifold ...................................................... 4 - 48
xii Z-60/34 Part No. 75861

June 2015
TABLE OF CONTENTS
8-5 Jib Boom / Platform Rotate Manifold Components

(before serial number 4461) ........................................................................ 4 - 50
(from serial number 4461 to serial number 10425) ...................................... 4 - 51
(from serial number 10426 to serial number 11003) .................................... 4 - 52
(from serial number 11004 to 11477) .......................................................... 4 - 53
(from serial number 11478) ......................................................................... 4 - 54
8-10 Brake/Two-Speed Manifold Components
8-11 Brake/Two-Speed Manifold Components
(from serial number 4461) ........................................................................... 4 - 57
8-12 2WD Drive Manifold Components
8-13 2WD Drive Manifold Components
8-14 4WD Traction Manifold Components .......................................................... 4 - 62
(before serial number 10154)
8-15 4WD Traction Manifold Components .......................................................... 4 - 64
(from serial number 10154)
8-16 Valve Adjustments, Traction Manifolds ...................................................... 4 - 66
8-17 Directional Valve Manifold Components ..................................................... 4 - 67
8-18 Directional Valve Linkage ........................................................................... 4 - 68
8-19 Valve Adjustments, Oscillate Directional Valve .......................................... 4 - 69
8-20 Turntable Rotation Manifold Components ................................................... 4 - 70
8-21 Oil Diverter Manifold (welder option) ........................................................... 4 - 71
8-22 Valve Coils ................................................................................................. 4 - 72
Part No. 75861 Z-60/34 xiii

June 2015
TABLE OF CONTENTS

Turntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 74
Axle Components
10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 75
10-2 Oscillate Cylinders ..................................................................................... 4 - 76
Generators
11-1 Valve Adjustment, Hydraulic Generator ...................................................... 4 - 77
Section 5 Fault Codes

Introduction ............................................................................................................ 5 - 1
Fault Code Chart - Control System ........................................................................ 5 - 2
Fault Code Chart - Ford LRG-425 EFI Engine ........................................................ 5 - 6
Fault Code Chart - Ford DSG-423 EFI Engine ...................................................... 5 - 12
Fault Code Chart - Ford MSG-425 EFI Engine ..................................................... 5 - 16
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Wire Connector Legend .......................................................................................... 6 - 2
Electrical Symbols Legend .................................................................................... 6 - 3
Hydraulic Symbols Legend .................................................................................... 6 - 4
Electrical Abbreviations Legend ............................................................................. 6 - 5
Ford DSG-423 EFI Engine Relay Layout ................................................................ 6 - 8
Ford MSG-425 EFI Engine Relay Layout ............................................................... 6 - 8
xiv Z-60/34 Part No. 75861

June 2015
TABLE OF CONTENTS
Section 6 Schematics, continued

Diesel Electrical Schematic,
(from serial number 4496 to serial number 5325) ........................................ 6 - 14
Diesel Electrical Schematic ANSI/CSA,
Diesel Electrical Schematic ANSI/CSA,

Diesel Electrical Schematic CE,
Diesel Electrical Schematic CE,
Diesel Ground Control Box Wiring Diagram,
Diesel Platform Control Box Wiring Diagram,

(from serial number 9066 to serial number 9696) ....................................... 6 - 48
Part No. 75861 Z-60/34 xv

June 2015
TABLE OF CONTENTS

Ford Electrical Schematic,


Ford Electrical Schematic, ANSI/CSA,
Ford Electrical Schematic, ANSI/CSA,
Ford Electrical Schematic, CE,
Ford Electrical Schematic, CE,
Ford Ground Control Box Wiring Diagram,
before serial number 4546) ......................................................................... 6 - 88
xvi Z-60/34 Part No. 75861

June 2015
TABLE OF CONTENTS

Ford Platform Control Box Wiring Diagram,
(from serial number 9799 to serial number 11788) ..................................... 6 - 104
(from serial number 11789) ........................................................................ 6 - 105
Engine Wire Harness,
Ford LRG-425 EFI Models ......................................................................... 6 - 108
Ford DSG-423 EFI Models (before serial number 6810) ............................ 6 - 109
Ford DSG-423 EFI Models (from serial number 6810 to 11788) ................ 6 - 112
Ford MSG-425 EFI Models (from serial number 11789) ............................ 6 - 113
Electrical Schematic, CTE Option (before serial number 9697) .......................... 6 - 116
Electrical Schematic, CTE Option (from serial number 9697) ............................. 6 - 117
Joystick Connector Diagram .............................................................................. 6 - 120
Hydraulic Generator Options (from serial number 10283) ................................... 6 - 121
Electrical Schematic, Welder Option .................................................................. 6 - 124
Part No. 75861 Z-60/34 xvii

June 2015
TABLE OF CONTENTS

Hydraulic Schematic, Welder Option ................................................................. 6 - 125
Hydraulic Schematic, 2WD Models
(before serial number 4461) ...................................................................... 6 - 128
(from serial number 4461 to 10282) .......................................................... 6 - 129
(from serial number 10283 to serial number 11003) .................................. 6 - 132
(from serial number 11004 to 11477) ........................................................ 6 - 133
(from serial number 11478) ....................................................................... 6 - 135
(before serial number 4461) ...................................................................... 6 - 138
(from serial number 4461to serial number 10282) ..................................... 6 - 139
(from serial number 10283 to serial number 11003) .................................. 6 - 142
(from serial number 11004 to 11477) ........................................................ 6 - 143
(from serial number 11478) ....................................................................... 6 - 145
xviii Z-60/34 Part No. 75861

June 2015 Section 2 • Specifications
Specifications
Machine Specifications Lug nut torque (before serial number 4551)
Tires and wheels Flanged or tapered lug nut, dry 170 ft-lbs
230 Nm
Tire size
(Rough terrain) 385-19.5 Flanged or tapered lug nut, lubricated 130 ft-lbs
176 Nm
Tire size
(Hi-flotation) 41/18LL x 22.5 Lug nut torque (after serial number 4550)
Tire ply rating Flanged lug nut, dry 240 ft-lbs

(Rough terrain) 16 325 Nm
Tire ply rating Flanged lug nut, lubricated 180 ft-lbs

(Hi-flotation) 14 244 Nm
Tire weight, new foam-filled (minimum) 425 lbs Tapered lug nut, dry 170 ft-lbs
(Rough terrain) 193 kg 230 Nm
Overall tire diameter 40.1 in Tapered lug nut, lubricated 130 ft-lbs
(Rough terrain) 102 cm 176 Nm
Overall tire diameter 41 in Fluid capacities

(Hi-flotation tires) 104 cm Fuel tank 20 gallons
Tire pressure (air-filled tires) 70 psi 75.7 liters
(Rough terrain) 4.8 bar LPG tank 33.5 pounds
15.2 kg
Tire pressure (air-filled tires) 60 psi
(Hi-flotation tires) 4.1 bar Hydraulic tank 45 gallons
170 liters
Wheel lugs 9 @ 5/8 -18
Hydraulic system 55 gallons
(including tank) 208.2 liters
Drive hubs (before serial number 4551) 17 fl oz
0.5 liters
For operational specifications, refer to the
Operator's Manual. Drive hubs (after serial number 4550) 20 fl oz
0.59 liters
Turntable rotation drive hub 8 fl oz
0.24 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
Part No. 75861 Z-60/34 2-1

Section 2 • Specifications June 2015
SPECIFICATIONS
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds
Jib boom up 20 to 25 seconds
Stowed 40 ft / 7.9-8.5 sec
12.2 m / 7.9-8.5 sec Jib boom down 15 to 20 seconds
Raised or Primary boom up 35 to 45 seconds

Extended position 40 ft / 42-48 sec
Secondary boom up 40 to 50 seconds
12.2 m / 42-48 sec
Gradeability See Operator's Manual Primary boom down 50 to 60 seconds
Braking distance, maximum Secondary boom down 35 to 45 seconds
High range on paved surface 3 to 4 ft Primary Boom extend 12 to 22 seconds

0.9 to 1.2 m Primary Boom retract 15 to 25 seconds
Turntable rotate, 360°

boom fully stowed 130 to 140 seconds
Turntable rotate, 360°

boom raised or extended 170 to 180 seconds
Platform level (ANSI / AUS)

(10° range of motion) 3 to 5 seconds
Platform level (CE)

(10° range of motion) 20 to 22 seconds
Platform rotate, 160° 9 to 15 seconds
2-2 Z-60/34 Part No. 75861

SPECIFICATIONS
Hydraulic Oil Specifications Continued use of Chevron Aviation

A hydraulic oil when ambient
Hydraulic Oil Specifications temperatures are consistently
above 32°F / 0°C may result in
Hydraulic oil type Chevron Rando HD MV equivalent component damage.
Viscosity grade Multi-viscosity
Viscosity index 200 Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
Cleanliness level, minimum 15/13 below 0°F / -18°C.
Water content, maximum 200 ppm Note: Use Shell Tellus S2 V 46 hydraulic oil when
Chevron Rando HD MV oil is fully compatible and oil temperatures consistently exceed 205°F / 96°C.
mixable with Shell Donax TG (Dexron III) oils.
Note: Genie specifications require additional
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
equipment and special installation instructions for
systems, have the ability to perform over a wide the approved optional fluids. Consult the Genie
temperature range, and the viscosity index should Service Department before use.
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
Eni ARNICA 32
Part No. 75861 Z-60/34 2-3

SPECIFICATIONS
Hydraulic Component Charge pump (before serial number 4551)

Specifications Type: fixed displacement gear pump
Drive pump (before serial number 4551) Displacement, 2WD models 0.37 cu in
6.1 cc
Type: bi-directional,
variable displacement piston pump Displacement, 4WD models 0.51 cu in
8.4 cc
Displacement per revolution, variable, 2WD models
0 to 1.70 cu in Flow rate @ 2500 rpm, 2WD models 4 gpm
0 to 28 cc 15.1 L/min
Displacement per revolution, variable, 4WD models Flow rate @ 2500 rpm, 4WD models 5.5 gpm
0 to 2.74 cu in 20.8 L/min
0 to 45 cc
Charge pressure @ 2500 rpm 250 psi
Flow rate @ 2500 rpm, 2WD models 0 to 18.5 gpm Neutral position 17.2 bar
0 to 70.0 L/min
Charge pump (after serial number 4550)
Flow rate @ 2500 rpm, 4WD models 0 to 30.1 gpm
0 to 113.9 L/min Type: gerotor pump
Drive pressure, maximum, 2WD models 4200 psi Displacement 0.85 cu in

290 bar 13.9 cc
Drive pressure, maximum, 4WD models 3625 psi Flow rate @ 2500 rpm 9 gpm
250 bar 34.1 L/min
Drive pump (after serial number 4550) Charge pressure @ 2500 rpm 310 psi
Neutral position 21.4 bar
Type: bi-directional,
variable displacement piston pump Function pump (before serial number 4551)
Displacement per revolution, variable, 4WD models Type gear, pressure balanced
0 to 2.8 cu in Displacement 1.37 cu in
0 to 46 cc 22.5 cc
Flow rate @ 2500 rpm 0 to 28 gpm Flow rate @ 2500 rpm 14.8 gpm
106 L/min 56 L/min
Drive pressure, maximum 3625 psi Function pump (after serial number 4550)
250 bar
Type gear, pressure balanced
Displacement 1.04 cu in
17 cc
Flow rate @ 2500 rpm 10.69 gpm

40.5 L/min
2-4 Z-60/34 Part No. 75861

SPECIFICATIONS
Oscillation pump (after serial number 4550) Brakes
Type gear, fixed displacement Brake release pressure 174 psi

12 bar
Displacement 0.37 cu in
6 cc Drive motors, 4WD and 2WD models
Auxiliary pump
Type gear, fixed displacement Displacement per revolution 1.71 cu in
high speed 28 cc
Displacement - static 0.151 gpm
2.47 L/min Displacement per revolution .87 cu in
low speed 14.2 cc
Auxiliary pump relief pressure 2400 psi
165 bar Drive motors, 4WD models
(after serial number 4550)
Function manifold
Displacement per revolution, 0.79 cu in
System relief valve pressure 2600 psi
high speed 13 cc
179.3 bar
Primary boom down 1800 psi
low speed 30 cc
relief valve pressure 124 bar
Drive motors, 2WD models
Secondary boom down 1600 psi
relief valve pressure 110 bar
Steer flow regulator 3.5 gpm
high speed 20.9 cc
13.2 L/min
Boom extend 2600 psi
low speed 35 cc
179.3 bar
Hydraulic filters
Oscillate pressure 750 psi
51.7 bar High pressure filter Beta 3 ≥ 200
Jib boom / platform rotate 1.5 gpm High pressure filter 102 psi
flow regulator 5. 7 L/min bypass pressure 7 bar
2WD Traction manifold Medium pressure filter Beta 3 ≥ 200
Hot oil relief pressure 300 psi Medium pressure filter 51 psi
(before serial number 4461) 20.7 bar bypass pressure 3.5 bar
Hot oil relief pressure 280 psi Hydraulic tank 10 micron with
(after serial number 4460) 19.3 bar return filter 25 psi / 1.7 bar bypass
4WD Traction manifold Drive motor case drain Beta 10 ≥ 2
return filter
Hot oil relief pressure 250 psi
(before serial number 10154) 17.2 bar
Hot oil relief pressure 280 psi

(after serial number 10153) 19.3 bar
Part No. 75861 Z-60/34 2-5

SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 36 in-lbs / 4.1 Nm
SAE No. 4 10 ft-lbs / 13.6 Nm
SAE No. 6 14 ft-lbs / 19 Nm
2-6 Z-60/34 Part No. 75861

SPECIFICATIONS
Ford LRG-425 EFI Engine Oil pressure switch specifications
Displacement 153 cu in Torque 8-18 ft-lbs

2.5 liters 11-24 Nm
Number of cylinders 4 Oil pressure switch point 3-5 psi

0.21-0.34 bar
Bore & stroke 3.78 x 3.4 in
96.01 x 86.36 mm Starter motor
Horsepower Normal engine cranking speed 200 to 250 rpm

Gross intermittent 70 @ 2500 rpm Current draw, normal load 140-200A
Continuous 60 @ 2500 rpm
Gross intermittent 52 kW @ 2500 rpm Current draw, maximum load 800A
Continuous 44.7 kW @ 2500 rpm
Current draw, no load 70A
Firing order 1-3-4-2
Maximum circuit voltage drop 0.5V DC
Low idle 1600 rpm while starting (normal temperature)
Frequency 396.8 Hz
Brush length, new 0.66 in
High idle 2500 rpm 16.8 mm
Frequency 620 Hz
Brush length wear limit 0.25 in
Compression ratio 9.4:1 6.35 mm
Compression pressure (approx.) Battery
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder Type 12V DC, Group 31
Valve clearances - 0.035 to 0.055 in Quantity 1

collapsed tappet 0.889 to 1.397 mm
Cold cranking ampere 1000A
Lubrication system
Reserve capacity @ 25A rate 200 minutes
Oil pressure 40 to 60 psi
(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Oil capacity 4.5 quarts Electronic fuel pump

(including filter) 4.3 liters Fuel pressure, static 64 psi
4.4 bar
Oil viscosity requirements Fuel flow rate 0.58 gpm

2.18 L/min
Unit ships with 5W-30 oil.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Part No. 75861 Z-60/34 2-7

SPECIFICATIONS
Ignition System
Spark plug type Motorcraft AWSF-52-C

Spark plug type Motorcraft AGSF-32-FM

Spark plug gap 0.042 to 0.046 inches

1.07 to 1.17 mm
Spark plug torque 5-10 ft-lbs

7-14 Nm
Engine coolant
Capacity 11.5 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, 13.8V DC
2-8 Z-60/34 Part No. 75861

SPECIFICATIONS
Ford DSG-423 EFI Engine Fuel requirement
Displacement 140.4 cu in For fuel requirements, refer to the engine Operator's

2.3 liters Manual on your machine.
Number of cylinders 4 Ignition system
Bore & stroke 3.44 x 3.7 inches Spark plug type Motorcraft AGSF-32-FEC
87.5 x 94 mm Spark plug gap 0.049 to 0.053 inches
Horsepower 1.244 to 1.346 mm
Continuous horsepower 59 @ 2500 rpm Engine coolant
Peak horsepower 69 @ 2500 rpm
Continuous horsepower 44 kW @ 2500 rpm Capacity 10 quarts
Peak horsepower 51 kW @ 2500 rpm 9.5 liters
Firing order 1-3-4-2 Cylinder head temperature sending unit
Low function idle (computer controlled) 1600 rpm Fault code set temperature 280°F
Frequency 53.3 Hz 138°C
High function idle (computer controlled) 2500 rpm Engine shut-down temperature 300°F
Frequency 83.3 Hz 149°C
Compression ratio 9.7:1 Starter motor
Compression pressure (approx.) Normal engine cranking speed 200 to 250 rpm
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder Current draw, normal load 140-200A
Lubrication system Current draw, maximum load 800A
Oil pressure 29 to 39 psi Alternator

(at operating temperature @ 2500 rpm) 2 to 2.7 bar
Oil capacity 4 quarts
(including filter) 3.8 liters Battery
Oil viscosity requirements Type 12V DC, Group 31
Unit ships with 5-W20 oil. Quantity 1

Extreme operating temperatures may require the use of Cold cranking ampere @ 0°F 1000A
engine Operator's Manual on your machine. Reserve capacity @ 25A rate 200 minutes
Electronic fuel pump Torque
Fuel pressure, static 64 psi Flywheel bolts 83 ft-lbs
4.4 bar
Fuel flow rate 0.43 gpm

1.6 L/min
Part No. 75861 Z-60/34 2-9

SPECIFICATIONS
Ford MSG-425 EFI Engine Electronic fuel pump
Displacement 152.5 cu in Fuel pressure, static 60 psi

2.5 liters 4.14 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.50 x 3.94 inches
89 x 100 mm Ignition system
Horsepower Spark plug type Motorcraft AGSF-32-FEC

Continuous horsepower 60 @ 2500 rpm Spark plug gap 0.049 to 0.053 inches
Continuous horsepower 44.7 kW @ 2500 rpm 1.244 to 1.346 mm
Firing order 1-3-4-2 Engine coolant
Idle speed (computer controlled) 1000 rpm Capacity 10 quarts
Low function idle (computer controlled) 1600 rpm 9.5 liters
Operating pressure 13-18 psi
High function idle (computer controlled) 2500 rpm Normal operating temperature 205° F
Governor Electronic Cylinder head temperature sending unit
Compression ratio 9.7:1 Fault code set temperature 280°F

138°C
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be Engine shut-down temperature 300°F
at least 75% of highest cylinder 149°C
Lubrication system

(at operating temperature @ 2500 rpm) 2 to 2.7 bar
Oil capacity 6.7 quarts

(including filter) 6.4 liters
Oil switch pressure point 7-9 psi
0.48 to 0.62 bar
2 - 10 Z-60/34 Part No. 75861

SPECIFICATIONS
Ford MSG-425 Engine, continued
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Current draw, maximum load 800A
Alternator
Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Part No. 75861 Z-60/34 2 - 11

SPECIFICATIONS
Deutz Engine F4L 1011F Injection system
Displacement 166.7 cu in Injection pump make OMAP

2.732 liters Injection pump pressure 4351 psi
Number of cylinders 4 300 bar
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
Horsepower 56 @ 3000 rpm Fuel requirement

42 kW @ 3000 rpm For fuel requirement, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.
Compression ratio 18.5:1 Alternator output 60A, 14V
Compression pressure 362 to 435 psi Starter motor

25 to 30 bar Current draw, no load 90A
Low idle 1500 rpm Brush length, new 0.7480 in
Frequency 313 Hz 19mm
High idle 2300 rpm Brush length, minimum 0.5 in
Frequency 479.9 Hz 12.7 mm
Governor centrifugal mechanical Battery
Valve clearance, cold Type 12V, Group 31
Intake 0.012 in Quantity 1
0.3 mm
Exhaust 0.020 in
0.5 mm Reserve capacity @ 25A rate 200 minutes
Lubrication system Fan belt deflection 3 /8
to 1/2 inch
9 to 12 mm
Oil pressure (hot @ 2000 rpm) 60 to 70 psi
4.1 to 4.8 bar
Oil capacity 11 quarts

(including filter) 10.5 liters
Oil viscosity requirements

2 - 12 Z-60/34 Part No. 75861

SPECIFICATIONS
Deutz F3L 1011F Engine Injection system
Displacement 125 cu in Injection pump make OMAP

2.05 liters Injection pump pressure 4351 psi
Number of cylinders 3 300 bar
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
Horsepower 43 @ 2800 rpm Fuel requirement

32 kW @ 2800 rpm For fuel requirement, refer to the engine Operator's
Firing order 1-2-3 Manual on your machine.
Compression ratio 18.5:1 Alternator output 55A, 14V
Compression pressure 362 to 435 psi Starter motor

25 to 30 bar Current draw, no load 90A
Low idle 1500 rpm Brush length, new 0.7480 in
Frequency 313 Hz 19 mm
High idle 2300 rpm Brush length, minimum 0.5 in
Frequency 479.9 Hz 12.7 mm
Governor centrifugal mechanical Battery
Valve clearance, cold Type 12V, Group 31
Intake 0.012 in Quantity 1
0.3 mm
Exhaust 0.020 in
0.5 mm Reserve capacity @ 25A rate 200 minutes
Lubrication system Fan belt deflection 3 /8
to 1/2 inch
9 to 12 mm
1.8 to 6.0 bar
Oil capacity 8.5 quarts

(including filter) 8 liters
Oil viscosity requirements

Part No. 75861 Z-60/34 2 - 13

SPECIFICATIONS
Deutz F3L 2011 Engine Lubrication system

Deutz D2011L03i Engine Oil pressure, hot @ 2000 rpm 40-60 psi
2.8 to 4.1 bar
Displacement 142 cu in
2.33 liters Oil capacity 8.5 quarts
(including filter) 8 liters
Number of cylinders 3 (Deutz F3L2011 Engine)
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011Lo3i Engine)
Horsepower
Net intermittent 48.7 @ 2800 rpm Oil viscosity requirements
Net continuous 46.2 @ 2800 rpm
Unit ships with 15-W40 oil.
Net intermittent 36 kW @ 2800 rpm
Net continuous 34.5 kW @ 2800 rpm
Firing order 1-2-3 engine Operator's Manual on your machine.
Low idle 1500 rpm Oil temperature switch

Frequency 313 Hz
Torque 8-18 ft-lbs
High idle 2500 rpm 11-24 Nm
Frequency 521.7 Hz
Compression ratio 19:1 104° C
Compression pressure 362 to 435 psi Oil pressure switch

25 to 30 bar
Torque 8-18 ft-lbs
Governor centrifugal mechanical 11-24 Nm
Valve clearance, cold Oil pressure switch point 7 psi

(Deutz F3L2011 Engine) .5 bar
Intake 0.012 in
0.3 mm Oil pressure switch point 22 psi
(Deutz D2011L03i Engine) 1.5 bar
Exhaust 0.020 in
0.5 mm
2 - 14 Z-60/34 Part No. 75861

SPECIFICATIONS
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's

Manual on your machine.
Starter motor
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
Battery
Type 12V, Group 31
Quantity 1
Alternator output 60A @ 14V DC
Fan belt deflection 3 /8

to 1/2 inch
9 to 12 mm
Part No. 75861 Z-60/34 2 - 15

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

2.2 liters (at 2000 rpm) 2.8 to 4.1 bar
Number of cylinders 4 Oil capacity 9.4 quarts to 11.2 quarts

(including filter) 8.9 liters to 10.6 liters
Bore and stroke 3.31 x 3.94 inches
84 x 100 mm Oil viscosity requirements
Horsepower Unit ships with 15-W40 oil.

gross intermittent 50 @ 2800 rpm alternative engine oils. For oil requirements, refer to the
continuous 41 @ 2800 rpm engine Operator's Manual on your machine.
gross intermittent 37.3 kW @ 2800 rpm
continuous 31 kW @ 2800 rpm Oil pressure sending unit
Firing order 1-3-4-2 Torque 8-18 ft-lbs

11-24 Nm
Low idle 1300 rpm
Frequency 200.4 Hz Oil pressure switch point 14.2 psi
1 bar
Low idle with generator option 1500 rpm
Frequency 231.3 Hz Fuel injection system
High idle 2500 rpm Injection pump make Zexel

Frquency 385.4 Hz Injection pressure 2133 psi
Compression ratio 22.4:1 147 bar
Compression pressure 426 psi Fuel requirement

29.4 bar For fuel requirement, refer to the engine Operator's
Pressure (psi) of lowest cylinder must Manual on your machine.
be within 50 psi / 3.45 bar of highest cylinder
Alternator output 65A @ 13.8V DC
Governor centrifugal mechanical
Fan belt deflection 3/8 to ½ in
Valve clearance, cold 9 to 12 mm
Intake 0.008 in Starter motor
0.2 mm
Exhaust 0.008 in
0.2 mm Brush length, new 0.7480 in
19 mm
Brush length, minimum 0.5 in

12.7 mm
2 - 16 Z-60/34 Part No. 75861

SPECIFICATIONS
Battery Machine Torque Specifications

Type 12V, Group 31 Platform rotator
Quantity 1 1-8 center bolt, dry 640 ft-lbs
Cold cranking ampere 1000A 868 Nm
Reserve capacity @ 25A rate 200 minutes 1-8 center bolt, Gr 5, lubricated 480 ft-lbs
651 Nm
Coolant temperature sending unit
3/8-16 bolts, Gr 8, lubricated 35 ft-lbs*
Torque 8-18 ft-lbs *(use blue thread-locking compound) 47 Nm
11-24 Nm
Drive motor and hubs
105° C Drive hub mounting bolts, lubricated 160 ft-lbs*
(before serial number 4569 and after 5572) 217Nm
*(use blue thread-locking compound)
Drive hub mounting bolts, lubricated 173 ft-lbs*

(between serial number 4569 and 5572) 235 Nm
*(use blue thread-locking compound)
Drive motor mounting bolts, dry 75 ft-lbs

(before serial number 4551) 101.6 Nm
Drive motor mounting bolts, lubricated 57 ft-lbs

(before serial number 4551) 77.3 Nm
Drive motor mounting bolts, dry 49 ft-lbs

(after serial number 4550) 66.4 Nm
Drive motor mounting bolts, lubricated 37 ft-lbs

(after serial number 4550) 50.1 Nm
Turntable bearing
Turntable bearing mounting bolts, lubed 180 ft-lbs

244 Nm
Turntable rotate assembly
Turntable motor mounting bolts 160 ft-lbs*

*(use blue thread-locking compound) 217 Nm
Part No. 75861 Z-60/34 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
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to -4 14 ft-lbs / 19 Nm
specification when they are removed and installed
-6 23 ft-lbs / 31.2 Nm
or when new hoses or fittings are installed.
-8 36 ft-lbs / 54.2 Nm
Seal-Lok™ Fittings
(hose end - ORFS) -10 62 ft-lbs / 84 Nm
SAE Dash size Torque -12 84 ft-lbs / 114 Nm
-4 10 ft-lbs / 13.6 Nm -16 125 ft-lbs / 169.5 Nm
-6 30 ft-lbs / 40.7 Nm -20 151 ft-lbs / 204.7 Nm
-8 40 ft-lbs / 54.2 Nm -24 184 ft-lbs / 249.5 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm

Jamb nut Non-adjustable
-16 110 ft-lbs / 150 Nm
fitting (Non-adj)
-20 140 ft-lbs / 190 Nm Adjustable
-24 180 ft-lbs / 245 Nm
fitting (Adj)
JIC 37° Fittings

SAE O-ring Boss Port
(swivel nut or hose connection)
(tube fitting - installed into Steel)
SAE Dash size Thread Size Flats
SAE Dash size Torque
-4 7/16-20 2
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-6 9/16-18 1 1/4 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-8 3/4-16 1
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-10 7/8-14 1 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-12 1 1/16-12 1 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm

37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-16 1 5/16-12 1
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-24 1 7/8-12 1 -12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
2 - 18 Z-60/34 Part No. 75861

Torque Procedure
a
Seal-Lok™ fittings
c b
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has Figure 1
been tightened beyond finger tight.
a hex nut
Note: The O-rings used in the Parker Seal Lok™ b reference mark
fittings and hose ends are custom-size O-rings. c body hex fitting
They are not standard SAE size O-rings. They are 3 Working clockwise on the body hex fitting, make
available in the O-ring field service kit (Genie part a second mark with a permanent ink marker to
number 49612). indicate the proper tightening position. Refer to
2 Lubricate the O-ring before installation. Figure 2.
3 Be sure that the face seal O-ring is seated and Note: Use the JIC 37° Fittings table on the previous
retained properly. page to determine the correct number of flats for
the proper tightening position.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger Note: The marks indicate that the correct tightening
tight. positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
5 Tighten the nut or fitting to the appropriate joint after it has been loosened.
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to b
confirm that there are no leaks. a
c
b
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of Figure 2
the fitting body (body hex fitting) and tighten the a body hex fitting
hex nut to the body hex fitting to hand-tight, b reference mark
approximately 30 in-lbs / 3.4 Nm. c second mark
2 Make a reference mark on one of the flats of the 4 Tighten the hex nut until the mark on the hex nut
hex nut, and continue it on to the body hex is aligned with the second mark on the body hex
fitting with a permanent ink marker. Refer to fitting.
Figure 1.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
Part No. 75861 Z-60/34 2 - 19

SPECIFICATIONS
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2 - 20 Z-60/34 Part No. 75861

June 2015 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

Observe and Obey: information and step-by-step instructions.
Symbols Legend
Maintenance inspections shall be completed by
a person trained and qualified on the Safety alert symbol—used to alert
maintenance of this machine. personnel to potential personal
injury hazards. Obey all safety
Scheduled maintenance inspections shall be
completed daily, quarterly, six months, annually to avoid possible injury or death.
and every 2 years as specified on the
Maintenance Inspection Report. Used to indicate the presence of
Failure to perform each procedure which, if not avoided, will result in
as presented and scheduled may death or serious injury.
cause death, serious injury or
substantial damage. Used to indicate the presence of a
Immediately tag and remove from service a which, if not avoided, could result
damaged or malfunctioning machine. in death or serious injury.
Repair any machine damage or malfunction With safety alert symbol—used to
before operating machine. indicate the presence of a
Use only Genie approved replacement parts.
which, if not avoided, may cause
Machines that have been out of service for a minor or moderate injury.
period longer than three months must complete Used to indicate the presence of a
the quarterly inspection. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may result in
maintenance procedure with the machine in the property damage.
following configuration: Note: Used to indicate operation or maintenance
• Machine parked on a firm, level surface information
• Boom in the stowed position Indicates that a specific result is expected after
• Turntable rotated with the boom between performing a series of steps.
the non-steer wheels
Indicates that an incorrect result has occurred
• Turntable secured with the turntable after performing a series of steps.
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 75861 Z-60/34 3-1

Section 3 • Scheduled Maintenance Procedures June 2015
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this 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
procedure, it conveys the meaning below. Report 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
Indicates that new parts will be required
Procedures Section and the Maintenance
to perform this procedure.
Inspection Report have been divided into five
subsections—A, B, C, D and E. Use the following
chart to determine which group(s) of procedures
Indicates that a cold motor, pump or are required to perform a scheduled inspection.
engine will be required to perform this
procedure.
Inspection Checklist
Daily or every 8 hours A

Indicates that a warm motor or pump
will be required to perform this Quarterly or every 250 hours A+B
procedure.
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that dealer service is required
to perform this procedure. Two years or every 2000 hours A+B+C+D+E
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 a minimum of 4 years or in compliance with your
employer, jobsite and governmental regulations and
requirements.
3-2 Z-60/34 Part No. 75861

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
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
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. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. 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 manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
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 Spouth 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
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc.
133192 Rev D
This page intentionally left blank.
3-4 Z-60/34 Part No. 75861


Model Checklist A Y N R Checklist B Y N R
A-1 Inspect the manuals B-1 Battery
Serial number and decals B-2 Electrical wiring
Date A-2 Pre-operation B-3 Air filter element
inspection
B-4 Key switch
Hour meter A-3 Function tests
B-5 Engine maintenance -
A-4 Engine maintenance - Deutz and Perkins
Machine owner all models models
Perform after 40 hours: B-6 Exhaust system
Inspected by (print)
A-5 30 Day Service B-7 Oil cooler and fins-
Inspector signature Perform every 40 hours: Deutz models
A-6 Filter condition indicator B-8 Tires, wheels and lug
Inspector title Perform after first 50 hours: nut torque
A-7 Engine maintenance - B-9 Drive hub maintenance
Inspector company
Deutz and Ford models B-10 Brake configuration
Instructions Perform every 50 hours: B-11 Engine idle select
• Make copies of this report to use for A-8 Engine maintenance- B-12 Fuel select -
each inspection. Perkins models Ford models
• Select the appropriate checklist(s) for Perform every 100 hours: B-13 Ground control
the type of inspection to be A-9 Fuel filter/water B-14 Directional
performed. separator - valve linkage
Deutz models B-15 Platform
Daily or 8 hour
A-10 Engine maintenance - self-leveling
Inspection: A
Ford models B-16 Drive brakes
Quarterly or 250 hour
A-11 Rotation bearing B-17 Drive speed -
Inspection: A+B
Perform after first 125 hours: stowed position
Six Month or 500 hour
Inspection: A+B+C A-12 Engine maintenance - B-18 Drive speed -
Deutz 1011F models raised position
Annual or 1000 hours
Perform after first 150 hours: B-19 Hydraulic oil analysis
Inspection: A+B+C+D
A-13 Drive hub oil B-20 Alarm package
2 Year or 2000 hour
Inspection: A+B+C+D+E Perform every 200 hours: B-21 Fuel and hydraulic cap
A-14 Engine maintenance - venting systems
• Place a check in the appropriate box Ford models Perform every 400 hours:
after each inspection procedure is
B-22 Engine maintenance -
completed.
Ford models
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag Comments
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. 75861 Z-60/34 3-5

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

C-1 Engine maintenance - E-1 Hydraulic oil
Serial number Deutz and Perkins E-2 Steer axle
models wheel bearings,
Date
C-2 Platform overload 2WD models
Hour meter (if equipped) Perform every 2000 hours:
C-3 Platform overload E-3 Engine maintenance -
Machine owner (if equipped) Deutz and
C-4 Air filter element - Perkins models
Inspected by (print) Deutz and Perkins Perform every 3000 hours:
models
Inspector signature E-4 Engine maintenance -
C-5 Fuel inline strainer - Deutz and
Deutz models Perkins models
Inspector title
C-6 Check engine rpm Perform every 4 years:
Inspector company Perform every 800 hours: E-5 Engine maintenance -
C-7 Engine maintenance - Ford models
Instructions Ford models Perform every 5000 hours:
• Make copies of both pages to use for Checklist D Y N R E-6 Engine maintenance -
each inspection. D-1 Boom wear pads Deutz models
• Select the appropriate checklist(s) for D-2 Turntable bearing bolts Perform every 6000 hours:
the type of inspection to be
D-3 Free-wheel E-7 Engine maintenance -
performed.
configuration Deutz
Daily or 8 hour D-4 Drive hub oil Perform every 12,000 hours:
Inspection: A D-5 Engine maintenance- E-8 Engine maintenance -
Quarterly or 250 hour Deutz and Perkins Deutz models
Inspection: A+B models
Six Month or 500 hour D-6 Hydraulic filters
Inspection: A+B+C D-7 Turntable bearing wear
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour Comments
Inspection: A+B+C+D+E
• Place a check in the appropriate box

after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 Z-60/34 Part No. 75861

Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed daily. Result: The machine is equipped with all
Maintaining the operator’s and safety manuals in required decals, and all decals are legible and
good condition is essential to safe machine in good condition.
operation. Manuals are included with each Result: The machine is not equipped with all
machine and should be stored in the container required decals, or one or more decals are
provided in the platform. An illegible or missing illegible or in poor condition. Remove the
manual will not provide safety and operational machine from service until the decals are
information necessary for a safe operating replaced.
condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie if replacement manuals or decals are
associated with using this machine. They also needed.
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 75861 Z-60/34 3-7

CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed daily. performed daily.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the Operator's Manual on your
Complete information to perform this procedure is machine.
available in the Operator's Manual on your
machine.
3-8 Z-60/34 Part No. 75861

A-4 Required maintenance procedures and additional

engine information are available in the Ford LRG-
Perform Engine Maintenance 425 EFI Operator Handbook (Ford part number FPP
194-302) or the Ford DSG-423 EFI Operator
Handbook (EDI part number 1060020) or the Ford
MSG-425 EFI Operator Handbook (Ford part
Engine specifications require that this procedure be number 1020010).
performed every 8 hours or daily, whichever comes
first. Ford LRG 425 EFI Operation Manual
Genie part number 84792
Deutz models
Required maintenance procedures and additional Ford DSG 423 EFI Operator Handbook
engine information are available in the Deutz 1011F Genie part number 119488
Operation Manual (Deutz part number 0297 9683) or
the Deutz 2011 Operation Manual (Deutz part Ford MSG-425 EFI Operator Handbook
number 0297 9929).
To access the engine:
Deutz 1011F Operation Manual 1 Remove the engine tray retaining fasteners
Genie part number 52883 located under the engine tray. Loosen the pivot
fastener located at the platform end of the
Deutz 2011 Operation Manual engine tray. Swing the engine tray out and
Genie part number 84794 away from the machine and secure it from
moving
Crushing hazard. Failure to secure
Perkins models the engine pivot plate from moving
could result in death or serious
Required maintenance procedures and additional injury.
engine information are available in the Perkins
404C-22 Operation Manual (Perkins part number
TPD 1443S).
Perkins 404C-22 Operation Manual

Ford models
Part No. 75861 Z-60/34 3-9

A-5 A-6
Perform 30 Day Service Check the High Pressure
Hydraulic Filter Condition
Indicator (if equipped)
The 30 day maintenance procedure is a one time Genie specifications require that this procedure be
sequence of procedures to be performed after the performed every 40 hours of operation.
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the Maintaining the hydraulic return filter in good
maintenance tables for continued scheduled condition is essential to good system performance
maintenance. and safe machine operation. The filter condition
indicator will show when the hydraulic flow is
1 Perform the following maintenance procedures: bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
remain in the hydraulic system and cause
• A-11 Grease the Turntable Bearing and
component damage.
Rotate Gear
• B-8 Inspect the Tires, Wheels and Lug Nut 1 Open the ground control side turntable cover.
Torque 2 Start the engine from the ground controls.
• B-9 Check the Drive Hub Oil Level and 3 Change the engine idle to high rpm (rabbit
Fastener Torque symbol).
• D-2 Check the Turnable Rotation Bearing 4 Visually inspect the filter condition indicator.
Bolts Result: The filter condition indicator should be
• D-6 Replace the Hydraulic Filter Elements operating with the plunger in the green area. If
the indicator displays the plunger in the red
area, this indicates that the hydraulic filter is
being bypassed and the filter should be
replaced. Refer to Maintenance Procedure,
Replace the Hydraulic Filter Elements.
3 - 10 Z-60/34 Part No. 75861

A-7 Ford models

Perform Engine Maintenance - Required maintenance procedures and additional
Deutz and Ford Models engine information are available in the Ford LRG-
425 EFI Operator Handbook (Ford part number FPP
Engine specifications require that this procedure be number 1020010).
performed after the first 50 hours of operation.
Deutz models Ford LRG 425 EFI Operation Manual

Required maintenance procedures and additional
engine information are available in the Deutz 1011F Ford DSG 423 EFI Operator Handbook
Operation Manual (Deutz part number 0297 9683) or Genie part number 119488
the Deutz 2011 Operation Manual (Deutz part
number 0297 9929). Ford MSG-425 EFI Operator Handbook
Deutz 1011F Operation Manual To access the engine:
1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
Deutz 2011 Operation Manual fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving
the engine pivot plate from moving
injury
Part No. 75861 Z-60/34 3 - 11

A-8 A-9
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Perkins Models Separator - Deutz Models
Engine specifications require that this procedure be Genie specifications require that this procedure be
performed every 50 hours. performed every 100 hours or monthly, whichever
comes first.
Perkins models
Proper maintenance of the fuel filter/water
separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
engine performance and/or hard starting, and
TPD 1443S).
continued use may result in component damge.
Extremely dirty conditions may require this
Perkins 404C-22 Operation Manual procedure be performed more often.
Explosion and fire hazard. Engine
To access the engine: fuels are combustible. Perform this
procedure in an open, well-
1 Remove the engine tray retaining fasteners ventilated area away from heaters,
located under the engine tray. Loosen the pivot sparks, flames and lighted
fastener located at the platform end of the tobacco. Always have an
engine tray. Swing the engine tray out and approved fire extinguisher within
away from the machine and secure it from easy reach.
moving
Note: Perform this procedure with the engine off.
the engine pivot plate from moving 1 Loosen the drain plug located at the bottom of
could result in death or serious the filter. Allow the water to drain into a suitable
injury container until fuel starts to come out.
Immediately tighten the drain plug.
3 - 12 Z-60/34 Part No. 75861

A-10
Perform Engine Maintenance -
Ford Models
a
Engine specifications require that this procedure be

a fuel filter performed every 100 hours.
b drain plug
2 Clean up any fuel that may have spilled. engine information are available in the Ford LRG-
3 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel MSG-425 EFI Operator Handbook (Ford part
leak is discovered, keep any number 1020010).
additional personnel from entering
the area and do not operate the Ford LRG 425 EFI Operation Manual
machine. Repair the leak Genie part number 84792
immediately.
Ford DSG 423 EFI Operator Handbook
Ford MSG-425 EFI Operator Handbook

moving
injury
Part No. 75861 Z-60/34 3 - 13

A-11 A-12
Grease the Turntable Rotation Perform Engine Maintenance -
Bearing and Rotate Gear Deutz 1011F Models
Genie specifications require that this procedure be Engine specifications require that this procedure be
performed every 100 hours of operation. Perform performed after the first 125 hours.
this procedure more often if dusty conditions exist.
Deutz models
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
engine information are available in the Deutz 1011F
machine performance and service life. Continued
Operation Manual (Deutz part number 0297 9683).
use of an improperly greased bearing and gear will
result in component damage.
Deutz 1011F Operation Manual
1 Raise the boom enugh to access the turntable Genie part number 52883
gearing.
2 Locate the grease fitting on the platform end of
the engine side bulkhead. 1 Remove the engine tray retaining fasteners
3 Pump grease into the turntable rotation bearing. located under the engine tray. Loosen the pivot
Rotate the turntable in increments of fastener located at the platform end of the
4 to 5 inches / 10 to 13 cm at a time and repeat engine tray. Swing the engine tray out and
this step until the entire bearing has been away from the machine and secure it from
greased. moving
4 Apply grease to each tooth of the drive gear, Crushing hazard. Failure to secure
located under the turntable. the engine pivot plate from moving
injury
Grease type
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
3 - 14 Z-60/34 Part No. 75861

A-13 After serial number 4550

Replace the Drive Hub Oil 1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs (b) is at the
lowest point. See illustration A.
2 Remove both plugs and drain the oil into a
Manufacturer drive hub specifications require that suitable container.
this one-time procedure be performed after the 3 Drive the machine until one plug (a) is just
first 150 hours. above horizontal. See illustration B.
Replacing the drive hub oil is essential for good 4 Fill the hub with oil from the top hole until the oil
machine performance and service life. Failure to level is even with the bottom of the side hole.
replace the torque hub oil after the first 150 hours Refer to Specifications, Machine Specifications.
of use may cause the machine to perform poorly
and continued use may cause component 5 Apply pipe thread sealant to the plugs. Install
damage. the plugs.
Before serial number 4551 6 Repeat steps 1 through 4 for all the other drive
hubs.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point. a
a
suitable container.
b
3 Drive the machine until one plug is at the top b
and the other is at 90 degrees.
Illustration A Illustration B
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Specifications, Machine Specifications.
5 Install the plugs. Use pipe thread sealant on
units with pipe plugs.
6 Repeat steps 1 through 5 for all the other drive
hubs.
models with pipe plugs a drive hub plugs
Part No. 75861 Z-60/34 3 - 15

A-14
Ford Models

performed every 200 hours.

Handbook (EDI part number 1060020) or the
Ford MSG-425 EFI Operator Handbook (Ford part
number 1020010).
Ford LRG 425 EFI Operation Manual




moving
injury
3 - 16 Z-60/34 Part No. 75861

Checklist B Procedures
B-1 7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Inspect the Battery follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Genie specifications require that this procedure be • Subtract 0.004 from the reading of each cell for
performed every 250 hours or quarterly, whichever every 10° / 5.5° C below 80° F / 26.7° C.
comes first.
Result: All battery cells display an adjusted
Proper battery condition is essential to good specific gravity of 1.277 or higher. The battery
engine performance and operational safety. is fully charged. Proceed to step 11.
Improper fluid levels or damaged cables and
Result: One or more battery cells display a
connections can result in engine component
specific gravity of 1.217 or below. Proceed to
damage and hazardous conditions.
step 8.
Electrocution/burn hazard. Contact 8 Perform an equalizing charge OR fully charge
with hot or live circuits could result the battery(s) and allow the battery(s) to rest at
in death or serious injury. Remove least 6 hours.
all rings, watches and other
jewelry. 9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Bodily injury hazard. Batteries hydrometer. Note the results.
contain acid. Avoid spilling or
contacting battery acid. Neutralize 10 Check the ambient air temperature and adjust
battery acid spills with baking soda the specific gravity reading for each cell as
and water. follows:
1 Put on protective clothing and eye wear. • Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
2 Be sure that the battery cable connections are
free of corrosion. • Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion Result: All battery cells display a specific gravity
on the battery terminals and cables. of 1.277 or greater. The battery is fully charged.
Proceed to step 13.
3 Be sure that the battery hold downs and cable
connections are tight. Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
4 Be sure that the battery separator wire the specific gravity of one or more cells is less
connections are tight (if equipped). than 1.217. Replace the battery.
5 Fully charge the battery(s) and allow the 11 Check the battery acid level. If needed,
battery(s) to rest at least 6 hours. replenish with distilled water to 1/8 inch / 3 mm
6 Remove the battery vent caps and check the below the bottom of the battery fill tube. Do not
specific gravity of each battery cell with a overfill.
hydrometer. Note the results. 12 Install the vent caps and neutralize any
electrolyte that may have spilled using baking
soda.
Part No. 75861 Z-60/34 3 - 17

CHECKLIST B PROCEDURES
B-2 4 Inspect for a liberal coating of dielectric grease

in the following locations:
Inspect the Electrical Wiring
• Between the ground and platform controls
• Between the ground and drive controls
• All harness connectors
Genie specifications require that this procedure be • Level sensor
performed every 250 hours or quarterly, whichever
comes first. 5 Open the turntable cover at the ground control
side of the machine.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 6 Inspect the following areas for burnt, chafed,
performance. Failure to find and replace burnt, corroded and loose wires:
chafed, corroded or pinched wires could result in • Inside of the ground control box
unsafe operating conditions and may cause
• Hydraulic manifold wiring
component damage.
Electrocution/burn hazard. Contact raise the boom above the turntable covers.
with hot or live circuits could result
in death or serious injury. Remove 8 Inspect the turntable area for burnt, chafed and
all rings, watches and other pinched cables.
jewelry. 9 Lower the boom to the stowed position and turn
1 Open the engine side turntable cover. the engine off.
2 Remove the engine tray retaining fasteners 10 Inspect the following areas for burnt, chafed,
located under the engine tray. Swing the engine corroded, pinched and loose wires:
tray out and away from the machine and secure • Cable track on the primary boom
it from moving.
• Cables on the primary, and jib booms
• Jib boom/Platform rotate manifold
could result in death or serious • Inside of the platform control box
injury. 11 Inspect for a liberal coating of dielectric grease
3 Inspect the following areas for burnt, chafed, in all connections between the ECM and the
corroded and loose wires: platform controls.
• Engine wiring harness 12 Swing the engine back to its original position
and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.
3 - 18 Z-60/34 Part No. 75861

B-3 3 Disconnect the latches and remove the end cap

of the air cleaner canister.
Inspect the Air Filter
4 Remove the filter element.
5 Clean the inside of the canister and the gasket
with a damp cloth.
Genie specifications require that this procedure be
6 Clean the filter using dry compressed air. Blow
out from inside to outside. Check filter gasket
comes first. Perform this procedure more often if
for damage.
dusty conditions exist.
7 Re-install the filter element, or if there are any
Maintaining the engine air filter in good condition is signs of loss of filtration, replace the element.
essential to good engine performance and service
life. Failure to perform this procedure can lead to 8 Install the end cap onto the canister. Secure the
poor engine performance and component damage. clamps.
Note: Perform this procedure with the engine off. Note: Be sure the dust discharge valve is pointing
down.
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
2 Inspect the dust discharge valve. If the valve
shows any signs of damage, replace the valve.
a clamp
b canister end cap
c dust discharge valve
Part No. 75861 Z-60/34 3 - 19

B-4 B-5
Test the Key Switch Perform Engine Maintenance -
Genie specifications require that this procedure be Deutz and Perkins Models
comes first.
Proper key switch action and response is essential

to safe machine operation. The machine can be
performed quarterly or every 250 hours, whichever
operated from the ground or platform controls and
comes first.
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to Deutz models
activate the appropriate control panel could cause
a hazardous operating situation. Required maintenance procedures and additional
1 Pull out the red Emergency Stop button to the Operation Manual (Deutz part number 0297 9683).
on position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the Genie part number 52883
engine and then turn the key switch to platform
control. Perkins models
3 Check all machine function from the ground Required maintenance procedures and additional
controls. engine information are available in the Perkins
Result: All machine functions should not TPD 1443S).
operate.
4 Turn the key switch to ground control. Perkins 404C-22 Operation Manual
5 Check all machine function from the platform
controls. To access the engine:
Result: All machine functions should not
operate.
6 Turn the key switch to the off position. fastener located at the platform end of the
Result: The engine should stop and no away from the machine and secure it from
functions should operate. moving
injury
3 - 20 Z-60/34 Part No. 75861

B-6 B-7
Check the Exhaust System Check the Oil Cooler and Cooling
Fins - Deutz Models

performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be
comes first. performed every 250 hours or quarterly, whichever
Maintaining the exhaust system is essential to comes first.
good engine performance and service life. Running Maintaining the oil cooler in good condition is
the engine with a damaged or leaking exhaust essential for good engine performance. Operating
system can cause component damage and unsafe a machine with a damaged oil cooler may result in
operating conditions. engine damage. Also, restricting air flow through
Bodily injury hazard. Do not the oil cooler will affect the performance of the
inspect while the engine is cooling system.
running. Remove the key to Bodily injury hazard. Do not
secure from operation. inspect while the engine
Burn hazard. Beware of hot is running. Remove the key to
engine components. Contact with secure from operation.
hot engine components may result Burn hazard. Beware of hot
in severe burns. engine components. Contact with
1 Remove the engine tray retaining fasteners hot engine components may result
located under the engine tray. Swing the engine in severe burns.
tray out and away from the machine and secure Oil cooler
it from moving.
injury.
2 Be sure that all nuts and bolts are tight. moving.
3 Inspect all welds for cracks. Crushing hazard. Failure to secure
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
injury.
5 Swing the engine back to its original position
2 Remove the fasteners from the engine side
and install the engine pivot plate retaining
cover, and remove the cover.
fasteners.
3 Inspect the oil cooler for leaks and physical
Crushing hazard. Failure to install
damage.
to secure it from moving could 4 Clean the oil cooler of debris and foreign
result in death or serious injury. material.
Part No. 75861 Z-60/34 3 - 21

a b c B-8
Inspect the Tires, Wheels
and Lug Nut Torque

comes first.
Maintaining the tires and wheels in good

condition including proper wheel fastener torque is
a oil cooler essential to safe operation and good performance.
b cylinder head cooling fins Tire and/or wheel failure could result in a machine
c fan blower fins tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
Cooling and fan blower fins
Bodily injury hazard. An over-
5 Inspect the fan blower fins for physical damage. inflated tire can explode and could
cause death or serious injury.
6 Clean the fan blower fins of debris and foreign
material. Tip-over hazard. Do not use
temporary flat tire repair products.
7 Inspect the head cooling passages and fins for
physical damage or foreign material, using a The tires on some machines are foam-filled and do
flashlight. not need air added to them.
8 Clean the cylinder head cooling passages of 1 Check all tire treads and sidewalls for cuts,
debris and foreign material. cracks, punctures and unusual wear.
9 Install the engine side cover. 2 Check each wheel for damage, bends and
cracks.
10 Swing the engine back to its original position
and install the engine pivot plate retaining 3 Check each lug nut for proper torque. Refer to
fasteners. Tighten the pivot fastener. Specifications, Machine Torque Specifications.
Crushing hazard. Failure to install Models with air-filled tires:
to secure it from moving could 4 Check pressure in each air-filled tire. Add air as
result in death or serious injury. necessary. Refer to Specifications, Machine
Specifications.
3 - 22 Z-60/34 Part No. 75861

B-9 Drive Hub (after serial number 4550)

Check the Drive Hub Oil Level 1 Drive the machine until one plug is just above
horizontal. See illustration B.
and Fastener Torque
Genie specifications require that this procedure be 3 Apply pipe thread sealant to the plugs. Install
performed every 250 hours or quarterly, whichever the plugs.
comes first.
4 Check the torque of the drive hub mounting
Failure to maintain proper drive hub oil levels may fasteners. Refer to Specifications, Machine
cause the machine to perform poorly and Torque Specifications.
continued use may cause component damage.
5 Repeat this procedure for each drive hub.
Drive Hub (before serial number 4551)
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other a
a
at 90 degrees.
2 Remove the plug located at 90 degrees and
check the oil level. b
b
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil Illustration A Illustration B
until the oil level is even with the bottom of the
side plug hole. Refer to Specifications, Machine
Specifications.
4 Install the plug(s) in the drive hub. Use pipe
thread sealant on units with pipe plugs.
5 Check the torque of the drive hub mounting
fasteners. Refer to Specifications, Machine
Torque Specifications.
6 Repeat this procedure for each drive hub.
Part No. 75861 Z-60/34 3 - 23

Turntable rotate drive hub (all models) B-10

1 Remove the plug located on the side of the hub Confirm the Proper
and check the oil level. Brake Configuration
Result: The oil level should be even with the
bottom of the plug hole.

a
comes first.
Proper brake configuration is essential to safe

operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
turntable drive hub operational.
a plug
1 Check each drive hub disconnect cap to be
2 If necessary, add oil until the oil level is even
sure it is in the engaged position.
with the bottom of the plug hole.
brake disengaged position
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
4 Check the torque of the turntable drive hub
mounting fasteners. Refer to Specifications, brake engaged position
Machine Torque Specifications.
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the bottom
of the drive pump.
a c
a drive pump
b screwdriver
c lift pump
d free-wheel valve
Note: The free-wheel valve should always remain

closed.
3 - 24 Z-60/34 Part No. 75861

B-11 B-12
Test the Engine Idle Select Test the Fuel Select Operation -
Genie specifications require that this procedure be Ford Models
comes first.
A properly operating engine idle select switch

is essential to good engine performance and safe
machine operation. There are two settings. Genie specifications require that this procedure be
Foot switch activated low idle (turtle symbol) comes first.
allows the operator to control individual boom
functions. The ability to select and switch between
gasoline and LPG fuels as needed is essential to
Foot switch activated high aa idle (rabbit symbol) safe machine operation. A fuel selection can be
should be used for normal machine operation. This made when the engine is running or not.
selection activates high idle only when the foot Switching malfunctions and/or the failure of the
switch is pressed down. engine to start and run properly in both fuel
modes and through all idle speeds can indicate
1 Pull out the red Emergency Stop button to the fuel system problems that could develop into a
on position at both the ground and platform hazardous situation.
controls.
Note: Perform this test after checking the gasoline
2 Start the engine from the ground controls then
and LPG fuel levels, and warming the engine to
move and hold the function enable/rpm select
normal operating temperature.
toggle switch to the high idle (rabbit symbol).
1 Move the fuel select switch to gasoline and then
Result: The engine should change to high idle.
move the engine idle control switch to foot
3 Release the function enable/rpm select toggle switch activated high idle (rabbit and foot switch
switch. symbol).
Result: The engine should return to low idle. 2 Start the engine from the platform controls and
allow it to run at low idle. Press down the foot
4 Turn the key switch to platform controls.
switch to allow the engine to run at high idle.
5 Move the engine idle control switch to foot
Result: The engine should start promptly and
switch activated high idle (rabbit and foot switch
operate smoothly in low and high idle.
symbol).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
Part No. 75861 Z-60/34 3 - 25

B-13
Test the Ground Control Override
comes first.
A properly functioning ground control override is

essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button on the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
3 - 26 Z-60/34 Part No. 75861

B-14 B-15
Check the Directional Valve Test the Platform Self-leveling
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 primary boom raising and lowering
with a oscillating axle. is 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 directional valve linkage is not loop hydraulic circuit with the master cylinder
operating correctly, the stability of the machine is located at the base of the boom.
compromised and it may tip over.
A platform self-leveling failure creates an unsafe
1 Remove the drive chassis cover from the non- working condition for platform and ground
steer end of the drive chassis. personnel.
2 Locate the directional valve inside of the non- 1 Start the engine from the ground controls and
steer axle and inspect the linkage for the lower the boom to the stowed position.
following:
2 Hold the function enable toggle switch to either
• Lock nut is tight against yoke side and adjust the platform to a level position
using the platform level toggle switch.
• Yoke clevis pins are installed
3 Raise and lower the primary boom through a full
• Cotter pins are installed through clevis cycle.
pins
Result: The platform should remain level at
• Linkage is properly attached to all times to within ±5 degrees.
directional valve
Part No. 75861 Z-60/34 3 - 27

B-16 B-17
Test the Drive Brakes Test the Drive Speed -
Stowed Position

comes first.
Proper brake action is essential to safe machine comes first.
operation. The drive brake function should operate
Proper drive function movement is essential to
smoothly, free of hesitation, jerking and unusual
safe machine operation. The drive function should
noise. Hydrostatic brakes and hydraulically-
respond quickly and smoothly to operator control.
released individual wheel brakes can appear to
Drive performance should also be free of
operate normally when they are actually not fully
hesitation, jerking and unusual noise over the
operational.
entire proportionally controlled speed range.
Collision hazard. Be sure that the
Note: Select a test area that is firm, level and free
machine is not in free-wheel or
of obstructions.
partial free-wheel configuration.
Refer to Maintenance Procedure, 1 Create start and finish lines by marking two
Confirm the Proper Brake lines on the ground 40 feet / 12.2 m apart.
Configuration.
2 Start the engine from the platform controls.
Note: Select a test area that is firm, level and free
of obstructions. 3 Move the engine idle control switch to
foot switch activated high idle (rabbit and foot
1 Mark a test line on the ground for reference. switch symbol), then lower the boom into the
stowed position.
4 Choose a point on the machine; i.e., contact
3 Move the engine idle control switch to
patch of a tire, as a visual reference for use
foot switch activated high idle (rabbit and
when crossing the start and finish lines.
foot switch symbol), then lower the boom into
the stowed position. 5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
when crossing the test line.
6 Continue at full speed and note the time when
5 Bring the machine to top drive speed before
the machine reference point crosses the finish
reaching the test line. Release the drive joystick
line. Refer to Specifications, Performance
when your reference point on the machine
Specifications.
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Specifications, Performance Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
3 - 28 Z-60/34 Part No. 75861

B-18 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
the machine reference point crosses the finish
line. Refer to Specifications, Peformance
Genie specifications require that this procedure be Specifications.
8 Lower the boom to the stowed position and
comes first.
extend the boom 1 foot / 30 cm.
Proper drive function movement is essential to 9 Choose a point on the machine; i.e., contact
safe machine operation. The drive function should patch of a tire, as a visual reference for use
respond quickly and smoothly to operator control. when crossing the start and finish lines.
Drive performance should also be free of
hesitation, jerking and unusual noise over the 10 Bring the machine to top drive speed before
entire proportionally controlled speed range. reaching the start line. Begin timing when your
reference point on the machine crosses the
Note: Select a test area that is firm, level and free start line.
of obstructions.
11 Continue at top speed and note the time when
1 Create start and finish lines by marking two the machine reference point crosses the finish
lines on the ground 40 feet / 12.2 m apart. line. Refer to Specifications, Performance
Specifications.
3 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
4 Raise the boom above horizontal.
when crossing the start and finish lines.
Part No. 75861 Z-60/34 3 - 29

B-19 B-20
Perform Hydraulic Oil Analysis Test the Alarm Package
(if equipped) and the
Descent Alarm
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Replacement or testing of the hydraulic oil is Note: The descent alarm is standard, beginning
essential for good machine performance and with serial number 7270.
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and The alarm package includes:
continued use may cause component damage.
Extremely dirty conditions may require oil changes • Travel alarm
to be performed more often. • Flashing beacons
Note: Before replacing the hydraulic oil, the oil may Alarms and beacons are installed to alert operators
be tested by an oil distributor for specific levels of and ground personnel of machine proximity and
contamination to verify that changing the oil is motion. The alarm package is installed on the
necessary. If the hydraulic oil is not replaced at turntable rear cover. Beacons are installed on both
the two year inspection, test the oil quarterly. turntable covers.
Replace the oil when it fails the test.
Refer to Maintenance Procedure, Test or Replace The alarms and beacons will operate with the
the Hydraulic Oil. engine running or not running.
1 Turn the key switch to ground controls and pull

out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: Both flashing beacons should be on and
flashing.
2 Hold the function enable switch to either side
and activate the boom toggle switch in the
down position, hold for a moment and then
release it.
Result: The descent alarm should sound when
the toggle switch is held down.
3 - 30 Z-60/34 Part No. 75861

3 Move the function enable/rpm select toggle B-21

switch to either side and activate the jib boom
toggle switch in the down position, hold for a Inspect the Fuel and Hydraulic
moment and then release it. Tank Cap Venting Systems
the toggle switch is held down.
4 Turn the key switch to platform controls. Genie specifications require that this procedure be
Result: The flashing beacons should be on performed quarterly or every 250 hours, whichever
and flashing. comes first. Perform this procedure more often if
5 Press down the foot switch. Move the boom
controller to the down position, hold for a A free-breathing fuel and hydraulic tank cap is
moment and then release it. essential for good machine performance and
service life. A dirty or clogged cap may cause the
machine to perform poorly and continued use may
the controller is held down.
cause component damage. Extremely dirty
6 Press down the foot switch. Move the jib boom conditions may require that the cap be inspected
toggle switch to the down position, hold for a more often.
moment and then release it.
Explosion and fire hazard. Engine
Result: The descent alarm should sound when fuels are combustible. Perform this
the controller is held down. procedure in an open, well-
ventilated area away from heaters,
7 Press down the foot switch. Move the drive
sparks, flames and lighted
controller off center, hold for a moment and
tobacco. Always have an
then release it. Move the drive controller off
approved fire extinguisher within
center in the opposite direction, hold for a
easy reach.
moment and then release it.
Gasoline/LPG models (before serial
Result: The travel alarm should sound when the
number 7924) and Diesel models (all):
drive controller is moved off center in either
direction. Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.

2 Check for proper venting.
Note: When checking for positive fuel tank cap
venting, air should pass freely through the cap.
Result: Air should pass through the fuel tank

cap. Proceed to step 4.
Result: Air is not passing through the fuel tank
cap. Clean or replace the cap. Proceed to step
3.
Part No. 75861 Z-60/34 3 - 31

3 Using a mild solvent, carefully wash the cap B-22

venting system. Dry using low pressure
compressed air. Repeat this procedure Perform Engine Maintenance -
beginning with step 2. Ford Models
4 Install the fuel tank cap onto the fuel tank.
All models:
5 Remove the breather cap from the hydraulic Engine specifications require that this procedure be
tank. performed every 400 hours.
6 Check for proper venting. Required maintenance procedures and additional

Result: Air should pass through the breather
cap. Proceed to step 8.
Result: If air does not pass through the breather Handbook (EDI part number 1060020) or the Ford
cap, clean or replace the cap. MSG-425 EFI Operator Handbook (Ford part
Proceed to step 7. number 1020010).
Note: When checking for positive tank cap venting,
air should pass freely through the cap. Ford LRG 425 EFI Operation Manual
7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure Ford DSG 423 EFI Operator Handbook
compressed air. Repeat this procedure Genie part number 119488
beginning with step 6.
8 Install the breather cap onto the hydraulic tank. Genie part number 215322
moving
injury
3 - 32 Z-60/34 Part No. 75861

Checklist C Procedures
C-1 Required maintenance procedures and additional
Perform Engine Maintenance - 404C-22 Operation Manual (Perkins part number
Deutz and Perkins Models TPD 1443S).

performed every 500 hours. To access the engine:
Proper engine maintenance, following the engine 1 Remove the engine tray retaining fasteners
manufacturer's maintenance schedule, is essential located under the engine tray. Loosen the pivot
to good engine performance and service life. fastener located at the platform end of the
Failure to perform the maintenance procedures engine tray. Swing the engine tray out and
can lead to poor engine performance and away from the machine and secure it from
component damage. moving
Deutz models
Required maintenance procedures and additional could result in death or serious
engine information are available in the Deutz 1011F injury
Operation Manual (Deutz part number 0297 9683) or
the Deutz 2011 Operation Manual (Deutz part
number 0297 9929).

Deutz 2011 Operation Manual

Perkins models
Part No. 75861 Z-60/34 3 - 33

CHECKLIST C PROCEDURES
C-2 C-3
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
performed every 500 hours or 6 months, whichever performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if comes first.
Testing the platform overload system regularly is
Application of lubrication to the platform overload essential to safe machine operation. Continued
mechanism is essential to safe machine operation. use of an improperly operating platform overload
Continued use of an improperly greased platform system could result in the system not sensing an
overload mechanism could result in the system not overloaded platform condition. Machine stablity
sensing an overloaded platform condition and will could be compromised resulting in the machine
result in component damage. tipping over.
1 Locate the grease fittings on each pivot pin of Note: Perform this procedure with the machine on
the platform overload assembly. a firm, level surface.
2 Thoroughly pump grease into each grease 1 Turn the key switch to platform control. Start the
fitting using a multi-purpose grease. engine and level the platform.
2 Determine the maximum platform capacity.
Grease type
Refer to the machine serial plate.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect test.
3 - 34 Z-60/34 Part No. 75861

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 Result: The alarm does not sound and the
are 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, How to Calibrate the Platform system. Refer to Repair Procedure, How to
Overload System (if equipped). 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. 7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm should sound.
Procedure, How to Calibrate the Platform The platform overload indicator lights should be
Overload System (if equipped). flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a two second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1
Part No. 75861 Z-60/34 3 - 35

8 Test all machine functions from the platform 14 Start the engine and test all machine functions
controls. from the ground controls.
Result: All platform control functions should not Result: All ground control functions should
operate. operate normally.
9 Turn the key switch to ground control. 15 Turn the key switch to platform control.
10 Test all machine functions from the ground 16 Test all machine functions from the platform
controls. controls.
Result: All ground control functions should not Result: All platform control functions should
operate. operate.
11 Activate the auxiliary power toggle switch. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure, How
Note: The engine will turn off when the auxiliary
to Calibrate the Platform Overload System (if
power is activated.
equipped).
12 Using auxiliary power, test all machine functions
17 Using a suitable lifting device, remove the
from the ground controls.
remaining test weights from the platform.
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
should turn off at both the ground and platform
controls and the alarm should not sound.
Note: There may be an two second delay before
the overload indicator lights and alarm turn off.
3 - 36 Z-60/34 Part No. 75861

C-4 C-5
Replace the Engine Air Filter Replace the In-line Fuel Strainer -
Element - Deutz and Perkins Deutz Models
Models

performed every 500 hours or 6 months, whichever
Genie specifications requires that this procedure
comes first.
be performed every 500 hours or 6 months,
whichever comes first. Replacing the diesel fuel strainer is essential for
good engine performance and service life. A dirty
Maintaining the engine air filter in good condition is
or clogged filter may cause the engine to perform
essential to good engine performance and service
poorly and continued use may cause component
life. Failure to perform this procedure can lead to
damage.
poor engine performance and component damage.
Explosion/burn and fire hazard.
1 Open the evacuator valve located on the air
Engine fuels are combustible.
cleaner cap by squeezing the sides together
Perform this procedure in an open,
with your fingers.
well-ventilated area away from
2 Disconnect the latches on the air cleaner cap. heaters, sparks, flames and lighted
Remove the end cap from the air cleaner tobacco. Always have an approved
canister. fire extinguisher within easy reach.
3 Remove the filter element. Note: Perform this procedure with the engine off.
4 Clean the inside of the canister and the gasket 1 Put on protective clothing and eye wear.
with a damp cloth.
2 Locate the inline strainer above the throttle
5 Install the new filter element. actuator solenoid.
6 Install the end cap on the canister and re- 4 Place a suitable container under the filter.
connect the latches.
5 Loosen the clamp holding the strainer to the
Note: Be sure the evacuator valve is pointing engine mount. Loosen the clamps securing the
down. fuel lines to the strainer. Remove and replace.
Part No. 75861 Z-60/34 3 - 37

C-6
Check and Adjust the
Engine RPM
f

performed every 500 hours or 6 months, whichever
comes first.
Maintaining the engine rpm at the proper setting for a b c d

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 a solenoid boot
b high idle adjustment nut
continued use may cause component damage. c yoke lock nut
d yoke
Note: This procedure will require two people. e low idle adjustment screw
f low idle lock nut
Ford Models
Note: The engine rpm is controlled by the ECM If high idle rpm is correct, disregard adjustment
and can only be adjusted by re-programming the step 4.
ECM. If rpm adjustment or service is required, 4 Loosen the yoke lock nut. Turn the high idle
please contact Genie Product Support OR your adjustment nut and solenoid boot
local Ford dealer. counterclockwise to increase the rpm or
Deutz Models clockwise to decrease the rpm. Tighten the
yoke lock nut and re-check the rpm.
1 Connect a tachometer to the engine. Start the
engine from the ground controls. Refer to Note: Be sure the solenoid fully retracts when
Specifications, Engine Specifications. activating high idle.
Skip to step 3 if the low idle rpm is correct. Perkins Models
2 Loosen the low idle lock nut and turn the low idle 1 Connect a tachometer to the engine. Start the
adjustment screw clockwise to increase the rpm engine from the ground controls. Refer to
or counterclockwise to decrease the rpm. Specifications, Engine Specifications.
Tighten the low idle lock nut and re-check the
rpm.
3 Move the function enable/rpm select toggle
switch to the high idle (rabbit symbol) position
at the ground controls. Refer to Specifications,
Engine Specifications.
3 - 38 Z-60/34 Part No. 75861

Skip to step 3 if the low idle rpm is correct. C-7

2 Loosen the low idle lock nut. Turn the low idle Perform Engine Maintenance -
adjustment screw clockwise to increase the Ford Models
rpm, or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
a b c d
a solenoid boot number 1020010).
b high idle adjustment nut
c clevis
d low idle lock nut and adjustment
Ford LRG 425 EFI Operation Manual
screw Genie part number 84792
3 Move the function enable toggle switch to the Ford DSG 423 EFI Operator Handbook
high idle (rabbit symbol) position. Refer to Genie part number 119488
Specifications , Engine Specifications.
If high idle rpm is correct, disregard adjustment Genie part number 215322
step 4.
4 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and re-check the rpm.
Note: Be sure the solenoid fully retracts when moving
activating high idle.
injury
Part No. 75861 Z-60/34 3 - 39

3 - 40 Z-60/34 Part No. 75861

Checklist D Procedures
D-1 Primary boom wear
pad specifications Minimum
Check the Boom Wear Pads
Top and side wear pads 3/8inch
(extension end of boom) 9.5 mm
Bottom wear pads 1/2 inch
Genie specifications requires that this procedure (extension end of boom) 12.7 mm
be performed every 1000 hours or annually, 1/2 inch
Top and bottom wear pads
whichever comes first. (pivot end of boom) 12.7 mm
Maintaining the boom wear pads in good condition Side wear pads 3/8 inch
is essential to safe machine operation. Wear pads (pivot end of boom) 9.5 mm
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued 4 Extend and retract the boom through the entire
use of extremely worn wear pads may result in range of motion to check for tight spots that
component damage and unsafe operating may cause binding or scraping of the boom.
conditions.
Note: Always maintain squareness between the
1 Measure each wear pad. Replace the wear pad outer and inner boom tubes.
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.
3 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
The minimum shim clearance for primary boom
wear pads is 0.070 inch / 1.8 mm and the
maximum allowable shim clearance is
0.188 inch / 4.8 mm.
Part No. 75861 Z-60/34 3 - 41

CHECKLIST D PROCEDURES
1
D-2 13
10 15
7
Check the Turntable Rotation 6 19
18
Bearing Bolts 12
3 4
11 17
Genie specifications requires that this procedure 20 5
be performed every 1000 hours or annually, 8 14

9
whichever comes first. 16
2
Maintaining proper torque on the turntable bearing Bolt torque sequence

bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe 3 Be sure that each turntable mounting bolt is
operating condition and component damage. torqued in sequence to specifications. Refer to
Specifications, Machine Torque Specifications.
1 Raise the primary boom and place safety
chocks on the secondary lift cylinder rod. 4 Start the engine from the ground controls.
Carefully lower the boom onto the lift cylinder 5 Raise the boom and remove the safety chock.
safety chock.
6 Lower the boom to the stowed position.
Crushing hazard. Keep hands
away from cylinders and all 7 Check to ensure that each lower bearing
moving parts when lowering the mounting bolt under the drive chassis is
boom. torqued in sequence to specifications. Refer to
Specifications, Machine Torque Specifications.
Note: The lift cylinder safety chock is available
1
through Genie (Genie part number 33484). 10 15
13 7
2 Turn the engine off. 6 19
18 12
3 4
11 17
20 5
8 14
16 9
2
Bolt torque sequence
3 - 42 Z-60/34 Part No. 75861

D-3 5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate with
Check the Free-wheel minimum effort.
Configuration 6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Genie specifications requires that this procedure
Collision hazard. Failure to
be performed every 1000 hours or annually,
re-engage the drive hubs may
whichever comes first.
cause death or serious injury and
Proper use of the free-wheel configuration is property damage.
essential to safe machine operation. The Steer Wheels: 4WD Models
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without 7 Chock the non-steer wheels to prevent the
operator knowledge may cause death or serious machine from rolling.
injury and property damage.
8 Center a lifting jack of ample capacity
Collision hazard. Select a work (20,000 lbs / 10,000 kg) under the drive chassis
site that is firm and level. between the steer tires.
Component damage hazard. If the 9 Lift the wheels off the ground and then place
machine must be towed, do not jack stands under the drive chassis for support.
exceed 2 mph / 3.2 km/h.
10 Disengage the drive hubs by turning over the
Non-steer Wheels: All Models drive hub disconnect caps on each
steer wheel hub.
1 Chock the steer wheels to prevent the machine
from rolling. 11 Manually rotate each steer wheel.
2 Center a lifting jack of sufficient capacity Result: Each steer wheel should rotate with
(20,000 lbs / 10,000 kg) under the drive chassis minimum effort.
between the non-steer tires. 12 Re-engage the drive hubs by turning over
3 Lift the wheels off the ground and then place the hub disconnect caps. Rotate each wheel to
jack stands under the drive chassis for support. check for engagement. Raise the machine and
remove the jack stands.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each Collision hazard. Failure to
non-steer wheel hub. re-engage the drive hubs may
cause death or serious injury and
property damage.
disengaged position
engaged position
Part No. 75861 Z-60/34 3 - 43

All Models: D-4

13 Be sure the free-wheel valve on the drive pump Replace the Drive Hub Oil
is closed (clockwise).
Note: The free-wheel valve is located on the
bottom of the drive pump.
Genie specifications requires that this procedure be
Note: The free-wheel valve should always remain performed every 1000 hours or annually, whichever
closed. comes first.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
b
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
a c continued use may cause component damage.
d Before serial number 4551
machine until one of the two plugs is at the
a drive pump lowest point.
b screwdriver
c lift pump 2 Remove both plugs and drain the oil into a
d free-wheel valve suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
5 Install the plugs. Use pipe thread sealant on
units with pipe plugs.
hubs.
3 - 44 Z-60/34 Part No. 75861

After serial number 4550

Turntable Rotate Drive Hub:
machine until one of the two plugs is at the Note: When removing a hose assembly or fitting,
lowest point. See illustration A. the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic Hose
suitable container.
and Fitting Torque Specifications.
3 Drive the machine until one plug is just above
horizontal. See illustration B. 1 Raise the secondary boom until the platform end
of the lower secondary boom arm is
4 Fill the hub with oil from the top hole until the oil approximately 8 feet / 2.4 m off the ground.
Refer to Specifications, Machine Specifications. 2 Secure the turntable from rotating with the
turntable rotation lock pin.
5 Apply pipe thread sealant to the plugs. Install
the plugs.
hubs.
a
a unlocked locked
3 Tag, disconnect and plug the hydraulic hoses

b from the turntable rotate drive motor. Cap the
b fittings on the drive motor.
turntable drive hub

a plug
4 Attach a suitable lifting device to the lifting eyes

located near the drive motor.
Part No. 75861 Z-60/34 3 - 45

5 Remove the drive hub mounting bolts. Carefully D-5

remove the turntable rotate drive hub assembly
from the machine.Illustration A Perform Engine Maintenance -
Illustration B Deutz and Perkins Models
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting Engine specifications require that this procedure be
device. performed every 1000 hours.
6 Remove the plug from the side of the drive hub. Deutz models
Drain the oil from the hub into a suitable
container. Required maintenance procedures and additional
7 Install the drive hub assembly onto the machine. Operation Manual (Deutz part number 0297 9683) or
Torque the drive hub mounting bolts to the Deutz 2011 Operation Manual (Deutz part
specification. Refer to Specifications, Machine number 0297 9929).
8 Fill the drive hub with oil from the side hole until Deutz 1011F Operation Manual
the oil level is even with the bottom of the hole. Genie part number 52883
Apply pipe thread sealant to the plug. Install the
plug. Deutz 2011 Operation Manual
Perkins models
TPD 1443S).


moving
injury
3 - 46 Z-60/34 Part No. 75861

D-6 Medium and high pressure filter

Replace the Hydraulic Filter Note: The medium pressure filter is for the charge
Elements pump and the high pressure filter (if equipped) is
for all machine functions except the drive circuit
and oscillating axle circuit.
10 Open the engine side turntable cover and

Genie specifications require that this procedure be locate the medium pressure filter mounted to
performed every 1000 hours or annually, the engine tray.
whichever comes first. Perform this procedure 11 Place a suitable container under each filter.
more often if dusty conditions exist.
12 Remove the filter housings by using a wrench
Replacement of the hydraulic filters is essential for on the nut provided on the bottom of the
good machine performance and service life. A dirty housings.
or clogged filter may cause the machine to perform
poorly and continued use may cause component 13 Remove the filter elements from the housings.
damage. Extremely dirty conditions may require 14 Inspect the housing seals and replace them if
that the filters be replaced more often. necessary.
Bodily injury hazard. Beware of 15 Install the new filter elements into the housings
hot oil. Contact with hot oil may and tighten them securely.
cause severe burns.
16 Clean up any oil that may have spilled during
Note: Perform this procedure with the engine off. the installation procedure.
Hydraulic return filter 17 Use a permanent ink marker to write the date
and number of hours from the hour meter on
1 Open the ground controls side turntable cover
the oil filter housings.
and locate the hydraulic return filter housing on
top of the hydraulic tank. 18 Start the engine from the ground controls.
2 Remove the filter element from the filter 19 Inspect the filter housings and related
housing. components to be sure that there are no leaks.
3 Install the new filter element into the filter
housing.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housing.
Part No. 75861 Z-60/34 3 - 47

D-7 4 Place a dial indicator between the drive chassis

and the turntable at a point that is directly
Inspect for Turntable Bearing under, or inline with, the boom and no more
Wear than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch /
2.5 cm from the turntable rotation bearing.
Genie specifications requires that this procedure be
performed every 1000 hours or annually, whichever
comes first. a
Periodic inspection of turntable bearing wear is

essential to safe machine operation, good machine
performance and service life. Continued use of a
b
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
c
Note: Perform this procedure with the machine on
a firm, level surface and the boom in the stowed
position. d
1 Grease the turntable bearing. Refer to a turntable

Maintenance Procedure, Grease the Turntable b dial indicator
c drive chassis
Bearing and Rotate Gear. d turntable rotation bearing
2 Torque the turntable bearing bolts to 5 At the dial indicator, adjust it to "zero" the
specification. Refer to Maintenance Procedure, indicator.
Check the Turntable Rotation Bearing Bolts.
6 Fully extend the boom and lower to a horizontal
3 Start the machine from the ground controls and position.
raise the boom to full height. Do not extend the
boom.
3 - 48 Z-60/34 Part No. 75861

7 Note the reading on the dial indicator.

Result: The measurement is less than
0.047 inch / 1.2 mm. The bearing is good.
Result: The measurement is more than
0.047 inch / 1.2 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero"
position.
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the boom to the stowed position and turn
the machine off.
12 Remove the dial indicator from the machine.
Part No. 75861 Z-60/34 3 - 49

Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil

performed every 2000 hours or 2 years, whichever open closed
comes first.
Component damage hazard. The
Replacement or testing of the hydraulic oil is engine must not be started with
essential for good machine performance and the hydraulic tank shut-off valves
service life. Dirty oil and suction strainers may in the closed position or
cause the machine to perform poorly and component damage will occur. If
continued use may cause component damage. the tank valves are closed,
Extremely dirty conditions may require oil changes remove the key from the key
to be performed more often. switch and tag the machine to
Note: Before replacing the hydraulic oil, the oil may inform personnel of the condition.
be tested by an oil distributor for specific levels of 4 Remove the drain plug and completely drain the
contamination to verify that changing the oil is tank into a suitable container. Refer to
necessary. If the hydraulic oil is not replaced at Specifications, Machine Specifications.
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test. 5 Tag, disconnect and plug the two suction hoses
and supply hose for the auxiliary pump from the
Note: Perform this procedure with the boom in the hydraulic tank. Cap the fittings on the tank.
stowed position.
Note: The hoses can be accessed through the
1 Ford models: Turn the valve on the LPG tank access hole under the turntable.
clockwise to the off position (if equipped). Then
slowly disconnect the hose from the LPG tank. 6 Disconnect and plug the return filter hydraulic
hose at the return filter. Cap the fitting on the
2 Ford models: Open the clamps from the LPG filter housing.
tank straps and remove the LPG tank from the
machine (if equipped). 7 Remove the ground controls side turntable
cover.
3 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the 8 Support the hydraulic tank with an appropriate
hydraulic tank through the access hole lifting device.
underneath the turntable. Close the valves. 9 Remove the hydraulic tank mounting fasteners.
3 - 50 Z-60/34 Part No. 75861

CHECKLIST E PROCEDURES
10 Remove the hydraulic tank from the machine. 20 Models with hydraulic tank shut-off valves:
Open the two hydraulic tank valves at the
Crushing hazard. The hydraulic
hydraulic tank.
tank could become unbalanced
and fall if not properly supported 21 Fill the tank with hydraulic oil until the level is
when removed from the machine. within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic 22 Clean up any oil that may have spilled.
return filter housing from the hydraulic tank.
23 Prime the pump. Refer to Repair Procedure,
12 Remove the suction strainers from the tank and How to Prime the Pump.
clean them using a mild solvent.
Note: Always use pipe thread sealant when
13 Rinse out the inside of the tank using a mild installing the suction hose fittings and the drain
solvent. plug.
14 Install the suction strainers using a thread
sealant on the threads.
15 Install the drain plug using a thread sealant on
the threads.
16 Install the hydraulic return filter housing onto the
hydraulic tank.
17 Install the hydraulic tank onto the machine.
18 Install the two suction hoses to the suction
strainers.
19 Install the supply hose for the auxiliary power
unit and the return filter hose.
Part No. 75861 Z-60/34 3 - 51

E-2 Skip to step 10 if there is no movement.

Grease the Steer Axle 6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
Wheel Bearings, 2WD Models
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torquing the
Genie specifications require that this procedure be castle nut to make sure the bearings seat properly.
performed every 2000 hours or 2 years, whichever
comes first. 8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
Maintaining the steer axle wheel bearings is
9 Check for wheel bearing wear by attempting to
essential for safe machine operation and service
move the wheel hub side to side, then up and
life. Operating the machine with loose or worn
down.
wheel bearings may cause an unsafe operating
condition and continued use may result in Result: If there is no side to side or up and
component damage. Extremely wet or dirty down movement, continue to step 11 to grease
conditions or regular steam cleaning and pressure the wheel bearings.
washing of the machine may require that this
procedure be performed more often. Result: If there is side to side or up and down
movement, continue to step 11 and replace the
1 Loosen the wheel lug nuts. Do not remove wheel bearings with new ones.
them.
Note: When replacing a wheel bearing, both the
2 Block the non-steering wheels. Center a lifting inner and outer bearings, including the pressed-in
jack under the steer axle. races, must be replaced.
3 Raise the machine 6 inches / 15 cm Place 10 Remove the dust cap from the hub. Remove the
blocks under the drive chassis for support. cotter pin from the castle nut.
4 Remove the lug nuts. Remove the tire and 11 Remove the castle nut.
wheel assembly.
12 Pull the hub off of the spindle. The washer and
5 Check for wheel bearing wear by attempting to outer bearing should fall loose from the hub.
move the wheel hub side to side, then up and
down. 13 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
Result: There should be no side to side or up rear bearing.
and down movement.
14 Pack both bearings with clean, fresh grease.
3 - 52 Z-60/34 Part No. 75861

15 Place the large inner bearing into the rear of the E-3
hub.
16 Install a new bearing grease seal into the hub by
pressing it evenly into the hub until it is flush.
Deutz 1011F and Perkins Models
Note: Always replace the bearing grease seal when
removing the hub.
17 Slide the hub onto the yoke spindle. Engine specifications require that this procedure be
Component damage hazard. Do
not apply excessive force or Proper engine maintenance, following the engine
damage to the lip of the seal may manufacturer's maintenance schedule, is essential
occur. to good engine performance and service life.
Failure to perform the maintenance procedures
18 Place the outer bearing into the hub. can lead to poor engine performance and
19 Install the washer and castle nut. component damage.

Deutz 1011F models
seat the bearings.
Note: Rotate the hub by hand while torquing the engine information is available in the Deutz 1011F
castle nut to make sure the bearings seat properly. Operation Manual (Deutz part number 0297 9683).
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm. Deutz 1011F Operation Manual
22 Install a new cotter pin. Bend the cotter pin
to lock it in. Perkins models
23 Install the dust cap, then the tire and wheel Required maintenance procedures and additional
assembly. Torque the wheel lug nuts to engine information are available in the Perkins
specification. Refer to Specifications, Machine 404C-22 Operation Manual (Perkins part number
Specifications. TPD 1443S).


located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
injury.
Part No. 75861 Z-60/34 3 - 53

E-4 Perkins models

Perform Engine Maintenance - Required maintenance procedures and additional
Deutz and Perkins Models engine information are available in the Perkins
TPD 1443S).

Engine specifications require that this procedure be Genie part number 94890
Proper engine maintenance, following the engine To access the engine:

manufacturer's maintenance schedule, is essential 1 Remove the engine tray retaining fasteners
to good engine performance and service life. located under the engine tray. Loosen the pivot
Failure to perform the maintenance procedures fastener located at the platform end of the
can lead to poor engine performance and engine tray. Swing the engine tray out and
component damage. away from the machine and secure it from
Required maintenance procedures and additional moving
engine information are available in the Deutz 1011F Crushing hazard. Failure to secure
Operation Manual (Deutz part number 0297 9683) or the engine pivot plate from moving
the Deutz 2011 Operation Manual (Deutz part could result in death or serious
number 0297 9929). injury

Deutz 2011 Operation Manual


moving
injury
3 - 54 Z-60/34 Part No. 75861

E-5 E-6
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Deutz 2011 Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 4 years. performed every 5000 hours.
Required maintenance procedures and additional Proper engine maintenance, following the engine
engine information are available in the Ford LRG- manufacturer's maintenance schedule, is essential
425 EFI Operator Handbook (Ford part number FPP to good engine performance and service life.
194-302) or the Ford DSG-423 EFI Operator Failure to perform the maintenance procedures
Handbook (EDI part number 1060020) or the Ford can lead to poor engine performance and
MSG-425 EFI Operator Handbook (Ford part component damage.
number 1020010).
engine information are available in the Deutz 2011
Ford LRG 425 EFI Operation Manual Operation Manual (Deutz part number 0297 9929).
Ford DSG 423 EFI Operator Handbook Deutz 2011 Operation Manual
Genie part number 119488 Genie part number 84794

1 Remove the engine tray retaining fasteners located under the engine tray. Loosen the pivot
located under the engine tray. Loosen the pivot fastener located at the platform end of the
fastener located at the platform end of the engine tray. Swing the engine tray out and
engine tray. Swing the engine tray out and away from the machine and secure it from
away from the machine and secure it from moving
moving
Crushing hazard. Failure to secure the engine pivot plate from moving
the engine pivot plate from moving could result in death or serious
could result in death or serious injury
injury
Part No. 75861 Z-60/34 3 - 55

E-7 E-8
Perform Engine Maintenance - Perform Engine Maintenance -
2011 Deutz Models Deutz 2011 Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 6000 hours. performed every 12,000 hours.
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. to good engine performance and service life.
Failure to perform the maintenance procedures Failure to perform the maintenance procedures
can lead to poor engine performance and can lead to poor engine performance and
component damage. component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the Deutz 2011 engine information are available in the Deutz 2011
Operation Manual (Deutz part number 0297 9929). Operation Manual (Deutz part number 0297 9929).
Deutz 2011 Operation Manual Deutz 2011 Operation Manual

Genie part number 84794 Genie part number 84794
To access the engine: To access the engine:

1 Remove the engine tray retaining fasteners 1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot located under the engine tray. Loosen the pivot
fastener located at the platform end of the fastener located at the platform end of the
engine tray. Swing the engine tray out and engine tray. Swing the engine tray out and
away from the machine and secure it from away from the machine and secure it from
moving moving
Crushing hazard. Failure to secure Crushing hazard. Failure to secure
the engine pivot plate from moving the engine pivot plate from moving
could result in death or serious could result in death or serious
injury injury
3 - 56 Z-60/34 Part No. 75861

June 2015 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
Repair any machine damage or malfunction injury hazards. Obey all safety
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
Read, understand and obey the safety rules
which, if not avoided, will result in
and operating instructions in the Genie Z-60/34
death or serious injury.
Operator’s Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use. which, if not avoided, could result
Use only Genie approved replacement parts. in death or serious injury.
Read each procedure completely and adhere With safety alert symbol—used to
to the instructions. Attempting shortcuts may indicate the presence of a
produce hazardous conditions. potentially hazardous situation
which, if not avoided, may cause
Unless otherwise specified, perform each minor or moderate injury.
repair procedure with the machine in the
following configuration:
• Machine parked on a flat, level surface which, if not avoided, may result in
• Boom in the stowed position property damage.
• Turntable rotated with the boom between Indicates that a specific result is expected after
the non-steering wheels performing a series of steps.
• Turntable secured with the turntable Indicates that an incorrect result has occurred
rotation lock pin after performing a series of steps.
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 75861 Z-60/34 4-1

Section 4 • Repair Procedures June 2015
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 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. Refer to the joystick controllers will need to be calibrated.
Repair Procedure, How to Calibrate a Joystick. Refer to Repair Procedure, How to Calibrate a
Each joystick controller should operate smoothly Joystick.
and provide proportional speed control over its
entire range of motion. How to Remove the ALC-500
Circuit Board
a
1 Push in the red Emergency Stop button to the off
position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to the
inside of the platform control box.
4 Attach a grounded wrist strap to the ground
screw inside the platform control box.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
d c b that is grounded at all times when
handling printed circuit boards OR
a ALC-500 circuit board use a grounded wrist strap.
b drive/steer joystick controller
c secondary boom up/down 5 Carefully disconnect the wire connectors from the
joystick controller circuit board.
d primary boom up/down and
turntable rotate left/right 6 Remove the ALC-500 circuit board mounting
joystick controller fasteners.
7 Carefully remove the ALC-500 circuit board from
the platform control box.
4-2 Z-60/34 Part No. 75861

PLATFORM CONTROLS
1-2 How to Adjust the Joystick

Joysticks Max-out Setting
The max-out setting of a joystick controls the
How to Calibrate a Joystick maximum speed of a joystick-controlled machine
The joysticks on this machine utilize digital Hall function. Whenever a hydraulic cylinder, drive
Effect technology for proportional control. If a motor or hydraulic pump is replaced, the max-out
joystick is disconnected or replaced, it must be setting should be adjusted to maintain optimum
calibrated before that particular machine function performance. The max-out settings on the joystick
will operate. can be changed to compensate for hydraulic pump
wear to maintain peak performance from the
Note: The joystick must be calibrated before the machine.
threshold, max-out or ramping can be set.
Note: Perform this procedure with the boom in the
Note: Perform this procedure with the engine off. stowed position.
1 Open the platform control box. 1 Pull out the red Emergency Stop button to the
2 Pull out the red Emergency Stop button to the controls.
controls. 2 Turn the key switch to platform control. Do not
start the engine.
3 Turn the key switch to platform control. Do not
start the engine. 3 Push in the red Emergency Stop button to the
off position at the platform controls.
4 Select a joystick to calibrate.
4 Do not press down the foot switch.
5 Disconnect the wire harness connector from the
joystick for approximately 10 seconds or until 5 Move and hold the drive enable toggle switch in
the alarm sounds. Connect the wire harness the right position and pull out the red
connector to the joystick. Emergency Stop button to the on position.
6 Move the joystick full stroke in either direction 6 When the alarm sounds, release the drive
and hold for 5 seconds. enable toggle switch.
7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds.
Result: The alarm should sound indicating
successful joystick calibration.
Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
Part No. 75861 Z-60/34 4-3

PLATFORM CONTROLS
7 Momentarily activate the drive enable toggle How to Adjust the Joystick
switch in the right direction 4 times.
Ramp Rate Setting
Result: There should be a pause and the alarm
should sound 4 times indicating that the The ramp rate setting of a joystick controls the time
machine is in max-out calibration mode. at which it takes for the joystick to reach maximum
output, when moved out of the neutral position.
8 Start the engine from the platform controls and The ramp rate settings of a joystick can be
press down the foot switch. changed to compensate for hydraulic pump wear
9 Start a timer and activate the machine function to maintain peak performance from the machine.
that needs to be adjusted. Record the time it Note: Perform this procedure with the boom in the
takes for that function to complete a full cycle stowed position.
(ie; boom up).
1 Pull out the red Emergency Stop button to the
10 Compare the machine function time with the
times in Specifications, Performance
controls.
Specifications to determine whether the function
time needs to increase or decrease. 2 Turn the key switch to platform control. Do not
start the engine.
11 While the joystick is activated, adjust the max-
out setting to achieve the proper function cycle 3 Push in the red Emergency Stop button to the
time. Momentarily move the drive enable toggle off position at the platform controls.
switch to the right to increase the time or
momentarily move the drive enable toggle 4 Do not press down the foot switch.
switch to the left to decrease the time. 5 Move and hold the drive enable toggle switch in
Note: Each time the drive enable toggle switch is the right position and pull out the red
momentarily moved, the time will change 2%. Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
12 Repeat steps 9 through 11 for each joystick
enable toggle switch.
controlled machine function.
7 Momentarily activate the drive enable toggle
13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
Result: The alarm should sound indicating that
should sound 6 times indicating that the
the settings have been saved in memory.
machine is in ramp rate calibration mode.
Note: Do not operate any machine function during
the 10 second waiting time.
4-4 Z-60/34 Part No. 75861

PLATFORM CONTROLS
8 Start the engine from the platform controls and Ramp rate (factory settings)
press down the foot switch.
Primary boom up/down
9 Start a timer and simultaneously move the accelerate 3 seconds
joystick in either direction full stroke. Note how decelerate 1 second
long it takes the function to reach maximum
speed. This is the ramp rate. Secondary boom up/down
accelerate 2 seconds
10 Compare the function ramp rate time with the decelerate 1 second
table below and determine whether the ramp
rate time needs to increase or decrease. Turntable rotate
11 While the joystick is activated, set the ramp decelerate 0.5 second
rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time Drive
or momentarily move the drive enable toggle
decelerate to neutral 0.5 second
switch in the left direction to decrease the time. decelerate, change of direction 0.5 second
Note: Each time the drive enable toggle switch is decelerate, coasting 0.75 second
momentarily moved, the time will change in 5% decelerate, braking 1.5 seconds
decelerate, shift from low to high speed
increments.
2WD and 4WD models 1.75 seconds
12 Repeat steps 9 through 11 for each joystick decelerate, shift from high to low speed
controlled machine function. 2WD models 1 second
decelerate, shift from high to low speed
13 Return the joystick to the neutral position and 4WD models 3.5 seconds
Result: The alarm should sound indicating that
Note: Do not operate any machine function during
Part No. 75861 Z-60/34 4-5

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 to the neutral
position. Just before the function stops moving,
1 Pull out the red Emergency Stop button to the move the drive enable toggle switch to either
on position at both the ground and platform 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.
12 Repeat steps 9 through 11 for each boom
3 Push in the red Emergency Stop button to the joystick-controlled machine function (boom up/
off position at the platform controls. down, boom extend/retract and turntable
rotate).
4 Do not press down the foot switch.
13 Return the joystick to the neutral position and
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position. Result: The alarm should sound indicating that
6 When the alarm sounds, release the drive
enable toggle switch. Note: Do not operate any machine function during
7 Momentarily activate the drive enable toggle
should sound 8 times indicating that the
machine is in threshold calibration mode.
4-6 Z-60/34 Part No. 75861

Platform Components
2-1 8 Support and secure the platform to an
appropriate lifting device.
Platform
9 Remove the platform mounting fasteners and
remove the platform from the machine.
How to Remove the Platform
Crushing hazard. The platform
1 Remove the cable clamps from the top of the could become unstable and fall
platform mounting weldment. when it is removed from the
2 Remove the clamp from the platform mounting machine if not properly supported.
weldment that holds the power to platform
cable.
3 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side.
4 Remove the foot switch mounting fasteners.
5 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
6 Tag and disconnect the foot switch wiring from
the foot switch. Remove the cable from the
back of the platform.
Electrocution/burn hazard. Contact
with electrically charged circuits
injury. Remove all rings, watches
and other jewelry.
7 Remove the platform control box mounting
fasteners. Lower the control box and set it
aside.
Cables can be damaged if they
are kinked or pinched.
Note: If your machine is equipped with an airline to
platform option, the airline must be disconnected
from the platform before removal.
Part No. 75861 Z-60/34 4-7

PLATFORM COMPONENTS
2-2 3 Lower the jib 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
entire range of boom motion. It operates in a
from the slave cylinder and connect the hoses
closed-circuit hydraulic loop with the master
together using a connector. Cap the fittings on
cylinder. The slave cylinder is equipped with
the cylinder.
counterbalance valves to prevent movement in
the event of a hydraulic line failure. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the Platform burn skin. Loosen hydraulic
Leveling Slave Cylinder connections very slowly to allow
the oil pressure to dissipate
Note: Before cylinder removal is considered, bleed gradually. Do not allow oil to
the slave cylinder to be sure there is no squirt or spray.
air in the closed loop.
5 Remove the pin retaining fasteners from the
Note: When removing a hose assembly or fitting, slave cylinder rod-end pivot pin. Do not remove
the O-ring (if equipped) on the fitting and/or the the pin.
hose end must be replaced. All connections must 6 Remove the pin retaining fastener from the
be torqued to specification during installation. slave cylinder barrel-end pivot pin. Do not
Refer to Specifications, Hydraulic Hose and Fitting remove the pin.
7 Support the slave cylinder with a lifting device.
1 Adjust the platform to a level position. Protect the cylinder rod from damage.
2 Raise the jib boom slightly and place blocks 8 Use a soft metal drift to remove the rod-end
under the platform for support. pivot pin.
Crushing hazard. The platform will
fall, if not properly supported,
when the slave cylinder rod-end
pivot pin is removed.
Component damage hazard. The
slave cylinder rod may become
damaged if not properly supported
when the pin is removed.
a
9 Use a soft metal drift and remove the barrel-end
pin.
10 Carefully remove the cylinder from the platform
leveling assembly.
a platform slave cylinder
4-8 Z-60/34 Part No. 75861

PLATFORM COMPONENTS
How to Bleed the Slave Cylinder 2-3

Note: Do not start the engine. Use auxiliary power Platform Rotator
for this procedure.
1 Connect a hydraulic hose between the two test

How to Bleed the Platform
ports at the barrel end of the slave cylinder. Rotator
2 Raise the jib boom to a horizontal position. Note: This procedure will require two people. Do
not start the engine. Use auxiliary power for this
3 Activate auxiliary power and move the platform
procedure.
level switch up and down through two platform
leveling cycles to remove any air that might be 1 Move the function enable toggle switch to either
in the system. side and activate the platform rotate toggle
switch to the right then the left through two
4 Remove the hydraulic hose from the test ports.
platform rotation cycles, then hold the switch to
Move the platform level switch up and down
the right position until the platform is fully
through a platform leveling cycle and inspect
rotated to the right.
the test ports for leaks.
2 Place a suitable container underneath the
4 Activate auxiliary power and hold the platform
platform rotator.
3 Open the top bleed screw on the rotator, but do
not remove it.
Bodily injury hazard. Spraying
burn skin. Loosen hydraulic
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.
Part No. 75861 Z-60/34 4-9

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

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 The platform overload system is designed to
screw. Close the bleed screw. prevent the machine from continuing to operate
when the load in the platform exceeds maximum
Crushing hazard. Keep clear of rated capacity. Refer to the machine serial label for
the platform during rotation. maximum capacity information.
5 Open the bottom bleed screw on the rotator, but If maximum platform capacity is exceeded, the
do not remove it. alarm will sound at the platform controls and the
Bodily injury hazard. Spraying platform overload indicator lights will flash at both
hydraulic oil can penetrate and the ground and platform controls. The ground and
burn skin. Loosen hydraulic platform controls will become disabled. Before
connections very slowly to allow normal machine operation can continue, the
the oil pressure to dissipate excess load will need to be removed from the
gradually. Do not allow oil to platform.
squirt or spray.
If the excess load cannot be removed or if the
6 Move the function enable toggle switch to either operator at the platform controls is unable to
side and hold the platform rotate toggle switch correct the overloaded condition, another person at
to the right position until the platform is fully the ground controls can operate the machine using
rotated to the right. Continue holding the toggle auxiliary power. There will be limited control of
switch until air stops coming out of the bleed boom functions from the ground controls when
screw. Close the bleed screw. using auxiliary power. Auxiliary power can be used
to correct the overloaded platform condition in
Crushing hazard. Keep clear of order to resume normal, safe operation of the
the platform during rotation. machine.
7 Clean up any hydraulic oil that may have
Note: Even though platform and ground controls
spilled.
are disabled when an overloaded condition is
8 Rotate the platform fully in both directions and detected, the engine will continue to run. If the
inspect the bleed screws for leaks. engine is shut off in an overloaded condition, it will
not be possible to re-start the engine until the
overloaded condition is corrected.
4 - 10 Z-60/34 Part No. 75861

PLATFORM COMPONENTS
How to Calibrate the Platform 5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
Overload System (if equipped) inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
Calibration of the platform overload system is Result: The overload indicator lights are
essential to safe machine operation. Continued flashing at the platform and ground controls,
use of an improperly calibrated platform overload and the alarm is sounding. Slowly tighten the
system could result in the system failing to sense load spring adjustment nut in a clockwise
an overloaded platform. The stability of the direction in 10° increments until the overload
machine is compromised and it could tip over. indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Note: Perform this procedure with the machine on
a firm, level surface. Note: The platform will need to be moved up and
down and allowed to settle between each
1 Turn the key switch to platform control. Start the adjustment.
engine and level the platform.
Note: There may be a 2 second delay before the
2 Determine the maximum platform capacity. platform overload indicator light and alarm
Refer to the machine serial plate. responds.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test

weight equal to the maximum platform capacity
at the center of the platform floor.
Part No. 75861 Z-60/34 4 - 11

6 Move the platform up and down by hand, so it 8 Add an additional 10 lb / 4.5 kg test weight to
bounces approximately 2.5 to 5 cm / 1 to 2 the platform.
inches. Allow the platform to settle.
Result: The overload indicator light is flashing at
Result: The overload indicator lights are off at both the ground and platform controls, and the
the platform and ground controls, and the alarm alarm is sounding. Proceed to step 9.
does not sound. Slowly loosen the load spring
Result: The overload indicator light is off at both
adjustment nut in a counterclockwise direction
the ground and platform controls, and the alarm
in 10° increments until the overload indicator
does not sound. Remove the additional 10 lb /
light flashes at both the platform and ground
4.5 kg test weight. Repeat this procedure
controls, and the alarm sounds. Proceed to
step 7.
Result: The overload indicator lights are
platform overload indicator light and alarm
flashing at the platform and ground controls,
responds.
and the alarm is sounding. Repeat this
procedure beginning with step 5. 9 Test all machine functions from the platform
Note: The platform will need to be moved up and controls.
down and allowed to settle between each Result: All platform control functions should not
adjustment. operate.
Note: There may be a 2 second delay before the 10 Turn the key switch to ground control.
platform overload indicator lights and alarm
responds. 11 Test all machine functions from the ground
controls.
7 Move the platform up and down by hand, so it
Result: All ground control functions should not
bounces approximately 2.5 to 5 cm / 1 to 2
operate.
inches. Allow the platform to settle.
12 Using a suitable lifting device, lift the test weight
Result: The overload indicator lights are off and
off the platform floor.
the alarm does not sound. Proceed to step 8.
Result: The platform overload indicator light
Result: The overload indicator lights are
should be off at both the ground and platform
flashing at the platform and ground controls,
controls and the alarm should not sound.
and the alarm is sounding. Repeat this
procedure beginning with step 5. Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
platform overload indicator light and alarm 13 Test all machine functions from the ground
responds. controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
4 - 12 Z-60/34 Part No. 75861

Boom Components
a b c d e d f
n m l k j i i h g
a jib boom
b extension boom
c primary boom
d lower tension link
e upper secondary boom
f upper pivot
g turntable bulkhead
h primary boom lift cylinder
i lower leveling link
j lower secondary boom
k secondary boom lift cylinder
l mid-pivot
m connecting link
n jib boom leveling link
Part No. 75861 Z-60/34 4 - 13

Jib Boom Components

3-1 5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
Jib Boom cylinder.
How to Remove the Jib Boom hydraulic oil can penetrate and
Note: Perform this procedure with the boom in the burn skin. Loosen hydraulic
stowed position. connections very slowly to allow
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or the squirt or spray.
hose end must be replaced. All connections must
be torqued to specification during installation. 6 Remove the pin retaining fasteners from the jib
Refer to Specifications, Hydraulic Hose and Fitting boom lift cylinder barrel-end pivot pin. Do not
Torque Specifications. remove the pin.
1 Remove the platform. Refer to Repair
from the jib boom manifold. Cap the fittings on
Procedure, How to Remove the Platform.
the manifold.
2 Remove the platform mounting weldment,
8 Tag and disconnect the wiring from the jib boom
the platform leveling slave cylinder and the
manifold.
platform rotator. Refer to Repair Procedure, How
to Remove the Platform Leveling Slave Bodily injury hazard. Spraying
Cylinder. hydraulic oil can penetrate and
3 Support the platform pivot weldment with an
4 Remove the pin retaining fasteners from the gradually. Do not allow oil to
platform pivot weldment to jib boom pivot pin. squirt or spray.
Use a soft metal drift to remove the pin.
9 Pull the hydraulic hoses up through the jib
Remove the platform pivot weldment from the
boom lift cylinder mounting bracket.
jib boom.
Crushing hazard. The platform
Hoses can be damaged if they are
pivot weldment may become
kinked or pinched.
unbalanced and fall when
removed from the machine if not
properly supported.
4 - 14 Z-60/34 Part No. 75861

JIB BOOM COMPONENTS
10 Remove the cable cover from the side of the 3-2

jib boom.
Jib Boom Lift Cylinder
11 Attach a lifting strap from an overhead crane to
the jib boom.
How to Remove the Jib Boom
12 Use a soft metal drift to remove the jib boom lift Lift Cylinder
cylinder barrel-end pivot pin.
13 Remove the pin retaining fasteners from the jib
stowed position.
boom pivot pin. Use a soft metal drift to remove
the pin. Note: When removing a hose assembly or fitting,
14 Remove the jib boom from the primary boom. the O-ring (if equipped) on the fitting and/or the
Crushing hazard. The jib boom be torqued to specification during installation.
could become unbalanced and fall Refer to Specifications, Hydraulic Hose and Fitting
if not properly supported when Torque Specifications.
removed from the machine.
1 Raise the jib boom slightly and place blocks
15 Remove the pin retaining fasteners from the jib under the platform mounting weldment for
boom lift cylinder rod-end pivot pin. Do not support. Lower the jib boom until the platform is
remove the pin. resting on the blocks.
16 Remove both of the jib boom leveling links from Note: Do not rest the entire weight of the boom on
the primary boom. the blocks.
17 Attach a lifting strap from an overhead crane to 2 Remove the pin retaining fasteners from the jib
the lug on the rod end of the jib boom lift boom lift cylinder rod-end pivot pin. Do not
cylinder. remove the pin.
18 Use a soft metal drift to remove the jib boom lift 3 Remove the pin retaining fasteners from the
cylinder rod-end pivot pin, and remove the jib platform leveling slave cylinder barrel-end pivot
boom lift cylinder from the primary boom. pin. Do not remove the pin.
Crushing hazard. The jib boom 4 Remove both of the jib boom leveling links from
lift cylinder may become the machine.
unbalanced and fall if not properly
when it is removed from the
machine if it is not properly
attached to the overhead crane.
Part No. 75861 Z-60/34 4 - 15

JIB BOOM COMPONENTS
5 Tag, disconnect and plug the jib boom lift

cylinder.
squirt or spray.
the lug on the rod end of the jib boom lift
cylinder.
7 Remove the pin retaining fasteners from the jib
boom lift cylinder barrel-end pivot pin.
8 Use a soft metal drift to remove the barrel-end
pivot pin.
9 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the machine.
Crushing hazard. The jib boom
lift cylinder could become
supported when removed from the
machine.
4 - 16 Z-60/34 Part No. 75861

Primary Boom Components

4-1 4 Tag, disconnect and plug the hydraulic hoses
from the platform leveling slave cylinder. Cap
Cable Track the fittings on the slave cylinder.
The primary boom cable track guides the cables Bodily injury hazard. Spraying
and hoses running up the boom. It can be repaired hydraulic oil can penetrate and
link by link without removing the cables and hoses burn skin. Loosen hydraulic
that run through it. Removing the entire primary connections very slowly to allow
boom cable track is only necessary when the oil pressure to dissipate
performing major repairs that involve removing the gradually. Do not allow oil to
primary boom. squirt or spray.
5 Pull the slave cylinder hydraulic hoses out of
How to Remove the Cable Track the protective sheath.
Note: When removing a hose assembly or fitting, 6 Tag and disconnect the wiring from the
the O-ring (if equipped) on the fitting and/or the jib boom/platform rotate manifold.
be torqued to specification during installation. 7 Remove the cable clamp from the platform
Refer to Specifications, Hydraulic Hose and Fitting rotator.
Torque Specifications. 8 Remove the cable cover from the side of the jib
1 Raise the jib boom slightly and place blocks boom.
under the platform mounting weldment. Then 9 Tag, disconnect and plug the hydraulic hoses
lower the jib boom until the platform is resting from the jib boom/platform rotate manifold.
on the blocks just enough to support the Cap the fittings on the jib boom/platform rotate
platform. manifold.
Note: Do not rest the entire weight of the boom on Bodily injury hazard. Spraying
the blocks. hydraulic oil can penetrate and
2 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
squirt or spray.
3 Disconnect the cables from the platform control
10 Remove the hose clamps from the top of the jib
box.
boom.
Note: If your machine is equipped with an air line to
11 Remove the hose and cable clamp from the
platform option, the air line must be disconnected
primary boom at the pivot end.
from the platform before removal.
12 Remove the retaining fastener from the cable
track tube at the platform end of the primary
Part No. 75861 Z-60/34 4 - 17

PRIMARY BOOM COMPONENTS
extension boom. How to Repair the Primary Boom

13 Remove the fasteners from the side panel on Cable Track
the lower cable track, then remove the panel.
Pull all of the cables out of the channel. Component damage hazard. The
primary boom cable track can be
14 Place blocks between the lower cable track and damaged if it is twisted.
the upper cable track tube and secure them
together. Note: A 7 link repair section of cable track is
available through the Genie Industries Service
Crushing hazard. If the lower Parts Department.
cable track and upper cable track
tube are not properly secured
together, the cable track could
become unbalanced and fall when
a
the cable track.
b
16 Remove the cable track guide fasteners from
the platform end of the primary boom.
17 Remove the cable track mounting fasteners that a link separation point
b lower clip
attach the lower cable track to the primary
boom. 1 Use a slotted screwdriver to pry down on the
18 Remove the cable track from the machine and lower clip.
place it on a structure capable of supporting it. 2 To remove a single link, open the lower clip
Crushing hazard. The cable track and then use a screwdriver to pry the link to the
could become unbalanced and fall side.
if not properly attached to the 3 Repeat steps 1 and 2 for each link.
overhead crane.
Cables and hoses can be
damaged if they are kinked or
pinched.
The primary boom cable track
can be damaged if it is twisted.
4 - 18 Z-60/34 Part No. 75861

4-2 5 Remove the hose and cable clamp from the

upper mid-pivot.
Primary Boom
6 Remove the primary boom drive speed limit
switch from the upper pivot. Do not disconnect
How to Remove the the wiring.
Primary Boom
7 Remove the primary extension boom drive
Bodily injury hazard. This speed limit switch mounted on the inside of the
procedure requires specific repair pivot end of the primary boom. Do not
skills, lifting equipment and a disconnect the wiring.
suitable workshop. Attempting this
8 At the engine side of the upper pivot, remove
procedure without these skills and
the retaining fasteners from the master cylinder
tools could result in death or
rod-end pivot pin. Use a slide hammer to
serious injury and significant
remove the pin.
component damage. Dealer
service is strongly recommended. 9 Pull the master cylinder back and secure it from
moving.
stowed position. 10 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
Note: When removing a hose assembly or fitting, cylinder.
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must Bodily injury hazard. Spraying
be torqued to specification during installation. hydraulic oil can penetrate and
Refer to Specifications, Hydraulic Hose and Fitting burn skin. Loosen hydraulic
Torque Specifications. connections very slowly to allow
1 Remove the platform. gradually. Do not allow oil to
Refer to Repair Procedure, How to Remove the squirt or spray.
Platform.
11 Attach a 5 ton / 5,000 kg overhead crane to the
2 Remove the platform rotator and platform center point of the primary boom. Lift the
mounting weldment. primary boom enough to access the primary
3 Remove the jib boom. boom lift cylinder rod-end pivot pin.
Refer to Repair Procedure, How to Remove the 12 Attach a similar lifting device to the primary
Jib Boom. boom lift cylinder.
4 Remove cable track. 13 Place a 24 inch / 60 cm long block of wood
See Repair Procedure, How to Remove the across the lower secondary boom leveling links
Cable Track. to support the primary boom lift cylinder.
Part No. 75861 Z-60/34 4 - 19

14 Remove the pin retaining fasteners from the How to Disassemble the
primary boom lift cylinder rod-end pivot pin.
Primary Boom
15 Use a soft metal drift to remove the pin.
Note: Complete disassembly of the primary boom
Crushing hazard. The primary is only necessary if the primary tube must be
boom lift cylinder and the primary replaced. The extension cylinder can only be
boom will fall if they are not removed after removing the extension boom from
properly supported when the pin is the primary boom. Refer to Repair Procedure, How
removed. to Remove the Primary Boom Extension Cylinder.
16 Lower the rod end of the primary boom lift 1 Remove the primary boom. Refer to Repair
cylinder onto the support block placed across Procedure, How to Remove the Primary Boom.
the lower secondary boom leveling links.
2 Place blocks under the extension cylinder for
17 Remove the pin retaining fasteners from the support.
primary boom pivot pin.
3 Remove the cotter pin from the extension
18 Use a soft metal drift to remove the primary cylinder barrel-end pivot pin.
boom pivot pin. Remove the primary boom and
place it on a structure capable of supporting it. 4 Use a soft metal drift to remove the pin.
Crushing hazard. The boom could 5 Remove and label the wear pads from the
become unbalanced and fall if not platform end of the primary boom.
properly supported when the pin is
Note: Pay careful attention to the location and
removed.
amount of shims used with each wear pad.
6 Support and slide the extension boom and

extension cylinder out of the platform end of the
primary boom.
Crushing hazard. The primary
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
4 - 20 Z-60/34 Part No. 75861

7 Remove the external snap rings from the 4-3

extension cylinder rod-end pivot pins.
Primary Boom Lift Cylinder
8 Use a soft metal drift to remove the pins.
9 Support and slide the extension cylinder out How to Remove the
of the platform end of the extension boom. Primary Boom Lift Cylinder
10 Remove and label the wear pads from the
Bodily injury hazard. This
extension boom.
procedure requires specific repair
Note: Pay careful attention to the location and skills, lifting equipment and a
amount of shims used with each wear pad. suitable workshop. Attempting this
tools result in death or serious
injury and significant component
damage. Dealer service is strongly
recommended.
Note: When removing a hose assembly or fitting,
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
1 Raise the primary boom enough to access the
primary boom for support. Do not lift the boom.
3 Place a 24 inch / 60 cm long block of wood
across the lower secondary boom leveling links
to support the primary boom lift cylinder.
4 Support the rod end of the primary boom lift
cylinder with an appropriate lifting device.
6 Remove the pin using a soft metal drift.
7 Lower the rod end of the cylinder onto the block
that was placed on the lower secondary boom
leveling links.
8 Lower the primary boom onto the boom rest.
Part No. 75861 Z-60/34 4 - 21

9 Raise the secondary boom enough to access 4-4

the primary boom lift cylinder barrel-end
pivot pin. Primary Boom Extension
Cylinder
from the primary boom lift cylinder. Cap the
fittings on the cylinder. The primary boom extension cylinder extends and
retracts the primary boom extension tube. It can
Bodily injury hazard. Spraying only be removed after removing the extension
hydraulic oil can penetrate and boom assembly. The extension cylinder is
burn skin. Loosen hydraulic equipped with counterbalance valves to prevent
connections very slowly to allow movement in the event of a hydraulic line failure.
gradually. Do not allow oil to How to Remove the Primary
squirt or spray.
Boom Extension Cylinder
11 Place another 24 inch / 60 cm long block of
wood across the lower secondary boom
leveling links to support the primary boom lift
skills, lifting equipment and a
cylinder.
12 Support the barrel end of the primary boom lift procedure without these skills and
cylinder with an appropriate lifting device. tools could result in death or
component damage. Dealer
primary boom lift cylinder barrel-end pivot pin.
service is strongly
14 Use a soft metal drift to remove the pin . recommended.
Crushing hazard. The primary Note: Perform this procedure with the boom in the
boom lift cylinder may fall if not stowed position.
properly supported when removed
from the machine. Note: When removing a hose assembly or fitting,
15 Lower the barrel end of the cylinder onto the hose end must be replaced. All connections must
block that was placed on the lower secondary be torqued to specification during installation.
boom leveling links. Refer to Specifications, Hydraulic Hose and Fitting
16 Lower the secondary boom onto the boom rest.
17 Carefully pull the lift cylinder toward the platform 1 Remove the platform.
end of the secondary boom. Refer to Repair Procedure, How to Remove the
Platform.
18 Support and secure the cylinder to an
19 Remove the cylinder from the machine.
boom lift cylinder may fall if not
properly supported when removed
from the machine.
4 - 22 Z-60/34 Part No. 75861

2 Remove the jib boom. Refer Repair Procedure, 10 Remove the extension boom from the primary
How to Remove the Jib Boom. boom.
3 Extend the extension boom approximately Crushing hazard. The extension
5 feet / 1.5 m. boom could become unbalanced
and fall when removed from the
4 Tag, disconnect and plug the extension cylinder
primary boom if not properly
hydraulic hoses from the extension cylinder.
supported.
Cap the fittings on the cylinder.
11 Remove the external snap rings from the
extension cylinder rod-end pivot pins.
burn skin. Loosen hydraulic 12 Remove the pins using a soft metal drift.
13 Support and slide the extension cylinder out of
the extension boom.
squirt or spray. Crushing hazard. The extension
cylinder could become unbalanced
extension boom if not properly
6 Remove the pin using a soft metal drift. supported.
7 Support the extension boom and remove the Component damage hazard. Be
wear pads from the primary boom. careful not to damage the
counterbalance valves on the
Note: Pay careful attention to the location and
primary boom extension cylinder
amount of shims used with each wear pad.
when removing the cylinder from
8 Slide the extension boom out using a suitable the primary boom.
pulling device until the extension boom wear
pads are just visible.
Crushing hazard. The extension
boom could become unbalanced
primary boom if not properly
supported.
9 Support the extension boom at the primary
boom end with a suitable lifting device.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
Part No. 75861 Z-60/34 4 - 23

How to Replace the Extension 8 Loosen the lock nut on the valve and bleed the
pressure from the counterbalance valve by
Cylinder Upper Counterbalance turning the external adjustment screw
Valve clockwise.
Note: This procedure will require two people. 9 Remove the counterbalance valve from the
cylinder.
Note: Adjust the primary boom to a horizontal
position before performing this procedure. Bodily injury hazard. Spraying
1 Using auxiliary power, raise the secondary burn skin. Loosen hydraulic valve
boom until the counterweight end of the primary very slowly to allow the oil
boom is just above the counterweight. pressure to dissipate
2 Using a suitable lifting device, support the
squirt or spray.
secondary boom assembly. Do not lift it.
10 Install the new counterbalance valve and torque
3 Extend the extension boom approximately
the valve to 35-40 ft-lbs / 47-54 Nm.
1 foot / 0.3 m. Turn the machine off.
11 Clean up any hydraulic oil that may have
spilled.
12 Support the barrel end of the extension cylinder
5 Use a soft metal drift and remove the pin.
with a pry bar or other suitable tool. Have
6 Support the barrel end of the extension cylinder another person use auxiliary power to extend
with a pry bar or other suitable tool. Have the extension cylinder until the pivot pin bore
another person use auxiliary power to retract aligns with the pin bore of the boom tube.
the extension cylinder until it clears the platform
13 Use a soft metal drift and install the pin.
leveling master cylinder (approximately
6 inches / 15 cm). 14 Install a new cotter pin into the extension
7 Allow the extension cylinder to rest on the
bottom of the boom tube.
4 - 24 Z-60/34 Part No. 75861

4-5
Platform Leveling Master
Cylinder
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the upper mid-pivot at the base of
the primary boom.

skills, lifting equipment and a
serious injury and significant 5 Tag, disconnect and plug the hydraulic hoses
component damage. Dealer from the master cylinder. Cap the fittings on the
service is strongly recommended. cylinder.
Note: Perform this procedure with the boom in the Bodily injury hazard. Spraying
stowed position. hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring (if equipped) on the fitting and/or the connections very slowly to allow
hose end must be replaced. All connections must the oil pressure to dissipate
be torqued to specification during installation. gradually. Do not allow oil to
Refer to Specifications, Hydraulic Hose and Fitting squirt or spray.
Torque Specifications. 6 Attach a lifting strap from an overhead crane to
1 Remove the pin retaining fasteners from the the lug on the rod end of the master cylinder.
master cylinder rod-end pivot pin. 7 Remove the pin retaining fasteners from the
2 use a soft metal drift to remove the pins. master cylinder barrel-end pivot pin.
8 Use a soft metal drift to remove the pins.
3 Raise the secondary boom until the upper
mid-pivot is above the turntable covers. 9 Lower the master cylinder down and out of the
4 Attach the lifting strap from an overhead crane upper pivot and remove it from the machine.
to the platform end of the lower secondary Crushing hazard. The master
boom arm for support. Do not apply any lifting cylinder could become unbalanced
pressure. and fall if not properly supported
when removed from the machine.
Part No. 75861 Z-60/34 4 - 25

Secondary Boom Components

5-1 4 Remove the engine side lower tension link from
the machine.
Secondary Boom
5 Repeat this step for the ground controls side
lower tension link.
How to Disassemble the
Secondary Boom Crushing hazard. The tension link
could become unbalanced and fall
Bodily injury hazard. The if not properly supported when
procedures in this section require removed from the machine.
specific repair skills, lifting
equipment and a suitable
connecting link at the upper secondary boom.
workshop. Attempting this
procedure without these skills and 7 Remove the pin using a soft metal drift.
serious injury and significant 8 Attach a securing strap from the upper pivot to
component damage. Dealer tension link pivot pin mounting tube on the
service is required. turntable bulkhead, to prevent the upper pivot
from moving.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the Attach a 5 ton / 5,000 kg overhead crane to the
secondary boom by following the disassembly center of the upper secondary boom.
steps in reverse order. 10 Remove the mounting fasteners from the
secondary boom lift cylinder rod-end pivot pin
mounting bracket.
hose end must be replaced. All connections must 11 Remove the pin retaining fasteners from both
be torqued to specification during installation. upper pivot to upper secondary boom pivot pins.
Refer to Specifications, Hydraulic Hose and Fitting Use a soft metal drift to remove the pins.
Crushing hazard. The upper mid-
Remove the primary boom. Refer to Repair pivot may fall when the pins are
Procedure, How to Remove the Primary Boom. removed if the upper mid-pivot is
not properly secured.
2 Remove all four pin retaining fasteners from the
two lower tension link pivot pins. Do not remove 12 Remove the pin retaining fasteners from the
the pins. lower mid-pivot to upper secondary boom pivot
pin.
3 Attach a lifting strap from an overhead crane at
the center of the lower tension link on the
engine side of the machine.
4 - 26 Z-60/34 Part No. 75861

SECONDARY BOOM COMPONENTS
13 Remove the lower mid-pivot to upper secondary 19 Remove the mounting fasteners from both of the
boom pivot pin using a soft metal drift, and turntable bulkhead covers, and remove both
remove the upper secondary boom from the turntable bulkhead covers.
machine.
20 Remove the hydraulic tank. Refer to
Crushing hazard. The upper Maintenance Procedure, Test or Replace the
secondary boom may become Hydraulic Oil.
supported when it is removed from
the lug on the primary boom lift cylinder, then lift
the machine.
the primary boom lift cylinder to a vertical
14 Remove both turntable covers. position.
15 Remove the two engine pivot plate retaining 22 Tag, disconnect and plug the primary boom lift
bolts. Then swing the engine out away from the cylinder hydraulic hoses. Cap the fittings on the
machine and secure it from moving. cylinder.
Crushing hazard. Failure to secure 23 Remove the pin retaining fasteners from the
the engine pivot plate from moving primary boom lift cylinder barrel-end pivot pin.
could result in death or serious Use a soft metal drift to remove the pins, and
injury. remove the primary boom lift cylinder from the
machine.
16 Disconnect the battery cables.
Electrocution hazard. Contact with
boom lift cylinder could become
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
machine.
17 Remove the battery hold down fasteners, and
24 Tag, disconnect and plug the secondary boom
remove the battery.
lift cylinder hydraulic hoses. Cap the fittings on
Bodily injury hazard. Batteries the cylinder.
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
18 Gasoline/LPG models: Remove the mounting the oil pressure to dissipate
fasteners from the ECM mounted to the engine gradually. Do not allow oil to
side bulkhead cover. squirt or spray.
Part No. 75861 Z-60/34 4 - 27

25 Attach a lifting strap from an overhead crane to 33 Tag, disconnect and plug the master cylinder
the lug on the rod end of the secondary boom hydraulic hoses. Cap the fittings on the cylinder.
lift cylinder.
26 Remove the pin retaining fasteners from the hydraulic oil can penetrate and
secondary boom lift cylinder pivot pins. burn skin. Loosen hydraulic
Remove the pins using a slide hammer, and
remove the secondary boom lift cylinder from
the machine.
squirt or spray.
Crushing hazard. The secondary
the lug on the rod end of the master cylinder.
supported when removed from the 35 Remove the pin retaining fasteners from the
machine. master cylinder barrel-end pivot pin.
27 Attach a securing strap from the mid-pivot to the 36 Remove the pin using a soft metal drift, and
lower secondary boom, to prevent the mid-pivot remove the master cylinder from the machine.
from moving.
Crushing hazard. The master
28 Number each electrical cable and its entry cylinder could become unbalanced
location at the platform control box. and fall if not properly supported
29 Disconnect the cables from the platform control
box. 37 Attach a lifting strap from an overhead crane to
the upper pivot, and remove the securing strap
30 Pull all of the electrical cables out of the cable
from the mid-pivot.
track. Do not pull out the hydraulic hoses.
38 Pull all of the hoses and cables out of the upper
31 Tag, disconnect and plug the platform rotator
mid-pivot.
and slave cylinder hydraulic hoses at the union,
located near the upper pivot. Component damage hazard.
Cables and hoses can be damaged
if they are kinked or pinched.
burn skin. Loosen hydraulic 39 Remove the secondary boom drive limit switch
connections very slowly to allow mounting fasteners from the lower secondary
the oil pressure to dissipate boom. Do not disconnect the wiring.
40 Pull all of the hoses and cables out of the
squirt or spray.
mid-pivot and lay them off to the side.
32 Remove the hose and cable covers from both of
the lower secondary boom leveling links.
Cables and hoses can be damaged
if they are kinked or pinched.
4 - 28 Z-60/34 Part No. 75861

41 Place blocks under each of the lower leveling 50 Attach a lifting strap from an overhead crane to
links for support at the turntable bulkhead end. the connecting link.
42 Remove the pin retaining fasteners from both of 51 Remove the pin retaining fasteners from the
the upper pivot to lower leveling link pivot pins. connecting link pivot pin at the lower secondary
boom.
43 Use a soft metal drift to remove the pins, and
remove the upper pivot from the machine. 52 Use a soft metal drift to remove the pins, and
remove the connecting link from the machine.
Crushing hazard. The upper pivot
could become unbalanced and fall Crushing hazard. The connecting
if not properly supported when link could become unbalanced and
removed from the machine. fall if not properly supported when
the center of the engine side lower leveling link. 53 Attach a 5 ton / 5,000 kg overhead crane to the
mid-pivot.
engine side lower leveling link pivot pin at the 54 Remove the pin retaining fasteners from the
mid-pivot. lower secondary boom pivot pin at the
mid-pivot.
remove the engine side lower leveling link from 55 Use a soft metal drift to remove the pins, and
the machine. remove the mid-pivot from the machine.
Crushing hazard. The engine side Crushing hazard. The mid-pivot
lower leveling link could become could become unbalanced and fall
unbalanced and fall if not properly if not properly supported when
supported when removed from the removed from the machine.
machine.
56 Remove the hose and cable covers from the
47 Attach a lifting strap from an overhead crane to lower secondary boom.
the center of the ground controls side lower
leveling link.
center point of the lower secondary boom.
ground controls side lower leveling link pivot pin
lower secondary boom pivot pin at the turntable
at the mid-pivot.
bulkhead.
49 Remove the pin using a soft metal drift, and
remove the ground controls side lower leveling
remove the lower secondary boom from the
link from the machine.
machine.
Crushing hazard. The ground
Crushing hazard. The lower
controls side lower leveling link
secondary boom could become
could become unbalanced and fall
if not properly supported when
machine.
Part No. 75861 Z-60/34 4 - 29

5-2 2 Tag, disconnect and plug the secondary boom

lift cylinder hydraulic hoses. Cap the fittings on
Secondary Boom Lift Cylinder the cylinder.
The secondary boom lift cylinder raises and Bodily injury hazard. Spraying
lowers the secondary boom. The secondary hydraulic oil can penetrate and
boom lift cylinder is 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 oil pressure to dissipate
How to Remove the squirt or spray.
Secondary Boom Lift Cylinder 3 Remove the mounting fasteners from
the secondary boom lift cylinder rod-end pivot
Bodily injury hazard. This pin mounting bracket.
skills, lifting equipment and a 4 Remove the retaining fasteners from the
suitable workshop. Attempting this secondary boom lift cylinder pivot pins.
procedure without these skills and 5 Remove the pins using a slide hammer, and
tools could result in death or remove the cylinder from the machine.
component damage. Crushing hazard. The secondary
Note: When removing a hose assembly or fitting, unbalanced and fall if not properly
the O-ring (if equipped) on the fitting and/or the supported when removed from the
hose end must be replaced. All connections must machine.
Refer to Specifications, Hydraulic Hose and Fitting
the lug on the rod end of the secondary boom
lift cylinder.
4 - 30 Z-60/34 Part No. 75861

Engines
6-1 6-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure, Check and Adjust The flex plate acts as a coupler between the
the Engine RPM. engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.
a b c d e
f
a pump
b pump shaft
c pump coupler
d flex plate with raised spline
e engine flywheel
f 0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.5 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
How to Remove the Flex Plate

Deutz models:
1 Remove the tailpipe bracket mounting fasteners

from the engine bell housing.
2 Support the drive pump assembly with an
3 Remove all of the engine bell housing fasteners.
4 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
kinked or pinched.
5 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
Part No. 75861 Z-60/34 4 - 31

ENGINES
Ford LRG-425 EFI models: 12 Remove all of the engine bell housing fasteners.
1 Disconnect the electrical connector for the 13 Carefully pull the pump and bell housing
oxygen sensor at the tailpipe. Do not remove assembly away from the engine and secure it
the oxygen sensor. from moving.
2 Remove the engine oil dipstick fasteners from Component damage hazard.
the muffler bracket. Remove the dipstick from Hoses can be damaged if they are
the engine. kinked or pinched.
3 Remove the muffler retaining fasteners from the 14 Remove the flex plate mounting fasteners.
exhaust pipe. Remove the flex plate from the flywheel.
4 Support the muffler and bracket assembly with Ford DSG-423 and MSG-425 models:
an overhead crane or other suitable lifting
1 Disconnect the electrical connectors from both
device.
oxygen sensors at the tailpipe and exhaust
5 Remove the muffler bracket mounting manifold. Do not remove the oxygen sensors.
fasteners. Carefully remove the muffler and
2 Remove the exhaust pipe fasteners at the
bracket assembly from the engine.
muffler.
6 Support the engine with a suitable lifting device.
3 Support the muffler and bracket assembly with
Do not lift it.
a suitable lifting device.
7 Remove the engine plate to vibration isolator
4 Remove the muffler bracket mounting fasteners
fasteners.
from the bell housing. Carefully remove the
8 Remove the engine mounting plate to bell muffler and bracket assembly from the engine.
housing fasteners.
5 Support the engine with an overhead crane or
9 Raise the engine slightly to take the weight off other suitable lifting device. Do not lift it.
of the engine mounting plate.
6 Remove the engine mounting plate to bell
10 Slide the engine mounting plate towards the housing fasteners.
pump as far as it will go.
7 Raise the engine slightly using the overhead
11 Support the drive pump assembly with an crane and place a block of wood under the oil
appropriate lifting device. pan for support.
8 Support the drive pump assembly with an
overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
4 - 32 Z-60/34 Part No. 75861

ENGINES
9 Remove all of the engine bell housing retaining How to Install the Flex Plate
fasteners.
1 Install the flex plate onto the engine flywheel
10 Carefully pull the pump and bell housing with the raised spline towards the pump.
assembly away from the engine and secure it
from moving. 2 Apply Loctite® removable thread sealant to the
screws. Torque the flex plate in a star pattern
Component damage hazard. using the following values.
kinked or pinched. Ford models:
Before serial number 7924: Torque the flex
11 Remove the flex plate mounting fasteners. plate mounting bolts in sequence to
Remove the flex plate from the flywheel. 24 ft-lbs / 32 Nm.
Perkins models: After serial number 7923: Torque the flex
plate mounting bolts in sequence to
1 Remove the fuel filter/water separator mounting 20 ft-lbs / 27 Nm.
fasteners.
Deutz models:
2 Remove the fuel filter/water separator and lay it Torque the flex plate mounting bolts in
to the side. Do not disconnect the hoses. sequence to 28 ft-lbs / 38 Nm.
3 Support the drive pump assembly with an Perkins models:
appropriate lifting device. Before serial number 8050: Torque the flex
4 Remove all of the engine bell housing fasteners. plate mounting bolts in sequence to
49 ft-lbs / 66 Nm.
5 Carefully pull the pump and bell housing After serial number 8049: Torque the flex
assembly away from the engine and secure it plate mounting bolts in sequence to
from moving. 14 ft-lbs / 19.1 Nm.
kinked or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
Part No. 75861 Z-60/34 4 - 33

ENGINES
3 Install the pump coupler onto the pump shaft 5 Install the pump and bell housing assembly.
with the set screw toward the pump. Leave the
Ford LRG-425 models:
appropriate gap between coupler and pump
Before serial number 4545: Torque the bell
end plate for your engine.
housing mounting bolts in sequence to
23 ft-lbs / 31 Nm.
a b c d e After serial number 4544: Torque the bell
housing mounting bolts labeled "C" in sequence
to 47 ft-lbs / 63 Nm. Torque the bell housing
mounting bolts labeled "B" in sequence to
61 ft-lbs / 83 Nm.
Ford DSG-423 and MSG-425 models:
Torque the bell housing mounting bolts labeled
f
"A" and "B" in sequence to 28 ft-lbs / 38 Nm
and the mounting bolts labeled "C" to 49 ft-lbs /
a pump
b pump shaft
66 Nm. Then torque the bell housing mounting
c pump coupler bolts labeled "A" and "B" in sequence to 40 ft-
d flex plate with raised spline lbs / 54 Nm and the mounting bolts labeled "C"
e engine flywheel to 70 ft-lbs / 95 Nm.
f 0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models Deutz models:
0.0625 inch / 1.5 mm gap - Ford LRG-425 Before serial number 4608: Torque the bell
0.080 inch / 2 mm gap - Ford DSG-423
housing mounting bolts in sequence to
4 Apply Loctite® removable thread sealant to the 28 ft-lbs / 38 Nm.
pump coupler set screw. Torque the set screw After serial number 4607: Torque the bell
to 61 ft-lbs / 83 Nm. housing mounting bolts in sequence to
47 ft-lbs / 63 Nm.
Perkins models:
Torque the bell housing mounting bolts labeled
"B" in sequence to 28 ft-lbs / 38 Nm and the
mounting bolts labeled "A" to 49 ft-lbs / 66 Nm.
Then torque the bell housing mounting bolts
labeled "B" in sequence to 40 ft-lbs / 54 Nm and
the mounting bolts labeled "A" to 70 ft-lbs / 95
Nm.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 - 34 Z-60/34 Part No. 75861

ENGINES
3 1 1 6
C C
6-3
5 8
7
C C
8 Engine Fault Codes - Ford
3 C
C 4 Models
7 6
C
How to Retrieve Engine Fault
9
C C
Codes
2 4 5 2
Ford models:
Ford LRG 425 models Ford LRG 425 models
(before serial number 4545) (after serial number 4544) The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
6 1 6
injection and make constant and instantaneous
1
10 C C
changes to ignition timing, fuel delivery and throttle
8 10 8
C C
position to maintain the engine's running condition
4 3
at its highest efficiency while at the same time
4 3
C C keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
11 12 11 C C
12 set parameters, the ECM will store a fault code in
C C memory that relates to the appropriate sensor and
7 5 C
7 C 5 will turn on the Check Engine Light.
2 9 9
2
Refer to Fault Codes Section, How to Retrieve
Deutz 1011 models Deutz 2011 models Engine Fault Codes. Use the Fault Code Charts to
(before serial number 4608) (after serial number 4607)
aid in identifying the fault.
6 1
A A
6
1 B
B
3
A
9
B
B
4 A 4 5
B
B B
C C B 7
8 B
7 B 5
2 3
2
Ford DSG 423 models Perkins models

Ford MSG 425 models
Part No. 75861 Z-60/34 4 - 35

Hydraulic Pumps
7-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
How to Remove the hydraulic oil can penetrate and
Function Pump connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or the gradually. Do not allow oil to
hose end must be replaced. All connections must squirt or spray.
be torqued to specification during installation. 3 Remove the pump mounting bolts. Carefully
Refer to Specifications, Hydraulic Hose and Fitting remove the pump.
Models without hydraulic tank shut-off valves:
1 Models without hydraulic tank shut-off
valves: Remove the drain plug from the Component damage hazard. Be
hydraulic tank and completely drain the tank sure to fill the hydraulic tank to
into a suitable container. Refer to specification and prime the pump
Specifications, Machine Specifications. after installing the pump.
Models with hydraulic tank shut-off valves: Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole Component damage hazard. Be
underneath the turntable. Close the valves. sure to open the two hydraulic
tank valves and prime the pump
Component damage hazard. The after 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
4 - 36 Z-60/34 Part No. 75861

HYDRAULIC PUMPS
7-2 2 Models without hydraulic tank shut-off

valves: Remove the drain plug from the
Drive Pump hydraulic tank and completely drain the tank
The drive pump is a bi-directional variable into a suitable container. See capacity
displacement piston pump. The pump output is specifications.
controlled by the electro-proportional controller, Models with hydraulic tank shut-off valves:
located on the pump. The only adjustment that can Locate the two hydraulic tank valves at the
be made to the pump is the neutral or null hydraulic tank through the access hole
adjustment. Any internal service to the pump underneath the turntable. Close the valves.
should only be performed at an authorized Sauer
Hydraulics center. Call Genie Product Support to Component damage hazard. The
locate your local authorized service center. engine must not be started with
the hydraulic tank shut-off valves
How to Remove the Drive Pump in the closed position or
component damage will occur. If
Component damage hazard. The the tank valves are closed,
work area and surfaces where this remove the key from the key
procedure will be performed must switch and tag the machine to
be clean and free of debris that inform personnel of the condition.
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
be torqued to specification during installation. open closed
Torque Specifications. 3 Tag and disconnect and plug the hydraulic
1 Disconnect the electrical connection at the hoses from the drive and function pumps.
electro-proportional controller located on the Cap the fittings on the pumps.
drive pump. Bodily injury hazard. Spraying
squirt or spray.
Part No. 75861 Z-60/34 4 - 37

HYDRAULIC PUMPS
4 Support the pump with a lifting device and How to Prime the Pump
remove the two drive pump mounting fasteners.
5 Carefully pull the drive pump out until the pump located under the engine tray. Loosen the pivot
coupler separates from the flex plate. fastener located at the platform end of the
6 Remove the drive pump from the machine. engine tray.
Component damage hazard. The 2 Swing the engine tray out and away from the
hydraulic pump may become machine.
unbalanced and fall if not properly 3 Connect a 0 to 600 psi / 0 to 50 bar pressure
supported. gauge to the test port on the drive pump.
Component damage hazard. 4 Ford models: Close the valve on the LPG tank
When installing the pump, do not then disconnect the hose from the tank. Move
force the pump coupler into the the fuel select switch to the LPG position.
flexplate or damage to the pump
shaft seal may occur. Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
Models without hydraulic tank shut-off valves: pump.
Component damage hazard. Be Deutz models: Hold the manual fuel shutoff
sure to fill the hydraulic tank to valve clockwise to the closed position.
specification and prime the pump
after installing the pump. a
Models with hydraulic tank shut-off valves:
Component damage hazard. Be

sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
a manual fuel shutoff valve
4 - 38 Z-60/34 Part No. 75861

HYDRAULIC PUMPS
5 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.
6 Ford models: Connect the LPG hose to the
LPG tank and open the valve on the tank. Move
the fuel select switch to the gasoline position.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel shutoff
valve.
check for hydraulic leaks.
Part No. 75861 Z-60/34 4 - 39

Manifolds
8-1
Function Manifold Components - View 1
The function manifold is located behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ....... A ........... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 3 position 4 way ....... B ........... Secondary boom up/down ................ 26-30 ft-lbs / 35-41 Nm
3 Solenoid valve, 3 position 4 way ....... C ........... Primary boom up/down ..................... 26-30 ft-lbs / 35-41 Nm
4 Counterbalance valve,
500 psi / 34.4 bar ............................... D ........... Platform level up/down
and motion control ............................ 30-35 ft-lbs / 41-47 Nm
500 psi / 34.4 bar ............................... E ........... Platform level up/down
6 Solenoid valve, 3 position 4 way ....... F ........... Platform level up/down .................... 26-30 ft-lbs / 35-41 Nm
7 Differential sensing valve,
150 psi / 10.3 bar ............................... G ........... Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ....... H ........... Boom extend ..................................... 30-35 ft-lbs / 41-47 Nm
9 Solenoid valve, 2 position 3 way ....... I ............ Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
10 Solenoid valve, 3 position 4 way ....... J ............ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... K ........... Boom extend ..................................... 10-12 ft-lbs / 14-16 Nm
12 Check valve ....................................... L ........... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
13 Flow regulator valve,
0.1 gpm / 0.37 L/min .......................... M .......... Flow control ....................................... 26-30 ft-lbs / 35-41 Nm
14 Check valve ....................................... N ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm
15 Check valve ....................................... O ........... Platform level up ............................... 10-12 ft-lbs / 14-16 Nm
16 Check valve ....................................... P ........... Platform level down .......................... 10-12 ft-lbs / 14-16 Nm
17 Check valve ....................................... Q ........... Primary boom up/down ..................... 10-12 ft-lbs / 14-16 Nm
18 Check valve ....................................... R ........... Secondary boom up/down ................ 10-12 ft-lbs / 14-16 Nm
3.5 gpm / 13.2 L/min .......................... S ........... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
20 Relief valve, 2400 psi / 165.4 bar ...... T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
21 Check valve, 50 psi / 3.45 bar ........... U ........... Pressure in from drive pump ............. 30-35 ft-lbs / 41-47 Nm
22 Differential sensing valve .................. V ........... Secondary boom up/down ................ 30-35 ft-lbs / 41-47 Nm
23 Differential sensing valve .................. W .......... Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm
4 - 40 Z-60/34 Part No. 75861

MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11
H
C
J
A B
G
D E
W
23
V
22
12
M
13
U
21
1
N
14
T
20
O
15
P
16
Q
17
R
S
18
19
Part No. 75861 Z-60/34 4 - 41

MANIFOLDS
8-2
Function Manifold Components - View 2
Index Schematic
1 Valve check ....................................... X ........... Boom retract ..................................... 10-12 ft-lbs / 14-16 Nm
2 Diagnostic nipple ............................... Y ........... Testing
3 Diagnostic nipple ............................... Z ........... Testing
4 Check valve, 30 psi / 2.1 bar ............. AA ......... To tank .............................................. 30-35 ft-lbs / 41-47 Nm
5 Proportional solenoid valve ............... AB ......... Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm
6 Proportional solenoid valve ............... AC ........ Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm
7 Relief valve, 1600 psi / 110.3 bar ...... AD ........ Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
8 Relief valve, 1800 psi / 124.1 bar ...... AE ......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
9 Free flow needle valve ...................... AF ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm
10 Proportional solenoid valve ............... AG ........ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
11 Differential sensing valve .................. AH ........ Function pressure control ................. 30-35 ft-lbs / 41-47 Nm
5 gpm / 18.9 L/min ............................. AI .......... Boom extend retract .......................... 30-35 ft-lbs / 41-47 Nm
1 gpm / 3.8 L/min ............................... AJ ......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
14 Solenoid valve, 3 position 4 way ....... AK ......... Jib up/down and platform
rotate left/right ................................... 26-30 ft-lbs / 35-41 Nm
15 Check valve ....................................... AL ......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
16 Check valve ....................................... AM ........ Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
4 - 42 Z-60/34 Part No. 75861

MANIFOLDS
1
AA
Y
X
AB
AC
AE
AD
AF
AH
AI
AJ
AG
AK
AM
AL
Part No. 75861 Z-60/34 4 - 43

MANIFOLDS
8-3
Function Manifold Components
from serial number 4461)
Index Schematic
1 Solenoid valve, 3 position 4 way ....... HA ........ Turntable rotate left/right ................... 33-37 ft-lbs / 45-50 Nm
2 Differential sensing valve,
150 psi / 10.3 bar ............................... HB ........ Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm
3 Solenoid valve, 3 position 4 way ....... HC ........ Platform level up/down ..................... 33-37 ft-lbs / 45-50 Nm
4 Solenoid valve, 3 position 4 way ....... HD ........ Primary boom up/down ..................... 33-37 ft-lbs / 45-50 Nm
5 Solenoid valve, 3 position 4 way ....... HE ........ Secondary boom up/down ................ 33-37 ft-lbs / 45-50 Nm
6 Solenoid valve, 3 position 4 way ....... HF ......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
7 Check valve, 50 psi / 3.45 bar ........... HG ........ Pressure in from drive pump ............. 30-35 ft-lbs / 41-47 Nm
8 Diagnostic nipple ............................... HH ........ Testing
3.5 gpm / 13.2 L/min .......................... HI .......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
10 Differential sensing valve .................. HJ ......... Secondary boom up/down ................ 30-35 ft-lbs / 41-47 Nm
11 Differential sensing valve .................. HK ........ Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm
500 psi / 34.4 bar ............................... HL ......... Platform level up/down
13 Proportional solenoid valve ............... HM ........ Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm
500 psi / 34.4 bar ............................... HN ........ Platform level up/down
15 Proportional solenoid valve ............... HO ........ Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm
16 Relief valve, 1800 psi / 124.1 bar ...... HP ........ Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
17 Free flow needle valve ...................... HQ ........ Platform level .................................... 30-35 ft-lbs / 41-47 Nm
18 Proportional solenoid valve ............... HR ........ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
0.1 gpm / 0.37 L/min .......................... HS ........ Flow control ....................................... 20-25 ft-lbs / 27-34 Nm
20 Differential sensing valve .................. HT ......... Function pressure control ................. 30-35 ft-lbs / 41-47 Nm
This parts list continues. Please turn the page.
4 - 44 Z-60/34 Part No. 75861

MANIFOLDS
1 2 3 4 5 6
HA HB HC HD HE HF
IM
39
HG
7
HH
8
HI
9
IL
38 HJ
10
IK
37 HK
11
IJ HL
36 12
HM 13
HN
14
HO
15
HP
16
iew
pV
To
II
35 HQ
17
IH HR
34 18
IG
33 HS
19
HT
20
w HU
Vie 21
nt
Fro
32 31 30 29 28 27 26
IF IE ID IC IB IA HZ
Shows valves
hidden from
above view
Top View Front View
HY HX HW HV
25 24 23 22
Part No. 75861 Z-60/34 4 - 45

MANIFOLDS
8-3
Function Manifold Components, continued
Index Schematic
21 Solenoid valve, 3 position 4 way ....... HU ........ Jib up/down and platform
rotate left/right ................................... 33-37 ft-lbs / 45-50 Nm
22 Check valve, 30 psi / 2.1 bar ............. HV ........ To tank .............................................. 30-35 ft-lbs / 41-47 Nm
23 Relief valve, 1600 psi / 110.3 bar ...... HW ....... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
5 gpm / 18.9 L/min ............................. HX ........ Boom extend retract .......................... 30-35 ft-lbs / 41-47 Nm
1.5 gpm / 5.6 L/min ............................ HY ........ Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
26 Relief valve, 2600 psi / 180 bar ........ HZ ......... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
27 Check valve ....................................... IA .......... Secondary boom up/down ............... 8-10 ft-lbs / 11-14 Nm
28 Check valve ....................................... IB .......... Primary boom up/down .................... 8-10 ft-lbs / 11-14 Nm
29 Check valve ....................................... IC .......... Platform level down .......................... 8-10 ft-lbs / 11-14 Nm
30 Check valve ....................................... ID .......... Platform level up ............................... 8-10 ft-lbs / 11-14 Nm
31 Check valve ....................................... IE .......... Turntable rotate left/right .................. 8-10 ft-lbs / 11-14 Nm
32 Check valve ....................................... IF .......... Boom extend .................................... 8-10 ft-lbs / 11-14 Nm
33 Check valve ....................................... IG .......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
34 Check valve ....................................... IH .......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
35 Valve check ....................................... II ............ Boom retract ..................................... 10-12 ft-lbs / 14-16 Nm
36 Solenoid valve, 2 position 3 way ...... IJ ........... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
37 Solenoid valve, 2 position 3 way ...... IK .......... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
38 Diagnostic nipple .............................. IL .......... Testing
39 Check valve ....................................... IM ......... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
4 - 46 Z-60/34 Part No. 75861

MANIFOLDS
1 2 3 4 5 6
HA HB HC HD HE HF
IM
39
HG
7
HH
8
HI
9
IL
38 HJ
10
IK
37 HK
11
IJ HL
36 12
HM 13
HN
14
HO
15
HP
16
iew
pV
To
II
35 HQ
17
IH HR
34 18
IG
33 HS
19
HT
20
w HU
Vie 21
nt
Fro
32 31 30 29 28 27 26
IF IE ID IC IB IA HZ
Shows valves
hidden from
above view
Top View Front View
HY HX HW HV
25 24 23 22
Part No. 75861 Z-60/34 4 - 47

MANIFOLDS
8-4 How to Adjust the Primary Boom

Valve Adjustments - 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 test port on the function manifold.
(Item Z before serial number 4461)
(Item IL after serial number 4460)
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold. 3 Hold the function enable switch to the high rpm
(Item Z before serial number 4461) position and activate and hold the primary
(Item IL after serial number 4460) boom down switch with the primary boom fully
lowered.
4 Observe the pressure reading on the pressure
3 Hold the function enable switch to the high rpm gauge. Refer to Specifications, Hydraulic
position and activate and hold the retract switch Component Specifications.
with the boom fully retracted.
5 Turn the engine off. Use a wrench to hold the
4 Observe the pressure reading on the pressure relief valve and remove the cap.
gauge. Refer to Specifications, Hydraulic (item AE before serial number 4461)
Component Specifications. (item HP after serial number 4460)
5 Turn the engine off. Use a wrench to hold the 6 Adjust the internal hex socket. Turn it clockwise
relief valve and remove the cap. to increase the pressure or counterclockwise to
(item T before serial number 4461) decrease the pressure. Install the relief valve
(item HZ after serial number 4460) 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 re-check relief
Tip-over hazard. Do not adjust valve pressure.
the relief valve higher than
specified. 8 Remove the pressure gauge.
valve pressure.
8 Remove the pressure gauge.
4 - 48 Z-60/34 Part No. 75861

MANIFOLDS
How to Adjust the Secondary

Boom Down Relief Valve
stowed position.

gauge to the test port (item Z) on the function
manifold.
3 Hold the function enable switch to the high rpm
position and activate and hold the secondary
boom down switch with the secondary boom
fully lowered.
4 Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Component Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
(item AD before serial number 4461)
(item HW after serial number 4460)
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
valve pressure.
8 Remove the pressure gauge.
Part No. 75861 Z-60/34 4 - 49

MANIFOLDS
8-5
Jib Boom / Platform Rotate Manifold Components
Index Schematic
1 Solenoid valve, 2 position 2 way ....... BA ......... Platform rotate .................................. 20-25 ft-lbs / 27-34 Nm
2 Solenoid valve, 2 position 2 way ....... BB ......... Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
3 Orifice, 0.031 inch / 0.787 mm .......... BC ........ Platform rotate circuit
4 Orifice, 0.031 inch / 0.787 mm .......... BD ........ Platform rotate circuit
1 2
BB
BA
BC
3
BD
4
4 - 50 Z-60/34 Part No. 75861

MANIFOLDS
8-6
(from serial number 4461 to serial number 10425)
Index Schematic
3 Counterbalance valve ....................... BH ........ Platform rotate left ............................. 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ....................... BJ ......... Platform rotate right .......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 2 way ...... BE ......... Platform rotate
Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
4 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
1
BH
Platform
Rotate Manifold
BJ
2
BE
3
Jib Manifold
BF
4
BG
5
Part No. 75861 Z-60/34 4 - 51

MANIFOLDS
8-7
Index Schematic
3 Counterbalance valve ....................... BH ........ Platform rotate left ............................. 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ....................... BJ ......... Platform rotate right .......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 2 way ...... BE ......... Platform rotate
Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
BN
2
BM
1
4 - 52 Z-60/34 Part No. 75861

MANIFOLDS
8-8
Index Schematic
1 Solenoid valve, 2 position 2 way ..... BP ......... Jib boom up/down ................... 19-21 ft-lbs / 25.8 - 28.6 Nm
2 Flow control valve ............................ BR ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
3 Check valve ...................................... BS ......... One way flow ................................ 12-14 ft-lbs / 16.3-19 Nm
4 Load shuttle valve ............................ BT ......... Controls direction of flow ......... 19-21 ft-lbs / 25.8 - 28.6 Nm
5 Check valve ...................................... BU ......... One way flow ................................ 12-14 ft-lbs / 16.3-19 Nm
1 2
BP BR
BU
5
BT
4
BS
3
Part No. 75861 Z-60/34 4 - 53

MANIFOLDS
8-9
Index Schematic
1 Solenoid valve, 2 position 2 way ..... BW ......... Jib boom up/down ................... 19-21 ft-lbs / 25.8 - 28.6 Nm
2 Check valve ...................................... BV ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
3 Check valve ...................................... BQ ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
4 Flow control valve ............................ BO ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
5 Flow control valve ............................ BK ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
BW
1
BV
2
BQ
3
BO
4
BK
5
4 - 54 Z-60/34 Part No. 75861

MANIFOLDS
Part No. 75861 Z-60/34 4 - 55

MANIFOLDS
8-10
Brake / Two Speed Manifold Components
The brake / Two speed manifold is mounted on the engine side bulkhead..
Index Schematic
1 Solenoid valve, 2 position 3 way ... DA ........... Releases brakes ............................. 20-25 ft-lbs / 37-34 Nm
2 Solenoid valve, 2 position 3 way ... DB ........... 2 speed motor shift ........................... 20-25 ft-lbs / 37-34 Nm
3 Orifice, 0.042 inch / 1.066 mm ....... DC ........... Controls flow to tank
4 Check valve .................................... DD ........... One way flow .................................... 10-12 ft-lbs / 14-16 Nm
1 2
DA
4 DD
DB
DC
4 - 56 Z-60/34 Part No. 75861

MANIFOLDS
8-11
Brake / Two Speed Manifold Components
The brake / Two speed manifold is mounted on the engine side bulkhead.
Index Schematic
1 Solenoid valve, 2 position 3 way .... EA ........... Releases brakes .............................. 47-52 ft-lbs / 64-70 Nm
2 Solenoid valve, 2 position 3 way .... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm
3 Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm
4 Orifice, 0.042 inch / 1.066 mm ....... ED ........... Controls flow to tank
1 2
EA EB
ED
4
EC
3
Part No. 75861 Z-60/34 4 - 57

MANIFOLDS
8-12
Traction Manifold Components, 2WD
The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Check valve ....................................... FA ......... Divider bypass circuit ........................ 30-35 ft-lbs / 41-47 Nm
2 Check valve ....................................... FB ......... Divider bypass circuit ........................ 30-35 ft-lbs / 41-47 Nm
3 Flow Divider / Combiner Valve .......... FC ......... Controls flow to drive motors in
forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
4 Orifice, 0.079 in / 2.01 mm ................ FD ......... Drive circuit
5 Orifice, 0.079 in / 2.01 mm ................ FE ......... Drive circuit
6 Relief valve, 300 psi / 20.6 bar .......... FF ......... Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm
7 Diagnostic nipple ............................... FG ........ Testing
8 Shuttle valve, 3 position 3 way .......... FH ......... Charge pressure, hot oil shuttle ........ 30-35 ft-lbs / 41-47 Nm
9 Diagnostic nipple ............................... FI .......... Testing
4 - 58 Z-60/34 Part No. 75861

MANIFOLDS
6 FI
FH FA
5 1
7 FB
1
FG
6 FC
FF 2
5
FE
4 FD
Part No. 75861 Z-60/34 4 - 59

MANIFOLDS
8-13
Index Schematic
1 Relief Valve, 280 psi / 19.3 bar ......... TT ......... Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
2 Flow Divider / Combiner Valve .......... WW ....... Controls flow to drive motors in
forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
3 Check Valve, 5 psi / 0.34 bar ............ SS ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4 Check Valve, 5 psi / 0.34 bar ............ XX ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5 Shuttle Valve, 3 position 3 way ......... UU ........ Controls flow to drive motors in
forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm
6 Orifice Plug, 0.07 inch / 1.78 mm ...... VV ......... Equalizes flow across flow
divider/combiner valve C
4 - 60 Z-60/34 Part No. 75861

MANIFOLDS
1
TT
WW
2
SS
3
XX
4
UU
5
VV
6
Part No. 75861 Z-60/34 4 - 61

MANIFOLDS
8-14
Index Schematic
1 Diagnostic fitting ................................ GA ........ Testing
2 Relief valve, 250 psi / 17.2 bar .......... GB ........ Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm
3 Check valve, 5 psi / 0.34 bar ............. GC ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
4 Flow divider/combiner valve .............. GD ........ Controls flow to flow
divider/combiner
valves GI and GO ....................... 90-100 ft-lbs / 120-133 Nm
5 Check valve, 5 psi / 0.34 bar ............. GE ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
6 Check valve, 5 psi / 0.34 bar ............. GF ........ Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm
7 Shuttle valve ...................................... GG ........ Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 67-73 Nm
8 Check valve, 5 psi / 0.34 bar ............. GH ........ Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm
9 Flow divider/combiner valve .............. GI .......... Controls flow from steer end
drive motors in forward
and reverse ................................. 90-100 ft-lbs / 120-133 Nm
10 Check valve, 5 psi / 0.34 bar ............. GJ ......... Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
2 gpm / 7.6 L/min .............................. GK ........ Equalizes pressure on both sides
of flow divider/combiner valve GI ...... 30-35 ft-lbs / 41-47 Nm
2 gpm / 7.6 L/min .............................. GL ......... Equalizes pressure on both sides
of flow divider/combiner valve ........... 30-35 ft-lbs / 41-47 Nm
2 gpm / 7.6 L/min .............................. GM ........ Equalizes pressure on both sides
of flow divider/combiner valve GO .... 30-35 ft-lbs / 41-47 Nm
14 Check valve, 5 psi / 0.34 bar ............. GN ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
15 Flow divider/combiner valve .............. GO ........ Controls flow from non-steer end
and reverse ................................. 90-100 ft-lbs / 120-133 Nm
4 - 62 Z-60/34 Part No. 75861

MANIFOLDS
1 2 3 4
GA GB GC
GO
16
15
GN STEER END
GM
14
GL
13
GK
12
GJ
11
GI
10
GD
5
GE
6
GH GG GF
9 8 7 NON-STEER END
Part No. 75861 Z-60/34 4 - 63

MANIFOLDS
8-15
Index Schematic
1 Relief valve, 280 psi / 19.3 bar ......... HA ........ Charge pressure circuit .................... 55-60 ft-lbs / 74-81 Nm
2 Flow divider/combiner valve ............. HB ........ Controls flow to non-steer end

and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3 Check valve ....................................... HC ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 74-81 Nm
4 Check valve ....................................... HD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
5 Check valve ....................................... HE ........ Non-steer end drive motor circuit . 80-90 ft-lbs / 108-122 Nm
6 Flow divider/combiner valve ............. HF ......... Controls flow to flow

divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
7 Orifice, 0.040 inch / 1 mm HG Equalizes pressure on both sides

of flow divider/combiner valve 6
8 Shuttle valve, 3 position 3 way ......... HH ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump .......................... 55-60 ft-lbs / 95-100 Nm
9 Check valve ....................................... HI .......... Steer end drive motor circuit .......... 55-60 ft-lbs / 95-100 Nm
10 Check valve ....................................... HJ ......... Steer end drive motor circuit ........ 80-90 ft-lbs / 108-122 Nm
11 Orifice, 0.040 inch / 1 mm .................. HK ........ Equalizes pressure on both sides

12 Flow divider/combiner valve ............. HL ......... Controls flow to steer end

and reverse ................................... 80-90 ft-lbs / 108-122 Nm
13 Check valve ....................................... HM ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
14 Orifice, 0.040 inch / 1 mm .................. HN ........ Equalizes pressure on both sides

4 - 64 Z-60/34 Part No. 75861

MANIFOLDS
Part No. 75861 Z-60/34 4 - 65

MANIFOLDS
8-16 4 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments, direction. Note the pressure reading on the
Traction Manifolds pressure gauge.
5 Turn the engine off, and remove the hot oil
How to Adjust the Hot Oil Shuttle shuttle relief valve cap.
Relief Valve 2WD Traction Manifold
(item FF before serial number 4551)
Note: The pressure differential between the charge
(item TT after serial number 4550)
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive 4WD Traction Manifold
manifold) is necessary to return hot oil from the (item GB).
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be 6 Adjust the internal hex socket clockwise to
maintained at 40 psi / 14.5 bar. increase the pressure or counterclockwise to
decrease the pressure. Install the valve cap.
Note: The following procedure will require two
6 Repeat steps 4 and 5 until the pressure reading
people.
on the guage is 40 psi / 2.8 bar less than the
1 Open the engine side turntable cover and pressure reading at the pump.
connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2 Start the engine from the platform controls and
allow the engine to run at high idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 50 bar pressure gauge to the
diagnostic nipple located on the traction
manifold.
Note: The traction manifold is located under the
non-steer end chassis cover.
4 - 66 Z-60/34 Part No. 75861

MANIFOLDS
8-17
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 ....................................................... Directional control
Part No. 75861 Z-60/34 4 - 67

MANIFOLDS
8-18 6 Remove the heim joint retaining fastener from

the axle.
Directional Valve Linkage
7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
How to Set Up the Oscillate the machine is completely level.
Directional Valve
8 Verify that the ground and drive chassis are
Note: Adjustment of the oscillate directional valve completely level.
linkage is only necessary when the linkage or
9 Adjust the heim joint until the hole lines up with
valve has been replaced.
the retaining fastener hole in the axle.
1 Lower the boom to the stowed position. 10 Install the heim joint to the axle and tighten the
2 Use a "bubble type" level to be sure the floor is jam nut.
completely level. 11 Check to be sure the drive chassis is
Tip-over hazard. Failure to completely level.
perform this procedure on a level 12 Measure the distance between the drive
floor could compromise the chassis and the non-steer axle on both sides
stability of the machine resulting in (from the inside of the drive chassis).
the machine tipping over.
Note: If the distance is not equal and the
3 Check the tire pressure in all four tires and add adjustment to the linkage was completed with the
air if needed to meet specification. ground and drive chassis level, repeat steps 6
Note: The tires on some machines are foam-filled through 11 OR consult Genie Industries Service
and do not need air added to them. Department.
4 Remove the drive chassis cover from the non-

steer end of the drive chassis.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
4 - 68 Z-60/34 Part No. 75861

MANIFOLDS
8-19 7 Locate the relief valve (figure a) on the

directional valve.
Valve Adjustments - Oscillate
8 Loosen the jam nut.
Relief Valve
9 Adjust the valve. Turn it clockwise to increase
How to Adjust the Oscillate Relief the pressure or counterclockwise to decrease
Valve Pressure the pressure. Tighten the jam nut.
Tip-over hazard. Do not adjust the
Note: The following procedure will require two
relief valve higher than specified.
people.
10 Manually activate the valve again to confirm the
1 Remove the drive chassis cover from the non- valve pressure.
steer end of the drive chassis.
11 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
gauge to the diagnostic nipple located near the
oscillate directional valve. 12 Install the cover on the non-steer end of the
drive chassis.
3 Disconnect the directional valve linkage, by
removing the heim joint and retaining fastener
from the axle.
4 Start the engine from the ground controls. Move
the engine idle toggle switch to the high idle
position.
5 With the engine running in high rpm, manually
activate the valve and observe the pressure
reading on the pressure gauge. Refer to
Specifications, Hydraulic Component a
Specifications.
a relief valve
Part No. 75861 Z-60/34 4 - 69

MANIFOLDS
8-20
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
1 Shuttle valve 2 position 3 way ........ CA ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ..................... CB ........... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ..................... CC ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
1 2 3
CB
123
12345
123
123
12345
12345
MM
12345 CC
123456
123456
123456
123456
NN
123456
CB
CA CC
123456
123456
123456
LL
123456
CA
4 - 70 Z-60/34 Part No. 75861

MANIFOLDS
8-21
Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
1 Pilot Operated Directional valve,

2 position 3 way ............................ CBA .......... Activates generator ...................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc,
0.031 inch / 0.79 mm ..................... CBB .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 3 way .. CBC ......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve,
280 psi @ 3.5 gpm / 19.3 bar @
13.2 L/min ...................................... CBD ......... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Pressure switch 200 psi / 18.6 bar CBE .......... Generator relay switch ................................ 16 ft-lbs / 22 Nm
6 Connector fitting ...................................................................................................................... 11 ft-lbs / 15 Nm
7 Check valve ................................... CBF .......... Prevents oil flowing into generator .. 35-40 ft-lbs / 47-54 Nm
Part No. 75861 Z-60/34 4 - 71

MANIFOLDS
8-22 Valve Coil Resistance

Valve Coils Specifications
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil. Zero resistance or infinite that your air temperature increases or decreases
resistance indicates the coil has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Description Specification

resistance values outside specification can
produce erratic operation. When coil resistance Proportional solenoid valve, 12V DC 6.3 Ω
decreases below specification, amperage (schematic items AB, AC and AG)
increases. As resistance rises above specification, Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 Ω
voltage increases. (schematic items H, I)
While valves may operate when coil resistance is Solenoid valve, 3 Position, 4 Way, 10V DC 6.3 Ω
outside specification, maintaining coils within (schematic items A, B, C, F, J, AK)
specification will help ensure proper valve function
over a wide range of operating temperatures. Proportional solenoid valve, 12V DC 3.7 Ω
(schematic items HM, HO and HR)
Solenoid valve, 2 Position, 3 Way 10V DC 6.3 Ω
(schematic items IJ, IK)
injury. Remove all rings, watches Solenoid valve, 3 Position, 4 Way 10V DC 5Ω
and other jewelry. (schematic items HA, HC, HD, HE, HU)
Note: If the machine has been in operation, allow Solenoid valve, 3 Position, 4 Way 10V DC 6.3 Ω
the coil to cool at least 3 hours before performing (schematic items HF)
this test.
Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 Ω
1 Tag and disconnect the wiring from the coil to (schematic items BA, BB, DA, DB)
be tested.
Solenoid valve, 2 Position, 3 Way, 10V DC 5Ω
2 Test the coil resistance using a multimeter set (schematic items BE, EA, EB)
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table. Solenoid valve, 2 Position, 3 Way, 12V DC 8Ω
(schematic items BP, BW)
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
4 - 72 Z-60/34 Part No. 75861

MANIFOLDS
How to Test a Coil Diode

a
Genie incorporates spike-suppressing diodes in all COIL AMMETER
of its directional valve coils except proportional e

valves and coils with a metal case. Properly
b
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes d - c
naturally occur within a function circuit following the
+
interruption of electrical current to a coil. Faulty 10 W 9V
diodes can fail to protect the electrical system, RESISTOR BATTERY
resulting in a tripped circuit breaker or component
d
damage.
+
c
-
with electrically charged circuits a multimeter or ammeter
b diode
c 9V DC battery
injury. Remove all rings, watches d 10ΩΩ resistor
and other jewelry. e coil
1 Test the coil for resistance. See How to Test a Note: Dotted lines in illustration indicate a
Coil. reversed connection as specified in
step 6
2 Connect a 10Ω Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the 4 Connect the negative lead to the other terminal
other end of the resistor to a terminal on the on the coil.
coil. Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
Ω
Resistor, 10Ω end of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
Note: The battery should read 9V DC or more battery. Note and record the current reading.
when measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
3 Set a multimeter to read DC current.
reading.
Note:The multimeter, when set to read DC current,
Result: Both current readings are greater than
should be capable of reading up to 800 mA.
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 75861 Z-60/34 4 - 73

Turntable Rotation Components

9-1 2 Secure the turntable from rotating with the
turntable rotation lock.
Turntable Rotation Assembly
Crushing hazard. The machine
could tip over when the turntable
How to Remove the Turntable rotation assembly is removed if
Rotation Assembly the turntable rotation lock is not in
the locked position.
the O-ring (if equipped) on the fitting and/or the 3 Tag, disconnect and plug the hydraulic hoses
hose end must be replaced. All connections must from the turntable rotation motor manifold. Cap
be torqued to specification during installation. the fittings on the manifold.
Note: Perform this procedure with the machine on a burn skin. Loosen hydraulic
firm and level surface. connections very slowly to allow
1 Raise the secondary boom until the platform gradually. Do not allow oil to squirt
end of the lower secondary boom arm is or spray.
approximately 8 feet / 2.4 m off the ground.
4 Attach a lifting strap from an overhead crane or
other suitable lifting device to the turntable
rotator assembly.
5 Remove the turntable rotation assembly
mounting fasteners.
6 Carefully remove the turntable rotation
assembly from the machine.
Crushing hazard. The turntable
unlocked locked rotation assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
4 - 74 Z-60/34 Part No. 75861

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 1 Be sure that both bearings are packed
them. with clean, fresh grease.
2 Block the non-steering wheels and place a 2 Place the large inner bearing into the rear
lifting jack of ample capacity under the steer of the hub.
axle.
3 Press the bearing seal evenly into the hub
3 Raise the machine 6 inches / 15 cm and place until it is flush.
blocks under the chassis for support.
4 Slide the hub onto the yoke spindle.
Crushing hazard. The machine
may fall if not properly supported.
not apply excessive force or
4 Remove the lug nuts. Remove the tire and damage to the lip of the seal may
wheel assembly. occur.
5 Remove the dust cap, cotter pin and 5 Place the outer bearing into the hub.
castle nut.
6 Install the washer and castle nut.
Note: Always use a new cotter pin when installing
a castle nut.
seat the bearing.
6 Pull the hub off the spindle. The washer and Note: Rotate the hub by hand while torquing the
outer bearing should fall loose from the hub. castle nut to make sure the bearings seat properly.
7 Place the hub on a flat surface and gently pry
8 Loosen the castle nut one turn, and then torque
the bearing seal out of the hub.
to 35 ft-lbs / 47 Nm.
8 Remove the rear bearing.
9 Install a new cotter pin. Bend the cotter pin
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 Sepecifications, Machine
Specifications.
Part No. 75861 Z-60/34 4 - 75

AXLE COMPONENTS
10-2 3 Tag, disconnect and plug the oscillating axle

Oscillate 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 the oil pressure to dissipate
adjustable. gradually. Do not allow oil to squirt
or spray.
How to Remove an Oscillating 4 Remove the pin retaining fasteners from the
Axle Cylinder rod-end pivot pin.
Note: Perform this procedure on a firm, level 5 Use a soft metal drift to remove the pin.
surface with the boom in the stowed position. 6 Attach a lifting strap from an overhead crane to
Note: When removing a hose assembly or fitting, the barrel end of the oscillating cylinder.
the O-ring (if equipped) on the fitting and/or the 7 Remove the pin retaining fasteners from the
hose end must be replaced. All connections must barrel-end pivot pin.
Refer to Specifications, Hydraulic Hose and Fitting 8 Use a soft metal drift to remove the pin.
Torque Specifications. Crushing hazard. The oscillate
1 Rotate the turntable until the boom is between cylinder may become unbalanced
the steer tires. and fall if not properly supported
2 Remove the fasteners from drive chassis cover
at the steer end. Remove the cover. 9 Remove the oscillate cylinder from the machine.
Crushing hazard. The oscillate
cylinder could become unbalanced
and fall if not properly supported
when it is removed from the
machine.
4 - 76 Z-60/34 Part No. 75861

Generators
11-1 5 Connect the positive and negative leads from a
multimeter of sufficient capacity to the electrical
Adjustments - Hydraulic outlet at the generator.
Generator Note: The multimeter, when set to read AC
voltage, should be capable of reading up to 125V
How to Adjust the 3000/3500W AC.
Generator Voltage (prior to serial Result: The reading on the multimeter should be
number 10283) 112 to 118V AC.
Bodily injury hazard. Spraying Result: If the reading on the multimeter is not
hydraulic oil can penetrate and 112 to 118V AC, proceed to step 6.
6 Turn the key switch to the off position.
the oil pressure to dissipate 7 Use a wrench to loosen the jam nut and adjust
gradually. Do not allow oil to squirt the generator flow regulator valve (item AM).
or spray.
injury. Remove all rings, watches a
and other jewelry.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Disconnect all electrical tools from the machine. a flow regulator
2 Start the engine from the platform controls. 8 Adjust the hex socket screw. Turn it clockwise
3 Press the generator select switch. to increase the voltage or counterclockwise to
decrease the voltage. Tighten the jam nut while
4 Connect an electrical tool, which does not draw holding the adjustment screw in place.
more than 15A, to the electrical outlet at the
platform controls and run the tool at full speed. Component damage hazard.
Failure to adjust the generator as
instructed may result in damage to
the generator or other electrical
equipment. Do not adjust the
generator to other than specified.
9 Repeat steps 2 through 5 to confirm the
generator AC voltage.
Part No. 75861 Z-60/34 4 - 77

How to Purge the Hydraulic Line

on the MTE Generator (from
serial number 10283)
and other jewelry.
Note: This procedure should be performed if the
hydaulic line to the generator has been removed.
Note: Perform this procedure with the machine on a

firm, level surface.
1 Locate the blue purge wire with the male spade
connector from the MTE generator harness.
2 Connect a jumper wire of sufficient length from
the positive battery terminal to the spade
connector on the purge wire.
3 Start the engine and turn on the generator. Allow
the generator to run for three minutes.
4 Turn off the generator and turn off the engine.
5 Remove the jumper wire from the positive
battery terminal and disconnect from the purge
wire.
6 Start the engine and turn on the generator. Using
a digital multimeter check the voltage at the
outlet.
Result: The generator produces a voltage ±10%
of rated output. The generator is ready for use.
Result: The generator output voltage is outside
the ±10% voltage range. Repeat the procedure
4 - 78 Z-60/34 Part No. 75861

June 2015 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie Z-60/
34 Operator’s Manual.
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.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each
from movement.
repair procedure with the machine in the
following configuration: Electrocution/burn hazard. Contact
• Machine parked on a firm, level surface with electrically charged circuits
• Boom in stowed position
• Turntable rotated with the boom between and other jewelry.
the non-steer wheels
• Turntable secured with the turntable hydraulic oil can penetrate and
rotation lock burn skin. Loosen hydraulic
• Key switch in the off position with the connections very slowly to allow
key removed the oil pressure to dissipate
• Wheels chocked gradually. Do not allow oil to
squirt or spray.
• All external AC power disconnected
from the machine Note: Perform all troubleshooting on a firm level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 75861 Z-60/34 5-1

Section 5 • Fault Codes June 2015
FAULT CODES
Fault Code Chart - 3 Determine the error source: The red LED
indicates the error source and will flash two
Control System separate codes. The first code will indicate
the first digit of the two digit code, flashing
How to Retrieve Control once per second. It will then pause for 1.5
seconds and flash the second digit once per
System Fault Codes 0.5 second.
Note: At least one fault code is present when the
Note: When the red LED is flashing the code, the
alarm at the platform controls produces two short
yellow LED will be on solid.
beeps every 30 seconds for 10 minutes.
4 Determine the error type: The yellow LED
Note: Perform this procedure with the engine off,
indidates the error type and will flash two
the key switch turned to platform controls and the
separate codes. The first code will indicate
red Emergency Stop button pulled out to the on
the first digit of the two digit code, flashing
position at both the ground and platform controls.
once per second. It will then pause for 1.5
1 Open the platform control box lid. seconds and 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.
5 Use the fault code table on the following
pages to aid in troubleshooting the machine
and other jewelry.
by pinpointing the area or component
2 Locate the red and yellow fault LEDs on the affected.
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-60/34 Part No. 75861

FAULT CODES
Error Source Error Type Condition Solution

ID Name ID Name
21 Boom 1 Joystick 11 Function is inoperative
Value at 5V Cycle power off,
(primary boom up/ 12 until joystick is
Value too high then on and
down) 15 calibrated. Alarm
Value too low problem should be
16 sounds indicating
Value at 0V corrected.
fault.
Function is inoperative
17 Not calibrated until joystick is Calibrate joystick
calibrated.
Initiate 1-second beep Self-clearing.
18 Just calibrated
of alarm. (transient)
22 Boom 1 directional Valve is operating Cycle power off,
valves outside of operational then on and
21 Fault
limits. Alarm sounds problem should be
indicating fault. corrected.
23 Boom 1 flow Valve is operating Cycle power off,
control valve 12 Value too high outside of operational then on and
15 Value too low limits. Alarm sounds problem should be
Normal function Calibrate valve
17 Not calibrated
except threshold for thresholds
one or both directions Self-clearing.
18 Just calibrated
is zero. (transient)
31 Boom 2 Joystick 11 Value at 5V Joystick is operating Cycle power off,
(secondary boom 12 Value too high outside of operational then on and
up/down or 15 Value too low limits. Alarm sounds problem should be
primary boom 16 Value at 0V indicating fault. corrected.
extend/retract) Function is inoperative
calibrated.
Initiate 1 second beep Self-clearing.
18 Just calibrated
32 Boom 2 directional Valve is operating Cycle power off,
valves outside of operational then on and
21 Fault
Continued on next page
Part No. 75861 Z-60/34 5-3

FAULT CODES

ID Name ID Name
33 Boom 2 flow Valve is operating Cycle power off,
control valve 12 Value too high outside of operational then on and
Normal function
except threshold for Calibrate valve
17 Not calibrated
one or both directions thresholds
is zero.
Self-clearing.
18 Just calibrated
(transient)
41 Turntable rotate 11 Value at 5V Joystick is operating Cycle power off,
joystick 12 Value too high outside of operational then on and
16 Value at 0V indicating fault. corrected.
Function is inoperative
calibrated.
18 Just calibrated
42 Turntable rotate Valve is operating Cycle power off,
directional valves outside of operational then on and
21 Fault
43 Turntable rotate Valve is operating Cycle power off,
flow control valve 12 Value too high outside of operational then on and
17 Not calibrated
except threshold for thresholds.
18 Just calibrated
44 Drive enable Drive enable function Cycle power off,
toggle switch is inoperative. then on and
21 Fault
problem should be
corrected.
5-4 Z-60/34 Part No. 75861

FAULT CODES

ID Name ID Name
51 Drive joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
15 Value too low zero and neutral. controller with
16 Value at 0V Alarm sounds problem corrected.
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate joystick
zero and neutral.
18 Just calibrated
53 Drive flow valve Limited speed and
(EDC) direction frozen at Power up
12 Value too high
zero and neutral. controller with
15 Value too low
Alarm sounds problem corrected.
indicating fault.
17 Not calibrated
except threshold for thresholds
18 Just calibrated
54 Drive brake valve Limited speed and
direction frozen at Power up
21 Fault zero and neutral. controller with
indicating fault.
55 High speed drive Motor speed frozen in
Power up
motor Valve the low state. Alarm
21 Fault controller with
sounds indicating
problem corrected.
fault.
61 Steer joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
15 Value too low zero and neutral. controller with
16 Value at 0V Alarm sounds problem corrected.
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate Joystick
zero and neutral.
18 Just calibrated
62 Steer directional Limited speed and
valves direction frozen at Power up
21 Fault zero and neutral. controller with
indicating fault.
Part No. 75861 Z-60/34 5-5

FORD LRG-425 FAULT CODES
Ford LRG-425 EFI Engine 5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
Fault Codes times. After the fault codes, the check engine
The ECM constantly monitors the engine by the light will blink a code 123 three times again
use of sensors on the engine. The ECM also indicating the end of the stored codes.
uses signals from the sensors to initiate
Note: If any fault codes are present, the ECM will
sequential fuel injection and make constant and
blink a three digit code three times for each code
instantaneous changes to ignition timing, fuel
stored in memory. It will blink the first digit of a
delivery and throttle position to maintain the
three digit code, pause, blink the second digit,
engine's running condition at its highest efficiency
pause, and then blink the third digit. For example:
while at the same time keeping exhaust
the check engine light blinks 5 consecutive
emissions to a minimum. When a sensor fails or
times, blinks 3 times and then 1 time. That would
returns signals that are outside of set
indicate code 531.
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor Note: Once a fault code has been retrieved and
and will turn on the Check Engine Light. the repair has been completed, the ECM memory
must be reset to clear the fault code from the
Note: Perform this procedure with the key switch
ECM. Refer to, How to Clear Engine Fault Codes
in the off position.
from the ECM.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of How to Clear Engine Fault
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.
3 Quickly activate and release the start toggle
locate the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from
4 Move and hold the run/test toggle switch to
the battery for a minimum of 5 minutes.
the test position.
Result: The check engine light should turn on.
Contact with electrically charged
The check engine light should begin to blink.
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
5-6 Z-60/34 Part No. 75861

Code Problem Cause Solution
Closed Loop Multiplier Heated Oxygen Sensor wiring and/or

111
Repair wiring and/or connections OR replace
High (LPG) connections open or shorted OR sensor is faulty sensor OR repair vacuum and exhaust leaks.
OR there are vacuum leaks or exhaust leaks.
112
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 1) open or shorted OR sensor is faulty.
Repair wiring and/or connections OR
replace sensor.
113
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 2) open or shorted OR sensor is faulty.
The post cat Heated Oxygen Sensor wiring

Post-cat oxygen and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114 sensor open sensor is cold, non-responsive or inactive for the post cat oxygen sensor.
60 seconds or longer.
Heated Oxygen Sensor wiring and/or Repair wiring and/or connections OR replace
connections open or shorted OR sensor is sensor OR repair any vacuum and exhaust leaks
Closed Loop Multiplier
121 High (Gasoline)
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
OR test the fuel pressure OR clean or replace the
fuel injectors.
injectors need cleaning or replacing.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
122
Closed Loop Multiplier or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low (Gasoline) fuel injectors are stuck open OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or

connections open or shorted OR sensor is
124
Closed Loop Multiplier
sensor OR replace fuel OR test and repair the
Low (LPG) faulty OR fuel quality is poor OR fuel system
fuel system components.
components may be faulty.
133 Gasoline cat monitor
Repair exhaust leaks OR there is an emissions

134
There are exhaust leaks OR the catalyst system
LPG cat monitor efficiency is below the acceptable level. compliance issue. Contact Ford Power Products
for assistance.
135 NG cat monitor

connections open or shorted OR sensor is Repair heated oxygen sensor wiring and/or
Adaptive Lean Fault -
141
faulty OR there are vacuum or exhaust leaks connections OR replace sensor OR repair
High Limit (Gasoline) OR one or more fuel injectors faulty or stuck vacuum and exhaust leaks OR test the fuel
closed OR fuel quality is poor OR fuel pressure OR clean or replace the fuel injectors.
pressure is too low.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
Adaptive Rich Fault -
142
or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low Limit (Gasoline) fuel injectors are stuck closed OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

connections open or shorted OR sensor is
143
Adaptive Learn High sensor OR repair any vacuum and exhaust
faulty OR there are vacuum leaks or exhaust
(LPG) leaks OR replace fuel OR test and repair the
leaks OR fuel quality is poor OR fuel system
fuel system components.
Engine wire harness may have an intermittent Repair short in engine wire harness
Adaptive Learn Low
144 (LPG)
short to 5V DC or 12V DC OR fuel system
OR test and repair the fuel system
components.
Part No. 75861 Z-60/34 5-7

161
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair
System Voltage Low
battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
162
Alternator is overcharging the battery when
System Voltage High Repair or replace the alternator.
engine RPM is greater than 1500 rpm.
IAT sensor wiring and/or connections are open or

211 IAT High Voltage shorted OR sensor is faulty OR engine intake air
temperature is too cold.
sensor OR direct warmer air into air intake.
IAT sensor wiring and/or connections are open or

212 IAT Low Voltage shorted OR sensor is faulty OR engine intake air
temperature is too hot.
sensor OR direct cooler air into air intake.
Air intake temperature is greater than 200° F with

213
IAT Higher Than
the engine greater than 1000 rpm OR air intake
Expected (1)
system has leaks OR IAT sensor is faulty. Check air intake system for damage and proper
routing of air intake components OR replace the
Air intake temperature is greater than 210° F with IAT sensor.
IAT Higher Than
214 Expected (2)
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair sensor
215 Oil Pressure Low and/or connections open or shorted OR engine wiring and/or connections OR fill engine oil level
to specification.
oil level too low.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR

221 CHT/ECT High Voltage sensor wires and/or connections open or shorted
OR sensor is faulty.
repair open or shorted wiring to sensor OR
replace sensor.
Engine cooling system is malfunctioning and
222 CHT/ECT Low Voltage overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240° F. Repair engine cooling system problems OR
223
CHT Higher Than repair open or shorted wiring to sensor OR
Expected (1) overheating the engine OR sensor wires and/or replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty specification.
Coolant temperature at the cylinder head is 250° F.

224
CHT Higher Than
Expected (2) overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
231
Open or shorted wiring and/or connections to MAP
MAP High Pressure
sensor OR sensor is faulty.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
232
Open or shorted wiring and/or connections to MAP
MAP Low Voltage
sensor OR sensor is faulty.
234 BP High Pressure MAP sensor is faulty OR ECM is faulty.

Replace MAP sensor OR replace the ECM.
235 BP Low Pressure MAP sensor is faulty OR ECM is faulty.
Crankshaft position sensor wiring and/or

242 Crank Sync Noise connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Crankshaft position sensor wiring and/or Be sure system ground connections are in place
243 Never Crank Synced
At Start
connections open or shorted OR there is a poor
and secure OR repair wiring and/or connections
to sensor OR replace sensor.
Crankshaft position sensor wiring and/or

244 Camshaft Sensor Loss connections open or shorted OR there is a poor
5-8 Z-60/34 Part No. 75861


Camshaft position sensor wiring and/or Be sure system ground connections are in place
245 Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and/or connections
system ground connection OR sensor is faulty. to sensor OR replace sensor.
253
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock sensor
Knock Sensor Open
shorted OR sensor is faulty. OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR repair
254 Excessive Knock Signal shorted OR there is excessive engine vibration
OR sensor is faulty.
wiring and/or connections to knock sensor OR
replace knock sensor.
311
Open wiring and/or connections to fuel injector #1
Injector Driver #1 Open
OR fuel injector #1 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #1
Wiring and/or connections to fuel injector #1 is OR replace fuel injector #1 OR replace the ECM.
312 Injector Driver #1 Shorted shorted OR fuel injector #1 is faulty OR
ECM is faulty.
313
ECM is faulty.
315
ECM is faulty.
321
ECM is faulty.
Open wiring and/or connections to fuel pump OR

351
Fuel Pump Loop Open or
fuel pump power shorted to ground OR fuel pump
High Side Short to Ground
is faulty. Repair wiring and/or connections to fuel pump OR
replace fuel pump.
352
Fuel Pump High Side Wiring and/or connections to fuel pump shorted to
Shorted to Power power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not opening

MegaJector Delivery completely OR the line between the MegaJector
353 Pressure Higher Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR
OR MegaJector is faulty. repair the line between the MegaJector and
Fuel pressure too low OR LPG lockoff not opening carburetor OR repair engine cooling system OR
MegaJector Delivery completely OR the line between the MegaJector replace the MegaJector.
354 Pressure Lower Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
The ECM doesn't get any response from the Check CAN circuits for continuity and shorts to
355 MegaJector
Communication Lost
MegaJector, or an incorrect response for 500ms
period or longer.
power or ground and for continuity and repair as
necessary OR replace the MegaJector.
The MegaJector detects voltage greater than 18
361 MegaJector Voltage
Supply High
volts for 5 seconds anytime the engine is cranking
Repair charging system OR replace the
MegaJector.
or running.
The MegaJector detects voltage less than 9.5 volts Repair VBAT power or ground circuit to ECM and
362
MegaJector Voltage
for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair
Supply Low
running. charging system OR replace the MegaJector.
Part No. 75861 Z-60/34 5-9

363 MegaJector Internal The MegaJector detects an internal fault. Open or

Actuator Fault Detection short in power, ground or CAN circuits.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
364 MegaJector Internal The MegaJector detects an internal circuitry failure.
Circuitry Fault Detection Open or short in power, ground or CAN circuits. necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.
MegaJector Internal The MegaJector detects an internal
365 Communication Fault communications failure. Open or short in power,
ground or CAN circuits.
Detection
411
Open wiring and/or connections to ignition
Coil Driver #1 Open
coil #1 OR ignition coil #1 is faulty. Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
412
Wiring and/or connections to ignition coil #1
Coil Driver #1 Shorted
shorted OR ignition coil #1 is faulty
413
Open wiring and/or connections to ignition
Coil Driver #2 Open
coil #2 OR ignition coil #2 is faulty. Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
414
Wiring and/or connections to ignition coil #2
Coil Driver #2 Shorted
shorted OR ignition coil #2 is faulty
511 FPP1 High Voltage
512 FPP1 Low Voltage
513 FPP1 Higher than IVS Limit

If this fault appears on your machine, contact
Not used.
the Genie Industries Service Department.
514 FPP1 Lower than IVS Limit
531 TPS1 (Signal Voltage) High The #1 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
532 TPS1 (Signal Voltage) Low sensor #1 is faulty.
to sensor OR replace throttle position sensor #1.
533 TPS2 (Signal Voltage) High The #2 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
534 TPS2 (Signal Voltage) Low sensor #2 is faulty.
to sensor OR replace throttle position sensor #2.
The throttle position sensor wiring and/or

535 TPS1 Higher than TPS2 connections for either TPS1 or TPS2 open or
Be sure engine harness wiring and connections
are in place and secure OR repair wiring and/or
shorted OR there is a poor system ground
connections to one or both TPS sensors OR
536 TPS1 Lower than TPS2 connection OR one or both throttle position
sensors are faulty.
replace one or both TPS sensors.
Governor actuator is stuck closed OR wiring

537 Throttle Unable to Open and/or connections open or shorted OR
governor actuator is faulty. Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Governor actuator is stuck open OR wiring
538 Throttle Unable to Close and/or connections open or shorted OR
governor actuator is faulty.
Engine harness wiring and/or connections open

545
Repair wiring and/or connections in engine
Governor Interlock Failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
5 - 10 Z-60/34 Part No. 75861

551 Max Governor Speed

Override
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
552 FPP1 Low Voltage sticking open OR there are air leaks between the
throttle body and cylinder head.
operation OR repair any air leaks between the
throttle body and cylinder head.
553 FPP1 Higher than IVS Limit
611 COP Failure
612 Invalid Interrupt
613 A/D Loss

Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
614 RTI 1 Loss secure OR replace ECM.
615 Flash Checksum Invalid
616 RAM Failure
631
External 5V DC Ref
Lower than Expected Engine harness wiring and/or connections open Locate and repair any engine harness wiring
or shorted to ground OR there is a faulty engine damage or shorts OR locate and troubleshoot or
632
External 5V DC Ref sensor OR ECM is faulty. repair faulty engine sensor OR replace ECM.
Higher than Expected
655 RTI2 Loss Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
656 RTI3 Loss
secure OR replace ECM.
Part No. 75861 Z-60/34 5 - 11

FORD DSG-423 FAULT CODES
Ford DSG-423 EFI Engine 5 Continue to hold the run/test toggle switch in
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
Fault Codes times. After the fault codes, the check engine
The ECM constantly monitors the engine by the light will blink a code 123 three times again
use of sensors on the engine. The ECM also indicating the end of the stored codes.
uses signals from the sensors to initiate
Note: If any fault codes are present, the ECM will
sequential fuel injection and make constant and
blink a three digit code three times for each code
instantaneous changes to ignition timing, fuel
stored in memory. It will blink the first digit of a
delivery and throttle position to maintain the
three digit code, pause, blink the second digit,
engine's running condition at its highest efficiency
pause, and then blink the third digit. For example:
while at the same time keeping exhaust
the check engine light blinks 5 consecutive
emissions to a minimum. When a sensor fails or
times, blinks 3 times and then 1 time. That would
indicate code 531.
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor Note: Once a fault code has been retrieved and
and will turn on the Check Engine Light. the repair has been completed, the ECM memory
must be reset to clear the fault code from the
Note: Perform this procedure with the key switch
from the ECM.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of How to Clear Engine Fault
the ground control box. Codes from the ECM
controls.
3 Quickly activate and release the start toggle
locate the battery.
4 Move and hold the run/test toggle switch to
the battery for a minimum of 5 minutes.
the test position.
Result: The check engine light should turn on.
Contact with electrically charged
The check engine light should begin to blink.
circuits could result in death or
battery.
5 - 12 Z-60/34 Part No. 75861

Code Description Code Description
111 CL (closed loop) high LPG 212 IAT (intake air temperature) low voltage
112 EGO open / lazy pre-cat 1 213 IAT (intake air temperature) higher than expected 1
113 EGO open / lazy pre-cat 2/post-cat 1 214 IAT (intake air temperature) higher than expected 2
114 EGO open / lazy post-cat 1 215 Oil pressure low
115 EGO open / lazy post-cat 2 221 ECT/CHT (engine/cylinder head temp) high voltage
121 CL (closed loop) high gasoline bank 1 222 ECT/CHT (engine/cylinder head temp) low voltage
122 CL (closed loop) low gasoline bank 1 223 CHT higher than expected 1
124 CL (closed loop) low LPG 224 CHT higher than expected 2
133 Gasoline catalyst monitor 1 225 ECT higher than expected 1
134 LPG catalyst monitor 226 ECT higher than expected 2
141 AL (adaptive learning) high gasoline bank 1 231 MAP (manifold absolute pressure) high pressure
142 AL (adaptive learning) low gasoline bank 1 232 MAP (manifold absolute pressure) low pressure
143 AL (adaptive learning) high LPG 234 BP (barometric pressure) high pressure
144 AL (adaptive learning) low LPG 235 BP (barometric pressure) low pressure
161 Battery voltage high 242 Crank sync noise
162 Battery voltage low 243 Never crank synced at start
163 AUX analog PD1 high 244 Cam loss
164 AUX analog PD1 low 245 Cam sync noise
165 AUX analog PU3 high 246 Crank loss
166 AUX analog PU3 low 253 Knock 1-2 sensor open 1
167 AUX analog PUD1 high 254 Knock 1-2 excessive signal 1
168 AUX analog PUD1 low
171 AUX analog PUD2 high
181 AUX DIG1 high
182 AUX DIG1 low
183 AUX DIG2 high
184 AUX DIG2 low
185 AUX DIG3 high
186 AUX DIG3 low
211 IAT (intake air temperature) high voltage
Part No. 75861 Z-60/34 5 - 13

261 FP (fuel pressure) high voltage 531 TPS1 (throttle position sensor) high voltage
262 FP (fuel pressure) low voltage 532 TPS1 (throttle position sensor) low voltage
271 FT (fuel temperature) gasoline high voltage 533 TPS2 (throttle position sensor) high voltage
272 FT (fuel temperature) gasoline low voltage 534 TPS2 (throttle position sensor) low voltage
273 FT (fuel temperature) gaseous fuel high voltage 535 TPS1 (throttle position sensor) higher than TPS2
274 FT (fuel temperature) gaseous fuel low voltage 536 TPS1 (throttle position sensor) lower than TPS2
311 Injector loop open OR low-side short to ground 1 537 Unable to reach higher TPS (throttle position sensor)
312 Injector coil shorted 1 538 Unable to reach lower TPS (throttle position sensor)
313 Injector loop open OR low-side short to ground 2 539 TPS 1-2 simultaneous voltages
314 Injector coil shorted 2 541 AUX analog PU1 high
315 Injector loop open OR low-side short to ground 3 542 AUX analog PU1 low
316 Injector coil shorted 3 543 AUX analog PU2 high
321 Injector loop open OR low-side short to ground 4 544 AUX analog PU2 low
322 Injector coil shorted 4 551 Max govern speed override
351 FPump motor loop open OR high-side shorted to ground 552 Fuel rev limit
352 Fpump motor high-side shorted to power 553 Spark rev limit
353 EPR delivery pressure higher than expected 611 COP failure
354 EPR delivery pressure lower than expected 612 Invalid interrupt
355 EPR comm lost 613 A/D loss
359 Fuel run-out longer than expected 614 RTI 1 loss
361 EPR voltage supply high 615 Flash checksum invalid
362 EPR voltage supply low
363 EPR internal actuator fault detection
364 EPR internal circuitry fault detection
365 EPR internal comm fault detection
411 Primary loop open OR low-side short to ground 1
412 Primary coil shorted 1
5 - 14 Z-60/34 Part No. 75861

616 RAM failure 744 PWM5 short to power
631 5VE1 low voltage 761 MIL (malfunction indicator light) control ground short
632 5VE1 high voltage 762 MIL (malfunction indicator light) open
633 5VE2 high voltage 763 MIL (malfunction indicator light) control short to power
634 5VE2 low voltage 771 Tach output ground short
635 5VE1-5VE2 simultaneous out-of-range 772 Tach output short to power
641 Rx inactive 1629 J1939 TSC1 message receipt lost
642 Rx noise 1630 J1939 ETC message receipt lost
643 Invalid packet format
644 Shutdown request
646 CAN Tx failure
647 CAN Rx failure
648 CAN address conflict failure
655 RTI 2 loss
656 RTI 3 loss
711 Relay control ground short
712 Relay coil open
713 Relay coil short to power
714 Fpump relay control ground short
715 Fpump relay coil open
716 Fpump relay coil short to power
721 Start relay control ground short
722 Start relay coil open
723 Start relay coil short to power
731 PWM1-gauge1 open / ground short
732 PWM1-gauge1 short to power
733 PWM2-gauge2 open / ground short
735 PWM3-gauge3 open / ground short For further engine fault code troubleshooting and
diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
741 PWM4 open / ground short Genie part number 119494.
742 PWM4 short to power
743 PWM5 open / ground short
Part No. 75861 Z-60/34 5 - 15

FORD MSG-425 FAULT CODES
Ford MSG-425 Engine Fault 5 Continue to hold the run/test toggle switch in
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
Fault Codes light 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 Note: If any fault codes are present, the ECM will
uses signals from the sensors to initiate blink a three digit code three times for each code
sequential fuel injection and make constant and stored in memory. It will blink the first digit of a
instantaneous changes to ignition timing, fuel three digit code, pause, blink the second digit,
delivery and throttle position to maintain the pause, and then blink the third digit. For example:
engine's running condition at its highest efficiency the check engine light blinks 5 consecutive
while at the same time keeping exhaust times, blinks 3 times and then 1 time. That would
emissions to a minimum. When a sensor fails or indicate code 531.
parameters, the ECM will store a fault code in Note: Once a fault code has been retrieved and
memory that relates to the appropriate sensor the repair has been completed, the ECM memory
and will turn on the Check Engine Light. must be reset to clear the fault code from the
Note: Perform this procedure with the key switch from the ECM.
How to Clear Engine Fault
1 Locate the run/test toggle switch on the side
of the ground control box. Codes from the ECM
controls.
3 Quickly activate and release the start toggle locate the battery.
4 Move and hold the run/test toggle switch to the battery for a minimum of 5 minutes.
the test position.
Result: The check engine light should turn on. Contact with electrically charged
The check engine light should begin to blink. circuits could result in death or
battery.
5 - 16 Z-60/34 Part No. 75861


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

Genie part number
162067
Part No. 75861 Z-60/34 5 - 17


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


Genie part number
162067
5 - 18 Z-60/34 Part No. 75861


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
shorted to ground 1157 CL high gasoline bank2
628 Fpump relay control ground short 1158 CL low gasoline bank2
629 FPump motor high-side shorted to power 1161 AL high LPG
629 Fpump relay coil short to power 1162 AL low LPG
642 5VE1 low voltage 1163 AL high NG
643 5VE1 high voltage 1164 AL low NG
650 MIL open 1165 LPG cat monitor
652 5VE2 low voltage 1166 NG cat monitor
653 5VE2 high voltage 1171 Megajector delivery pressure
higher than expected
685 Relay Coil Open
1172 Megajector delivery pressure
686 Relay Control ground short lower than expected
687 Relay coil short to power 1173 Megajector comm lost
1111 Fuel rev limit
1174 Megajector voltage supply high
1112 Spark rev limit
1175 Megajector voltage supply low
1121 FPP1/2 simultaneous voltages out of
1176 Megajector internal actuator fault
range detection


Genie part number
162067
Part No. 75861 Z-60/34 5 - 19


1177 Megajector internal circuitry fault 1541 AUX analog PUD1 high
detection
1178 Megajector internal comm fault detection
1311 Misfire detected
1551 AUX DIG1 high
1552 AUX DIG1 low
1553 AUX DIG2 high
1554 AUX DIG2 low
1555 AUX DIG3 high
1556 AUX DIG3 low
1511 AUX analog PU1 high
1561 AUX analog PD2 high
1512 AUX analog PU1 low
1562 AUX analog PD2 low
1611 5VE 1/2 simultaneous out of range
1612 RTI 1 loss
1613 RTI 2 loss
1614 RTI 3 loss
1521 CHT higher than expected 1
1615 A/D loss
1522 CHT higher than expected 2
1616 Invalid interrupt
1531 IVS/Brake/Trans-Park interlock failure
1621 Rx Inactive
1622 Rx Noise


Genie part number
162067
5 - 20 Z-60/34 Part No. 75861


1623 Invalid Packet Format 2120 FPP1 invalid voltage and FPP2
disagrees with IVS
1624 Shutdown Request
2121 FPP1 lower than FPP2
1625 Shutdown Request
2122 FPP1 high voltage
1626 CAN Tx failure
2123 FPP1 low voltage
1627 CAN Rx failure
2125 FPP2 invalid voltage and FPP1
1628 CAN addresss conflict failure disagrees with IVS
1629 J1939 TSC1 message receipt lost 2126 FPP1 higher than FPP2
1630 J1939 ETC message receipt lost 2127 FPP2 low voltage
1631 PWM1-Gauge1 open / ground short 2128 FPP2 high voltage
1632 PWM1-Gauge1 short to power 2130 IVS stuck at-idle, FPP1/2 match
1633 PWM2-Gauge2 open /ground short 2131 IVS stuck off-idle, FPP1/2 match
1634 PWM2-Gauge2 short to power 2135 TPS1/2 simultaneous voltages out of
1635 PWM3-Gauge3 open / ground short range
1636 PWM3-Gauge3 short to power 2139 FPP1 lower than IVS limit
1641 Buzzer control ground short 2140 FPP2 lower than IVS limit
1642 Buzzer open 2229 BP high pressure
1643 Buzzer control short to power 2300 Primary Loop Open or Low-side
Short to Ground
1644 MIL control ground short
2301 Primary Coil Shorted
1645 MIL control short to power
2303 Primary Loop Open or Low-side
2111 Unable to reach lower TPS Short to Ground
2112 Unable to reach higher TPS 2304 Primary Coil Shorted
2115 FPP1 higher than IVS limit 2306 Primary Loop Open or Low-side
2116 FPP2 higher than IVS limit Short to Ground


Genie part number
162067
Part No. 75861 Z-60/34 5 - 21

Code Description
Short to Ground
Short to Ground
Short to Ground
Short to Ground
Short to Ground
2618 Tach output ground short
2619 Tach output short to power


Genie part number
162067
5 - 22 Z-60/34 Part No. 75861

June 2015 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
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
gradually. Do not allow oil to squirt
Before Troubleshooting: or spray.
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 75861 Z-60/34 6-1

Section 6 • Schematics June 2015
Wire Connector Legend
C1 DT06-12SC C7: DTP06-4S

CIRCUIT NO. PIN NO.
C1
COLOR
RD C27AUX 1 COLOR CIRCUIT NO. PIN NO. C7
RD/BK C28TTA 2 BK P22BAT 1
RD/WH C29MS 3 WH P23SWBAT 2
WH C30FWD 4 BRN BATGND 3
WH/BK C31REV 5
C1 N/C 4 C7
WH/RD C32BRK 6
BK C33STR 7 GRAY
BK/WH C34SA 8
BK/RD C35RPM 9
BL C36SCC 10
BL/BK C37SCW 11
CABLE #1
BL/WH C132PLI 12
C5-GROUND BOX
C2 DT06-12SD PIN
CIRCUIT NO. FORD DEUTZ PERKINS
COLOR CIRCUIT NO. PIN NO. C2 FUNCTION HARNESS NO. ENGINE ENGINE ENGINE
BL/RD OPTION 1
1
OR C40LS1 2
CIRCUIT NO. COLOR 2 C41RPM OR/BK OR/BK OR/BK
OR/BK C41RPM 3 WH
3 C107AF WH WH
OR/RD P134PWR 4 C1PBU RD-3 GR/WH
4 C45GEN GR/WH GR/WH
GR C46HRN 5 C129DA RD/BK-3
5 R33STR BK BK(14) BK(14)
GR/BK JDALARM 6 C3PBF RD/WH-3
C2 6 C27AUX RD
GR/WH C45GEN 7 C2PBD RD/BK
NC 8 BLACK C5TRR WH/BK-3 -
7 - -
NC 9 C6TRF WH/RD-3
C7PBE BK-3 8 C21IGN-FEH16A WH
NC 10
NC 11 C8PBR BK/WH-3 BK/RD
9 C128RPM-FEH306 BK/RD BK/RD
NC 12 LS PWR BL/WH-3
10 C39LP-FEH674 BL/RD
C13DRE BL/WH-3
C134PWR RD-3 11 VSW WH
C3 DT06-12SA
C14PLU OR-3 12 C127TST GR
COLOR CIRCUIT NO. PIN NO. C15PLD OR/BK-3
C3 13 C108ESL-C24TSPS BL/WH WH WH
RD C1PBU 1
C17JU GR-3 WH/RD WH/RD WH/RD
RD/BK C2PBD 2 14 C26TSR
RD/WH C3PBF 3 C18JD GR/BK-3
15
WH C4TRL 4 P23BATSR RD
16 C25PS WH/BK WH/BK WH/BK
WH/BK C5TRR 5 C27AUX RD-1
WH/RD C6TRF 6 C28TTA RD/BK 17 C21IGN-FEH16A WH
BK C7PBE 7 C3 18
BK/WH C8PBR 8 GREEN
CABLE #3
BK/RD DLITE 9 19
C36STCC BL-1
BL C10SBU 10 WH/BK
C37STC BL/BK-1 20 C31REV WH/BK WH/BK
BL/BK C11SBD 11
A C40LS1 OR-1 21 C30FWD WH WH WH
BL/WH C12SBF 12
22 C34SA BK/WH BK/WH
C4 DT06-12SB 23 C32BRK WH/RD WH/RD WH/RD

C4
COLOR CIRCUIT NO. PIN NO. R43HRN BK 24 C29MS RD/WH RD/WH RD/WH
BL/RD C13DRE 1 C45GEN GR/WH-1
OR C14PLU 2
OR/BK C15PLD 3
4
C32TA WH/RD-1 12VDC TO PLATFORM
OR/RD C133PLA
C32BRK WH/RD-1
GR C17JU 5
P23FB RD C9 FS DT04-4P
GR/BK C18JD 6
GR/WH C19JSV 7
C4 COLOR CIRCUIT NO. PIN NO.
NC 8
NC 9 BROWN BK P22BAT 1
NC 10 WH P24BAT 2
NC 11 RD P25BAT 3 C9
NC 12 N/C 4
6-2 Z-60/34 Part No. 75861

Electrical Symbols Legend
FS1
BLK
BLK
P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START
Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value
Diode Hour meter

TS6
DOWN
UP
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
25A A B C
PULL IN
Fuse
HOLD
AUX MAIN
CR4
with amperage N.O.
Battery separator Control relay contact Fuel or RPM

normally open solenoid
CB1
15A
Starting aid:
glow plug or
Circuit breaker flame ignitor
with amperage Coil
Part No. 75861 Z-60/34 6-3

Hydraulic Symbols Legend
25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size
Solenoid operated 3 position, 2 position, 3 way, shuttle valve

Filter with 4 way, directional valve
bypass valve
relief setting
Check valve
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve
o
Brake
Pump Solenoid operated 2 position,

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

Motor with pressure balancing orifice
bi-directional Counterbalance valve
and flow percentages 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
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Solenoid operated
proportional valve
6-4 Z-60/34 Part No. 75861

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
Part No. 75861 Z-60/34 6-5

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)
6-6 Z-60/34 Part No. 75861

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
Part No. 75861 Z-60/34 6-7

Ford Engine Relay Layout
Ford DSG-423
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A
F6-10A
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
6-8 Z-60/34 Part No. 75861

Diesel Electrical Schematic - View 1

6 - 10
6-9

A B C D E F G H I J K L M N
1
RD/BK
TB41 C2-3 OR/BK
P26ESTP BK BK
LS18
P2 FS1
RD-(FS) C9-3 P25FS RD
2 C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH WH
RD C28TTA RD/BK
TS2 TS6
C134PWR OR/RD
C132PLI BL/WH
P22BAT BK
SEE NOTE 2
TS17
C41RPM OR/BK
ON GLOW
START
L4 TS4
H1 L48 TS1
P3
GENERATOR
HIGH RPM(FS)
PLUG
HORN D39
AUXILIARY
SEE NOTE 2
PUMP
ENGINE
D40
3
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
CB2 TB134
P1 RD TB132
15AMP. RD RD RD
C1-9
TB43
1 3 RD
KS1 TB22
C43HRN GR
C45GEN GR/WH
4 5 TS51 TS52 TS56 TS55
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
GRD
HIGH RPM
LOW RPM
6
START ENGINE
ON GLOW
FUNCTION ENA.
4
AUXILIARY
U33
PUMP
RD
7
PLUG
BK
BK
12 8 TB45
TB27
TB33
CB1
RD
TB20 15AMP. H6 L45 TB23 1 START RELAY

TB35
2 TACHOMETER
TB133 3 START INPUT TB34
TB28 TB24 4 AUX. ON IGN./START
RD 5 GROUND
6 BATTERY MODULE
L2
5 CB3
CR5 CR1
CR2 7 KEY PWR.
U1
BK/RD
20AMP. CR1 CR2
8 KEY BYPASS
NO CR5 NO
9 IGN./FUEL ON
NO 10 ENG. FAULT
TB21
NO CR3
GR/WH-45
OTS
RD-23
RD/BK-28
NO TB25 TB26
G2 G3
6
BK-43
NO CR4
OR/BK-41
RD-27
BK-33
WH-21
PR3
ALTERNATOR CR17 NO PR3
EXCT. NO
RD
WH
CR17 PR1
BK/RD-R4-E.H.
WH-24
WH-24
PR1
12 V BAT. BAT. NO
- PR2 PR2
WH/RD
WH/BK
DC +
NO
+
FB S7
STA.
+
AUX
M2 PUMP STARTER OPS S2 S1 OTS
HM G1 Y29
H2 G6
BK
REGULATOR FAN M1
IND. _ NC NO
7
-
BRN
BRN
OIL PRESSURE GAUGE
STARTER MOTOR
FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
SWITCH
WATER TEMP
OPTION
FLASHING BEACONS
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
IGN./START RELAY
HOUR METER
VOLT METER
OPTION
GENERATOR
AUXILIARY PUMP
HIGH RPM SOLENOID

SWITCH
OIL PRESSURE
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

IN THE STOWED POSITION AND KEYSWITCH "OFF".
2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
6 - 10 Z-60/34 Part No. 75861

Section 6 • Schematics

6 - 11
1
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TB31 TB30
C1P-4 C30EDC+ WH C30EDC+ WH A B

8 15 DRIVE EDC FORWARD
L1
B
J1
C1P-5 C31EDC- WH/BK C31EDC- WH/BK D C

DRE LED BL/RD 16 DRIVE EDC REVERSE
16
H4
TS15
DRE B BL/BK TRAVEL ALARM OPTION

7
TB32
DRIVE ENABLE C1P-6 C32BRK WH/RD C32BRK WH/RD

6 19 BRAKE RELEASE VALVE
Z-60/34
DRE A BL/WH
DRIVE & STEERING
7 20
RKOUT 6 WH 5
TB36 TB37
YOUT 5 BL 4
C
JC3
C1P-11 C37STCC BL/BK C37STCC BL/BK

J1
4 18 STEER RIGHT
PWR 3 OR 13
GND 2 BRN 14 C1P-10 C36STC BL C36STC BL
STEER LEFT
17
1
C3P-6 C6TRF WH/RD
11
C3P-5 C5TRR WH/BK
9
TB4
C3P-4 C4TRL WH
10
C4TRL WH
D
TURNTABLE ROTATE LEFT

.5 R5
C5TRR WH/BK
TS62
TURNTABLE ROTATE RIGHT

TB5
PRI UP/DN & TT ROTATE
7 C6TRF WH/RD TURNTABLE ROTATE

6 FLOW CONTROL
TB6
TB1
R4
YOUT 5 BK 2
7.5
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
UP
TB2
PWR 3 OR 11
Part No. 75861
PRIMARY BOOM
DOWN C2PBD RD/BK
TS61
GND 2 12
J2
BRN PRIMARY BOOM DOWN

E
1
TB3
June 2015
C3PBF RD/WH PRIMARY BOOM

FLOW CONTROL
6
C3P-1 C1PBU RD
C3P-2 C2PBD RD/BK
7
C6-19 RD/BK
C3P-3 C3PBF RD/WH DESCENT ALARM OPTION
8
H3
C3P-12
SECONDARY BOOM UP/DWN
F
14
7
C3P-11
6 13 C105BU BL
SECONDARY BOOM UP
OUT 5 YEL 3 C3P-10
12
JC1
TB10
4
J1
C115BD BL/BK
PWR 3 OR 9 SECONDARY BOOM DOWN
UP
GND 2 BRN 10 SECONDARY BOOM
DOWN C125BF BL/WH SECONDARY BOOM
TS60
1
TB11
FLOW CONTROL
G
TB12
JOYSTICK CONTROL CARD
BRN
1 CABLE #6 4 WH
NCHO
SECONDARY BOOM
TB13
P24FS WH
2 CABLE #6 3 BK OPERATION
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

J3
P24FS WH C4P-1 C13DRE BL/RD C13DRE BL/RD

4
TB43
3
TB40
P26ESTP BK
3 CABLE #7 4 WH NCHO
C2P-2 C40LS1 OR C40LS1 OR PRIMARY BOOM
4 CABLE #7 3 BK OPERATION
H
TB44
CABLE #8 4 WH
NOHC
BOOM RETRACTED
TB46
C46PWR WH 3 BK OPERATION
CR27
CR30
POSITION EXCEPT AS NOTED.

OPTION
NC
NO
2
DRIVE
CABLE #5 WH
NOHC
LIFT/
LS3
TB46
CE
C46PWR WH 1 BK DRIVE ENABLE

I
C3P-8 C8PBR BK/WH

RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
TS63
C8PBR BK/WH
RETRACT
BOOM RETRACT
BOOM
EXTEND
WH
C7PBE BK
NOTE:
BOOM EXTEND
TB7
J
C4P-2 C14PLU OR
UPPLATFORM LEVEL
TB14
DOWN C15PLD OR/BK
TS9
TS59
C4P-3
C14PLU OR
PLAT LEVEL UP
UP PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2P-6 JDALARM GR/BK
K
CR13
C4P-6 C18JD GR/BK

NC
DOWN
TB18
JIB BOOM
UP C4P-5 C17JU GR
TS8
C18JD GR/BK
PLATFORM ROTATE RIGHT / JIB DOWN
TS58
DOWN
JIB BOOM
UP C17JU GR
PLATFORM ROTATE LEFT / JIB UP
TS57
TB17
RIGHT
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
L
TS7
LEFT
WH
C4P-7
C19JSV GR/WH
TB19
AMP
C19JSV GR/WH
7
CR13
6
5
3
4
2
1
Y18
Joystick Adaptor Harness

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
BRN
M
RKOUT
XOUT
YOUT
JIB VALVE
PWR
GND
JIB VALVES
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
RD/BK
OR/BK
BRN
WH
RD
RD
BK
Deutsch
3
1
2
N
5
6
4

6 - 11
6 - 12

6 - 14
6 - 13

1
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2 FUSE 10A
2 C9-1 BK BK-(FS)
FS1
TS48
WH-(FS) C9-2 P24FS WH

WH
RD C28TTA RD/BK
2 C.E. OPTION ONLY TS2
C134PWR OR/RD
C132PLI BL/WH
TS6
P22BAT BK
1
2
WORK LIGHT
WHEN C.E. OPTION IS NOT
DRIVE LIGHT
C41RPM OR/BK
INSTALLED A JUMPER HARNESS TS17
START
ON GLOW
L4 TS4
CONNECTS PIN 4 TO PIN 5
WH
WH
AND PIN 6 TO PIN 7 TS1
L48
PLUG
HIGH RPM(FS)
P3 H1
GENERATOR
LS18 - PLATFORM OVERLOAD
SWITCH HORN D39
ENGINE
PUMP AUXILIARY
C3P-9
D40
3 L30 L30
C1-12
C2-4
TB132 IS WAGO TERMINAL BLOCK 36
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134
BK
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
2 1 3
KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
4 5
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
BK/RD
GRD
4 6
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
FUNCTION ENA.
U33
RD
PLUG
7 D3 PBOX GND
BK
ENGINE
D2
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34
TB28 4 AUX. ON IGN./START
5 RD
TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT
TB21 NO
WH
CR3
NO
C5-3
C5-2
C5-22
D33
C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS CR23
6 NO
TB25 TB26 CR23
NO
G2 G3
C5-13 WH
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1 S1
BK/RD-C5-8
C5-11
12 V BAT. BAT. NO PR2

+ - PR2
DC D52 NO
S2
RD
NO
RD
RD
S7
+
FB
STA. G6
M1 NC
+ Y29
STARTER
7 AUX
M2 PUMP HM G1 S2
S1
BK
REGULATOR H2
FAN _
- IND. L29 L29
NC C4B-9 C4B-11
NO
BRN
BR
BRN
VOLT METER
STARTER MOTOR
FUEL RELAY
SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH PERKINS
WATER TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
WORK LIGHTS
OPTION
DRIVE LIGHT
TILT ALARM
OPTION
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
DEUTZ SHUTDOWN
OIL PRESSURE GAUGE
AUXILIARY PUMP
OIL PRESSURE
SWITCH PERKINS
HIGH RPM SOLENOID

DEUTZ ONLY
FUEL SOLENOID
(OPTION)
COOLING FAN
WATER TEMP GAUGE

TEMP. SWITCH
HYDRAULIC OIL
DEUTZ ONLY
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
1 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION
6 - 14 Z-60/34 Part No. 75861

6 - 15
1
BRN
GROUND
C41RPM OR/BK
A
ES0434
C2P-3
5
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
C1P-4 C30EDC+ WH C5-21 C30EDC+ WH
HI

C29MS RD/WH
L1
J1
B
C1P-5 C31EDC- WH/BK C5-20 C31EDC- WH/BK

D

16
H3
TS15

7
TB32
DRIVE ENABLE
Y2
6 C1P-6 C32BRK WH/RD C5-23 C32BRK WH/RD

DRE A BL/WH 19 BRAKE RELEASE VALVE
Z-60/34
Y27
C1P-3 C29MS RD/WH C5-24 C29MS RD/WH

20 MOTOR STROKE
TB36 TB37
Y3
C
7 C1P-11 C37STCC BL/BK C37STCC BL/BK

18 STEER CCW
DRIVE & STEERING
RKOUT 6 WH 5
Y4
YOUT 5 BL 4 C1P-10 C36STC BL C36STC BL

17 STEER CW
JC3
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
TURNTABLE ROTATE CW
D
LEFT
TTROTATE
Y29
R4 RIGHT C5TRR WH/BK

TS62
7.5 TURNTABLE ROTATE CCW

TB5
Y13
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
PRIMARY BOOM UP
J1
OR UP
TB2
PWR 3 11 PRIMARY BOOM

Y21
DOWN C2PBD RD/BK

TS61
GND 2 BRN 12
Part No. 75861
J2
PRIMARY BOOM DOWN

1
E
TB3
Y12

June 2015
FLOW CONTROL
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK
SECONDARY BOOM UP/DN

7 8
H4
6 C3P-12
14
OUT 5 YEL 3
F
C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
Y53
GND 2 BRN 10 C10SBU BL

1 SECONDARY BOOM UP
UP
TB11 TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

TS60
SECONDARY BOOM DOWN

Y14
C12SBF BL/WH SECONDARY BOOM

FLOW CONTROL
TB12
G
BRN

1 WH
NCHO
P24FS WH SECONDARY BOOM

TB13
2 BK OPERATION
P24FS WH C13DRE BL/RD
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO
C2P-2 C40LS1 OR PRIMARY BOOM
4 OPERATION
TB40
BK
SJ1 WH
H

WH
NOHC
BOOM RETRACTED
BK OPERATION
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
C22PWR RD BK DRIVE ENABLE
NOTE:
I
C3P-8 C8PBR BK/WH

RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH
C7PBE BK BOOM EXTEND

TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
J
DOWN C15PLD OR/BK TB14

TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
C4P-6 C18JD GR/BK

NC
K
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
L
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
AMP
Y18
BRN
7
6
5
3
4
2
1

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
JIB VALVE
M
JIB VALVE
RKOUT
XOUT
YOUT
PWR
GND
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6 Deutsch
N
3
1
2
5
6
4

6 - 15
6 - 16

6 - 18
6 - 17

1 BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2 FUSE 10A
FS1 TS48
C9-1 BK BK-(FS)
2 WH
RD C28TTA RD/BK
2 C.E. OPTION ONLY TS2
C134PWR OR/RD
C132PLI BL/WH
TS6
P22BAT BK
2
WORK LIGHT
WHEN C.E. OPTION IS NOT
DRIVE LIGHT
C41RPM OR/BK
INSTALLED A JUMPER HARNESS TS17
START
ON GLOW
L4 TS4
CONNECTS PIN 4 TO PIN 5
WH
WH
AND PIN 6 TO PIN 7 TS1
GENERATOR
L48
PLUG
HIGH RPM(FS)
LS18 - PLATFORM OVERLOAD P3 H1
SWITCH HORN D39
ENGINE
PUMP AUXILIARY
C3P-9
D40
L30 L30
C1-12
C2-4
3 TB132 IS WAGO TERMINAL BLOCK 36
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
CB2 TB134
BK
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
2 1 3
KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
4 5
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
BK/RD
GRD
6
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
FUNCTION ENA.
4 U33
RD
PLUG
7 D3 4 PBOX GND
BK
D64
ENGINE
D2
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34 TB9
TB24 5 GROUND MODULE
RD
6 BATTERY
7 KEY PWR. L2
5 CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT FUSE 10A
TB21 NO
FUSE 70A
BL/WH WH FUSE 70A

WH
CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
3
RD-134
RD/BK-28
C5-5
OTS CR23
C5-13 WH
TB25 TB26 CR23
NO NO
G2 G3
6
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
BK/RD-C5-8
C5-11
12 V BAT. BAT. NO PR2 PR7

+ - PR2 PR7
J144-6
J144-4
DC D52 NO
RD
NO
RD
RD
S7
+
FB
STA. G6 5
M1
+ Y29
AUX STARTER
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
7 -
NC NO
C4B-9 C4B-11
BRN
BR
BRN
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
AUXILIARY PUMP
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
HIGH IDLE RELAY

8 NOTE:
3 70A FUSE ADDED AT SERIAL NUMBER 7479
4 DIODE D64 ADDED AT SERIAL NUMBER 9066
5 SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 9340
6 - 18 Z-60/34 Part No. 75861

6 - 19
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30
DRIVE MODE C1-4 C30EDC+ WH C5-21 C30EDC+ WH A B

C29MS RD/WH
TB31
L1
J1
C31EDC- WH/BK
B
C1-5 C31EDC- WH/BK C5-20 D C

16
H3

TS15
7
TB32
DRIVE ENABLE C32BRK WH/RD

Y2
6 C1-6 C32BRK WH/RD C5-23

Z-60/34
Y27
C1-3 C29MS RD/WH C5-24

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
C37STCC BL/BK C37STCC BL/BK

C
C1-11
YOUT 4 WH/RD 5 18 STEER CCW
JC3
TB36
XOUT 3 BL/WH 4
J1
Y4
C1-10 C36STC BL C36STC BL

PWR 2 OR 13 17 STEER CW
GND 1 BR 14
11
C3-6 C6TRF WH/RD
8
C3-5 C5TRR WH/BK

9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D
Y29
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13
C6TRF WH/RD TURNTABLE ROTATE

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
XOUT 3 WH/RD 1 PRIMARY BOOM UP

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
PRIMARY BOOM DOWN

Part No. 75861
GND 1 BR 12
E
TB3
Y12

8
June 2015
FLOW CONTROL
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
F
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
C11SBD BL/BK
8
DOWN
SECONDARY BOOM DOWN
TS60
TB11
ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

Y14

FLOW CONTROL
TB12
G
BR
1
NO
NC
13
WH
22 21
43
P24FS WH BK SECONDARY BOOM
JOYSTICKS CHANGED FROM 7 PIN TO 6 PIN AT SERIAL NUMBER 7227

TB13
2 OPERATION
14
DESCENT ALARM ADDED TO BASE BOM AT SERIAL NUMBER 7270

J3
P24FS WH C4-1 C13DRE BL/RD

4
SJ2 WH
3
P26ESTP BK
3
NO
NC
JIB TIME DELAY CIRCUIT ADDED AT SERIAL NUMBER 9066

13
WH
22 21
21
C2-2 C40LS1 OR BK PRIMARY BOOM

14
4 OPERATION
TB40
SJ1 WH

H
NO
NC
22 21
13 BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8
I
C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
8
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
J
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
C4-6 C18JD GR/BK

NC
DOWN
K
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
L
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
AMP
7
6
5
3
4
2
1
Y18
JIB VALVE

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
M
RKOUT
XOUT
YOUT
PWR
GND
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6 Deutsch
3
1
2
N
5
6
4

6 - 19
6 - 20
Diesel Electrical Schematic, ANSI / CSA - View 1

6 - 22
6 - 21

1 RD
BL/WH
RD/BK
TB41
C2-3
OR/BK OR/BK
P26ESTP BK
BK
F18
FUSE 10A
2 P2
C9-1 BK BK-(FS)
FS1
TS48

WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
WORK LIGHT
DRIVE LIGHT
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
WH
TS1
GENERATOR
PLUG
HIGH RPM(FS)
P3
HORN L48
H1
ENGINE
PUMP AUXILIARY
D39
C3P-9
3 D40 L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
CB2 TB134 D12
BK
BK
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
KS1 1 3
TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
4 5
BK/RD
4 GRD
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6
FUNCTION ENA.
RD
PLUG
RD
D3 PBOX GND
BK
C32 7 D64
ENGINE
TB133 D4
BK
CONN. TB45
12 PLUG 8
GBOX
GND TB27
TB33
D13 D14
CB1
D2 TB23
1 START RELAY 2
TB20 15AMP.
GR/BK
2 TACHOMETER TB35
D6 3 START INPUT TB34 TB9
4 AUX. ON IGN./START
5 RD
TB28 TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
TB21 NO
FUSE 70A
BL/WH WH FUSE 70A

WH
CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS CR23
C5-13 WH
6 NO
TB25 TB26 CR23
NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11

+ - PR2 PR7
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
STARTER
7 AUX
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
AUXILIARY PUMP
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
2 DIODE ADDED BETWEEN TB35 AND TB45 AT SERIAL NUMBER 10283.
6 - 22 Z-60/34 Part No. 75861


6 - 23
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1
B
C1-5 C31EDC- WH/BK C5-20 C31EDC- WH/BK D C

16
H3

TS15
7
TB32

Y2

Z-60/34
Y27

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
C37STCC BL/BK C37STCC BL/BK

C
C1-11
JC3
TB36
XOUT 3 BL/WH 4
J1
Y4

GND 1 BR 14
11
C3-6 C6TRF WH/RD
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D
Y29
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
PRIMARY BOOM DOWN

Part No. 75861
GND 1 BR 12
E
TB3
Y12

June 2015
FLOW CONTROL
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
F
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

SECONDARY BOOM DOWN
TS60
TB11

Y14

FLOW CONTROL
TB12
G
BR
1
NO
NC
14 13
WH
22 21
43

TB13
2 OPERATION

J3

4
SJ2 WH
3
P26ESTP BK
3
NO
NC

14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH

H
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8
I
C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
J
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
DOWN
K
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
L
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
M
6
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 23
6 - 24
Diesel Electrical Schematic ANSI / CSA - View 1

6 - 26
6 - 25

1 RD
BL/WH
RD/BK
TB41
C2-3
OR/BK OR/BK
P26ESTP BK
BK
2 P2
C9-1 BK BK-(FS)
FS1
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
L30 L30 TS4

TS1
GENERATOR
PLUG
HIGH RPM(FS)
P3
HORN L48
H1
ENGINE
PUMP AUXILIARY
D39
BK
BK
3 D40
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
CB2 TB134 D12
15AMP. RD
RD
C1-9
TB43 RD
KS1 1 3
TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
4 5
GRD
4
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6
FUNCTION ENA.
RD
PLUG
RD
D3
BK
C32 7 D64
BR
ENGINE
TB133 D4
BK
CONN. TB45
12 PLUG 8
GBOX
GND TB27
TB33
D13 D14
CB1
D2 TB23
1 START RELAY 2
TB20 15AMP.
GR/BK
2 TACHOMETER TB35
D6 3 START INPUT TB34
5 RD
TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CR2 8 KEY BYPASS U1
BK/RD
CB3 CR45 CR1 9 IGN./FUEL ON
CR45 CR1
NO NO CR2 10 ENG. FAULT FUSE 10A
20AMP.
TB21 NO
FUSE 70A
BL/WH WH FUSE 70A

WH
CR3
NO
CR5
C5-3
C5-2
C5-22
CR5
C21IGN2 WH
GR/WH-45
NO
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23
6 NO
TB25 TB26 CR23
NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11

+ - PR2 PR7
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
AUX STARTER
7 M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
WORK LIGHTS
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
WORK LIGHTS RELAY (OPTION)
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
OPTION
TILT ALARM
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
AUXILIARY PUMP
OPTION
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
6 - 26 Z-60/34 Part No. 75861

6 - 27
1
C7-3 BR-2
GROUND
C41RPM OR/BK
A
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
TB30

C29MS RD/WH
TB31
B
L1
J1

16
H3

TS15
7
TB32
DRIVE ENABLE C5-23 C32BRK WH/RD

Y2
6 C1-6 C32BRK WH/RD

19 BRAKE RELEASE VALVE
Z-60/34
DRE A BL/WH
Y27

20 MOTOR STROKE
6
TB37
C
DRIVE & STEERING
RKOUT 5 BL/WH
Y3
C1-11 C37STCC BL/BK C37STCC BL/BK

JC3
TB36
XOUT 3 BL/WH 4
J1
C36STC BL
Y4
C1-10 C36STC BL
GND 1 BR 14
C3-6 C6TRF WH/RD
11
8
C3-5 C5TRR WH/BK

9
C3-4 C4TRL WH
TB4
10
Y23
D
C4TRL WH
Y29
C5TRR WH/BK
R4
TS62
7.5 TURNTABLE ROTATE RIGHT

TB5
Y13
TURNTABLE ROTATE
6 C6TRF WH/RD
5 FLOW CONTROL
TB6
R5
TB1
5
Y22
YOUT 4 RD/WH
JC2
2
C1PBU RD
J1

UP
Part No. 75861
TB2
PWR 2 OR 11 PRIMARY BOOM

Y21
DOWN C2PBD RD/BK

E
TS61
J2
GND 1 BR 12 PRIMARY BOOM DOWN

June 2015
TB3
Y12

8
FLOW CONTROL
C3-1 C1PBU RD
6
D30
C3-2 C2PBD RD/BK

7
C3-3 RD/BK
8
6
H4
F
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
J1
D29
C3-10
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

8
SECONDARY BOOM DOWN

TS60
TB11
Y14

G
FLOW CONTROL
TB12
BR
1
NO
NC
13
WH
22 21
SECONDARY BOOM
43
P24FS WH BK
2
TB13
OPERATION

14
J3

4
SJ2 WH
3
P26ESTP BK
3

NO
NC
WH
13
22 21

21
BK
EDC GROUND MOVED TO TB9 AT SERIAL NUMBER 11904

C2-2 C40LS1 OR PRIMARY BOOM
H
4
14
OPERATION
TB40
SJ1 WH
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21 BK

CR27
CR30
NO
NC
OPTION
NO
NC
22 21
DRIVE
13
LS3
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
I
14
43
BK
C3-8 C8PBR BK/WH
RETRACT
NOTE:
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
9
6
RETRACT
1.
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
J
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
K

CR13
C4-6 C18JD GR/BK

NC
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
TS58
DOWN
JIB BOOM
Y17
UP C17JU GR
RIGHT
TB17
TS57
PLAT ROTATE
L
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
M
Y18
JIB VALVE
JIB TIME
JIB VALVE
CIRCUIT
CR14
DELAY
6
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N
Diesel Electrical Schematic ANSI/CSA - View 2

6 - 27
6 - 28
Diesel Electrical Schematic, CE - View 1

6 - 30
6 - 29

1 RD
BL/WH
C132PLI2 BK
RD/BK
TB41
C2-3
OR/BK OR/BK
D89
P26ESTP BK
BK
LS18A F18
FUSE 10A
2 PBOX
LS18 P2
C9-1 BK BK
FS1
TS48

GND D88
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
R20
WORK LIGHT
DRIVE LIGHT
4.7 K
C41RPM OR/BK
BK
TS1 TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
WH
C4-10
PUMP AUXILIARY
2 SEC
GENERATOR
PLUG
NO
HIGH RPM(FS)
P3
HORN H1 30A
ENGINE
L48
D39
C3P-9
3 U35
C1-1
L30 L30
C1-12
C2-4
TB132 IS WAGO TERMINAL BLOCK 36 D40

PBOX
C2-7
C1-7
C1-8
C2-5
C7-1
GND
C4-4
C1-2
C7-2
CB2 D12
BK
TB134
BK
15AMP. RD
RD
C1-9
TB43 RD
1 3
KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
C21IGN WH
4 5
BK/RD
GRD
4
ON GLOW
2 SEC
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6 NO
FUNCTION ENA.
LOAD
RD
10A
PLUG
RD
SENSE D3 PBOX GND
BK
MODULE 7 D4 D64
ENGINE
TB133 U34 TB45
BK
GBOX 12 8
GND TB27
D2 TB23 TB33 D14
CB1 D13
1 START RELAY 2
TB20 15AMP.
GR/BK
H6 2 TACHOMETER
D6 3 START INPUT
L45 TB34 TB9 TB35
4 AUX. ON IGN./START
5 RD
TB28 TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CB3 8 KEY BYPASS U1
BK/RD
CR1 CR2 9 IGN./FUEL ON
20AMP. CR5 CR1
TB21 NO
FUSE 70A
BL/WH WH FUSE 70A

WH
CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
RD/BK-28
C5-5
OTS CR23
C5-13 WH
6 NO
TB25 TB26 CR23
NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11

+ - PR2 PR7
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
STARTER
7 AUX
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
AUXILIARY PUMP
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
6 - 30 Z-60/34 Part No. 75861


6 - 31
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1
C5-20 C31EDC- WH/BK

B
C1-5 C31EDC- WH/BK D C

16
H3

TS15
7
TB32

Y2

Z-60/34
Y27

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING

C

JC3
TB36
XOUT 3 BL/WH 4
J1
Y4

GND 1 BR 14
11
C3-6 C6TRF WH/RD
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D
Y29
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
PRIMARY BOOM DOWN

Part No. 75861
GND 1 BR 12
E
TB3
Y12

June 2015
FLOW CONTROL
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
F
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

SECONDARY BOOM DOWN
TS60
TB11

Y14

FLOW CONTROL
TB12
G
BR
1
NO
NC
14 13
WH
22 21
43

TB13
2 OPERATION

J3

4
SJ2 WH
3
P26ESTP BK
3
NO
NC

14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH

H
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
I
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
J
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
DOWN
K
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
L
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
M
6
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 31
6 - 32

6 - 34
6 - 33

1 RD
BL/WH
C132PLI BK
RD/BK
TB41
C2-3
OR/BK OR/BK
D89 P26ESTP BK
BK
LS18A
2 LS18
P2
C9-1 BK
BK-(FS)
FS1
PBOX WH-(FS) C9-2 P24FS WH
GND D88
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
R20
4.7 K
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
L30 L30 TS4

2 SEC TS1
GENERATOR
PLUG
NO
HIGH RPM(FS)
P3
HORN H1 30A
C4-10
ENGINE
L48
PUMP AUXILIARY
D39
BK
BK
3 U35
C1-12
C2-4
TB132 IS WAGO TERMINAL BLOCK 36 D40 PBOX
C2-7
C1-7
C1-8
C2-5
C7-1
GND
C4-4
C1-2
C1-1
C7-2
CB2 TB134 D12
15AMP. RD
RD
C1-9
TB43 RD
KS1 1 3
TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
TS51 TS52 TS56 TS55
P23BAT WH
PLAT
C21IGN WH
4 5
GRD
4 2 SEC
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6 NO
LOAD
FUNCTION ENA.
10A
RD
SENSE
PLUG
RD
D3
MODULE
BK
7
ENGINE
D64
BR
TB133 D4 U34
TB45
BK
GBOX 12 8
GND TB27
D2 TB23 TB33 D14
CB1 D13
1 START RELAY 2
TB20 15AMP.
GR/BK
2 TACHOMETER TB35
H6 D6 3 START INPUT
L45 TB34
5 RD
TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
8 KEY BYPASS U1
BK/RD
CB3 CR45 CR1 CR2 9 IGN./FUEL ON
CR45 CR1
NO NO CR2 10 ENG. FAULT FUSE 10A
20AMP.
TB21 NO
FUSE 70A
BL/WH WH FUSE 70A

WH
CR3
CR5 NO
CR5
C5-3
C5-2
C5-22
NO
C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23
6 NO
TB25 TB26 CR23
NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11

+ - PR2 PR7
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
AUX STARTER
7 M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
WORK LIGHTS
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
OPTION
TILT ALARM
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
AUXILIARY PUMP
OPTION
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
6 - 34 Z-60/34 Part No. 75861


6 - 35
1
C7-3 BR-2
GROUND
C41RPM OR/BK
A
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1
B

16
H3

TS15
7
TB32

Y2
6 C1-6 C32BRK WH/RD

Z-60/34
Y27

20 MOTOR STROKE
6
TB37
DRIVE & STEERING
RKOUT 5 BL/WH
Y3
C37STCC BL/BK
C
C1-11 C37STCC BL/BK

JC3
TB36
XOUT 3 BL/WH 4
J1
C36STC BL
Y4
C1-10 C36STC BL
GND 1 BR 14
C3-6 C6TRF WH/RD
11
8
C3-5 C5TRR WH/BK

9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D
Y29
C5TRR WH/BK
R4
TS62

TB5
Y13
TURNTABLE ROTATE
6 C6TRF WH/RD
5 FLOW CONTROL
TB6
R5
TB1
5
Y22
YOUT 4 RD/WH
JC2
2
C1PBU RD
J1

UP
TB2
PWR 2 OR 11 PRIMARY BOOM

Y21
DOWN C2PBD RD/BK

Part No. 75861
TS61
J2

E
TB3
Y12

June 2015
FLOW CONTROL
C3-1 C1PBU RD
6
D30
C3-2 C2PBD RD/BK

7
C3-3 RD/BK
8
6
H4
C3-12
5 14
F
OUT 4 WH/BK 3 C3-11

JC1
13
3
J1
D29
C3-10
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

8
SECONDARY BOOM DOWN

TS60
TB11
Y14

FLOW CONTROL
TB12
G
BR
1
NO
NC
13
WH
22 21
SECONDARY BOOM
43
P24FS WH BK
2
TB13
OPERATION

14
J3

4
SJ2 WH
3
P26ESTP BK
3

NO
NC
WH
13
22 21

21
BK

C2-2 C40LS1 OR PRIMARY BOOM
4
14
OPERATION
TB40
SJ1 WH
H
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21
BK

CR27
CR30
NO
NC
OPTION
NO
NC
22 21
DRIVE
13
LS3
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
I
C3-8 C8PBR BK/WH

RETRACT
NOTE:
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
9
6
RETRACT
1.
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
J
DOWN C15PLD OR/BK

TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
K
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
TS58
DOWN
JIB BOOM
Y17
UP C17JU GR
RIGHT
TB17
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
L
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
Y18
JIB VALVE
M
JIB TIME
JIB VALVE
CIRCUIT
CR14
DELAY
6
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 35
6 - 36
Diesel Ground Control Box Wiring Diagram

6 - 38
6 - 37

1 VOLT METER OIL PRESSURE OIL TEMP
H6 U33
RD-H6+ - C23-1
RD-C23-1 BL/WH-38D - C23-3
PLATFORM LOAD
RD-42B
C23
BK-22C - C23-4
BK-C7-1 - C23-5
GN/BK-L45 RD-TS11 - C23-6
GN/BK-16A RD-TS14 - C23-7 G1 G2 G3
WHT-21A GN/BK-16B - C23-8
BRN-GROUND BR-GND - C23-12
BLK-22A
P2 WHT-23A
ENGINE WH -8 46 WH -5 WH-23A LIMIT SWITCH POWER
2 STARTER NC RD 42A
C23-6
GR/WH-4 GR/WH-1 45 GENERATOR OPTION
NC WH -7 44 BK -8 LIMIT SWITCH J1
KS1 WH -6 43 BK -7 LIMIT SWITCH J2
KEY OR/RD-1 42 RD H6
RD-4 RD KS1 C134PWR
SWITCH BRN-GROUND
OR/BK-E.H. OR/BK-1 41 OR/BK-ISM#2 PULSE PICKUP
B BK -6 OR-1 40 C40LS1 STOWED +
3 1 3 MFD WT/BK-25A WT/RD-26A
RD
TS51 BL/RD-1 39 BL/RD S.P. L.P./GAS

B1 BL/WH C23-3 BL/WH-1 38 C132PLI
4 2 AUXILIARY
PUMP BL/BK-4 BL/BK-1 37 STEER LEFT 1 WHT-21A
CABLE
#8 BL-4 BL-1 36 STEER RIGHT GND
BK/RD-1 35 BK/RD CR3#30 BK/RD S.P. RPM
BK/WH-E.H. BK/WH-1 34 BK/WH S.P. GLOW PLUG/CHECK ENGINE
BK-1 33 BK-ISM#3 BK S.P. START
3 D2 WH/RD - E.H. WH/RD-1 32 BRAKE
WH/BK-E.H. WH/BK-1 31 E.D.C.-
PERKINS SHUTDOWN ONLY LABEL DESCRIPTION
CABLE WH-1 30 E.D.C.+
#7 WH -E.H.
RD/WH-E.H. RD/WH-1 29 MOTOR SPEED P1 EMERGENCY STOP BUTTON
RED-27A RD/BK-4 RD/BK-1 28 TILT ALARM DIODE WITH 44B-GR/BK+2B-BL/BK KS1 KEY SWITCH
BLU-10A RD -4 RD-1 27 ISM#4 RD S.P. AUXILIARY POWER
BLU/BLK-11A TS51 AUXILIARY SWITCH
WH/RD-E.H. 26 WH/RD S.P. OIL TEMP SENDER L2
BLK/WHT-8A TS52 ENGINE START SWITCH
BLK-7A WH/BK-E.H. 25 WH/BK S.P. OIL PRESSURE SENDER CHECK ENGINE
L2 CABLE 24 RD-CR2#30 RD CB1 ENGINE POWER LED WH/RD-C5-14
CHECK ENGINE L45 GR/BK H6 #6 RD-4 WH-2 23 WH-ISM#7 WH S.P.+ WH-46A KEYSWITCH POWER
LED D33 TS55 FUNCTION ENABLESWITCH
BL/WH-ISM#10 C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM BL/WH-ISM#10
WH-E.H. WH-CR2#87 WH-E.H. 21 WH-SP IGNITION POWER WH/BK-C5-16 TS57 PLATFORM ROTATE SWITCH
RD-S.P.(CB3)20 RD-S.P.(CB2) RD-S.P.(CB1)
4 RED-1A
RD -E.H.
GR/WH-3 19 GR/WH S.P.
12V BATTERY SUPPLY
JIB VALVE
TS58 JIB BOOM SWITCH
GR/BK-4 GR/BK-3 18 GR/BK S.P. PLATFORM ROTATE R TS59 PLATFORM LEVEL SWITCH
RED/BLK-2A CABLE
GR-4 GR-3 17 GR S.P. PLATFORM ROTATE L
2 PERKINS SHUTDOWN COMMONIZED WITH
TS60 SECONDARY BOOM UP/DOWN SWITCH
#5 DEUTZ AT SERIAL NUMBER 5326
OR/RD-3 16 GN/BK C23-8 GN/BK-H6 C133PLT TS61 PRIMARY BOOM UP/DOWN SWITCH
+ RED/WHT-3A OR/BK-4 OR/BK-3 15 OR/BK S.P. PLATFORM LEVEL DOWN
TS62 TURNTABLE ROTATE SWITCH
TS60 OR-4 OR-3 14 OR S.P. PLATFORM LEVEL UP
HM BOOM BK -5 OR/RD-3 13 DRIVE ENABLE TS63 BOOM EXTEND/RETRACT SWITCH
UP/DOWN BL/WH-4 BL/WH-3 12 BL/WH S.P. SECONDARY BOOM F.C.
- TS61 TS63 CABLE 11 TS64 RUN/TEST SWITCH
BOOM EXTEND/ BL/BK-4 BL/BK-3 BL/BK S.P. SECONDARY BOOM DOWN
BOOM #1
RETRACT BL/WH -12A BL-4 BL-3 10 BL S.P. SECONDARY BOOM UP CB1 CIRCUIT BREAKER, ENGINE, 15A
UP/DOWN
R5 WHT/BLK-5A BK/RD-3 9
WHT-4A CB2 CIRCUIT BREAKER, CONTROL, 15A
BK/WH-4 BK/WH-3 8 BK/WH S.P. BOOM RETRACT
5 CB3 CIRCUIT BREAKER, HYD COOLER, 20A
5 BK-4
WH/RD-4
BK-3
WH/RD-3
7
6
BK S.P.
WH/RD S.P.
BOOM EXTEND
TURNTABLE ROTATE F.C. HM HOUR METER
WH/BK-4 WH/BK-3 5 WH/BK S.P. TURNTABLE ROTATE R
TS62 WH-4 WH-3 4 WH S.P. TURNTABLE ROTATE L
7.5
TS58 TURNTABLE RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
R4
JIB BOOM ROTATE RD/BK-4 RD/BK-3 2 RD/BK S.P. PRIMARY BOOM DOWN
RD-4 RD-3 1 RD S.P.
DRIVE LIGHT OPTION RELAY R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
PRIMARY BOOM UP
D3 G1 VOLT METER GAGE
WH/RD S.P. CABLE D C B A
#2 RD-CB3 SP G2 OIL PRESSURE GAGE
BK-CR1#86 START RELAY
1
CR23 G3 WATER TEMP. GAGE
OR/BK-41B TACHOMETER
TS56 TS52 GRN-17A 2 H2 SERVICE HORN
TS57 BK-33D START INPUT
3
GLOW PLUG ENGINE START H3 TRAVEL BUZZER
PLATFORM RD-27B AUXILIARY ONIGN./START
6 ROTATE GRN/BLK-18A BR-GROUND
4
GROUND5
MODULE BK/RD-9B
H4 DESCENT BUZZER
RD-CR1#30 BATTERY
GRN/WHT-19A 6 CR1 IGN/START RELAY
WH-23B
TS59 KEY POWER
7
PLATFORM RD TO LIGHT CR2 IGN./POWER RELAY
KEY BYPASS
8
LEVEL WH-CR2#86 IGN./FUEL ON CR3 HIGH IDLE (RPM) CUTOUT RELAY
ORG/BLK-15A CABLE BL/WHT-L2-
9 RD-C4B-12
ORG-14A #3 ENGINE FAULT
10 CR4 RPM RELAY
WARNING SENDER BRN GND
TS55 CR5 SERVICE HORN RELAY
FUNCTION RD-S.P. (CB3)
ENABLE RD-24B
CR17 HYDRAULIC COOLER FAN RELAY
CB3 CABLE WH-ISM#9 GR-1 CR
CB1 CB2 OIL COOLER/ #4 WH-H.C. CR18 CE PLATFORM LEVEL RELAY
RD-ISM#6 BK-22B RELAY
7 ENGINE, 15A CONTROL, 15A OPTION, 20A
CR2 CR5 LEGEND H6 PLATFORM OVERLOAD ALARM
CR1 CR17
BK-ISM#1 L45 PLATFORM OVERLOAD LED
87 V33 PLATFORM OVERLOAD MODULE
CR17 #30 BK-E.H. 87A LS1 (CABLE#6) PRIMARY BOOM STOWED LIMIT SWITCH
WH-21D RD-H.C. BK-4
RED-20C BR-GROUND LS2 (CABLE#5) DRIVE ENABLE LIMIT SWITCH
HYDRAULIC 86 85
BLK-33A COOLER
30
BK/RD-35B LS3 (CABLE#7) BOOM RETRACTED LIMIT SWITCH
BLK/RED-35A
LS4 (CABLE#8) SECONDARY BOOM STOWED LIMIT SWITCH
RD C23-7 CR4
CR3 (CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
RED-20A
RED-20B (CABLE#2) TO PLATFORM C-BOX, TERMINAL 22-23
1 RPM FILTER ADDED AT SERIAL NUMBER 4461
8 BK/WH-34A (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19
RED-24A ENGINE BK/RD-E.H. (CABLE#4) TO FUNCTION MANIFOLD
HARNESS
GROUND STUD PR1 AUXILARY POWER RELAY
BR BR PR2 GLOW PLUG POWER RELAY
BK-H.C. + BR-H.C.
BR-2
6 - 38 Z-60/34 Part No. 75861


N M L K J I H G F E D C B A
1
RD-H6+ - C32-1 WH-21A G1 G2 G3
BL/WH-38D - C32-3
BK-22C - C32-4
U33 C32 BK-C7B-1 - C32-5 RD-C32-1
PLATFORM LOAD RD-TS51 - C32-6 RD-42B
RD-TS55 - C32-7 GR/BK-L45 H6
GR/BK-16B - C32-8 GR/BK-16A BR (GROUND)
BR - GND - C32-12 LOAD SENSE OPTION - TIMER RELAY LABEL DESCRIPTION
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION WH/BK-25A P1 EMERGENCY STOP BUTTON
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM WH/RD-26A KS1 KEY SWITCH
GR-C2B-5 43 GR-CR5#86 HORN DEUTZ RD-C23-6 TS51 AUXILIARY SWITCH
2
RD-4 OR/RD-C2B-4 42 RD H6 RD KS1 WH-CR2#86
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 BR- 3MF CAP
C134PWR ONLY WH-ISM#9 TS52 ENGINE START SWITCH
PULSE PICKUP KEY SWITCH
OR-4 OR-C2B-2 40 C40LS1 STOWED KS1 TS56 GLOW PLUG SWITCH
P1 TS51
BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS B TS55 FUNCTION ENABLE SWITCH
RD-CB2 RD-TB134(A)C
BL/WH - C23-3 BL/WH-C1B-12 38 C132PLI 3MF NC 1
TS57 PLATFORM ROTATE SWITCH
RD
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT 3
NC B1 TS58 JIB BOOM SWITCH
BL-4 BL-C1B-10 36 STEER RIGHT BR-GND
35 GND WH-23A 4 2 TS59 PLATFORM LEVEL SWITCH
BK/RD-C1B-9 BK/RD-CR3#30 BK/RD S.P. RPM RD-42A
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG TS60 SECONDARY BOOM UP/DOWN SWITCH
BK-C1B-7 33 BK-ISM#3 BK S.P. START BK-22A
BK-C3B-10 TS61 PRIMARY BOOM UP/DOWN SWITCH
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD -4 BRAKE RD-27A
WH/BK -C5-20 WH/BK-C1B-5 31 E.D.C.-
TS62 TURNTABLE ROTATE SWITCH 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ TS63 BOOM EXTEND/RETRACT SWITCH
GR/BK-H6- REPLACE WIRE WITH THIS WIRING DIAGRAM
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM
RD -4 RD-C1B-1 27 RD-ISM#4 RD S.P. AUXILIARY POWER WH-21A CB1 CIRCUIT BREAKER, ENGINE, 15A
WH/RD-C5-14 26 WH/RD S.P. OIL TEMP. SENDER CB2 CIRCUIT BREAKER, CONTROL, 15A
WH/BK-C5-16 25 WH/BK S.P. OIL PRESSURE SENDER HM CB3 CIRCUIT BREAKER, OPTION, 20A
24 RD-CR1#30 RD CB1 ENGINE POWER BR (GROUND) L2
L45 HM HOUR METER
WH-C7B-2 23 WH-ISM#7 WH S.P. KEYSWITCH POWER
BL/WH-4 BK - C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM BL/WH-ISM-10
WH-C5-3+C5-11 WH - H.C. 21 WH-CR2#87 WH-SP IGNITION POWER R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
WL
20 WH-C5-13
RD-4 (12V) RD-S.P.(CB3) RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE RD/WH-3A
R5 RESISTOR, 5 OHM, TURN. AUX. FUNC. 4
RD/BK-2A G1 VOLT METER GAGE
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L G2 OIL PRESSURE GAGE
BL/BK-11A
OR/RD-C4B-4 16 GR/BK C23-8 GR/BK-H6- C133PLT G3 WATER TEMP. GAGE
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN H2 SERVICE HORN
HC
OR-4 OR-C4B-2 14 OR S.P. PLATFORM LEVEL UP

BL/RD-4 BL/RD-C4B-1 13 DRIVE ENABLE BL-10A H3 TRAVEL BUZZER
12V TO PLAT
BL/WH-4 BL/WH-C3B-12 12 BL/WH S.P. SECONDARY BOOM F.C. TS63 H4 DESCENT BUZZER
BR-GND STUD BL/WH-12A TS60 TS61
3 BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN CR1 IGN/START RELAY
1 BK-C32-5 BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP BK/WH-8A DRIVE LIGHT OPTION RELAY
C7B
9 BK/RD-CR23#86 CR2 IGN./POWER RELAY

WH-23C BK/RD-C3B-9 DRIVE LIGHT OPTION BK-7A
2 HIGH IDLE (RPM) CUTOUT RELAY
8 RD-1A CR3
BK/WH-4
BK-4
BK/WH-C3B-8
BK-C3B-7 7
BK/WH S.P.
BK S.P.
BOOM RETRACT
BOOM EXTEND GR/BK-44A
RD-24D
CR23 CR4 RPM RELAY
5
WH/RD S.P. FUSE 10A
WH/RD-4 WH/RD-C3B-6 6 TURNTABLE ROTATE F.C. TS62
BK/WH-34A CR5 SERVICE HORN RELAY
(GY)
WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L 30

C1B
TS56 TS52 CB3 BR-C4B-9

WH-4 WH-C3B-4 4 WH S.P. TURNTABLE ROTATE R D64 BR
1 GND
5
RD/WH-4 RD/WH-C3B-3 3 RD/WH S.P. PRIMARY BOOM F.C. 87A CR17 HYDRAULIC COOLER FAN RELAY
19/18 CABLES
2 11B-RD/BK-4 86 85 BR-C4B-11
RD/BK-4 RD/BK-C3B-2 RD/BK S.P. PRIMARY BOOM DOWN BK-33A
(BK)
CR23
C2B
87 DRIVE LIGHT OPTION RELAY

RD-4 RD-C3B-1 1 RD S.P. PRIMARY BOOM UP RD- 20C TS58 RD-C4B-10
R5 H6 PLATFORM OVERLOAD ALARM
D C B A RD-CR17#30 RD-C4B-12
L45 PLATFORM OVERLOAD LED
(GR)
WH/BK-5A
C3B
BK-CR1#86 BK/RD-9B
1 START RELAY WH/RD-6A U33 PLATFORM OVERLOAD MODULE
OR/BK-41B WH-4A
2 TACHOMETER
BK-33B L2 CHECK ENGINE LED
3 START INPUT IGN./START 6
(BR)
RD-27B
C4B
4 AUX. ON MODULE R4
BR-GND. GROUND
5 7.5 C1B TO PLATFORM C-BOX, TERMINAL 27-38
RD-CR2#30 BATTERY
6
WH-23B KEY PWR. TS57 C2B TO PLATFORM C-BOX, TERMINAL 39-45
7 D14 CB1 CB2 HYDRAULIC OIL COOLER OPTION RELAY
FUNCTIONS
8 KEY BYPASS C3B TO PLATFORM C-BOX, TERMINAL 1-12

WH-CR2#86
9 IGN./FUEL ON C4B TO PLATFORM C-BOX, TERMINAL 13-19
WH-L2- RD-H.C.
10 ENG. FAULT TS55 C5 ENGINE HARNESS
4
RD-ISM#6 RD-C23-7 CR17

BK/RD-35B TS59 C7B TO PLATFORM C-BOX, TERMINAL 22-23
WH-ISM#9 D13 87
RD-24B BK/RD-35A 85 86 BK-H.C.
CR1 CR2 CR3 CR4 87A PR1 AUXILARY POWER RELAY
RD- 20A PR2 GLOW PLUG POWER RELAY
30
BK-ISM#1
30 30 30 RD- 24A 30 7
87A RD- 20B
87A 87A 87A
ENGINE
86 85 86 85 86 85 86 85 RD- P1 E-STOP RD-CB3 SP

87 87 87 87
OR/BK-15A
C5
BK-C5-5
OR-14A BRN GND
WH-21B BK/RD-C5-8
CR5 GR-17A
87 86 BK-4 GR/WH-19A
85
87A GR/BK-18A
30 GR-43B
BK-22B 1 DIODE D64 ADDED AT SERIAL NUMBER 9066

8
GROUND STUD WIRING
HARNESS:
TO BASE
BR ALL BR WIRES
GROUND STUD
Part No. 75861 Z-60/34 6 - 39


6 - 39
6 - 40

6 - 42
6 - 41

1
RD-H6+ - C32-1 WH-21A G1 G2 G3
BL/WH-38D - C32-3
BK-22C - C32-4
U33 C32 BK-C7B-1 - C32-5 RD-C32-1
RD-TS55 - C32-7 GR/BK-L45 H6
GR/BK-16B - C32-8 GR/BK-133A BR (GROUND)
BR - GND - C32-12 LOAD SENSE OPTION - TIMER RELAY LABEL DESCRIPTION
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GR/BK-35B GENERATOR OPTION WH/BK-25A P1 EMERGENCY STOP BUTTON
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM WH/RD-26A KS1 KEY SWITCH
GR-C2B-5 43 GR-CR5#86 HORN
2 RD-U34-2 134A
RD-C23-6 WH-CR2#86 TS51
TS52
AUXILIARY SWITCH
ENGINE START SWITCH
RD-4 OR/RD-C2B-4 134 RD H6+ RD KS1 C134PWR WH-ISM#9
KEY SWITCH TS56 GLOW PLUG SWITCH
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 BR- 3MF CAP PULSE PICKUP DEUTZ ONLY P1 KS1
OR-C2B-2 40 TS51
OR-4 C40LS1 STOWED B TS55 FUNCTION ENABLE SWITCH
RD-CB2 RD-TB134(A)C
BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS NC 1
RD
BL/WH - C23-3 BL/WH-C1B-12 132 C132PLI 3
NC B1 TS58 JIB BOOM SWITCH
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT BR-GND
BL-4 36 WH-23A 4 2 TS59 PLATFORM LEVEL SWITCH
BL-C1B-10 STEER RIGHT RD-42A
BK/RD-C1B-9 35 BK/RD-CR3#30 GR/WH 45B BK/RD S.P. RPM D4 TS60 SECONDARY BOOM UP/DOWN SWITCH
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG BK-22A
BK-C3B-10 TS61 PRIMARY BOOM UP/DOWN SWITCH
BK-C1B-7 33 BK-ISM#3 BK S.P. START RD-27A
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD -4 TS62 TURNTABLE ROTATE SWITCH
BRAKE
3 WH/BK -C5-20
WH -C5-21
WH/BK-C1B-5
WH-C1B-4
31
30
E.D.C.-
E.D.C.+
GR/BK-H6- REPLACE WIRE WITH THIS WIRING DIAGRAM
TS63 BOOM EXTEND/RETRACT SWITCH
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED

RD/BK -4 RD/BK-C1B-2 28 TILT ALARM WH-21A CB1 CIRCUIT BREAKER, ENGINE, 15A
RD -4 RD-C1B-1 27 RD-ISM#4 RD S.P. AUXILIARY POWER CB2 CIRCUIT BREAKER, CONTROL, 15A
WH/RD-C5-14 26 WH/RD S.P. OIL TEMP. SENDER HM CB3 CIRCUIT BREAKER, OPTION, 20A
WH/BK-C5-16 25 WH/BK S.P. OIL PRESSURE SENDER BR (GROUND) L2
L45 HM HOUR METER
RD-D.L.CR23#30 24 RD-CR1#30 RD CB1 ENGINE POWER
WH-C7B-2 23 WH-ISM#7 WH S.P. KEYSWITCH POWER BL/WH-ISM-10 DRIVE LIGHT OPTION RELAY
1 BL/WH-4 BK - C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
WL
WH-C5-3+C5-11 WH - H.C. 21 WH-CR2#87 +D.L.CR23#86WH-SP WH-C5-13

IGNITION POWER RD-24D R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
RD-4 (12V) RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY RD/WH-3A CR23
FUSE 10A G1 VOLT METER GAGE
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE RD/BK-2A
4 GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R
BL/BK-11A
30
BR-C4B-9
G2 OIL PRESSURE GAGE
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L BR G3 WATER TEMP. GAGE
GND
OR/RD-C4B-4 16 GR/BK C23-8 GR/BK-H6- C133PLT 87A BR-C4B-11 H2 SERVICE HORN
HC
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN 86 85

87 H3 TRAVEL BUZZER
OR-4 OR-C4B-2 14 OR S.P. PLATFORM LEVEL UP BL-10A RD-C4B-10
BL/RD-4 BL/RD-C4B-1 13 DRIVE ENABLE TS63 RD-C4B-12 H4 DESCENT BUZZER
12V TO PLAT
SECONDARY BOOM F.C. BL/WH-12A TS60 TS61

3 BR-GND STUD BL/WH-4 BL/WH-C3B-12 12 BL/WH S.P. WH - 21B CR1 IGN/START RELAY
BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. BK/WH-8A
1 BK-C32-5 SECONDARY BOOM DOWN
C7B
10 CR2 IGN./POWER RELAY

BL-4 BL-C3B-10 BL S.P. SECONDARY BOOM UP BK-7A
2 WH-23C HIGH IDLE (RPM) CUTOUT RELAY
1 BR C5-7 BR C3B-9 9 EDC RETURN RD-1A CR3
BK/WH-4 BK/WH-C3B-8 8 BK/WH S.P. BOOM RETRACT GR/BK-44A CR4 RPM RELAY
BK-4 BK-C3B-7 7 BK S.P. BOOM EXTEND TS62
BK/WH-34A CR5 SERVICE HORN RELAY
6 WH/RD S.P.
5
(GY)
WH/RD-4 WH/RD-C3B-6 TURNTABLE ROTATE F.C.

C1B
TS56 TS52 CB3

WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L D64 HYDRAULIC OIL COOLER OPTION RELAY
5
WH-4 WH-C3B-4 4 WH S.P. TURNTABLE ROTATE R CR17 HYDRAULIC COOLER FAN RELAY
19/18 CABLES
RD/WH-4 RD/WH-C3B-3 3 RD/WH S.P. PRIMARY BOOM F.C. BK-33A

(BK)
RD-H.C. CR23
C2B
WORK LIGHTS OPTION RELAY

RD/BK-4 RD/BK-C3B-2 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN RD- 20C TS58
R5 CR17 Cr45 DRIVE LIGHT OPTION RELAY
RD-4 RD-C3B-1 1 RD S.P. PRIMARY BOOM UP RD-CR17#30
87 H6 PLATFORM OVERLOAD ALARM
BK-H.C.
(GR)
D C B A WH/BK-5A 85 86
C3B
WH/RD-6A 87A L45 PLATFORM OVERLOAD LED

BK-CR1#86 WH-4A
1 START RELAY U33 PLATFORM OVERLOAD MODULE
OR/BK-41B 30
(BR)
TACHOMETER
C4B
2 L2 CHECK ENGINE LED

BK-33B R4
RD-27B
3 START INPUT IGN./START D27
AUX. ON 7.5
4 MODULE RD-CB3 SP
BR-GND. GROUND C1B TO PLATFORM C-BOX, TERMINAL 27-38
5 TS57
6 RD-CR2#30
6 BATTERY D14 CB1 CB2 C2B TO PLATFORM C-BOX, TERMINAL 39-45
FUNCTIONS
WH-23B BR GND
7 KEY PWR. C3B TO PLATFORM C-BOX, TERMINAL 1-12
8 KEY BYPASS
WH-CR2#86 TS55 C4B TO PLATFORM C-BOX, TERMINAL 13-19
9 IGN./FUEL ON
4
WH-L2- RD-C23-7 TS59

10 ENG. FAULT D13 C5 ENGINE HARNESS
RD-ISM#6 BK/RD-35B BK/RD-35A C7B TO PLATFORM C-BOX, TERMINAL 22-23
WH-ISM#9 CR4 WORK LIGHTS OPTION RELAY
RD-24B RD- 20A PR1 AUXILARY POWER RELAY
CR1 CR2 CR3
RD- 24A WH - W.L. PR2 GLOW PLUG POWER RELAY
30 30 30 30 RD- 20B CR45
ENGINE
BK-ISM#1 RD- P1 E-STOP 87 WH-C21IGN

87A 87A 87A 87A OR/BK-15A 85 86
85
C5
85 86
7 BK-C5-5
86
87
85 86
87
85 86
87 87
OR-14A
87A
GR-17A 30
WH-21B BK/RD-C5-8 GR/WH-19A
CR5
87 86 BK-4 GR/BK-18A RD-CB3 SP
85
87A
BR GND
30 GR-43B
BK-22B
WIRING
8 GROUND STUD HARNESS:
TO BASE
BR ALL BR WIRES
GROUND STUD 9 BK/RD-CR23#86

TERMINAL 9 BEFORE SERIAL NUMBER 10388 BK/RD-C3B-9 DRIVE LIGHT OPTION
1 9
TERMINAL 9 FROM SERIAL NUMBER 10388 TO SERIAL NUMBER 11903 SPARE
TERMINAL 9 FROM SERIAL NUMBER 11904 BR C5-7 BR C3B-9 9 EDC RETURN
6 - 42 Z-60/34 Part No. 75861

September 2013 Section 6 • Schematics
Diesel Platform Control Box Wiring Diagram

6 - 44
6 - 43

P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
P24FS WH
BRN
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
ALC-500
3
J3
1
J1 J2
9 11
1 1
DRIVE LT BK/RD C3P-9

C34SA BK/WH C1P-8
C28TTA RD/BK C1P-2
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
C35RPM BK/RD C1P-9

C134PWR RD C2P-4
C29MS RD/WH C1P-3

C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2

C31EDC- WH/BK C1P-5
C1PBU RD C3P-1
C30EDC+ WH C1P-4
C41RPM OR/BK C2P-3
C12SBF BL/WH C3P-12
C40LS1 OR C2P-2
C11SBD BL/BK C3P-11
C13DRE BL/RD C4P-1
C10SBU BL C3P-10
C6TRF WH/RD C3P-6
C39LP BL/RD C2P-1
C45GEN GR/WH C2P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C37STCC BL/BK C1P-11
C36STC BL C1P-10
C132PLI BK C1P-12
RD H1
RD P2
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
JDALARM GR/BK C2P-6
COMPONENT INDEX
JC2 BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
3 JC1 BOOM SECONDARY JOYSTICK:
C28TTA RD/BK C1P-2 C1P
C2P
JC3 DRIVE PROPORTIONAL JOYSTICK
D40
L1 DRIVE ENABLE LED C3P C3P
L4 C.E. PLATFORM LED
GR/BK C4P-4 C4P
L48 TILT ALARM LED
BRN
P2 EMERGENCY STOP BUTTON BATGND C7P-3 C7P

P3 HORN SWITCH
TS1 AUXILIARY SWITCH
TS2 START ENGINE SWITCH
D39
F.S.
TS3 FUEL SELECT SWITCH (FORD EFI ONLY)
RED-TILT
RED/BLK-28
TS4 HI/L0 RPM SWITCH
4 TS6 GLOW PLUG OPTION
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH C7P C9P LS18 OPT.
JIB
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
TS14 DRIVE SPEED SWITCH
TS15 DRIVE ENABLE SWITCH
H1
TS17 GENERATOR OPTION
TS48 WORK/DRIVE LIGHT ( OPTION )
TILT
ALARM 19/18 CONTROL CABLE 12V BATT F.S.
DETAIL A: LIFT/DRIVE OPTION

1 10A FUSE ADDED AT SERIAL NUMBER 4496.
5 REPLACE WIRE WITH THIS WIRING DIAGRAM
10 AMP FUSE 7
BRN BATGND TS48
WORK/DRIVE LIGHT
6
(GND STUD) TS15
7 7 DRIVE ENABLE
5
6 6
CR27 4
WH TS7
WH TS1
5 5
3
RD WL2
4 4
WH/RD C32BRK 2
BOOM
DLITE/ RD WL2
(SPLICE TO C32BRK) 3 EXTEND/ 3 JC3

1
6 2
RETRACT
2
+
JC2 JC1
CR30 1 1
L48
TS13
CR13 L1
WH-24
+
L4
CP2-2 OR R40LS1
RD WL1
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BL/WH-DE1 J1-6
(SPLICE TO R40LS1)
BRN J1-14
BRN J1-10
BRN J1-12
GR/BK H1
RD/BK H1
BK/WH-8
OR J1-13
YEL J1-3
OR J1-11
WH J1-5
WH J1-5
OR J1-9
WH-JIB
BK J1-2
RD J1-1
BL J1-4
WH-24
BK-22
7
BK-7
BRN
RD-P2
WH-24
GR/WH-45
C34SA BK/WH C1P-8

BK-33
RD-25
WH-24
BK/RD-35
GR/WH-45
P26BAT BK C9P-1
P22BAT BK C7P-1
RD L48
BK-33
RD-25
GR-43
OR-14
RD LS18
RD L4
WH-24
BK/RD-35
WH-23
OR/BK-15
WH-24
WH-JIB
C27AUX RD C1P-1
C19JSV GR/WH
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
C29MS RD/WH J1-8

JDALARM GR/BK-44 C3P-9
REMOVE FOR
GENERATOR OPTION
D12
CE SEE DETAIL A D12
TS4
TS4
NC
1
2
TS2 TS9 TS7 WH TS1 RD
TS2 1
8 HIGH/LOW GR TS8
TS14
NC
DRIVE HIGH/LOW
NO
RPM
3
4
SPEED RPM
1
WH
NC
START
RD TS6 START
1
GENERATOR WH HIGH/LOW RD
HORN JIB AUXILIARY GLOW PLUG GENERATOR P2
NOTE: (OPTION) PLATFORM PLATFORM
P3 PUMP NOTE: (OPTION) EMERGENCY STOP
DASHED LINES INDICATE OPTION WIRES TS17 LEVEL ROTATE
GR/BK DASHED LINES INDICATE OPTION WIRES TS17
1 GENERATOR OPTION BEFORE SERIAL NUMBER 5716 D27
6 - 44 Z-60/34 Part No. 75861

6 - 45
1
8
A
RD L48
EMERGENCY STOP
RD LS18
1 1 1
P22BAT BK C7P-1
NC NC
P2
J1-5 BL/WH JC3-5 NC

J1-4 WH/RD JC3-4 P26BAT BK C9P-1
J1-5 BL/WH JC3-3 2 2 2
J1-13 OR JC3-2 WH-23
J1-14 BR JC3-1
Jc3
OPT.
B
RD-P2
DRIVE/STEER
RD P2
RD H1
LS18
GENERATOR
Z-60/34
GR/WH-45
(OPTION)
C132PLI BK C1P-12
TS17
+
+
C
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12
DASHED LINES INDICATE OPTION WIRES

HIGH/LOW
C19JSV GR/WH JIB BK/RD-35

RPM
C18JD GR/BK C4P-6 WH-24

JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
TS4
GR/BK H1
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
RD
C7PBE BK C3P-7 RD/BK H1

P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
D

NOTE:
C3P
TS2
C45GEN GR/WH C2P-7

F.S.
C9P
TS48-WL1 RD C2P-12
BK-33
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1 RD-25
START
JDALARM GR/BK C2P-6

WH-24
DRIVE ENABLE
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11
BL/RD-DE3 J1-16 C34SA BK/WH C1P-8

3
Part No. 75861
C6TRF WH/RD C3P-6 BL/WH-DE1 J1-6

J3
BK-22
E
TS6
C10SBU BL C3P-10 BL/BK-DE2 J1-7

C13DRE BL/RD C4P-1
12V BATT
June 2015
C11SBD BL/BK C3P-11

P24FS WH C40LS1 OR C2P-2 J1-3 WH/BK JC1-4
C7P
HIGH/LOW
C12SBF BL/WH C3P-12

TS14
C41RPM OR/BK C2P-3 J1-9 OR JC1-2

P24FS WH
C30EDC+ WH C1P-4 WH-24
Jc1
BRN C1PBU RD C3P-1 J1-10 BR JC1-1

C7P
C31EDC- WH/BK C1P-5 C29MS RD/WH J1-8

C2PBD RD/BK C3P-2
DRIVE
SPEED
6
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P

AUXILIARY
C5TRR WH/BK C3P-5

PUMP
C4P(BR)
ALC-500
C32BRK WH/RD C1P-6 C27AUX RD C1P-1

SECONDARY BOOM
C4TRL WH C3P-4
F
TS1
C29MS RD/WH C1P-3

UP/DOWN
J2
WH
WH-JIB
C3P
WH-JIB
C134PWR RD C2P-4 JDALARM GR/BK-44 C3P-9
C3P(GR)
C35RPM BK/RD C1P-9
BRN
TS8
C34SA BK/WH C1P-8

CE SEE DETAIL A
CR13
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE
C27AUX RD C1P-1 DLITE/ RD WL2

RD/BK L4 BK/WH-8
GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
JC1-2 BRN C19JSV GR/WH
G
C1P(GY) RD WL1
D27
JC2-5 BK
TS48
JC2-3 OR C19JSV GR/WH JIB

J1-2 RD/WH JC2-4
JC1-5 YEL J1-1 WH/RD JC2-3 TS7
JC2-2 BRN
C18JD GR/BK C4P-6
JC3-5 BL J1-11 OR JC2-2
JC2
WH
JC3-3 OR J1-12 BR JC2-1
JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2
PLATFORM
C28TTA RD/BK C1P-2
6
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
H
RD L4 3
D40
HORN
GR-43 NO
P3
H1
RED/BLK-28 4
D39
ALARM
GR/BK L48
TILT
RED-TILT RED-TILT
BRN
I
BRN BATGND
(GND STUD)
WH TS1
J
REPLACE WIRE WITH THIS WIRING DIAGRAM

PRIMARY BOOM EXTEND/RETRACT SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
BOOM PROPORTIONAL JOYSTICK:
DRIVE PROPORTIONAL JOYSTICK

BOOM SECONDARY JOYSTICK:
WORK/DRIVE LIGHT ( OPTION )
CR27
CR30
PLATFORM ROTATE SWITCH
EMERGENCY STOP BUTTON
PLATFORM LEVEL SWITCH
DRIVE ENABLE SWITCH

START ENGINE SWITCH
DRIVE SPEED SWITCH

JIB UP/DOWN SWITCH
GENERATOR OPTION
GLOW PLUG OPTION
COMPONENT INDEX
C.E. PLATFORM LED

COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH
HI/L0 RPM SWITCH

JIB DELAY RELAY
TILT ALARM LED

JIB TIME DELAY
HORN SWITCH
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
TILT ALARM
CP2-2 OR R40LS1
WH/RD C32BRK
K
WH TS7
CR14
TS13
TS15
TS48
TS17
TS14
JC1
TS6
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
C1
P3
P2
L1
L4
L
M
N

6 - 45
6 - 46

6 - 48
6 - 47
N
M
L
K
WH
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7 RD L48
BR BK
BR JC3
EMERGENCY STOP
BR GND RD C134PWR RD LS18 RD LS18

RD-E-STOP 1 1 1
P134PWR RD-H1+ P22BAT BK C7P-1
GR/WH
CR13-#86 GR/WH BR
NC NC
P2
J1-5 BL/WH JC3-5 NC

RD LS18 CABLE
C1
GR/WH
J1-5 BL/WH JC3-3 2 2 2

RD OUTPUT
J1-13 OR JC3-2 WH-23

J1-14 BR JC3-1
GR/WH +
CR14
P134PWR RD
Jc3
BR -
J
JIB
OPT.
GR/WH RD
6
RD-P2
DRIVE/STEER
GENERATOR
LS18
GR/WH-45
(OPTION)
TS17
BK C1P-12
I
+
+
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12

HIGH/LOW

RPM

JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
TS4
GR/BK H1
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
RD
P26BAT BK C9P-1
H
P25FS RD C9P-3
P24FS WH C9P-2
NOTE:
C3P
TS2
C45GEN GR/WH C2P-7
F.S.
C9P
TS48-WL1 RD C2P-12
BK-33
F.S.
TS48-WL2 RD C2P-11
START
JDALARM GR/BK C2P-6
WH-24
DRIVE ENABLE
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11

3
1
G

J3
BK-22
TS6
C13DRE BL/RD C4P-1
12V BATT
C11SBD BL/BK C3P-11

C7P
HIGH/LOW
C12SBF BL/WH C3P-12
TS14
P24FS WH
Jc1

C7P

C2PBD RD/BK C3P-2
DRIVE
SPEED
6
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P
AUXILIARY
F
C5TRR WH/BK C3P-5
PUMP
C4P(BR)
ALC-500

SECONDARY BOOM
C4TRL WH C3P-4
TS1
C29MS RD/WH C1P-3
UP/DOWN
J2
WH
WH-JIB
C3P
WH-JIB
C3P(GR)
C35RPM BK/RD C1P-9
June 2015
Part No. 75861

BRN
TS8
C34SA BK/WH C1P-8
CE SEE DETAIL A
CR13
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE

RD/BK L4 BK/WH-8
GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
E
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
C1P(GY) RD WL1
D27
JC2-5 BK
TS48
J1-2 RD/WH JC2-4
JC1-5 YEL J1-1 WH/RD JC2-3
TS7
JC2-2 BRN
C18JD GR/BK C4P-6
JC3-5 BL J1-11 OR JC2-2
JC2
WH
JC3-3 OR J1-12 BR JC2-1
JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2
PLATFORM
C28TTA RD/BK C1P-2
1
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
RD L4 3
D40
HORN
GR-43 NO
P3
H1
RED/BLK-28 4
D39
ALARM
GR/BK L48
TILT
RED-TILT RED-TILT
BRN
C
Z-60/34
BRN BATGND
(GND STUD)
WH TS1
B


DRIVE ENABLE SWITCH

START ENGINE SWITCH
DRIVE SPEED SWITCH

JIB UP/DOWN SWITCH
GENERATOR OPTION
GLOW PLUG OPTION
COMPONENT INDEX
C.E. PLATFORM LED

COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH
HI/L0 RPM SWITCH
CR27
CR30
JIB DELAY RELAY

TILT ALARM LED
JIB TIME DELAY
HORN SWITCH
TILT ALARM
A
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
CP2-2 OR R40LS1
WH/RD C32BRK
CR14
TS13
TS15
TS48
TS17
TS14
TS6
JC1
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
C1
P3
P2
L1
L4
WH TS7
6 - 48
1
8
6 - 49
1
WH
PBOX WIRING
A
C19JSV GR/WH TS7

HARNESS
C19JSV GR/WH C4P-7 RD L48

BR BK
BR JC3
EMERGENCY STOP
BR GND RD RD LS18
RD-E-STOP 1 1 1
P134PWR RD-H1+ P22BAT BK C7P-1
GR/WH
CR13-#86 GR/WH BR
NC NC
P2
J1-5 BL/WH JC3-5 NC

RD LS18 CABLE

C1
GR/WH
J1-5 BL/WH JC3-3 2 2 2

RD OUTPUT
J1-13 OR JC3-2 WH-23

J1-14 BR JC3-1
GR/WH +
CR14
JC3
P134PWR RD
BR -
JIB
OPT.
GR/WH RD
B
R20
P134PWR RD RD-P2
4700
LOAD SENSE OPTION
RD-H1+
DRIVE/STEER
U35
COM
GENERATOR
LS18
NO
Z-60/34
GR/WH-45
(OPTION)
2
5
3
D88
TS17
P26ESTP BK E-STOP R26ESTP BK C9P-1

BR GND
D89
+
+
C
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12

HIGH/LOW

RPM

JIB
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
TS4
GR/BK H1
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
RD

P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
D

NOTE:
C3P
TS2
C45GEN GR/WH C2P-7

F.S.
C9P
TS48-WL1 RD C2P-12
BK-33
F.S.
TS48-WL2 RD C2P-11
START
JDALARM GR/BK C2P-6

WH-24
DRIVE ENABLE
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11

3
Part No. 75861

J3
BK-22
E
TS6

C13DRE BL/RD C4P-1
June 2015
12V BATT
C11SBD BL/BK C3P-11

C7P
HIGH/LOW
C12SBF BL/WH C3P-12

TS14

P24FS WH
JC1

C7P

C2PBD RD/BK C3P-2
DRIVE
SPEED
6
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P

AUXILIARY
C5TRR WH/BK C3P-5

PUMP
C4P(BR)
ALC-500

SECONDARY BOOM
C4TRL WH C3P-4
F
TS1
C29MS RD/WH C1P-3

UP/DOWN
J2
WH
WH-JIB
C3P
WH-JIB
C3P(GR)
C35RPM BK/RD C1P-9
BRN
TS8
C34SA BK/WH C1P-8

CE SEE DETAIL A
CR13
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE

RD/BK L4 BK/WH-8 GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
G
C1P(GY) RD WL1
D27
JC2-5 BK
TS48

J1-2 RD/WH JC2-4
JC1-5 YEL J1-1 WH/RD JC2-3
TS7
JC2-2 BRN
C18JD GR/BK C4P-6
JC3-5 BL J1-11 OR JC2-2
JC2
WH
1
JC3-3 OR J1-12 BR JC2-1

JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2
PLATFORM
C28TTA RD/BK C1P-2
6
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
H
RD L4 3
D40
HORN
GR-43 NO
P3
H1
RED/BLK-28 4
D39
ALARM
GR/BK L48
TILT
RED-TILT RED-TILT
BRN
I
PLATFORM BOX AT SERIAL NUMBER 10388

WORK LIGHT OPTION REMOVED FROM
BRN BATGND
(GND STUD)

WH TS1
DRIVE ENABLE SWITCH

START ENGINE SWITCH
DRIVE SPEED SWITCH

JIB UP/DOWN SWITCH
GENERATOR OPTION
GLOW PLUG OPTION
J
COMPONENT INDEX
C.E. PLATFORM LED

COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH

HI/L0 RPM SWITCH
JIB DELAY RELAY
TILT ALARM LED

JIB TIME DELAY
HORN SWITCH
TILT ALARM
CR27
CR30
1
CR14
TS13
TS15
TS48
TS17
TS14
JC1
TS6
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
C1
P3
P2
L1
L4
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
WH/RD C32BRK
CP2-2 OR R40LS1
K
WH TS7
L
M
N

6 - 49
6 - 50
Ford Electrical Schematic - View 1

6 - 52
6 - 51
December 2015

1 RD/BK
TB41 C2-3 OR/BK
P26ESTP BK BK
P2 FS1 RD-(FS)
BK-(FS) C9-3 P25FS RD
C9-1 BK
WH-(FS) C9-2 P24FS WH WH
2 RD C28TTA RD/BK
TS2
C134PWR OR/RD
P22BAT BK
SEE NOTE 2
GENERATOR
TS17
C41RPM OR/BK
L4 TS4
TS3
H1 L48 TS1
P3
HIGH RPM(FS)
TB 132 IS WAGO TERMINAL BLOCK 38 HORN D39
C1-7
D40 SEE NOTE 2
C2-7
C2-1
C2-4
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
3
RD
CB2 P1
TB134
C1-9
RD
15AMP. RD RD
RD
TB43
TS51
C35ESPD BK/RD
KS1 TB22 TS52 TS55
C45GEN GR/WH
C27AUX RD
C133PLA OR/RD
C28TTA RD/BK
P23BAT WH
TS53
C33STR BK
PLAT
FUNCTION ENA.
LOW RPM
HIGH RPM
START
GRD TB39
RD
ENGINE
C43HRN GR
BK
4
TB27
TB33
TB23 1 START RELAY

RD
CB1 2 TACHOMETER TB45 TB35

TB20 15AMP. 3 START INPUT
4 AUX. ON IGN./START TS22
5 GROUND
TB133 TB28 TB24 6 BATTERY MODULE
RD 7 KEY PWR.
U1 L2
TEST
RUN
8 KEY BYPASS
CB3 CR5 9 IGN./FUEL ON
CR1
5 20AMP. NO CR5
CR1 CR2
NO
10 ENG. FAULT
NO
CR2
TB21
P24BAT
GR/WH-45
OTS
RD-23
RD/BK-28
NO TB24
TB25
C35RPM2
C211GN2
G2 TB26 G3
BK-43
C38ESL
OR/BK-41
RD-27
BK-33
WH-21
C39LP
6
TSW
ALTERNATOR CR17 CR17
NO
RD
WH
EXCT. PR1
WH/BK
WH-24
WH-24
WH/RD
PR1
NO
OR/RD (FEH 307A) PIN23

BAT. BAT. PR2 PR2
BL/WH (FEH 787) PIN5

-
BK/RD (FEH 458) PIN3

12 V DC +
BK/WH (FEH 72) PIN7

BR (FEH 570C) PIN34
NO
WH (FEH 306) PIN24

WH (FEH 16A) PIN1
S7
RD (FEH 361) PIN9

+
BL (FEH 658) PIN6

FB G6 FUEL
DGRN (FEH 242)
STA.
PUMP
RD (FEH 361A)
M1 + OPS S2 S1 OTS
AUX Y29
M2 PUMP HM G1 NO
H2
BK
REGULATOR STARTER
- IND.
FAN _ NC
7
BRN
BRN
(OPTION)
TEMP. SWITCH
HYDRAULIC OIL
STARTER MOTOR
RELAY
IGN./START RELAY
GENERATOR
SERVICE HORN
RELAY
SWITCH
COOLING FAN
FUEL PUMP
OPTION
HOUR METER
SWITCH
LEVEL SENSOR
FLASHING BEACONS
TILT ALARM
OIL PRESSURE
FUEL RELAY
OIL PRESSURE GAUGE
OPTION
WATER TEMP
WATER TEMP GAUGE

SERVICE HORN
VOLT METER
AUXILIARY POWER
AUXILIARY PUMP
FORD
ENGINE
HARNESS
LOCKOUT
LPG
SOLENOID
FORD
42 PIN PLUG
8
NOTE:
2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
6 - 52 Z-60/34 Part No. 75861


6 - 53
1
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TB30
Y51
C1P-4 C30EDC+ WH C30EDC+ WH A B

B
L1
J1
C1P-5 C31EDC- WH/BK C31EDC- WH/BK D C

16
TB31
H3
TS15

7
Y2

Z-60/34
6 C1P-6 C32BRK WH/RD

TB32
7 20
DRIVE & STEERING
RKOUT 6 WH 5
TB37
C
YOUT 5 BL 4
Y3
JC3
C1P-11 C37STCC BL/BK C37STCC BL/BK

J1
4 18 STEER RIGHT
PWR 3 OR 13
Y4
C1P-10 C36STC BL C36STC BL

GND 2 BRN 14 17 STEER LEFT
TB36
1
C3P-6 C6TRF WH/RD
11
C3P-5 C5TRR WH/BK
9
C3P-4 C4TRL WH
Y23
D
10
C4TRL WH
TB4
Y29
5 R5
C5TRR WH/BK
TS62

TB5
Y13

6 FLOW CONTROL
TB6
R4
TB1
YOUT 5 BK
7.5
Y22
2
JC2
Part No. 75861
PRIMARY BOOM UP
J1
TB2
PWR 3 OR 11 UP PRIMARY BOOM

Y21
E
DOWN C2PBD RD/BK

TS61
J2
GND 2 BRN 12 PRIMARY BOOM DOWN

June 2015
1
TB3
Y12

FLOW CONTROL
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
H4
C3P-3 C6-19 RD/BK

C3PBF RD/WH DESCENT ALARM OPTION
F
8
C3P-12
14
Y53
7 C3P-11
13 C105BU BL
6 SECONDARY BOOM UP
OUT 5 YEL C3P-10
Y52
3 12
JC1
4 C115BD BL/BK
J1
UP SECONDARY BOOM DOWN

TB10
PWR 3 OR 9 SECONDARY BOOM

Y14
GND 2 BRN 10 DOWN C125BF BL/WH

TS60
SECONDARY BOOM
1 FLOW CONTROL
TB11
G
TB12
BRN
NCHO
1 CABLE #6 WH
SECONDARY BOOM
TB13
P24FS WH
2 BK OPERATION
J3
P24FS WH C4P-1 C13DRE BL/RD C13DRE BL/RD CABLE #6

TB43
4 3
P26ESTP BK
3
NCHO
CABLE #7
H
WH
C2P-2 C40LS1 OR C40LS1 OR PRIMARY BOOM
4 BK OPERATION
TB40
CABLE #7
TB44
NOHC
CABLE #8 WH
BOOM RETRACTED
TB46
C46PWR WH BK OPERATION
CR30
CR27
CE NO
NC
OPTION
NOHC
WH
I
DRIVE
LS3
LIFT/
TB46
C46PWR WH BK DRIVE ENABLE
C3P-8 C8PBR BK/WH
RETRACT
BOOM
TS13
EXTEND C7PBE BK
Y25
C3P-7
TS63
C8PBR BK/WH
BOOM RETRACT
RETRACT
TB8
Y26
BOOM
J
WH
EXTEND C7PBE BK BOOM EXTEND

TB7
C4P-2 C14PLU OR
UP PLATFORM LEVEL
TS9
DOWN C15PLD OR/BK
Y19 Y20
C4P-3
TS59
C14PLU OR
PLAT LEVEL UP
TB14
UP PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
K
TB44
GR/BK-44 C2P-6 JDALARM GR/BK
CR13
NC
C4P-6 C18JD GR/BK

DOWN
UP JIB BOOM
TS8
C4P-5 C17JU GR
Y16
C18JD GR/BK
TS58
PLATFORM ROTATE RIGHT / JIB DOWN
TB18
DOWN
Y17
JIB BOOM
UP C17JU GR
L
PLATFORM ROTATE LEFT / JIB UP
TS57
TB17
RIGHT
PLAT ROTATE RIGHT
LEFT PLAT ROTATE
TS7
LEFT
WH
AMP
7
6
5
3
4
2
1
C4P-7
C19JSV GR/WH

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
TB19
Pin1
CR13
C19JSV GR/WH
M
RKOUT
Y18
XOUT
YOUT
PWR
GND
BRN
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVES JIB VALVES
Deutsch
3
1
2
N
RD/BK
OR/BK
BRN
5
6
4
WH
RD
RD
BK

6 - 53
6 - 54

6 - 56
6 - 55
N
BRN
RD
RD
WH
BL/WH
BK
RD/BK
OR/BK
HIGH RPM(FS) C1-9

C35ESPD BK/RD
TS55
LOW RPM
FUNCTION ENA.
M
HIGH RPM
TS4
TB35
TS17
TB45
Y29
C2-7 C45GEN GR/WH GR/WH-45 GENERATOR

OPTION
GENERATOR
L
C3-9 DLITE BK/RD

CR23
L29
RD DRIVE LIGHT
TS49
WH C4B-12 OPTION
PBOX GND
L29
BK
L30
RD WORK LIGHTS
K
FUSE 10A
C4B-11 OPTION
CR23
NO
WH BK
L30
F18
RD (FEH 361A)
HARNESS
LPG
ENGINE
FORD
LOCKOUT
DGRN (FEH 242) SOLENOID
J
G1
VOLT METER
WH-21
HM
HOUR METER
+
G6
_
G3
WATER TEMP GAUGE

I
TB26
C5-14 WH/RD
OTS
L2
OPS
TB25
C5-16 WH/BK
C1-7 C33STR BK
TS2
G2
OIL PRESSURE GAUGE

C2-3
TS52
H
TS22
CR1
ENGINE
START
BK
TB33
CR1
NO
C5-12 C127TST GR PIN 18

CR2
C5-17 C21IGN WH PIN 21

C5-13 C38ESL BL/WH PIN 6
42 PIN PLUG
C5-9 C35RPM BK/RD PIN 23
G
CR2
BK PIN 15
NO
C5-5 R33STR
FORD
TB21
C2-1 BR PIN34
TB41
TB24
C5-8 R21IGN
TB39
WH PIN 24
TS3
C5-10 C39LP BL/RD PIN 7

TS53
VBATT RD PIN 9
3
CR39
BL/WH PIN 5
P24FS WH
P25FS RD
P26ESTP BK

C28TTA RD/BK
PUMP
FUEL
THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

FUEL PUMP
F
C5-11 VSW WH PIN 1

C9-3
C9-2

C33STR BK PIN 13
CR39
NC
REFER TO E0375 FOR FORD HARNESS

TS51
START RELAY
June 2015
Part No. 75861

WH-(FS)
RD-(FS)
BK-33
PR2
TB27
TS1
STARTER
STARTER MOTOR
PR2
NO
E
RD
FS1
BK-(FS)
C1-1 C27AUX RD RD-27 AUXILIARY POWER

RELAY
PR1
PUMP
NOTE:
AUXILIARY PUMP
AUX
C9-1 BK
PR1
NO
3
C7-2 P23BAT WH
TB23
P2
L48
TB28
S7
D
RD/BK-28 WH TILT ALARM
M2
C1-2 C28TTA RD/BK
D40
RD-23 RD BK BRN
LEVEL SENSOR
FLASHING BEACONS
FB
OPTION
CR5
HORN
P3
C2-5 C43HRN GR SERVICE HORN

RELAY
C
CR5
NO
RD
TB43
BK-43
SERVICE HORN
Z-60/34
H2
P22BAT BK C7-1
CR17
OTS
NO
C134PWR OR/RD C2-4
HYDRAULIC OIL
TEMP. SWITCH
CR17
NO
M1
COOLING FAN
FAN
TB134
(OPTION)
RD
C41RPM OR/BK
B
C41RPM OR/BK PIN 2

42 PIN FORD CONNECTOR
TB22
EXCT.
STA.
BAT.
IND.
-
PLAT
GRD
ALTERNATOR
OHM
RD
REGULATOR
510
KS1
RD
20AMP.
15AMP.
BAT.
+
CB3
CB1
A
P1
RD
TB20
-
15AMP.
CB2
12 V
DC
RD
6 - 56
1
8
6 - 57
1
BRN
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
HI

C29MS RD/WH
L1
J1

D
C
B

16
H3
TS15

7
TB32
DRIVE ENABLE
Y2

Y27
Z-60/34

20 MOTOR STROKE
TB36 TB37
Y3

18 STEER CCW
C
DRIVE & STEERING
RKOUT 6 WH 5
Y4

17 STEER CW
JC3
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
LEFT TURNTABLE ROTATE CW
TTROTATE
Y29
D

TS62

TB5
Y13
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
PRIMARY BOOM UP
J1
OR UP
TB2

Y21
DOWN C2PBD RD/BK

TS61
GND 2 BRN 12
J2
PRIMARY BOOM DOWN

1
Part No. 75861
TB3
Y12
E

FLOW CONTROL
June 2015
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK

7 8
H4
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
F
J1
PWR 3 OR 9 C3P-10
12
Y53

1 SECONDARY BOOM UP
UP
TB11 TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

TS60
SECONDARY BOOM DOWN

Y14

FLOW CONTROL
TB12
G
BRN
1 WH
NCHO

TB13
2 BK OPERATION
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO

4 OPERATION
TB40
BK
SJ1 WH

WH
NOHC
H
BOOM RETRACTED
BK OPERATION
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
I
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH

TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
J
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
C4P-6 C18JD GR/BK

NC
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
K
C18JD GR/BK
TS58 DOWN
JIB BOOM
Y17
UP C17JU GR
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
C4P-7
L
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
Y18
BRN
JIB VALVE
JIB VALVE
M
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
N

6 - 57
6 - 58

6 - 60
6 - 59
N
BRN
RD
RD
WH
BL/WH
BK
RD/BK
OR/BK
HIGH RPM(FS) C1-9

C35ESPD BK/RD
TS55
LOW RPM
FUNCTION ENA.
M
HIGH RPM
TS4
TB35
TS17
TB45
Y29
C2-7 C45GEN GR/WH GR/WH-45 GENERATOR

OPTION
GENERATOR
L
C3-9 DLITE BK/RD

CR23
L29
RD DRIVE LIGHT
TS49
WH C4B-12 OPTION
PBOX GND
L29
BK
L30
RD WORK LIGHTS
K
FUSE 10A
C4B-11 OPTION
CR23
NO
WH BK
FUSE 10A
L30
F18
RD (FEH 361A)
HARNESS
LPG
ENGINE
FORD
LOCKOUT
DGRN (FEH 242) SOLENOID
J
G1
VOLT METER
WH-21
HM
HOUR METER
+
G6
_
G3
WATER TEMP GAUGE

I
TB26
C5-14 WH/RD
OTS
L2
OPS
TB25
C5-16 WH/BK
C1-7 C33STR BK
TS2
G2
OIL PRESSURE GAUGE

C2-3
TS52
H
TS22
CR1
ENGINE
START
BK
TB33
CR1
NO
C5-12 C127TST GR PIN 18

CR2
C5-17 C21IGN WH PIN 21

42 PIN PLUG
G
CR2
BK PIN 15
NO
C5-5 R33STR
FORD
TB21
C2-1 BR PIN34
TB41
TB24
C5-8 R21IGN
TB39
WH PIN 24
TS3

TS53
VBATT RD PIN 9
CR39
BL/WH PIN 5
P24FS WH
P25FS RD
P26ESTP BK
C28TTA RD/BK
PUMP
FUEL
FUEL PUMP
F
C5-11 VSW WH PIN 1

C9-3
C9-2
C33STR BK PIN 13
CR39
NC
TS51
START RELAY
June 2015
Part No. 75861

WH-(FS)
RD-(FS)
BK-33
PR2
TB27
TS1
STARTER
STARTER MOTOR
PR2
NO
E
RD
FS1
BK-(FS)
C1-1 C27AUX RD RD-27 AUXILIARY POWER

RELAY
PR1
PUMP
AUXILIARY PUMP
AUX
C9-1 BK
PR1
NO
C7-2 P23BAT WH
TB23
P2
L48
TB28
S7
D
RD/BK-28 WH TILT ALARM
M2
C1-2 C28TTA RD/BK
D40
RD-23 RD BK BRN
LEVEL SENSOR
FLASHING BEACONS
FB
OPTION
CR5
HORN
P3

RELAY
C
CR5
NO
RD
TB43
BK-43
SERVICE HORN
Z-60/34
H2
P22BAT BK C7-1
CR17
OTS
NO
C134PWR OR/RD C2-4
HYDRAULIC OIL
TEMP. SWITCH
CR17
NO
M1
COOLING FAN
FAN
TB134
(OPTION)
RD
C41RPM OR/BK
B
C41RPM OR/BK PIN 2

TB22
EXCT.
STA.
BAT.
IND.
-
PLAT
GRD
ALTERNATOR
OHM
RD
REGULATOR
510
KS1
RD
20AMP.
15AMP.
BAT.
+
A
CB3
CB1
P1
RD
TB20
-
15AMP.
CB2
12 V
DC
RD
6 - 60
1
8
6 - 61
1
BRN
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
HI

C29MS RD/WH
L1
J1

D
B

16
H3
TS15

7
TB32
DRIVE ENABLE
Y2

Y27
Z-60/34

20 MOTOR STROKE
TB36 TB37
Y3

18 STEER CCW
C
DRIVE & STEERING
RKOUT 6 WH 5
Y4

17 STEER CW
JC3
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
TTROTATE
Y29
D

TS62

TB5
Y13
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
PRIMARY BOOM UP
J1
OR UP
TB2

Y21
DOWN C2PBD RD/BK

TS61
GND 2 BRN 12
J2
PRIMARY BOOM DOWN

Part No. 75861
1
TB3
Y12
E

FLOW CONTROL
June 2015
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK

7 8
H4
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
F
J1
PWR 3 OR 9 C3P-10
12
Y53

1 SECONDARY BOOM UP
UP
TB11 TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

TS60
SECONDARY BOOM DOWN

Y14

FLOW CONTROL
TB12
G
BRN
1 WH
NCHO

TB13
2 BK OPERATION
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO

4 OPERATION
TB40
BK
SJ1 WH

WH
NOHC
H
BOOM RETRACTED
BK OPERATION
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
I
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH

TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
J
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
C4P-6 C18JD GR/BK

NC
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
K
C18JD GR/BK
TS58 DOWN
JIB BOOM
Y17
UP C17JU GR
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
C4P-7
L
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
Y18
BRN
JIB VALVE
JIB VALVE
M
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
N

6 - 60
6 - 62

6 - 64
6 - 63
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
M
HIGH RPM(FS) C1-9 C35ESPD BK/RD

TS4
TS55
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
L
TS17
TB45
Y29
C2-7 C45GEN GR/WH GR/WH GENERATOR

OPTION
GENERATOR
CR23
C3-9 DLITE BK/RD

K
L29
DRIVELIGHT
TB9
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
TS48
WH BK
L29
PBOX GND
RD WORK LIGHTS
WORKLIGHT
FUSE 10A
C4B-10 OPTION
CR23
FUSE 10A
C4-9
NO
WH BK
F18
L30
J
G1
VOLT METER
R21IGN WH
HM
HOUR METER
G6
+
_
I
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

TB33
CR1
C1-7 C33STR BK
TS2
H
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
D BK/BL
RD/GN
TS22
LPG LOCKOUT
WH/BK
G

C5-3 C107AF WH
500
R4
WATER TEMP GAUGE

G3
TB26

C26TSR WH/RD PIN 39
TB39
C5-14
C2-1
C5-12 C127TSW GR PIN 3
CR2
TS3
LP C5-17 C21IGN WH PIN 16

FUEL
TS53
GAS LP C5-9 C35RPM BK/RD PIN 23

FUEL
F
GAS C5-5 R33STR BK PIN 15

TB21
CR2
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK
TB24
C5-8 R21IGN WH PIN 24 FORD

42 PIN PLUG
FUEL PUMP
C135FP BL/WH PIN 5
June 2015
Part No. 75861

CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
FUEL
RD-(FS)
TS51
AUXILIARY
PUMP AUXILIARY C5-11 VSW WH PIN 1
PUMP
NOTE:
CR39
E
C9-3
C9-2
NC
TB27
L2
RD
FS1
1K
R2
C1-1 C27AUX RD RD AUXILIARY POWER
C9-1
RELAY
PR1
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
D
C7-2 P23BAT WH
P2
TB28
L48
RD/BK WH TILT ALARM
M2
C1-2 C28TTA RD/BK

S7
RD RD BK BRN LEVEL SENSOR

FLASHING BEACONS
FB
OPTION
CR5
HORN
C
P3
RELAY
Z-60/34
TB43
CR5
NO
R34HRN BK
SERVICE HORN
P22BAT BK C7-1
H2
CR17
OTS
NO
C134PWR RD C2-4 WH BK HYDRAULIC OIL
TEMP. SWITCH
CR17
M1
NO
BR COOLING FAN
TB134
RD
FAN
(OPTION)
B
RD
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
TB41
BLUE/PINK
FORD ENGINE HARNESS
TB22
START RELAY
PLAT
GRD
CB1
CB3
STARTER MOTOR
KS1
A
1
2
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 64
1
8

6 - 65
1
BRN
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
HI

C29MS RD/WH
L1
J1
C5-20
B
C1P-5 C31EDC- WH/BK C31EDC- WH/BK

D

16
H3
TS15

7
TB32
DRIVE ENABLE
Y2

Z-60/34
Y27

20 MOTOR STROKE
TB36 TB37
Y3
C37STCC BL/BK
C
7 C1P-11 C37STCC BL/BK

18 STEER CCW
DRIVE & STEERING
RKOUT 6 WH 5
Y4

17 STEER CW
JC3
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D
TTROTATE
Y29

TS62

TB5
Y13
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
5
Y22
JC2
PRIMARY BOOM UP
J1
OR UP
TB2

Y21
DOWN C2PBD RD/BK

TS61
GND 2 BRN 12
Part No. 75861
J2
PRIMARY BOOM DOWN

1
E
TB3
Y12

June 2015
FLOW CONTROL
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK

7 8
H4
6 C3P-12
14
OUT 5 YEL 3
F
C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
Y53

1 SECONDARY BOOM UP
UP
TB11 TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

TS60
SECONDARY BOOM DOWN

Y14

FLOW CONTROL
TB12
G
BRN
1 WH
NCHO

TB13
2 BK OPERATION
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO

4 OPERATION
TB40
BK
SJ1 WH
H

WH
NOHC
BOOM RETRACTED
BK OPERATION
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE

I
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH

TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
J
DOWN C15PLD OR/BK

TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
C4P-6 C18JD GR/BK

NC
K
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
TS58
DOWN
JIB BOOM
Y17
UP C17JU GR
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
L
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
AMP
7
6
5
3
4
2
1
Y18
BRN

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
JIB VALVE
M
JIB VALVE
RKOUT
XOUT
YOUT
PWR
GND
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6 Deutsch
3
1
2
N
5
6
4

6 - 65
6 - 66

6 - 68
6 - 67
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
M
RD
HIGH RPM(FS) C1-9 C35ESPD BK/RD

TS4
TS55
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
L
TS17
TB45
Y29

OPTION
GENERATOR
K
CR23
C3-9 DLITE BK/RD

L29
DRIVELIGHT
TB9
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
TS48
WH BK
L29
PBOX GND
RD WORK LIGHTS
WORKLIGHT
FUSE 10A
C4B-10 OPTION
CR23
C4-9
FUSE 10A
NO
WH BK
F18
L30
J
G1
VOLT METER
R21IGN WH
HM
HOUR METER
G6
+
_
I
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

TB33
CR1
H
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
D BK/BL
L2 LED LAMP REPLACED WITH INCANDESCENT LAMP AT SERIAL NUMBER 9066

RD/GN
TS22
LPG LOCKOUT
WH/BK
G

C5-3
WATER TEMP GAUGE
G3

TB26

C26TSR WH/RD PIN 39
TB39
C5-14
RESISTOR R2 REMOVED AT SERIAL NUMBER 7924.

C2-1
RELAY PR8 ADDED AT SERIAL NUMBER 9917

CR2
TS3

FUEL
TS53
GAS LP
F

FUEL
TB21
CR2
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK
TB24

42 PIN PLUG
June 2015
Part No. 75861

FUEL PUMP
C135FP BL/WH PIN 5
CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
FUEL
RD-(FS)
TS51
AUXILIARY
E
PUMP
NOTE:
CR39
C9-3
C9-2
NC
4
2
TB27
L2
RD
FS1
1K
R2
1
C9-1
RELAY
PR1
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
D
C7-2 P23BAT WH
P2
TB28
L48
TILT ALARM
RD/BK WH
M2
C1-2 C28TTA RD/BK
S7
RD RD BK BRN LEVEL SENSOR
FLASHING BEACONS
FB
OPTION
C
CR5
HORN
P3
Z-60/34
RELAY
TB43
CR5
NO
R34HRN BK
SERVICE HORN
P22BAT BK C7-1
H2
CR17
OTS
NO
C134PWR RD C2-4 WH BK HYDRAULIC OIL
TEMP. SWITCH
CR17
M1
NO
RD BR COOLING FAN
FAN
TB42
3
(OPTION)
B
RD
TB41
GND BR
BLUE/PINK
FORD ENGINE HARNESS
PR8
NO
TB22
4
START RELAY
PLAT
RD
GRD
CB1
CB3
STARTER MOTOR
KS1
A
1
2
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 68
1
8

6 - 69
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1

B

16
H3

TS15
7
TB32

Y2

Y27
Z-60/34

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING

18 STEER CCW
C
YOUT 4 WH/RD 5
JC3
TB36
XOUT 3 BL/WH 4
J1
Y4

GND 1 BR 14
C3-6 C6TRF WH/RD
11
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
Y29
D
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
Part No. 75861
TB3
Y12
C3PBF RD/WH
E
PRIMARY BOOM
FLOW CONTROL
C3-1 C1PBU RD
June 2015
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
F
C3-10
J1
D29
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

SECONDARY BOOM DOWN
TS60
TB11

Y14

FLOW CONTROL
TB12
BR
G
1
NO
NC
14 13
WH
22 21
43

TB13
2 OPERATION

J3

4
SJ2 WH
3
P26ESTP BK
3
NO
NC

14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH

NO
NC
22 21
13
H
BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
I
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
J
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
K

TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
L
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
M
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 69
6 - 70
Ford Electrical Schematic, ANSI / CSA - View 1

6 - 72
6 - 71
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
RD
M
D12
HIGH RPM(FS) C1-9 C35RPM BK/RD

TS4
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
L
TS17
TB45
Y29

OPTION
GENERATOR
K
WORK LIGHTS
OPTION
CR23
L29
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
C4B-10
CR23
C4-9
FUSE 10A
NO
WH BK
L30
J
G1
VOLT METER
R21IGN WH
HM
HOUR METER
G6
+
_
I
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

TB33
CR1
H
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
D BK/BL
RD/GN

TS22
LPG LOCKOUT
WH/BK
G
C5-3

WATER TEMP GAUGE
G3
TB26
TB39
C5-14 C26TSR WH/RD PIN 39

C2-1
CR2
TS3

FUEL
TS53
D10
GAS LP
F

TB24
FUEL
TB21
CR2
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK

42 PIN PLUG
June 2015
Part No. 75861

FUEL PUMP
C135FP BL/WH PIN 5
D3
CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
D4
FUEL
RD-(FS)
NOTE:
TS51
AUXILIARY
E
PUMP
CR39
C9-3
C9-2
NC
TB27
L2
RD
FS1

C9-1
RELAY
PR1
CR45
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
CR45
NO
D
NO
C7-2 P23BAT WH
P2
TB28
L48
RD/BK WH TILT ALARM
M2
C1-2 C28TTA RD/BK
S7
D40
RD RD BK BRN
D2
LEVEL SENSOR
D39
FLASHING BEACONS
FB
OPTION
C
CR5
HORN
P3
Z-60/34
(from serial number 10388 to 11788)
RELAY
TB43
CR5
NO
R34HRN BK
TB133
P22BAT BK SERVICE HORN
H2
CR17
OTS
NO
TB132
WH BK HYDRAULIC OIL
8
7
5
TEMP. SWITCH
CR17
M1
C132PLI1 BL/WH C1-12
NO
CONN.
3
BR COOLING FAN
PLUG
RD
FAN
C32
P134PWR RD C2-4 (OPTION)
B
RD
12
6
4
TB41
GND BR
BLUE/PINK
TB134
FORD ENGINE HARNESS
PR8
NO
TB22
START RELAY
PLAT
RD
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
A
KS1
1
2
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 72
1
8

6 - 73
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1

B

16
H3

TS15
7
TB32

Y2

Y27
Z-60/34

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING

18 STEER CCW
C
YOUT 4 WH/RD 5
JC3
TB36
XOUT 3 BL/WH 4
J1
Y4

GND 1 BR 14
C3-6 C6TRF WH/RD
11
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
Y29
D
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
Part No. 75861
TB3
Y12

E
FLOW CONTROL
C3-1 C1PBU RD
June 2015
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
F
C3-10
J1
D29
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

SECONDARY BOOM DOWN
TS60
TB11

Y14

FLOW CONTROL
TB12
BR
G
1
NO
NC
14 13
WH
22 21
43

TB13
2 OPERATION

J3

4
SJ2 WH
3
P26ESTP BK
3
NO
NC

14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH

NO
NC
22 21
13
BOOM RETRACTED
H
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
I
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
J
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
K

TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
L
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
M
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 73
6 - 74

6 -76
6 - 75
N
BL/WH
BRN
WH
RD
RD
RD/BK
OR/BK
BK
RD
D12

TS4
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
M
HIGH RPM
TB35
D13
TS17
TB45
Y29

OPTION
GENERATOR
L
WORK LIGHTS
OPTION
L29
CR23
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
K
C4B-10
CR23
C4-9
NO
FUSE 10A
WH BK
L30
J
VOLT METER
G1
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
I
G2
OIL PRESSURE GAUGE

TB33
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
H
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
CR1
DIAGNOSTIC
NO
D BK/BL
RD/GN
TS22

LPG LOCKOUT
WH/BK

WATER TEMP GAUGE
G3
G
TB26
C26TSR WH/RD PIN 39

TB39
C5-14
C2-1
CR2
TS3

FUEL
TS53
D10

TB24
FUEL
TB21
CR2
NO
P24FS WH
P26ESTP BK
C28TTA RD/BK
P25FS RD

42 PIN PLUG
F

C135FP BL/WH PIN 5
FUEL PUMP
D3
CR39
C135RET BL PIN 18
WH-(FS)
TS1
PUMP
D4
FUEL
RD-(FS)
NOTE:
TS51
June 2015
Part No. 75861

AUXILIARY
PUMP
CR39
C9-3
C9-2
NC
E
TB27
L2
RD
FS1

C9-1
RELAY
PR1
CR45
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
CR45
NO
C7-2 P23BAT WH
P2
TB28
D
L48
RD/BK WH TILT ALARM
M2
C1-2 C28TTA RD/BK
S7
D40
RD RD BK BRN
D2
LEVEL SENSOR
D39
FLASHING BEACONS
FB
OPTION
CR5
HORN
P3
C43HRN GR
C
C2-5 SERVICE HORN

RELAY
TB43
CR5
NO
R34HRN BK
Z-60/34
TB133
H2
OTS
CR17
NO
TB132
WH BK HYDRAULIC OIL
8
7
5
TEMP. SWITCH
M1
CR17
NO
CONN.
3
BR COOLING FAN
PLUG
RD
FAN
C32
1
RD
B
12
6
4
TB41
BLUE/PINK
TB134
FORD ENGINE HARNESS
TB22
START RELAY
PLAT
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
A
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 76
1
8
6 - 77
1
C7-3 BR-2
GROUND
C41RPM OR/BK
A
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
B
J1

16
H3
TS15

7
TB32

Y27 Y2
6 C1-6 C32BRK WH/RD

Z-60/34

20 MOTOR STROKE
6
DRIVE & STEERING
TB36 TB37
RKOUT 5BL/WH
C
Y3

YOUT 4WH/RD 5 18 STEER CCW
JC3
XOUT 3BL/WH 4
J1
C36STC BL
Y4
C1-10 C36STC BL STEER CW

PWR 2 OR 13 17
GND 1 BR 14
11 C3-6 C6TRF WH/RD
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
D

Y29
C5TRR WH/BK
R4
TS62

TB5
Y13

FLOW CONTROL
TB6
5
R5
TB1
5
Y22
YOUT 4 RD/WH
JC2
2 PRIMARY BOOM C1PBU RD

J1

UP
TB2
PWR 2 OR 11
Y21
Part No. 75861
DOWN C2PBD RD/BK

TS61
J2

E
TB3
Y12
June 2015

FLOW CONTROL
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 C3PBF RD/WH RD/BK

8 DESCENT ALARMN
6
H4
C3-12
5 14
F
OUT 4 WH/BK 3 C3-11

JC1
13
3
D29
J1
C3-10
PWR 2 OR 9 12
Y53
GND 1 BR 10 SECONDARY BOOM C10SBU BL

SECONDARY BOOM UP
UP
TB10
Y52
DOWN C11SBD BL/BK

TS60
SECONDARY BOOM DOWN

TB11
Y14

FLOW CONTROL
TB12
G
BR
1
NO
NC
14 13
WH
22 21

SECONDARY BOOM
43
P24FS WH BK
TB13
2 OPERATION
J3

SJ2 WH
4 3

P26ESTP BK 3
NO
NC
14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH
H
NO
NC
22 21
14 13
BOOM RETRACTED
WH
21 OPERATION
BK

CR27
CR30
NO
NC
OPTION
NO
NC
DRIVE
22 21
14 13
LS3
LIFT/
P23PWR RD DRIVE ENABLE

CE
WH
43
BK
I
C3-8 C8PBR BK/WH

RETRACT
NOTE:
EXTEND
TS13
C7PBE BK
TB8
C3-7
Y25
BOOM BOOM C8PBR BK/WH
TS63
BOOM RETRACT
8
7
6
RETRACT
1.
Y26
EXTEND
WH

C4-2 C14PLU OR TB7
J
UP
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3 PLATFORM LEVEL C14PLU OR
TS59
PLATFORM LEVEL PLAT LEVEL UP

UP
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
GR/BK-44 TB44
C2-6 JDALARM GR/BK
K
CR13
C4-6 C18JD GR/BK

NC
DOWN
UP
TB18
C4-5 C17JU GR
TS8
Y16
JIB BOOM C18JD GR/BK
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
PLAT ROTATE PLATFORM ROTATE CW / JIB UP
TS7
PLAT ROTATE
TB17
RIGHT
TS57
LEFT RIGHT
LEFT
L
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
+
_
Y18
JIB VALVE
M
JIB TIME
CIRCUIT
JIB VALVE
CR14
DELAY
6
BL/WH
RD/BK
OR/BK
RD
RD
WH
BR
RD
BK
N

6 - 77
6 - 78
Ford Electrical Schematic, CE - View 1

6 - 80
6 - 79
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
RD
M
D12

TS4
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
L
TS17
TB45
Y29

OPTION
GENERATOR
K
WORK LIGHTS
OPTION
CR23
L29
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
C4B-10
CR23
C4-9
FUSE 10A
NO
WH BK
L30
J
G1
VOLT METER
R21IGN WH
HM
HOUR METER
G6
+
_
I
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

TB33
CR1
H
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START A GY/RD
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
P24PWR D BK/BL
RD/GN
10A

NO
TS22
WH/BK LPG LOCKOUT

G
2 SEC
U34
C4-10

WATER TEMP GAUGE
G3
TB26
TB39

C2-1
CR2
TS3

FUEL
TS53
D10
F

TB24
FUEL
TB21
CR2
C28TTA RD/BK
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK

42 PIN PLUG
June 2015
Part No. 75861

FUEL PUMP
C135FP BL/WH PIN 5
D3
CR39
C135RET BL PIN 18
TS1
PUMP
D4
FUEL
NOTE:
TS51
AUXILIARY
PUMP AUXILIARY
C9-2
C9-3
C5-11 VSW WH PIN 1

E
PUMP
CR39
NC
FS1

TB27
L2
BK
RD
C1-1 C27AUX RD
RD AUXILIARY POWER
C9-1
RELAY
PR1
CR45
U35
PUMP
30A
AUXILIARY PUMP
NO
PBOX
2 SEC
GND
PR1
TB23
CR45
NO
D
NO
C7-2 P23BAT WH
P2
TB28
C1-2
RD/BK WH TILT ALARM
M2
C28TTA RD/BK
D40
H1
S7
D39
RD RD BK BRN
D2
LEVEL SENSOR
4.7 K
R20
C132PLI2 BK
L4 GR/BK C4-4 FLASHING BEACONS
FB
OPTION
C
C133PLA OR/RD
CR5
HORN
P3
C43HRN GR
LS18A
C2-5 SERVICE HORN
Z-60/34
LS18
RELAY
TB43
CR5
NO
R34HRN BK
TB133
H2
GN/BK
CR17
OTS
NO
TB132
WH BK HYDRAULIC OIL
8
7
5
L45
TEMP. SWITCH
CR17
M1
NO
CONN.
3
BR COOLING FAN
PLUG
RD
FAN
D89
D88
C32
B
1
PBOX
GND
12
6
H6
4
TB41
GND BR
BLUE/PINK
TB134
FORD ENGINE HARNESS
PR8
NO
TB22
START RELAY
PLAT
RD
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
A
KS1
1
2
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 80
1
8

6 - 81
1
BR-2
GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
Y51
TB30

C29MS RD/WH
TB31
L1
J1

B

16
H3

TS15
7
TB32

Y2

Y27
Z-60/34

20 MOTOR STROKE
6
TB37
RKOUT 5 BL/WH
Y3
DRIVE & STEERING

18 STEER CCW
C
YOUT 4 WH/RD 5
JC3
TB36
XOUT 3 BL/WH 4
J1
Y4

GND 1 BR 14
C3-6 C6TRF WH/RD
11
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
Y29
D
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13

6
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1

UP
TB2
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
Part No. 75861
TB3
Y12
C3PBF RD/WH
E
PRIMARY BOOM
FLOW CONTROL
C3-1 C1PBU RD
June 2015
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
8
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
F
C3-10
J1
D29
PWR 2 OR 9 12
Y53
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
DOWN C11SBD BL/BK

SECONDARY BOOM DOWN
TS60
TB11

Y14

FLOW CONTROL
TB12
BR
G
1
NO
NC
14 13
WH
22 21
43

TB13
2 OPERATION

J3

4
SJ2 WH
3
P26ESTP BK
3
NO
NC

14 13
WH
22 21
21

4 OPERATION
TB40
SJ1 WH

NO
NC
22 21
13
BOOM RETRACTED
H
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
I
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
J
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
CR13
C4-6 C18JD GR/BK

NC
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
K

TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
L
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
M
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N

6 - 81
6 - 82

6 - 84
6 - 83
N
BRN
BL/WH
RD
RD
WH
BK
RD/BK
OR/BK
RD
D12

TS4
ENGINE SPEED
TS55
D14
LOW RPM
M
FUNCTION ENA.
HIGH RPM
TB35
D13
TS17
TB45
Y29

OPTION
GENERATOR
L
WORK LIGHTS
OPTION
L29
CR23
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
K
C4B-10
C4-9
CR23
NO
FUSE 10A
WH BK
L30
J
VOLT METER
G1
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
I
G2
OIL PRESSURE GAUGE

TB33
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START A GY/RD
GY/YL
H
B
FORD ENGINE
C RD GASOLINE SENSOR
HARNESS
CR1
NO
DIAGNOSTIC
P24PWR D BK/BL
RD/GN
10A
NO
TS22
WH/BK LPG LOCKOUT

2 SEC
U34
C4-10
WATER TEMP GAUGE
G3
G

TB26

TB39
C2-1
CR2
TS3

FUEL
TS53
D10

TB24
FUEL
TB21
CR2
NO
C28TTA RD/BK
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK

F
42 PIN PLUG
C135FP BL/WH PIN 5
FUEL PUMP
D3
PUMP
CR39
C135RET BL PIN 18
FUEL
TS1
D4
NOTE:
June 2015
Part No. 75861

TS51
AUXILIARY
PUMP AUXILIARY VSW
C9-2
C5-11
C9-3
WH PIN 1
PUMP
CR39
NC
FS1

E
TB27
L2
BK
RD
C1-1 C27AUX RD
RD AUXILIARY POWER
C9-1
RELAY
PR1
CR45
U35
PUMP
30A
AUXILIARY PUMP
NO
2 SEC
PBOX
GND
PR1
TB23
NO
CR45
NO
C7-2 P23BAT WH
P2
D
TB28
C1-2
RD/BK WH TILT ALARM
M2
C28TTA RD/BK
D40
H1
S7
D39
RD RD BK BRN
D2
LEVEL SENSOR
4.7 K
R20
C132PLI2 BK
L4
GR/BK C4-4 FLASHING BEACONS
FB
OPTION
C133PLA OR/RD
CR5
HORN
P3
LS18A
C

LS18
RELAY
TB43
CR5
NO
R34HRN BK
Z-60/34
TB133
H2
GN/BK
OTS
CR17
NO
TB132
WH BK HYDRAULIC OIL
L45
7
5
TEMP. SWITCH
FAN M1
CR17
NO
CONN.
3
BR COOLING FAN
PLUG
RD
D89
D88
C32
1
B
PBOX
GND
12
H6
6
4
TB41
BLUE/PINK
TB134
FORD ENGINE HARNESS
TB22
START RELAY
PLAT
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
KS1
1
2
3
A
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 84
1
8

Part No. 75861 Z-60/34 6 - 85


6 - 85
6 - 86
Ford Ground Control Box Wiring Diagram

6 - 88
6 - 87

1 VOLT METER OIL PRESSURE OIL TEMP
H6 U33
RD-H6+ - C23-1
RD-C23-1 BL/WH-38D - C23-3
PLATFORM LOAD
RD-42B
C23
BK-22C - C23-4
BK-C7-1 - C23-5
GN/BK-L45 RD-TS11 - C23-6
GN/BK-16A RD-TS14 - C23-7 G1 G2 G3
WHT-21A GN/BK-16B - C23-8
BRN-GROUND BR-GND - C23-12
BLK-22A
P2 WHT-23A
ENGINE WH -8 46 WH -5 WH-23A LIMIT SWITCH POWER
2 STARTER NC RD 42A
C23-6
GR/WH-4 GR/WH-1 45 GENERATOR OPTION
NC WH -7 44 BK -8 LIMIT SWITCH J1
KS1 WH -6 43 BK -7 LIMIT SWITCH J2
KEY OR/RD-1 42 RD H6
RD-4 RD KS1 C134PWR
SWITCH BRN-GROUND
OR/BK-E.H. OR/BK-1 41 OR/BK-ISM#2 PULSE PICKUP
B BK -6 OR-1 40 C40LS1 STOWED +
3 1 3 MFD WT/BK-25A WT/RD-26A
RD
TS51 BL/RD-1 39 BL/RD S.P. L.P./GAS

B1 BL/WH C23-3 BL/WH-1 38 C132PLI
4 2 AUXILIARY
PUMP BL/BK-4 BL/BK-1 37 STEER LEFT 1 WHT-21A
CABLE
#8 BL-4 BL-1 36 STEER RIGHT GND
BK/RD-1 35 BK/RD CR3#30 BK/RD S.P. RPM
BK/WH-E.H. BK/WH-1 34 BK/WH S.P. GLOW PLUG/CHECK ENGINE
BK-1 33 BK-ISM#3 BK S.P. START
3 D2 WH/RD - E.H. WH/RD-1 32 BRAKE
WH/BK-E.H. WH/BK-1 31 E.D.C.-
PERKINS SHUTDOWN ONLY LABEL DESCRIPTION
CABLE WH-1 30 E.D.C.+
#7 WH -E.H.
RD/WH-E.H. RD/WH-1 29 MOTOR SPEED P1 EMERGENCY STOP BUTTON
RED-27A RD/BK-4 RD/BK-1 28 TILT ALARM DIODE WITH 44B-GR/BK+2B-BL/BK KS1 KEY SWITCH
BLU-10A RD -4 RD-1 27 ISM#4 RD S.P. AUXILIARY POWER
BLU/BLK-11A TS51 AUXILIARY SWITCH
WH/RD-E.H. 26 WH/RD S.P. OIL TEMP SENDER L2
BLK/WHT-8A TS52 ENGINE START SWITCH
BLK-7A WH/BK-E.H. 25 WH/BK S.P. OIL PRESSURE SENDER CHECK ENGINE
L2 CABLE 24 RD-CR2#30 RD CB1 ENGINE POWER LED WH/RD-C5-14
CHECK ENGINE L45 GR/BK H6 #6 RD-4 WH-2 23 WH-ISM#7 WH S.P.+ WH-46A KEYSWITCH POWER
LED D33 TS55 FUNCTION ENABLESWITCH
BL/WH-ISM#10 C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM BL/WH-ISM#10
WH-E.H. WH-CR2#87 WH-E.H. 21 WH-SP IGNITION POWER WH/BK-C5-16 TS57 PLATFORM ROTATE SWITCH
RD-S.P.(CB3)20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY
4 RED-1A
RD -E.H.
GR/WH-3 19 GR/WH S.P. JIB VALVE
TS58 JIB BOOM SWITCH
GR/BK-4 GR/BK-3 18 GR/BK S.P. PLATFORM ROTATE R TS59 PLATFORM LEVEL SWITCH
RED/BLK-2A CABLE
GR-4 GR-3 17 GR S.P. PLATFORM ROTATE L
2 PERKINS SHUTDOWN COMMONIZED WITH
TS60 SECONDARY BOOM UP/DOWN SWITCH
#5 DEUTZ AT SERIAL NUMBER 5326
OR/RD-3 16 GN/BK C23-8 GN/BK-H6 C133PLT TS61 PRIMARY BOOM UP/DOWN SWITCH
+ RED/WHT-3A OR/BK-4 OR/BK-3 15 OR/BK S.P. PLATFORM LEVEL DOWN
TS62 TURNTABLE ROTATE SWITCH
TS60 OR-4 OR-3 14 OR S.P. PLATFORM LEVEL UP
HM BOOM BK -5 OR/RD-3 13 DRIVE ENABLE TS63 BOOM EXTEND/RETRACT SWITCH
UP/DOWN BL/WH-4 BL/WH-3 12 BL/WH S.P. SECONDARY BOOM F.C.
- TS61 TS63 CABLE 11 TS64 RUN/TEST SWITCH
BOOM EXTEND/ BL/BK-4 BL/BK-3 BL/BK S.P. SECONDARY BOOM DOWN
BOOM #1
RETRACT BL/WH -12A BL-4 BL-3 10 BL S.P. SECONDARY BOOM UP CB1 CIRCUIT BREAKER, ENGINE, 15A
UP/DOWN
R5 WHT/BLK-5A BK/RD-3 9
WHT-4A CB2 CIRCUIT BREAKER, CONTROL, 15A
BK/WH-4 BK/WH-3 8 BK/WH S.P. BOOM RETRACT
5 CB3 CIRCUIT BREAKER, HYD COOLER, 20A
5 BK-4
WH/RD-4
BK-3
WH/RD-3
7
6
BK S.P.
WH/RD S.P.
BOOM EXTEND
TURNTABLE ROTATE F.C. HM HOUR METER
WH/BK-4 WH/BK-3 5 WH/BK S.P. TURNTABLE ROTATE R
TS62 WH-4 WH-3 4 WH S.P. TURNTABLE ROTATE L
7.5
TS58 TURNTABLE RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
R4
JIB BOOM ROTATE RD/BK-4 RD/BK-3 2 RD/BK S.P. PRIMARY BOOM DOWN
RD-4 RD-3 1 RD S.P.
DRIVE LIGHT OPTION RELAY R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
PRIMARY BOOM UP
D3 G1 VOLT METER GAGE
WH/RD S.P. CABLE D C B A
#2 RD-CB3 SP G2 OIL PRESSURE GAGE
BK-CR1#86 START RELAY
1
CR23 G3 WATER TEMP. GAGE
OR/BK-41B TACHOMETER
TS56 TS52 GRN-17A 2 H2 SERVICE HORN
TS57 BK-33D START INPUT
3
GLOW PLUG ENGINE START H3 TRAVEL BUZZER
PLATFORM RD-27B AUXILIARY ONIGN./START
6 ROTATE GRN/BLK-18A BR-GROUND
4
GROUND5
MODULE BK/RD-9B
H4 DESCENT BUZZER
RD-CR1#30 BATTERY
GRN/WHT-19A 6 CR1 IGN/START RELAY
WH-23B
TS59 KEY POWER
7
PLATFORM RD TO LIGHT CR2 IGN./POWER RELAY
KEY BYPASS
8
LEVEL WH-CR2#86 IGN./FUEL ON CR3 HIGH IDLE (RPM) CUTOUT RELAY
ORG/BLK-15A CABLE BL/WHT-L2-
9 RD-C4B-12
ORG-14A #3 ENGINE FAULT
10 CR4 RPM RELAY
WARNING SENDER BRN GND
TS55 CR5 SERVICE HORN RELAY
FUNCTION RD-S.P. (CB3)
ENABLE RD-24B
CR17 HYDRAULIC COOLER FAN RELAY
CB3 CABLE WH-ISM#9 GR-1 CR
CB1 CB2 OIL COOLER/ #4 WH-H.C. CR18 CE PLATFORM LEVEL RELAY
RD-ISM#6 BK-22B RELAY
7 ENGINE, 15A CONTROL, 15A OPTION, 20A
CR1 CR2 CR17 CR5 LEGEND H6 PLATFORM OVERLOAD ALARM
BK-ISM#1 L45 PLATFORM OVERLOAD LED
87 V33 PLATFORM OVERLOAD MODULE
CR17 #30 BK-E.H. 87A LS1 (CABLE#6) PRIMARY BOOM STOWED LIMIT SWITCH
WH-21D RD-H.C. BK-4
RED-20C BR-GROUND LS2 (CABLE#5) DRIVE ENABLE LIMIT SWITCH
HYDRAULIC 86 85
BLK-33A COOLER
30
BK/RD-35B LS3 (CABLE#7) BOOM RETRACTED LIMIT SWITCH
BLK/RED-35A
LS4 (CABLE#8) SECONDARY BOOM STOWED LIMIT SWITCH
RD C23-7 CR4
CR3 (CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
RED-20A
RED-20B (CABLE#2) TO PLATFORM C-BOX, TERMINAL 22-23
1 RPM FILTER ADDED AT SERIAL NUMBER 4461
8 BK/WH-34A (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19
RED-24A ENGINE BK/RD-E.H. (CABLE#4) TO FUNCTION MANIFOLD
HARNESS
GROUND STUD PR1 AUXILARY POWER RELAY
BR BR PR2 GLOW PLUG POWER RELAY
BK-H.C. + BR-H.C.
BR-2
6 - 88 Z-60/34 Part No. 75861


1
VOLT METER OIL PRESSURE OIL TEMP
G2 G3
WHT-21A 46 SPARE G1
BRN-GROUND GR/WH-4 GR/WH-1 45 GENERATOR OPTION
GR/BK-1 44 GR/BK-11B JDALARM
BLK-22A
GR-1 43 GR-CR5#85 HORN
WHT-23A RD-4 OR/RD-1 42 RD H6 RD KS1 C134PWR
RD 42A OR/BK-C5-2 OR/BK-1 41 PULSE PICKUP
KEY
OR-4
BL/RD-C5-10
OR-1
BL/RD-1
40
39 BL/RD S.P.
C40LS1 STOWED
L.P./GAS
BRN-GROUND
WT/BK-25A WT/RD-26A
2
BL/WH C23-3 BL/WH-1 38 C132PLI WHT-21A
SWITCH BL/BK-4 BL/BK-1 37 STEER LEFT
KS1 BL-4 BL-1 36 STEER RIGHT
B BK/RD-C5-9 BK/RD-1 35 BK/RD S.P. RPM
1 TS51
BK/WH-1 34 BK/WH S.P. GLOW PLUG/CHECK ENGINE
RD
3 BK-1 33 BK-CR1#85 D5 BK S.P. LABEL DESCRIPTION
START
B1 WH/RD-C5-23 WH/RD-1 32 WH/RD-4 BRAKE
4 2 AUXILIARY SWITCH P1 EMERGENCY STOP BUTTON
WH/BK-C5-20 WH/BK-1 31 E.D.C.-
P2 WH- C5-21 30 KS1 KEY SWITCH
WH-1 E.D.C.+
NC RD/WH-C5-24 RD/WH-1 29 MOTOR SPEED TS51 AUXILIARY SWITCH
RD/BK -4 RD/BK-1 28 TILT ALARM
NC RD -4 RD-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER TS52 ENGINE START SWITCH
WH/RD-C5-14 26 WT/RD S.P. OIL TEMP. SENDER
D3 TS53 LP/GAS SWITCH
WH/BK-C5-16 25 WT/BK S.P. OIL PRESSURE SENDER
D2
WH-2
24 RD-CR2#30
23 WH-CR39#30
RD CB1
WH S.P.
ENGINE POWER
KEYSWITCH POWER
TS55 FUNCTION ENABLESWITCH 3
BL/WH-4 C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM
BL/RD-39A WH-C5-3+C5-8 21 WH-CR2#87 WH-SP IGNITION POWER TS58 JIB BOOM SWITCH
RED-27A RD- 12 VOLT RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY TS59 PLATFORM LEVEL SWITCH
BLU-10A GR/WH-3 19 GR/WH S.P. JIB VALVE
BLU/BLK-11A GR/BK-4 GR/BK-3 18 GR/BK S.P. PLATFORM ROTATE R TS60 SECONDARY BOOM UP/DOWN SWITCH
BLK/WHT-8A GR-4 GR-3 17 GR S.P. PLATFORM ROTATE L TS61 PRIMARY BOOM UP/DOWN SWITCH
TS53 BLK-7A OR/RD-3 16 GR/BK C23-8 GN/BK-H6 C133PLT
OR/BK-4 OR/BK-3 15 OR/BK S.P. PLATFORM LEVEL DOWN TS62 TURNTABLE ROTATE SWITCH
L2
OPTION OR-4 OR-3 14 OR S.P. PLATFORM LEVEL UP TS63 BOOM EXTEND/RETRACT SWITCH
LP/GAS BL/RD-4 BL/RD-3 13 DRIVE ENABLE
SWITCH BL/WH-4 BL/WH-3 12 BL/WH S.P. SECONDARY BOOM F.C. TS22 RUN/TEST SWITCH
BL/WH-C5-13
BL/BK-4 BL/BK-3 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN CB1 CIRCUIT BREAKER, ENGINE, 15A
BL-4 BL-3 10 BL S.P. SECONDARY BOOM UP
RED-1A
RED/BLK-2A BK/WH-4
BK/RD-3
BK/WH-3
9 BK/RD-CR23#86
8 BK/WH S.P.
DRIVE LIGHT OPTION
BOOM RETRACT
CB2
CB3
CIRCUIT BREAKER, CONTROL, 15A
CIRCUIT BREAKER, HYD COOLER, 20A
4
BK-4 BK-3 7 BK S.P. BOOM EXTEND
+
WH/RD-4 WH/RD-3 6 WH/RD S.P. TURNTABLE ROTATE F.C. HM HOUR METER
HYDRAULIC WH/BK-4 WH/BK-3 5 WH/BK S.P. TURNTABLE ROTATE R
HM RED/WHT-3A COOLER
WH-4 WH-3 4 WH S.P. TURNTABLE ROTATE L
TS60 RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
TS63 SECONDARY BOOM RD/BK-4 RD/BK-3 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN
- R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
BOOM UP/DOWN SWITCH RD-4 RD-3 1 RD S.P. PRIMARY BOOM UP
TS61 EXTEND/RETRACT G1 VOLT METER GAGE
PRIMARY BOOM D C B A
SWITCH BL/WH -12A G2 OIL PRESSURE GAGE
UP/DOWN SWITCH WHT/BLK-5A
WHT-4A G3 WATER TEMP. GAGE
CABLE
H2 SERVICE HORN
#1 DRIVE LIGHT OPTION RELAY
TURNTABLE H3 TRAVEL BUZZER
R4
ROTATE
SWITCH RD-CB3 SP H4 DESCENT BUZZER
5
TS62
7.5 CR1 IGN/START RELAY
5
CR23 CR2 IGN./POWER RELAY

R5
BK/RD-9B
RD-24B
WH/RD-6A RD TO LIGHT
CABLE CR5 SERVICE HORN RELAY
JIB BOOM SWITCH #2
TS58 GR/BK-44A CR1 CR2 RD TO LIGHT CR39 AUX FUNCTION
BK-33B BRN GND CR17 HYDRAULIC COOLER FAN RELAY
PLATFORM GRN-17A
LEVEL SWITCH
TS59 PLATFORM H6 PLATFORM OVERLOAD ALARM
TS52 ROTATE
SWITCH
GRN/BLK-18A BK-C5-5 WH-21B
L45 PLATFORM OVERLOAD LED 6
CB3 TS57 GRN/WHT-19A WH-C5-17
U33 PLATFORM OVERLOAD MODULE
ENGINE HYD COOLER, CR
START 20A CABLE
SWITCH #3 RELAY
ORG/BLK-15A
OR-H.C. LEGEND
ORG-14A BK-4 WH-C5-11
CR17 #30
RED-20C
(CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
TS22 87 (CABLE#2) TO PLATFORM C-BOX, TERMINAL 22-23
FUNCTION (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19
ENABLESWITCH CR5 CR39 CR17 87A
GR-43B RD-27B (CABLE#4) TO FUNCTION MANIFOLD
TS55 CABLE BK-H.C.
CB1 CB2 #4 BK-22B
RD-CB3 SP 86 85 PR1 AUXILARY POWER RELAY 7
WH-23B
ENGINE, 15A CONTROL, 15A 30 PR2 GLOW PLUG POWER RELAY
GR-C5-12
BLK-33A
BLK/RED-35A
C5
BR
RED-20B BR
ENGINE BR-H.C.
RED-20A HARNESS
RED-24A BR-2
GROUND STUD
8
Part No. 75861 Z-60/34 6 - 89


6 - 89
6 - 90

6 - 92
6 - 91

1
WH-21A G1 G2 G3
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM
RD-4 RD-C2B-4 42 RD KS1 C134PWR BR (GROUND)
OR/BK -C5-2 OR/BK-C2B-3 41 PULSE PICKUP
OR-4 OR-C2B-2 40 C40LS1 STOWED
DESCRIPTION LABEL
BL/RD -C5-10 BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS WH/BK-25A
BL/WH-C1B-12 38 C132PLI EMERGENCY STOP BUTTON P1
WH/RD-26A
BL/BK-4 37 KEY SWITCH KS1
2 BL-4
BL/BK-C1B-11
BL-C1B-10 36
STEER LEFT
STEER RIGHT AUXILIARY SWITCH TS51
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM ENGINE START SWITCH TS52
BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG KEY SWITCH AUXILIARY
P1 KS1 LP/GAS SWITCH TS53
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START TS51
B FUNCTION ENABLE SWITCH TS55
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE RD-CB2
NC 1
WH/BK -C5-20 WH/BK-C1B-5 31 PLATFORM ROTATE SWITCH TS57
RD
E.D.C.- 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ NC B1 JIB BOOM SWITCH TS58
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM RD-42A
SECONDARY BOOM UP/DOWN SWITCH TS60
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
WH/RD -C5-14 26 WH/RD S.P. OIL TEMP. SENDER
RD-27A TURNTABLE ROTATE SWITCH TS62
3 WH/BK -C5-16 25
24 RD-CR1#30
WH/BK S.P.
RD CB1
OIL PRESSURE SENDER
ENGINE POWER
BL/RD-39A BOOM EXTEND/RETRACT SWITCH TS63
RUN/TEST WH-C7B-2 23 WH-CR39#30 WH S.P. KEYSWITCH POWER RUN/TEST SWITCH TS22
TS22 BL/WH-4 22 CIRCUIT BREAKER, ENGINE, 15A CB1
BK-C7B-1 BK-CR5#30 BK S.P. POWER TO PLATFORM
WH-C5-3+C5-8 21 WH-CR2#87 WH-SP IGNITION POWER WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD-4 (12V) RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY LP/GAS CIRCUIT BREAKER, OPTION, 20A CB3
L2 TS53
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE HM HOUR METER HM
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BR (GROUND) RESISTOR, 1K OHM/2W, #104333 R3
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L
GR-C5-12 16 RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
OR/RD-C4B-4 C133PLT BL/WH-C5-13
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN R3 RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
14 DRIVE LIGHT OPTION RELAY VOLT METER GAGE G1
OR-4 OR-C4B-2 OR S.P. PLATFORM LEVEL UP 1 1K
4 BL/RD-4
BL/WH-4
BL/RD-C4B-1
BL/WH-C3B-12
13
12 BL/WH S.P.
DRIVE ENABLE
SECONDARY BOOM F.C.
RD/WH-3A
RD/BK-2A
RD-24D
CR23
OIL PRESSURE GAGE G2
PRIMARY FUSE 10A WATER TEMP. GAGE G3
BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN BOOM
BL/BK-11A BOOM SERVICE HORN H2
BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP UP/DOWN 30
EXTEND/RETRACT BR-C4B-9 TRAVEL BUZZER H3
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION BR
GND
HC
BK/WH-4 BK/WH-C3B-8 8 BK/WH S.P. BOOM RETRACT 87A DESCENT BUZZER H4

86 85 BR-C4B-11
BK-4 BK-C3B-7 7 BK S.P. BOOM EXTEND BL-10A SECONDARY 87 IGN/START RELAY CR1
WH/RD-4 WH/RD-C3B-6 6 WH/RD S.P. TURNTABLE ROTATE F.C. BOOM TS63 RD-C4B-10 IGN./POWER RELAY CR2
BR-GND STUD BL/WH-12A UP/DOWN TS60 TS61 RD-C4B-12
3 WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L HIGH IDLE (RPM) CUTOUT RELAY CR3
12V TO PLAT
4
1 BK-22C WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R BK/WH-8A BK/RD-9B
C7B
RPM RELAY CR4

2 WH-23C SERVICE HORN RELAY CR5
RD/BK-4 RD/BK-C3B-2 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN RD-1A
5 RD-4 RD-C3B-1 1 RD S.P. PRIMARY BOOM UP GR/BK-44A
TURNTABLE
AUX FUNCTION
HYDRAULIC COOLER FAN RELAY
CR39
CR17
TS62
D C B A ROTATE
ENGINE DRIVE LIGHT OPTION RELAY CR23
(GY)
C1B
START CHECK ENGINE LED #110395 L2
5
TS52 HYDRAULIC OIL COOLER OPTION RELAY
TO PLATFORM C-BOX, TERMINAL 27-38 C1B
BK-33A CB3
(BK)
C2B

WH-23B RD- 20C TS58 RD-H.C.
19/18 CABLES
JIB BOOM R5 TO PLATFORM C-BOX, TERMINAL 1-12 C3B

RD-CR17#30 CR17
WH-C5-11 TO PLATFORM C-BOX, TERMINAL 13-19 C4B
WH/BK-5A
(GR)
C3B
87
WH/RD-6A 85 86 BK-H.C. ENGINE HARNESS C5
WH-4A 87A
RD-24B TO PLATFORM C-BOX, TERMINAL 22-23 C7B
(BR)
AUXILARY POWER RELAY PR1

C4B
CR2 CR39
6 CR1
R4
7.5
30
GLOW PLUG POWER RELAY PR2
30 30 30 PLATFORM
TS57 ROTATE RD-CB3 SP
BK-33B D14 CB1 CB2
87A 87A 87A
86 85 86 85 86 85 BRN GND
87 87 87
FUNCTIONS
TS55
BK-C5-5 FUNCTION
4
WH-21B
ENABLE D13 TS59
WH-C5-17
BK/RD-35A PLATFORM
LEVEL
BK-4 RD-27B RD- 20A
CR5
RD- 24A
7 85
87
86
GR-43B
RD- 20B
87A RD- P1 E-STOP
ENGINE
OR/BK-15A
C5
30
OR-14A
GR-17A
BK-22B GR/WH-19A
GR/BK-18A
8 GROUND STUD
WIRING
HARNESS:
TO BASE
BR ALL BR WIRES
1 RESISTOR R1 ADDED AT SERIAL NUMBER 6316
GROUND STUD
6 - 92 Z-60/34 Part No. 75861


1
WH-21A G1 G2 G3
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM
LOAD SENSE OPTION - TIMER RELAY
RD-4 RD-C2B-4 42 RD KS1 C134PWR BR (GROUND)
OR/BK -C5-2 OR/BK-C2B-3 41 PULSE PICKUP
OR-4 OR-C2B-2 40 C40LS1 STOWED
DESCRIPTION LABEL
BL/RD -C5-10 BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS WH/BK-25A WH-CR2#86
BL/WH-C1B-12 38 C132PLI EMERGENCY STOP BUTTON P1
WH/RD-26A
BL/BK-4 37 WH-ISM#9 KEY SWITCH KS1
BL-4
BL/BK-C1B-11
BL-C1B-10 36
STEER LEFT
STEER RIGHT AUXILIARY SWITCH TS51
2
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM ENGINE START SWITCH TS52
BK/WH-C1B-8 34 BK/WH S.P. KEY SWITCH
RD-TB134(A)C
GLOW PLUG AUXILIARY
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START TS51
B FUNCTION ENABLE SWITCH TS55
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE RD-CB2 BR-GND
NC 1
WH/BK -C5-20 WH/BK-C1B-5 31 PLATFORM ROTATE SWITCH TS57
RD
E.D.C.- 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ NC B1 U34 JIB BOOM SWITCH TS58
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM RD-42A BK-C3B-10
SECONDARY BOOM UP/DOWN SWITCH TS60
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
WH/RD -C5-14 26 WH/RD S.P. OIL TEMP. SENDER
RD-27A REPLACE WIRE WITH THIS WIRING DIAGRAM TURNTABLE ROTATE SWITCH TS62
WH/BK -C5-16 25
24 RD-CR1#30
WH/BK S.P.
RD CB1
OIL PRESSURE SENDER
ENGINE POWER
BL/RD-39A BOOM EXTEND/RETRACT SWITCH TS63 3
RUN/TEST WH-C7B-2 23 WH-CR39#30 WH S.P. KEYSWITCH POWER RUN/TEST SWITCH TS22
TS22 BL/WH-4 BK-C7B-1 22 BK-CR5#30 BK S.P. POWER TO PLATFORM 1 CIRCUIT BREAKER, ENGINE, 15A CB1
WH-C5-3+C5-8 21 R3 2
WH-CR2#87 WH-SP IGNITION POWER WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD-S.P.(CB3) 20 LP/GAS
1K
RD-4 (12V) RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY CIRCUIT BREAKER, OPTION, 20A CB3
L2 TS53
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE HM HOUR METER HM
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BR (GROUND) RESISTOR, 1K OHM/2W, #104333 R3
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L
GR-C5-12 16 DRIVE LIGHT OPTION RELAY RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
OR/RD-C4B-4 C133PLT BL/WH-C5-13
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN RD-24D RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
CR23
OR-4 OR-C4B-2 14 OR S.P. PLATFORM LEVEL UP FUSE 10A VOLT METER GAGE G1
BL/RD-4 BL/RD-C4B-1 13 DRIVE ENABLE RD/WH-3A
4
WL
OIL PRESSURE GAGE G2

BL/WH-C3B-12 SECONDARY BOOM F.C. RD/BK-2A 30
BL/WH-4 12 BL/WH S.P. BR-C4B-9 WATER TEMP. GAGE G3
PRIMARY BR
BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN BOOM GND
BL/BK-11A BOOM 87A SERVICE HORN H2
BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP UP/DOWN BR-C4B-11
EXTEND/RETRACT 86 85 TRAVEL BUZZER H3
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION 3 87
RD-C4B-10
HC
BK/WH-4 BK/WH-C3B-8 8 BK/WH S.P. BOOM RETRACT DESCENT BUZZER H4

BL-10A RD-C4B-12 IGN/START RELAY CR1
BK-4 BK-C3B-7 7 BK S.P. BOOM EXTEND SECONDARY
WH/RD-4 WH/RD-C3B-6 6 WH/RD S.P. TURNTABLE ROTATE F.C. BOOM TS63 BK/RD-9B IGN./POWER RELAY CR2
BR-GND STUD BL/WH-12A UP/DOWN TS60 TS61
3 WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L HIGH IDLE (RPM) CUTOUT RELAY CR3
12V TO PLAT
4
1 BK-22C WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R BK/WH-8A
C7B
RPM RELAY CR4

RD/BK-4 RD/BK-C3B-2 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN RD-1A
AUX FUNCTION CR39
RD-4 RD-C3B-1 1 RD S.P. PRIMARY BOOM UP GR/BK-44A
TURNTABLE TS62 HYDRAULIC COOLER FAN RELAY CR17
5
D C B A ROTATE
ENGINE DRIVE LIGHT OPTION RELAY CR23
(GY)
C1B
START CHECK ENGINE LED/INCANDESCENT LAMP L2

DRIVE LIGHT OPTION RELAY
5
TS52
RD-24D TO PLATFORM C-BOX, TERMINAL 27-38 C1B
BK-33A CB3
(BK)
CR23
C2B
FUSE 10A TO PLATFORM C-BOX, TERMINAL 39-45 C2B

WH-23B RD- 20C TS58
19/18 CABLES
JIB BOOM R5 TO PLATFORM C-BOX, TERMINAL 1-12 C3B

RD-CR17#30 30
WH-C5-11 TO PLATFORM C-BOX, TERMINAL 13-19 C4B
WH/BK-5A BR-C4B-9
(GR)
BR
C3B
WH/RD-6A GND ENGINE HARNESS C5

WH-4A 87A
RD-24B 86 85 BR-C4B-11 TO PLATFORM C-BOX, TERMINAL 22-23 C7B
87
(BR)
RD-C4B-10 AUXILARY POWER RELAY PR1

C4B
CR1 CR2 CR39

R4
7.5
RD-C4B-12 GLOW PLUG POWER RELAY PR2 6
30 30 30 PLATFORM BK/RD-9B
TS57 ROTATE
BK-33B D14 CB1 CB2
87A 87A 87A
86 85 86 85 86 85
87 87
FUNCTIONS
87
TS55
BK-C5-5 FUNCTION
4
WH-21B
ENABLE D13
WH-C5-17 TS59
BK/RD-35A PLATFORM HYDRAULIC OIL COOLER OPTION RELAY
LEVEL
BK-4 RD-27B RD- 20A
CR5 RD-H.C.
RD- 24A
85
87
86
GR-43B
RD- 20B
CR17
87
7
87A RD- P1 E-STOP 85 86 BK-H.C.
ENGINE
87A
OR/BK-15A
C5
30
OR-14A 30
GR-17A
BK-22B GR/WH-19A
RD-CB3 SP
GR/BK-18A
BRN GND
GROUND STUD
WIRING
HARNESS:
8
TO BASE 1 RESISTOR R3 REMOVED AT SERIAL NUMBER 7924
BR ALL BR WIRES 2 LED 2 CHANGED TO INCANDESCENT LAMP AT SERIAL NUMBER 9066
3 DRIVE LIGHT OPTION MOVED AT SERIAL NUMBER 10388
GROUND STUD
Part No. 75861 Z-60/34 6 - 93


6 - 93
6 - 94

6 - 96
6 - 95

1
RD-H6+ - C32-1 LOAD SENSE OPTION - TIMER RELAY
WH-21A G1 G2 G3
BL/WH-132D - C32-3
BK-22C - C32-4
U33 C32 RD-C32-1
BK-C7-1 - C32-5
RD-TS55 - C32-7 GR/BK-L45 H6
GR/BK-133B - C32-8 GR/BK-133A WH-CR2#86
BR (GROUND)
BR - GND - C32-12 WH-ISM#9
46 SPARE
DESCRIPTION LABEL
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION WH/BK-25A RD-TB134(A)C
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM EMERGENCY STOP BUTTON P1
WH/RD-26A
2 GR-C2B-5 43 GR-CR5#85 HORN KEY SWITCH KS1
RD-U34-2 134A BR-GND AUXILIARY SWITCH TS51
RD-4 RD-C2B-4 134 RD-H6+ RD KS1 C134PWR ENGINE START SWITCH TS52
OR/BK -C5-2 OR/BK-C2B-3 41 PULSE PICKUP KEY SWITCH AUXILIARY U34
OR-4 OR-C2B-2 40 C40LS1 STOWED TS51
B BK-C3B-10 FUNCTION ENABLE SWITCH TS55
BL/RD -C5-10 BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS RD-CB2
NC 1 PLATFORM ROTATE SWITCH TS57
BL/WH-C1B-12 132 C132PLI
RD
D2 3
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT NC B1 JIB BOOM SWITCH TS58
BL-4 BL-C1B-10 36 STEER RIGHT WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM RD-42A SECONDARY BOOM UP/DOWN SWITCH TS60
D4 D3
BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START
3 WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE
RD-27A
BL/RD-39A
TURNTABLE ROTATE SWITCH
BOOM EXTEND/RETRACT SWITCH
TS62
TS63
WH/BK -C5-20 WH/BK-C1B-5 31 E.D.C.-
RUN/TEST WH -C5-21 WH-C1B-4 30 E.D.C.+ RUN/TEST SWITCH TS22
TS22 RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED CIRCUIT BREAKER, ENGINE, 15A CB1
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER LP/GAS DRIVE LIGHT OPTION RELAY
L2 CIRCUIT BREAKER, OPTION, 20A CB3
WH/RD -C5-14 26 WH/RD S.P. OIL TEMP. SENDER TS53 RD-24D
HM HOUR METER HM
25 WH/BK S.P. OIL PRESSURE SENDER CR23
WH/BK -C5-16 BR (GROUND) FUSE 10A
RESISTOR, 1K OHM/2W, #104333 R3
24 RD-CR1#30 RD CB1 ENGINE POWER
GR-C5-12 23 WH-CR39#30 D10 30 RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
WH-C7B-2 WH S.P. KEYSWITCH POWER BL/WH-C5-13 BR-C4B-9
BL/WH-4 22 BK-CR5#30 BR RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
BK-C7B-1 BK S.P. POWER TO PLATFORM GND
WH-C5-3+C5-8 21 WH-CR2#87 87A VOLT METER GAGE G1
WH-SP IGNITION POWER BR-C4B-11
4 1
86 85
WL
RD-4 (12V) RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY RD/WH-3A 87 OIL PRESSURE GAGE G2
RD/BK-2A RD-C4B-10
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE WATER TEMP. GAGE G3
PRIMARY RD-C4B-12
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BOOM
BL/BK-11A BOOM SERVICE HORN H2
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L BK/RD-9B
UP/DOWN TRAVEL BUZZER H3
OR/RD-C4B-4 16 C133PLT EXTEND/RETRACT
HC
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN DESCENT BUZZER H4

OR-4 OR-C4B-2 14 OR S.P. PLATFORM LEVEL UP BL-10A SECONDARY IGN/START RELAY CR1
BL/RD-4 BL/RD-C4B-1 13 DRIVE ENABLE BOOM TS63 IGN./POWER RELAY CR2
BR-GND STUD BL/WH-4 BL/WH-C3B-12 12 SECONDARY BOOM F.C. BL/WH-12A UP/DOWN TS60 TS61
3 BL/WH S.P. HIGH IDLE (RPM) CUTOUT RELAY CR3
12V TO PLAT
BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK

1 BK-22C BL/BK S.P. SECONDARY BOOM DOWN BK/WH-8A
C7B
HYDRAULIC OIL COOLER OPTION RELAY RPM RELAY CR4

BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP BK-7A
RD-1A
5 1
BK/WH-4
BR-C3B-9
BK/WH-C3B-8
9
8
BK/WH S.P.
BK/WH S.P.
EDC RETURN
BOOM RETRACT GR/BK-44A RD-H.C. AUX FUNCTION CR39
BK-4 BK-C3B-7 7 BK S.P. BOOM EXTEND TURNTABLE TS62 CR17 HYDRAULIC COOLER FAN RELAY CR17
WH/RD S.P. ROTATE DRIVE LIGHT OPTION RELAY CR23
(GY)
WH/RD-4 WH/RD-C3B-6 6 TURNTABLE ROTATE F.C. ENGINE 87

C1B
85 86 BK-H.C.
WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L START WORK LIGHTS OPTION RELAY Cr45
87A
5
4 TS52
WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R CHECK ENGINE LIGHT L2
RD/WH-4 RD/WH-C3B-3 3 BK-33A CB3
(BK)
RD/WH S.P. PRIMARY BOOM F.C. TO PLATFORM C-BOX, TERMINAL 27-38 C1B
C2B
30
RD- 20C TS58
19/18 CABLES
RD/BK-4 RD/BK-C3B-2 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN R5

JIB BOOM TO PLATFORM C-BOX, TERMINAL 39-45 C2B
RD-4 RD-C3B-1 1 RD S.P. PRIMARY BOOM UP RD-CR17#30
WH/BK-5A
(GR)
RD-CB3 SP
C3B
D C B A WH/RD-6A TO PLATFORM C-BOX, TERMINAL 13-19 C4B

WH-23B
WH-4A ENGINE HARNESS C5
BRN GND
WH-C5-11
6 TO PLATFORM C-BOX, TERMINAL 22-23 C7B
(BR)
C4B
R4 AUXILARY POWER RELAY PR1

7.5
RD-24B PLATFORM GLOW PLUG POWER RELAY PR2
CR2 CR39 TS57 ROTATE D28 LOAD SENSE TIME DELAY RELAY (10A) U34
CR1 D14 CB1 CB2
30 30 30
FUNCTIONS
WORK LIGHTS OPTION RELAY

BK-33B TS55
FUNCTION
4
87A 87A 87A

86 85 86 85 86 85 ENABLE D13 WH - W.L.
87 87 87 TS59
BK/RD-35A PLATFORM CR45
BK-C5-5 WH-21B LEVEL
RD- 20A 87 WH-C21IGN
85 86
7 WH-C5-17 RD- 24A 87A
BK-4 RD-27B RD- 20B

30
CR5 RD- P1 E-STOP
ENGINE
OR/BK-15A
C5
87 GR-43B
85 86 RD-CB3 SP
OR-14A
87A
GR-17A
BR GND
30 GR/WH-19A
GR/BK-18A
BK-22B
8 WIRING
GROUND STUD HARNESS:
TERMINAL 9 BEFORE SERIAL NUMBER 10388 BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION
TO BASE 1
TERMINAL 9 NOT USED FROM SERIAL NUMBER 10388 TO SERIAL NUMBER 11903 9 SPARE
TERMINAL 9 FROM SERIAL NUMBER 11904 BR C5-7 BR C3B-9 9 EDC RETURN
BR ALL BR WIRES
GROUND STUD
6 - 96 Z-60/34 Part No. 75861

Ford Platform Control Box Wiring Diagram

P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
P24FS WH
BRN
ALC-500
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
3
COMPONENT INDEX PART NUMBER J3
1
JC2 BOOM PROPORTIONAL JOYSTICK: 62390
JC1 BOOM SECONDARY JOYSTICK: 62391 J1 J2

9 11
JC3 DRIVE PROPORTIONAL JOYSTICK 75565
L1 DRIVE ENABLE LED 56298 1 1
P2 EMERGENCY STOP BUTTON 66812, 94506
C132PLI BK C1P-12
RD H1
RD P2
P3 HORN SWITCH 66813, 66816 2

JDALARM GR/BK C2P-6
C34SA BK/WH C1P-8
C28TTA RD/BK C1P-2
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
C35RPM BK/RD C1P-9

C134PWR RD C2P-4
C29MS RD/WH C1P-3

C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2

C31EDC- WH/BK C1P-5
C1PBU RD C3P-1
C30EDC+ WH C1P-4
C41RPM OR/BK C2P-3
C12SBF BL/WH C3P-12
C40LS1 OR C2P-2
C11SBD BL/BK C3P-11
C13DRE BL/RD C4P-1
C10SBU BL C3P-10
C6TRF WH/RD C3P-6
C39LP BL/RD C2P-1
C45GEN GR/WH C2P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C36STC BL C1P-10
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
DLITE BK/RD C3P-9
TS1 AUXILIARY SWITCH 42730
TS2 START ENGINE SWITCH 13037
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
TS4 HI/L0 RPM SWITCH 13038
L4 CHASSIS TILT LED 56298
TS7 PLATFORM ROTATE SWITCH 16397
TS8 JIB UP/DOWN SWITCH 13037
TS9 PLATFORM LEVEL SWITCH 13037
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037
TS15 DRIVE ENABLE SWITCH 13037

TS17 SWITCH TOGGLE SPDT 2POS MNT 56457 C28TTA RD/BK C1P-2 C1P
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
C2P
3
D40
C3P C3P
GR/BK C4P-4 C4P
BRN
DETAIL A: LIFT/DRIVE OPTION BATGND C7P-3 C7P
C19JSV GR/WH
C4P-7 AND TS8
BRN
BRN BATGND
D39
F.S.
RED-TILT
RED/BLK-28
(GND STUD)
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
WH TS7
CR27 4
WH TS1 C7P C9P
JIB LS18 OPT.
WH/RD C32BRK
H1
(SPLICE TO C32BRK)
TILT
ALALRM 19/18 CONTROL CABLE 12V BATT F.S.
CR30
OR R40LS1 WORK /DRIVE LITE

10 AMP FUSE
5
(SPLICE TO R40LS1) TS48 DRV.ENA
PRIMARY BOOM 7 7 7
TS15
UP / DOWN DRIVE / STEER
6 6 6
5 5 5
PRIMARY
BOOM
4 EXTEND/ 4 4
RETRACT
JC2
RD WL2
3 3 3
TURNTABLE
2
JC1
2
+ JC3
2
6
ROTATE 1 1 1
TS13 L1
CR13
WH-24
DRIVE LT BK/RD-C3P-9
+
RD WL1
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
L4
BRN J1-10
BRN J1-14
BRN J1-12
GND
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
BK/WH-8
WH J1-5
WH J1-5
OR J1-9
BK J1-2
BL J1-4
RD J1-1
WH-JIB
WH-24
BK-22
BK-7
BRN
RD
GR/WH-45
C19JSV GR/WH JIB

OR/BK-15
OR-14
C18JD GR/BK C4P-6
BK/RD-35
WH-24
C17JU GR C4P-5
WH-JIB
C27AUX RD C1P-1
C29MS RD/WH J1-8
WH-23
P26BAT BK C9P-1
C19JSV GR/WH
WH-24
BK-22
WH-24
RD-TILT
P22BAT BK C7P-1
RD
BL/RD-39
GR-43
RD
WH-24
GR/WH-45
WH-TS4
WH-TS47
TS2
WH
TS17 RD START TS9 TS7 TS8 TS1
TS14 TS2 TS4
GR
GENERATOR HIGH/LOW
(OPTION) WH
P3
DRIVE TS17 RD START
RPM
FUEL SELECT
TS3
P2
8
HORN PLATFORM
1 GENERATOR OPTION CHANGED PLATFORM WH
ROTATE GR/BK
JIB AUXILIARY SPEED
1 GENERATOR REMOVE FOR EMERGENCY STOP
AT SERIAL NUMBER 5716 LEVEL PUMP HIGH/LOW (OPTION) GENERATOR OPTION
CE SEE DETAIL A
Part No. 75861 Z-60/34 6 - 97


6 - 97
6 - 98

6 - 100
6 - 99
N
M
L
K
EMERGENCY STOP
RD-TILT
P2
OPT.
J
P22BAT BK C7P-1
BK-22
P26BAT BK C9P-1
WH-23
FUEL SELECT
TS3
RD P2
RD H1
LS18
BL/RD-39
C132PLI BK C1P-12 RD
I
P23SWBAT WH C7P-2
P22BAT BK C7P-1 RD
TS4
HIGH/LOW
C19JSV GR/WH
JIB
C19JSV GR/WH JIB C4P-7 AND TS8

RPM
WH-24
L4
C18JD GR/BK C4P-6 BRN BK/RD-35

C17JU GR C4P-5
C15PLD OR/BK C4P-3 RD/BK H1
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
TS2
C7PBE BK C3P-7
START
P26BAT BK C9P-1
1
6
P25FS RD C9P-3
P24FS WH C9P-2
H
JDALARM GR/BK C2P-6 BL/WH J1-5 JC3-5

JC3-4
RD
DRIVE LT BK/RD C3P-9 WH/RD J1-4
JC3-3
GENERATOR
BL/WH J1-5
DRIVE / STEER
C3P
C45GEN GR/WH C2P-7
(OPTION)
OR J1-13 JC3-2
F.S.
C9P
TS48-WL1 RD C2P-12
BRN J1-14 JC3-1
TS17
F.S.
JC3
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE BK/RD C3P-9
GR/WH-45
P26BAT BK
11
3
WH-24
C6TRF WH/RD C3P-6
J3
+
G
L1
C10SBU BL C3P-10
DRV.ENA
C13DRE BL/RD C4P-1

12V BATT
BL/RD-DE3 J1-16
C11SBD BL/BK C3P-11
BL/WH-DE1 J1-6
TS15
P24FS WH C40LS1 OR C2P-2

C7P
HIGH/LOW
BK-22
TS14
C12SBF BL/WH C3P-12
SPEED
DRIVE
P24FS WH C41RPM OR/BK C2P-3 BL/BK-DE2 J1-7 WH-24
C30EDC+ WH C1P-4 C29MS RD/WH J1-8
WH/BK J1-3 JC1-4
BRN C1PBU RD C3P-1
C7P
CE SEE DETAIL A
C31EDC- WH/BK C1P-5 OR J1-9 JC1-2
C2PBD RD/BK C3P-2
C36STC BL C1P-10
JC1
BRN J1-10 JC1-1

C3PBF RD/WH C3P-3
AUXILIARY
ALC-500
WH-24
C4P
PUMP
C5TRR WH/BK C3P-5
6
C4P(BR) C27AUX RD C1P-1

10 AMP FUSE
C32BRK WH/RD C1P-6
TS1
C4TRL WH C3P-4 BRN
WH
F
C29MS RD/WH C1P-3

J2
C3P
C134PWR RD C2P-4 WH-JIB WH-JIB

C3P(GR)
C35RPM BK/RD C1P-9
JC1
C34SA BK/WH C1P-8
19/18 CONTROL CABLE
C2P
C33STR BK C1P-7
CR13
C27AUX RD C1P-1
JIB
June 2015
Part No. 75861

TS8
RD/BK L4
C2P(BK)
BK/WH-8
RETRACT
ROTATE GR/BK
PRIMARY
EXTEND/
C1P
WH
GR
PLATFORM
BOOM
J1
BK-7
9
JC1-3 OR
TS13
WORK /DRIVE LITE
JC2-4 RD C17JU GR C4P-5
JC1-2 BRN WH-24
C1P(GY)
TS48
JC2-5 BK
E
JC2-3 OR RD WL2 C19JSV GR/WH

JC1-5 YEL RD WL1
JC2-2 BRN C19JSV GR/WH JIB
BK J1-2 JC2-4
JC3-5 BL
TS7
RD J1-1 JC2-3
JC3-3 OR
JC3-4,6 WH C18JD GR/BK C4P-6
OR J1-11 JC2-2
WH
JC2
JC3-2 BRN BRN J1-12 JC2-1
C28TTA RD/BK C1P-2
DRE A BL/WH C28TTA RD/BK C1P-2
PLATFORM
DRE B BL/BK
1
BATGND C7P-3
TS9
LEVEL
C13LED BL/RD
GR/BK C4P-4
OR-14
C29MS RD/WH
PRIMARY BOOM
OR/BK-15
TURNTABLE
UP / DOWN
D
ROTATE
D40
H1
P3
RED/BLK-28
ALALRM
D39 RD
HORN
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
BRN
C
Z-60/34
PART NUMBER
66812, 94506
66813, 66816
62390
62391
75565
56298
42730
13037
13038
16397
13037
13037
13037
13037
56457
56457
56298
27378
BRN BATGND
(GND STUD)
WH TS1
B

SWITCH TOGGLE SPDT 2POS MNT



CR27
CR30
DRIVE ENABLE SWITCH

START ENGINE SWITCH
JIB UP/DOWN SWITCH

COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH
HI/L0 RPM SWITCH

CHASSIS TILT LED
HORN SWITCH
A
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
WH/RD C32BRK
OR R40LS1
WH TS7
TS48-9
TS13
TS15
TS17
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L4
P2
P3
L1
6 - 100
1
8

COMPONENT INDEX
1
P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
H1 TILT ALARM
P24FS WH
BRN
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
CR13-#86 GR/WH
C1 JIB TIME DELAY ALC-500
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
P134PWR RD-H1+
BR GND
RD-E-STOP
BR JC3
CR14 JIB TIME DELAY RELAY 3
J3
1
J1 J2
COMPONENT INDEX PART NUMBER 9 11
JC2 BOOM PROPORTIONAL JOYSTICK: 62390
GR/WH
PRIMARY UP/DN , TURNTABLE ROTATE 1 1 CR14
GR/WH
JC1 BOOM SECONDARY JOYSTICK: 62391 2

C34SA BK/WH C1P-8
C28TTA RD/BK C1P-2
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
C35RPM BK/RD C1P-9

C134PWR RD C2P-4
C29MS RD/WH C1P-3

C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2

C31EDC- WH/BK C1P-5
C1PBU RD C3P-1
C30EDC+ WH C1P-4
C41RPM OR/BK C2P-3
C12SBF BL/WH C3P-12
C40LS1 OR C2P-2
C11SBD BL/BK C3P-11
C13DRE BL/RD C4P-1
C10SBU BL C3P-10
C6TRF WH/RD C3P-6
C39LP BL/RD C2P-1
C45GEN GR/WH C2P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C36STC BL C1P-10
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
JDALARM GR/BK C2P-6
JC3 DRIVE PROPORTIONAL JOYSTICK 75565
P134PWR RD
L1 DRIVE ENABLE LED 56298
P2 EMERGENCY STOP BUTTON 66812, 94506
P3 HORN SWITCH 66813, 66816
TS1 AUXILIARY SWITCH 42730
RD
TS2 START ENGINE SWITCH 13037
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
GR/WH +
TS4 HI/L0 RPM SWITCH 13038
RD
RD OUTPUT
BR
BR
L4 CHASSIS TILT LED 56298 BR - C1
TS7 PLATFORM ROTATE SWITCH 16397
TS8 JIB UP/DOWN SWITCH 13037
C28TTA RD/BK C1P-2
TS9
TS13
13037
13037
C1P
3
C2P
D40
TS15 DRIVE ENABLE SWITCH 13037 C3P C3P
WH
TS17 SWITCH TOGGLE SPDT 2POS MNT 56457
BK
GR/BK C4P-4 C4P
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
BRN
GR/WH
BATGND C7P-3 C7P
BK C1P-12
JIB
D39
F.S.
RD LS18 CABLE
C134PWR RD LS18
RED-TILT
RED/BLK-28
DETAIL A: LIFT/DRIVE OPTION BEFORE SERIAL NUMBER 9697
4
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
BRN BATGND
C7P C9P JIB LS18 OPT.
(GND STUD)
H1
CR27
WH TS7
WH TS1 TILT
ALARM 19/18 CONTROL CABLE 12V BATT F.S.
WH/RD C32BRK
(SPLICE TO C32BRK)
10 AMP FUSE 5
WORK /DRIVE LITE
CR30 TS48
PRIMARY BOOM DRV.ENA
TS15
UP / DOWN DRIVE / STEER
CP2-2 OR R40LS1
(SPLICE TO R40LS1) 6
PRIMARY 6 6
BOOM
JC2 EXTEND/ JC1
1 1 1
RETRACT
JC2
RD WL2
6
TURNTABLE JC1 + JC3
ROTATE
TS13 L1
DETAIL A: LIFT/DRIVE OPTION FROM SERIAL NUMBER 9697 CR13
BRN J1-10
OR J1-9
WH/BK J1-3
WH-24
BL/WH J1-5
BRN J1-14
BRN J1-12
BRN BATGND
OR J1-11
WH/RD C32BRK
OR J1-13
RD J1-1
+
BK J1-2
RD WL1
WH/RD J1-4
BL/WH J1-5
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
(SPLICE TO C32BRK) (GND STUD) L4
RD/BK H1
BK/WH-8
WH-JIB
WH-24
BK-22
JC2-2
JC2-1
JC2-3
JC2-4
JC1-1
CR27
BK-7
JC1-2
JC1-4
JC3-1
JC3-2
JC3-3
JC3-5
JC3-4
WH TS7
BRN
7
RD
WH TS1
C19JSV GR/WH JIB

OR/BK-15
OR-14
C18JD GR/BK C4P-6
BK/RD-35
WH-24
C17JU GR C4P-5
WH-JIB
C27AUX RD C1P-1
C29MS RD/WH J1-8
WH-23
P26BAT BK C9P-1
C19JSV GR/WH
WH-24
BK-22
WH-24
RD-TILT
P22BAT BK C7P-1
RD
BL/RD-39
GR-43
RD
GR/WH-45
OR R40LS1
(SPLICE TO R40LS1)
CR30
WH
TS9 TS7 TS8 TS1
TS14 TS2 TS4
GR TS17 HIGH/LOW
P3
WH
START
RPM TS3
P2
8
DRIVE RD FUEL SELECT
HORN WH PLATFORM JIB AUXILIARY
PLATFORM SPEED GENERATOR EMERGENCY STOP
LEVEL ROTATE GR/BK PUMP HIGH/LOW (OPTION)
CE SEE DETAIL A
Part No. 75861 Z-60/34 6 - 101


6 - 101
6 - 102
June 2015 December
Section 2011
6 • Schematics

6 - 104
6 - 103
N
M
L
WH
K
PBOX WIRING
C19JSV GR/WH TS7

HARNESS
C19JSV GR/WH C4P-7 BK

BR
BR JC3
BR GND RD
RD-E-STOP
P134PWR RD-H1+
GR/WH
CR13-#86 GR/WH BR
RD LS18 CABLE
C1
GR/WH
RD OUTPUT
GR/WH +
CR14
EMERGENCY STOP
P134PWR RD
BR -
RD-TILT
P2
JIB
J
P22BAT BK C7P-1
OPT.
GR/WH RD
BK-22
P26BAT BK C9P-1
R20
P134PWR RD
4700 WH-23
LOAD SENSE OPTION
RD-H1+
U35
FUEL SELECT
TS3
COM
LS18
NO
BL/RD-39
2
5
3
D88
RD
BR GND
D89
I
P23SWBAT WH C7P-2
P22BAT BK C7P-1 RD
TS4
HIGH/LOW
+
C19JSV GR/WH JIB

RPM
WH-24
L4
C18JD GR/BK C4P-6

JIB
BK/RD-35
C17JU GR C4P-5
C15PLD OR/BK C4P-3 RD/BK H1
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
C7PBE BK C3P-7 TS2
START
P26BAT BK C9P-1
1
6
P25FS RD C9P-3
P24FS WH C9P-2
H
BL/WH J1-5 JC3-5

JC3-4
RD
JDALARM GR/ BK C2P-6 WH/RD J1-4
DRIVE LT BK/RD C3P-9 JC3-3
GENERATOR
BL/WH J1-5
DRIVE / STEER
C45GEN GR/WH C2P-7
(OPTION)
OR J1-13 JC3-2
F.S.
C9P
TS48-WL1 RD C2P-12
C3P
BRN J1-14 JC3-1
TS17
F.S.
JC3
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
JDALARM GR/BK C2P-6
GR/WH-45
P26BAT BK
11
3
WH-24
C6TRF WH/RD C3P-6
J3
+
G
L1
C10SBU BL C3P-10
DRV.ENA
C13DRE BL/RD C4P-1 BL/RD-DE3 J1-16

12V BATT
C11SBD BL/BK C3P-11

BL/WH-DE1 J1-6
TS15

C7P
HIGH/LOW
BK-22
TS14
C12SBF BL/WH C3P-12
SPEED
DRIVE
C30EDC+ WH C1P-4 C29MS RD/WH J1-8
WH/BK J1-3 JC1-4
BRN C1PBU RD C3P-1
C7P
CE SEE DETAIL A
C2PBD RD/BK C3P-2
C36STC BL C1P-10
JC1
BRN J1-10 JC1-1

C3PBF RD/WH C3P-3
AUXILIARY
WH-24
C4P
PUMP
C5TRR WH/BK C3P-5
6
1
C4P(BR) C27AUX RD C1P-1
ALC-500
10 AMP FUSE
C32BRK WH/RD C1P-6
TS1
C4TRL WH C3P-4 BRN
WH
F
C29MS RD/WH C1P-3

J2
C3P
C134PWR RD C2P-4 WH-JIB WH-JIB

C3P(GR)
C35RPM BK/RD C1P-9
JC1
C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE
CR13
C27AUX RD C1P-1
JIB
TS8
June 2015
Part No. 75861

RD/BK L4
C2P(BK)
BK/WH-8
RETRACT
ROTATE GR/BK
PRIMARY
EXTEND/
C1P
WH
GR
PLATFORM
BOOM
J1
BK-7
9
JC1-3 OR
TS13
WORK /DRIVE LITE
JC1-2 BRN WH-24
C1P(GY)
TS48
JC2-5 BK
E
JC2-3 OR RD WL2 C19JSV GR/WH

JC1-5 YEL RD WL1
BK J1-2 JC2-4
JC3-5 BL
TS7
RD J1-1 JC2-3
1
JC3-3 OR
OR J1-11 JC2-2
WH
JC2
JC3-2 BRN BRN J1-12 JC2-1
C28TTA RD/BK C1P-2
PLATFORM
DRE B BL/BK
1
BATGND C7P-3
TS9
LEVEL
C13LED BL/RD
GR/BK C4P-4
OR-14
C29MS RD/WH
PRIMARY BOOM
OR/BK-15
TURNTABLE
UP / DOWN
D
ROTATE
D40
H1
Ford PlatformControl Box Wiring Diagram
P3
RED/BLK-28
D39 RD
HORN
ALARM
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
BRN
C
Z-60/34
JIB TIME DELAY RELAY
PLATFORM BOX AT SERIAL NUMBER 10388

JIB TIME DELAY
PART NUMBER
66812, 94506
66813, 66816
WORK LIGHT OPTION REMOVED FROM

TILT ALARM
COMPONENT INDEX
62390
62391
75565
56298
42730
13037
13038
16397
13037
13037
13037
13037
56457
56457
56298
27378
BRN BATGND
(GND STUD)
WH TS1
CR14
B

H1
C1




CR27
CR30
1
DRIVE ENABLE SWITCH
START ENGINE SWITCH
JIB UP/DOWN SWITCH

COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH
HI/L0 RPM SWITCH

CHASSIS TILT LED
HORN SWITCH
A
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
WH/RD C32BRK
OR R40LS1
WH TS7
TS48-9
TS13
TS15
TS17
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L4
P2
P3
L1
6 - 104
1
8

6 - 105
WH
A
PBOX WIRING
C19JSV GR/WH TS7

HARNESS
C19JSV GR/WH C4P-7

EMERGENCY STOP
BR BK
BR JC3
BR GND RD-TILT
P2
RD
RD-E-STOP
P134PWR RD-H1+
P22BAT BK C7P-1
GR/WH
BR
CR13-#86 GR/WH BK-22
RD LS18 CABLE
P26BAT BK C9P-1
C1
GR/WH
WH-23
RD OUTPUT
GR/WH +
CR14
P134PWR RD
BR -
FUEL SELECT
OPT.
RD-P2
TS3
B
JIB
GR/WH RD BL/RD-39
RD
D11
R20
P134PWR RD
4700
LOAD SENSE OPTION
RD-H1+
LS18
Z-60/34
U35
COM
NO
2
5
3
D88

TS4
HIGH/LOW
BR GND
D89
C
RPM
WH-24
BK/RD-35
+
+
P23SWBAT WH C7P-2
L48
D12
P22BAT BK C7P-1
L4
C19JSV GR/WH JIB GR/BK H1

JIB
C18JD GR/BK C4P-6

C17JU GR C4P-5 RD/BK H1
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
TS2
C7PBE BK C3P-7
START
P26BAT BK C9P-1
1
D
P25FS RD C9P-3
P24FS WH C9P-2
BL/WH J1-5JC3-5
DRIVE / STEER
WH/RD J1-4JC3-4
RD
JDALARM GR/ BK C2P-6

DRIVE LT BK/RD C3P-9 BL/WH J1-5 JC3-3
GENERATOR
C9P
F.S.
C45GEN GR/WH C2P-7

(OPTION)
OR J1-13 JC3-2
C3P
TS48-WL1 RD C2P-12 BRN J1-14 JC3-1

TS17
JC3
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
JDALARM GR/BK C2P-6
GR/WH-45
P26BAT BK
Part No. 75861
E
11
3
WH-24
C6TRF WH/RD C3P-6
12V BATT
June 2015
J3
+
DRV.ENA
L1
C10SBU BL C3P-10
C13DRE BL/RD C4P-1 BL/RD-DE3 J1-16
C7P
C11SBD BL/BK C3P-11

BL/WH-DE1 J1-6
TS15

HIGH/LOW
TS14
BK-22
C12SBF BL/WH C3P-12
SPEED
DRIVE

C30EDC+ WH C1P-4 WH/BK J1-3 JC1-4 C29MS RD/WH J1-8
BRN C1PBU RD C3P-1
C7P

C2PBD RD/BK C3P-2
CE SEE DETAIL A
C36STC BL C1P-10
JC1
BRN J1-10 JC1-1

C3PBF RD/WH C3P-3
F
AUXILIARY
C4P
C37STCC BL/BK C1P-11 WH-24

PUMP
C5TRR WH/BK C3P-5

C4P(BR)
ALC-500
C27AUX RD C1P-1
6
C32BRK WH/RD C1P-6

19/18 CONTROL CABLE
TS1
C4TRL WH C3P-4 BRN

WH
C29MS RD/WH C1P-3

J2
C3P
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C3P(GR) WH-JIB WH-JIB
JC1
C34SA BK/WH C1P-8

C2P
C33STR BK C1P-7
CR13
C27AUX RD C1P-1
JIB
TS8
RD/BK L4
C2P(BK)
ROTATE GR/BK
BK/WH-8
G
PRIMARY
RETRACT
BOOM
EXTEND/
C1P
WH
GR
J1
BK-7
PLATFORM
9
1
JC1-3 OR
WH-24
TS13
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR C19JSV GR/WH
JC1-5 YEL RD WL1
BK J1-2 JC2-4
JC3-5 BL
TS7
RD J1-1 JC2-3
JC3-3 OR
OR J1-11 JC2-2
C28TTA RD/BK C1P-2
WH
JC3-2 BRN
JC2
BRN J1-12 JC2-1

BATGND C7P-3
DRE B BL/BK
H
TS9
GR/BK C4P-4
C13LED BL/RD
PLATFORM
LEVEL
OR-14
C29MS RD/WH
PRIMARY BOOM
TURNTABLE
UP / DOWN
OR/BK-15
ROTATE
D40
H1
P3
RED/BLK-28
D39 RD
ALARM
HORN
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
I
BRN
JIB TIME DELAY RELAY
BRN BATGND
(GND STUD)
WH TS1
JIB TIME DELAY
J
TILT ALARM
COMPONENT INDEX




CR14

H1
C1
CR27
CR30
START ENGINE SWITCH
DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH
COMPONENT INDEX
DRIVE ENABLE LED
AUXILIARY SWITCH
HI/L0 RPM SWITCH

CHASSIS TILT LED
K
HORN SWITCH
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
WH/RD C32BRK
OR R40LS1
WH TS7
TS48-9
TS13
TS15
TS17
JC2
JC1
JC3
TS1
TS2
TS3
TS4
TS7
TS8
TS9
L4
P2
P3
L1
L
M
N

6 - 105
6 - 106
Engine Wire Harness

Ford LRG-425 EFI Models
6 - 108
6 - 107
Engine Wire Harness

Ford LRG-425 EFI Models
1 6 361 R 16 361 R 16 361 R 16 361 R 16 361 R 16

INJ +
INJ 1
7 555 T 16 555 T 16 FORD
8 557 BR-Y 16 557 BR-Y 16
INJ 3
INJ 4
9 558 BR-LB 16 558 BR-LB 16 42 PIN
10 556 W 16 556 W 16
INJ 2
INJ 5
11 743 GY 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2
570 BK-W 16 39 R-W 18
CONNECTOR
12 359 GY-R 18 16 WATER TEMP
INJ 6
31
AUX OUT 2
EGR
21 18 O-Y 18 WATER
19 198 DG-O 18 ACT TEMP
AUX ANA PD1
20 358 LG-BK 18
2 MAP
FPP 1
15 151 LB-BK 18 151 LB-BK 151 LB-BK
14 FPP1
27 743 GY 18 307 BK-Y 18 307 BK-Y 18
IAT 25 IVS
28 354 LG-R 18 354 LG-R 18 359 GY-R 18
ECT
17 307 BK-Y 18 570 BK-W 16
IVS F1 30A
18 150 DG-W 18 570 BK-W 16 570 BK-W 12 570 BK-W 12 34 GROUND
AUX ANA PU1
16 114 LB-Y 18
ECT 570 BK-W 16
FPP 2
22 352 BR-LG 18 F2 5A
EGR PWM 16 R-LG 18 16 R-LG 18
23 360 BR-PK 18 1 VSW
EGR RECIRC
1 570 BK-W 16 570 BK-W 16
POWER GROUND
2 570 BK-W 16 570 BK-W 16 MAP_CONN
POWER GROUND F3 20A
13 359 GY-R 18 570 BK-W 16
3 ANA_RTN
14 351 BR-W 18 351 BR-W 18 351 BR-W 18 TWR
361 R 14 361 R 14 361 R 12
9 VBATT
5 VOLT REF C
3 16 R-LG 18 16 R-LG 18 361 R 14
VSW
33 350 GY 18 358 LG-BK 18 358 LG-BK 18
CRANK - B
32 349 DB 18 359 GY-R 18 359 GY-R 18
CRANK + A
35 452 GY-R 18 18 O-Y 18 18 O-Y 18
CAM - 38 EGR ANA IN
34 282 DB-O 18 198 DG-O 18 198 DG-O 18
CAM + 32 ANA AUX PD1
4 361 R 16 150 DG-W 18 150 DG-W 18
VBAT CAM CRANK 37 ANA AUX PU1
5 361 R 16 361 R 14 114 LB-Y 18 114 LB-Y 18
VBAT 12 FPP2
25 392 R-LG 18 352 BR-LG 18 352 BR-LG 18
EGO 2 40 EGR PWM
24 74 GY-LB 18 360 BR-PK 18 360 BR-PK 18
EGO 1 41 EGR REC
26 O2 SENSOR
4 EGO 3
29
361 R 14
359 GY-R 18 359 GY-R 18
KNK + 33 ANA RTN
30
KNK - 351 BR-W 18 351 BR-W 18
31 VREF
J1 BLACK 361A R 16 361A R 16 O2 MTRTWR6 MTRSHD6

TWR SHD
THROTTLE
FUEL PUMP
16 R-LG 18 32 R-LB 16
13 STARTER CONTROL
570 BK-W 16 570 BK-W 16 SENSOR 355 GY-W 18
A A
355 GY-W 18
6
86 30 STARTER
357 Y-W 18 357 Y-W 18 RELAY RELAY
74 GY-LB 18 392 R-LG 18 B B 5
151 LB-BK 18 151 LB-BK 18
C C 4 85 87 87A
359 GY-R 18 359 GY-R 18 317 GY-O 18 317 GY-O 18 86 30 32 R-LB 16
D D 1 15 STARTER IN (INTERUPT)
359 GY-R 18 351 BR-W 18 32 R-LB 16
E E 3 39 STARTER IN (AUTOCRANK)
J2 GREY 351 BR-W 18
F F
359 GY-R 18
2
85 87 87A
5 SPK PWR GROUND

4 570 BK-W 16 TWR
242 DG 18
342 LG-P 18 342 LG-P 18
1 A
850 Y-BK 18 1 2 3
COIL 1 1 COIL 1
2 851 Y-R 18 361A R 16
2 VBAT 361A R 16 FPP_COMM F4 15A
COIL 2 B 359 GY-R 18 D 787A PK-BK 16 787A PK-BK 16
3 RTN 5 FUEL PUMP
COIL 3 3 COIL 2 351 BR-W 18 C
13 5V
COIL 4 LOCKOFF SOLENOID 669 DG-W 18 B
24 TX
COIL 5 458 O-BK 18 A
25 RX 86 30 POWER
COIL 6 TWR
STARTER LOCKOUT
22 342 LG-P 18 RELAY
23 242 DG 18
FUEL LOCKOFF 85 87 87A
9 926A LB-O 18 926A LB-O 18
FUEL PUMP F5 15A
32 15 R-Y 18 15 R-Y 18 361 R 16 361 R 16
6 RELAY CONTROL
TPS1
30 355 GY-W 18
31 357 Y-W 18
TPS2 253 DG-W 18
28 151 LB-BK 18 OIL PRESSURE
DBW +
29 317 GY-O 18
DBW -
6 511 LG-R 18 511 LG-R 18 511 LG-R 18
BRAKE SWITCH 4 BRAKE
7 253 DG-W 18 253 DG-W 18 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 11 T-Y 18
TACH 2 TACH
27 658 PK-LG 18 658 PK-LG 18 658 PK-LG 18
MIL 6 MIL
10 238 DG-Y 18 238 DG-Y 18
FUEL PUMP MON
5 71 O-LG 18 71 O-LG 18 71 O-LG 18
AUX OUT 1 21 AUX OUT1
14 72 Y-BK 18 72 Y-BK 18
7 FUEL SELECT
AUX ANA PU2
15 148 Y-R 18 148 Y-R 18
72 Y-BK 18
148 Y-R 18
7 FUEL SELECT
10 AUX ANA PU2
16 306 T-LB 18 306 T-LB 18 306 T-LB 18
GOV SELECT 1 24 GOV SELECT 1
17 307 BK-Y 18 307 BK-Y 18 307 BK-Y 18
GOV SELECT 2 23 GOV SELECT 2
11 169 LG-BK 18 169 LG-BK 18 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18
GASEOUS TRIM
33 349A DB 18 349A DB 18 349A DB 18
OVERSPEED 30 OVERSPEED
18 662 DG-P 18 662 DG-P 18 662 DG-P 18
CAN + 28 CAN +
19 459 O-LG 18 459 O-LG 18 459 O-LG 18
CAN - 29 CAN -
20 642 DG-O 18 642 DG-O 18 642 DG-O 18
RS 485 + 11 RS 485+
8 RS 485 -
21
34
461 O 18
669 DG-W 18
461 O 18
669 DG-W 18
461 O 18
669 DG-W 18
3 RS 485-
RS 232 TX 20 RS 232+
35 458 O-BK 18 458 O-BK 18 458 O-BK 18
RS 232 RX 18 RS 232-
TWR SHD
570 BK-W 16
TRIM VALVE A A PLUG (GROUND)
TWR 361A R 16
77 DB-Y 18 B B PLUG (RELAY POWER)
A 459 O-LG 18
361A R 16 361A R 16 C C PLUG (CAN -)
B 662 DG-P 18
D D PLUG (CAN +)
WPTWR2_GY MTRTWR4 MTRSHD4
6 - 108 Z-60/34 Part No. 75861

Engine Wire Harness

Ford DSG-423 EFI Models (before serial number 6810)
IGNITION COILS HO2S #1

1
R 16 R 16 R 16 HO2S #2
ENGINE ECM Y/BK 18
CONNECTOR W/PK 18 BK/LG 18 GY/R 18 SHD
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
11
W/LG 18 W/LG 18 C INTERFACE
2
UEGPR DG/O 18
12 D
AUX ANA PD1 W/LG 18
13
(FRP) AUX ANA PD2
CAN1 +
14 DG/P 18 DG/P 18
MTRTWR4 FORD
15 O/LG 18 O/LG 18
CAN1 - 42 PIN
16
CAN2 -
17 BR/W 18 CONNECTOR
CAN2 + LG/R 18 LG/R 18
18
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
3
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32 LB/R 18 36 ROADSPEED -
5V RTN 2
33 LB/R 18 LG/BK 18
PULSE IN 35 ROADSPEED +
34 T/LB 18 T/LB 18 T/LB 18
GOV 1 24 GOV SELECT 1
35 DG/W 18 BK/W 16
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
(FUELSELECT)AUX DIG1
TPS 1
TPS 2
48
49
50
Y/W 18
Y/DB 18 10A ECM 4
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63
INJ HS T 16
64
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
BATT(+) R 12 R 12 R 14
INJ2 LS
INJ3 LS
INJ4 LS
66
67
BR/LB 16
W 16 GY/W 18
Y/W 18
GY/W 18
Y/W 18 6 RING
5
68 R 16
INJ5 LS BK/W 16 LB/DG 18 LB/DG 18 5 3
69
GROUND BR/W 18 BR/W 18 4 2
70
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER 1
RELAY
73 R/Y 18 ALTERNATOR
74 PK/LG 18
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND GY/O 18
82
DBW - R/BK 18
83 R/BK 18 21 AUX PWM 5
AUX PWM5 REC
AUX PWM5
AUX PWM1
84
85
R/BK 18
O/LG 18
R/W 18
R/W 18
BK/O 18
R/W 18
BK/O 18
16 AUX PWM 4
6
86 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC BK/R 16 BK/R 16
90 BK/R 16 18 FUEL PUMP -
FUEL PUMP AUX PWM3 O/LG 18 O/LG 18
39 AUX OUT1
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232-
A
INJECTOR CYL #2 GY/R 18
FUEL PUMP
B LB/PK 16
F4 15 START IN INTERUPT
R 16 BN/LB 16 LPG W/PK 16 19 START IN AUTOCRANK
TEMPERATURE
GY/R 18 1
ANA RTN
PK/BK 16 PK/BK 16 PK/BK 16 5 FUEL PUMP +
7
BR/W 18 2 15A
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON DG/P 18 3
CAN +
INJECTOR CYL #3
LG/P 18 85
FPP O/LG 18 1
CAN -
BK/W 18 6
GROUND
4
R 16 T 16 PK/BK 16 PK/BK 16
5
8
UNUSED
UNUSED
UNUSED
8
F1
R16 R/LB 16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 CONNECTOR
87
R 16 R 16
ES0400A
R/T 18 86
87A
15A RELAYED POWER
Part No. 75861 Z-60/34 6 - 109

Engine Wire Harness

Ford DSG-423 EFI Models (before serial number 6810)
6 - 109
6 - 110
Engine Wire Harness

Ford DSG-423 Models (from serial number 6810 to serial number 11788)
6 - 112
6 - 111
Engine Wire Harness

Ford DSG-423 Models (from serial number 6810 to serial number 11788)
1 HO2S #1
IGNITION COILS
R 16 R 16 R 16 HO2S #2
ENGINE ECM Y/BK 18
CONNECTOR W/PK 18 BK/LG 18 GY/R 18 SHD
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
11 C INTERFACE
2
UEGPR DG/O 18 W/LG 18 W/LG 18
12 D
AUX ANA PD1 W/LG 18
13
(FRP) AUX ANA PD2
CAN1 +
14 DG/P 18 DG/P 18
MTRTWR4 FORD
15 O/LG 18 O/LG 18
CAN1 - 42 PIN
16
CAN2 -
17 BR/W 18 CONNECTOR
CAN2 + LG/R 18 LG/R 18
18
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
3 SPEED +
SPEED -
5V EXT 2
30
31
LB/R 18 1
LG/W
DG/BK LB/R 18
32 36 ROADSPEED -
5V RTN 2
33 LB/R 18 LG/BK 18
PULSE IN 35 ROADSPEED +
34 T/LB 18 T/LB 18 T/LB 18
GOV 1 24 GOV SELECT 1
35 DG/W 18 BK/W 16
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
4 (FUELSELECT)AUX DIG1
TPS 1
TPS 2
48
49
Y/W 18
Y/DB 18 10A ECM
50
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63
INJ HS T 16
64
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
BATT(+) R 12 R 12 R 14
5 INJ2 LS
INJ3 LS
INJ4 LS
66
67
BR/LB 16
W 16 GY/W 18
Y/W 18
GY/W 18
Y/W 18 6 RING
68 R 16
INJ5 LS BK/W 16 LB/DG 18 LB/DG 18 5 3
69
GROUND BR/W 18 BR/W 18 4 2
70 R/LG 18
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER 1
RELAY
73 R/Y 18 ALTERNATOR
74 PK/LG 18
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND GY/O 18
82
DBW - R/BK 18
83 R/BK 18 21 AUX PWM 5
6 AUX PWM5 REC
AUX PWM5
AUX PWM1
84
85
R/BK 18
O/LG 18
R/W 18
R/W 18
BK/O 18
R/W 18 16 AUX PWM 4
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC BK/R 16 BK/R 16
90 BK/R 16 18 FUEL PUMP -
FUEL PUMP AUX PWM3 O/LG 18 O/LG 18
39 AUX OUT1
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232-
A
INJECTOR CYL #2 GY/R 18
FUEL PUMP
B LB/PK 16
F4 15 START IN INTERUPT
R 16 BN/LB 16 LPG W/PK 16 19 START IN AUTOCRANK
7 TEMPERATURE
GY/R 18 1
ANA RTN
PK/BK 16 PK/BK 16 PK/BK 16 5 FUEL PUMP +
BR/W 18 2 15A
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16

75861

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

75861

Încărcat de

Drepturi de autor:

Formate disponibile

Introduction June 2015

Important Serial Number Information

Basic mechanical, hydraulic and electrical skills are

Machine Design Life

Genie and "Z" are registered trademarks of

ii Z-60/34 Part No. 75861

E1 6/2015 Introduction TOC, Checklist B Procedures

Maintenance Inspection Report

2-1_Section 2_Specifications Page #. Electronic Version

Part No. 75861 Z-60/34 iii

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

2-1_Section 2_Specifications Page #. Electronic Version

iv Z-60/34 Part No. 75861

Rated work load (including occupants): 500 lb / 227 kg

Terex South Dakota, Inc.

Part No. 75861 Z-60/34 v

Do Not Perform Maintenance

vi Z-60/34 Part No. 75861

Personal Safety Be sure to wear protective eye wear and

Part No. 75861 Z-60/34 vii

Section 1 Safety Rules

viii Z-60/34 Part No. 75861

Section 3 Scheduled Maintenance Procedures

Part No. 75861 Z-60/34 ix

Section 3 Scheduled Maintenance Procedures, continued

x Z-60/34 Part No. 75861

Section 3 Scheduled Maintenance Procedures, continued

Section 4 Repair Procedures

Part No. 75861 Z-60/34 xi

Section 4 Repair Procedures, continued

xii Z-60/34 Part No. 75861

Section 4 Repair Procedures, continued

8-5 Jib Boom / Platform Rotate Manifold Components

Part No. 75861 Z-60/34 xiii

Section 4 Repair Procedures, continued

Section 5 Fault Codes

xiv Z-60/34 Part No. 75861

Section 6 Schematics, continued

Diesel Electrical Schematic ANSI/CSA,

Diesel Platform Control Box Wiring Diagram,

Part No. 75861 Z-60/34 xv

Section 6 Schematics, continued

Ford Electrical Schematic,

Ford Electrical Schematic,

xvi Z-60/34 Part No. 75861

Section 6 Schematics, continued

Part No. 75861 Z-60/34 xvii

Section 6 Schematics, continued

xviii Z-60/34 Part No. 75861

Tire ply rating Flanged lug nut, dry 240 ft-lbs

Tire ply rating Flanged lug nut, lubricated 180 ft-lbs

Overall tire diameter 41 in Fluid capacities

Part No. 75861 Z-60/34 2-1

Performance Specifications Boom function speeds, maximum

Raised or Primary boom up 35 to 45 seconds

Braking distance, maximum Secondary boom down 35 to 45 seconds

High range on paved surface 3 to 4 ft Primary Boom extend 12 to 22 seconds

Turntable rotate, 360°

Turntable rotate, 360°

Platform level (ANSI / AUS)

Platform level (CE)

Platform rotate, 160° 9 to 15 seconds

2-2 Z-60/34 Part No. 75861