z60 06 - 12345 - simeri oy henkilönostin palvelut booms...perkins 404c-22 engine specifications ......

July 2012

Z-60/34 Part No. 75861ii

Introduction

Serial Number Information

Genie offers the following Service Manuals forthese models:

Title Part No.

Z-60/34 Service Manual(before serial number 1090) ................................. 30105

Z-60/34 Service Manual(from serial number 1090 to 4000) ....................... 52856

Introduction

Copyright © 2011 by Terex Corporation

75861 Rev D December 2011Third Edition, Fourth Printing

Genie and "Z" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-60/34Operator's Manual before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine owner anduser. It also provides troubleshooting fault codesand repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop. In theseinstances, we strongly recommend thatmaintenance and repair be performed at anauthorized dealer service center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genielift.come-mail: [email protected]

July 2012

Part No. 75861 Z-60/34

Z60 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Terex South Dakota, Inc.

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5-

CAN B.354.4-

Model: Z-60/34

Serial number: Z6006-12345

Electrical schematic number: ES0423

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 60 ft 4 in/ 18.3 m

Maximum platform reach : 34 ft / 10.4 m

Serial number(stamped on chassis)

Serial label(located on back

of tank sidebulkhead)

(located on groundcontrol box)

OR

iii

Serial Number LegendINTRODUCTION

Section 1 • Serial Number Legend

July 2012

Z-60/34 Part No. 75861

Section 1 • Safety Rules

Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-60/34Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

iv

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Part No. 75861 Z-60/34 v

SAFETY RULES

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.

Section 1 • Safety Rules

July 2012

Z-60/34 Part No. 75861

Table of Contents

Introduction

Important Information ................................................................................................... ii

Serial Number Legend ................................................................................................. iii

Section 1 Rev Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

G Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Hydraulic Oil Specifications ................................................................................... 2 - 3

Hydraulic Component Specifications ...................................................................... 2 - 4

Manifold Component Specifications ....................................................................... 2 - 6

Valve Coil Resistance Specifications ..................................................................... 2 - 6

Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 7

Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 9

Deutz F4L-1011F Engine Specifications .............................................................. 2 - 10

Deutz F3L-1011F Engine Specifications .............................................................. 2 - 11

Deutz F3L-2011/Deutz D2011L03i Engine Specifications ..................................... 2 - 12

Perkins 404C-22 Engine Specifications ............................................................... 2 - 14

Machine Torque Specifications ............................................................................ 2 - 15

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 16

SAE and Metric Fasteners Torque Charts ............................................................ 2 - 17

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Part No. 75861 Z-60/34

TABLE OF CONTENTS

vii

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

D Checklist A Procedures

A-1 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 Models ............................................. 3 - 14

A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15

A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 16

D 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

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Z-60/34 Part No. 75861

TABLE OF CONTENTS

Section 3 Rev 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 Check and Adjust the Engine RPM ............................................................ 3 - 25

B-12 Test the Engine Idle Select ........................................................................ 3 - 26

B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 27

B-14 Test the Ground Control Override ............................................................... 3 - 28

B-15 Check the Directional Valve Linkage .......................................................... 3 - 28

B-16 Test the Platform Self-leveling ................................................................... 3 - 29

B-17 Test the Drive Brakes ................................................................................ 3 - 29

B-18 Test the Drive Speed - Stowed Position ..................................................... 3 - 30

B-19 Test the Drive Speed - Raised or Extended Position .................................. 3 - 30

B-20 Perform Hydraulic Oil Analysis ................................................................... 3 - 31

B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 32

B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 33

B-23 Perform Engine Maintenance - Ford Models ............................................... 3 - 34

B Checklist C Procedures

C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 35

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 36

C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 36

C-4 Replace the Air Filter Element - Diesel Models ........................................... 3 - 39

C-5 Replace the Fuel Inline Strainer- Deutz Models .......................................... 3 - 39

C-6 Perform Engine Maintenance - Ford Models ............................................... 3 - 40

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Part No. 75861 Z-60/34

Section 3 Rev Scheduled Maintenance Procedures, continued

C 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 - 45

D-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 46

D-6 Replace the Hydraulic Filters ...................................................................... 3 - 47

D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 48

B 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 - Ford Models ............................................... 3 - 54

E-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 54

E-6 Perform Engine Maintenance - Deutz 2011 Models .................................... 3 - 55



E-9 Perform Engine Maintenance - Ford Models ............................................... 3 - 57

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

C Platform Controls

1-1 ALC-500 Circuit Board .................................................................................. 4 - 2

1-2 Joysticks ..................................................................................................... 4 - 3

B 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

ix

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TABLE OF CONTENTS

x

Section 4 Rev Repair Procedures, continued

A Jib Boom Components

3-1 Jib Boom.................................................................................................... 4 - 14

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 15

B Primary Boom Components

4-1 Cable Track ................................................................................................ 4 - 16

4-2 Primary Boom ............................................................................................ 4 - 19

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 22

4-4 Primary Boom Extension Cylinder .............................................................. 4 - 23

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 26

B Secondary Boom Components

5-1 Secondary Boom........................................................................................ 4 - 27

5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 32

D Engines

6-1 RPM Adjustment ........................................................................................ 4 - 33

6-2 Flex Plate................................................................................................... 4 - 33

6-3 Engine Fault Codes - Ford Models ............................................................. 4 - 37

B Hydraulic Pumps

7-1 Function Pump ........................................................................................... 4 - 38

7-2 Drive Pump ................................................................................................ 4 - 39

E 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 (after serial number 4460) ........................ 4 - 46

8-4 Valve Adjustments - Function Manifold ...................................................... 4 - 50

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Part No. 75861 Z-60/34 xi


8-5 Jib Boom / Platform Rotate Manifold Components(before serial number 4461) ....................................................................... 4 - 52

8-6 Jib Boom / Platform Rotate Manifold Components(from serial number 4461 to serial number 10425) ...................................... 4 - 53

8-7 Jib Boom / Platform Rotate Manifold Components(from serial number 10426 to serial number 11003) .................................... 4 - 54

8-8 Jib Boom / Platform Rotate Manifold Components(after serial number 11003) ......................................................................... 4 - 55

8-9 Brake/Two-Speed Manifold Components(before serial number 4461) ........................................................................ 4 - 56

8-10 Brake/Two-Speed Manifold Components(after serial number 4460) ........................................................................... 4 - 57

8-11 2WD Drive Manifold Components(before serial number 4551) ........................................................................ 4 - 58

8-12 2WD Drive Manifold Components(after serial number 4550) ........................................................................... 4 - 60

8-13 4WD Traction Manifold Components .......................................................... 4 - 62(before serial number 10154)

8-14 4WD Traction Manifold Components .......................................................... 4 - 64(after serial number 10153)

8-15 Valve Adjustments, Traction Manifolds ...................................................... 4 - 66

8-16 Directional Valve Manifold Components ..................................................... 4 - 67

8-17 Directional Valve Linkage ........................................................................... 4 - 68

8-18 Valve Adjustments, Oscillate Directional Valve .......................................... 4 - 69

8-19 Turntable Rotation Manifold Components ................................................... 4 - 70

8-20 Drive Oil Diverter Manifold (welder option) .................................................. 4 - 71

8-21 Valve Coils ................................................................................................. 4 - 72

TABLE OF CONTENTS

July 2012

Z-60/34 Part No. 75861

TABLE OF CONTENTS


A Turntable Rotation Components

9-1 Turntable Rotation Assembly ..................................................................... 4 - 74

A Axle Components

10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 75

10-2 Oscillate Axle ............................................................................................. 4 - 76

A Generators

11-1 Adjustments, Hydraulic Generator .............................................................. 4 - 77

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

A Fault Code Chart - Control System ........................................................................ 5 - 2

A Fault Code Chart - Ford LRG-425 EFI Engine ........................................................ 5 - 6

A Fault Code Chart - Ford DSG-423 EFI Engine ...................................................... 5 - 12

Section 6 Rev Schematics

Introduction ............................................................................................................6 - 1

A Wire Connector Legend ..........................................................................................6 - 2

A Electrical Symbols Legend ....................................................................................6 - 3

A Hydraulic Symbols Legend ....................................................................................6 - 4

A Ford DSG-423 EFI Engine Relay Layout ................................................................6 - 5

B Diesel Electrical Schematic,(before serial number 4496) ..........................................................................6 - 8

A Diesel Electrical Schematic,(from serial number 4496 to serial number 5325) ........................................ 6 - 12

A Diesel Electrical Schematic,(from serial number 5326 to serial number 9798) ........................................ 6 - 16

xii

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Part No. 75861 Z-60/34 xiii

Section 6 Rev Schematics, continued

A Diesel Electrical Schematic ANSI/CSA,(from serial number 9799 to serial number 10387) ...................................... 6 - 20

A Diesel Electrical Schematic ANSI/CSA,(from serial number 10388) ......................................................................... 6 - 24

A Diesel Electrical Schematic CE,(from serial number 9799 to serial number 10387) ...................................... 6 - 28

A Diesel Electrical Schematic CE,(from serial number 10388) ......................................................................... 6 - 32

B Diesel Ground Control Box Wiring Diagram,(before serial number 5716 ......................................................................... 6 - 36

B Diesel Ground Control Box Wiring Diagram,(from serial number 5716 to serial number 9798) ........................................ 6 - 37

B Diesel Ground Control Box Wiring Diagram,(from serial number 9798) ........................................................................... 6 - 40

B Diesel Platform Control Box Wiring Diagram,(before serial number 7227) ........................................................................ 6 - 42

B Diesel Platform Control Box Wiring Diagram,(from serial number 7227 to serial number 9065) ........................................ 6 - 43

B Diesel Platform Control Box Wiring Diagram,(from serial number 9066 to serial number 9696) ....................................... 6 - 46

B Diesel Platform Control Box Wiring Diagram,(from serial number 9697) ........................................................................... 6 - 47

B Ford Electrical Schematic,(before serial number 4546) ........................................................................ 6 - 50

B Ford Electrical Schematic,(from serial number 4545 to serial number 5715) ........................................ 6 - 54

B Ford Electrical Schematic,(from serial number 5716 to serial number 6315) ........................................ 6 - 58

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TABLE OF CONTENTS

xiv


B Ford Electrical Schematic,(from serial number 6316 to serial number 7226) ....................................... 6 - 62

B Ford Electrical Schematic,(from serial number 7227 to serial number 10387) ...................................... 6 - 66

B Ford Electrical Schematic, ANSI/CSA,(from serial number 10388) ......................................................................... 6 - 70

B Ford Electrical Schematic, CE,(from serial number 10388) ......................................................................... 6 - 74

B Ford Ground Control Box Wiring Diagram,before serial number 4546) ......................................................................... 6 - 78

B Ford Ground Control Box Wiring Diagram,(from serial number 4546 to serial number 5715) ....................................... 6 - 79

B Ford Ground Control Box Wiring Diagram,(from serial number 5716 to serial number 7226) ....................................... 6 - 82

B Ford Ground Control Box Wiring Diagram,(from serial number 7227 to serial number 9798) ........................................ 6 - 83

B Ford Ground Control Box Wiring Diagram,(from serial number 9799) ........................................................................... 6 - 86

A Ford Platform Control Box Wiring Diagram,(before serial number 7227) ........................................................................ 6 - 87

B Ford Platform Control Box Wiring Diagram,(from serial number 7227 to serial number 9065) ........................................ 6 - 90

B Ford Platform Control Box Wiring Diagram,(from serial number 9066 to serial number 9798) ........................................ 6 - 91

B Ford Platform Control Box Wiring Diagram,(from serial number 9799) ........................................................................... 6 - 93

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Part No. 75861 Z-60/34 xv


A Engine Wire Harness,Ford LRG-425 EFI Models .......................................................................... 6 - 96

A Engine Wire Harness,Ford DSG-423 EFI Models (before serial number 6810) .............................. 6 - 97

A Engine Wire Harness,Ford DSG-423 EFI Models (after serial number 6809) ................................ 6 - 99

A Electrical Schematic, CTE Option (before serial number 9697) .......................... 6 - 102

A Electrical Schematic, CTE Option (from serial number 9697) ............................. 6 - 103

A Joystick Connector Diagram .............................................................................. 6 - 106

A Hydraulic Generator Options .............................................................................. 6 - 107

B Electrical Schematic, Hydraulic Welder Option .................................................. 6 - 110

C Hydraulic Schematic, Welder Option ................................................................. 6 - 111

A Hydraulic Schematic, 2WD Models(before serial number 4461) ...................................................................... 6 - 114

A Hydraulic Schematic, 2WD Models(from serial number 4461 to 10282) .......................................................... 6 - 115

C Hydraulic Schematic, 2WD Models(from serial number 10283 to serial number 11003) .................................. 6 - 118

A Hydraulic Schematic, 2WD Models(from serial number 11004) ....................................................................... 6 - 119

A Hydraulic Schematic, 4WD Models(before serial number 4461) ...................................................................... 6 - 122

A Hydraulic Schematic, 4WD Models(from serial number 4461to serial number 10282) ..................................... 6 - 123

C Hydraulic Schematic, 4WD Models(from serial number 10283 to serial number 11003) .................................. 6 - 126

A Hydraulic Schematic, 4WD Models(from serial number 11004) ....................................................................... 6 - 127

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Section 2 • SpecificationsJuly 2012

REV G

Part No. 75861 Z-60/34 2 - 1

Specifications

Lug nut torque (before serial number 4551)

Flanged or tapered lug nut, dry 170 ft-lbs230 Nm

Flanged or tapered lug nut, lubricated 130 ft-lbs176 Nm

Lug nut torque (after serial number 4550)

Flanged lug nut, dry 240 ft-lbs325 Nm

Flanged lug nut, lubricated 180 ft-lbs244 Nm

Tapered lug nut, dry 170 ft-lbs230 Nm

Tapered lug nut, lubricated 130 ft-lbs176 Nm

Fluid capacities

Fuel tank 20 gallons75.7 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208.2 liters

Drive hubs (before serial number 4551) 17 fl oz0.5 liters

Drive hubs (after serial number 4550) 20 fl oz0.59 liters

Turntable rotation drive hub 8 fl oz0.24 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

Machine Specifications

Tires and wheels

Tire size(Rough terrain) 385-19.5

Tire size(Hi-flotation) 41/18LL x 22.5

Tire ply rating(Rough terrain) 16

Tire ply rating(Hi-flotation) 14

Tire weight, new foam-filled (minimum) 425 lbs(Rough terrain) 193 kg

Overall tire diameter 40.1 in(Rough terrain) 102 cm

Overall tire diameter 41 in(Hi-flotation tires) 104 cm

Tire pressure (air-filled tires) 70 psi(Rough terrain) 4.8 bar

Tire pressure (air-filled tires) 60 psi(Hi-flotation tires) 4.1 bar

Wheel lugs 9 @ 5/8 -18

For operational specifications, refer to theOperator's Manual.

Section 2 • Specifications July 2012

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

SPECIFICATIONS

Boom function speeds, maximumfrom platform controls

Jib boom up 20 to 25 seconds

Jib boom down 15 to 20 seconds

Primary boom up 35 to 45 seconds

Secondary boom up 40 to 50 seconds

Primary boom down 50 to 60 seconds

Secondary boom down 35 to 45 seconds

Primary Boom extend 12 to 22 seconds

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


Performance Specifications

Drive speeds

Stowed 40 ft / 7.9-8.5 sec12.2 m / 7.9-8.5 sec

Raised orExtended position 40 ft / 42-48 sec

12.2 m / 42-48 sec

Gradeability See Operator's Manual

Braking distance, maximum

High range on paved surface 3 to 4 ft0.9 to 1.2 m


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Part No. 75861 Z-60/34 2 - 3

SPECIFICATIONS


Continued use of ChevronAviation A hydraulic oil whenambient temperatures areconsistently above 32°F / 0°C mayresult in component damage.

Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistently below0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD PremiumMV equivalent

Viscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rando HD Premium MV oil is fullycompatible and mixable with Shell Donax TG (DexronIII) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio SE 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A


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2 - 4 Z-60/34 Part No. 75861

SPECIFICATIONS

Hydraulic ComponentSpecifications

Drive pump (before serial number 4551)

Type: bi-directional,variable displacement piston pump

Displacement per revolution, variable, 2WD models0 to 1.70 cu in

0 to 28 cc

Displacement per revolution, variable, 4WD models 0 to 2.74 cu in

0 to 45 cc

Flow rate @ 2500 rpm, 2WD models 0 to 18.5 gpm0 to 70.0 L/min

Flow rate @ 2500 rpm, 4WD models 0 to 30.1 gpm0 to 113.9 L/min

Drive pressure, maximum, 2WD models 4200 psi290 bar

Drive pressure, maximum, 4WD models 3625 psi250 bar

Drive pump (after serial number 4550)

Type: bi-directional,variable displacement piston pump

Displacement per revolution, variable, 4WD models 0 to 2.8 cu in

0 to 46 cc

Flow rate @ 2500 rpm 0 to 28 gpm106 L/min

Drive pressure, maximum 3625 psi250 bar

Charge pump (before serial number 4551)

Type: fixed displacement gear pump

Displacement, 2WD models 0.37 cu in6.1 cc

Displacement, 4WD models 0.51 cu in8.4 cc

Flow rate @ 2500 rpm, 2WD models 4 gpm15.1 L/min

Flow rate @ 2500 rpm, 4WD models 5.5 gpm20.8 L/min

Charge pressure @ 2500 rpm 250 psiNeutral position 17.2 bar

Charge pump (after serial number 4550)

Type: gerotor pump

Displacement 0.85 cu in13.9 cc

Flow rate @ 2500 rpm 9 gpm34.1 L/min

Charge pressure @ 2500 rpm 310 psiNeutral position 21.4 bar

Function pump (before serial number 4551)

Type gear, pressure balanced

Displacement 1.37 cu in22.5 cc

Flow rate @ 2500 rpm 14.8 gpm56 L/min

Function pump (after serial number 4550)

Type gear, pressure balanced

Displacement 1.04 cu in17 cc

Flow rate @ 2500 rpm 10.69 gpm40.5 L/min



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Part No. 75861 Z-60/34 2 - 5

Oscillation pump (after serial number 4550)

Type gear, fixed displacement

Displacement 0.37 cu in6 cc

Auxiliary pump

Type gear, fixed displacement

Displacement - static 0.151 gpm2.47 L/min

Auxiliary pump relief pressure 2400 psi165 bar

Function manifold

System relief valve pressure 2600 psi179.3 bar

Primary boom down 1800 psirelief valve pressure 124 bar

Secondary boom down 1600 psirelief valve pressure 110 bar

Steer flow regulator 3.5 gpm13.2 L/min

Boom extend 2600 psi179.3 bar

Oscillate pressure 750 psi51.7 bar

Jib boom / platform rotate 1.5 gpmflow regulator 5. 7 L/min

2WD Traction manifold

Hot oil relief pressure 300 psi(before serial number 4461) 20.7 bar

Hot oil relief pressure 280 psi(after serial number 4460) 19.3 bar

4WD Traction manifold

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

Brakes

Brake release pressure 174 psi12 bar

Drive motors, 4WD and 2WD models(before serial number 4551)

Displacement per revolution 1.71 cu inhigh speed 28 cc

Displacement per revolution .87 cu inlow speed 14.2 cc

Drive motors, 4WD models(after serial number 4550)

Displacement per revolution, 0.79 cu inhigh speed 13 cc

Displacement per revolution, 1.83 cu inlow speed 30 cc

Drive motors, 2WD models(after serial number 4550)

Displacement per revolution, 1.28 cu inhigh speed 20.9 cc

Displacement per revolution, 2.14 cu inlow speed 35 cc

Hydraulic filters

High pressure filter Beta 3 200

High pressure filter 102 psibypass pressure 7 bar

Medium pressure filter Beta 3 200

Medium pressure filter 51 psibypass pressure 3.5 bar

Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass

Drive motor case drain Beta 10 2return filter

SPECIFICATIONS



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SPECIFICATIONS


Manifold ComponentSpecifications

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




Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Description Specification

Proportional solenoid valve, 12V DC 6.3 (schematic items AB, AC and AG)

Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 (schematic items H, I)

Solenoid valve, 3 Position, 4 Way, 10V DC 6.3 (schematic items A, B, C, F, J, AK)

Proportional solenoid valve, 12V DC 3.7 (schematic items HM, HO and HR)

Solenoid valve, 2 Position, 3 Way 10V DC 6.3 (schematic items IJ, IK)

Solenoid valve, 3 Position, 4 Way 10V DC 5 (schematic items HA, HC, HD, HE, HU)

Solenoid valve, 3 Position, 4 Way 10V DC 6.3 (schematic items HF)

Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 (schematic items BA, BB, DA, DB)

Solenoid valve, 2 Position, 3 Way, 10V DC 5 (schematic items BE, EA, EB)


REV G

Part No. 75861 Z-60/34 2 - 7

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

HorsepowerGross intermittent 70 @ 2500 rpmContinuous 60 @ 2500 rpmGross intermittent 52 kW @ 2500 rpmContinuous 44.7 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpmFrequency 396.8 Hz

High idle 2500 rpmFrequency 620 Hz

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 incollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 4.5 quarts(including filter) 4.3 liters

Oil viscosity requirements

Unit ships with 5W-30 oil.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.

Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 3-5 psi0.21-0.34 bar

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, no load 70A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Brush length, new 0.66 in16.8 mm

Brush length wear limit 0.25 in6.35 mm

Battery

Type 12V DC, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min


SPECIFICATIONS


REV G

2 - 8 Z-60/34 Part No. 75861

SPECIFICATIONS

Ignition System

Spark plug type Motorcraft AWSF-52-C(before serial number 4546)

Spark plug type Motorcraft AGSF-32-FM(after serial number 4545)

Spark plug gap 0.042 to 0.046 inches1.07 to 1.17 mm

Spark plug torque 5-10 ft-lbs7-14 Nm

Engine coolant

Capacity 11.5 quarts10.9 liters

Coolant temperature switch


Temperature switch point 230° F112° C

Alternator

Output 95A, 13.8V DC


REV G

Part No. 75861 Z-60/34 2 - 9

Ford DSG-423 EFI Engine

Displacement 140.4 cu in2.3 liters


Bore & stroke 3.44 x 3.7 inches87.5 x 94 mm

HorsepowerContinuous horsepower 59 @ 2500 rpmPeak horsepower 69 @ 2500 rpmContinuous horsepower 44 kW @ 2500 rpmPeak horsepower 51 kW @ 2500 rpm


Low function idle (computer controlled) 1600 rpmFrequency 53.3 Hz

High function idle (computer controlled) 2500 rpmFrequency 83.3 Hz


Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder

Lubrication system

Oil pressure 29 to 39 psi(at operating temperature @ 2500 rpm) 2 to 2.7 bar

Oil capacity 4 quarts(including filter) 3.8 liters


Unit ships with 5-W20 oil.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.

Fuel requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Ignition system

Spark plug type Motorcraft AGSF-32-FEC

Spark plug gap 0.049 to 0.053 inches1.244 to 1.346 mm

Engine coolant

Capacity 10 quarts9.5 liters

Cylinder head temperature sending unit

Fault code set temperature 280°F138°C

Engine shut-down temperature 300°F149°C

Starter motor

Normal engine cranking speed 200 to 250 rpm


Current draw, maximum load 800A

Alternator

Output 95A, 13.8V DC

Battery

Type 12V DC, Group 31

Quantity 1

Cold cranking ampere @ 0°F 1000A


Torque

Flywheel bolts 83 ft-lbs


Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.43 gpm1.6 L/min

SPECIFICATIONS


REV G

2 - 10 Z-60/34 Part No. 75861

SPECIFICATIONS

Deutz Engine F4L 1011F

Displacement 166.7 cu in2.732 liters


Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower 56 @ 3000 rpm42 kW @ 3000 rpm



Compression pressure 362 to 435 psi25 to 30 bar

Low idle 1500 rpmFrequency 313 Hz

High idle 2300 rpmFrequency 479.9 Hz

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure (hot @ 2000 rpm) 60 to 70 psi4.1 to 4.8 bar

Oil capacity 11 quarts(including filter) 10.5 liters


Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.

Injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement

For fuel requirement, refer to the engine Operator'sManual on your machine.

Alternator output 60A, 14V

Starter motor


Brush length, new 0.7480 in19mm

Brush length, minimum 0.5 in12.7 mm

Battery

Type 12V, Group 31

Quantity 1



Fan belt deflection 3/8 to 1/2 inch9 to 12 mm



REV G

Part No. 75861 Z-60/34 2 - 11

Injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar


Fuel requirement


Alternator output 55A, 14V

Starter motor


Brush length, new 0.7480 in19 mm


Battery

Type 12V, Group 31

Quantity 1




Deutz F3L 1011F Engine




Horsepower 43 @ 2800 rpm32 kW @ 2800 rpm

Firing order 1 - 2 - 3









Lubrication system

Oil pressure 26 to 87 psi1.8 to 6.0 bar

Oil capacity 8.5 quarts(including filter) 8 liters


Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.


SPECIFICATIONS


REV G

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

SPECIFICATIONS

Deutz F3L 2011 EngineDeutz D2011L03i Engine




Horsepower

Net intermittent 48.7 @ 2800 rpmNet continuous 46.2 @ 2800 rpmNet intermittent 36 kW @ 2800 rpmNet continuous 34.5 kW @ 2800 rpm

Firing order 1 - 2 - 3



Compression ratio 19:1






Lubrication system

Oil pressure, hot @ 2000 rpm 40-60 psi2.8 to 4.1 bar

Oil capacity 8.5 quarts(including filter) 8 liters(Deutz F3L2011 Engine)

Oil capacity 9.5 quarts(including filter) 9 liters(Deutz D2011Lo3i Engine)



Oil temperature switch


Temperature switch point 220° F104° C

Oil pressure switch


Oil pressure switch point 7 psi(Deutz F3L2011 Engine) .5 bar

Oil pressure switch point 22 psi(Deutz D2011L03i Engine) 1.5 bar


REV G

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

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15000 psi1034 bar


Fuel requirement


Starter motor


Brush length, new 0.72 in18.5 mm

Brush length, minimum 0.27 in7 mm

Battery

Type 12V, Group 31

Quantity 1



Alternator output 60A @ 14V DC


SPECIFICATIONS


REV G

2 - 14 Z-60/34 Part No. 75861

Perkins 404-22 Engine




Horsepower

gross intermittent 50 @ 2800 rpmcontinuous 41 @ 2800 rpmgross intermittent 37.3 kW @ 2800 rpmcontinuous 31 kW @ 2800 rpm


Low idle 1300 rpmFrequency 200.4 Hz

Low idle with generator option 1500 rpmFrequency 231.3 Hz

High idle 2500 rpmFrquency 385.4 Hz


Compression pressure 426 psi29.4 bar

Pressure (psi) of lowest cylinder mustbe within 50 psi / 3.45 bar of highest cylinder





Lubrication system

Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar

Oil capacity 9.4 quarts to 11.2 quarts(including filter) 8.9 liters to 10.6 liters



Oil pressure sending unit


Oil pressure switch point 14.2 psi1 bar

Fuel injection system

Injection pump make Zexel

Injection pressure 2133 psi147 bar

Fuel requirement


Alternator output 65A @ 13.8V DC

Fan belt deflection 3/8 to ½ in9 to 12 mm

Starter motor


Brush length, new 0.7480 in19 mm



SPECIFICATIONS


REV G

Part No. 75861 Z-60/34 2 - 15

SPECIFICATIONS

Battery

Type 12V, Group 31

Quantity 1



Coolant temperature sending unit


Temperature switch point 221° F 105° C


Machine Torque Specifications

Platform rotator

1-8 center bolt, dry 640 ft-lbs868 Nm

1-8 center bolt, Gr 5, lubricated 480 ft-lbs651 Nm

3/8 -16 bolts, Gr 8, lubricated 35 ft-lbs**(use blue thread-locking compound) 47 Nm

Drive motor and hubs

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-lbs244 Nm

Turntable rotate assembly

Turntable motor mounting bolts 160 ft-lbs**(use blue thread-locking compound) 217 Nm


REV G

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

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.Tolerance is +10%-0.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 14 ft-lbs / 18.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 48.8 Nm

-10 62 ft-lbs / 84.1 Nm

-12 84 ft-lbs / 113.9 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 250 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® Fittings (ORFS)(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40.7 Nm

-8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 149 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 244 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.Tolerance is +10%-0.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

SPECIFICATIONS


REV G

Part No. 75861 Z-60/34 2 - 17

SPECIFICATIONS

Size

(mm)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 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 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

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 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 42.610 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 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this m anual •

A574 High Strength Black Oxide Bolts

Grade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

10.9 12.98.84.6


REV G

2 - 18 Z-60/34 Part No. 75861


Part No. 75861 Z-60/34 3 - 1

August 2007 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than three months must completethe quarterly inspection.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom betweenthe non-steer wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetyinformation and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


Note: Used to indicate operation or maintenanceinformation

Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

3 - 2 Z-60/34 Part No. 75861

March 2007Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor, pump orengine will be required to perform thisprocedure.

Indicates that a warm motor or pumpwill be required to perform thisprocedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery PreparationReport to use for each inspection. Store completedforms as required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, every six months, annual andtwo years. The Scheduled MaintenanceProcedures Section and the MaintenanceInspection Report have been divided into fivesubsections—A, B, C, D and E. Use the followingchart to determine which group(s) of proceduresare required to perform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-Delivery Preparation

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

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removedfrom service.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.

3 - 4 Z-60/34 Part No. 75861

August 2007Section 3 • Scheduled Maintenance Procedures


Part No. 75861 Z-60/34 3 - 5


Checklist A - Rev D Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Function tests

A-4 Engine maintenance -all models

Perform after 40 hours:

A-5 30 Day Service

Perform every 40 hours:

A-6 Filter condition indicator

Perform after first 50 hours:

A-7 Engine maintenance -Deutz and Ford models


A-8 Engine maintenance-Perkins models


A-9 Fuel filter/waterseparator -Deutz models

A-10 Engine maintenance -Ford models

A-11 Rotation bearing


A-12 Engine maintenance -Deutz 1011F models


A-13 Drive hub oil


A-14 Engine maintenance -Ford models

Checklist B - Rev D Y N R

B-1 Battery

B-2 Electrical wiring

B-3 Air filter element

B-4 Key switch

B-5 Engine maintenance -Deutz and Perkinsmodels

B-6 Exhaust system

B-7 Oil cooler and fins-Deutz models

B-8 Tires, wheels and lugnut torque

B-9 Drive hub maintenance

B-10 Brake configuration

B-11 Engine RPM

B-12 Engine idle select

B-13 Fuel select -Ford models

B-14 Ground control

B-15 Directionalvalve linkage

B-16 Platformself-leveling

B-17 Drive brakes

B-18 Drive speed -stowed position

B-19 Drive speed -raised position

B-20 Hydraulic oil analysis

B-21 Alarm package

B-22 Fuel and hydraulic capventing systems


B-23 Engine maintenance -Ford models

Maintenance Inspection Report

Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments

April 2012

3 - 6 Z-60/34 Part No. 75861


Checklist C - Rev B Y N R

C-1 Engine maintenance -Deutz and Perkinsmodels

C-2 Platform overload(if equipped)

C-3 Platform overload(if equipped)

C-4 Air filter element -Deutz and Perkinsmodels

C-5 Fuel inline strainer -Deutz models


C-6 Engine maintenance -Ford models

Checklist D - Rev C Y N R

D-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Free-wheelconfiguration

D-4 Drive hub oil

D-5 Engine maintenance-Deutz and Perkinsmodels

D-6 Hydraulic filters

D-7 Turntable bearing wear

MAINTENANCE INSPECTION REPORT

Checklist E - Rev B Y N R

E-1 Hydraulic oil

E-2 Steer axlewheel bearings,2WD models


E-3 Engine maintenance -Deutz andPerkins models


E-4 Engine maintenance -Ford models




E-6 Engine maintenance -Deutz models



Perform every 12,000 hours:

E-8 Engine maintenance -Deutz models

Perform every 4 years:

E-9 Engine maintenance -Ford models

Comments

Instructions· Make copies of both pages to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

April 2012

Part No. 75861 Z-60/34 3 - 7


Checklist A ProceduresREV D

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

3 - 8 Z-60/34 Part No. 75861


REV D

A-3Perform Function TestsGenie specifications require that this procedure beperformed daily.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the Operator's Manual on yourmachine.

A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed daily.

Completing a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Operator's Manual on yourmachine.

CHECKLIST A PROCEDURES

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


CHECKLIST A PROCEDURES

A-4Perform Engine Maintenance

Engine specifications require that this procedurebe performed every 8 hours or daily, whichevercomes first.

Deutz models

Required maintenance procedures and additionalengine information are available in the

Deutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0297 9929).

Deutz 1011F Operation ManualGenie part number 52883

Deutz 2011 Operation ManualGenie part number 84794

Perkins models

Required maintenance procedures and additionalengine information are available in thePerkins 404C-22 Operation Manual(Perkins part number TPD 1443S).

Perkins 404C-22 Operation ManualGenie part number 94890

Ford models

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFord DSG-423 EFI Operator Handbook(EDI part number 1060020).

Ford LRG 425 EFI Operation ManualGenie part number 84792

Ford DSG 423 EFI Operator HandbookGenie part number 119488

To access the engine:

1 Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving

Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.

REV D

3 - 10 Z-60/34 Part No. 75861


CHECKLIST A PROCEDURES REV D

A-6Check the High PressureHydraulic Filter ConditionIndicator (if equipped)Genie specifications require that this procedure beperformed every 40 hours of operation.

Maintaining the hydraulic return filter in goodcondition is essential to good system performanceand safe machine operation. The filter conditionindicator will show when the hydraulic flow isbypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Open the ground control side turntable cover.

2 Start the engine from the ground controls.

3 Change the engine idle to high rpm (rabbitsymbol).

4 Visually inspect the filter condition indicator.

Result: The filter condition indicator should beoperating with the plunger in the green area. Ifthe indicator displays the plunger in the redarea, this indicates that the hydraulic filter isbeing bypassed and the filter should bereplaced. See D-6, Replace the Hydraulic FilterElements.

A-5Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-11 Grease the Turntable Bearing andRotate Gear

• B-8 Inspect the Tires, Wheels and Lug NutTorque

• B-9 Check the Drive Hub Oil Level andFastener Torque

• D-2 Check the Turnable Rotation BearingBolts

• D-6 Replace the Hydraulic Filter Elements

Part No. 75861 Z-60/34 3 - 11


A-7Perform Engine Maintenance -Deutz and Ford Models

Engine specifications require that this procedurebe performed after the first 50 hours of operation.

Deutz models

Required maintenance procedures and additionalengine information are available in the

Deutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0297 9929).



CHECKLIST A PROCEDURESREV D

Ford models






Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury

3 - 12 Z-60/34 Part No. 75861


REV DCHECKLIST A PROCEDURES

A-9Inspect the Fuel Filter/WaterSeparator - Deutz Models

Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Note: Perform this procedure with the engine off.

1 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

A-8Perform Engine Maintenance -Perkins Models

Engine specifications require that this procedurebe performed every 50 hours.

Perkins models






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


a

b

a fuel filterb drain plug

2 Clean up any fuel that may have spilled.

3 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

REV D CHECKLIST A PROCEDURES

A-10Perform Engine Maintenance -Ford Models








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



A-12Perform Engine Maintenance -Deutz 1011F Models

Engine specifications require that this procedurebe performed after the first 125 hours.

Deutz models

Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).





A-11Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Raise the boom enugh to access the turntablegearing.

2 Locate the grease fitting on the platform end ofthe engine side bulkhead.

3 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of4 to 5 inches / 10 to 13 cm at a time and repeatthis step until the entire bearing has beengreased.

4 Apply grease to each tooth of the drive gear,located under the turntable.

Grease type

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

Part No. 75861 Z-60/34 3 - 15


aa

bb

CHECKLIST A PROCEDURESREV D

A-13Replace the Drive Hub Oil

Manufacturer drive hub specifications require thatthis one-time procedure be performed after thefirst 150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil after the first 150 hoursof use may cause the machine to perform poorlyand continued use may cause componentdamage.

Before serial number 4551

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Section 2, Specifications.

5 Install the plugs. Use pipe thread sealant onunits with pipe plugs.

6 Repeat steps 1 through 5 for all the other drivehubs.

models with pipe plugs a drive hub plugs

a

After serial number 4550

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs (b) is at thelowest point. See illustration A.


3 Drive the machine until one plug (a) is justabove horizontal. See illustration B.


5 Apply pipe thread sealant to the plugs. Installthe plugs.


Illustration A Illustration B

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



A-14Perform Engine Maintenance -Ford Models








Part No. 75861 Z-60/34 3 - 17


REV DChecklist B Procedures

B-1Inspect the Battery

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Be sure that the battery separator wireconnections are tight (if equipped).

5 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 13.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.217. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled using bakingsoda.

3 - 18 Z-60/34 Part No. 75861


CHECKLIST B PROCEDURES REV D

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.


1 Open the engine side turntable cover.

2 Remove the engine tray retaining fastenerslocated under the engine tray. Swing the enginetray out and away from the machine and secureit from moving.


3 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Engine wiring harness

4 Inspect for a liberal coating of dielectric greasein the following locations:

• Between the ground and platform controls

• Between the ground and drive controls

• All harness connectors

• Level sensor

5 Open the turntable cover at the ground controlside of the machine.

6 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Inside of the ground control box

• Hydraulic manifold wiring

7 Start the engine from the ground controls andraise the boom above the turntable covers.

8 Inspect the turntable area for burnt, chafed andpinched cables.

9 Lower the boom to the stowed position and turnthe engine off.

10 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

• Cable track on the primary boom

• Cables on the primary, and jib booms

• Jib boom/Platform rotate manifold

• Inside of the platform control box

11 Inspect for a liberal coating of dielectric greasein all connections between the ECM and theplatform controls.

12 Swing the engine back to its original positionand install the engine pivot plate retainingfasteners.

Crushing hazard. Failure to installthe fasteners into the engine trayto secure it from moving couldresult in death or serious injury.

Part No. 75861 Z-60/34 3 - 19


B-3Inspect the Air Filter

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

2 Inspect the dust discharge valve. If the valveshows any signs of damage, replace the valve.

a clampb canister end capc dust discharge valve

3 Disconnect the latches and remove the end capof the air cleaner canister.

4 Remove the filter element.

5 Clean the inside of the canister and the gasketwith a damp cloth.

6 Clean the filter using dry compressed air. Blowout from inside to outside. Check filter gasketfor damage.

7 Re-install the filter element, or if there are anysigns of loss of filtration, replace the element.

8 Install the end cap onto the canister. Secure theclamps.

Note: Be sure the dust discharge valve is pointingdown.

CHECKLIST B PROCEDURESREV D

3 - 20 Z-60/34 Part No. 75861



B-5Perform Engine Maintenance -Deutz and Perkins Models

Engine specifications require that this procedurebe performed quarterly or every 250 hours,whichever comes first.

Deutz models

Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).


Perkins models






B-4Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and nofunctions should operate.

Part No. 75861 Z-60/34 3 - 21


B-7Check the Oil Cooler and CoolingFins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.

Oil cooler

1 Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving.


2 Remove the fasteners from the engine sidecover, and remove the cover.

3 Inspect the oil cooler for leaks and physicaldamage.

4 Clean the oil cooler of debris and foreignmaterial.

B-6Check the Exhaust System


Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.



2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

5 Swing the engine back to its original positionand install the engine pivot plate retainingfasteners.


REV D CHECKLIST B PROCEDURES

3 - 22 Z-60/34 Part No. 75861



B-8Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition including proper wheel fastener torque isessential to safe operation and good performance.Tire and/or wheel failure could result in a machinetip-over. Component damage may also result ifproblems are not discovered and repaired in atimely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

The tires on some machines are foam-filled and donot need air added to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

Models with air-filled tires:

4 Check pressure in each air-filled tire. Add air asnecessary. Refer to Section 2, Specifications.

a oil coolerb cylinder head cooling finsc fan blower fins

Cooling and fan blower fins

5 Inspect the fan blower fins for physical damage.

6 Clean the fan blower fins of debris and foreignmaterial.

7 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

8 Clean the cylinder head cooling passages ofdebris and foreign material.

9 Install the engine side cover.

10 Swing the engine back to its original positionand install the engine pivot plate retainingfasteners. Tighten the pivot fastener.


cba

Part No. 75861 Z-60/34 3 - 23


aa

bb

Turntable rotate drive hub (all models)

1 Remove the plug located on the side of the huband check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

turntable drive huba plug

2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole.

3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.

4 Check the torque of the turntable drive hubmounting fasteners. Refer to Section 2,Specifications.

B-9Check the Drive Hub Oil Leveland Fastener Torque


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.

Drive Hub (before serial number 4551)

1 Drive the machine to rotate the hub until theplugs are located one on top and the otherat 90 degrees.

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole. Refer to Section 2,Specifications.

4 Install the plug(s) in the drive hub. Use pipethread sealant on units with pipe plugs.

5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.


Drive Hub (after serial number 4550)

1 Drive the machine until one plug is just abovehorizontal. See illustration B.

a



4 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

5 Repeat this procedure for each drive hub.


a


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



brake disengaged position

brake engaged position

a

d

c

b

B-10Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on thebottom of the drive pump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

Note: The free-wheel valve should always remainclosed.

Part No. 75861 Z-60/34 3 - 25


f

e

c dba

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and re-check the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

Perkins Models

1 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSection 2, Specifications.

B-11Check and Adjust theEngine RPM


Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Note: This procedure will require two people.

Ford Models

Note: The engine rpm is controlled by the ECMand can only be adjusted by re-programming theECM. If rpm adjustment or service is required,please contact Genie Industries ServiceDepartment OR your local Ford dealer.

Deutz Models

1 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSection 2, Specifications.

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

2 Loosen the low idle lock nut and turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and re-check therpm.

3 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) positionat the ground controls. Refer to Section 2,Specifications.


aa

3 - 26 Z-60/34 Part No. 75861


REV DCHECKLIST B PROCEDURES

a b c d

B-12Test the Engine Idle SelectGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.

Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions.

Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.


2 Start the engine from the ground controls thenmove and hold the function enable/rpm selecttoggle switch to the high idle (rabbit symbol).

Result: The engine should change to high idle.

3 Release the function enable/rpm select toggleswitch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

6 Press down the foot switch.

Result: The engine should change to high idle.

7 Move the engine idle control switch to footswitch activated low idle (turtle symbol).

Result: The engine should change to low idle.

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

2 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase therpm, or counterclockwise to decrease the rpm.

Tighten the low idle lock nut and confirm therpm.

a solenoid bootb high idle adjustment nutc clevisd low idle lock nut and adjustment

screw

3 Move the function enable toggle switch to thehigh idle (rabbit symbol) position. Refer toSection 2, Specifications.

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and re-check the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

Part No. 75861 Z-60/34 3 - 27


2 Start the engine from the platform controls andallow it to run at low idle. Press down the footswitch to allow the engine to run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

3 Release the foot switch and shut the engine offby pushing the red Emergency Stop buttonin to the off position.

4 Move the fuel select switch to LPG.

5 Start the engine and allow it to run atlow idle. Press down the foot switch to allow theengine to run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

Note: The engine may hesitate momentarily andthen continue to run on the selected fuel ifswitched while running.

B-13Test the Fuel Select Operation -Ford Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Note: Perform this test after checking the gasolineand LPG fuel levels, and warming the engine tonormal operating temperature.

1 Move the fuel select switch to gasoline and thenmove the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).


3 - 28 Z-60/34 Part No. 75861



B-14Test the Ground Control OverrideGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the red EmergencyStop button on the platform controls is in the on oroff position. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the platform red Emergency Stopbutton to the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

B-15Check the Directional ValveLinkage


Note: Perform this test only on models equippedwith a oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Remove the drive chassis cover from the non-steer end of the drive chassis.

2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:

• Lock nut is tight against yoke

• Yoke clevis pins are installed

• Cotter pins are installed through clevispins

• Linkage is properly attached todirectional valve

Part No. 75861 Z-60/34 3 - 29


B-17Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-10, Confirm the ProperBrake Configuration.

Note: Select a test area that is firm, level and freeof obstructions.

1 Mark a test line on the ground for reference.

2 Start the engine from the platform controls.

3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch symbol), then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

B-16Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of primary boom raising and loweringis essential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.

A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.

1 Start the engine from the ground controls andlower the boom to the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the primary boom through a fullcycle.

Result: The platform should remain level atall times to within ±5 degrees.


3 - 30 Z-60/34 Part No. 75861



B-19Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switchsymbol).

4 Raise the boom above horizontal.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

B-18Test the Drive Speed -Stowed Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch symbol), then lower the boom into thestowed position.


5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

Part No. 75861 Z-60/34 3 - 31


B-20Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.See E-1, Test or Replace the Hydraulic Oil.


7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

8 Lower the boom to the stowed position andextend the boom 1 foot / 30 cm.



11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


3 - 32 Z-60/34 Part No. 75861



3 Move the function enable/rpm select toggleswitch to either side and activate the jib boomtoggle switch in the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe toggle switch is held down.

4 Turn the key switch to platform controls.

Result: The flashing beacons should be onand flashing.

5 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe controller is held down.

6 Press down the foot switch. Move the jib boomtoggle switch to the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe controller is held down.

7 Press down the foot switch. Move the drivecontroller off center, hold for a moment andthen release it. Move the drive controller offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive controller is moved off center in eitherdirection.

B-21Test the Alarm Package(if equipped) and theDescent AlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Note: The descent alarm is standard, beginningwith serial number 7270.

The alarm package includes:

• Travel alarm

• Flashing beacons

Alarms and beacons are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable rear cover. Beacons are installed on bothturntable covers.

The alarms and beacons will operate with theengine running or not running.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: Both flashing beacons should be on andflashing.

2 Hold the function enable switch to either sideand activate the boom toggle switch in thedown position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe toggle switch is held down.

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



3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

All models:

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air should pass through the breathercap. Proceed to step 8.

Result: If air does not pass through the breathercap, clean or replace the cap.Proceed to step 7.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

B-22Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie specifications require that this procedure beperformed quarterly or every 250 hours, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

A free-breathing fuel and hydraulic tank cap isessential for good machine performance andservice life. A dirty or clogged cap may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the cap be inspectedmore often.


Gasoline/LPG models (before serialnumber 7924) and Diesel models (all):


1 Remove the cap from the fuel tank.

2 Check for proper venting.

Note: When checking for positive fuel tank capventing, air should pass freely through the cap.

Result: Air should pass through the fuel tankcap. Proceed to step 4.

Result: Air is not passing through the fuel tankcap. Clean or replace the cap.Proceed to step 3.

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


B-23Perform Engine Maintenance -Ford Models









Part No. 75861 Z-60/34 3 - 35


REV BChecklist C Procedures

C-1Perform Engine Maintenance -Deutz and Perkins Models


Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.

Deutz models

Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0297 9929).



Perkins models






3 - 36 Z-60/34 Part No. 75861


REVBCHECKLIST C PROCEDURES

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect test.

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting using a multi-purpose grease.

Grease type

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

Part No. 75861 Z-60/34 3 - 37


4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a two second delay before theoverload indicator lights flash and the alarmsounds.

CHECKLIST C PROCEDURESREV B

3 - 38 Z-60/34 Part No. 75861


REV BCHECKLIST C PROCEDURES

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Activate the auxiliary power toggle switch.

Note: The engine will turn off when the auxiliarypower is activated.

12 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

13 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be an two second delay beforethe overload indicator lights and alarm turn off.

14 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.

15 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).

17 Using a suitable lifting device, remove theremaining test weights from the platform.

Part No. 75861 Z-60/34 3 - 39


C-5Replace the In-line Fuel Strainer -Deutz Models

Engine specifications require that this procedurebe performed every 500 hours or 6 months,whichever comes first.

Replacing the diesel fuel strainer is essential forgood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage.



1 Put on protective clothing and eye wear.

2 Locate the inline strainer above the throttleactuator solenoid.

4 Place a suitable container under the filter.

5 Loosen the clamp holding the strainer to theengine mount. Loosen the clamps securing thefuel lines to the strainer. Remove and replace.

C-4Replace the Engine Air FilterElement - Deutz and PerkinsModels

Genie specifications requires that this procedurebe performed every 500 hours or 6 months,whichever comes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.

1 Open the evacuator valve located on the aircleaner cap by squeezing the sides togetherwith your fingers.

2 Disconnect the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

3 Remove the filter element.

4 Clean the inside of the canister and the gasketwith a damp cloth.

5 Install the new filter element.

6 Install the end cap on the canister and re-connect the latches.

Note: Be sure the evacuator valve is pointingdown.

CHECKLIST C PROCEDURESREV B

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


C-6Perform Engine Maintenance -Ford Models



Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR theFord DSG-423 EFI Operator Handbook(EDI part number 1060020).






CHECKLIST C PROCEDURES REV B

Part No. 75861 Z-60/34 3 - 41


D-1Check the Boom Wear Pads

Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever comes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecification, shim as necessary to obtainminimum clearance with zero binding.


3 Raise the end of the primary boom to acomfortable working height (chest high), thenextend the boom 1 foot / 30 cm.

The minimum shim clearance for primary boomwear pads is 0.070 inch / 1.8 mm and themaximum allowable shim clearance is0.188 inch / 4.8 mm.

Primary boom wearpad specifications Minimum

Top and side wear pads 3/8 inch(extension end of boom) 9.5 mm

Bottom wear pads 1/2 inch(extension end of boom) 12.7 mm

Top and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm

Side wear pads 3/8 inch(pivot end of boom) 9.5 mm

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Note: Always maintain squareness between theouter and inner boom tubes.

Checklist D ProceduresREV C

April 2012

3 - 42 Z-60/34 Part No. 75861

April 2012Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES REV C

1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

Bolt torque sequence

3 Be sure that each turntable mounting bolt istorqued in sequence to specifications. Refer toSection 2, Specifications.


5 Raise the boom and remove the safety chock.

6 Lower the boom to the stowed position.

7 Check to ensure that each lower bearingmounting bolt under the drive chassis istorqued in sequence to specifications. Refer toSection 2, Specifications.

D-2

Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the boom and place the safetychock on the lift cylinder rod.Carefully lower the boom onto the lift cylindersafety chock.

Crushing hazard. Keep handsaway from cylinders and allmoving parts when lowering theboom.

Note: The lift cylinder safety chock is availablethrough Genie (Genie part number 33484).

2 Turn the engine off.

Part No. 75861 Z-60/34 3 - 43

April 2012 Section 3 • Scheduled Maintenance Procedures

1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

Bolt torque sequence

disengaged position

engaged position

D-3

Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer Wheels: All Models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of sufficient capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

CHECKLIST D PROCEDURESREV C

3 - 44 Z-60/34 Part No. 75861



All Models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on thebottom of the drive pump.

Note: The free-wheel valve should always remainclosed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

a

d

c

b

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

Steer Wheels: 4WD Models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

Part No. 75861 Z-60/34 3 - 45


aa

bb

D-4Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

Before serial number 4551

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.


3 Drive the machine until one plug is at the topand the other is at 90 degrees.


5 Install the plugs. Use pipe thread sealant onunits with pipe plugs.



Turntable Rotate Drive Hub:

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Raise the secondary boom until the platformend of the lower secondary boom arm isapproximately 8 feet / 2.4 m off the ground.

REV C CHECKLIST D PROCEDURES

After serial number 4550

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point. See illustration A.


3 Drive the machine until one plug is just abovehorizontal. See illustration B.





a

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


REV CCHECKLIST D PROCEDURES

2 Secure the turntable from rotating with theturntable rotation lock pin.

3 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

turntable drive huba plug

unlocked locked

a

4 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

5 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.

6 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

7 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer toSection 2, Specifications.

8 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.

Part No. 75861 Z-60/34 3 - 47


D-6Replace the Hydraulic FilterElements

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first. Perform this proceduremore often if dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the filter element from the filterhousing.

3 Install the new filter element into the filterhousing.

4 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housing.

CHECKLIST D PROCEDURESREV C

D-5Perform Engine Maintenance -Deutz and Perkins Models


Deutz models




Perkins models






3 - 48 Z-60/34 Part No. 75861



D-7Inspect for Turntable BearingWear


Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Note: Perform this procedure with the machine ona firm, level surface and the boom in the stowedposition.

1 Grease the turntable bearing. See A-12, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-2, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

Medium and high pressure filter

Note: The medium pressure filter is for the chargepump and the high pressure filter (if equipped) isfor all machine functions except the drive circuitand oscillating axle circuit.

10 Open the engine side turntable cover andlocate the medium pressure filter mounted tothe engine tray.

11 Place a suitable container under each filter.

12 Remove the filter housings by using a wrenchon the nut provided on the bottom of thehousings.

13 Remove the filter elements from the housings.

14 Inspect the housing seals and replace them ifnecessary.

15 Install the new filter elements into the housingsand tighten them securely.

16 Clean up any oil that may have spilled duringthe installation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

Part No. 75861 Z-60/34 3 - 49


7 Note the reading on the dial indicator.

Result: The measurement is less than0.047 inch / 1.2 mm. The bearing is good.

Result: The measurement is more than0.047 inch / 1.2 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero"position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.

REV C CHECKLIST D PROCEDURES

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch /2.5 cm from the turntable rotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Fully extend the boom and lower to a horizontalposition.

a

b

c

d

3 - 50 Z-60/34 Part No. 75861


Component damage hazard. Theengine must not be started withthe hydraulic tank shut-off valvesin the closed position orcomponent damage will occur. Ifthe tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

4 Remove the drain plug and completely drain thetank into a suitable container. Refer toSection 2, Specifications.

5 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

Note: The hoses can be accessed through theaccess hole under the turntable.

6 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.

7 Remove the ground controls side turntablecover.

8 Support the hydraulic tank with an appropriatelifting device.

9 Remove the hydraulic tank mounting fasteners.

E-1Test or Replace the Hydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: Perform this procedure with the boom in thestowed position.

1 Ford models: Turn the valve on the LPG tankclockwise to the off position (if equipped). Thenslowly disconnect the hose from the LPG tank.

2 Ford models: Open the clamps from the LPGtank straps and remove the LPG tank from themachine (if equipped).

3 Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

Checklist E Procedures

open closed

REV B

Part No. 75861 Z-60/34 3 - 51


CHECKLIST E PROCEDURESREV B

10 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

11 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

12 Remove the suction strainers from the tank andclean them using a mild solvent.

13 Rinse out the inside of the tank using a mildsolvent.

14 Install the suction strainers using a threadsealant on the threads.

15 Install the drain plug using a thread sealant onthe threads.

16 Install the hydraulic return filter housing onto thehydraulic tank.

17 Install the hydraulic tank onto the machine.

18 Install the two suction hoses to the suctionstrainers.

19 Install the supply hose for the auxiliary powerunit and the return filter hose.

20 Models with hydraulic tank shut-off valves:Open the two hydraulic tank valves at thehydraulic tank.

21 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

22 Clean up any oil that may have spilled.

23 Prime the pump. Refer to Repair Procedure7-2, How to Prime the Pump.

Note: Always use pipe thread sealant wheninstalling the suction hose fittings and the drainplug.

3 - 52 Z-60/34 Part No. 75861


CHECKLIST E PROCEDURES REV B

E-2Grease the Steer AxleWheel Bearings, 2WD Models

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steering wheels. Center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm Placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue to step 11 to greasethe wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

14 Pack both bearings with clean, fresh grease.

Part No. 75861 Z-60/34 3 - 53


15 Place the large inner bearing into the rear of thehub.

16 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen removing the hub.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.


21 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

E-3Perform Engine Maintenance -Deutz 1011F and Perkins Models



Deutz 1011F models

Required maintenance procedures and additionalengine information is available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).


Perkins models







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



E-5Perform Engine Maintenance -Deutz and Perkins Models









E-4Perform Engine Maintenance -Ford Models








Part No. 75861 Z-60/34 3 - 55


Perkins models






E-6Perform Engine Maintenance -Deutz 2011 Models



Required maintenance procedures and additionalengine information are available in theDeutz 2011 Operation Manual(Deutz part number 0297 9929).






3 - 56 Z-60/34 Part No. 75861



E-8Perform Engine Maintenance -Deutz 2011 Models

Engine specifications require that this procedurebe performed every 12,000 hours.







E-7Perform Engine Maintenance -2011 Deutz Models








Part No. 75861 Z-60/34 3 - 57


E-9Perform Engine Maintenance -Ford Models

Engine specifications require that this procedurebe performed every 4 years.







REV B CHECKLIST E PROCEDURES

3 - 58 Z-60/34 Part No. 75861



Part No. 75861 Z-60/34 4 - 1

August 2007 Section 4 • Repair Procedures

Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. To re-assemble,perform the disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie Z-60/34Operator’s Manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

• Machine parked on a flat, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steering wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

4 - 2 Z-60/34 Part No. 75861

August 2007Section 4 • Repair Procedures

The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down

joystick controllerd primary boom up/down and

turntable rotate left/rightjoystick controller

1-1ALC-500 Circuit Board

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Note: When the ALC-500 circuit board is replaced,the joystick controllers will need to be calibrated.See 1-2, How to Calibrate a Joystick.

How to Remove the ALC-500Circuit Board1 Push in the red Emergency Stop button to the off

position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted to theinside of the platform control box.

Platform Controls

bcd

a

REV C

Part No. 75861 Z-60/34 4 - 3


1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.



2 Turn the key switch to platform control. Do notstart the engine.

3 Select a joystick to calibrate.

4 Move the joystick full stroke in either directionand hold for 5 seconds.

5 Return the joystick to the neutral position,pause for a moment, then move the joystick fullstroke in the opposite direction. Hold for 5seconds and return the joystick to the neutralposition.

Result: The alarm should sound indicatingsuccessful joystick calibration.

6 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

Note: No machine fuction should operate whileperforming the joystick calibration procedure.

PLATFORM CONTROLS

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit boardfrom the platform control box.

REV C

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


PLATFORM CONTROLS

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the red Emergency Stop button to theoff position at the platform controls.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time with thetimes in Section 2, Specifications to determinewhether the function time needs to increase ordecrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch to the left to increase the time ormomentarily move the drive enable toggleswitch to the right to decrease the time.

Note: Each time the drive enable toggle switch ismomentarily moved, the time will change 2%.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

13 Return the joystick to the neutral position andwait for approximately 10 seconds.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Note: Do not operate any machine function duringthe 10 second waiting time.

REV C

Part No. 75861 Z-60/34 4 - 5


PLATFORM CONTROLS

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position.The ramp rate settings of a joystick can bechanged to compensate for hydraulic pump wearto maintain peak performance from the machine.









Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.


9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Note: Each time the drive enable toggle switch ismomentarily moved, the time will change in 5%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.




Ramp rate (factory settings)

Primary boom up/downaccelerate 3 secondsdecelerate 1 second

Secondary boom up/downaccelerate 2 secondsdecelerate 1 second

Turntable rotateaccelerate 2 secondsdecelerate 0.5 second

Driveaccelerate 2 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1.5 secondsdecelerate, shift from low to high speed2WD and 4WD models 1.75 secondsdecelerate, shift from high to low speed2WD models 1 seconddecelerate, shift from high to low speed4WD models 3.5 seconds

REV C

4 - 6 Z-60/34 Part No. 75861


PLATFORM CONTROLS

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.









Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.


9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntablerotate).




REV C

Part No. 75861 Z-60/34 4 - 7


Platform Components

2-1Platform

How to Remove the Platform1 Remove the cable clamps from the top of the

platform mounting weldment.

2 Remove the clamp from the platform mountingweldment that holds the power to platformcable.

3 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side.

4 Remove the foot switch mounting fasteners.

5 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.

6 Tag and disconnect the foot switch wiring fromthe foot switch. Remove the cable from theback of the platform.


7 Remove the platform control box mountingfasteners. Lower the control box and set itaside.

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

Note: If your machine is equipped with an airline toplatform option, the airline must be disconnectedfrom the platform before removal.

8 Support and secure the platform to anappropriate lifting device.

9 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformcould become unstable and fallwhen it is removed from themachine if not properly supported.

REV B

4 - 8 Z-60/34 Part No. 75861


REV BPLATFORM COMPONENTS

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave CylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is noair in the closed loop.

Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Adjust the platform to a level position.

2 Raise the jib boom slightly and place blocksunder the platform for support.

a platform slave cylinder

3 Lower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

4 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder and connect the hosestogether using a connector. Cap the fittings onthe cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

5 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

6 Remove the pin retaining fastener from theslave cylinder barrel-end pivot pin. Do notremove the pin.

7 Support the slave cylinder with a lifting device.Protect the cylinder rod from damage.

8 Use a soft metal drift to remove the rod-endpivot pin.

Crushing hazard. The platform willfall, if not properly supported,when the slave cylinder rod-endpivot pin is removed.

Component damage hazard. Theslave cylinder rod may becomedamaged if not properly supportedwhen the pin is removed.

9 Use a soft metal drift and remove the barrel-endpin.

10 Carefully remove the cylinder from the platformleveling assembly.

a

Part No. 75861 Z-60/34 4 - 9


REV B

How to Bleed the Slave CylinderNote: Do not start the engine. Use auxiliary powerfor this procedure.

1 Connect a hydraulic hose between the two testports at the barrel end of the slave cylinder.

2 Raise the jib boom to a horizontal position.

3 Activate auxiliary power and move the platformlevel switch up and down through two platformleveling cycles to remove any air that might bein the system.

4 Remove the hydraulic hose from the test ports.Move the platform level switch up and downthrough a platform leveling cycle and inspectthe test ports for leaks.

4 Activate auxiliary power and hold the platform

PLATFORM COMPONENTS

2-3Platform Rotator

How to Bleed the PlatformRotatorNote: This procedure will require two people. Donot start the engine. Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Place a suitable container underneath theplatform rotator.

3 Open the top bleed screw on the rotator, but donot remove it.


4 - 10 Z-60/34 Part No. 75861


REV BPLATFORM COMPONENTS

2-4Platform Overload System

The platform overload system is designed toprevent the machine from continuing to operatewhen the load in the platform exceeds maximumrated capacity. Refer to the machine serial label formaximum capacity information.

If maximum platform capacity is exceeded, thealarm will sound at the platform controls and theplatform overload indicator lights will flash at boththe ground and platform controls. The ground andplatform controls will become disabled. Beforenormal machine operation can continue, theexcess load will need to be removed from theplatform.

If the excess load cannot be removed or if theoperator at the platform controls is unable tocorrect the overloaded condition, another person atthe ground controls can operate the machine usingauxiliary power. There will be limited control ofboom functions from the ground controls whenusing auxiliary power. Auxiliary power can be usedto correct the overloaded platform condition inorder to resume normal, safe operation of themachine.

Note: Even though platform and ground controlsare disabled when an overloaded condition isdetected, the engine will continue to run. If theengine is shut off in an overloaded condition, it willnot be possible to re-start the engine until theoverloaded condition is corrected.

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Open the bottom bleed screw on the rotator, butdo not remove it.


6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Clean up any hydraulic oil that may havespilled.

8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.

Part No. 75861 Z-60/34 4 - 11


REV B PLATFORM COMPONENTS

How to Calibrate the PlatformOverload System (if equipped)

Calibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.


1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.

4 - 12 Z-60/34 Part No. 75861


REV B

8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.



Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds. Proceed tostep 7.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.


Part No. 75861 Z-60/34 4 - 13


REV A

c d

h gm l jk iin

dba e f

a jib boomb extension boomc primary boomd lower tension linke upper secondary boomf upper pivotg turntable bulkheadh primary boom lift cylinderi lower leveling linkj lower secondary boomk secondary boom lift cylinderl mid-pivotm connecting linkn jib boom leveling link

Boom Components

4 - 14 Z-60/34 Part No. 75861


REV BJib Boom Components

3-1Jib Boom

How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.


1 Remove the platform. Refer to Section 2-1, Howto Remove the Platform.

2 Remove the platform mounting weldment,the platform leveling slave cylinder and theplatform rotator. Refer to Section 2-2, How toRemove the Platform Leveling Slave Cylinder.

3 Support the platform pivot weldment with anappropriate lifting device.

4 Remove the pin retaining fasteners from theplatform pivot weldment to jib boom pivot pin.Use a soft metal drift to remove the pin.Remove the platform pivot weldment from thejib boom.

Crushing hazard. The platformpivot weldment may becomeunbalanced and fall whenremoved from the machine if notproperly supported.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Do notremove the pin.

7 Tag, disconnect and plug the hydraulic hosesfrom the jib boom manifold. Cap the fittings onthe manifold.

8 Tag and disconnect the wiring from the jib boommanifold.


9 Pull the hydraulic hoses up through the jibboom lift cylinder mounting bracket.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

Part No. 75861 Z-60/34 4 - 15


REV A JIB BOOM COMPONENTS

10 Remove the cable cover from the side of thejib boom.

11 Attach a lifting strap from an overhead crane tothe jib boom.

12 Use a soft metal drift to remove the jib boom liftcylinder barrel-end pivot pin.

13 Remove the pin retaining fasteners from the jibboom pivot pin. Use a soft metal drift to removethe pin.

14 Remove the jib boom from the primary boom.

Crushing hazard. The jib boomcould become unbalanced and fallif not properly supported whenremoved from the machine.

15 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

16 Remove both of the jib boom leveling links fromthe primary boom.

17 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

18 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, and remove the jibboom lift cylinder from the primary boom.

Crushing hazard. The jib boomlift cylinder may becomeunbalanced and fall if not properlywhen it is removed from themachine if it is not properlyattached to the overhead crane.

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.


1 Raise the jib boom slightly and place blocksunder the platform mounting weldment forsupport. Lower the jib boom until the platform isresting on the blocks.


2 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

3 Remove the pin retaining fasteners from theplatform leveling slave cylinder barrel-end pivotpin. Do not remove the pin.

4 Remove both of the jib boom leveling links fromthe machine.

4 - 16 Z-60/34 Part No. 75861


REV A

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

7 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the barrel-endpivot pin.

9 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder from the machine.

Crushing hazard. The jib boomlift cylinder could becomeunbalanced and fall if not properlysupported when removed from themachine.

JIB BOOM COMPONENTS

Part No. 75861 Z-60/34 4 - 17


REV BPrimary Boom Components

4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.


2 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

3 Disconnect the cables from the platform controlbox.

Note: If your machine is equipped with an air line toplatform option, the air line must be disconnectedfrom the platform before removal.

4 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling slave cylinder. Capthe fittings on the slave cylinder.


5 Pull the slave cylinder hydraulic hoses out ofthe protective sheath.

6 Tag and disconnect the wiring from thejib boom/platform rotate manifold.

7 Remove the cable clamp from the platformrotator.

8 Remove the cable cover from the side of the jibboom.

9 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold.Cap the fittings on the jib boom/platform rotatemanifold.


4 - 18 Z-60/34 Part No. 75861


REV BPRIMARY BOOM COMPONENTS

10 Remove the hose clamps from the top of the jibboom.

11 Remove the hose and cable clamp from theprimary boom at the pivot end.

12 Remove the retaining fastener from the cabletrack tube at the platform end of the primaryextension boom.

13 Remove the fasteners from the side panel onthe lower cable track, then remove the panel.Pull all of the cables out of the channel.

14 Place blocks between the lower cable track andthe upper cable track tube and secure themtogether.

Crushing hazard. If the lowercable track and upper cable tracktube are not properly securedtogether, the cable track couldbecome unbalanced and fall whenremoved from the machine.

15 Attach a lifting strap from an overhead crane tothe cable track.

16 Remove the cable track guide fasteners fromthe platform end of the primary boom.

17 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

18 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

Component damage hazard.The primary boom cable trackcan be damaged if it is twisted.

Part No. 75861 Z-60/34 4 - 19


REV B

How to Repair the Primary BoomCable Track

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

Note: A 7 link repair section of cable track isavailable through the Genie Industries ServiceParts Department.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 To remove a single link, open the lower clipand then use a screwdriver to pry the link to theside.

3 Repeat steps 1 and 2 for each link.

a

b

4-2Primary Boom

How to Remove thePrimary Boom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



1 Remove the platform.Refer to 2-1, How to Remove the Platform.

2 Remove the platform rotator and platformmounting weldment.

3 Remove the jib boom.Refer to 3-1, How to Remove the Jib Boom.

4 Remove cable track.See 4-1, How to Remove the Cable Track.

5 Remove the hose and cable clamp from theupper mid-pivot.

PRIMARY BOOM COMPONENTS

4 - 20 Z-60/34 Part No. 75861



6 Remove the primary boom drive speed limitswitch from the upper pivot. Do not disconnectthe wiring.

7 Remove the primary extension boom drivespeed limit switch mounted on the inside of thepivot end of the primary boom. Do notdisconnect the wiring.

8 At the engine side of the upper pivot, removethe retaining fasteners from the master cylinderrod-end pivot pin. Use a slide hammer toremove the pin.

9 Pull the master cylinder back and secure it frommoving.

10 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


11 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the primary boom. Lift theprimary boom enough to access the primaryboom lift cylinder rod-end pivot pin.

12 Attach a similar lifting device to the primaryboom lift cylinder.

13 Place a 24 inch / 60 cm long block of woodacross the lower secondary boom leveling linksto support the primary boom lift cylinder.

14 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin.

15 Use a soft metal drift to remove the pin.

Crushing hazard. The primaryboom lift cylinder and the primaryboom will fall if they are notproperly supported when the pin isremoved.

16 Lower the rod end of the primary boom liftcylinder onto the support block placed acrossthe lower secondary boom leveling links.

17 Remove the pin retaining fasteners from theprimary boom pivot pin.

18 Use a soft metal drift to remove the primaryboom pivot pin. Remove the primary boom andplace it on a structure capable of supporting it.

Crushing hazard. The boom couldbecome unbalanced and fall if notproperly supported when the pin isremoved.

Part No. 75861 Z-60/34 4 - 21


REV B

How to Disassemble thePrimary BoomNote: Complete disassembly of the primary boomis only necessary if the primary tube must bereplaced. The extension cylinder can only beremoved after removing the extension boom fromthe primary boom. See 4-4, How to Remove thePrimary Boom Extension Cylinder.

1 Remove the primary boom.See How to Remove the Primary Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the cotter pin from the extensioncylinder barrel-end pivot pin.


5 Remove and label the wear pads from theplatform end of the primary boom.

Note: Pay careful attention to the location andamount of shims used with each wear pad.

6 Support and slide the extension boom andextension cylinder out of the platform end of theprimary boom.

Crushing hazard. The primaryboom extension tube couldbecome unbalanced and fall whenremoved from the primary boomtube if not properly supported.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

7 Remove the external snap rings from theextension cylinder rod-end pivot pins.

8 Use a soft metal drift to remove the pins.

9 Support and slide the extension cylinder outof the platform end of the extension boom.

10 Remove and label the wear pads from theextension boom.



4 - 22 Z-60/34 Part No. 75861



4-3Primary Boom Lift Cylinder

How to Remove thePrimary Boom Lift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools result in death or seriousinjury and significant componentdamage. Dealer service is stronglyrecommended.


1 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.

2 Attach a 5 ton / 5,000 kg overhead crane to theprimary boom for support. Do not lift the boom.

3 Place a 24 inch / 60 cm long block of woodacross the lower secondary boom leveling linksto support the primary boom lift cylinder.

4 Support the rod end of the primary boom liftcylinder with an appropriate lifting device.

5 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin.

6 Remove the pin using a soft metal drift.

7 Lower the rod end of the cylinder onto the blockthat was placed on the lower secondary boomleveling links.

8 Lower the primary boom onto the boom rest.

9 Raise the secondary boom enough to accessthe primary boom lift cylinder barrel-endpivot pin.

10 Tag, disconnect and plug the hydraulic hosesfrom the primary boom lift cylinder. Cap thefittings on the cylinder.


11 Place another 24 inch / 60 cm long block ofwood across the lower secondary boomleveling links to support the primary boom liftcylinder.

Part No. 75861 Z-60/34 4 - 23


REV B

12 Support the barrel end of the primary boom liftcylinder with an appropriate lifting device.

13 Remove the pin retaining fasteners from theprimary boom lift cylinder barrel-end pivot pin.

14 Use a soft metal drift to remove the pin .

Crushing hazard. The primaryboom lift cylinder may fall if notproperly supported when removedfrom the machine.

15 Lower the barrel end of the cylinder onto theblock that was placed on the lower secondaryboom leveling links.

16 Lower the secondary boom onto the boom rest.

17 Carefully pull the lift cylinder toward the platformend of the secondary boom.

18 Support and secure the cylinder to anappropriate lifting device.

19 Remove the cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder may fall if notproperly supported when removedfrom the machine.

4-4Primary Boom ExtensionCylinder

The primary boom extension cylinder extends andretracts the primary boom extension tube. It canonly be removed after removing the extensionboom assembly. The extension cylinder isequipped with counterbalance valves to preventmovement in the event of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is stronglyrecommended.



1 Remove the platform.Refer to 2-1, How to Remove the Platform.


4 - 24 Z-60/34 Part No. 75861



2 Remove the jib boom.Refer to 3-1, How to Remove the Jib Boom.

3 Extend the extension boom approximately5 feet / 1.5 m.

4 Tag, disconnect and plug the extension cylinderhydraulic hoses from the extension cylinder.Cap the fittings on the cylinder.




7 Support the extension boom and remove thewear pads from the primary boom.


8 Slide the extension boom out using a suitablepulling device until the extension boom wearpads are just visible.

Crushing hazard. The extensionboom could become unbalancedand fall when removed from theprimary boom if not properlysupported.

9 Support the extension boom at the primaryboom end with a suitable lifting device.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

10 Remove the extension boom from the primaryboom.

Crushing hazard. The extensionboom could become unbalancedand fall when removed from theprimary boom if not properlysupported.

11 Remove the external snap rings from theextension cylinder rod-end pivot pins.

12 Remove the pins using a soft metal drift.

13 Support and slide the extension cylinder out ofthe extension boom.

Crushing hazard. The extensioncylinder could become unbalancedand fall when removed from theextension boom if not properlysupported.

Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe primary boom.

Part No. 75861 Z-60/34 4 - 25


REV B

How to Replace the ExtensionCylinder Upper CounterbalanceValveNote: This procedure will require two people.

Note: Adjust the primary boom to a horizontalposition before performing this procedure.

1 Using auxiliary power, raise the secondaryboom until the counterweight end of the primaryboom is just above the counterweight.

2 Using a suitable lifting device, support thesecondary boom assembly. Do not lift it.

3 Extend the extension boom approximately1 foot / 0.3 m. Turn the machine off.


5 Use a soft metal drift and remove the pin.

6 Support the barrel end of the extension cylinderwith a pry bar or other suitable tool. Haveanother person use auxiliary power to retractthe extension cylinder until it clears the platformleveling master cylinder (approximately6 inches / 15 cm).

7 Allow the extension cylinder to rest on thebottom of the boom tube.

8 Loosen the lock nut on the valve and bleed thepressure from the counterbalance valve byturning the external adjustment screwclockwise.

9 Remove the counterbalance valve from thecylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulic valvevery slowly to allow the oilpressure to dissipategradually. Do not allow oil tosquirt or spray.

10 Install the new counterbalance valve and torquethe valve to 35-40 ft-lbs / 47-54 Nm.

11 Clean up any hydraulic oil that may havespilled.

12 Support the barrel end of the extension cylinderwith a pry bar or other suitable tool. Haveanother person use auxiliary power to extendthe extension cylinder until the pivot pin borealigns with the pin bore of the boom tube.

13 Use a soft metal drift and install the pin.

14 Install a new cotter pin into the extensioncylinder barrel-end pivot pin.


4 - 26 Z-60/34 Part No. 75861

February 2008Section 4 • Repair Procedures

REV A

4-5Platform Leveling MasterCylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed circuit hydraulicloop that keeps the platform level through theentire range of boom motion. The master cylinderis located inside the upper mid-pivot at the base ofthe primary boom.

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



1 Remove the pin retaining fasteners from themaster cylinder rod-end pivot pin.

2 use a soft metal drift to remove the pins.

3 Raise the secondary boom until the uppermid-pivot is above the turntable covers.

4 Attach the lifting strap from an overhead craneto the platform end of the lower secondaryboom arm for support. Do not apply any liftingpressure.

5 Tag, disconnect and plug the hydraulic hosesfrom the master cylinder. Cap the fittings on thecylinder.


6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

7 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pins.

9 Lower the master cylinder down and out of theupper pivot and remove it from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.

Secondary Boom Components

Part No. 75861 Z-60/34 4 - 27


REV B SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.


1 Remove the primary boom. Refer to 4-2,How to Remove the Primary Boom.

2 Remove all four pin retaining fasteners from thetwo lower tension link pivot pins. Do not removethe pins.

3 Attach a lifting strap from an overhead crane atthe center of the lower tension link on theengine side of the machine.

4 Remove the engine side lower tension link fromthe machine.

5 Repeat this step for the ground controls sidelower tension link.

Crushing hazard. The tension linkcould become unbalanced and fallif not properly supported whenremoved from the machine.

6 Remove the pin retaining fasteners from theconnecting link at the upper secondary boom.


8 Attach a securing strap from the upper pivot totension link pivot pin mounting tube on theturntable bulkhead, to prevent the upper pivotfrom moving.

4 - 28 Z-60/34 Part No. 75861


REV B

9 Attach a 5 ton / 5,000 kg overhead crane to thecenter of the upper secondary boom.

10 Remove the mounting fasteners from thesecondary boom lift cylinder rod-end pivot pinmounting bracket.

11 Remove the pin retaining fasteners from bothupper pivot to upper secondary boom pivotpins. Use a soft metal drift to remove the pins.

Crushing hazard. The upper mid-pivot may fall when the pins areremoved if the upper mid-pivot isnot properly secured.

12 Remove the pin retaining fasteners from thelower mid-pivot to upper secondary boom pivotpin.

13 Remove the lower mid-pivot to upper secondaryboom pivot pin using a soft metal drift, andremove the upper secondary boom from themachine.

Crushing hazard. The uppersecondary boom may becomeunbalanced and fall if not properlysupported when it is removed fromthe machine.

14 Remove both turntable covers.

15 Remove the two engine pivot plate retainingbolts. Then swing the engine out away from themachine and secure it from moving.


16 Disconnect the battery cables.


17 Remove the battery hold down fasteners, andremove the battery.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

18 Gasoline/LPG models: Remove the mountingfasteners from the ECM mounted to the engineside bulkhead cover.

19 Remove the mounting fasteners from both ofthe turntable bulkhead covers, and remove bothturntable bulkhead covers.

SECONDARY BOOM COMPONENTS

Part No. 75861 Z-60/34 4 - 29


REV B

20 Remove the hydraulic tank.Refer to Section Three, E-1 Test or Replacethe Hydraulic Oil.

21 Attach a lifting strap from an overhead crane tothe lug on the primary boom lift cylinder, then liftthe primary boom lift cylinder to a verticalposition.

22 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.

23 Remove the pin retaining fasteners from theprimary boom lift cylinder barrel-end pivot pin.Use a soft metal drift to remove the pins, andremove the primary boom lift cylinder from themachine.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported when removed from themachine.

24 Tag, disconnect and plug the secondary boomlift cylinder hydraulic hoses. Cap the fittings onthe cylinder.


25 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

26 Remove the pin retaining fasteners from thesecondary boom lift cylinder pivot pins.

Remove the pins using a slide hammer, andremove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall if not properlysupported when removed from themachine.

27 Attach a securing strap from the mid-pivot to thelower secondary boom, to prevent the mid-pivotfrom moving.

28 Number each electrical cable and its entrylocation at the platform control box.

29 Disconnect the cables from the platform controlbox.

30 Pull all of the electrical cables out of the cabletrack. Do not pull out the hydraulic hoses.

31 Tag, disconnect and plug the platform rotatorand slave cylinder hydraulic hoses at the union,located near the upper pivot.


32 Remove the hose and cable covers from both ofthe lower secondary boom leveling links.

33 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.



4 - 30 Z-60/34 Part No. 75861


REV BSECONDARY BOOM COMPONENTS

34 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

35 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

36 Remove the pin using a soft metal drift, andremove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.

37 Attach a lifting strap from an overhead crane tothe upper pivot, and remove the securing strapfrom the mid-pivot.

38 Pull all of the hoses and cables out of the uppermid-pivot.


39 Remove the secondary boom drive limit switchmounting fasteners from the lower secondaryboom. Do not disconnect the wiring.

40 Pull all of the hoses and cables out of themid-pivot and lay them off to the side.


41 Place blocks under each of the lower levelinglinks for support at the turntable bulkhead end.

42 Remove the pin retaining fasteners from both ofthe upper pivot to lower leveling link pivot pins.

43 Use a soft metal drift to remove the pins, andremove the upper pivot from the machine.

Crushing hazard. The upper pivotcould become unbalanced and fallif not properly supported whenremoved from the machine.

44 Attach a lifting strap from an overhead crane tothe center of the engine side lower leveling link.

45 Remove the pin retaining fasteners from theengine side lower leveling link pivot pin at themid-pivot.

46 Use a soft metal drift to remove the pins, andremove the engine side lower leveling link fromthe machine.

Crushing hazard. The engine sidelower leveling link could becomeunbalanced and fall if not properlysupported when removed from themachine.

47 Attach a lifting strap from an overhead crane tothe center of the ground controls side lowerleveling link.

Part No. 75861 Z-60/34 4 - 31


REV B SECONDARY BOOM COMPONENTS

48 Remove the pin retaining fasteners from theground controls side lower leveling link pivot pinat the mid-pivot.

49 Remove the pin using a soft metal drift, andremove the ground controls side lower levelinglink from the machine.

Crushing hazard. The groundcontrols side lower leveling linkcould become unbalanced and fallif not properly supported whenremoved from the machine.

50 Attach a lifting strap from an overhead crane tothe connecting link.

51 Remove the pin retaining fasteners from theconnecting link pivot pin at the lower secondaryboom.

52 Use a soft metal drift to remove the pins, andremove the connecting link from the machine.

Crushing hazard. The connectinglink could become unbalanced andfall if not properly supported whenremoved from the machine.

53 Attach a 5 ton / 5,000 kg overhead crane to themid-pivot.

54 Remove the pin retaining fasteners from thelower secondary boom pivot pin at themid-pivot.

55 Use a soft metal drift to remove the pins, andremove the mid-pivot from the machine.

Crushing hazard. The mid-pivotcould become unbalanced and fallif not properly supported whenremoved from the machine.

56 Remove the hose and cable covers from thelower secondary boom.

57 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the lower secondary boom.

58 Remove the pin retaining fasteners from thelower secondary boom pivot pin at the turntablebulkhead.

59 Use a soft metal drift to remove the pins, andremove the lower secondary boom from themachine.

Crushing hazard. The lowersecondary boom could becomeunbalanced and fall if not properlysupported when removed from themachine.

4 - 32 Z-60/34 Part No. 75861



5-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises andlowers the secondary boom. The secondaryboom lift cylinder is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

How to Remove theSecondary Boom Lift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage.


1 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

2 Tag, disconnect and plug the secondary boomlift cylinder hydraulic hoses. Cap the fittings onthe cylinder.


3 Remove the mounting fasteners fromthe secondary boom lift cylinder rod-end pivotpin mounting bracket.

4 Remove the retaining fasteners from thesecondary boom lift cylinder pivot pins.

5 Remove the pins using a slide hammer, andremove the cylinder from the machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall if not properlysupported when removed from themachine.

REV B

Part No. 75861 Z-60/34 4 - 33


6-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drive thepump.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.18 inch / 4.6 mm gap - Deutz Models

0.070 inch / 1.8 mm gap - Perkins Models0.0625 inch / 1.5 mm gap - Ford LRG-4250.080 inch / 2 mm gap - Ford DSG-423

How to Remove the Flex PlateDeutz models:

1 Remove the tailpipe bracket mounting fastenersfrom the engine bell housing.

2 Support the drive pump assembly with anappropriate lifting device.

3 Remove all of the engine bell housing fasteners.

4 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.


5 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.

6-1RPM Adjustment

Refer to Maintenance Procedure B-11, Check andAdjust the Engine RPM.

Engines

a b c d e

f

REV D

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


ENGINES

Ford LRG-425 EFI models:

1 Disconnect the electrical connector for theoxygen sensor at the tailpipe. Do not removethe oxygen sensor.

2 Remove the engine oil dipstick fasteners fromthe muffler bracket. Remove the dipstick fromthe engine.

3 Remove the muffler retaining fasteners from theexhaust pipe.

4 Support the muffler and bracket assembly withan overhead crane or other suitable liftingdevice.

5 Remove the muffler bracket mountingfasteners. Carefully remove the muffler andbracket assembly from the engine.

6 Support the engine with a suitable lifting device.Do not lift it.

7 Remove the engine plate to vibration isolatorfasteners.

8 Remove the engine mounting plate to bellhousing fasteners.

9 Raise the engine slightly to take the weight offof the engine mounting plate.

10 Slide the engine mounting plate towards thepump as far as it will go.






Ford DSG-423 EFI models:

1 Disconnect the electrical connectors from bothoxygen sensors at the tailpipe and exhaustmanifold. Do not remove the oxygen sensors.

2 Remove the exhaust pipe fasteners at themuffler.

3 Support the muffler and bracket assembly witha suitable lifting device.

4 Remove the muffler bracket mounting fastenersfrom the bell housing. Carefully remove themuffler and bracket assembly from the engine.

5 Support the engine with an overhead crane orother suitable lifting device. Do not lift it.

6 Remove the engine mounting plate to bellhousing fasteners.

7 Raise the engine slightly using the overheadcrane and place a block of wood under the oilpan for support.

8 Support the drive pump assembly with anoverhead crane or other suitable lifting device.Do not apply any lifting pressure.

REV D

Part No. 75861 Z-60/34 4 - 35


How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Apply Loctite® removable thread sealant to thescrews. Torque the flex plate in a star patternusing the following values.

Ford models:Before serial number 7924: Torque the flexplate mounting bolts in sequence to24 ft-lbs / 32 Nm.After serial number 7923: Torque the flexplate mounting bolts in sequence to20 ft-lbs / 27 Nm.

Deutz models:Torque the flex plate mounting bolts insequence to 28 ft-lbs / 38 Nm.

Perkins models:Before serial number 8050: Torque the flexplate mounting bolts in sequence to49 ft-lbs / 66 Nm.After serial number 8049: Torque the flexplate mounting bolts in sequence to14 ft-lbs / 19.1 Nm.

ENGINES

9 Remove all of the engine bell housing retainingfasteners.




Perkins models:

1 Remove the fuel filter/water separator mountingfasteners.

2 Remove the fuel filter/water separator and lay itto the side. Do not disconnect the hoses.






REV D

4 - 36 Z-60/34 Part No. 75861


ENGINES

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.18 inch / 4.6 mm gap - Deutz Models

0.070 inch / 1.8 mm gap - Perkins Models0.0625 inch / 1.5 mm gap - Ford LRG-4250.080 inch / 2 mm gap - Ford DSG-423

4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

a b c d e

f

5 Install the pump and bell housing assembly.

Ford LRG-425 models:Before serial number 4545: Torque the bellhousing mounting bolts in sequence to23 ft-lbs / 31 Nm.After serial number 4544: Torque the bellhousing mounting bolts labeled "C" in sequenceto 47 ft-lbs / 63 Nm. Torque the bell housingmounting bolts labeled "B" in sequence to61 ft-lbs / 83 Nm.

Ford DSG-423 models:Torque the bell housing mounting bolts labeled"A" and "B" in sequence to 28 ft-lbs / 38 Nmand the mounting bolts labeled "C" to 49 ft-lbs /66 Nm. Then torque the bell housing mountingbolts labeled "A" and "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "C"to 70 ft-lbs / 95 Nm.

Deutz models:Before serial number 4608: Torque the bellhousing mounting bolts in sequence to28 ft-lbs / 38 Nm.After serial number 4607: Torque the bellhousing mounting bolts in sequence to47 ft-lbs / 63 Nm.

Perkins models:Torque the bell housing mounting bolts labeled"B" in sequence to 28 ft-lbs / 38 Nm and themounting bolts labeled "A" to 49 ft-lbs / 66 Nm.Then torque the bell housing mounting boltslabeled "B" in sequence to 40 ft-lbs / 54 Nm andthe mounting bolts labeled "A" to 70 ft-lbs / 95Nm.

Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

REV D

Part No. 75861 Z-60/34 4 - 37


ENGINES

6-3Engine Fault Codes - FordModels

How to Retrieve Engine FaultCodesFord models:

The ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Refer to Section 5, How to Retrieve Engine FaultCodes. Use the Fault Code Chart within Section 5to aid in identifying the fault.

REV C

1 6

5 2

34

C C

CC

CC

CC

7 8

9

C

6 1

9

5

7

32

8

4

A A

B

B

B

B

B

B

BCC

BB

A

A

B

1

2

3

4

5

6

7

Ford LRG 425 models(after serial number 4544)

Ford DSG 423 models Perkins models

10

6 1

8

4

11

7 5

92

12

3

C

C C

C

C

C

C

CC

C

C

C

Deutz 2011 models(after serial number 4607)

Deutz 1011 models(before serial number 4608)

Ford LRG 425 models(before serial number 4545)

1

2

3

4

5

67

8

1

2

34

5

6

7

8

9

10

11 12

4 - 38 Z-60/34 Part No. 75861


REV BHydraulic Pumps

7-1Function Pump

How to Remove theFunction PumpNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer toSection 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.


2 Tag, disconnect and plug the function pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulictank valves and prime the pumpafter installing the pump.

open closed

Part No. 75861 Z-60/34 4 - 39


REV B HYDRAULIC PUMPS

7-2Drive PumpThe drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electro-proportional controller,located on the pump. The only adjustment that canbe made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorized SauerHydraulics center. Call Genie Industries ServiceDepartment to locate your local authorized servicecenter.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.

Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer toSection 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Disconnect the electrical connection at theelectro-proportional controller located on thedrive pump.

2 Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.


3 Tag and disconnect and plug the hydraulichoses from the drive and function pumps.Cap the fittings on the pumps.


open closed

4 - 40 Z-60/34 Part No. 75861


REV B

How to Prime the Pump1 Remove the engine tray retaining fasteners

located under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray.

2 Swing the engine tray out and away from themachine.

3 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to the test port on the drive pump.

4 Ford models: Close the valve on the LPG tankthen disconnect the hose from the tank. Movethe fuel select switch to the LPG position.

Perkins models: Disconnect the engine wiringharness from the fuel solenoid at the injectorpump.

Deutz models: Hold the manual fuel shutoffvalve clockwise to the closed position.

a manual fuel shutoff valve

a

4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if not properlysupported.

Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulictank valves and prime the pumpafter installing the pump.

HYDRAULIC PUMPS

Part No. 75861 Z-60/34 4 - 41


REV B

5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

6 Ford models: Connect the LPG hose to theLPG tank and open the valve on the tank. Movethe fuel select switch to the gasoline position.

Perkins models: Connect the engine wiringharness to the fuel solenoid.

Deutz models: Release the manual fuel shutoffvalve.

7 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS

4 - 42 Z-60/34 Part No. 75861

December 2011Section 4 • Repair Procedures

REV E

8-1Function Manifold Components - View 1(before serial number 4461)

The function manifold is located behind the ground control box.

Index SchematicNo. 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

5 Counterbalance valve,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

19 Flow regulator valve,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

Manifolds

Part No. 75861 Z-60/34 4 - 43

December 2011 Section 4 • Repair Procedures

REV E MANIFOLDS

1

20

13

1 74 5 11

14

1515

16

17

18

19

21

12

22

23

2 3 6 8 9 10

H

I

A B

C

D E

F

G

L

M

N

O

P

Q

R

K

J

S

T

U

V

W

4 - 44 Z-60/34 Part No. 75861


REV E

8-2Function Manifold Components - View 2(before serial number 4461)



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

12 Flow regulator valve,5 gpm / 18.9 L/min ............................. AI .......... Boom extend retract ..........................30-35 ft-lbs / 41-47 Nm

13 Flow regulator valve,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

MANIFOLDS

Part No. 75861 Z-60/34 4 - 45


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1

Z

AA

AB

AC

AD

AE

AF

AG

AH

AI

AJ

AK

AM

AL

X

Y

4 - 46 Z-60/34 Part No. 75861


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8-3Function Manifold Components(after serial number 4460)



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

9 Flow regulator valve,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

12 Counterbalance valve,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

14 Counterbalance valve,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

19 Flow regulator valve,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.

MANIFOLDS

Part No. 75861 Z-60/34 4 - 47


REV E MANIFOLDS

Top View

Top View

Front View

Front View

Shows valveshidden fromabove view

37

39

36

38

5 6

7

8

9

10

11

34

35

33

31 3032 29 28 27 26

25 24 2223

12

14

13

15

16

17

18

19

21

20

1 2 3 4

HA HC HDHB HE HF

HH

HI

HJ

HK

HL

HM

HN

HG

HP

HQ

HS

HR

HT

HU

HO

HVHWHXHY

IG

IH

II

HZIAICIDIEIF IB

IL

IM

IK

IJ

4 - 48 Z-60/34 Part No. 75861


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8-3Function Manifold Components, continued(after serial number 4460)



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

24 Flow regulator valve,5 gpm / 18.9 L/min ............................. HX ........ Boom extend retract ..........................30-35 ft-lbs / 41-47 Nm

25 Flow regulator valve,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

MANIFOLDS

Part No. 75861 Z-60/34 4 - 49


REV E MANIFOLDS

Top View

Top View

Front View

Front View

Shows valveshidden fromabove view

37

39

36

38

5 6

7

8

9

10

11

34

35

33

31 3032 29 28 27 26

25 24 2223

12

14

13

15

16

17

18

19

21

20

1 2 3 4

HA HC HDHB HE HF

HH

HI

HJ

HK

HL

HM

HN

HG

HP

HQ

HS

HR

HT

HU

HO

HVHWHXHY

IG

IH

II

HZIAICIDIEIF IB

IL

IM

IK

IJ

4 - 50 Z-60/34 Part No. 75861


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8-4Valve Adjustments -Function Manifold

How to Adjust the SystemRelief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the function manifold.(Item Z before serial number 4461)(Item IL after serial number 4460)


3 Hold the function enable switch to the high rpmposition and activate and hold the retract switchwith the boom fully retracted.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap.(item T before serial number 4461)(item HZ after serial number 4460)

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

7 Repeat steps 2 through 5 and re-check reliefvalve pressure.

8 Remove the pressure gauge.

How to Adjust the Primary BoomDown Relief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the function manifold.(Item Z before serial number 4461)(Item IL after serial number 4460)


3 Hold the function enable switch to the high rpmposition and activate and hold the primaryboom down switch with the primary boom fullylowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap.(item AE before serial number 4461)(item HP after serial number 4460)





MANIFOLDS

Part No. 75861 Z-60/34 4 - 51


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How to Adjust the SecondaryBoom Down Relief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port (item Z) on the functionmanifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap.(item AD before serial number 4461)(item HW after serial number 4460)





4 - 52 Z-60/34 Part No. 75861


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8-5Jib Boom / Platform Rotate Manifold Components(before serial number 4461)


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

MANIFOLDS

BA

BB

BC

BD3

4

1 2

Part No. 75861 Z-60/34 4 - 53


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8-6Jib Boom / Platform Rotate Manifold Components(from serial number 4461 to serial number 10245)


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


BH

BJ

BE

BF

PlatformRotate Manifold

BG

Jib Manifold

1

3

2

5

4

MANIFOLDS

4 - 54 Z-60/34 Part No. 75861


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8-7Jib Boom / Platform Rotate Manifold Components(from serial number 10246 to serial number 11003)


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



1

2BN

BM

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


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8-8Jib Boom / Platform Rotate Manifold Components(after serial number 11003)


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

MANIFOLDS

4

3

BP

1

BS

BR

2

5BU

BT

4 - 56 Z-60/34 Part No. 75861


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8-9Brake / Two Speed Manifold Components(before serial number 4461)

The brake / Two speed manifold is mounted on the engine side bulkhead..


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

DA

DB

DC

DD

1 2

3

4

Part No. 75861 Z-60/34 4 - 57


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8-10Brake / Two Speed Manifold Components(after serial number 4460)

The brake / Two speed manifold is mounted on the engine side bulkhead.


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

4

3

1 2

EA EB

EC

ED

MANIFOLDS

4 - 58 Z-60/34 Part No. 75861


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8-11Traction Manifold Components, 2WD(before serial number 4551)

The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.


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 inforward 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

Part No. 75861 Z-60/34 4 - 59


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6

6

71

4

1

2

3

3

5

5

FA

FB

FC

FD

FE

FF

FG

FH

FI

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


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8-12Traction Manifold Components, 2WD(after serial number 4550)



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 inforward 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 inforward and reverse ..........................50-55 ft-lbs / 67-73 Nm

6 Orifice Plug, 0.07 inch / 1.78 mm ...... VV ......... Equalizes flow across flowdivider/combiner valve C

MANIFOLDS

Part No. 75861 Z-60/34 4 - 61


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TT

WW

SS

XX

UU

VV

1

6

2

5

3

4

MANIFOLDS

4 - 62 Z-60/34 Part No. 75861


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8-13Traction Manifold Components, 4WD(before serial number 10154)



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 enddrive motors in forwardand 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

11 Flow regulator valve, 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

12 Flow regulator valve, 2 gpm / 7.6 L/min .............................. GL ......... Equalizes pressure on both sides of flow divider/combiner valve ........... 30-35 ft-lbs / 41-47 Nm

13 Flow regulator valve, 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 enddrive motors in forward

and reverse ................................. 90-100 ft-lbs / 120-133 Nm

Part No. 75861 Z-60/34 4 - 63


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STEER END

NON-STEER END

16

15

14

13

12

10

11

9 8 7

6

5

4321

GA GB GC

GD

GE

GFGGGH

GI

GJ

GK

GL

GM

GN

GO

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


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8-14Traction Manifold Components, 4WD(after serial number 10153)



1 Relief Valve, 280 psi / 19.3 bar ......... HA ........ Charge pressure circuit .................... 55-60 ft-lbs / 75-81 Nm

2 Flow divider/combiner valve ............. HB ........ Controls flow to non-steer end drive motors in forward and reverse ....... 80-90 ft-lbs / 108-122 Nm

3 Check valve, 5 psi / 0.34 bar ............. HC ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 75-81 Nm

4 Check valve, 5 psi / 0.34 bar ............. HD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 75-81 Nm

5 Check valve, 5 psi / 0.34 bar ............. HE ........ Controls flow to flow divider/combiner.......................................................................... valves 2 and 3 ................................ 70-75 ft-lbs / 95-102 Nm

6 Flow divider/combiner valve ............. HF ......... Non-steer end drive motor circuit . 80-90 ft-lbs / 108-122 Nm

7 Orifice, 0.040" .................................... HG ........ Equalizes pressure on both sides.......................................................................... of flow divider/combinder valve HF

8 Orifice, 0.040" .................................... HH ........ Equalizes pressure on both sides.......................................................................... of flow divider/combinder valve HB

9 Orifice, 0.040" .................................... HI .......... Equalizes pressure on both sides.......................................................................... of flow divider/combinder valve HM

10 Shuttle Valve ..................................... HJ ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 47-54 Nm

11 Check valve, 5 psi / 0.34 bar ............. HK ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 75-81 Nm

12 Check valve, 5 psi / 0.34 bar ............. HL ......... Charge pressure circuit that.......................................................................... directs hot oil out of low.......................................................................... pressure side of drive pump ........... 70-75 ft-lbs / 95-102 Nm

13 Flow divider/combiner valve ............. HM ........ Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

14 Check valve, 5 psi / 0.34 bar ............. HN ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 75-81 Nm

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


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HA

HB

HC

HD

HE

HF

HGHHHI

HJ

HK

HL

HM

HN

9 8 7

10

11

13

6

5

3

2

4

1

14

12

MANIFOLDS

4 - 66 Z-60/34 Part No. 75861


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8-15Valve Adjustments,Traction Manifolds

How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in the drivemanifold) is necessary to return hot oil from theclosed loop drive circuit to the hydraulic tank forcooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.

Note: The following procedure will require twopeople.

1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 50 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Start the engine from the platform controls andallow the engine to run at high idle. Note thepressure reading on the pressure gauge.

3 Turn the engine off and connect a0 to 600 psi / 0 to 50 bar pressure gauge to thediagnostic nipple located on the tractionmanifold.

Note: The traction manifold is located under thenon-steer end chassis cover.

4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.

5 Turn the engine off, and remove the hot oilshuttle relief valve cap.

2WD Traction Manifold(item FF before serial number 4551)(item TT after serial number 4550)

4WD Traction Manifold(item GB).

6 Adjust the internal hex socket clockwise toincrease the pressure or counterclockwise todecrease the pressure. Install the valve cap.

6 Repeat steps 4 and 5 until the pressure readingon the guage is 40 psi / 2.8 bar less than thepressure reading at the pump.

Part No. 75861 Z-60/34 4 - 67


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8-16Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end.

IndexNo. Description Function Torque

1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm

2 Spool valve ....................................................... Directional control

1

2

MANIFOLDS

4 - 68 Z-60/34 Part No. 75861


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8-17Directional Valve Linkage

How to Set Up the OscillateDirectional ValveNote: Adjustment of the oscillate directional valvelinkage is only necessary when the linkage orvalve has been replaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor iscompletely level.

Tip-over hazard. Failure toperform this procedure on a levelfloor could compromise thestability of the machine resulting inthe machine tipping over.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

Note: The tires on some machines are foam-filledand do not need air added to them.


5 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

6 Remove the heim joint retaining fastener fromthe axle.

7 To level the drive chassis, start the engine andpush up or pull down on the threaded rod untilthe machine is completely level.

8 Verify that the ground and drive chassis arecompletely level.

9 Adjust the heim joint until the hole lines up withthe retaining fastener hole in the axle.

10 Install the heim joint to the axle and tighten thejam nut.

11 Check to be sure the drive chassis iscompletely level.

12 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside of the drive chassis).

Note: If the distance is not equal and theadjustment to the linkage was completed with theground and drive chassis level, repeat steps 6through 11 OR consult Genie Industries ServiceDepartment.

Part No. 75861 Z-60/34 4 - 69


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a

8-18Valve Adjustments - OscillateRelief Valve

How to Adjust the Oscillate ReliefValve PressureNote: The following procedure will require twopeople.


2 Connect a 0 to 2000 psi / 0 to 150 bar pressuregauge to the diagnostic nipple located near theoscillate directional valve.

3 Disconnect the directional valve linkage, byremoving the heim joint and retaining fastenerfrom the axle.

4 Start the engine from the ground controls. Movethe engine idle toggle switch to the high idleposition.

5 With the engine running in high rpm, manuallyactivate the valve and observe the pressurereading on the pressure gauge. Refer toSection 2, Specifications.

7 Locate the relief valve (figure a) on thedirectional valve.

8 Loosen the jam nut.

9 Adjust the valve. Turn it clockwise to increasethe pressure or counterclockwise to decreasethe pressure. Tighten the jam nut.

Tip-over hazard. Do not adjust therelief valve higher than specified.

10 Manually activate the valve again to confirm thevalve pressure.

11 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.

12 Install the cover on the non-steer end of thedrive chassis.

a relief valve

MANIFOLDS

4 - 70 Z-60/34 Part No. 75861


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8-19Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.


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

321

LL

MM

NN

12312312312345123451234512345

123456123456123456123456123456

123456123456123456123456

CA

CB

CCCA

CB

CC

Part No. 75861 Z-60/34 4 - 71


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8-20Oil Diverter Manifold Components (welder option)The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.


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

MANIFOLDS

4 - 72 Z-60/34 Part No. 75861


REV EMANIFOLDS

8-21Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infiniteresistance indicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification canproduce erratic operation. When coil resistancedecreases below specification, amperageincreases. As resistance rises above specification,voltage increases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil tobe tested.

2 Test the coil resistance using a multimeter setto resistance (. Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.

Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Description Specification

Proportional solenoid valve, 12V DC 6.3 (schematic items AB, AC and AG)

Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 (schematic items H, I)

Solenoid valve, 3 Position, 4 Way, 10V DC 6.3 (schematic items A, B, C, F, J, AK)

Proportional solenoid valve, 12V DC 3.7 (schematic items HM, HO and HR)

Solenoid valve, 2 Position, 3 Way 10V DC 6.3 (schematic items IJ, IK)

Solenoid valve, 3 Position, 4 Way 10V DC 5 (schematic items HA, HC, HD, HE, HU)

Solenoid valve, 3 Position, 4 Way 10V DC 6.3 (schematic items HF)

Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 (schematic items BA, BB, DA, DB)

Solenoid valve, 2 Position, 3 Way, 10V DC 5 (schematic items BE, EA, EB)

Part No. 75861 Z-60/34 4 - 73


REV E

9VBATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

e

b

a

c

c

d

d

a multimeter or ammeterb diodec 9V DC batteryd 10 resistore coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

4 Connect the negative lead to the other terminalon the coil.

If testing a single-terminal coil,connect the negative lead to theinternal metallic ring at either endof the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

How to Test a Coil DiodeGenie incorporates spike-suppressing diodes in allof its directional valve coils except proportionalvalves and coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.


1 Test the coil for resistance. See How to Test aCoil.

2 Connect a 10 resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Resistor, 10Genie part number 27287

Note: The battery should read 9V DC or morewhen measured across the terminals.

3 Set a multimeter to read DC current.

The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.

MANIFOLDS

4 - 74 Z-60/34 Part No. 75861


REV ATurntable Rotation Components

9-1Turntable Rotation Assembly

How to Remove the TurntableRotation AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

Note: Perform this procedure with the machine ona firm and level surface.

1 Raise the secondary boom until the platformend of the lower secondary boom arm isapproximately 8 feet / 2.4 m off the ground.

unlocked locked

2 Secure the turntable from rotating with theturntable rotation lock.

Crushing hazard. The machinecould tip over when the turntablerotation assembly is removed ifthe turntable rotation lock is not inthe locked position.

3 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

4 Attach a lifting strap from an overhead crane orother suitable lifting device to the turntablerotator assembly.

5 Remove the turntable rotation assemblymounting fasteners.

6 Carefully remove the turntable rotationassembly from the machine.

Crushing hazard. The turntablerotation assembly could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

Part No. 75861 Z-60/34 4 - 75


REV AAxle Components

10-1Hub and Bearings, 2WD Models

How to Remove theHub and Bearings, 2WD Models1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steering wheels and place alifting jack of ample capacity under the steeraxle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the chassis for support.

Crushing hazard. The machinemay fall if not properly supported.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Remove the dust cap, cotter pin andcastle nut.

Note: Always use a new cotter pin when installinga castle nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub.

8 Remove the rear bearing.

How to Install the Hub andBearings, 2WD ModelsNote: When replacing a wheel bearing, both theinner and outer bearings including the pressed-inraces must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearing.


8 Loosen the castle nut one turn, and then torqueto 35 ft-lbs / 47 Nm.

9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.

Note: Always use a new cotter pin when installinga castle nut.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

4 - 76 Z-60/34 Part No. 75861


REV AAXLE COMPONENTS

10-2Oscillate Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are notadjustable.

How to Remove an OscillatingAxle CylinderNote: Perform this procedure on a firm, levelsurface with the boom in the stowed position.


1 Rotate the turntable until the boom is betweenthe steer tires.

2 Remove the fasteners from drive chassis coverat the steer end. Remove the cover.

3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


4 Remove the pin retaining fasteners from therod-end pivot pin.


6 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

7 Remove the pin retaining fasteners from thebarrel-end pivot pin.


Crushing hazard. The oscillatecylinder may become unbalancedand fall if not properly supportedwhen removed from the machine.

9 Remove the oscillate cylinder from the machine.

Crushing hazard. The oscillatecylinder could become unbalancedand fall if not properly supportedwhen it is removed from themachine.

Part No. 75861 Z-60/34 4 - 77


REV A

a

Generators

11-1Adjustments - HydraulicGenerator

How to Adjust the 3000/3500WGenerator Voltage (prior to serialnumber 10283)




1 Disconnect all electrical tools from the machine.


3 Press the generator select switch.

4 Connect an electrical tool, which does not drawmore than 15A, to the electrical outlet at theplatform controls and run the tool at full speed.

5 Connect the positive and negative leads from amultimeter of sufficient capacity to the electricaloutlet at the generator.

Note: The multimeter, when set to read ACvoltage, should be capable of reading up to 125VAC.

Result: The reading on the multimeter should be112 to 118V AC.

Result: If the reading on the multimeter is not112 to 118V AC, proceed to step 6.

6 Turn the key switch to the off position.

7 Use a wrench to loosen the jam nut and adjustthe generator flow regulator valve (item AM).

a flow regulator

8 Adjust the hex socket screw. Turn it clockwiseto increase the voltage or counterclockwise todecrease the voltage. Tighten the jam nut whileholding the adjustment screw in place.

Component damage hazard.Failure to adjust the generator asinstructed may result in damage tothe generator or other electricalequipment. Do not adjust thegenerator to other than specified.

9 Repeat steps 2 through 5 to confirm thegenerator AC voltage.

4 - 78 Z-60/34 Part No. 75861


How to Purge the Hydraulic Lineon the MTE Generator (fromserial number 10283)


Note: This procedure should be performed if thehydaulic line to the generator has been removed.

Note: Perform this procedure with the machine on afirm, level surface.

1 Locate the blue purge wire with the male spadeconnector from the MTE generator harness.

2 Connect a jumper wire of sufficient length fromthe positive battery terminal to the spadeconnector on the purge wire.

3 Start the engine and turn on the generator. Allowthe generator to run for three minutes.

4 Turn off the generator and turn off the engine.

5 Remove the jumper wire from the positivebattery terminal and disconnect from the purgewire.

6 Start the engine and turn on the generator. Usinga digital multimeter check the voltage at theoutlet.

Result: The generator produces a voltage ±10%of rated output. The generator is ready for use.

Result: The generator output voltage is outsidethe ±10% voltage range. Repeat the procedurebeginning with step 2.

Part No. 75861 Z-60/34 5 - 1

August 2007 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-60/34 Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Perform all troubleshooting on a firm levelsurface.

Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· Wheels chocked

· All external AC power disconnectedfrom the machine

5 - 2 Z-60/34 Part No. 75861

August 2007Section 5 • Fault Codes

REV AFAULT CODES

Fault Code Chart -Control System

How to Retrieve Control SystemFault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.

Note: Perform this procedure with the engine off,the key switch turned to platform controls and thered Emergency Stop button pulled out to the onposition at both the ground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

Note: When the red LED is flashing the code, theyellow LED will be on solid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

Note: When the yellow LED is flashing the code,the red LED will be on solid.

5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.

Part No. 75861 Z-60/34 5 - 3


REV A

Continued on next page

FAULT CODES

Error Source Error TypeID Name ID Name

Condition Solution11121516

Value at 5VValue too highValue too lowValue at 0V

Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.

Power upcontroller withproblem corrected.

17 Not calibratedJoystick speed anddirection frozen atzero and neutral.

Calibrate joystick.

21 Boom 1 Joystick(primary boom up/down)

18 Just calibrated Initiate 1-second beepof alarm.

Self-clearing.(transient)

22 Boom 1 directionalvalves

21 Fault



1215

Value too highValue too low



17 Not calibrated Calibrate valvethresholds.

23 Boom 1 flowcontrol valve

18 Just calibrated

Normal functionexcept threshold forone or both directionsis zero.


11121516





Calibrate joystick.

31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)

18 Just calibrated Initiate 1 second beepof alarm.


32 Boom 2 directionalvalves

21 Fault



5 - 4 Z-60/34 Part No. 75861


REV AFAULT CODES


Condition Solution

1215




17 Not calibratedCalibrate valvethresholds.

33 Boom 2 flowcontrol valve

18 Just calibrated



11121516





Calibrate joystick.

41 Turntable rotatejoystick



42 Turntable rotatedirectional valves

21 Fault



1215




17 Not calibrated Calibrate valvethresholds.

43 Turntable rotateflow control valve

18 Just calibrated



44 Drive enableoverride switches 21 Fault

Enable overridedirection is frozen atneutral.


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


REV A FAULT CODES


Condition Solution11121516





Calibrate joystick

51 Drive joystick



1215




17 Not calibrated Calibrate valvethresholds

53 Drive flow valve(EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drivemotor Valve 21 Fault

Motor speed frozen inthe low state. Alarmsounds indicatingfault.


11121516





Calibrate Joystick

61 Steer joystick



62 Steer directionalvalves

21 Fault



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


REV AFAULT CODES

Ford LRG-425 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Note: Perform this procedure with the key switch inthe off position.

1 Open the ground controls side cover and locatethe run/test toggle switch on the side of theground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch to thetest position.

Result: The check engine light should turn on.The check engine light should begin to blink.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 three times.After the fault codes, the check engine light willblink a code 123 three times again indicating theend of the stored codes.

Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree digit code, pause, blink the second digit,pause, and then blink the third digit. For example:the check engine light blinks 5 consecutive times,blinks 3 times and then 1 time. That would indicatecode 531.

Note: Once a fault code has been retrieved and therepair has been completed, the ECM memory mustbe reset to clear the fault code from the ECM. SeeHow to Clear Engine Fault Codes from the ECM.

How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.

Part No. 75861 Z-60/34 5 - 7


REV A FAULT CODES

Code Problem Cause Solution

111

112

113

114

121

122

124

133

134

135

141

142

143

144

Closed Loop MultiplierHigh (LPG)

HO2S Open/Inactive(Bank 1)

HO2S Open/Inactive(Bank 2)

Post-cat oxygensensor open

Closed Loop MultiplierHigh (Gasoline)

Closed Loop MultiplierLow (Gasoline)

Closed Loop MultiplierLow (LPG)

Gasoline cat monitor

LPG cat monitor

NG cat monitor

Adaptive Lean Fault -High Limit (Gasoline)

Adaptive Rich Fault -Low Limit (Gasoline)

Adaptive Learn High(LPG)

Adaptive Learn Low(LPG)

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor is faultyOR there are vacuum leaks or exhaust leaks.

Heated Oxygen Sensor wiring and/or connectionsopen or shorted OR sensor is faulty.

The post cat Heated Oxygen Sensor wiringand/or connections are open or shorted ORsensor is cold, non-responsive or inactive for60 seconds or longer.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum leaks or exhaustleaks OR fuel pressure is low OR the fuelinjectors need cleaning or replacing.

MAP, IAT or ECT sensors not in correct positionOR wiring and/or connections for sensors openor shorted OR sensor is faulty OR one or morefuel injectors are stuck open OR there iselectro-magnetic interference from a faultycrankshaft and/or camshaft position sensor.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR fuel quality is poor OR fuel systemcomponents may be faulty.

There are exhaust leaks OR the catalyst systemefficiency is below the acceptable level.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum or exhaust leaksOR one or more fuel injectors faulty or stuckclosed OR fuel quality is poor OR fuelpressure is too low.

MAP, IAT or ECT sensors not in correct positionOR wiring and/or connections for sensors openor shorted OR sensor is faulty OR one or morefuel injectors are stuck closed OR there iselectro-magnetic interference from a faultycrankshaft and/or camshaft position sensor.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum leaks or exhaustleaks OR fuel quality is poor OR fuel systemcomponents may be faulty.

Engine wire harness may have an intermittentshort to 5V DC or 12V DC OR fuel systemcomponents may be faulty.

Heated Oxygen Sensor wiring and/or connectionsopen or shorted OR sensor is faulty.

Repair wiring and/or connections OR replacesensor OR repair vacuum and exhaust leaks.

Repair wiring and/or connections ORreplace sensor.

Repair wiring and/or connections OR replacethe post cat oxygen sensor.

Repair wiring and/or connections OR replacesensor OR repair any vacuum and exhaust leaksOR test the fuel pressure OR clean or replace thefuel injectors.

Adjust or replace sensors OR clean or repairfuel injectors.

Repair wiring and/or connections OR replacesensor OR replace fuel OR test and repair thefuel system components.

Repair exhaust leaks OR there is an emissionscompliance issue. Contact Ford Power Productsfor assistance.

Repair heated oxygen sensor wiring and/orconnections OR replace sensor OR repairvacuum and exhaust leaks OR test the fuelpressure OR clean or replace the fuel injectors.

Repair wiring and/or connections OR replacesensor OR repair any vacuum and exhaustleaks OR replace fuel OR test and repair thefuel system components.

Repair short in engine wire harnessOR test and repair the fuel systemcomponents.

Adjust or replace sensors OR clean or repairfuel injectors.

5 - 8 Z-60/34 Part No. 75861


REV AFAULT CODES


242 Crank Sync NoiseCrankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

235 BP Low Pressure MAP sensor is faulty OR ECM is faulty.

234 BP High Pressure MAP sensor is faulty OR ECM is faulty.

232 MAP Low VoltageOpen or shorted wiring and/or connections to MAPsensor OR sensor is faulty.

231 MAP High PressureOpen or shorted wiring and/or connections to MAPsensor OR sensor is faulty.

215 Oil Pressure LowFaulty oil pressure sensor OR sensor wiringand/or connections open or shorted OR engineoil level too low.

Replace oil pressure sensor OR repair sensorwiring and/or connections OR fill engine oil levelto specification.

214IAT Higher ThanExpected (2)

Air intake temperature is greater than 210 F withthe engine greater than 1000 rpm OR air intakesystem has leaks OR IAT sensor is faulty.

°

213IAT Higher ThanExpected (1)

Air intake temperature is greater than 200 F withthe engine greater than 1000 rpm OR air intakesystem has leaks OR IAT sensor is faulty.

°

212 IAT Low VoltageIAT sensor wiring and/or connections are open orshorted OR sensor is faulty OR engine intake airtemperature is too hot.

Repair wiring and/or connections OR replacesensor OR direct cooler air into air intake.

224CHT Higher ThanExpected (2)

Coolant temperature at the cylinder head is 250 F.Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

°

223CHT Higher ThanExpected (1)

Coolant temperature at the cylinder head is 240 F.Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

°Repair engine cooling system problems ORrepair open or shorted wiring to sensor ORreplace sensor OR fill engine coolant level tospecification.

222 CHT/ECT Low Voltage

Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

221 CHT/ECT High VoltageEngine cooling system is malfunctioning ORsensor wires and/or connections open or shortedOR sensor is faulty.

Repair engine cooling system problems ORrepair open or shorted wiring to sensor ORreplace sensor.

211 IAT High VoltageIAT sensor wiring and/or connections are open orshorted OR sensor is faulty OR engine intake airtemperature is too cold.

Repair wiring and/or connections OR replacesensor OR direct warmer air into air intake.

162 System Voltage HighAlternator is overcharging the battery whenengine RPM is greater than 1500 rpm.

Repair or replace the alternator.

161 System Voltage LowBattery is faulty OR alternator is not charging ORbattery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repairbattery supply wiring to ECM.

Camshaft Sensor Loss244Crankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

243Never Crank SyncedAt Start

Crankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace sensor.

Check air intake system for damage and properrouting of air intake components OR replace theIAT sensor.

Repair wiring and/or connections to sensor ORreplace MAP sensor.

Replace MAP sensor OR replace the ECM.

Part No. 75861 Z-60/34 5 - 9


REV A FAULT CODES


253 Knock Sensor OpenKnock sensor wiring and/or connections open orshorted OR sensor is faulty.

Repair wiring and/or connections to knock sensorOR replace knock sensor.

Camshaft Sensor Noise

Camshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

245Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace sensor.

Excessive Knock SignalKnock sensor wiring and/or connections open orshorted OR there is excessive engine vibrationOR sensor is faulty.

254Check for excessive engine vibration OR repairwiring and/or connections to knock sensor ORreplace knock sensor.

Injector Driver #1 OpenOpen wiring and/or connections to fuel injector #1OR fuel injector #1 is faulty OR ECM is faulty.311

Repair wiring and/or connections to fuel injector #1OR replace fuel injector #1 OR replace the ECM.

Injector Driver #1 ShortedWiring and/or connections to fuel injector #1 isshorted OR fuel injector #1 is faulty ORECM is faulty.

312




314




316




322

Fuel Pump Loop Open orHigh Side Short to Ground

Open wiring and/or connections to fuel pump ORfuel pump power shorted to ground OR fuel pumpis faulty.

351Repair wiring and/or connections to fuel pump ORreplace fuel pump.Wiring and/or connections to fuel pump shorted to

power OR fuel pump is faulty.352Fuel Pump High SideShorted to Power

Fuel pressure too high OR LPG lockoff not openingcompletely OR the line between the MegaJectorand carburetor is kinked or restricted or is leakingOR engine cooling system is not operating properlyOR MegaJector is faulty.

353MegaJector DeliveryPressure Higher ThanExpected Check fuel pressure OR repair LPG lockoff OR

repair the line between the MegaJector andcarburetor OR repair engine cooling system ORreplace the MegaJector.

Fuel pressure too low OR LPG lockoff not openingcompletely OR the line between the MegaJectorand carburetor is kinked or restricted or is leakingOR engine cooling system is not operating properlyOR MegaJector is faulty.

354MegaJector DeliveryPressure Lower ThanExpected

The ECM doesn't get any response from theMegaJector, or an incorrect response for 500msperiod or longer.

355MegaJectorCommunication Lost

Check CAN circuits for continuity and shorts topower or ground and for continuity and repair asnecessary OR replace the MegaJector.

The MegaJector detects voltage greater than 18volts for 5 seconds anytime the engine is crankingor running.

361MegaJector VoltageSupply High

Repair charging system OR replace theMegaJector.

The MegaJector detects voltage less than 9.5 voltsfor 5 seconds anytime the engine is cranking orrunning.

362Repair VBAT power or ground circuit to ECM andMegaJector OR replace battery OR repaircharging system OR replace the MegaJector.

MegaJector VoltageSupply Low

5 - 10 Z-60/34 Part No. 75861


REV AFAULT CODES


MegaJector InternalActuator Fault Detection

The MegaJector detects an internal fault. Open orshort in power, ground or CAN circuits.363

Check Power, Ground and CAN circuits atMegaJector and all connections and repair asnecessary OR MegaJector has an internal fault.Contact Ford Power Products for assistance.

MegaJector InternalCircuitry Fault Detection

The MegaJector detects an internal circuitry failure.Open or short in power, ground or CAN circuits.364

MegaJector InternalCommunication FaultDetection

The MegaJector detects an internalcommunications failure. Open or short in power,ground or CAN circuits.

365

Open wiring and/or connections to ignitioncoil #1 OR ignition coil #1 is faulty. Repair wiring and/or connections to ignition

coil #1 OR replace ignition coil #1.

Coil Driver #1 Open411

Wiring and/or connections to ignition coil #1shorted OR ignition coil #1 is faulty

Coil Driver #1 Shorted412

Open wiring and/or connections to ignitioncoil #2 OR ignition coil #2 is faulty. Repair wiring and/or connections to ignition

coil #2 OR replace ignition coil #2.

Coil Driver #2 Open413

Wiring and/or connections to ignition coil #2shorted OR ignition coil #2 is faulty

Coil Driver #2 Shorted414

Not used.

FPP1 High Voltage511

If this fault appears on your machine, contactthe Genie Industries Service Department.

512 FPP1 Low Voltage

513 FPP1 Higher than IVS Limit

514

521 FPP2 High Voltage

FPP1 Lower than IVS Limit

522 FPP2 High Voltage

The #1 throttle position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR throttle positionsensor #1 is faulty.

531 TPS1 (Signal Voltage) High Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace throttle position sensor #1.

532 TPS1 (Signal Voltage) Low

The #2 throttle position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR throttle positionsensor #2 is faulty.

533 TPS2 (Signal Voltage) High Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace throttle position sensor #2.

534 TPS2 (Signal Voltage) Low

The throttle position sensor wiring and/orconnections for either TPS1 or TPS2 open orshorted OR there is a poor system groundconnection OR one or both throttle positionsensors are faulty.

TPS1 Higher than TPS2535

536 TPS1 Lower than TPS2

Be sure engine harness wiring and connectionsare in place and secure OR repair wiring and/orconnections to one or both TPS sensors ORreplace one or both TPS sensors.

Governor actuator is stuck closed OR wiringand/or connections open or shorted ORgovernor actuator is faulty.

Throttle Unable to Open537Repair wiring and/or connections to governoractuator OR replace the governor actuator.

Governor actuator is stuck open OR wiringand/or connections open or shorted ORgovernor actuator is faulty.

Throttle Unable to Close538

Engine harness wiring and/or connections openor shorted OR there is a poor system groundconnection OR ECM is faulty.

Governor Interlock Failure545Repair wiring and/or connections in engineharness OR replace the ECM.

Part No. 75861 Z-60/34 5 - 11


REV A FAULT CODES


ECM needs to be re-programmed OR throttle issticking open OR there are air leaks between thethrottle body and cylinder head.

Max Governor SpeedOverride

Re-program ECM OR repair binding throttleoperation OR repair any air leaks between thethrottle body and cylinder head.

551

552 FPP1 Low Voltage

553 FPP1 Higher than IVS Limit

Loose wire connections to ECM OR ECM is faulty.

COP Failure611

Locate and repair any engine harness wiringdamage or shorts to ECM to be sure they aresecure OR replace ECM.

612 Invalid Interrupt

613 A/D Loss

614

615 Flash Checksum Invalid

RTI 1 Loss

616 RAM Failure

Locate and repair any engine harness wiringdamage or shorts OR locate and troubleshoot orrepair faulty engine sensor OR replace ECM.

External 5V DC RefLower than Expected Engine harness wiring and/or connections open

or shorted to ground OR there is a faulty enginesensor OR ECM is faulty.

631

632External 5V DC RefHigher than Expected

Locate and repair any engine harness wiringdamage or shorts to ECM to be sure they aresecure OR replace ECM.

RTI2 Loss655

656 RTI3 Loss

Loose wire connections to ECM OR ECM is faulty.

5 - 12 Z-60/34 Part No. 75861


REV AFAULT CODES

Ford DSG-423 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Note: Perform this procedure with the key switch inthe off position.

1 Open the ground controls side cover and locatethe run/test toggle switch on the side of theground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch to thetest position.

Result: The check engine light should turn on.The check engine light should begin to blink.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 three times.After the fault codes, the check engine light willblink a code 123 three times again indicating theend of the stored codes.

Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree digit code, pause, blink the second digit,pause, and then blink the third digit. For example:the check engine light blinks 5 consecutive times,blinks 3 times and then 1 time. That would indicatecode 531.

Note: Once a fault code has been retrieved and therepair has been completed, the ECM memory mustbe reset to clear the fault code from the ECM. SeeHow to Clear Engine Fault Codes from the ECM.

How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.

Part No. 75861 Z-60/34 5 - 13


FAULT CODES

Code Description

212

213

214

215 Oil pressure low

222

223

224

CHT higher than expected 1

225

IAT (intake air temperature) low voltage

IAT (intake air temperature) higher than expected 1

IAT (intake air temperature) higher than expected 2

221 ECT/CHT (engine/cylinder head temp) high voltage

ECT/CHT (engine/cylinder head temp) low voltage

CHT higher than expected 2

ECT higher than expected 1

226

231

232

MAP (manifold absolute pressure) high pressure

234

ECT higher than expected 2

MAP (manifold absolute pressure) low pressure

BP (barometric pressure) high pressure

235

242

243

Crank sync noise

244

Never crank synced at start

Cam loss

BP (barometric pressure) low pressure

245

246

253

Crank loss

254

Knock 1-2 sensor open 1

Cam sync noise

Knock 1-2 excessive signal 1

Code Description

111 CL (closed loop) high LPG

112 EGO open / lazy pre-cat 1

113

114 EGO open / lazy post-cat 1

EGO open / lazy pre-cat 2/post-cat 1

115

121

122

124

EGO open / lazy post-cat 2

CL (closed loop) high gasoline bank 1

CL (closed loop) low gasoline bank 1

CL (closed loop) low LPG

133

134

141

142

Gasoline catalyst monitor 1

LPG catalyst monitor

AL (adaptive learning) high gasoline bank 1

AL (adaptive learning) low gasoline bank 1

143

144

161

162

Battery voltage high

AL (adaptive learning) high LPG

AL (adaptive learning) low LPG

Battery voltage low

163

164

165

166

AUX analog PD1 high

AUX analog PD1 low

AUX analog PU3 high

AUX analog PU3 low

167

168

171

172

AUX analog PUD1 high

AUX analog PUD1 low


AUX analog PUD2 low

173

174

181

182


AUX analog PUD3 low

AUX DIG1 high

AUX DIG1 low

183

184

185

186

211 IAT (intake air temperature) high voltage

AUX DIG2 high

AUX DIG2 low

AUX DIG3 high

AUX DIG3 low

5 - 14 Z-60/34 Part No. 75861


REV AFAULT CODES

Code Description

261 FP (fuel pressure) high voltage

262

271

272

FT (fuel temperature) gasoline high voltage

273

274

311

312

Injector loop open OR low-side short to ground 1

313

314

315

316


Injector coil shorted 2



321

322

351

352

FPump motor loop open OR high-side shorted to ground



Fpump motor high-side shorted to power

353

354

355

359

EPR delivery pressure higher than expected

EPR delivery pressure lower than expected

EPR comm lost

Fuel run-out longer than expected

361

362

363

364

EPR voltage supply high

EPR voltage supply low

EPR internal actuator fault detection

EPR internal circuitry fault detection

365

411

412

413

EPR internal comm fault detection

Primary loop open OR low-side short to ground 1

Primary coil shorted 1


414

415

416

421

422 Primary coil shorted 4





FP (fuel pressure) low voltage

FT (fuel temperature) gasoline low voltage

FT (fuel temperature) gaseous fuel high voltage

FT (fuel temperature) gaseous fuel low voltage


Code Description

531

532

533

534

536

537

538

Unable to reach higher TPS (throttle position sensor)

539

TPS1 (throttle position sensor) high voltage

535 TPS1 (throttle position sensor) higher than TPS2

TPS1 (throttle position sensor) lower than TPS2

Unable to reach lower TPS (throttle position sensor)

TPS 1-2 simultaneous voltages

541

542

543

544

AUX analog PU1 high

551

552

553

Fuel rev limit

611

Spark rev limit

COP failure

Max govern speed override

612

613

614

A/D loss

615

RTI 1 loss

Invalid interrupt

Flash checksum invalid

TPS1 (throttle position sensor) low voltage

TPS2 (throttle position sensor) high voltage

TPS2 (throttle position sensor) low voltage

AUX analog PU1 low

AUX analog PU2 high

AUX analog PU2 low

Part No. 75861 Z-60/34 5 - 15


REV A FAULT CODES

For further engine fault code troubleshooting anddiagnostic information, refer to the Ford DSG-423EFI Service Manual (EDI part number 1060040).Genie part number 119494.


Code Description

744

761

762

763

772

1629

1630

J1939 TSC1 message receipt lost

PWM5 short to power

771 Tach output ground short

Tach output short to power

J1939 ETC message receipt lost

MIL (malfunction indicator light) control ground short

MIL (malfunction indicator light) open

MIL (malfunction indicator light) control short to power

Code Description

616 RAM failure

631

632

633

5VE1 high voltage

634

635

641

642

Rx inactive

643

644

646

647

Invalid packet format

Shutdown request

CAN Tx failure

CAN Rx failure

648

655

656

711

RTI 3 loss

CAN address conflict failure

RTI 2 loss

Relay control ground short

712

713

714

715

Relay coil open

Relay coil short to power

Fpump relay control ground short

Fpump relay coil open

716

721

722

723

Fpump relay coil short to power

Start relay control ground short

Start relay coil open

Start relay coil short to power

731

732

733

734

PWM1-gauge1 open / ground short

PWM1-gauge1 short to power

735

736

741

742

743

5VE1 low voltage

5VE1-5VE2 simultaneous out-of-range

Rx noise

5VE2 high voltage

5VE2 low voltage





PWM4 open / ground short

PWM4 short to power

PWM5 open / ground short

5 - 16 Z-60/34 Part No. 75861



FAULT CODES

Part No. 75861 Z-60/34 6 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in yourOperator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Section 6 • SchematicsAugust 2007

6 - 2 Z-60/34 Part No. 75861

August 2007Section 6 • Schematics

Wire Connector LegendREV A

WH/RD

10

12

11

C34SA

C35RPM

C36SCC

C33STR

C32BRK

BK/WH

BL

BK/RD

BK

C4

8

9

7

6

COLOR

WH

CIRCUIT NO. PIN NO.

C27AUX

C30FWD

C31REV

C29MS

C28TTA

RD/WH

WH/BK

RD/BK

RD

3

4

5

2

1

BL/BK C37SCW

BL/WH C132PLI

6

C12SBF

GR/BK

12

10

C45GEN

NC

GR/WH

9

11

8

7

OR/RD

COLOR

C40LS1

C41RPM

C46HRN

OPTION

GR

OR/BK

OR

BL/RD

5

4

2

3

1

C2

C1 DT06-12SC

C2 DT06-12SD

NC

NC

NC

NC

BROWN

BLACK

GRAY

GREEN

C3

C1

C7BK

WH

BRN

COLOR

P23SWBAT

BATGND

N/C

P22BAT

C7: DTP06-4S

4

2

3

1

A

WH/RD-3

OR-1C40LS1

WH/BK-3

BK-3

GR/WH-1

BK/WH-3C8PBR

C7PBE

C45GEN

C6TRF

C5TRR

GR/BK-3

GR-3

OR/BK-3

OR-3

RD/BK-3

RD-3

RD/WH-3

COLOR

C15PLD

C14PLU

C129DA

C1PBU

C3PBF

C18JD

C17JU

WH/RD-1

RD-1

BL-1

BL/BK-1C37STC

C36STCC

C27AUX

BL/WH-3

RD-3

RD/BK

RD

RD

BKR43HRN

P23FB

C32BRK

P23BATSR

C28TTA

C134PWR

C13DRE

FUNCTION HARNESS

C1

C2

11NC

NC 12

6C6TRFWH/RD

GR/BK

GR/WH

OR/RD

COLOR

OR/BK

BL/RD

BL/WH

BL/BK

BK

BK/RD

BL

BK/WH

GR

OR

C18JD

NC

C19JSV

NC

NC

P134PWR

C14PLU

C15PLD

C17JU

C13DRE

8

10

9

7

6

3

4

5

2

1

C4 DT06-12SB

11

12

10

C11SBD

C7PBE

C10SBU

DLITE

C8PBR

9

8

7

RD

RD/BK

WH/BK

RD/WH

WH

COLOR

C3 DT06-12SA

C2PBD

C3PBF

C5TRR

C4TRL

C1PBU

5

4

2

3

1

C4

C3

C7

VSW

C30FWD

C31REV

C32BRK

C29MS

C34SA22

24

23

20

21

19

C26TSR

C25PS16

18

17

15

14

C39LP-FEH67410

C108ESL-C24TSPS

C127TST

13

12

11

-

C128RPM-FEH306

8

9

7

C107AF

C41RPM

C27AUX

R33STR

C45GEN

5

6

4

2

3

1

CIRCUIT NO.PIN

NO.

BK/RD

BL/WH

BL/RD

WH/RD

WH/BK

BK/RD

BK/WH

RD/WH

WH/RD

WH/BK

WH

WH/BK

WH

WH/RD

RD/WH

BK/WH

WH/RD

RD/WH

WH

WH/BK

WH/BK

BK/RD

WH/RD

WH

GR

-

DEUTZ

ENGINE

OR/BKOR/BK

BK

WH

BK(14)

WH

C5-GROUND BOX

OR/BK

BK(14)

GR/WH

ENGINE

PERKINS

C2PBD RD/BK

CIRCUIT NO.

C9 FS DT04-4P

RD

WH

BK

COLOR

3P25BAT

N/C 4

P24BAT

CIRCUIT NO. PIN NO.

P22BAT 1

2

12VDC TO PLATFORM

C9

CA

BL

E#

3

-

WH

CA

BL

E#

1

C133PLA

JDALARMRD

WHC21IGN-FEH16A

WH/RD

WH/BK

C21IGN-FEH16A WH

GR/WH GR/WH

WH WH

BL/WH-3LS PWR

C32TA WH/RD-1

FORD

ENGINECIRCUIT NO. PIN NO.

CIRCUIT NO. PIN NO.

CIRCUIT NO. PIN NO.

CIRCUIT NO. PIN NO.

Part No. 75861 Z-60/34 6 - 3

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Battery separator

MA

INA

UX

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B

August 2007 Section 6 • Schematics

REV AElectrical Symbols Legend

6 - 4 Z-60/34 Part No. 75861


Hydraulic Symbols Legend

Pumpfixed displacement

Motorbi-directional

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

REV A

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

Power

Relay

Starter

Relay

Fuel

Pump

Relay

F5-15A

F4-15AF3-10A

F2-5AF1-10A

Empty

August 2007 Section 6 • Schematics

Ford DSG-423 Engine Relay LayoutREV A

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



December 2011Section 6 • Schematics

6 - 7

Diesel Electrical Schematic - View 1(before serial number 4496)

6 - 8

A B C D E F G H I J K L M N

1

2

3

4

5

6

7

8


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

REV ADiesel Electrical Schematic - View 1(before serial number 4496)

NO

BR

N

TB24

6 BATTERY

STA

RT

ER

MO

TO

R

H2M1REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMPBK

OR

/BK

-41

12 VDC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-23

RD

-27

RD

/BK

-28

BK

-43

CR5

PR1

RD

WH

NOW

AT

ER

TE

MP

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

SW

ITC

H

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NC

OTS

NO

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

WH

-24

WH

-24

OPS S2

TB25 TB26

CR1 CR1CR2NO

TB21

7

1098

CR2

ENG. FAULT

KEY BYPASSIGN./FUEL ON

KEY PWR.

GR

/WH

-45

FB S7

M2G6

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

AU

XIL

IAR

Y

AU

XIL

IAR

Y

PU

MP

PU

MP

EN

GIN

E

ON

GL

OW

PL

UG

STA

RT

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND

TACHOMETERSTART INPUT

IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NOOTS

CR17NO CR17

CB320AMP.

TB134P1

RD

TB22

PLATGRD

KS1

RD

H6 L45

6

U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

LS18

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

D40

D39

FU

NC

TIO

NE

NA

.

WH

/BK

WH

/RD

L2U1

CR5NO

PR1

PR2 PR2NO

WH

-21

L4

L48

GL

OW

PL

UG

OP

TIO

N

PR3NOPR3

C3

4S

AB

K/W

H

TB34

BK

ON

TS56

C1

-8

TS6

STARTERAUXHM

STA

RT

EN

GIN

E

GL

OW

PL

UG

BK

/RD

BK

/RD

-R4

-E.H

.

NO CR4

NO CR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN

2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

IN THE STOWED POSITION AND KEYSWITCH "OFF".

1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

SEE NOTE 2

SEE NOTE 2

S1Y29

N M L K J I H G F E D C B A

1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 9

REV A Diesel Electrical Schematic - View 2(before serial number 4496)

WH WH

JIB

VA

LVE

S

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

P-6

BRN

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

TS15 L1

GR

OU

ND

BR

N

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

BRN

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H3

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

H4

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

P-7

TS57

C4

P-5

C4

P-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2

C1

3D

RE

BL

/RD

TS63

C4

P-1

C3

P-2

C3

P-3

TS9

WH

TS7

Y18

BK

OR/BK

JOYSTICK CONTROL CARD

TS13

CE

OPTION

LIFT/DRIVE

4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16 15

19

20

17

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5

TB4

TB32TB37TB36 TB31 TB30

C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-11

C1

P-1

0

C1

P-4

C1

P-5

BR

N-2

C2

P-3

RD

BK

BR

N

OR

J26

J1

12 1

11 2

9

7

PRI UP/DN & TT ROTATEYO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

EA

BL

/WH

DR

EB

BL

/BK

BR

N

OR

BL

WH

DR

EL

ED

BL

/RD

J11

3

14 54 6

J1

7

16 8

15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

AB

DC

C6

-19

RD

/BK

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

P-1

0

C3

P-11

C3

P-1

2

12

13

14

R4

7.5.5 R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

25

BF

BL

/WH

C11

5B

DB

L/B

K

C1

05

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

NOHC

BK

WH

TB43TB44

NOHC NCHO NCHO

CA

BL

E#

6

CA

BL

E#

6

CA

BL

E#

7

CA

BL

E#

7

CA

BL

E#

8

C4

6P

WR

WH

CA

BL

E#

5

C4

6P

WR

WH

TB46TB46

1 2 3 4 3 4 3 4

WH

BK

WH

BK

WH

BK

LS

3D

RIV

EE

NA

BL

E

RIG

HT

LE

FT

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

RIG

HT

LE

FT

PL

AT

RO

TA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

POSITION EXCEPT AS NOTED.

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

NOTE:

YE

L

BR

N

OR

J1

10 39

7

SECONDARY BOOM UP/DWN

OU

T

GN

D

1 2 43 5 6

PW

R

JC1

7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7

Joystick Adaptor Harness

1

2

34

5

6

Deutsch


6 - 106 - 9

Diesel Electrical Schematic - View 2(before serial number 4496)


6 - 11

Diesel Electrical Schematic - View 1(from serial number 4496 to serial number 5325)

6 - 12


1

2

3

4

5

6

7

8


6 - 12 Z-60/34 Part No. 75861

REV ADiesel Electrical Schematic - View 1(from serial number 4496 to serial number 5325)

BR

N

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

H6 L45

6

U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

LS18

RD

L4

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D2

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2S

WIT

CH

PE

RK

INS

SW

ITC

HP

ER

KIN

S

WA

TE

RT

EM

PE

RA

TU

RE

OIL

PR

ES

SU

RE

NO

S1

BR

RD

WH

BK

STARTERAUX HM

STA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

BK

/RD

BK

/RD

-C5

-8

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN


ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

2

2

1.

2 C.E. OPTION ONLY

WHEN C.E. OPTION IS NOTINSTALLED A JUMPER HARNESS

CONNECTS PIN 4 TO PIN 5AND PIN 6 TO PIN 7

LS18 - PLATFORM OVERLOADSWITCH

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

BK

/RD

C4B-9 C4B-11

TB132 IS WAGO TERMINAL BLOCK 36133 IS WAGO TERMINAL BLOCK 16

TB 134 IS WAGO TERMINAL BLOCK 42TB

STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

1 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION

1

DE

UT

ZO

NLY

D33

NC

S2NO

S1

DE

UT

ZS

HU

TD

OW

N

DE

UT

ZO

NLY


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 13

REV A

WH WH

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

OP

TI O

N

PL

AT

FO

RM

RO

TA

TE

CC

W/

JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

CW

/JIB

UP

BRN

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

EL

EA

SE

VA

L VE

TR

AV

EL

AL

AR

MO

PT

ION

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

CW

TU

RN

TA

BL

ER

OTA

TE

CC

W

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

P-7

TS57

C4

P-5

C4

P-6

C3

PB

FR

D/ W

H

C2

PB

DR

D/ B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2TS63

C4

P-1

C3

P-2

C3

P-3

TS9

WH

TS7

BK

OR/BK


TS13

4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/ BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-11

C1

P-1

0

C1

P-4

C1

P-5 B

RN

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 1

11 2

9

7


UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

EA

BL

/WH

DR

EB

BL

/ BK

BR

N

OR

BL

WH

DR

EL

ED

BL

/RD

J1

13

14 54 6

J1

7

16 8

15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

A

B

D

C

RD

/BK

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10TB11

TB12

TS60

C3

P-1

0

C3

P-11

C3

P-1

2

12

13

14

R4

7.5

5R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

NOHC

BK

WH

NOHC NCHO NCHO

C2

2P

WR

RD

WH

BK

WH

BK

WH

BK

LS

3D

RIV

EE

NA

BL

E

Y17 Y16 Y20Y19 Y25Y26 Y53Y52 Y12Y14 Y22Y21 Y23Y29Y13 Y3Y4 Y2

Y51

SJ1 WH SJ2 WH

XO

UT

JC1

PW

R

653 421

GN

D

OU

T

SECONDARY BOOM UP/DN

7

39

10

OR

BR

N

YE

L

J1

C2

9M

SR

D/W

H

TS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1P

-3C

29

MS

RD

/WH

C5

-24

Y27

BL/WH

C2

9M

SR

D/W

H

LOHI

CR30NO

NCCR27

CE

OPTION

LIFT/DRIVE

GR

OU

ND

BR

N



NOTE:

JIB

VA

LVE

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

P-6

BRN

JIB

VA

LVE

CR13

TS8

GR

/BK

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18 LE

FT

RIG

HT

PL

AT

RO

TA

TE

UP

DO

WN

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

PL

AT

FO

RM

LE

VE

LU

P

UP

DO

WN

JIB

BO

OM

LE

FT

RIG

HT

PL

AT

RO

TA

TE

DO

WN

PR

IMA

RY

BO

OM

UP

RI G

HT

TT

RO

TA

TE

LE

FT

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

ES0434


7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch


6 - 146 - 13



6 - 15 6 - 16



1

2

3

4

5

6

7

8


6 - 16 Z-60/34 Part No. 75861

REV A

BR

N

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

H6 L45

6

U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

LS18

RD

L4

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D2

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

TB9

BR

RD

WH

BK

BL/WH WH

STARTERAUX HM

STA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

-C5

-8

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

2

2

1.

2 C.E. OPTION ONLY

WHEN C.E. OPTION IS NOTINSTALLED A JUMPER HARNESS

CONNECTS PIN 4 TO PIN 5AND PIN 6 TO PIN 7

LS18 - PLATFORM OVERLOADSWITCH

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

FUSE 10A

BK

/RD

C4B-9 C4B-11



STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

5

3 70A FUSE ADDED AT SERIAL NUMBER 7479

D644

4 DIODE D64 ADDED AT SERIAL NUMBER 9066

FUSE 70A

3

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

5 SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 9340



1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 17

REV A Diesel Electrical Schematic - View 2(from serial number 5326 to serial number 9798)

WH WH

JIB

VA

LVE

JIB TIMEDELAYCIRCUIT

JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9

PRI UP/DN & TT ROTATE

YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE

Y17 Y16 Y20Y19 Y25Y26 Y53Y52 Y12Y14 Y22Y21 Y23Y29Y13 Y3Y4 Y2Y51

SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14C

5-2

1

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE


ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H

6 JIB TIME DELAY CIRCUIT ADDED AT SERIAL NUMBER 9066

6

7 DESCENT ALARM ADDED TO BASE BOM AT SERIAL NUMBER 7270

8 JOYSTICKS CHANGED FROM 7 PIN TO 6 PIN AT SERIAL NUMBER 7227

8 8 8

7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch


6 - 186 - 17



6 - 196 - 20

Diesel Electrical Schematic, ANSI / CSA - View 1(from serial number 9799 to serial number 10387)


1

2

3

4

5

6

7

8


6 - 20 Z-60/34 Part No. 75861

REV ADiesel Electrical Schematic, ANSI / CSA - View 1(from serial number 9799 to serial number 10387)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6

C32CONN.PLUG12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

TB9

BR

RD

WH

BK

BL/WH WH

STARTERAUX HMS

TA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

1.

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

FUSE 10A

BK

/RD

C4B-9 C4B-11



STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

2

2 DIODE ADDED BETWEEN AND AT SERIAL NUMBER 10283.TB35 TB45


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 21

REV A Diesel Electrical Schematic, ANSI / CSA - View 2(from serial number 9799 to serial number 10387)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 226 - 21

Diesel Electrical Schematic, ANSI / CSA - View 2(from serial number 9799 to serial number 10387)


6 - 23

Diesel Electrical Schematic ANSI / CSA - View 1(from serial number 10388)

6 - 24


1

2

3

4

5

6

7

8


6 - 24 Z-60/34 Part No. 75861

REV ADiesel Electrical Schematic ANSI / CSA - View 1(from serial number 10388)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO

CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6

C32CONN.PLUG12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

BR

RD

WH

BK

BL/WH WH

STARTERAUX HMS

TA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

1.

L30L30

BR

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

FUSE 10A

C4B-9 C4B-11



STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

2


NOCR45

CR45

WO

RK

LIG

HT

SR

EL

AY

(OP

TIO

N)


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 25

REV A Diesel Electrical Schematic ANSI / CSA - View 2(from serial number 10388)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61C

4T

RL

WH

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14C

5-2

1

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 26

Diesel Electrical Schematic ANSI/CSA - View 2(from serial number 10388)

6 - 25


6 - 27

Diesel Electrical Schematic, CE - View 1(from serial number 9799 to serial number 10387)

6 - 28


1

2

3

4

5

6

7

8


6 - 28 Z-60/34 Part No. 75861

REV ADiesel Electrical Schematic, CE - View 1(from serial number 9799 to serial number 10387)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098

CR2ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6LOADSENSEMODULE

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

TB9

BR

RD

WH

BK

BL/WH WH

STARTERAUX HMS

TA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

1.

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

FUSE 10A

BK

/RD

C4B-9 C4B-11



STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

H6L45

D88

D89

PBOXGND

R204.7 K

LS18

LS18A

PBOXGND

2 SEC

U35

NO30A

BK

2 SEC

U34

NO10A

C2

1IG

NW

H

C4

-10

C132PLI2 BK

2



1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 29

REV A Diesel Electrical Schematic, CE - View 2(from serial number 9799 to serial number 10387)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61C

4T

RL

WH

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14C

5-2

1

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 30

Diesel Electrical Schematic, CE - View 2(from serial number 9799 to serial number 10387)

6 - 29


6 - 31

Diesel Electrical Schematic, CE - View 1(from serial number 10388)

6 - 32


1

2

3

4

5

6

7

8


6 - 32 Z-60/34 Part No. 75861

REV ADiesel Electrical Schematic, CE - View 1(from serial number 10388)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098

CR2ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)

BK-(FS)FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6 LOADSENSEMODULE

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

D40

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

BR

RD

WH

BK

BL/WH WH

STARTERAUX HMS

TA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

1.

L30L30

BR

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

FUSE 10A

C4B-9 C4B-11



STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

2


NOCR45

CR45

WO

RK

LIG

HT

SR

EL

AY

(OP

TIO

N)

H1L48

D39

H6L45

PBOXGND

R204.7 K

LS18

LS18A

PBOXGND

2 SEC

U35

NO30A

2 SEC

U34

NO10A

C2

1IG

NW

H

C4

-10

C132PLI BK

D88

D89


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 33

REV A Diesel Electrical Schematic, CE - View 2(from serial number 10388)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61C

4T

RL

WH

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14C

5-2

1

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 34

Diesel Electrical Schematic, CE - View 2(from serial number 10388)

6 - 33


6 - 35

Diesel Ground Control Box Wiring Diagram(before serial number 5716)

6 - 36


1

2

3

4

5

6

7

8


6 - 36 Z-60/34 Part No. 75861

REV ADiesel Ground Control Box Wiring Diagram(before serial number 5716)

RED-20B

RED-24A

BK/WH-34A

RED-20A

7.5

BLK/RED-35A

BLK-33A

ORG-14A

GRN/WHT-19A

ORG/BLK-15A

GRN/BLK-18A

GRN-17A

WHT/BLK-5AWHT-4A

RED/WHT-3A

RED/BLK-2ARED-1A

BLU/BLK-11ABLK/WHT-8ABLK-7A

BLU-10ARED-27A

WHT-23ABLK-22A

WHT-21ABRN-GROUND

BL/WH -12A

WH/RD S.P.

RD 42A

GR/BK H6

RD C23-7

RED-20C

CR17 #30

C23-6

WH-E.H.

BL/WH-ISM#10

SWITCH

AUXILIARYPUMP

KS1

RD

B

B1

1

24

3

KEY

DESCRIPTION

PLATFORM LEVEL SWITCH

EMERGENCY STOP BUTTON

CIRCUIT BREAKER, CONTROL, 15A

CIRCUIT BREAKER, ENGINE, 15A

SECONDARY BOOM UP/DOWN SWITCH

PLATFORM ROTATE SWITCH

ENGINE START SWITCH

TS63

TS62

CB1

CB2

HM HOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58

FUNCTION ENABLESWITCH

JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH

RESISTOR, 7.5 OHM, TURN. ROT. FUNC.R4

TS64 RUN/TEST SWITCH

TO FUNCTION MANIFOLD(CABLE#4)

GLOW PLUG POWER RELAY

AUXILARY POWER RELAY

PR2

PR1

TO PLATFORM C-BOX, TERMINAL 1-19



RPM RELAY

SECONDARY BOOM STOWED LIMIT SWITCH

BOOM RETRACTED LIMIT SWITCH

DRIVE ENABLE LIMIT SWITCH

PRIMARY BOOM STOWED LIMIT SWITCH

CE PLATFORM LEVEL RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

CR18

(CABLE#1)

(CABLE#2)

(CABLE#3)

LS4 (CABLE#8)

LS3 (CABLE#7)

LS2 (CABLE#5)

LS1 (CABLE#6)

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5

HYDRAULIC COOLER FAN RELAY

HIGH IDLE (RPM) CUTOUT RELAY

CB3 CIRCUIT BREAKER, HYD COOLER, 20A

RESISTOR, 5 OHM, TURN. AUX. FUNC.

G1

G2

G3 WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE

H6 PLATFORM OVERLOAD ALARM

L45 PLATFORM OVERLOAD LED

V33 PLATFORM OVERLOAD MODULE

BOOM EXTEND/RETRACT SWITCH

TURNTABLE ROTATE SWITCH

PRIMARY BOOM UP/DOWN SWITCH

L2

HM

NC

NC

P2

TS51

TS60

TS62TS58

TS55

TS59

TS57

R4

TS52

CB1ENGINE, 15A

FUNCTIONENABLE

PLATFORM

PLATFORM

TURNTABLE

BOOM

ENGINESTARTER

BOOM EXTEND/

UP/DOWN

RETRACT

ROTATEJIB BOOM

ROTATE

LEVEL

GLOW PLUG ENGINE START

CONTROL, 15AOIL COOLER/OPTION, 20A

CB2

5

R5

TS56

D2

D3

+

-

CB3

TS63

L45

CRRELAY

LEGEND

3086 85

87

87A

VOLT METER

G1

OIL TEMP

G3

OIL PRESSURE

G2

WHT-21A

BRN-GROUND

WT/BK-25A WT/RD-26A

TS61BOOM

CHECK ENGINE

LED

UP/DOWN

HARNESSENGINE

#4CABLE

#3CABLE

CABLE#2

#1CABLE

CABLE#5

CABLE#6

#7CABLE

CABLE#8

BR

C23-4

BK-ISM#3

RD S.P.

GROUND STUD

RD-4

BL/WH C23-3 BL/WH-1

RD H6 RD KS1

GN/BK C23-8 GN/BK-H6 C133PLT

C132PLI

OR/RD-3

BR-2

BR

BK-H.C. + BR-H.C.

PLATFORM LOADU33

C23

GN/BK-16B - C23-8

BK-C7-1 - C23-5BK-22C - C23-4

RD-TS14 - C23-7

RD-H6+ - C23-1

BR-GND - C23-12

RD-TS11 - C23-6

BL/WH-38D - C23-3

GN/BK-16A

GN/BK-L45

RD-C23-1

RD-42B

H6

D C B A

23

1

12

3

2

456

98

7

10

11

13

14

17

1516

18

19

20

22

21

34

26

24

25

2827

31

30

29

33

32

40

37

3536

39

38

41

4243

444546

RD-S.P.(CB2)

BK-CR5#30

RD-CR2#30

WH-ISM#7

ISM#4

OR/BK-ISM#2

BK/RD CR3#30

BK -8

BK -7

WH -5

WH-2

RD-3

WH/RD-3

WH/BK-3

RD/WH-3

BK/WH-3

BL/WH-3

OR/BK-3

GR/BK-3

GR/WH-3

RD/BK-3

WH-3

BK/RD-3

BK-3

BL/BK-3

BL-3

GR-3

OR-3

WH-E.H.

BK/WH-1

RD/BK-1RD-1

WH/RD-1

WH-1WH/BK-1

BK-1

BK/RD-1BL-1BL/BK-1

BL/RD-1

GR/WH-1

OR/BK-1

RD/WH-1

OR/RD-3

RD-S.P.(CB3)

OR-1

OR/RD-1

WH S.P.+ WH-46A

RD S.P.

WH/BK S.P.

RD/WH S.P.RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

BK/WH S.P.

RD CB1

BK S.P.

BK/RD S.P.

BL/RD S.P.

WH-23A

BL/WH S.P.

WH/RD S.P.

WH/RD S.P.WH/BK S.P.

KEYSWITCH POWER

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE RTURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UPSECONDARY BOOM DOWN

TURNTABLE ROTATE F.C.

PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWNPLATFORM LEVEL UP

12V BATTERY SUPPLYIGNITION POWER

JIB VALVE

ENGINE POWER

TILT ALARMAUXILIARY POWER

GLOW PLUG/CHECK ENGINE

E.D.C.-

E.D.C.+

BRAKESTART

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

MOTOR SPEED

LIMIT SWITCH POWER

C40LS1 STOWED

LIMIT SWITCH J1LIMIT SWITCH J2

C134PWR

OIL TEMP SENDER

OIL PRESSURE SENDER

BK/WH-E.H.

RD-4

RD-4

BK -5

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4RD/BK-4

WH/BK-4WH/RD-4

BL/BK-4

GR-4

RD -E.H.WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

WH -E.H.

RD/BK-4

WH/BK-E.H.

RD -4

WH/RD - E.H.

GR/WH-4

OR/BK-E.H.

BL/BK-4BL-4

RD/WH-E.H.

WH/RD-E.H.

WH/BK-E.H.

BL/WH-4

WH -8

WH -7

WH -6

BK -6

BL/WHT-L2-

WH-23B

WARNING SENDER

BR-GROUND

BATTERY

GROUND

KEY POWER

KEY BYPASS

ENGINE FAULTIGN./FUEL ON

WH-CR2#86

RD-CR1#30

9

10

7

8

6

5

TACHOMETER

START INPUT

AUXILIARY ON

START RELAYBK-CR1#86

RD-27BBK-33DOR/BK-41B

3

4

2

1

IGN./STARTMODULE

BK-4

BK-22B

WH-ISM#9

WH-21D

BK-ISM#1

BK-E.H.

RD-ISM#6

GR-1

RD-24B

WH-H.C.

RD-H.C.

CR3 CR4

BR-GROUND

BK/RD-35B

BK/RD-E.H.

CR1 CR2 CR5CR17

HYDRAULICCOOLER

RD-S.P. (CB3)

GND

3 MFD+

RD-CB3 SP

DRIVE LIGHT OPTION RELAY

CR23

BK/RD-9B

RD-C4B-12

BRN GND

RD TO LIGHT

L2CHECK ENGINE

LED

D33

WH/RD-C5-14

WH/BK-C5-16

BL/WH-ISM#10

PERKINS SHUTDOWN ONLY

RPM FILTER ADDED AT SERIAL NUMBER 44611

PERKINS SHUTDOWN COMMONIZED WITHDEUTZ AT SERIAL NUMBER 5326

1

DIODE WITH 44B-GR/BK+2B-BL/BK

2


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 37

REV A Diesel Ground Control Box Wiring Diagram(from serial number 5716 to serial number 9798)

WH S.P.23 KEYSWITCH POWERWH-C7B-2

RD-4 RD-C3B-1 1 RD S.P.

D C B A

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK/WH-C3B-8

BL/WH-C3B-12

OR/BK-C4B-3

GR/BK-C4B-6GR/WH-C4B-7

BL/RD-4

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4

RD/BK-4

WH/BK-4

WH/RD-4

BL/BK-4

RD/BK-C3B-2

WH-C3B-4

BK/RD-C3B-9

BK-C3B-7

BL/BK-C3B-11

BL-C3B-10

GR-4

RD-4 (12V)WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

GR-C4B-5

OR-C4B-2

BK - C23-4

12

32

4

5

6

9

8

7

10

11

WH/BK S.P.

RD/WH S.P.

RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

13

14

17

15

16

RD-S.P.(CB2)

BK-CR5#30

18

19

20

22

21

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE R

TURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UP

SECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

12V BATTERY SUPPLY

IGNITION POWER

JIB VALVE

BK/WH-C1B-8

BK-ISM#3

WH -C5-21

RD/BK -4

WH/BK -C5-20

RD -4

WH/RD -C5-23

RD/BK-C1B-2

RD-C1B-1

WH/RD-C1B-6

WH-C1B-4

WH/BK-C1B-5

BK-C1B-7

GR/WH-4

OR/BK-C5-2

BK/RD-C1B-9

BL-C1B-10

BL/BK-C1B-11

BL/RD-C2B-1

GR/WH-C2B-7

OR/BK-C2B-3

BK/WH S.P.34

RD-CR1#30

RD-ISM#426

24

25

28

27

31

30

29

33

32

RD S.P.

RD CB1

BK S.P.

40

37

35

36

39

38

OR/BK-ISM#241

42

43

44

45

BK/RD S.P.

BL/RD S.P.

46

ENGINE POWER

TILT ALARM

AUXILIARY POWER

GLOW PLUG

E.D.C.-

E.D.C.+

BRAKESTART

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

BL/BK-4BL-4

MOTOR SPEEDRD/WH -C5-24 RD/WH-C1B-3

BL/WH-4

BL/RD-C4B-1

RD-S.P.(CB3)

SPARE

C40LS1 STOWED

JDALARMHORN

OR-C2B-2OR-4

BL/WH S.P.

WH/RD S.P.

C134PWROR/RD-C2B-4RD-4

BL/WH - C23-3 BL/WH-C1B-12

RD H6 RD KS1

GR/BK C23-8 GR/BK-H6- C133PLT

C132PLI

OR/RD-C4B-4

WH-C5-3+C5-11 WH - H.C.

BL/WH-4

GR/BK-C2B-6 GR/BK-11B GR/BK S.P.

11B-RD/BK-4

GR-C2B-5 GR-CR5#86

44B-GR/BK+2B-BL/BK

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

4C

3B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

HC

(BK

)(G

Y)

(BR

)(G

R)

7.5

5

WH/RD -4PRIMARY BOOM UP/DOWN SWITCH



GROUND STUD

KEY SWITCH

B

B1

1

24

3

RD

KS1

BK/WH-C5-22BK/RD-CR3#30

WH-ISM#7

GND

3MF

BR- 3MF CAP

DEUTZONLY

HARNESS:TO BASE

WIRING

WH-23C

BK-C32-5

BR-GND STUD

ALL BR WIRESBR

GROUND STUD

DESCRIPTION







ENGINE START SWITCH

TS63

TS62

CB1

CB2

HM HOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58

FUNCTION ENABLE SWITCH

JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH


TO PLATFORM C-BOX, TERMINAL 13-19C4B



PR2

PR1




RPM RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

C1B

C2B

C3B

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5



CB3 CIRCUIT BREAKER, OPTION, 20A


G1

G2

G3 WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE



U33 PLATFORM OVERLOAD MODULE

C5 ENGINE HARNESS

IGN./START

MODULEAUX. ON4

WH-CR2#86

WH-23BRD-CR2#30BR-GND.

KEY BYPASS

ENG. FAULTIGN./FUEL ON

10

8

9

67

5BATTERYKEY PWR.

GROUND

RD-27BBK-33BOR/BK-41BBK-CR1#86


START RELAY

321

WH-L2-

C7B TO PLATFORM C-BOX, TERMINAL 22-23RD-C23-7

BL/WH-12A

BL/BK-11A

BL-10A

GR/BK-18A

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

RD- 24A

RD- 20A

BK/RD-35A

WH/BK-5AWH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

GR/BK-44A

BK-33A

BK/WH-8A

BK-7A

RD/WH-3ARD/BK-2A

RD-1A

BR (GROUND)

WH-21A

RD-27A

BK-22A

BL/WH-ISM-10

TS63

TS58

TS55

D13

TS52

D14 CB2CB1

R4

CB3

HML2

RD-42AWH-23A

RD-CB2

NC

NC

P1

TS59

TS62

TS61

TS51

WH-C5-13

G1 G2 G3

WH/BK-25A

WH-21A

BR (GROUND)

WH/RD-26A

RD-C23-6

TS56 GLOW PLUG SWITCH

R5

TS57

L2 CHECK ENGINE LED

CR23 DRIVE LIGHT OPTION RELAY

OIL TEMP. SENDER

OIL PRESSURE SENDER

WH/RD S.P.

WH/BK S.P.WH/RD-C5-14

WH/BK-C5-16

DRIVE LIGHT OPTIONBK/RD-CR23#86

RD-24D


CR23

BR

RD-C4B-12

BK/RD-9B

RD-C4B-10

HYDRAULIC OIL COOLER OPTION RELAY

FUSE 10A

BR-C4B-11

GNDBR-C4B-9

TS60

H6

U33

PLATFORM LOADC32

BL/WH-38D - C32-3

RD-C32-1RD-42BRD-TS51 - C32-6

BR - GND - C32-12

RD-H6+ - C32-1

RD-TS55 - C32-7 GR/BK-L45GR/BK-16A

BK-22C - C32-4BK-C7B-1 - C32-5

GR/BK-16B - C32-8

L45

GR/BK-H6-

86 8587A

87

30

30

87A85 86

87

RD-CB3 SP

CR17

RD-H.C.

BK-H.C.

BRN GND

BK-ISM#1

BK-C5-5

WH-21B

RD-ISM#6WH-ISM#9RD-24B

CR1 CR2

BK/RD-C5-8

BK/RD-35B

CR3 CR4

BK-22B

GR-43B

CR5

8587 86

87A

30

30

8587A

8786

30

8587A

8786

30

8587A

8786

30

8587A

8786

BK-4

TS56BK/WH-34A

D64

WL

DIODE D64 ADDED AT SERIAL NUMBER 90661

1

WH-CR2#86

WH-ISM#9

RD-TB134(A)C

BR-GND

BK-C3B-10

REPLACE WIRE WITH THIS WIRING DIAGRAM

LOAD SENSE OPTION - TIMER RELAY


6 - 38

Diesel Ground Control Box Wiring Diagram(from serial number 5716 to serial number 9798)

6 - 37


6 - 396 - 40

Diesel Ground Control Box Wiring Diagram(from serial number 9799)


1

2

3

4

5

6

7

8


6 - 40 Z-60/34 Part No. 75861

REV ADiesel Ground Control Box Wiring Diagram(from serial number 9799)



D C B A

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK/WH-C3B-8

BL/WH-C3B-12

OR/BK-C4B-3

GR/BK-C4B-6GR/WH-C4B-7

BL/RD-4

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4

RD/BK-4

WH/BK-4

WH/RD-4

BL/BK-4

RD/BK-C3B-2

WH-C3B-4

BK-C3B-7

BL/BK-C3B-11

BL-C3B-10

GR-4

RD-4 (12V)WH-CR2#87 +D.L.CR23#86

GR/BK-4

OR-4

OR/BK-4

GR-C4B-5

OR-C4B-2

BK - C23-4

12

32

4

5

6

8

7

10

11

WH/BK S.P.

RD/WH S.P.

RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

13

14

17

15

16

RD-S.P.(CB2)

BK-CR5#30

18

19

20

22

21

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE R

TURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UP

SECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

12V BATTERY SUPPLY

IGNITION POWER

JIB VALVE

BK/WH-C1B-8

BK-ISM#3

WH -C5-21

RD/BK -4

WH/BK -C5-20

RD -4

WH/RD -C5-23

RD/BK-C1B-2

RD-C1B-1

WH/RD-C1B-6

WH-C1B-4

WH/BK-C1B-5

BK-C1B-7

GR/WH-4

OR/BK-C5-2

BK/RD-C1B-9

BL-C1B-10

BL/BK-C1B-11

BL/RD-C2B-1

GR/WH-C2B-7

OR/BK-C2B-3

BK/WH S.P.34

RD-CR1#30

RD-ISM#426

24

25

28

27

31

30

29

33

32

RD S.P.

RD CB1

BK S.P.

40

37

35

36

39

132

OR/BK-ISM#241134

43

44

45

BK/RD S.P.

BL/RD S.P.

46

ENGINE POWER

TILT ALARM

AUXILIARY POWER

GLOW PLUG

E.D.C.-

E.D.C.+

BRAKESTART

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP DEUTZ ONLY

SECONDARY BOOM F.C.

BL/BK-4BL-4


BL/WH-4

BL/RD-C4B-1

RD-S.P.(CB3)

SPARE

C40LS1 STOWED

JDALARMHORN

OR-C2B-2OR-4

BL/WH S.P.

WH/RD S.P.

C134PWROR/RD-C2B-4RD-4

BL/WH - C23-3 BL/WH-C1B-12

RD H6+ RD KS1

GR/BK C23-8 GR/BK-H6- C133PLT

C132PLI

OR/RD-C4B-4

WH-C5-3+C5-11 WH - H.C.

BL/WH-4

GR/BK-C2B-6 GR/BK-11B GR/BK S.P.

11B-RD/BK-4

GR-C2B-5 GR-CR5#86

44B-GR/BK+2B-BL/BK

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

4C

3B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

HC

(BK

)(G

Y)

(BR

)(G

R)

7.5

5

WH/RD -4




GROUND STUD

KEY SWITCH

B

B1

1

24

3

RD

KS1

BK/WH-C5-22BK/RD-CR3#30 GR/WH 45B

WH-ISM#7

BR- 3MF CAP

HARNESS:TO BASE

WIRING

WH-23C

BK-C32-5

BR-GND STUD

ALL BR WIRESBR

GROUND STUD

DESCRIPTION







ENGINE START SWITCH

TS63

TS62

CB1

CB2

HM HOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH


TO PLATFORM C-BOX, TERMINAL 13-19C4B



PR2

PR1




RPM RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

C1B

C2B

C3B

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5



CB3 CIRCUIT BREAKER, OPTION, 20A


G1

G2

G3 WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE




C5 ENGINE HARNESS

IGN./START

MODULEAUX. ON4

WH-CR2#86

WH-23BRD-CR2#30BR-GND.

KEY BYPASS

ENG. FAULTIGN./FUEL ON

10

8

9

67

5BATTERYKEY PWR.

GROUND

RD-27BBK-33BOR/BK-41BBK-CR1#86


START RELAY

321

WH-L2-

C7B TO PLATFORM C-BOX, TERMINAL 22-23

RD-C23-7

BL/WH-12A

BL/BK-11A

BL-10A

GR/BK-18A

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

RD- 24A

RD- 20A

BK/RD-35A

WH/BK-5AWH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

GR/BK-44A

BK-33A

BK/WH-8A

BK-7A

RD/WH-3ARD/BK-2A

RD-1A

BR (GROUND)

WH-21A

RD-27A

BK-22A

BL/WH-ISM-10

TS63

TS58

TS55

D13

TS52

D14 CB2CB1

R4

CB3

HML2

RD-42AWH-23A

RD-CB2

NC

NC

P1

TS59

TS62

TS61

TS51

WH-C5-13

G1 G2 G3

WH/BK-25A

WH-21A

BR (GROUND)

WH/RD-26A

RD-C23-6

TS56 GLOW PLUG SWITCH

R5

TS57

L2 CHECK ENGINE LED

CR23 WORK LIGHTS OPTION RELAY

OIL TEMP. SENDER

OIL PRESSURE SENDER

WH/RD S.P.

WH/BK S.P.WH/RD-C5-14

WH/BK-C5-16

RD-24D


CR23

BR

RD-C4B-12

WH - 21B

RD-C4B-10


FUSE 10A

BR-C4B-11

GNDBR-C4B-9

TS60

H6

U33

PLATFORM LOADC32

BL/WH-38D - C32-3

RD-C32-1RD-134BRD-TS51 - C32-6

BR - GND - C32-12

RD-H6+ - C32-1


BK-22C - C32-4BK-C7B-1 - C32-5

GR/BK-16B - C32-8

L45

GR/BK-H6-

86 8587A

87

30

30

87A85 86

87

RD-CB3 SP

CR17

RD-H.C.

BK-H.C.

BR GND

BK-ISM#1

BK-C5-5

WH-21B

RD-ISM#6WH-ISM#9RD-24B

CR1 CR2

BK/RD-C5-8

BK/RD-35B

CR3

CR4

BK-22B

GR-43B

CR5

8587 86

87A

30

30

8587A

8786

30

8587A

8786

30

8587A

8786

30

8587A

8786

BK-4

TS56BK/WH-34A

D64

GR/BK-35B

134ARD-U34-2

RD-D.L.CR23#30

WL

Cr45 DRIVE LIGHT OPTION RELAY

WH-CR2#86

WH-ISM#9

RD-TB134(A)C

BR-GND

BK-C3B-10



WORK LIGHTS OPTION RELAY

30

87A85 86

87

RD-CB3 SP

CR45

WH - W.L.

WH-C21IGN

BR GND

D4

D27

BK/RD-C3B-9 9 DRIVE LIGHT OPTIONBK/RD-CR23#86

1 DRIVE LIGHT OPTION REMOVED FROM TERMINAL 9 AT SERIAL NUMBER 10388.

1

1

December 2011


6 - 41

Diesel Platform Control Box Wiring Diagram(before serial number 7227)

6 - 42

December 2011


1

2

3

4

5

6

7

8


6 - 42 Z-60/34 Part No. 75861

REV ADiesel Platform Control Box Wiring Diagram(before serial number 7227)

TS48

HI/L0 RPM SWITCH

WORK/DRIVE LIGHT ( OPTION )

PRIMARY BOOM EXTEND/RETRACT SWITCH


GENERATOR OPTION

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

TS6

TS7

BOOM SECONDARY JOYSTICK:

PRIMARY UP/DN , TURNTABLE ROTATE

C.E. PLATFORM LED

FUEL SELECT SWITCH (FORD EFI ONLY)

DRIVE PROPORTIONAL JOYSTICK

BOOM PROPORTIONAL JOYSTICK:

HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

L4

JC3

COMPONENT INDEX

JC1

JC2

DRIVE SPEED SWITCHTS14

TILT ALARM LEDL48

EMERGENCY STOP BUTTONP2

OR

J1

-9

EMERGENCY STOP

P2

RPMHIGH/LOW

TS4

START

TS2

DRIVE ENABLE

TS15

L1

HIGH/LOW

SPEED

DRIVETS14

AUXILIARYPUMP

TS13

BOOMEXTEND/

RETRACT

PLATFORM

TS7

PLATFORM

LEVEL

TS9

P3

HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

RD

LS

18

RD

L4

WH

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

C2

9M

SR

D/W

HJ1

-8

WH

WH

BK

/RD

-35

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4W

HJ1

-5

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3

JC1JC2

WH

-24

4

2

1

3

5

6

7

WH

-24

BK

-22

WH

-24

WH

J1

-5

L4

GR

/BK

H1

RD

/BK

H1

L48

RD

-P2

RD

L4

8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

RD

34

NO

CE SEE DETAIL A

+

+

WORK/DRIVE LIGHTTS48

RD

WL

1

RD

WL

2D

LIT

E/

TS8

JIB

GR/BK

GR

JD

AL

AR

MG

R/B

K-4

4C

3P

-9

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

12

NC 12

NC

2

NC

1

GR

/WH

-45

10 AMP FUSE

RD

WL

2

NOTE:DASHED LINES INDICATE OPTION WIRES

GLOW PLUG OPTION

D27

RDGENERATOR

(OPTION)TS17

D12

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

IL T

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2C

41

RP

MO

R/B

KC

2P

-3C

30

ED

C+

WH

C1

P-4

C1

PB

UR

DC

3P

-1C

31

ED

C-

WH

/BK

C1

P-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11C

3P

BF

RD

/WH

C3

P-3

C3

6S

TC

BL

C1

P-1

0

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

DR

IVE

LTB

K/R

DC

3P

-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/B

KC

2P

-6

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

RD

H1

RD

P2

C1

32

PL

IB

KC

1P

-12

RPMHIGH/LOW

TS4

START

TS2

RD

-25

BK

-33

BK

/RD

-35

WH

-24

GR

/WH

-45


RDGENERATOR

(OPTION)TS17

D12

WH

-24

REMOVE FORGENERATOR OPTION

1 GENERATOR OPTION BEFORE SERIAL NUMBER 5716

1

CR30

DETAIL A: LIFT/DRIVE OPTION

CR27

(SPLICE TO R40LS1)

CP2-2 OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)

1 10A FUSE ADDED AT SERIAL NUMBER 4496.


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 43

REV A Diesel Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)

TS48

HI/L0 RPM SWITCH




GENERATOR OPTION

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

TS6

TS7



C.E. PLATFORM LED




HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

L4

JC3

COMPONENT INDEX

JC1

JC2


TILT ALARM LEDL48


J1

-9O

RJC

1-2

EMERGENCY STOP

P2

RPMHIGH/LOW

TS4

START

TS2

DRIVE ENABLE

TS15

L1

HIGH/LOW

SPEED

DRIVETS14

AUXILIARYPUMP

TS13

BOOMEXTEND/

RETRACT

PLATFORM

TS7

PLATFORM

LEVEL

TS9

P3

HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

RD

LS

18

RD

L4

WH

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

C2

9M

SR

D/W

HJ1

-8

WH

WH

BK

/RD

-35

BL

/BK

-DE

2J1

-7

J1

-13

OR

JC

3-2

J1

-14

BR

JC

3-1

J1

-4W

H/R

DJC

3-4

J1

-5B

L/W

HJC

3-5

J1

-10

BR

JC

1-1

J1

-3W

H/B

KJC

1-4

J1

-11O

RJC

2-2

J1

-12

BR

JC

2-1

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

Jc3

Jc1JC2

WH

-24

WH

-24

BK

-22

WH

-24

J1

-5B

L/W

HJC

3-3

L4

GR

/BK

H1

RD

/BK

H1

L48

RD

-P2

RD

L4

8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

RD

34

NO

CE SEE DETAIL A

+

+


RD

WL

1

RD

WL

2D

LIT

E/

TS8

JIB

GR/BK

GR

JD

AL

AR

MG

R/B

K-4

4C

3P

-9CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

12

NC 12

NC

2

NC

1

GR

/WH

-45

10 AMP FUSE

RD

WL

2


GLOW PLUG OPTION

D27

RDGENERATOR

(OPTION)TS17

D12

1

6

1

6

1

6

TURNTABLE ROTATESECONDARY BOOM

UP/DOWN

DRIVE/STEER

+

TILT ALARM

JIB TIME DELAY

JIB DELAY RELAYCR14

C1

COMPONENT INDEX

JC1

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2C

41

RP

MO

R/B

KC

2P

-3C

30

ED

C+

WH

C1

P-4

C1

PB

UR

DC

3P

-1C

31

ED

C-

WH

/BK

C1

P-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

C3

PB

FR

D/W

HC

3P

-3C

36

ST

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

DR

IVE

LTB

K/R

DC

3P

-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/B

KC

2P

-6

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

RD

H1

RD

P2

C1

32

PL

IB

KC

1P

-12

CR30


CR27

(SPLICE TO R40LS1)

CP2-2 OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)


6 - 44

Diesel Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)

6 - 43


6 - 45

Diesel Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9696)

6 - 46


1

2

3

4

5

6

7

8


6 - 46 Z-60/34 Part No. 75861

REV ADiesel Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9696)

TS48

HI/L0 RPM SWITCH




GENERATOR OPTION

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

TS6

TS7



C.E. PLATFORM LED




HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

L4

JC3

COMPONENT INDEX

JC1

JC2

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-1

1C

40

LS

1O

RC

2P

-2C

12

SB

FB

L/W

HC

3P

-12

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4C

1P

BU

RD

C3

P-1

C3

1E

DC

-W

H/B

KC

1P

-5C

2P

BD

RD

/BK

C3

P-2

C3

7S

TC

CB

L/B

KC

1P

-11

C3

PB

FR

D/W

HC

3P

-3C

36

ST

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

DR

IVE

LTB

K/R

DC

3P

-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/B

KC

2P

-6

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

P1

34

PW

RR

D-H

1+

RD

-E-S

TO

P

BR

JC

3B

RG

ND

C1

9JS

VG

R/W

HC

4P

-7C

19

JS

VG

R/W

HT

S7

RD LS18 CABLE

WHB

K

GR/WH +

RD OUTPUT

BR -

GR/WH

RD

GR

/WH

CR

13

-#8

6G

R/W

H

P1

34

PW

RR

D

GR/WHCR14

C1

RD

BR

BR

JIB


TILT ALARM LEDL48


J1

-9O

RJC

1-2

EMERGENCY STOP

P2

RPMHIGH/LOW

TS4

START

TS2

DRIVE ENABLE

TS15

L1

HIGH/LOW

SPEED

DRIVETS14

AUXILIARYPUMP

TS13

BOOMEXTEND/

RETRACT

PLATFORM

TS7

PLATFORM

LEVEL

TS9

P3

HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

RD

LS

18

RD

L4

WH

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

C2

9M

SR

D/W

HJ1

-8

WH

WH

BK

/RD

-35

BL

/BK

-DE

2J1

-7

J1

-13

OR

JC

3-2

J1

-14

BR

JC

3-1

J1

-4W

H/R

DJC

3-4

J1

-5B

L/W

HJC

3-5

J1

-10

BR

JC

1-1

J1

-3W

H/B

KJC

1-4

J1

-11O

RJC

2-2

J1

-12

BR

JC

2-1

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

Jc3

Jc1JC2

WH

-24

WH

-24

BK

-22

WH

-24

J1

-5B

L/W

HJC

3-3

L4

GR

/BK

H1

RD

/BK

H1

L48

RD

-P2

RD

L4

8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

RD

34

NO

CE SEE DETAIL A

+

+


RD

WL

1

RD

WL

2D

LIT

E/

TS8

JIB

GR/BK

GR

JD

AL

AR

MG

R/B

K-4

4C

3P

-9

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

12

NC 12

NC

2

NC

1

GR

/WH

-45

10 AMP FUSE

RD

WL

2


GLOW PLUG OPTION

D27

RDGENERATOR

(OPTION)TS17

D12

1

6

1

6

1

6


UP/DOWN

DRIVE/STEER

+

BK C1P-12

BK

C1

34

PW

RR

DL

S1

8

TILT ALARM

JIB TIME DELAY

JIB DELAY RELAYCR14

C1

COMPONENT INDEX

JC1

CR30


CR27

(SPLICE TO R40LS1)

CP2-2 OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 47

REV A Diesel Platform Control Box Wiring Diagram(from serial number 9697)

CR30

TS48

HI/L0 RPM SWITCH


CR27




GENERATOR OPTION

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

TS6

TS7



C.E. PLATFORM LED




HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

L4

JC3

COMPONENT INDEX

JC1

JC2

(SPLICE TO R40LS1)

CP2-2 OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-1

1C

40

LS

1O

RC

2P

-2C

12

SB

FB

L/W

HC

3P

-12

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4C

1P

BU

RD

C3

P-1

C3

1E

DC

-W

H/B

KC

1P

-5C

2P

BD

RD

/BK

C3

P-2

C3

7S

TC

CB

L/B

KC

1P

-11C

3P

BF

RD

/WH

C3

P-3

C3

6S

TC

BL

C1

P-1

0

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

DR

IVE

LTB

K/R

DC

3P

-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/B

KC

2P

-6

TS

48

-WL

2R

DC

2P

-1 1

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

47

00

R2

0

P1

34

PW

RR

D-H

1+

RD

-E-S

TO

P

BR

JC

3B

RG

ND

C1

9JS

VG

R/W

HC

4P

-7C

19

JS

VG

R/W

HT

S7

LOAD SENSE OPTION

P1

34

PW

RR

D

RD

-H1

+

BR

GN

D

P2

6E

ST

PB

KE

-ST

OP

U35

R2

6E

ST

PB

KC

9P

-1

5

NO23

COM

RD LS18 CABLE

D88

D89

WHB

K

GR/WH +

RD OUTPUT

BR -

GR/WH

RD

GR

/WH

CR

13

-#8

6G

R/W

H

P1

34

PW

RR

D

GR/WHCR14

C1

RD

BR

BR

JIB


TILT ALARM LEDL48


HARNESSPBOX WIRING

J1

-9O

RJC

1-2

EMERGENCY STOP

P2

RPMHIGH/LOW

TS4

START

TS2

DRIVE ENABLE

TS15

L1

HIGH/LOW

SPEED

DRIVETS14

AUXILIARYPUMP

TS13

BOOMEXTEND/

RETRACT

PLATFORM

TS7

PLATFORM

LEVEL

TS9

P3

HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

RD

LS

18

RD

L4

WH

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

C2

9M

SR

D/W

HJ1

-8

WH

WH

BK

/RD

-35

BL

/BK

-DE

2J1

-7

J1

-13

OR

JC

3-2

J1

-14

BR

JC

3-1

J1

-4W

H/R

DJC

3-4

J1

-5B

L/W

HJC

3-5

J1

-10

BR

JC

1-1

J1

-3W

H/B

KJC

1-4

J1

-11O

RJC

2-2

J1

-12

BR

JC

2-1

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

JC3

JC1JC2

WH

-24

WH

-24

BK

-22

WH

-24

J1

-5B

L/W

HJC

3-3

L4

GR

/BK

H1

RD

/BK

H1

L48

RD

-P2

RD

L4

8

C3

4S

AB

K/W

HC

1P

-8

TS6GLOW PLUG

RD

34

NO

CE SEE DETAIL A

+

+


RD

WL

1

RD

WL

2D

LIT

E/

TS8

JIB

GR/BK

GR

JD

AL

AR

MG

R/B

K-4

4C

3P

-9CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

12

NC 12

NC

2

NC

1

GR

/WH

-45

10 AMP FUSE

RD

WL

2


GLOW PLUG OPTION

D27

RDGENERATOR

(OPTION)TS17

D12

1

6

1

6

1

6


UP/DOWN

DRIVE/STEER

+

TILT ALARM

JIB TIME DELAY

JIB DELAY RELAYCR14

C1

COMPONENT INDEX

JC1

1

1 WORK LIGHT OPTION REMOVED FROMPLATFORM BOX AT SERIAL NUMBER 10388


6 - 48

Diesel Platform Control Box Wiring Diagram(from serial number 9697)

6 - 47


6 - 49

Ford Electrical Schematic - View 1(before serial number 4546)

6 - 50


1

2

3

4

5

6

7

8


6 - 50 Z-60/34 Part No. 75861


2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.



NOTE:

NO

BR

N

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

RT

ILT

AL

AR

M

PUMPBK

OR

/BK

-41

12 V DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-23

RD

-27

RD

/BK

-28

BK

-43

CR5

PR1

RD

WH

NO

WA

TE

RT

EM

P

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_S

WIT

CH

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NC

OTSNO

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

WH

-24

WH

-24

OPS

TB25TB26

CR1CR1 CR2

NO

TB21

CR2

GR

/WH

-45

FB

TB41

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

BK

TS52

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TO

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HR

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(FS

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RE

GA

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WA

TE

RT

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(OP

TIO

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OL

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FA

N

TE

MP.

SW

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UL

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CR17

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34

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RT EN

GIN

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RN

(FE

H2

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(FE

H3

61

A)

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FORD

FU

EL

PU

MP

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C3

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C3

5R

PM

2

TS

W

P24BATTB24

OR

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(FE

H3

07

A)

PIN

23

WH

(FE

H1

6A

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IN1

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(FE

H6

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H3

06

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H4

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(FE

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2)

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7

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(FE

H5

70

C)

PIN

34

BL

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(FE

H7

87

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IN5

RD

(FE

H3

61

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IN9

RU

N

TS22

TE

ST

TS53

TB39

TS3

C2

-1

LP

G

SO

LE

NO

IDL

OC

KO

UT

6 BATTERY7

1098

ENG. FAULT


KEY PWR.

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

U1

TB 132 IS WAGO TERMINAL BLOCK 38TB 133 IS WAGO TERMINAL BLOCK 16TB 134 IS WAGO TERMINAL BLOCK 42

REV B

December 2011


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 51

WH WH

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OU

ND

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N

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RIM

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DR

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AB

LE

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AL

AR

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VA

LVE

S

CR13

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C1

7JU

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C1

8JD

GR

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Y18


7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch

JC1

PW

R

653 421

GN

D

OU

T


7

39

10

OR

BR

N

YE

L

J1

REV B

December 2011


6 - 526 - 51



6 - 53

Ford Electrical Schematic - View 1(from serial number 4546 to serial number 5715)

6 - 54


1

2

3

4

5

6

7

8


6 - 54 Z-60/34 Part No. 75861

REV AFord Electrical Schematic - View 1(from serial number 4546 to serial number 5715)

BR

N

STA

RT

ER

MO

TO

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H2REGULATOR

- IND.

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+

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ALTERNATOR

EXCT.

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WH

NO

PR1

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OTS

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TIO

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OP

TIO

N

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NE

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TO

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BK

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+

OPS

TB25 TB26

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GR

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FB

TB41

15AMP.TB20

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RD

15AMP.

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8T

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HIG

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RD

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TS4

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GE

NE

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TO

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HIG

HR

PM

(FS

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G2 G3

G1

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OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

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AU

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(OP

TIO

N)

CO

OLIN

GFA

N

TE

MP.

SW

ITC

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YD

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ULIC

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OTS

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20AMP.

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34

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BL/WH

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HM

STA

RT

EN

GIN

E

FAN

DG

RN

(FE

H2

42

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(FE

H3

61

A)

ENGINEHARNESS

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FU

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MP

LP

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SO

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ID

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CK

OU

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BL/W

HP

IN5

FUELPUMP

BK

PIN

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BK

PIN

15

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9LP

BL/R

DP

IN7

RD

PIN

9

WH

PIN

1

C3

8E

SL

BL/W

HP

IN6

GR

PIN

18

C1

27

TS

T

BR

PIN

34

BK

/RD

PIN

23

C3

5R

PM

WH

PIN

21

VS

W VB

AT

T

C3

3S

TR

C2

1IG

N

R3

3S

TR

C5

-11 C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

R2

1IG

NW

HP

IN2

4C

5-8

42 PIN PLUG

FORD

C2

-1

TB39

TS53

TS3

CR1CR1

NONO

TB24

CR2CR2

CR39

NCCR39

TS22

TB21

42

PIN

FO

RD

CO

NN

EC

TO

RO

R/B

KP

IN2

C4

1R

PM

C5

-14

C5

-16

2

REFER TO E0375 FOR FORD HARNESS3

2

NOTE:



THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

C4

B-1

2

C4

B-1

1

L30 L30

L29L29

FUSE 10A

C3

-9D

LIT

EB

K/R

D

PBOX GND

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

RD

RD

TS49

WH

WH

BK

BK

F18

3


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 55

REV A Ford Electrical Schematic - View 2(from serial number 4546 to serial number 5715)

WH WH

OP

ER

AT

ION

BO

OM

RE

TR

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EE

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TB17

TB18

TB15

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R/W

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RD

C4

P-7

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C4

P-5

C4

P-6

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D/W

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C2

PB

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D/B

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C1

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LU

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5P

LD

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TB14

TB8

TB7

TB13TB40

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PB

EB

K

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2TS63

C4

P-1

C3

P-2

C3

P-3

TS9

WH

TS7

BK

OR/BK


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4

P2

4F

SW

H

P2

4F

SW

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P2

6E

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19

20

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10

C3

0E

DC

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H

C3

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/ RD

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TC

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C1

P-5 B

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P-3

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BK

BR

N

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EA

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EB

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76

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H

C3

2B

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WH

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7S

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C3

6S

TC

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TR

FW

H/R

D

C5

TR

RW

H/ B

K

C4

TR

LW

H

C1

PB

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D

C2

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DR

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D

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TB12

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C3

P-1

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P-1

2

12

13

14

R4

7.5

5R5

DO

WN

SE

CO

ND

AR

YB

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MU

P

C1

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BF

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SE

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P

SE

CO

ND

AR

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MD

OW

N

SE

CO

ND

AR

YB

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MF

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WC

ON

TR

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NOHC

BK

WH

NOHC NCHO NCHO

C2

2P

WR

RD

WH

BK

WH

BK

WH

BK

LS

3D

RIV

EE

NA

BL

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Y51

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OPTION

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GR

OU

ND

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N



NOTE:

JIB

VA

LVE

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

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44

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FT

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AT

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TA

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LE

FT

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EN

AB

LE

DR

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MO

DE


6 - 566 - 55



6 - 57


6 - 58


1

2

3

4

5

6

7

8


6 - 58 Z-60/34 Part No. 75861


BR

N

STA

RT

ER

MO

TO

R

H2REGULATOR

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AU

XIL

IAR

YP

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P

AU

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NE

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TO

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C3

3S

TR

C2

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N

R3

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C5

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C5

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C5

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C5

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C5

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FORD

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TB21

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PIN

FO

RD

CO

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TO

RO

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C5

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C5

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TIO

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RD

RD

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WH

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BK

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FUSE 10A


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 59


WH WH

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

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LE

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PL

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EA

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SE

CO

ND

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653 421

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39

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C2

9M

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LOHI

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NCCR27

CE

OPTION

LIFT/DRIVE

GR

OU

ND

BR

N



NOTE:

JIB

VA

LVE

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

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TB

44

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P-6

BRN

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8JD

GR

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Y18 LE

FT

RIG

HT

PL

AT

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TA

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UP

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DO

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FO

RM

LE

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EX

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UP

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OM

LE

FT

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RO

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WN

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BO

OM

UP

RIG

HT

TT

RO

TA

TE

LE

FT

DR

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EN

AB

LE

DR

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MO

DE


6 - 60


6 - 59


6 - 61


6 - 62


1

2

3

4

5

6

7

8


6 - 62 Z-60/34 Part No. 75861


C5

- 16

C5

-14

C5

-3

TB39

C2

6T

SR

WH

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PIN

39

R2

1K

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IN5

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FUELPUMP

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15

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L/R

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PIN

1

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8E

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BL

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PIN

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23

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PL

UG

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C5

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C4

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-9

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L30L30



NOTE:

HM

WO

RK

LIG

HT

DR

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LIG

HT

GA

S

FU

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LP

GA

S FU

EL

STA

RT

EN

GIN

E

STA

RT

EN

GIN

ER4

50

0C

10

7A

FW

H

TB 132 IS WAGO TERMINAL BLOCK 38TB 133 IS WAGO TERMINAL BLOCK 16TB 134 IS WAGO TERMINAL BLOCK 42


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 63

REV A

WH WH

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

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RY

BO

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TS57

C4

P-5

C4

P-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2TS63

C4

P-1

C3

P-2

C3

P-3

TS9

WH

TS7

BK

OR/BK


TS13

4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/ B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61C

4T

RL

WH

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-11

C1

P-1

0

C1

P-4

C1

P- 5 B

RN

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 1

11 2

9

7


UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

EA

BL

/WH

DR

EB

BL

/BK

BR

N

OR

BL

WH

DR

EL

ED

BL

/ RD

J1

13

14 54 6

J1

7

16 8

15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/ R

D

C5

TR

RW

H/ B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/ B

K

C3

PB

FR

D/ W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

A

B

D

C

RD

/BK

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10TB11

TB12

TS60

C3

P-1

0

C3

P-11

C3

P-1

2

12

13

14

R4

7.5

5R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

NOHC

BK

WH

NOHC NCHO NCHO

C2

2P

WR

RD

WH

BK

WH

BK

WH

BK

LS

3D

RIV

EE

NA

BL

E


Y51

SJ1 WH SJ2 WH

XO

UT

JC1

PW

R

653 421

GN

D

OU

T


7

39

10

OR

BR

N

YE

L

J1

C2

9M

SR

D/W

H

TS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1P

-3C

29

MS

RD

/ WH

C5

-24

Y27

BL/WH

C2

9M

SR

D/W

H

LOHI

CR30NO

NCCR27

CE

OPTION

LIFT/DRIVE

GR

OU

ND

BR

N



NOTE:

JIB

VA

LVE

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

P-6

BRN

JIB

VA

LVE

CR13

TS8

GR

/BK

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18 LE

FT

RIG

HT

PL

AT

RO

TA

TE

UP

DO

WN

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

PL

AT

FO

RM

LE

VE

LU

P

UP

DO

WN

JIB

BO

OM

LE

FT

RIG

HT

PL

AT

RO

TA

TE

DO

WN

PR

IMA

RY

BO

OM

UP

RIG

HT

TT

RO

TA

TE

LE

FT

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch



6 - 646 - 63



6 - 65


6 - 66


1

2

3

4

5

6

7

8


6 - 66 Z-60/34 Part No. 75861


C5

- 16

C5

-14

TB39

C2

6T

SR

WH

/RD

PIN

39

R2

1K

DIAGNOSTIC

WH

/BK

LP

GL

OC

KO

UT

FORDENGINEHARNESS

RD

/GNB

L/W

HP

IN5

FUEL PUMP

FUELPUMP

BK

PIN

15

C3

9L

PB

L/R

DP

IN7

WH

PIN

1

C3

8E

SL

BL

/WH

PIN

6

TS22

GR

PIN

3C

12

7T

SW

BK

/RD

PIN

23

C3

5R

PM

42

PIN

PL

UG

FO

RD

WH

PIN

16

VS

W

C2

1IG

N

R3

3S

TR

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

R2

1IG

NW

HP

IN2

4C

5-8

ABCDB

K/B

L

RD

GY

/YL

GY

/RD

GA

SO

LIN

ES

EN

SO

R

BL

PIN

18

C1

35

FP

C1

35

RE

T

C4

1R

PM

OR

/BK

PIN

24

2P

INF

OR

DC

ON

NE

CT

OR

TB21

GRD

PLAT

RD

KS1

2

4

1

3B

B1

WH

BK

RD

BR

C5

-2

BL/WH

CR39

NCCR39

CR2CR2

TB24

NO NO

CR1CR1

TS3

TS53

C2

-1

AU

XIL

IAR

YP

UM

PA

UX

ILIA

RY

PU

MP

LP

Y29

G6

M2

S7

M1

C4

1R

PM

OR

/BK

L2

WH

/BK

FU

NC

TIO

NE

NA

.

L48

C2

-3

RD/BK

C28TTA RD/BK

P2

P3

C7

-1

HORN

P2

2B

AT

BK

C2

-4C

13

4P

WR

RD

TB22

P1TB42

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OL

ING

FA

N(O

PT

ION

)

FAN

TB43

WA

TE

RT

EM

PG

AU

GE

OIL

PR

ES

SU

RE

GA

UG

E

VO

L TM

ET

ER

G1

G3 G2

HIG

HR

PM

(FS

)

GE

NE

RA

TO

R

C1

-9

TS4

TS17

OR/BK

BK

WH

RD

RD

TS55

TB35

LO

WR

PM

HIG

HR

PM

C3

5E

SP

DB

K/R

D

BRN

P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

-7

TB45

C4

5G

EN

GR

/WH

C1

-7

TS52

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1BK-(FS)

WH-(FS)

RD-(FS)C9-1

TS1

C1

-1

C7

-2

C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

RD

CB1

15

AM

P.

RD

P2

0B

AT

RD

CB

2

TB20 15AMP.

TB41

FB

GR

/WH

R2

1IG

NW

H

TB26 TB25

OPS

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

_

HO

UR

ME

TE

R

PR1

NO

WH

RD PR1

CR5NOCR5

R3

4H

RN

BK

RD

/BK

RD

RD

+

DC12 V

BK PUMP

TILT

AL

AR

M

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

BR

N

TB9

CR23NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

FUSE 10A

C4-9 C4-11

F18

BK

BK

WH

WH

TS48

PBOX GND

DL

ITE

BK

/RD

C3

-9

FUSE 10A

L30L30



NOTE:

HM

WO

RK

LIG

HT

DR

IVE

LIG

HT

GA

S

FU

EL

LP

GA

S FU

EL

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

C5

-3

L2 LED LAMP REPLACED WITH INCANDESCENT LAMP AT SERIAL NUMBER 90662

1 RESISTOR R2 REMOVED AT SERIAL NUMBER 7924.

2

1

RD

JIB TIME DELAY CIRCUIT ADDED AT SERIAL NUMBER 90663

3

FO

RD

EN

GIN

EH

AR

NE

SS

STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

BL

UE

/PIN

K

NOPR8

GN

DB

R

RD 4

RELAY ADDED AT SERIAL NUMBER 9917PR84


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 67


WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 68


6 - 67


6 - 696 - 70

Ford Electrical Schematic, ANSI / CSA - View 1(from serial number 10388)


1

2

3

4

5

6

7

8


6 - 70 Z-60/34 Part No. 75861

REV AFord Electrical Schematic, ANSI / CSA - View 1(from serial number 10388)

C5

-16

C5

-14

TB39

C2

6T

SR

WH

/RD

PIN

39

DIAGNOSTIC

WH

/BK

LP

GL

OC

KO

UT

FORDENGINEHARNESS

RD

/GNB

L/W

HP

IN5

FUEL PUMP

FUELPUMP

BK

PIN

15

C3

9L

PB

L/R

DP

IN7

WH

PIN

1

C3

8E

SL

BL

/WH

PIN

6

TS22

GR

PIN

3C

12

7T

SW

BK

/RD

PIN

23

C3

5R

PM

42

PIN

PL

UG

FO

RD

WH

PIN

16

VS

W

C2

1IG

N

R3

3S

TR

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

R2

1IG

NW

HP

IN2

4C

5-8

ABCDB

K/B

L

RD

GY

/YL

GY

/RD

GA

SO

LIN

ES

EN

SO

R

BL

PIN

18

C1

35

FP

C1

35

RE

T

FO

RD

EN

GIN

EH

AR

NE

SS

C4

1R

PM

OR

/BK

PIN

24

2P

INF

OR

DC

ON

NE

CT

OR

TB21

BL

UE

/PIN

K

GRD

PLAT

RD

KS1

2

4

1

3B

B1

WH

BK

RD

BR

C5

-2

BL/WH

CR39

NCCR39

CR2CR2

TB24

NO NO

CR1CR1

TS3

TS53

C2

-1

AU

XIL

IAR

YP

UM

PA

UX

ILIA

RY

PU

MP

LP

Y29

G6

M2

S7

M1

C4

1R

PM

OR

/BK

L2

WH

/BK

FU

NC

TIO

NE

NA

.

L48

C2

-3

RD/BK

C28TTA RD/BK

P2

P3HORN

P2

2B

AT

BK

TB22

P1TB134

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OL

ING

FA

N(O

PT

ION

)

FAN

TB43

WA

TE

RT

EM

PG

AU

GE

OIL

PR

ES

SU

RE

GA

UG

E

VO

LTM

ET

ER

G1

G3 G2

HIG

HR

PM

(FS

)

GE

NE

RA

TO

R

C1

- 9

TS4

TS17

OR/BK

BK

WH

RD

RD

TS55

TB35

LO

WR

PM

HIG

HR

PM

C3

5R

PM

BK

/RD

BRN

P26ESTP BK

P25FS RD

P24FS WH

TS2C

2-7

TB45

C4

5G

EN

GR

/WH

C1

-7

TS52

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1BK-(FS)

WH-(FS)

RD-(FS)C9-1

TS1

C1

-1

C7

-2

C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

RD

CB1

15

AM

P.

RD

P2

0B

AT

RD

CB

2

TB20 15AMP.

TB41

FB

GR

/WH

R2

1IG

NW

H

TB26 TB25

OPS

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

_

HO

UR

ME

TE

R

STA

RT

RE

LA

Y

PR1

NO

WH

RD PR1

CR5NO

CR5

R3

4H

RN

BK

RD

/BK

RD

RD

+

DC12 V

BK PUMP

TILT

AL

AR

M

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

BR

N

CR23NO

CR23

L29

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

FUSE 10A

C4-9 C4-11

BK

BK

WH

WH

WO

RK

LIG

HT

L30L30



NOTE:

HM

GA

S

FU

EL

LP

GA

S FU

EL

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

C5

-3

TB133

6

C32CONN.PLUG12 8

7

1

4

3

5

D39

D40

RD

TB132

C2

-4

C1

-12

P1

34

PW

RR

D

C1

32

PL

I1B

L/W

H

GBOX GND

D10

D3

D4

D2

D13

D14

NOPR8

GN

DB

R

RD

WO

RK

LIG

HT

S

OP

TIO

N

CR45NOCR45

WO

RK

LIG

HT

SR

EL

AY

(OP

TIO

N)

EN

GI N

ES

PE

ED

D12


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 71

REV A Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 10388)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

H

TS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 726 - 71

Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 10388)


6 - 736 - 74

Ford Electrical Schematic, CE - View 1(from serial number 10388)


1

2

3

4

5

6

7

8


6 - 74 Z-60/34 Part No. 75861

REV AFord Electrical Schematic, CE - View 1(from serial number 10388)

C5

-16

C5

-14

TB39

C2

6T

SR

WH

/RD

PIN

39

DIAGNOSTIC

WH

/BK

LP

GL

OC

KO

UT

FORDENGINEHARNESS

RD

/GNB

L/W

HP

IN5

FUEL PUMP

FUELPUMP

BK

PIN

15

C3

9L

PB

L/R

DP

IN7

WH

PIN

1

C3

8E

SL

BL

/WH

PIN

6

TS22

GR

PIN

3C

12

7T

SW

BK

/RD

PIN

23

C3

5R

PM

42

PIN

PL

UG

FO

RD

WH

PIN

16

VS

W

C2

1IG

N

R3

3S

TR

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

R2

1IG

NW

HP

IN2

4C

5-8

ABCDB

K/B

L

RD

GY

/YL

GY

/RD

GA

SO

LIN

ES

EN

SO

R

BL

PIN

18

C1

35

FP

C1

35

RE

T

FO

RD

EN

GIN

EH

AR

NE

SS

C4

1R

PM

OR

/BK

PIN

24

2P

INF

OR

DC

ON

NE

CT

OR

TB21

BL

UE

/PIN

K

GRD

PLAT

RD

KS1

2

4

1

3B

B1

WH

BK

RD

BR

C5

-2

CR39

NCCR39

CR2CR2

TB24

NO NO

CR1CR1

TS3

TS53

C2

-1

AU

XIL

IAR

YP

UM

PA

UX

ILIA

RY

PU

MP

LP

G6

M2

S7

M1

C4

1R

PM

OR

/BK

L2

WH

/BK

C2

-3

C28TTA RD/BK

P2

P3HORN

P2

2B

AT

BK

TB22

P1TB134

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OL

ING

FA

N(O

PT

ION

)

FAN

TB43

WA

TE

RT

EM

PG

AU

GE

OIL

PR

ES

SU

RE

GA

UG

E

VO

L TM

ET

ER

G1

G3 G2

P26ESTP BK

P25FS RD

P24FS WH

TS2

C1

-7

TS52

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1BKC9-1

TS1

C1

-1

C7

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

RD

CB1

15

AM

P.

P2

0B

AT

RD

CB

2

TB20 15AMP.

TB41

FB

R2

1IG

NW

H

TB26 TB25

OPS

+

OP

TIO

NF

LA

SH

ING

BE

AC

ON

S

_

HO

UR

ME

TE

R

STA

RT

RE

LA

Y

PR1

NO

WH

RD PR1

CR5NOCR5

R3

4H

RN

BK

RD

/BK

RD

RD

+

DC12 V

BK PUMP

TILT

AL

AR

M

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

BR

N



NOTE:

HM

GA

S

FU

EL

LP

GA

S FU

EL

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

TB133

6

C32CONN.PLUG12 8

7

1

4

3

5

TB132

C2

-4

C1

-12

P1

34

PW

RR

D

C1

32

PL

I1B

L/W

H

GBOX GND

D10

D3

D4

D2

NOPR8

GN

DB

R

RD

C1

-2

C4

-4

D40

H1L4

D39

PBOXGND

R204.7 K

LS18

LS18A

D88

D89

2 SEC

U34

NO10A

P2

4P

WR

GN

/BK

2 SEC

U35

NO30A

C28TTA RD/BK

GR

/BK

C1

33

PL

AO

R/R

D

PBOXGND

C132PLI2 BK

C4

-10

L45H6

BL/WH

Y29

FU

NC

TIO

NE

NA

.

RD/BK

HIG

HR

PM

(FS

)

GE

NE

RA

TO

R

C1

-9

TS4

TS17

OR/BK

BK

WH

RD

RD

TS55

TB35

LO

WR

PM

HIG

HR

PM

C3

5R

PM

BK

/RD

BRN

C2

-7

TB45

C4

5G

EN

GR

/WH

GR

/WH

GE

NE

RA

TO

RO

PT

ION

CR23NO

CR23

L29

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

FUSE 10A

C4-9 C4-11

BK

BK

WH

WH

WO

RK

LIG

HT

L30L30

RD

D13

D14

WO

RK

LIG

HT

S

OP

TIO

N

EN

GIN

ES

PE

ED

D12

CR45NOCR45

WO

RK

LIG

HT

SR

EL

AY

(OP

TIO

N)


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 75

REV A Ford Electrical Schematic, CE - View 2(from serial number 10388)

WH WH

JIB

VA

LVE


JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB

44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

Y18

GR

OU

ND

BR

OP

ER

AT

ION

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

SE

CO

ND

AR

YB

OO

M

DE

SC

EN

TA

LA

RM

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

OP

ER

AT

ION

BO

OM

EX

TE

ND

OP

ER

AT

ION

BO

OM

RE

TR

AC

TE

D

H4

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

W

ST

EE

RC

CW

H3

TS59

TB19

TB17

TB18

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK16

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

TB1

TB2TB5 TB4


C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5 BR

-2

C2

-3

WH

/RD

RD

/WH

BR

OR

J2

6

J1

12 111 2

9


YO

UT

XO

UT

GN

D1 2 43 5 6

PW

R

JC2

DR

EA

BL/W

H

DR

EB

BL/B

KBR

OR

BL/W

H

WH

/RD

DR

ELE

DB

L/R

D

J1

13

14 54 6

J1

7

16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

6

DRIVE & STEERING

JC3

TS15 L1

5

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

RD

/BK

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

TB10

TB11

TB12

TS60

C3

-10

C3

-11

C3

-12

12

13

14

R4

7.5

5

R5

DO

WN

SE

CO

ND

AR

YB

OO

MU

P

C1

2S

BF

BL/W

H

C1

1S

BD

BL/B

K

C1

0S

BU

BL

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

P2

3P

WR

RD

LS

3

DR

IVE

EN

AB

LE


SJ1 WH

SJ2 WH

XO

UT

JC1

PW

R

542 31G

ND

OU

T


6

3910

ORBR

WH

/BK

J1

C2

9M

SR

D/W

HTS14

C5

-21

C5

-20

C5

-23

MO

TO

RS

TR

OK

EC

1-3

C2

9M

SR

D/W

HC

5-2

4

Y27

BL/WH

RIG

HT

LE

FT

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

RIG

HT

LE

FT

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PLA

TF

OR

MLE

VE

L

EX

TE

ND

RE

TR

AC

TBO

OM

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TBO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

DR

IVE

EN

AB

LE

DR

IVE

MO

DE



NOTE:

1.

RD

CR14

_

+

D29 D30

14

NO

13

BK

WH

22 21

NC

NO

13NC

14

WH

2122

BK

34

NO

13NC

14

WH

2122

BK

12

14

NO

13

BK

WH

22 21

NC

12 34

BL/W

H


6



6 - 766 - 75

Ford Electrical Schematic, CE - View 2(from serial number 10388)


6 - 77

Ford Ground Control Box Wiring Diagram(before serial number 4545)

6 - 78


1

2

3

4

5

6

7

8

March 2011Section 6 • Schematics

6 - 78 Z-60/34 Part No. 75861

Ford Ground Control Box Wiring Diagram(before serial number 4545)

RED-20B

RED-24A

BK/WH-34A

RED-20A

7.5

BLK/RED-35A

BLK-33A

ORG-14A

GRN/WHT-19A

ORG/BLK-15A

GRN/BLK-18A

GRN-17A

WHT/BLK-5AWHT-4A

RED/WHT-3A

RED/BLK-2ARED-1A

BLU/BLK-11ABLK/WHT-8ABLK-7A

BLU-10ARED-27A

WHT-23ABLK-22A

WHT-21ABRN-GROUND

BL/WH -12A

WH/RD S.P.

RD 42A

GR/BK H6

RD C23-7

RED-20C

CR17 #30

C23-6

WH-E.H.

BL/WH-ISM#10

SWITCH

AUXILIARYPUMP

KS1

RD

B

B1

1

24

3

KEY

DESCRIPTION







ENGINE START SWITCH

TS63

TS62

CB1

CB2

HM HOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH






PR2

PR1




RPM RELAY

SECONDARY BOOM STOWED LIMIT SWITCH

BOOM RETRACTED LIMIT SWITCH

DRIVE ENABLE LIMIT SWITCH

PRIMARY BOOM STOWED LIMIT SWITCH

CE PLATFORM LEVEL RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

CR18

(CABLE#1)

(CABLE#2)

(CABLE#3)

LS4 (CABLE#8)

LS3 (CABLE#7)

LS2 (CABLE#5)

LS1 (CABLE#6)

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5





G1

G2

G3 WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE



V33 PLATFORM OVERLOAD MODULE




L2

HM

NC

NC

P2

TS51

TS60

TS62TS58

TS55

TS59

TS57

R4

TS52

CB1ENGINE, 15A

FUNCTIONENABLE

PLATFORM

PLATFORM

TURNTABLE

BOOM

ENGINESTARTER

BOOM EXTEND/

UP/DOWN

RETRACT

ROTATEJIB BOOM

ROTATE

LEVEL

GLOW PLUG ENGINE START

CONTROL, 15AOIL COOLER/OPTION, 20A

CB2

5

R5

TS56

D2

D3

+

-

CB3

TS63

L45

CRRELAY

LEGEND

3086 85

87

87A

VOLT METER

G1

OIL TEMP

G3

OIL PRESSURE

G2

WHT-21A

BRN-GROUND

WT/BK-25A WT/RD-26A

TS61BOOM

CHECK ENGINE

LED

UP/DOWN

HARNESSENGINE

#4CABLE

#3CABLE

CABLE#2

#1CABLE

CABLE#5

CABLE#6

#7CABLE

CABLE#8

BR

C23-4

BK-ISM#3

RD S.P.

GROUND STUD

RD-4

BL/WH C23-3 BL/WH-1

RD H6 RD KS1

GN/BK C23-8 GN/BK-H6 C133PLT

C132PLI

OR/RD-3

BR-2

BR

BK-H.C. + BR-H.C.

PLATFORM LOADU33

C23

GN/BK-16B - C23-8

BK-C7-1 - C23-5BK-22C - C23-4

RD-TS14 - C23-7

RD-H6+ - C23-1

BR-GND - C23-12

RD-TS11 - C23-6

BL/WH-38D - C23-3

GN/BK-16A

GN/BK-L45

RD-C23-1

RD-42B

H6

D C B A

23

1

12

3

2

456

98

7

10

11

13

14

17

1516

18

19

20

22

21

34

26

24

25

2827

31

30

29

33

32

40

37

3536

39

38

41

4243

444546

RD-S.P.(CB2)

BK-CR5#30

RD-CR2#30

WH-ISM#7

ISM#4

OR/BK-ISM#2

BK/RD CR3#30

BK -8

BK -7

WH -5

WH-2

RD-3

WH/RD-3

WH/BK-3

RD/WH-3

BK/WH-3

BL/WH-3

OR/BK-3

GR/BK-3

GR/WH-3

RD/BK-3

WH-3

BK/RD-3

BK-3

BL/BK-3

BL-3

GR-3

OR-3

WH-E.H.

BK/WH-1

RD/BK-1RD-1

WH/RD-1

WH-1WH/BK-1

BK-1

BK/RD-1BL-1BL/BK-1

BL/RD-1

GR/WH-1

OR/BK-1

RD/WH-1

OR/RD-3

RD-S.P.(CB3)

OR-1

OR/RD-1

WH S.P.+ WH-46A

RD S.P.

WH/BK S.P.

RD/WH S.P.RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

BK/WH S.P.

RD CB1

BK S.P.

BK/RD S.P.

BL/RD S.P.

WH-23A

BL/WH S.P.

WH/RD S.P.

WH/RD S.P.WH/BK S.P.

KEYSWITCH POWER

PRIMARY BOOM UP

DRIVE ENABLE


PRIMARY BOOM DOWN

SECONDARY BOOM UPSECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWNPLATFORM LEVEL UP

12V BATTERY SUPPLYIGNITION POWER

JIB VALVE

ENGINE POWER

TILT ALARMAUXILIARY POWER


E.D.C.-

E.D.C.+

BRAKESTART

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

MOTOR SPEED

LIMIT SWITCH POWER

C40LS1 STOWED

LIMIT SWITCH J1LIMIT SWITCH J2

C134PWR

OIL TEMP SENDER

OIL PRESSURE SENDER

BK/WH-E.H.

RD-4

RD-4

BK -5

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4RD/BK-4

WH/BK-4WH/RD-4

BL/BK-4

GR-4

RD -E.H.WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

WH -E.H.

RD/BK-4

WH/BK-E.H.

RD -4

WH/RD - E.H.

GR/WH-4

OR/BK-E.H.

BL/BK-4BL-4

RD/WH-E.H.

WH/RD-E.H.

WH/BK-E.H.

BL/WH-4

WH -8

WH -7

WH -6

BK -6

BL/WHT-L2-

WH-23B

WARNING SENDER

BR-GROUND

BATTERY

GROUND

KEY POWER

KEY BYPASS

ENGINE FAULTIGN./FUEL ON

WH-CR2#86

RD-CR1#30

9

10

7

8

6

5

TACHOMETER

START INPUT

AUXILIARY ON

START RELAYBK-CR1#86

RD-27BBK-33DOR/BK-41B

3

4

2

1

IGN./STARTMODULE

BK-4

BK-22B

WH-ISM#9

WH-21D

BK-ISM#1

BK-E.H.

RD-ISM#6

GR-1

RD-24B

WH-H.C.

RD-H.C.

CR3 CR4

BR-GROUND

BK/RD-35B

BK/RD-E.H.

CR1 CR2 CR5CR17

HYDRAULICCOOLER

RD-S.P. (CB3)

GND

3 MFD+

RD-CB3 SP


CR23

BK/RD-9B

RD-C4B-12

BRN GND

RD TO LIGHT

L2CHECK ENGINE

LED

D33

WH/RD-C5-14

WH/BK-C5-16

BL/WH-ISM#10

PERKINS SHUTDOWN ONLY

RPM FILTER ADDED AT SERIAL NUMBER 44611

PERKINS SHUTDOWN COMMONIZED WITHDEUTZ AT SERIAL NUMBER 5326

1

DIODE WITH 44B-GR/BK+2B-BL/BK

2

REV B

December 2011


1

2

3

4

5

6

7

8

March 2011Section 6 • Schematics

Part No. 75861 Z-60/34 6 - 79

Ford Ground Control Box Wiring Diagram(from serial number 4546 to serial number 5715)

BR

BR-2

BR

RELAY

LEGEND

30

86 85

87

87A

BR-H.C.

SWITCH

KS1

RD

B

B1

1

24

3

KEY

HM

NC

NC

P2

TS51

TS61

TS60

TS62

TS58

TS55

TS59

TS57

R4

TS52

CB1 CB2

5

R5

D2

+

-

CB3

TS63

TS53

D3

RED-20B

RED-24A

RED-20A

7.5

BLK/RED-35A

BLK-33A

ORG-14A

GRN/WHT-19A

ORG/BLK-15A

GRN/BLK-18A

GRN-17A

WHT/BLK-5A

WHT-4A

RED/WHT-3A

RED/BLK-2A

RED-1A

BLU/BLK-11ABLK/WHT-8A

BLK-7A

BLU-10ARED-27A

WHT-23A

BLK-22A

CR

GROUND STUD

WHT-21A

BRN-GROUND

BL/WH -12A

WH/RD-6A

RD 42A

RED-20C

CR17 #30

BL/RD-39A

BL/WH-C5-13

HARNESSENGINE

#4

CABLE

#2

CABLE

CABLE

#1

#3

CABLE

OPTION

HYDRAULICCOOLER

C5

OR/RD-3

C132PLI

C133PLTGN/BK-H6GR/BK C23-8

RD KS1RD H6

BL/WH-1BL/WH C23-3

RD-4

WT/BK S.P.

WT/RD S.P.

OIL PRESSURE SENDER

OIL TEMP. SENDER

OR/RD-1 C134PWR

WH/RD S.P.

BL/WH S.P.

OR-4 OR-1

HORNJDALARM

C40LS1 STOWED

SPARE

RD-S.P.(CB3)

BL/RD-3

BL/WH-4

RD/WH-1 MOTOR SPEED

BL-4BL/BK-4

SECONDARY BOOM F.C.

PULSE PICKUP

GENERATOR OPTION

L.P./GAS

RPM

STEER LEFT

STEER RIGHT

STARTBRAKE

E.D.C.+

E.D.C.-


AUXILIARY POWER

TILT ALARM

ENGINE POWER

46

BL/RD S.P.

BK/RD S.P.

45

44

43

42

41

38

39

36

35

37

40

BK S.P.

RD CB1

RD S.P.

32

33

29

30

31

27

28

25

24

26

RD-CR2#30

34 BK/WH S.P.

OR/BK-1

GR/WH-1

BL/RD-1

BL/BK-1

BL-1

BK/RD-1

GR/WH-4

BK-1

WH/BK-1

WH-1

WH/RD-1

RD/BK-1

RD -4

RD/BK -4

BK/WH-1

JIB VALVE

IGNITION POWER

12V BATTERY SUPPLY

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE L

PLATFORM ROTATE R

POWER TO PLATFORM

BOOM EXTEND

BOOM RETRACT

PRIMARY BOOM F.C.


SECONDARY BOOM DOWN

SECONDARY BOOM UP

PRIMARY BOOM DOWN


DRIVE ENABLE

PRIMARY BOOM UP

BK S.P.

RD-S.P.(CB1)

GR/BK S.P.

GR S.P.

OR S.P.

OR/BK S.P.

21

22

20

19

18

BK-CR5#30

RD-S.P.(CB2)

16

15

17

14

13

WH-SP

GR/WH S.P.

BL S.P.

BK S.P.

BL/BK S.P.

BK/WH S.P.

WH S.P.

RD/BK S.P.

RD/WH S.P.

WH/BK S.P.

11

10

7

8

9

6

5

4

23

12

C23-4

OR-3

GR-3

OR/BK-4

OR-4

GR/BK-4

BL/WH-4

GR-4

BL-3

BL/BK-3

BK-3

BK/RD-3

WH-3

RD/BK-3

BL/BK-4

WH/RD-4

WH/BK-4

RD/BK-4

RD/WH-4

WH-4

BK/WH-4

BL-4

BK-4

BL/RD-4

GR/WH-3GR/BK-3

OR/BK-3

BL/WH-3

BK/WH-3

RD/WH-3

WH/BK-3

WH/RD-3

ABCD

RD S.P.1RD-3RD-4

WH-2 KEYSWITCH POWER23 WH S.P.

OR/BK-C5-2

WH/RD-C5-23

WH/BK-C5-20

WH- C5-21

WH/RD-C5-14WH/BK-C5-16

RD- 12 VOLT

WH/RD-4

D5

11B-RD/BK-4

BK/RD-C5-9

WH-C5-3+C5-8

RD-CR39#85

BK-CR1#85

BL/RD-C5-10

GR/BK-11B

GR-CR5#85

44B-GR/BK+2B-BL/BK

WH-CR2#87

RD/WH-C5-24

WH-CR39#30

GR-1

GR/BK-1

RD-1

GR/BK-44A



DESCRIPTION







ENGINE START SWITCH


TS63

TS62

CB1

CB2

HM HOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH





PR2

PR1

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

CR17

CR5

CR2

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5




G1

G2

G3 WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE




L2

TS53 LP/GAS SWITCH




TO PLATFORM C-BOX, TERMINAL 27-46(CABLE#1)

(CABLE#2)

(CABLE#3)

CR39 AUX FUNCTION

VOLT METER

G1

OIL TEMP

G3

OIL PRESSURE

G2

WHT-21A

BRN-GROUND

WT/BK-25A WT/RD-26A

RD-CB3 SP


CR23

BK/RD-9B

RD TO LIGHT

BRN GND

RD TO LIGHT

BK/RD-CR23#86 DRIVE LIGHT OPTION

GR-C5-12

BK-C5-5

TS22

WH-C5-17

WH-21B

BK-33B

RD-24B

CR1 CR2

RD-27B

BK-22B

GR-43B

CR5 CR39

RD-CB3 SP

WH-C5-11

CR17

BK-4 OR-H.C.

BK-H.C.

WH-23B

BOOMEXTEND/RETRACTSWITCH

TURNTABLEROTATESWITCH

PLATFORMLEVEL SWITCH

SECONDARY BOOMUP/DOWN SWITCH

PLATFORMROTATESWITCH

ENGINESTARTSWITCH

PRIMARY BOOMUP/DOWN SWITCH

FUNCTIONENABLESWITCH

JIB BOOM SWITCH

AUXILIARY SWITCH

LP/GASSWITCH

CONTROL, 15AENGINE, 15A

HYD COOLER,20A

December 2011

REV A


6 - 80


6 - 79


6 - 816 - 82



1

2

3

4

5

6

7

8


6 - 82 Z-60/34 Part No. 75861

REV AFord Ground Control Box Wiring Diagram(from serial number 5716 to serial number 7226)

TS60

HARNESS:

TO BASE

WIRING

WH-23C

BK-22C

BR-GND STUD

ALL BR WIRESBR

GROUND STUD

RD-27B

CR39

30

8687A

8785

8687

87A85

30

8587

87A86

30

86 8587A

87

30

TS22

GR-C5-12

BK-C5-5

WH-C5-17

WH-21B

BK-33B

RD-24B

CR1 CR2

BK-22B

GR-43B

CR5

WH-C5-11

BK-4

WH-23B

86 8587A

87

30

30

87A85 86

87

RD-CB3 SP

CR17

RD-H.C.

BK-H.C.

BRN GND

KEY SWITCH

B

B1

1

24

3

RD

KS1

GROUND STUD

R3

1K

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

GR/BK-44A

GR/BK-18A

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

RD- 24A

RD- 20A

BK/RD-35A

WH/BK-5AWH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

BK-33A

TS58

TS55

D13

TS52

D14 CB2CB1

R4

CB3

TS59

TS57

TS62

R5

BL/WH-12A

BL/BK-11A

BL-10A

BK/WH-8A

BK-7A

RD/WH-3A

RD/BK-2A

RD-1A

BR (GROUND)

WH-21A

RD-27A

BK-22A

BL/RD-39A

BL/WH-C5-13

TS63

HML2

RD-42AWH-23A

RD-CB2

NC

NC

P1

TS61

TS51

TS53

R3RESISTOR, 1K OHM/2W, #104333

DRIVE LIGHT OPTION RELAY CR23

CHECK ENGINE LED #110395 L2

AUX FUNCTION CR39

RUN/TEST SWITCH TS22

LP/GAS SWITCH TS53



DESCRIPTION







ENGINE START SWITCH


TS63

TS62

CB1

CB2

HMHOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH

RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4

TO PLATFORM C-BOX, TERMINAL 13-19 C4B



PR2

PR1




RPM RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

C1B

C2B

C3B

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5



CB3CIRCUIT BREAKER, OPTION, 20A


G1

G2

G3WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE

C5ENGINE HARNESS

C7BTO PLATFORM C-BOX, TERMINAL 22-23

OIL TEMP. SENDER

OIL PRESSURE SENDER

WH/RD S.P.

WH/BK S.P.

GR/BK S.P.

4

5

7.5

WH-CR39#30

WH/RD-4

D5BK-CR1#86

GR-CR5#85

WH/BK -C5-16

WH/RD -C5-14

BK/RD -C5-9

BL/RD -C5-10



D C B A

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK/WH-C3B-8

BL/WH-C3B-12

OR/BK-C4B-3

GR/BK-C4B-6

GR/WH-C4B-7

BL/RD-4

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4

RD/BK-4

WH/BK-4

WH/RD-4

BL/BK-4

RD/BK-C3B-2

WH-C3B-4

BK/RD-C3B-9

BK-C3B-7

BL/BK-C3B-11

BL-C3B-10

GR-4

RD-4 (12V)

WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

GR-C4B-5

OR-C4B-2

BK-C7B-1

12

3

2

4

5

6

9

8

7

10

11

WH/BK S.P.

RD/WH S.P.

RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

13

14

17

15

16

RD-S.P.(CB2)

BK-CR5#30

18

19

20

22

21

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE R

TURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UP

SECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

12V BATTERY SUPPLY

IGNITION POWER

JIB VALVE

BK/WH-C1B-8

WH -C5-21

RD/BK -4

WH/BK -C5-20

RD -4

WH/RD -C5-23

RD/BK-C1B-2

RD-C1B-1

WH/RD-C1B-6

WH-C1B-4

WH/BK-C1B-5

BK-C1B-7

GR/WH-4

OR/BK -C5-2

BK/RD-C1B-9

BL-C1B-10

BL/BK-C1B-11

BL/RD-C2B-1

GR/WH-C2B-7

OR/BK-C2B-3

BK/WH S.P.34

RD-CR1#30

RD-CR39#85

26

24

25

28

27

31

30

29

33

32

RD S.P.

RD CB1

BK S.P.

40

37

35

36

39

38

41

42

43

44

45

BK/RD S.P.

BL/RD S.P.

46

ENGINE POWER

TILT ALARM

AUXILIARY POWER

GLOW PLUG

E.D.C.-

E.D.C.+

BRAKE

START

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

BL/BK-4

BL-4


BL/WH-4

BL/RD-C4B-1

RD-S.P.(CB3)

SPARE

C40LS1 STOWED

JDALARM

HORN

OR-C2B-2OR-4

BL/WH S.P.

WH/RD S.P.

C134PWRRD-C2B-4RD-4

BL/WH-C1B-12

RD KS1

C133PLT

C132PLI

OR/RD-C4B-4

WH-C5-3+C5-8

BL/WH-4

GR/BK-C2B-6 GR/BK-11B

11B-RD/BK-4

GR-C2B-5

44B-GR/BK+2B-BL/BK

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C3

B

19

/18

CA

BL

ES C

2B

C4

B

3

2

C7

B 1

HC

(BK

)(G

Y)

(BR

)(G

R)


RD-24D


CR23

BR

RD-C4B-12

BK/RD-9B

RD-C4B-10


FUSE 10A

BR-C4B-11

GND

BR-C4B-9

FUNCTIONENABLE

LP/GAS

ENGINESTART

PLATFORMROTATE

JIB BOOM

PLATFORMLEVEL

SECONDARYBOOMUP/DOWN

PRIMARYBOOMUP/DOWN

TURNTABLEROTATE

RUN/TEST

BOOMEXTEND/RETRACT

AUXILIARY

1

1 RESISTOR R1 ADDED AT SERIAL NUMBER 6316


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 83

REV A Ford Ground Control Box Wiring Diagram(from serial number 7227 to serial number 9798)

TS60

HARNESS:

TO BASE

WIRING

WH-23C

BK-22C

BR-GND STUD

ALL BR WIRESBR

GROUND STUD

RD-27B

CR39

30

8687A

8785

8687

87A85

30

8587

87A86

30

86 8587A

87

30

TS22

GR-C5-12

BK-C5-5

WH-C5-17

WH-21B

BK-33B

RD-24B

CR1 CR2

BK-22B

GR-43B

CR5

WH-C5-11

BK-4

WH-23B

86 8587A

87

30

30

87A85 86

87

RD-CB3 SP

CR17

RD-H.C.

BK-H.C.

BRN GND

KEY SWITCH

B

B1

1

24

3

RD

KS1

GROUND STUD

R3

1K

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

GR/BK-44A

GR/BK-18A

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

RD- 24A

RD- 20A

BK/RD-35A

WH/BK-5AWH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

BK-33A

TS58

TS55

D13

TS52

D14 CB2CB1

R4

CB3

TS59

TS57

TS62

R5

BL/WH-12A

BL/BK-11A

BL-10A

BK/WH-8A

BK-7A

RD/WH-3A

RD/BK-2A

RD-1A

BR (GROUND)

WH-21A

RD-27A

BK-22A

BL/RD-39A

BL/WH-C5-13

TS63

HML2

RD-42AWH-23A

RD-CB2

NC

NC

P1

TS61

TS51

TS53



CHECK ENGINE LED/INCANDESCENT LAMP L2

AUX FUNCTION CR39


LP/GAS SWITCH TS53



DESCRIPTION







ENGINE START SWITCH


TS63

TS62

CB1

CB2

HMHOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH





PR2

PR1




RPM RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

C1B

C2B

C3B

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5





G1

G2

G3WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE

C5ENGINE HARNESS


OIL TEMP. SENDER

OIL PRESSURE SENDER

WH/RD S.P.

WH/BK S.P.

GR/BK S.P.4

5

7.5

WH-CR39#30

WH/RD-4

D5BK-CR1#86

GR-CR5#85

WH/BK -C5-16

WH/RD -C5-14

BK/RD -C5-9

BL/RD -C5-10



D C B A

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK/WH-C3B-8

BL/WH-C3B-12

OR/BK-C4B-3

GR/BK-C4B-6

GR/WH-C4B-7

BL/RD-4

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4

RD/BK-4

WH/BK-4

WH/RD-4

BL/BK-4

RD/BK-C3B-2

WH-C3B-4

BK/RD-C3B-9

BK-C3B-7

BL/BK-C3B-11

BL-C3B-10

GR-4

RD-4 (12V)

WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

GR-C4B-5

OR-C4B-2

BK-C7B-1

12

3

2

4

5

6

9

8

7

10

11

WH/BK S.P.

RD/WH S.P.

RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

13

14

17

15

16

RD-S.P.(CB2)

BK-CR5#30

18

19

20

22

21

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE R

TURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UP

SECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

12V BATTERY SUPPLY

IGNITION POWER

JIB VALVE

BK/WH-C1B-8

WH -C5-21

RD/BK -4

WH/BK -C5-20

RD -4

WH/RD -C5-23

RD/BK-C1B-2

RD-C1B-1

WH/RD-C1B-6

WH-C1B-4

WH/BK-C1B-5

BK-C1B-7

GR/WH-4

OR/BK -C5-2

BK/RD-C1B-9

BL-C1B-10

BL/BK-C1B-11

BL/RD-C2B-1

GR/WH-C2B-7

OR/BK-C2B-3

BK/WH S.P.34

RD-CR1#30

RD-CR39#85

26

24

25

28

27

31

30

29

33

32

RD S.P.

RD CB1

BK S.P.

40

37

35

36

39

38

41

42

43

44

45

BK/RD S.P.

BL/RD S.P.

46

ENGINE POWER

TILT ALARM

AUXILIARY POWER

GLOW PLUG

E.D.C.-

E.D.C.+

BRAKE

START

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

BL/BK-4

BL-4


BL/WH-4

BL/RD-C4B-1

RD-S.P.(CB3)

SPARE

C40LS1 STOWED

JDALARM

HORN

OR-C2B-2OR-4

BL/WH S.P.

WH/RD S.P.

C134PWRRD-C2B-4RD-4

BL/WH-C1B-12

RD KS1

C133PLT

C132PLI

OR/RD-C4B-4

WH-C5-3+C5-8

BL/WH-4


11B-RD/BK-4

GR-C2B-5

44B-GR/BK+2B-BL/BK

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C3

B

19

/18

CA

BL

ES C

2B

C4

B

3

2

C7

B 1

HC

(BK

)(G

Y)

(BR

)(G

R)


RD-24D


CR23

BR

RD-C4B-12

BK/RD-9B

RD-C4B-10


FUSE 10A

BR-C4B-11

GND

BR-C4B-9

FUNCTIONENABLE

LP/GAS

ENGINESTART

PLATFORMROTATE

JIB BOOM

PLATFORMLEVEL


PRIMARYBOOMUP/DOWN

TURNTABLEROTATE

RUN/TEST

BOOMEXTEND/RETRACT

AUXILIARY

RESISTOR R3 REMOVED AT SERIAL NUMBER 79241

12

LED 2 CHANGED TO INCANDESCENT LAMP AT SERIAL NUMBER 90662

3

DRIVE LIGHT OPTION MOVED AT SERIAL NUMBER 103883

86 8587A

87

30

RD-24D


CR23

BR

RD-C4B-12

BK/RD-9B

RD-C4B-10

FUSE 10A

BR-C4B-11

GND

BR-C4B-9

WH-CR2#86

WH-ISM#9

RD-TB134(A)C

BR-GND

BK-C3B-10



U34

WL


6 - 846 - 83



6 - 856 - 86

Ford Ground Control Box Wiring Diagram(from serial number 9799)


1

2

3

4

5

6

7

8


6 - 86 Z-60/34 Part No. 75861

REV AFord Ground Control Box Wiring Diagram(from serial number 9799)

TS60

HARNESS:

TO BASE

WIRING

WH-23C

BK-22C

BR-GND STUD

ALL BR WIRESBR

GROUND STUD

RD-27B

CR39

30

8687A

8785

8687

87A85

30

8587

87A86

30

86 8587A

87

30

TS22

GR-C5-12

BK-C5-5

WH-C5-17

WH-21B

BK-33B

RD-24B

CR1 CR2

BK-22B

GR-43B

CR5

WH-C5-11

BK-4

WH-23B

86 8587A

87

30

30

87A85 86

87

RD-CB3 SP

CR17

RD-H.C.

BK-H.C.

BRN GND

KEY SWITCH

B

B1

1

24

3

RD

KS1

GROUND STUD

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

GR/BK-44A

GR/BK-18A

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

RD- 24A

RD- 20A

BK/RD-35A

WH/BK-5AWH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

BK-33A

TS58

TS55

D13

TS52

D14 CB2CB1

R4

CB3

TS59

TS57

TS62

R5

BL/WH-12A

BL/BK-11A

BL-10A

BK/WH-8A

BK-7A

RD/WH-3A

RD/BK-2A

RD-1A

BR (GROUND)

WH-21A

RD-27A

BK-22A

BL/RD-39A

BL/WH-C5-13

TS63

HML2

RD-42AWH-23A

RD-CB2

NC

NC

P1

TS61

TS51

TS53



CHECK ENGINE LIGHT L2

AUX FUNCTION CR39


LP/GAS SWITCH TS53



DESCRIPTION







ENGINE START SWITCH


TS63

TS62

CB1

CB2

HMHOUR METER

KS1

TS51

TS52

TS57

TS55

P1

LABEL

TS60

TS59

TS61

TS58


JIB BOOM SWITCH

AUXILIARY SWITCH

KEY SWITCH





PR2

PR1




RPM RELAY

IGN./POWER RELAY

IGN/START RELAY

SERVICE HORN RELAY

C1B

C2B

C3B

CR17

CR4

CR5

CR2

CR3

CR1

DESCENT BUZZER

TRAVEL BUZZER

SERVICE HORN

H4

H3

H2

R5





G1

G2

G3WATER TEMP. GAGE

OIL PRESSURE GAGE

VOLT METER GAGE

C5ENGINE HARNESS


OIL TEMP. SENDER

OIL PRESSURE SENDER

WH/RD S.P.

WH/BK S.P.

GR/BK S.P.

4

5

7.5

WH-CR39#30

WH/RD-4

D5BK-CR1#86

GR-CR5#85

WH/BK -C5-16

WH/RD -C5-14

BK/RD -C5-9

BL/RD -C5-10



D C B A

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK/WH-C3B-8

BL/WH-C3B-12

OR/BK-C4B-3

GR/BK-C4B-6

GR/WH-C4B-7

BL/RD-4

BK-4

BL-4

BK/WH-4

WH-4

RD/WH-4

RD/BK-4

WH/BK-4

WH/RD-4

BL/BK-4

RD/BK-C3B-2

WH-C3B-4

BK/RD-C3B-9

BK-C3B-7

BL/BK-C3B-11

BL-C3B-10

GR-4

RD-4 (12V)

WH-CR2#87

GR/BK-4

OR-4

OR/BK-4

GR-C4B-5

OR-C4B-2

BK-C7B-1

12

3

2

4

5

6

9

8

7

10

11

WH/BK S.P.

RD/WH S.P.

RD/BK S.P.

WH S.P.

BK/WH S.P.

BL/BK S.P.

BK S.P.

BL S.P.

GR/WH S.P.

WH-SP

13

14

17

15

16

RD-S.P.(CB2)

BK-CR5#30

18

19

20

22

21

OR/BK S.P.

OR S.P.

GR S.P.

GR/BK S.P.

RD-S.P.(CB1)

BK S.P.

PRIMARY BOOM UP

DRIVE ENABLE

TURNTABLE ROTATE R

TURNTABLE ROTATE L

PRIMARY BOOM DOWN

SECONDARY BOOM UP

SECONDARY BOOM DOWN


PRIMARY BOOM F.C.

BOOM RETRACT

BOOM EXTEND

POWER TO PLATFORM

PLATFORM ROTATE R

PLATFORM ROTATE L

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

12V BATTERY SUPPLY

IGNITION POWER

JIB VALVE

BK/WH-C1B-8

WH -C5-21

RD/BK -4

WH/BK -C5-20

RD -4

WH/RD -C5-23

RD/BK-C1B-2

RD-C1B-1

WH/RD-C1B-6

WH-C1B-4

WH/BK-C1B-5

BK-C1B-7

GR/WH-4

OR/BK -C5-2

BK/RD-C1B-9

BL-C1B-10

BL/BK-C1B-11

BL/RD-C2B-1

GR/WH-C2B-7

OR/BK-C2B-3

BK/WH S.P.34

RD-CR1#30

RD-CR39#85

26

24

25

28

27

31

30

29

33

32

RD S.P.

RD CB1

BK S.P.

40

37

35

36

39

132

41

134

43

44

45

BK/RD S.P.

BL/RD S.P.

46

ENGINE POWER

TILT ALARM

AUXILIARY POWER

GLOW PLUG

E.D.C.-

E.D.C.+

BRAKE

START

STEER RIGHT

STEER LEFT

RPM

L.P./GAS

GENERATOR OPTION

PULSE PICKUP

SECONDARY BOOM F.C.

BL/BK-4

BL-4


BL/WH-4

BL/RD-C4B-1

RD-S.P.(CB3)

SPARE

C40LS1 STOWED

JDALARM

HORN

OR-C2B-2OR-4

BL/WH S.P.

WH/RD S.P.

C134PWRRD-C2B-4RD-4

BL/WH-C1B-12

RD KS1

C133PLT

C132PLI

OR/RD-C4B-4

WH-C5-3+C5-8

BL/WH-4


11B-RD/BK-4

GR-C2B-5

44B-GR/BK+2B-BL/BK

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C3

B

19

/18

CA

BL

ES C

2B

C4

B

3

2

C7

B 1

HC

(BK

)(G

Y)

(BR

)(G

R)


RD-24D


CR23

BR

RD-C4B-12

BK/RD-9B

RD-C4B-10


FUSE 10A

BR-C4B-11

GND

BR-C4B-9

FUNCTIONENABLE

LP/GAS

ENGINESTART

PLATFORMROTATE

JIB BOOM

PLATFORMLEVEL


PRIMARYBOOMUP/DOWN

TURNTABLEROTATE

RUN/TEST

BOOMEXTEND/RETRACT

AUXILIARY

D2

D4 D3

D10

D28

H6

U33

PLATFORM LOADC32

BL/WH-132D - C32-3

RD-C32-1RD-134BRD-TS51 - C32-6

BR - GND - C32-12

RD-H6+ - C32-1


BK-22C - C32-4BK-C7-1 - C32-5

GR/BK-133B - C32-8 WH-CR2#86

WH-ISM#9

RD-TB134(A)C

BR-GND

BK-C3B-10



WORK LIGHTS OPTION RELAY

30

87A85 86

87

RD-CB3 SP

CR45

WH - W.L.

WH-C21IGN

BR GND

U34

WORK LIGHTS OPTION RELAY Cr45

LOAD SENSE TIME DELAY RELAY (10A) U34

134ARD-U34-2

RD-H6+

WL

1 DRIVE LIGHT OPTION REMOVED FROM TERMINAL 9ADDED TO GROUND BOX AT SERIAL NUMBER 10388.

1

1


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 87

REV A Ford Platform Control Box Wiring Diagram(before serial number 7227)

CR30

TS48-9

HI/L0 RPM SWITCH


CR27




SWITCH TOGGLE SPDT 2POS MNT

CHASSIS TILT LED

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

L4

TS7

27378

56457

13037

13037

56298

13037

13037

16397

66813, 66816

66812, 94506

PART NUMBER







HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

P2

JC3

COMPONENT INDEX

JC1

JC2

56457

13038

13037

42730

75565

56298

62391

62390

(SPLICE TO R40LS1)

OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)

+

4

2

1

3

5

6

7

4

2

1

3

5

6

7C

29

MS

RD

/WH

J1

-8

C2

7A

UX

RD

C1

P-1

C1

7JU

GR

C4

P-5

C1

9JS

VG

R/W

HJIB

C1

8JD

GR

/BK

C4

P-6

ROTATEPLATFORM

P3HORN

TS9

PLATFORMLEVEL

WH

TS7

CE SEE DETAIL A

WH

PUMPAUXILIARY

WH

TS1TS14

SPEEDDRIVE

HIGH/LOW

5

GR

-43

RD

OR

/BK

-15

OR

-14

RD

J1

-1B

KJ1

-2

BR

NJ1

-12

OR

J1

-11

3

2

4

JC2

1

7

6

BK

-7

BK

/WH

-8

BR

NJ1

- 10

WH

- 24

TS13

JC1

RETRACTEXTEND/BOOM

PRIMARY

WH

-24

OR

J1

-9

YE

LJ1

- 3

BK

- 22

BL

/BK

-DE

2J1

-7

BL

/WH

-DE

1J1

-6

BL

/ RD

-DE

3J1

-16

WH

-24

DR

IVE

LT

BK

/RD

-C3

P-9

L1

+

TS15DRV.ENA

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

START

TS2 TS4

RPMHIGH/LOW

P2

EMERGENCY STOP

RD

/BK

H1

WH

-24

BK

/RD

- 35

RD

L4

JC3

WH

J1

-5B

K-2

2

WH

J1

- 5B

LJ1

-4

BR

NJ1

-14

OR

J1

-13

WH

- 23

RD

-TILT

C1

9JS

VG

R/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GR/BK

GR

JIB

TS8

WH

-JIB

WH

-JIB

BR

N

WH

-24

CR13

DRIVE LITE

10 AMP FUSE

GR

/WH

-45

TS17

(OPTION)GENERATOR

RD

RD

WL

1

RD

WL

2

WORK /

TS48

BL

/RD

-39

FUEL SELECT

TS3

RD

D4

0

RE

D/B

LK

-28

H1

TILTALALRM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2C

41

RP

MO

R/B

KC

2P

-3C

30

ED

C+

WH

C1

P-4

C1

PB

UR

DC

3P

-1C

31

ED

C-

WH

/BK

C1

P-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11C

3P

BF

RD

/WH

C3

P-3

C3

6S

TC

BL

C1

P-1

0

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

BR

N

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6D

RIV

ELT

BK

/RD

C3

P-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

RD

P2

RD

H1

P2

6B

AT

BK

DL

ITE

BK

/RD

C3

P-9

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/ R

DC

2P

- 1

DRIVE / STEER

PRIMARY BOOMUP / DOWN

TURNTABLEROTATE

WH

-TS

4

WH

-24

WH

-TS

47

REMOVE FORGENERATOR OPTION

START

TS2

GR

/WH

-45

TS17

(OPTION)GENERATOR

RD

GND

1 GENERATOR OPTION CHANGEDAT SERIAL NUMBER 5716 1


6 - 88

Ford Platform Control Box Wiring Diagram(before serial number 7227)

6 - 87


6 - 89

Ford Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)

6 - 90


1

2

3

4

5

6

7

8


6 - 90 Z-60/34 Part No. 75861

REV AFord Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)

TS48-9

HI/L0 RPM SWITCH





CHASSIS TILT LED

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

L4

TS7

27378

56457

13037

13037

56298

13037

13037

16397

66813, 66816

66812, 94506

PART NUMBER







HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

P2

JC3

COMPONENT INDEX

JC1

JC2

56457

13038

13037

42730

75565

56298

62391

62390

CE SEE DETAIL A

+

C2

9M

SR

D/W

HJ1

-8

C2

7A

UX

RD

C1

P-1

C1

7JU

GR

C4

P-5

C1

9JS

VG

R/W

HJIB

C1

8JD

GR

/BK

C4

P-6

ROTATEPLATFORM

P3HORN

TS9

PLATFORMLEVEL

WH

TS7WH

PUMPAUXILIARY

WH

TS1TS14

SPEEDDRIVE

HIGH/LOW

GR

-43

RD

OR

/BK

-15

OR

-14

RD

J1

-1B

KJ1

-2

BR

NJ1

-12

OR

J1

-11

JC2

BK

-7

BK

/WH

-8

BR

NJ1

-10

WH

-24

TS13

JC1

RETRACTEXTEND/BOOM

PRIMARY

WH

-24

OR

J1

-9

WH

/BK

J1

-3

BK

-22

BL

/BK

-DE

2J1

-7

BL

/WH

-DE

1J1

-6

BL

/RD

-DE

3J1

-16

WH

-24

DR

IVE

LTB

K/R

D-C

3P

-9

L1

+

TS15DRV.ENA

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

START

TS2 TS4

RPMHIGH/LOW

P2

EMERGENCY STOP

RD

/BK

H1

WH

-24

BK

/RD

-35

RD

L4

JC3

BK

-22

WH

-23

RD

-TILT

C1

9JS

VG

R/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GR/BK

GR

JIB

TS8

WH

-JIB

WH

-JIB

BR

N

WH

-24

CR13

DRIVE LITE

10 AMP FUSE

GR

/WH

-45

TS17

(OPTION)GENERATOR

RD

RD

WL

1

RD

WL

2

WORK /

TS48

BL

/RD

-39

FUEL SELECT

TS3

RD

DRIVE / STEER


TURNTABLEROTATE

JC21

6

JC11

6

1

6

BL

/WH

J1

-5

BL

/WH

J1

-5

WH

/RD

J1

-4

BR

NJ1

-14

OR

J1

-13

JC

3-1

JC

3-2

JC

3-3

JC

3-4

JC

3-5

JC

1-1

JC

1-2

JC

1-4

JC

2-1

JC

2-2

JC

2-3

JC

2-4

D4

0

RE

D/B

LK

-28

H1

TILTALALRM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-1

1C

40

LS

1O

RC

2P

-2C

12

SB

FB

L/W

HC

3P

-12

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4C

1P

BU

RD

C3

P-1

C3

1E

DC

-W

H/B

KC

1P

-5C

2P

BD

RD

/BK

C3

P-2

C3

7S

TC

CB

L/B

KC

1P

-11

C3

PB

FR

D/W

HC

3P

-3C

36

ST

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

BR

N

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6D

RIV

ELT

BK

/RD

C3

P-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

RD

P2

RD

H1

P2

6B

AT

BK

DL

ITE

BK

/RD

C3

P-9

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

CR30


CR27

(SPLICE TO R40LS1)

OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 91

REV A Ford Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9798)

CR30

TS48-9

HI/L0 RPM SWITCH

DETAIL A: LIFT/DRIVE OPTION FROM SERIAL NUMBER 9697

CR27





CHASSIS TILT LED

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

L4

TS7

27378

56457

13037

13037

56298

13037

13037

16397

66813, 66816

66812, 94506

PART NUMBER







HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

P2

JC3

COMPONENT INDEX

JC1

JC2

56457

13038

13037

42730

75565

56298

62391

62390

(SPLICE TO R40LS1)

OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)

CE SEE DETAIL A

+

C2

9M

SR

D/W

HJ1

-8

C2

7A

UX

RD

C1

P-1

C1

7JU

GR

C4

P-5

C1

9JS

VG

R/W

HJIB

C1

8JD

GR

/BK

C4

P-6

ROTATEPLATFORM

P3HORN

TS9

PLATFORMLEVEL

WH

TS7WH

PUMPAUXILIARY

WH

TS1TS14

SPEEDDRIVE

HIGH/LOWG

R-4

3

RD

OR

/BK

-15

OR

-14

RD

J1

-1B

KJ1

-2

BR

NJ1

-12

OR

J1

-11

JC2

BK

-7

BK

/WH

-8

BR

NJ1

- 10

WH

-24

TS13

JC1

RETRACTEXTEND/BOOM

PRIMARY

WH

-24

OR

J1

-9

WH

/BK

J1

-3

BK

-22

BL

/BK

-DE

2J1

-7

BL

/WH

-DE

1J1

-6

BL

/ RD

-DE

3J1

-16

WH

-24

DR

IVE

L TB

K/R

D-C

3P

-9

L1

+

TS15DRV.ENA

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

START

TS2 TS4

RPMHIGH/LOW

P2

EMERGENCY STOP

RD

/BK

H1

WH

-24

BK

/ RD

-35

RD

L4

JC3

BK

-22

WH

-23

RD

-TI LT

C1

9JS

VG

R/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GR/BK

GR

JIB

TS8

WH

-JIB

WH

-JIB

BR

N

WH

-24

CR13

DRIVE LITE

10 AMP FUSE

GR

/WH

-45

TS17

(OPTION)GENERATOR

RD

RD

WL

1

RD

WL

2

WORK /

TS48

BL

/RD

-39

FUEL SELECT

TS3

RD

DRIVE / STEER


TURNTABLEROTATE

JC21

6

JC11

6

1

6

BL

/WH

J1

- 5

BL

/WH

J1

-5

WH

/RD

J1

-4

BR

NJ1

-14

OR

J1

- 13

JC

3-1

JC

3-2

JC

3-3

JC

3-4

JC

3-5

JC

1-1

JC

1-2

JC

1-4

JC

2-1

JC

2-2

JC

2-3

JC

2-4

CR14 JIB TIME DELAY RELAY

JIB TIME DELAY

TILT ALARMH1

C1

COMPONENT INDEX

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-1

1C

40

LS

1O

RC

2P

-2C

12

SB

FB

L/W

HC

3P

-12

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4C

1P

BU

RD

C3

P-1

C3

1E

DC

-W

H/B

KC

1P

-5C

2P

BD

RD

/BK

C3

P-2

C3

7S

TC

CB

L/B

KC

1P

-11

C3

PB

FR

D/W

HC

3P

-3C

36

ST

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

DR

IVE

LTB

K/R

DC

3P

-9

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/B

KC

2P

-6

TS

48

- WL

2R

DC

2P

- 11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

P1

34

PW

RR

D-H

1+

RD

-E-S

TO

P

BR

JC

3B

RG

ND

C1

9JS

VG

R/W

HC

4P

-7C

19

JS

VG

R/W

HT

S7

RD LS18 CABLE

WHB

K

GR/WH +

RD OUTPUT

BR -

GR/WH

RD

GR

/WH

CR

13

-#8

6G

R/W

H

P1

34

PW

RR

D

GR/WHCR14

C1

RD

BR

BR

JIB

BK C1P-12

BK

C1

34

PW

RR

DL

S1

8

CR30

DETAIL A: LIFT/DRIVE OPTION BEFORE SERIAL NUMBER 9697

CR27

(SPLICE TO R40LS1)

CP2-2 OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)


6 - 926 - 91

Ford Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9798)

December 2011


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 93

REV B Ford Platform Control Box Wiring Diagram(from serial number 9799)

CR30

TS48-9

HI/L0 RPM SWITCH


CR27





CHASSIS TILT LED

DRIVE ENABLE SWITCH

JIB UP/DOWN SWITCH


TS15

TS17

TS13

TS9

TS8

L4

TS7

27378

56457

13037

13037

56298

13037

13037

16397

66813, 66816

66812, 94506

PART NUMBER







HORN SWITCH

START ENGINE SWITCH

AUXILIARY SWITCH

DRIVE ENABLE LED

P3

TS2

TS3

TS4

TS1

L1

P2

JC3

COMPONENT INDEX

JC1

JC2

56457

13038

13037

42730

75565

56298

62391

62390

(SPLICE TO R40LS1)

OR R40LS1


WH/RD C32BRK

(SPLICE TO C32BRK)

WH TS7WH TS1

BRN BATGND

(GND STUD)

CE SEE DETAIL A

+

C2

9M

SR

D/W

HJ1

-8

C2

7A

UX

RD

C1

P-1

C1

7JU

GR

C4

P-5

C1

9JS

VG

R/W

HJIB

C1

8JD

GR

/BK

C4

P-6

ROTATEPLATFORM

P3HORN

TS9

PLATFORMLEVEL

WH

TS7WH

PUMPAUXILIARY

WH

TS1TS14

SPEEDDRIVE

HIGH/LOW

GR

-43

RD

OR

/BK

-15

OR

-14

RD

J1

-1B

KJ1

-2

BR

NJ1

-12

OR

J1

-11

JC2

BK

-7

BK

/WH

-8

BR

NJ1

-10

WH

- 24

TS13

JC1

RETRACTEXTEND/BOOM

PRIMARY

WH

-24

OR

J1

-9

WH

/BK

J1

- 3

BK

- 22

BL

/BK

-DE

2J1

-7

BL

/ WH

-DE

1J1

-6

BL

/ RD

-DE

3J1

-16

WH

-24

DR

I VE

LT

BK

/RD

- C3

P-9

L1

+

TS15DRV.ENA

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

START

TS2 TS4

RPMHIGH/LOW

P2

EMERGENCY STOP

RD

/BK

H1

WH

-24

BK

/RD

-35

RD

L4

JC3

BK

-22

WH

-23

RD

-TI LT

C1

9JS

VG

R/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GR/BK

GR

JIB

TS8

WH

-JIB

WH

-JIB

BR

N

WH

-24

CR13

DRIVE LITE

10 AMP FUSE

GR

/WH

-45

TS17

(OPTION)GENERATOR

RD

RD

WL

1

RD

WL

2

WORK /

TS48

BL

/RD

-39

FUEL SELECT

TS3

RD

DRIVE / STEER


TURNTABLEROTATE

JC21

6

JC11

6

1

6

BL

/WH

J1

- 5

BL

/WH

J1

-5

WH

/ RD

J1

-4

BR

NJ1

-14

OR

J1

- 13

JC

3-1

JC

3-2

JC

3-3

JC

3-4

JC

3- 5

JC

1-1

JC

1-2

JC

1-4

JC

2-1

JC

2-2

JC

2-3

JC

2-4

D4

0

RE

D/B

LK

-28

H1

TILTALARM

RE

D-T

ILT

D3

9

BR

N

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3P

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

13

LE

DB

L/R

DD

RE

BB

L/B

K

DR

EA

BL

/WH

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

8

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

HJC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

C2P

9

1

J1

RD

/BK

L4

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11S

BD

BL

/BK

C3

P-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2C

41

RP

MO

R/B

KC

2P

-3C

30

ED

C+

WH

C1

P-4

C1

PB

UR

DC

3P

-1C

31

ED

C-

WH

/BK

C1

P-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11C

3P

BF

RD

/WH

C3

P-3

C3

6S

TC

BL

C1

P-1

0

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

J2

1

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C1

7JU

GR

C4

P-5

C4

5G

EN

GR

/WH

C2

P-7

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

P2

6B

AT

BK

JD

AL

AR

MG

R/ B

KC

2P

- 6

TS

48

- WL

2R

DC

2P

- 11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

47

00

R2

0

P1

34

PW

RR

D-H

1+

RD

-E-S

TO

P

BR

JC

3B

RG

ND

C1

9JS

VG

R/W

HC

4P

-7C

19

JS

VG

R/W

HT

S7

LOAD SENSE OPTION

P1

34

PW

RR

D

RD

-H1

+

BR

GN

D

P2

6E

ST

PB

KE

-ST

OP

U35

R2

6E

ST

PB

KC

9P

-1

5

NO23

COM

RD LS18 CABLE

D88

D89

WHB

K

GR/WH +

RD OUTPUT

BR -

GR/WH

RD

GR

/WH

CR

13

-#8

6G

R/W

H

P1

34

PW

RR

D

GR/WHCR14

C1

RD

BR

BR

JIB

HARNESSPBOX WIRING

DR

IVE

LTB

K/R

DC

3P

-9

CR14 JIB TIME DELAY RELAY

JIB TIME DELAY

TILT ALARMH1

C1

COMPONENT INDEX P2

4F

SW

H

1

1 WORK LIGHT OPTION REMOVED FROMPLATFORM BOX AT SERIAL NUMBER 10388

December 2011

REV A


6 - 946 - 93

Ford PlatformControl Box Wiring Diagram(from serial number 9799)


6 - 95

Engine Wire HarnessFord LRG-425 EFI Models

6 - 96


1

2

3

4

5

6

7

8


6 - 96 Z-60/34 Part No. 75861

REV A

351 BR-W 18

359 GY-R 18

358 LG-BK 18

TWR

B

A

C

MAP_CONN

361 R 16 361 R 16 361 R 16

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

ACT

151 LB-BK

307 BK-Y 18

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

34 GROUND

25 IVS

14 FPP1

39 R-W 18570 BK-W 1616 WATER TEMP

WATERTEMP

30AF1

16 R-LG 181 VSW

5AF216 R-LG 18

20AF3

ECT

361 R 12361 R 14361 R 14

351 BR-W 18

359 GY-R 18

351 BR-W 18

359 GY-R 1833 ANA RTN

31 VREF

9 VBATT

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 1838 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM

41 EGR REC360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

361 R 16

16 R-LG 18

307 BK-Y 18

351 BR-W 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

354 LG-R 18

151 LB-BK 18

198 DG-O 18

18 O-Y 18

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

358 LG-BK 18

743 GY 18

145 VOLT REF

3VSW

23EGR RECIRC

22EGR PWM

2POWER GROUND

1POWER GROUND

21EGR

20MAP

27IAT

16FPP 2

15FPP 1

11INJ 5

6INJ +

7INJ 1

12INJ 6

28ECT

17IVS

13ANA_RTN

18AUX ANA PU1

19AUX ANA PD1

31AUX OUT 2

8INJ 3

9INJ 4

10INJ 2

J1 BLACK

74 GY-LB 1824EGO 1

452 GY-R 18

282 DB-O 18

349 DB 18

350 GY 18

34CAM +

35CAM -

32CRANK +

33CRANK -

30KNK -

29KNK +

26EGO 3

570 BK-W 16

570 BK-W 16

351 BR-W 18

359 GY-R 18

354 LG-R 18

358 LG-BK 18

361 R 16

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

359 GY-R 18

743 GY 18

16 R-LG 18

151 LB-BK

570 BK-W 16

CRANK361 R 14361 R 16

361 R 16

5VBAT

VBAT4

392 R-LG 1825EGO 2

570 BK-W 16

359 GY-R 18

74 GY-LB 18

361A R 16

392 R-LG 18

361A R 16

359 GY-R 18

570 BK-W 16

O2 SENSOR

O2SENSOR

361 R 14

CAM

307 BK-Y 18

359 GY-R 18

361A R 16

851 Y-R 18

850 Y-BK 18

LOCKOFF SOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

361A R 16

172 LB-R 18

169 LG-BK 18

148 Y-R 18

317 GY-O 18

15 R-Y 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

77 DB-Y 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

238 DG-Y 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

926A LB-O 18

242 DG 18

342 LG-P 18

570 BK-W 16

TWR

B

A

WPTWR2_GY

TWR

A

B

J2 GREY

33OVERSPEED

5AUX OUT 1

13COIL 4

3COIL 3

2COIL 2

1COIL 1

4SPK PWR GROUND

35RS 232 RX

34RS 232 TX

21RS 485 -

20RS 485 +

19CAN -

18CAN +

12ROAD SPEED -

11ROAD SPEED +

17GOV SELECT 2

16GOV SELECT 1

10FUEL PUMP MON

8TACH

7OIL PRESSURE

6BRAKE SWITCH

31TPS2

30TPS1

23FUEL LOCKOFF

22STARTER LOCKOUT

14FUEL SELECT

15AUX ANA PU2

27MIL

26GASEOUS TRIM

29DBW -

28DBW +

24COIL 5

25COIL 6

32RELAY CONTROL

9FUEL PUMP

COIL 2

VBAT

COIL 11

12

2

3

3

15 R-Y 18

926A LB-O 18

172 LB-R 18

169 LG-BK 18

148 Y-R 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

238 DG-Y 18

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18SHDA

E

F

B

C

D

MTRSHD6TWR

D

C

B

F

E

A

MTRTWR6

2

3

1

4

5

6

THROTTLE

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

351 BR-W 18

359 GY-R 18351 BR-W 18

359 GY-R 18

FPP_COMMD

C

A

TWR

RTN

5V

RX

BTX

351 BR-W 18

359 GY-R 18

458 O-BK 18

669 DG-W 18

87A85

86 30

87

458 O-BK 18

342 LG-P 18

15 STARTER IN (INTERUPT)

13 STARTER CONTROL

39 STARTER IN (AUTOCRANK)32 R-LB 16

32 R-LB 16

32 R-LB 16

5 FUEL PUMP787A PK-BK 16

87A85

86 30

87

16 R-LG 18

342 LG-P 18

361 R 14

87A85

86 30

87

15AF4

FUEL PUMPRELAY

787A PK-BK 16

361 R 1615AF5

21 AUX OUT1

20 RS 232+

18 RS 232-

3 RS 485-

11 RS 485+

172 LB-R 18

169 LG-BK 18

148 Y-R 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 184 BRAKE

26 OIL PRES

2 TACH

6 MIL

7 FUEL SELECT

10 AUX ANA PU2

24 GOV SELECT 1

23 GOV SELECT 2

35 ROADSPEED +

36 ROADSPEED -

30 OVERSPEED

28 CAN +

29 CAN -

570 BK-W 16

361A R 16

459 O-LG 18

662 DG-P 18

MTRSHD4

TWR

D

C

B

A

MTRTWR4

PLUG (GROUND)

PLUG (RELAY POWER)

PLUG (CAN +)

PLUG (CAN -)

SHD

D

B

A

C

253 DG-W 18OIL PRESSURE

361 R 16

STARTERRELAY

POWERRELAY

FORD42 PIN

CONNECTOR

Engine Wire HarnessFord LRG-425 EFI Models


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 97

REV A Engine Wire HarnessFord DSG-423 EFI Models (before serial number 6810)

R/W 18

W/BK 18

PK/LG 18

BR/Y 16

BK/LG 18

O 18

LB/BK 18

GY/W 18

R/LG 18

W/LB 18

LG/W

DG/W 18

DG/BK

DBL 18

LG/BK 18

GY/R 18

DG/P

W/PK 18

W/PK 18

GY/R 18

(FPP2)

T/GN 18

R/BK 18

BK/R 16

GY/O 18

R/T 16

R/Y 18

BK/W 16

BK/R 16

LB/O 18

W 16

T 16

BK/LB 18

R/T 16

BR/LB 16

BK/W 16

DG 18

Y/W 18

Y/R 18

LB/Y 18

P/LB 18

T/Y 18

BK/O 18

LG/R 18

GY 18

W/R 18

BK/Y 18

DB/W 18

T/LB 18

GY 18

GY/R 18

LB/R 18

GY/Y 18

BR/W 18

W/LG 18

GY/LB 18

BK/W 16

Y/BK 18

Y/RD 18

RD/T 14

DG 18

O 18

GY/R 18

GY 18

BR/W 18

FP REC

LB/DG 18

DG/P 18

R/LG 18

Y/BK 18

O/LG 18

FUEL PUMP

LG/P 18

(FUEL PUMP)

DG/P 18

Y/DB 18

DB/O 18

DG/O 18

O/LG 18

W/BK 18

R 16

Y/RD 18

GY/R 18

8CAN -

5UNUSED

25V REF

1ANA RTN

3PC TX

4PC RX

6UNUSED

7CAN +

DIAGNOSTIC CONNECTOR

82DBW -

79VBAT

73RELAY

70INJ6 LS

67INJ4 LS

64INJ1 LS

61EGOH 2

55PC TX

52KNOCK -

43TACH

37ECT

34GOV 1

315V EXT 2

28CAM -

25CRANK +

22EGO2

195V EXT 1

16CAN2 -

10UEGOP

81GROUND

80DBW +

69GROUND

68INJ5 LS

72STARTER

74MIL

75UEGO H

77LOCKOFF

60VBAT

56PC RX

62EGOH 1

63INJ HS

65INJ2 LS

44VSW

47TPS 1

48TPS 2

51KNOCK +

53FPP1

325V RTN 2

33PULSE IN

36IAT

205V RTN

21EGO1

23MAP

26CRANK -

29SPEED +

27CAM +

17CAN2 +

14CAN1 +

15CAN1 -

9UEGOC

8UEGOS

11UEGPR

30SPEED -

66INJ3 LS

88AUX PWM4 REC

85AUX PWM1

76AUX PWM7

58KNOCK 2-

49(FUELSELECT)AUX DIG1

46AUX ANA PUD1

40(IVS) AUX ANA PU3

13(FRP) AUX ANA PD2

7SPK_COIL3B

4SPK_GND

1SPK_COIL1A

87AUX PWM2

83AUX PWM5 REC

84AUX PWM5

86AUX PWM4

89AUX PWM3 REC

71AUX PWM8

59VBAT PROT

57KNOCK 2+

45AUX ANA PUD2

50AUX DIG 2

35OIL PRESS

38(FRT) AUX ANA PU1

39(LPTEMP) AUX ANA PU2

41(BRAKE) AUX DIG 3

24AUX ANA PUD3

12AUX ANA PD1

2SPK_COIL1B

3SPARK_COIL2A

5SPK_COIL2B

78AUX PWM6

90AUX PWM3

54FPP2-IVS

42(GOV2) AUX DIG 4

6SPK_COIL3A

18AUX ANA PD3

O/LG 18

BR/W 18

BR/W 18

LG/BK 18

DG/P 18

B

A

LPG

TEMPERATURE

A

B

TWR

LPG

LOCKOFF

BOSCHTMAP

R 16

W/R 18

GY/R 18

DG/P 18

Y/R 18

KNOCK

SENSOR

GY 18

DBL 18

CRANK

DB/O 18

GY/R 18

CAM

CYL #2

DG/P 18

4

3

2

1

BK/W 16

PK/BK 16

GY/LB 18

R 16

GY/Y 18

W/LG 18

DG/P 18

O/LG 18

BR/W 18

LG/R 18

GY/R 18

R/LG 18

GY/R 18

Y/W 18

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R/LG 18

R/T 14

LB/O 18

O 18

DG 18

W/LB 18

T/GN 18

P/LB 18

Y/DB 18

O/LG 18

BK/R 16

PK/LG 18

T/Y 18

DG/W 18

BK/O 18

R/W 18

R/BK 18

R/Y 18

LG/P 18

GY/R 18

BR/W 18

BK/LG 18

LB/Y 18

DB/W 18

DG/O 18

BK/Y 18

BK/LB 18

LB/BK 18

BK/W 16

BK/W 16

BK/W 16

T/LB 18

LB/R 18

DG/BK

LG/W

R 16

T 16R 16

R 16

R 16

W 16

INJECTOR CYL #2

R 16

BN/LB 16

BR/Y 16

R 16

IGNITION COILS

CYL #3 CYL #4 CYL #1

INJECTOR CYL #4

INJECTOR CYL #3

INJECTOR CYL #1

ENGINE ECM

CONNECTOR

ES0400A

GY/R 18

Y/W 18

R 14

31 VREF

23 GOV SELECT 2

1 VSW

36 ROADSPEED -

R/LB 16

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R 16

R 16R 16

87A

RING

BATT(+)

LB/PK 16

W/PK 16

R/LB 16

R 14

33 ANA RTN

32 ANA AUX PD1

12 FPP2

37 AUX ANA PU2B

14 FPP1

35 ROADSPEED +

24 GOV SELECT 1

BK/W 18

W 18 W 18

R/T 18

R/Y 18

LB/PK 16

PK/BK 16

LG/P 18

R/LG 18

R 16

R 12

R/T 14

R/LG 18

O/LG 18

RELAYED POWER

F5

15A

EPR

F1

10A

R16

PK/BK 16 PK/BK 16

F2

VSW5A

GROUND

RING

DG/P 18

RING

STARTER

SOLENOID

3

2

6

5

1

4

BOSCH THROTTLE

FUEL PUMP

F4

15A

DG/W 18

87

30

85

86RELAY

OMRON

FPP

STARTER RELAY

ECM

F3

10A

SHD

R/LG 18

CAN

TERMINATION

CONNECTOR

BR/W 18

BK/Y 18

R/LG 18

LB/R 18

87A

85

86

87

30

POWER RELAY

GY/R 18

LB/Y 18

DG/O 18

DB/W 18

LB/BK 18

T/LB 18

LG/BK 18

TWR

2

1

3

ALTERNATOR

6GROUND

3CAN +

4UNUSED

5UNUSED

7POWER

8UNUSED

1CAN -

CAN + TERM

EPR

CONNECTOR

18 FUEL PUMP -

3 RS 232-

4 BRAKE

7 FUEL SELECT

6 MIL

25 IVS

5 FUEL PUMP +

29 CAN -

28 CAN +

11 RS 232+

26 OIL PRES

39 AUX OUT1

27 AUX OUT 2

2 TACH

10 AUX ANA PD1B

15 START IN INTERUPT

19 START IN AUTOCRANK

O 18

BK/R 16

LB/PK 16

W/PK 16

W/LB 18

Y/DB 18

PK/LG 18

BK/O 18

PK/BK 16

DG 18

DG/P 18

O/LG 18

T/GN 18

T/Y 18

DG/W 18

P/LB 18

O/LG 18

21 AUX PWM 5

16 AUX PWM 4

R/BK 18

R/W 18

R 16

PK/BK 16

LB/O 18

R/LG 18

R 16

87A

85

86

87

30

FUEL PUMP RELAY

BK/LG 18

HO2S #2

GY/LB 18

GY/R 18

R 16

GY/R 18

BR/W 18

R 16

LG/R 18

W/LG 18

BK/LB 18

LG/W 18

GY/YL 18

GY/R 18

MTRTWR4

CHT

D

B

A

C

SHD

HO2S #1

GASOLINE

SENSOR

INTERFACE

A

B

C

D

TWRGY/R 18

R 12

2

OIL PRESSURE

GROUND

RING

BK/W 12

FORD

42 PIN

CONNECTOR

BR 16 BR 1634 GND


6 - 98

Engine Wire HarnessFord DSG-423 EFI Models (before serial number 6810)

6 - 97

December 2011


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 99

REV B

R/W 18

W/BK 18

PK/LG 18

BR/Y 16

BK/LG 18

O 18

LB/BK 18

GY/W 18

R/LG 18

W/LB 18

LG/W

DG/W 18

DG/BK

DBL 18

LG/BK 18

GY/R 18

DG/P

W/PK 18

W/PK 18

GY/R 18

(FPP2)

T/GN 18

R/BK 18

BK/R 16

GY/O 18

R/T 16

R/Y 18

BK/W 16

BK/R 16

LB/O 18

W 16

T 16

BK/LB 18

R/T 16

BR/LB 16

BK/W 16

DG 18

Y/W 18

Y/R 18

LB/Y 18

P/LB 18

T/Y 18

BK/O 18

LG/R 18

GY 18

W/R 18

BK/Y 18

DB/W 18

T/LB 18

GY 18

GY/R 18

LB/R 18

GY/Y 18

BR/W 18

W/LG 18

GY/LB 18

BK/W 16

Y/BK 18

Y/RD 18

RD/T 14

DG 18

O 18

GY/R 18

GY 18

BR/W 18

FP REC

LB/DG 18

DG/P 18

R/LG 18

Y/BK 18

O/LG 18

FUEL PUMP

LG/P 18

(FUEL PUMP)

DG/P 18

Y/DB 18

DB/O 18

DG/O 18

O/LG 18

W/BK 18

R 16

Y/RD 18

GY/R 18

8CAN -

5UNUSED

25V REF

1ANA RTN

3PC TX

4PC RX

6UNUSED

7CAN +

DIAGNOSTIC CONNECTOR

82DBW -

79VBAT

73RELAY

70INJ6 LS

67INJ4 LS

64INJ1 LS

61EGOH 2

55PC TX

52KNOCK -

43TACH

37ECT

34GOV 1

315V EXT 2

28CAM -

25CRANK +

22EGO2

195V EXT 1

16CAN2 -

10UEGOP

81GROUND

80DBW +

69GROUND

68INJ5 LS

72STARTER

74MIL

75UEGO H

77LOCKOFF

60VBAT

56PC RX

62EGOH 1

63INJ HS

65INJ2 LS

44VSW

47TPS 1

48TPS 2

51KNOCK +

53FPP1

325V RTN 2

33PULSE IN

36IAT

205V RTN

21EGO1

23MAP

26CRANK -

29SPEED +

27CAM +

17CAN2 +

14CAN1 +

15CAN1 -

9UEGOC

8UEGOS

11UEGPR

30SPEED -

66INJ3 LS

88AUX PWM4 REC

85AUX PWM1

76AUX PWM7

58KNOCK 2-

49(FUELSELECT)AUX DIG1

46AUX ANA PUD1

40(IVS) AUX ANA PU3

13(FRP) AUX ANA PD2

7SPK_COIL3B

4SPK_GND

1SPK_COIL1A

87AUX PWM2

83AUX PWM5 REC

84AUX PWM5

86AUX PWM4

89AUX PWM3 REC

71AUX PWM8

59VBAT PROT

57KNOCK 2+

45AUX ANA PUD2

50AUX DIG 2

35OIL PRESS

38(FRT) AUX ANA PU1

39(LPTEMP) AUX ANA PU2

41(BRAKE) AUX DIG 3

24AUX ANA PUD3

12AUX ANA PD1

2SPK_COIL1B

3SPARK_COIL2A

5SPK_COIL2B

78AUX PWM6

90AUX PWM3

54FPP2-IVS

42(GOV2) AUX DIG 4

6SPK_COIL3A

18AUX ANA PD3

O/LG 18

BR/W 18

BR/W 18

LG/BK 18

DG/P 18

B

A

LPG

TEMPERATURE

A

B

TWR

LPG

LOCKOFF

BOSCHTMAP

R 16

W/R 18

GY/R 18

DG/P 18

Y/R 18

KNOCK

SENSOR

GY 18

DBL 18

CRANK

DB/O 18

GY/R 18

CAM

CYL #2

DG/P 18

4

3

2

1

BK/W 16

PK/BK 16

GY/LB 18

R 16

GY/Y 18

W/LG 18

DG/P 18

O/LG 18

BR/W 18

LG/R 18

GY/R 18

R/LG 18

GY/R 18

Y/W 18

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R/LG 18

R/T 14

LB/O 18

O 18

DG 18

W/LB 18

T/GN 18

P/LB 18

Y/DB 18

O/LG 18

BK/R 16

PK/LG 18

T/Y 18

DG/W 18

BK/O 18

R/W 18

R/BK 18

R/Y 18

LG/P 18

GY/R 18

BR/W 18

BK/LG 18

LB/Y 18

DB/W 18

DG/O 18

BK/Y 18

BK/LB 18

LB/BK 18

BK/W 16

BK/W 16

BK/W 16

T/LB 18

LB/R 18

DG/BK

LG/W

R 16

T 16R 16

R 16

R 16

W 16

INJECTOR CYL #2

R 16

BN/LB 16

BR/Y 16

R 16

IGNITION COILS

CYL #3 CYL #4 CYL #1

INJECTOR CYL #4

INJECTOR CYL #3

INJECTOR CYL #1

ENGINE ECM

CONNECTOR

ES0400A

GY/R 18

Y/W 18

R 14

31 VREF

23 GOV SELECT 2

1 VSW

36 ROADSPEED -

R/LB 16

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R 16

R 16R 16

87A

RING

BATT(+)

LB/PK 16

W/PK 16

R/LB 16

R 14

33 ANA RTN

32 ANA AUX PD1

12 FPP2

37 AUX ANA PU2B

14 FPP1

35 ROADSPEED +

24 GOV SELECT 1

BK/W 18

W 18 W 18

R/T 18

R/Y 18

LB/PK 16

PK/BK 16

LG/P 18

R/LG 18

R 16

R 12

R/T 14

R/LG 18

O/LG 18

RELAYED POWER

F5

15A

EPR

F1

10A

R16

PK/BK 16 PK/BK 16

R/LG 18

F2

VSW5A

GROUND

RING

DG/P 18

RING

STARTER

SOLENOID

3

2

6

5

1

4

BOSCH THROTTLE

FUEL PUMP

F4

15A

DG/W 18

87

30

85

86RELAY

OMRON

FPP

STARTER RELAY

ECM

F3

10A

SHD

R/LG 18

CAN

TERMINATION

CONNECTOR

BR/W 18

BK/Y 18

R/LG 18

LB/R 18

87A

85

86

87

30

POWER RELAY

GY/R 18

LB/Y 18

DG/O 18

DB/W 18

LB/BK 18

T/LB 18

LG/BK 18

TWR

2

1

3

ALTERNATOR

6GROUND

3CAN +

4UNUSED

5UNUSED

7POWER

8UNUSED

1CAN -

CAN + TERM

EPR

CONNECTOR

18 FUEL PUMP -

3 RS 232-

4 BRAKE

7 FUEL SELECT

6 MIL

25 IVS

5 FUEL PUMP +

29 CAN -

28 CAN +

11 RS 232+

26 OIL PRES

39 AUX OUT1

27 AUX OUT 2

2 TACH

10 AUX ANA PD1B

15 START IN INTERUPT

19 START IN AUTOCRANK

O 18

BK/R 16

LB/PK 16

W/PK 16

W/LB 18

Y/DB 18

PK/LG 18

BK/O 18

PK/BK 16

DG 18

DG/P 18

O/LG 18

T/GN 18

T/Y 18

DG/W 18

P/LB 18

O/LG 18

21 AUX PWM 5

16 AUX PWM 4

R/BK 18

R/W 18

R 16

PK/BK 16

LB/O 18

R/LG 18

R 16

87A

85

86

87

30

FUEL PUMP RELAY

BK/LG 18

HO2S #2

GY/LB 18

GY/R 18

R 16

GY/R 18

BR/W 18

R 16

LG/R 18

W/LG 18

BK/LB 18

LG/W 18

GY/YL 18

GY/R 18

MTRTWR4

CHT

D

B

A

C

SHD

HO2S #1

GASOLINE

SENSOR

INTERFACE

A

B

C

D

TWRGY/R 18

R 12

2

OIL PRESSURE

GROUND

RING

BK/W 12

FORD

42 PIN

CONNECTOR

BR 16 BR 1634 GND

Engine Wire HarnessFord DSG-423 EFI Models (after serial number 6809)

December 2011


6 - 100

Engine Wire HarnessFord DSG-423 EFI Models (after serial number 6809)

6 - 99


6 - 1016 - 102

Electrical Schematic - CTE Option(before serial number 9697)


1

2

3

4

5

6

7

8


6 - 102 Z-60/34 Part No. 75861

REV A

C2

1-1

C2

0-1

SCHEMATIC - PLATFORM LEVEL CUTOUT

PL

AT

LE

VE

LD

OW

N

C2

1-2

PL

AT

LE

VE

LU

P

C2

0-2

GROUND

R1

5P

LD

OR

/BK

CR21

C1

5P

LD

OR

/BK

TB15

TB22

TB134P22LS BK

LIM

ITS

WIT

CH

ES

TB14

R1

4P

LU

OR

CR20

C1

4P

LU

OR

TB40

CR

21

CR

20

UP

RE

LA

Y

PL

AT

LE

VE

L

BR

N

11"

DO

WN

RE

LA

Y

PL

AT

LE

VE

L

26"

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

BO

OM

ST

OW

ED

WIRING DIAGRAM

14"

14"

C4

0L

S1

OR

CR

20

#3

0

OR

-TS

59

OR

/BK

-TS

59

1415

40

GR

OU

ND

BO

LT

C1

4P

LU

OR

FU

NC

HA

RN

C1

5P

LD

OR

/BK

FU

NC

TH

AR

N

14"

7.5

"

BR

N7

.5"

14"

OR

-CA

BL

E1

C1

4P

LU

OR

CA

BL

E3

C1

5P

LD

OR

/BK

CA

BL

E3

C1

4P

LU

OR

CR

20

#8

6

C1

5P

LD

OR

/BK

CR

21

#8

6

14

15

40

RD

-H6

+R

D-K

S1

-2S

.P.

42

P1

34

PW

R4

2R

D-4

+L

SP

WR

-4O

R/R

D-C

AB

LE

1

OR

-4

C1

4P

LU

OR

14

-DC

15

PL

DO

R/B

K1

5-D

BR

-GN

DS

TU

D

C4

0L

S1

OR

40

-A

FUNCTHARN

C3

4S

AB

K/W

HC

1P

-8

FUNCTIONHARNESS

Electrical Schematic - CTE Option(before serial number 9697)


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 103

REV A Electrical Schematic - CTE Option(from serial number 9697)

C2

1-1

C2

0-1

SCHEMATIC - PLATFORM LEVEL CUTOUT

PL

AT

LE

VE

LD

OW

N

C2

1-2

PL

AT

LE

VE

LU

P

C2

0-2

GROUND

R1

5P

LD

OR

/BK

CR21

C1

5P

LD

OR

/BK

TB15

TB22

TB134P22LS BK

LIM

ITS

WIT

CH

ES

TB14

R1

4P

LU

OR

CR20

C1

4P

LU

OR TB40

CR

21

CR

20

UP

RE

LA

Y

PL

AT

LE

VE

L

BR

N

DO

WN

RE

LA

Y

PL

AT

LE

VE

L

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

BO

OM

ST

OW

ED

WIRING DIAGRAM

C4

0L

S1

OR

CR

20

#3

0

OR

-TS

59

OR

/BK

-TS

59

14

15

40

GR

OU

ND

BO

LT

C1

4P

LU

OR

C6

-14

C1

5P

LD

OR

/BK

C6

-15

BR

N

OR

C2

B-2

C1

4P

LU

OR

C4

B-2

C1

5P

LD

OR

/BK

C4

B-3

C1

4P

LU

OR

CR

20

#8

6

C1

5P

LD

OR

/BK

CR

21

#8

6

14

15

40

RD

-H6

+

RD

-KS

1-2

S.P

.4

2P

13

4P

WR

42

RD

-C6

-23

+L

SP

WR

-C6

-30

OR

/RD

-C2

B-4

OR

C6

-40

C1

4P

LU

OR

14

-D

C1

5P

LD

OR

/BK

15

-D

BR

-GN

DS

TU

D

C4

0L

S1

OR

40

-A

FUNCTIONHARNESS


6 - 1046 - 103

Electrical Schematic - CTE Option(from serial number 9697)


6 - 105

Joystick Connector Diagram

6 - 106


1

2

3

4

5

6

7

8


6 - 106 Z-60/34 Part No. 75861

REV AJoystick Connector Diagram


8 7 20

17

181110

J2

6 912

13

14

1

SEC BOOM UP/DN

BR

N

OR

WH

/BK

431 2 65

10 9 3

1 42 3 5 6


631 2 4 5

DRIVE & STEERING

WH

/RD

RD

/WH

2

BR

N

OR

BR

N

OR

WH

/RD

BL

/WH

5 4

13

1411

12

YO

UT

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL

/WH

XO

UT

J1 J1 J1

J1

-5B

L/W

HJC

3-5

J1

-4W

H/R

DJC

3-4

J1

-5B

L/W

HJC

3-3

J1

-13

OR

JC

3-2

J1

-14

BR

JC

3-1

JC3

DRIVE/STEERJ1

-3W

H/B

KJC

1-4

J1

-9O

RJC

1-2

J1

-10

BR

JC

1-1

JC1

SEC BOOM UP/DN

JC2

TT ROTATE

UP/DOWN

PRI. BOOM

J1

-11O

RJC

2-2

J1

-12

BR

JC

2-1

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


8 7 20

17

181110

RD

BK

BR

N

OR

J2

6

J1

12 1

11 2

9

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

BR

N

OR

BL

WH

J1

13

14 54

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

12

13

14

XO

UT

JC1

PW

R

653 421

GN

D

OU

T


7

39

10

OR

BR

N

YE

L

J1


4

2

1

3

5

6

7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4W

HJ1

-5

OR

J1

- 9

BR

NJ1

- 10

YE

LJ1

- 3

OR

J1

-11B

RN

J1

-12

BK

J1

-2R

DJ1

-1

JC3

JC1JC2

4

2

1

3

5

6

7

WH

J1

-5

UP/DOWN

PRI. BOOM

TT ROTATE

SEC BOOM UP/DN

DRIVE/STEER

Note: Production changed

from 7 pin to 6 pin connector

at serial number 7227 Deutsch- 6 Pin Connector

AMP- 7 Pin Connector


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 107

REV A Hydraulic Generator Options(from serial number 10283)

SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONSC

45

GE

N-G

R/W

H-4

C4

5G

EN

-GR

/WH

-4

T2

T1

YELLOW

RED

WHITE

GREEN

T3

T4

8

5

BLACK

BLACK

BLACK

WHITE

BLACK

WHITE

WHITE

BLACK

GREEN

WHITE

BLACK L1

L2

GND

C4

5G

EN

-GR

/WH

-4

BA

TG

ND

-BR

-4

1 2 43

3 421

GR

/WH

BR

BL

PLU

G

PURGE-BL

DTP04-4P

GREEN

RED

BLACK

BLUE

YELLOW

WHITEBLACK BLACK

WHITE

YELLOW

BLUE

BLACK

RED

GREEN

DTP04-4P

PURGE-BL

PLU

G

BL

BR

GR

/WH

1 2 43

3 421

BA

TG

ND

-BR

GND

L2

L1BLACK

WHITE

GREEN

BLACK

WHITE

WHITE

BLACK

WHITE

BLACK

RED

RED

5

8

T4

T3

BLACK

WHITE

BLACK

WHITE

T1

T2

T2

T1

YELLOW

RED

WHITE

GREEN

T3

T4

8

5

BLACK

BLACK

BLACK

WHITE

BLACK

WHITE

WHITE

BLACK

GREEN

L2

L1

BA

TG

ND

-BR

-4

1 2 43

3 421

GR

/WH

BR

BL

PLU

G

PURGE-BL

DTP04-4P

BLACK

RED

GREEN

WHITE

BLACK

BLUE

YELLOW

WHITE

BLACK

GND

GENERATORJUMPER HARNESS

ACGENERATOR

ACGENERATOR

GENERATORJUMPER HARNESS

120VAC, 50Hz, 1 PH 120VAC, 60Hz, 1 PH

240VAC, 50Hz, 1 PH

GENERATORJUMPERHARNESS

ACGENERATOR


6 - 1086 - 107

Hydraulic Generator Options(from serial number 10283)


6 - 1096 - 110

Electrical Schematic - Welder Option


1

2

3

4

5

6

7

8


6 - 110 Z-60/34 Part No. 75861

REV AElectrical Schematic - Welder Option

19

CR66OMRON RELAY

PS4

U36

NC

N.O.

P2

C32BRK WH/RD

75

3

18

642

PILOT PRESSURE SIGNALFROM GENERATOR MANIFOLD

TB24TIME DELAY MODULE4 SECOND

8 N.C.

2 COM

1 N.O.

3 GND 5 SW INPUT

DR

IVE

ED

C-

DR

IVE

ED

C+

B C

U4

AD

C5

-21

C5

-20

C1

B-5

C1

B-4

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C1

P-5

C1

P-4

16

15

ALC-500

C2

P-7

C2

B-7

C4

5G

EN

GR

/WH

TB45

P25FS-RD

P24FS-WH

TS4RPM

SELECT

TB35

C3

5R

PM

BK

/RD

C1

B-9

C1

P-9

RP

MH

I

RP

ML

O

FOOTSWITCH

2 4

6

81 3

5 7

RS232RxD

A1 BATTERY + (RED/WHITE)A2 SENSOR POWER +5 VDC (RED)A3 BATTERY- (BRN)

B1 VALVE 0 FWD COIL (GRN)B2 VALVE 1 NCB3 DIGITAL OUTPUT BYPASS (GRN/BLK)

C1 TxD (YLW)C2 RxD (GRN)

C3 /BOOT

D1 ANALOG 0 JOYSTICK (WHT)D2 ANALOG 1 NCD3 DIG IN 3 NC

E1 NOT USEDE2 NOT USEDE3 NOT USED

F1 DIG IN 0F2 DIG IN 1 GENERATOR ON (GRN/WHT)

F3 DIG IN 2

RS232TxD

CR

4H

IGH

IDL

ER

EL

AY

C4

5G

EN

GR

/WH

V151HG GR

V150HG GR/BK

1k ohms124 ohms

124 ohms

ABC

20

P26BAT-BK

TB29

2

1

3

C1

B-3

C1

P-3

C2

9M

SR

D/W

H

BY

PA

SS

CO

IL

MO

TO

RS

TR

OK

EV

ALV

E

SX Controller

CR50OMRONRELAY

TB41

C5

-18

C5

-24

C5

-1

C6

-39

P22BAT

D65D98

DIVERTER MANIFOLD

PRESSURE SWITCH200 PSI

D99

WH

RE

D

RE

D

RD

-1

BL

K-2

TS47GENERATOR

ON

C57-1C57-2Y75-1

Y75-2

TB32

C3

2B

RK

WH

/RD

C1

P-6

BR

AK

ER

EL

EA

SE

C5

-23

J159-1

WHWH/RDJ129

TB21

C5

-6

C4

1R

PM

OR

/BK

C1

B-4

C1

B-5

C5

-21

C5

-20

D12

C1

B-6

C5

-12


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 111

REV AREV B Hydraulic Schematic - Welder Option

OIL COOLER

0.031 inch /0.79 mm

WELDERMANIFOLD

DRIVE PUMP

B

A

3.5 GPM

PMP B CLR PMP A

270 PSI / 18.6 BAR@ 3.5 GPM

MTR B MTR A

21 GPM /79.5 L/min

G1

G2

21

GP

M/

79

.5L

/min

G2 G1

21CC

TANK

13

GENERATOR12.5 KW

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

PRESSURE SWITCH200 PSI / 13.8 BARN.O.


6 - 1126 - 111

Hydraulic Schematic - Welder Option


6 - 113

Hydraulic Schematic - 2WD Models(before serial number 4461)

6 - 114


1

2

3

4

5

6

7

8


6 - 114 Z-60/34 Part No. 75861

REV AHydraulic Schematic - 2WD Models(before serial number 4461)

PLATFORMROTATE

ROTARYHYDRAULIC

STEERING

COUPLER

OSCILLATE

FILTERPRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 GPM8.3 L/min

15.5 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTER SLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN

PRESSUREFILTER

HIGH

SECONDARY LIFT4.1 GPM

MANIFOLD

OPTIONALGENERATOR

GENERATOROPTIONAL

OPTIONAL

F

E

D

C

B

A

A

A

B

B

C

C

C

D

D

F

G G G G

E

E

C

G

PRESSRATIO

COUNTERBALANCE VALVE

V1

.030

V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

10.3 bar

87 psi5.9 bar

290 psi19.9 bar

5 15 1.5

25 psi1.7 bar

3 psi3 psi0.20 bar0.20 bar

4200 psi289.5 bar

E

LS TEST

ø.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

.042

BRAKE

10:1 2500 PSI

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2400 psi165.4 bar

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

176 3 82 9 4

TEST

TEST

PRESS

0.1 gpm0.37 L/min

OUT

87 psi5.9 bar

3000 PSI3:1

30 psi2.1 bar

30 psi2.1 bar

2.1 bar30 psi

O.C. IN

O.C. OUT

25 psi2 bar

TEST

IN

CDR

CDL

LEFTREAR

RIGHTREAR

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

700 psi51.7 bar

ø.030

M1B

P1

P2

T TEST 2 M2BM2A

TEST 3 TEST 1 M1A

250 psi17.2 bar

2400 psi165.4 bar

150 psi

3000 PSI4.5:1

FUNCTION MANIFOLD

X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEEDX

BRAKE/

2WD TRACTION MANIFOLD

X XX

F

DB DA

U

ST

Z

A

AH AI

X

N

G J

CA

CB

CC

AG

AA AB

R

B

VAD

Q C

AC

W

M

AJ

L

AF

F

P

AM

ALAK

AEY

I

H

K

FI

FA FE

FD

FH

FB

FF

FG

FC

DC

DD

O

BD

BC

BA

BB

E

D

Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.

Changed to 750 psi atat serial number 11003


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 115

REV A

PLATFORMROTATE

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN

PRESSUREFILTER

HIGH

SECONDARY LIFT4.1 gpm

15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

C

C

D

D

F

F

E

E

C

2400 psi165.4 bar

OPTIONAL

MANIFOLDGENERATOR

GENERATOROPTIONAL

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

310 psi21.4 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

0.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2600 psi172.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

87 psi5.9 bar

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

0.030

150 psi10.3 bar

SET @ .6 GPM2.3 L/min

X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CC

BE

BG

CA

BF

HF

G G G G

RIGHTLEFT

21CC

PUMPDRIVE

FUNCTIONMANIFOLD

HYD.ROTARYCOUPLER

WELDER

OPTION

30

GP

M

30

GP

M

30

GP

M

30

GP

M

G2

21

GP

M

G1

21

GP

M

CL

R3

.5G

PM

PM

PB

MT

RB

MT

RA

PM

PA

TO AUX SUCTION

E

270 PSI @

3.5 GPM

G2 G1

I MANIFOLD

12.5 KW GENERATOR

3 1

B

A

13

SWV

CY

CX

CW

CV

CU

750 PSI

B

A

OUT

IN

TEST

TRACTION MANIFOLD

CYLINDERSSTEERING RIGHTLEFT

OSCILLATE VALVE

ROTARYHYDRAULIC

COUPLER

7

7

REARRIGHT

REARLEFT M3

CDL

M1

50%

50%

M4

M2

CDR

280 PSI

TEST BA

6 8 3 1 2 54

2A 2C13 542B

A

B

B

A

0.070

T

8A8B8C6C6B6A

XX

TT

SS

UU

WW

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

Hydraulic Schematic - 2WD Models(from serial number 4461 to serial number 10282)



6 - 1166 - 115



6 - 117


6 - 118


1

2

3

4

5

6

7

8


6 - 118 Z-60/34 Part No. 75861

REV A

PLATFORMROTATE

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN


15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

C

C

D

D

F

F

E

E

C

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

310 psi21.4 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

0.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2600 psi172.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

0.030

150 psi10.3 bar


X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CC

BE

BG

CA

BF

HF

G G G G

RIGHTLEFT

21CC

PUMPDRIVE

FUNCTIONMANIFOLD

HYD.ROTARYCOUPLER

WELDER

OPTION

30

GP

M

30

GP

M

30

GP

M

30

GP

M

G2

21

GP

M

G1

21

GP

M

CL

R3

.5G

PM

PM

PB

MT

RB

MT

RA

PM

PA

TO AUX SUCTION

E

270 PSI @

3.5 GPM

G2 G1

I MANIFOLD

12.5 KW GENERATOR

3 1

B

A

13

SWV

CY

CX

CW

CV

CU

750 PSI

B

A

OUT

IN

TEST

TRACTION MANIFOLD


OSCILLATE VALVE

ROTARYHYDRAULIC

COUPLER

7

7

REARRIGHT

REARLEFT M3

CDL

M1

50%

50%

M4

M2

CDR

280 PSI

TEST BA

6 8 3 1 2 54

2A 2C13 542B

A

B

B

A

0.070

T

8A8B8C6C6B6A

XX

TT

SS

UU

WW

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

V1

V2

JIB SELECTMANIFOLD

J2

J1

PR1

PR2

JIB MANIFOLDCHANGED AT SN 10426

P -12

F -12

RELIEF VALVESET @ 2700 PSI

HYDRAULIC GENERATOR OPTION

X X

XX

XX

Hydraulic Schematic - 2WD Models(from serial number 10283 to 11003)


REV C


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 119

REV A Hydraulic Schematic - 2WD Models(from serial number 11004)

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN


15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

F

F

E

E

C

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

310 psi21.4 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

T1

2600 psi172.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

150 psi10.3 bar


X

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CCCA

HF

G G G G

RIGHTLEFT

750 PSI

B

A

OUT

IN

TEST

TRACTION MANIFOLD


OSCILLATE VALVE

ROTARYHYDRAULIC

COUPLER

7

7

REARRIGHT

REARLEFT M3

CDL

M1

50%

50%

M4

M2

CDR

280 PSI

TEST BA

6 8 3 1 2 54

2A 2C13 542B

A

B

B

A

0.070

T

8A8B8C6C6B6A

XX

TT

SS

UU

WW

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

P -12

F -12



X X

XX

XX

PLATFORM ROTATE

Z60 JIB BOOM

C

C

D

D

J1

PR1

PR2

J2

V2

PR2

PR1

V1

J1

J2

JIB SELECTMANIFOLD

BP

BS

BTBU

BR



6 - 120

Hydraulic Schematic - 2WD Models(from serial number 11004)

6 - 119


6 - 121


6 - 122


1

2

3

4

5

6

7

8


6 - 122 Z-60/34 Part No. 75861

REV A

PLATFORMROTATE

ROTARYHYDRAULIC

COUPLER

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN

PRESSUREFILTER

HIGH


15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

A

B

B

C

C

C

D

D

F

F

E

E

C

2400 psi165.4 bar

OPTIONAL

MANIFOLDGENERATOR

GENERATOROPTIONAL

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

310 psi21.4 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

ø.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2400 psi165.4 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

87 psi5.9 bar

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

ø.030

150 psi10.3 bar


X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CC

BE

BG

CA

BF

HF

7

7

6 8 3 1 2 54

2A 2C138A6A 54

800 PSI

B

A

OUT

IN

TEST

2B

CYLINDERSSTEERINGLEFT

OSCILLATE VALVE

RIGHT

G G G G

RIGHTLEFT

21CC

PUMPDRIVE

FUNCTIONMANIFOLD

HYD.ROTARYCOUPLER

WELDER

OPTION

30

GP

M

30

GP

M

30

GP

M

30

GP

M

G2

21

GP

M

G1

21

GP

M

CL

R3

. 5G

PM

PM

PB

MT

RB

MT

RA

PM

PA

TO AUX SUCTION

E

270 PSI @

3.5 GPM

G2 G1

I MANIFOLD

12.5 KW GENERATOR

3 1

B

A

13

SWV

CY

CX

CW

CV

CU

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

CDR

CDL

LEFTREAR

RIGHTREAR

T

250 psi17.2 bar

M3

M1

50%

2.0 gpm

7.5 L/min

50%

50%50%

2.0 gpm

2.0 gpm

7.5 L/min

7.5 L/min

50%M5

M7

TEST A B

M4

M2FRONTLEFT

M6

RIGHT

M8

FRONT

4WD TRACTION MANIFOLD

X

50%

GA

GC

GG

GI

GK

GD

GL

GJ

GH

GF

GN

GE

GB

GM

GO



Changed to 750 psi atat serial number 11003


1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 123

REV A Hydraulic Schematic - 4WD Models(from serial number 4461 to serial number 10282)

PLATFORMROTATE

ROTARYHYDRAULIC

COUPLER

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN

PRESSUREFILTER

HIGH


15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

C

C

D

D

F

F

E

E

C

2400 psi165.4 bar

OPTIONAL

MANIFOLDGENERATOR

GENERATOROPTIONAL

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

290 psi20 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

0.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2600 psi179.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

87 psi5.9 bar

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

0.030

150 psi10.3 bar


X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

GM

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CC

BE

BG

CA

BF

HF

7

7

REARRIGHT

REARLEFT M1

CDL

T

M2 LEFTFRONT

M3

50%

50%

M7

M5

CDR

50%

250 PSI

50%

TEST BA

6 8 3 1

M4

50%

50%

FRONTRIGHTM8

M6

2 54

2A 2C138A6A6C8C 54

750 PSI

B

A

OUT

IN

TEST

2B

A

B

A

B

A

B

A

B

0.040

0.040

0.040

6B8B

MANIFOLDTRACTION


OSCILLATE VALVE

RIGHT

G G G G

RIGHTLEFT

GO

GB

GE GC

GG

GD

GL

GI

GK

GN GJ

GF GH

BOOMEXTEND/RETRACT

5 gpm18.9 L/min


REV C


6 - 1246 - 123



6 - 1256 - 126



1

2

3

4

5

6

7

8


6 - 126 Z-60/34 Part No. 75861

REV A

PLATFORMROTATE

ROTARYHYDRAULIC

COUPLER

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

X

X

2.2 gpm3.8 L/min

PRIMARY LIFT

AUX. PUMP

LEVELPLATFORM

MASTERSLAVE

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN


15.5 L/min

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

C

C

D

D

F

F

E

E

C

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

290 psi20 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

0.030

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

V1

V2

J1

PR1

PR2

J2

T1

2600 psi179.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

0.030

150 psi10.3 bar


X

MANIFOLDJIB SELECT

X

X

MANIFOLD2 SPEED

X BRAKE/

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

GM

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CC

BE

BG

CA

BF

HF

7

7

REARRIGHT

REARLEFT M1

CDL

T

M2 LEFTFRONT

M3

50%

50%

M7

M5

CDR

50%

250 PSI

50%

TEST BA

6 8 3 1

M4

50%

50%

FRONTRIGHTM8

M6

2 54

2A 2C138A6A6C8C 54

750 PSI

B

A

OUT

IN

TEST

2B

A

B

A

B

A

B

A

B

0.040

0.040

0.040

6B8B

MANIFOLDTRACTION


OSCILLATE VALVE

RIGHT

G G G G

RIGHTLEFT

GO

GB

GE GC

GG

GD

GL

GI

GK

GN GJ

GF GH

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

P -12

F -12



V1

V2

JIB SELECTMANIFOLD

J2

J1

PR1

PR2

MANIFOLD CHANGEDAT SN 10426

X X

XX

XX




1

2

3

4

5

6

7

8


Part No. 75861 Z-60/34 6 - 127

REV A Hydraulic Schematic - 4WD Models(from serial number 11004)

PLATFORM ROTATE

ROTARYHYDRAULIC

COUPLER

FILTER

PRESSURE

MEDIUM

FUNCTIONPUMP

DRIVE PUMP

RESERVOIR

AUX. PUMP

MASTER

TURNTABLEROTATE

Z60 JIB BOOM

1 gpm3.8 L/min

OIL COOLER

FILTERRETURN

OPTIONAL

FUNCTION MANIFOLD

A

G

B

B

C

C

D

D

F

F

V1

.030V2

S1

1800 psi124.1 bar

EXT

3.5 gpm13.2 L/min

87 PSI5.9 bar

290 psi20 bar

9 15 1.5

25 psi1.7 bar

250 bar3625 psi

E

LS TEST

1.5 gpm

5.7 L/min

2SPEED

M

ST1

ST2

0.042

BRAKE

TANK

RET

SW1

SW2

PR1

PR2

P1

P2

PL2

PL1

CP

T2

AUX

T2

J1

PR1

PR2

J2

T1

2600 psi179.3 bar

PTEST

TEST

PRESS

0.1 gpm0.37 L/min

30 psi2.1 bar

30 psi2.1 bar

30 psi

2.1 bar

O.C. IN

O.C. OUT

25 psi

1.7 bar

3 psi0.20 bar

TEST

B

A

S2

S1

1600 psi110.3 bar

5 gpm18.9 bar

150 psi10.3 bar


2.2 gpm3.8 L/min

PRIMARY LIFT

C

X

X

X

MANIFOLD2 SPEED

X BRAKE/


15.5 L/min

C

3 psi0.20 bar

F

E

D

C

B

A

G

PRESSRATIO


10:1 2500 PSI

3500 PSI3:1

1.5:1 3000 PSI

2000 PSI3:1

2500 PSI4.5:1

3000 PSI3:1

3000 PSI4.5:1

EB

EC

ED

EA

HG

HI HZ

IF

HX

HT

IJ

IK

II

IE

HR

GM

IL

HS

HY

HU IG

IH

IM

HQ

HC

IC

IA

HMHE

HJ HW

HP

HD

HK

IB

HO

HH

HBHA

CB

ID HN

HL

CCCA

HF

7

7

REARRIGHT

REARLEFT M1

CDL

T

M2 LEFTFRONT

M3

50%

50%

M7

M5

CDR

50%

280 PSI

50%

TEST BA

6 8 3 1

M4

50%

50%

FRONTRIGHTM8

M6

2 54

2A 2C138A6A6C8C 54

750 PSI

B

A

OUT

IN

TEST

2B

A

B

A

B

A

B

A

B

0.040

0.040

0.040

6B8B

MANIFOLDTRACTION


OSCILLATE VALVE

RIGHT

G G G G

RIGHTLEFT

GO

GB

GE GC

GG

GD

GL

GI

GK

GN GJ

GF GH

BOOMEXTEND/RETRACT

5 gpm18.9 L/min

P -12

F -12



X X

XX

XX

V2

PR2

PR1

V1

J1

J2

X

X

LEVELPLATFORM

SLAVE

E

E JIB SELECTMANIFOLD

BP

BS

BTBU

BR



6 - 1286 - 127

Hydraulic Schematic - 4WD Models(from serial number 11004)

Dis

trib

ute

d B

y:

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

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Fax +86 21 53852569

Genie SingaporePhone +65 67533544

Fax +65 67533544

Genie JapanPhone +81 3 6436 2020

Fax +81 3 5445 1231

Genie KoreaPhone +82 2 558 7267

Fax +82 2 558 3910

Genie BrasilPhone +55 11 4082 5600

Fax +55 22 4082 5630

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 57 51 00

Fax +46 31 57 51 04

Genie FrancePhone +33 2 37 26 09 99

Fax +33 2 37 26 09 98

Genie IbericaPhone +34 93 572 5090

Fax +34 93 572 5091

Genie GermanyPhone 0800 180 9017

Phone +49 4221 491 810

Fax +49 4221 491 820

Genie U.K.Phone +44 1476 584333

Fax +44 1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

z60 06 - 12345 - simeri oy henkilönostin palvelut booms...perkins 404c-22 engine specifications ......

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