June 2015
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 E September 2013Third Edition, Fifth 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]
June 2015
Part No. 75861 Z-60/34
Revision Date Section Procedure / Schematic Page / Description
E 9/2013 New Printing
E1 6/2015 Introduction TOC, Checklist B Procedures
Maintenance Inspection Report
E2 6/2015 Maintenance Inspection ReportC-6 and C-7
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Section 5_Fault Codes.6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page numberhighlighted in blue to view the update.
Revision History
iii
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Z-60/34 Part No. 75861
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 5.6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page numberhighlighted in blue to view the update.
iv
June 2015
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
v
Serial Number LegendINTRODUCTION
Section 1 • Serial Number Legend
June 2015
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 perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules- employer’s safety rules and worksite
regulations- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
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Part No. 75861 Z-60/34 vii
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
June 2015
Z-60/34 Part No. 75861
Table of Contents
Introduction
Important Information ................................................................................................... ii
Revision History.......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 1 Safety Rules
General Safety Rules .................................................................................................. vi
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 3
Hydraulic Component Specifications ...................................................................... 2 - 4
Manifold Component Specifications ....................................................................... 2 - 6
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 7
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 9
Ford MSG-425 EFI Engine Specifications ............................................................ 2 - 10
Deutz F4L-1011F Engine Specifications .............................................................. 2 - 12
Deutz F3L-1011F Engine Specifications .............................................................. 2 - 13
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ..................................... 2 - 14
Perkins 404C-22 Engine Specifications ............................................................... 2 - 16
Machine Torque Specifications ............................................................................ 2 - 17
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 18
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 10
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TABLE OF CONTENTS
ix
Section 3 Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance - All Models .................................................... 3 - 9
A-5 Perform 30 Day Service ............................................................................. 3 - 10
A-6 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10
A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 11
A-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12
A-9 Inspect the Fuel Filter/Water Separator - Deutz Models ............................. 3 - 12
A-10 Perform Engine Maintenance - Ford Models ............................................... 3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-12 Perform Engine Maintenance - Deutz 1011 F Models ................................. 3 - 14
A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15
A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 16
Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 17
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3 Inspect the Air Filter ................................................................................... 3 - 19
B-4 Test the Key Switch ................................................................................... 3 - 20
B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 20
B-6 Check the Exhaust System ....................................................................... 3 - 21
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TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
B-7 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 21
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-10 Confirm the Proper Brake Configuration...................................................... 3 - 24
B-11 Test the Engine Idle Select ........................................................................ 3 - 25
B-12 Test the Fuel Select Operation - Ford Models ............................................ 3 - 25
B-13 Test the Ground Control Override ............................................................... 3 - 26
B-14 Check the Directional Valve Linkage .......................................................... 3 - 27
B-15 Test the Platform Self-leveling ................................................................... 3 - 27
B-16 Test the Drive Brakes ................................................................................ 3 - 28
B-17 Test the Drive Speed - Stowed Position ..................................................... 3 - 28
B-18 Test the Drive Speed - Raised or Extended Position .................................. 3 - 29
B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 30
B-20 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 30
B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 31
B-22 Perform Engine Maintenance - Ford Models ............................................... 3 - 32
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 33
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 34
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 34
C-4 Replace the Air Filter Element - Deutz and Perkins Models........................ 3 - 37
C-5 Replace the Fuel Inline Strainer- Deutz Models .......................................... 3 - 37
C-6 Check and Adjust the Engine RPM ............................................................ 3 - 38
C-7 Perform Engine Maintenance - Ford Models ............................................... 3 - 39
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Part No. 75861 Z-60/34
Section 3 Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 41
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42
D-3 Check the Free-wheel Configuration ........................................................... 3 - 43
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 44
D-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 46
D-6 Replace the Hydraulic Filter Elements ........................................................ 3 - 47
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 48
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52
E-3 Perform Engine Maintenance - Deutz 1011F and Perkins Models .............. 3 - 53
E-4 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 54
E-5 Perform Engine Maintenance - Ford Models ............................................... 3 - 55
E-6 Perform Engine Maintenance - Deutz 2011 Models .................................... 3 - 55
E-7 Perform Engine Maintenance - Deutz 2011 Models .................................... 3 - 56
E-8 Perform Engine Maintenance - Deutz 2011 Models .................................... 3 - 56
Section 4 Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 How to Remove the Platform........................................................................ 4 - 7
2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-3 Platform Rotator ........................................................................................... 4 - 9
2-4 Platform Overload System ......................................................................... 4 - 10
xi
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xii
Section 4 Repair Procedures, continued
Jib Boom Components
3-1 Jib Boom.................................................................................................... 4 - 14
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 15
Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 17
4-2 Primary Boom ............................................................................................ 4 - 19
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 21
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 22
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 25
Secondary Boom Components
5-1 Secondary Boom........................................................................................ 4 - 26
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 30
Engines
6-1 RPM Adjustment ........................................................................................ 4 - 31
6-2 Flex Plate................................................................................................... 4 - 31
6-3 Engine Fault Codes - Ford Models ............................................................. 4 - 35
Hydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 36
7-2 Drive Pump ................................................................................................ 4 - 37
Manifolds
8-1 Function Manifold Components - View 1(before serial number 4461) ....................................................................... 4 - 42
8-2 Function Manifold Components - View 2(before serial number 4461) ....................................................................... 4 - 44
8-3 Function Manifold Components (from serial number 4461) ......................... 4 - 46
8-4 Valve Adjustments - Function Manifold ...................................................... 4 - 48
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Section 4 Repair Procedures, continued
8-5 Jib Boom / Platform Rotate Manifold Components(before serial number 4461) ........................................................................ 4 - 50
8-6 Jib Boom / Platform Rotate Manifold Components(from serial number 4461 to serial number 10425) ...................................... 4 - 51
8-7 Jib Boom / Platform Rotate Manifold Components(from serial number 10426 to serial number 11003) .................................... 4 - 52
8-8 Jib Boom / Platform Rotate Manifold Components(from serial number 11004 to 11477) .......................................................... 4 - 53
8-9 Jib Boom / Platform Rotate Manifold Components(from serial number 11478) ......................................................................... 4 - 54
8-10 Brake/Two-Speed Manifold Components(before serial number 4461) ........................................................................ 4 - 56
8-11 Brake/Two-Speed Manifold Components(from serial number 4461) ........................................................................... 4 - 57
8-12 2WD Drive Manifold Components(before serial number 4551) ........................................................................ 4 - 58
8-13 2WD Drive Manifold Components(from serial number 4551) ........................................................................... 4 - 60
8-14 4WD Traction Manifold Components .......................................................... 4 - 62(before serial number 10154)
8-15 4WD Traction Manifold Components .......................................................... 4 - 64(from serial number 10154)
8-16 Valve Adjustments, Traction Manifolds ...................................................... 4 - 66
8-17 Directional Valve Manifold Components ..................................................... 4 - 67
8-18 Directional Valve Linkage ........................................................................... 4 - 68
8-19 Valve Adjustments, Oscillate Directional Valve .......................................... 4 - 69
8-20 Turntable Rotation Manifold Components ................................................... 4 - 70
8-21 Oil Diverter Manifold (welder option) ........................................................... 4 - 71
8-22 Valve Coils ................................................................................................. 4 - 72
TABLE OF CONTENTS
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Z-60/34 Part No. 75861
TABLE OF CONTENTS
Section 4 Repair Procedures, continued
Turntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 74
Axle Components
10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 75
10-2 Oscillate Cylinders ..................................................................................... 4 - 76
Generators
11-1 Valve Adjustment, Hydraulic Generator ...................................................... 4 - 77
Section 5 Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Code Chart - Control System ........................................................................ 5 - 2
Fault Code Chart - Ford LRG-425 EFI Engine ........................................................ 5 - 6
Fault Code Chart - Ford DSG-423 EFI Engine ...................................................... 5 - 12
Fault Code Chart - Ford MSG-425 EFI Engine ..................................................... 5 - 16
Section 6 Schematics
Introduction ............................................................................................................6 - 1
Wire Connector Legend ..........................................................................................6 - 2
Electrical Symbols Legend ....................................................................................6 - 3
Hydraulic Symbols Legend ....................................................................................6 - 4
Electrical Abbreviations Legend .............................................................................6 - 5
Ford DSG-423 EFI Engine Relay Layout ................................................................6 - 8
Ford MSG-425 EFI Engine Relay Layout ...............................................................6 - 8
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Part No. 75861 Z-60/34 xv
Section 6 Schematics, continued
Diesel Electrical Schematic,(before serial number 4496) ........................................................................ 6 - 10
Diesel Electrical Schematic,(from serial number 4496 to serial number 5325) ........................................ 6 - 14
Diesel Electrical Schematic,(from serial number 5326 to serial number 9798) ........................................ 6 - 18
Diesel Electrical Schematic ANSI/CSA,(from serial number 9799 to serial number 10387) ...................................... 6 - 22
Diesel Electrical Schematic ANSI/CSA,(from serial number 10388) ......................................................................... 6 - 26
Diesel Electrical Schematic CE,(from serial number 9799 to serial number 10387) ...................................... 6 - 30
Diesel Electrical Schematic CE,(from serial number 10388) ......................................................................... 6 - 34
Diesel Ground Control Box Wiring Diagram,(before serial number 5716) ........................................................................ 6 - 38
Diesel Ground Control Box Wiring Diagram,(from serial number 5716 to serial number 9798) ........................................ 6 - 39
Diesel Ground Control Box Wiring Diagram,(from serial number 9799) ........................................................................... 6 - 42
Diesel Platform Control Box Wiring Diagram,(before serial number 7227) ........................................................................ 6 - 44
Diesel Platform Control Box Wiring Diagram,(from serial number 7227 to serial number 9065) ........................................ 6 - 45
Diesel Platform Control Box Wiring Diagram,(from serial number 9066 to serial number 9696) ....................................... 6 - 48
TABLE OF CONTENTS
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TABLE OF CONTENTS
xvi
Section 6 Schematics, continued
Diesel Platform Control Box Wiring Diagram,(from serial number 9697) ........................................................................... 6 - 49
Ford Electrical Schematic,(before serial number 4546) ........................................................................ 6 - 52
Ford Electrical Schematic,(from serial number 4546 to serial number 5715) ........................................ 6 - 56
Ford Electrical Schematic,(from serial number 5716 to serial number 6315) ........................................ 6 - 60
Ford Electrical Schematic,(from serial number 6316 to serial number 7226) ....................................... 6 - 64
Ford Electrical Schematic,(from serial number 7227 to serial number 10387) ...................................... 6 - 68
Ford Electrical Schematic, ANSI/CSA,(from serial number 10388 to serial number 11788) .................................... 6 - 72
Ford Electrical Schematic, ANSI/CSA,(from serial number 11789) ......................................................................... 6 - 76
Ford Electrical Schematic, CE,(from serial number 10388 to serial number 11788) .................................... 6 - 80
Ford Electrical Schematic, CE,(from serial number 11789) ......................................................................... 6 - 84
Ford Ground Control Box Wiring Diagram,before serial number 4546) ......................................................................... 6 - 88
Ford Ground Control Box Wiring Diagram,(from serial number 4546 to serial number 5715) ....................................... 6 - 89
Ford Ground Control Box Wiring Diagram,(from serial number 5716 to serial number 7226) ....................................... 6 - 92
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Part No. 75861 Z-60/34 xvii
Section 6 Schematics, continued
Ford Ground Control Box Wiring Diagram,(from serial number 7227 to serial number 9798) ........................................ 6 - 93
Ford Ground Control Box Wiring Diagram,(from serial number 9799) ........................................................................... 6 - 96
Ford Platform Control Box Wiring Diagram,(before serial number 7227) ........................................................................ 6 - 97
Ford Platform Control Box Wiring Diagram,(from serial number 7227 to serial number 9065) .......................................6 - 100
Ford Platform Control Box Wiring Diagram,(from serial number 9066 to serial number 9798) .......................................6 - 101
Ford Platform Control Box Wiring Diagram,(from serial number 9799 to serial number 11788) .....................................6 - 104
Ford Platform Control Box Wiring Diagram,(from serial number 11789) ........................................................................6 - 105
Engine Wire Harness,Ford LRG-425 EFI Models .........................................................................6 - 108
Engine Wire Harness,Ford DSG-423 EFI Models (before serial number 6810) ............................ 6 - 109
Engine Wire Harness,Ford DSG-423 EFI Models (from serial number 6810 to 11788) ................ 6 - 112
Engine Wire Harness,Ford MSG-425 EFI Models (from serial number 11789) ............................ 6 - 113
Electrical Schematic, CTE Option (before serial number 9697) .......................... 6 - 116
Electrical Schematic, CTE Option (from serial number 9697) ............................. 6 - 117
Joystick Connector Diagram .............................................................................. 6 - 120
Hydraulic Generator Options (from serial number 10283) ................................... 6 - 121
Electrical Schematic, Welder Option .................................................................. 6 - 124
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Z-60/34 Part No. 75861xviii
Section 6 Schematics, continued
Hydraulic Schematic, Welder Option ................................................................. 6 - 125
Hydraulic Schematic, 2WD Models(before serial number 4461) ...................................................................... 6 - 128
Hydraulic Schematic, 2WD Models(from serial number 4461 to 10282) .......................................................... 6 - 129
Hydraulic Schematic, 2WD Models(from serial number 10283 to serial number 11003) .................................. 6 - 132
Hydraulic Schematic, 2WD Models(from serial number 11004 to 11477) ........................................................ 6 - 133
Hydraulic Schematic, 2WD Models(from serial number 11478) ....................................................................... 6 - 135
Hydraulic Schematic, 4WD Models(before serial number 4461) ...................................................................... 6 - 138
Hydraulic Schematic, 4WD Models(from serial number 4461to serial number 10282) ..................................... 6 - 139
Hydraulic Schematic, 4WD Models(from serial number 10283 to serial number 11003) .................................. 6 - 142
Hydraulic Schematic, 4WD Models(from serial number 11004 to 11477) ........................................................ 6 - 143
Hydraulic Schematic, 4WD Models(from serial number 11478) ....................................................................... 6 - 145
TABLE OF CONTENTS
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 1
Specifications
Lug nut torque (before serial number 4551)
Flanged or tapered lug nut, dry 170 ft-lbs
230 Nm
Flanged or tapered lug nut, lubricated 130 ft-lbs
176 Nm
Lug nut torque (after serial number 4550)
Flanged lug nut, dry 240 ft-lbs
325 Nm
Flanged lug nut, lubricated 180 ft-lbs
244 Nm
Tapered lug nut, dry 170 ft-lbs
230 Nm
Tapered lug nut, lubricated 130 ft-lbs
176 Nm
Fluid capacities
Fuel tank 20 gallons
75.7 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 55 gallons
(including tank) 208.2 liters
Drive hubs (before serial number 4551) 17 fl oz
0.5 liters
Drive hubs (after serial number 4550) 20 fl oz
0.59 liters
Turntable rotation drive hub 8 fl oz
0.24 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
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 June 2015
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
Platform rotate, 160° 9 to 15 seconds
Performance Specifications
Drive speeds
Stowed 40 ft / 7.9-8.5 sec
12.2 m / 7.9-8.5 sec
Raised or
Extended 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 ft
0.9 to 1.2 m
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 3
SPECIFICATIONS
Hydraulic Oil Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD MV equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rando HD MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Eni ARNICA 32
Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.
Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.
Note: Use Shell Tellus S2 V 46 hydraulic oil whenoil temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieService Department before use.
Section 2 • Specifications June 2015
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 models
0 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 gpm
0 to 70.0 L/min
Flow rate @ 2500 rpm, 4WD models 0 to 30.1 gpm
0 to 113.9 L/min
Drive pressure, maximum, 2WD models 4200 psi
290 bar
Drive pressure, maximum, 4WD models 3625 psi
250 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 gpm
106 L/min
Drive pressure, maximum 3625 psi
250 bar
Charge pump (before serial number 4551)
Type: fixed displacement gear pump
Displacement, 2WD models 0.37 cu in
6.1 cc
Displacement, 4WD models 0.51 cu in
8.4 cc
Flow rate @ 2500 rpm, 2WD models 4 gpm
15.1 L/min
Flow rate @ 2500 rpm, 4WD models 5.5 gpm
20.8 L/min
Charge pressure @ 2500 rpm 250 psi
Neutral position 17.2 bar
Charge pump (after serial number 4550)
Type: gerotor pump
Displacement 0.85 cu in
13.9 cc
Flow rate @ 2500 rpm 9 gpm
34.1 L/min
Charge pressure @ 2500 rpm 310 psi
Neutral position 21.4 bar
Function pump (before serial number 4551)
Type gear, pressure balanced
Displacement 1.37 cu in
22.5 cc
Flow rate @ 2500 rpm 14.8 gpm
56 L/min
Function pump (after serial number 4550)
Type gear, pressure balanced
Displacement 1.04 cu in
17 cc
Flow rate @ 2500 rpm 10.69 gpm
40.5 L/min
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 5
Oscillation pump (after serial number 4550)
Type gear, fixed displacement
Displacement 0.37 cu in
6 cc
Auxiliary pump
Type gear, fixed displacement
Displacement - static 0.151 gpm
2.47 L/min
Auxiliary pump relief pressure 2400 psi
165 bar
Function manifold
System relief valve pressure 2600 psi
179.3 bar
Primary boom down 1800 psi
relief valve pressure 124 bar
Secondary boom down 1600 psi
relief valve pressure 110 bar
Steer flow regulator 3.5 gpm
13.2 L/min
Boom extend 2600 psi
179.3 bar
Oscillate pressure 750 psi
51.7 bar
Jib boom / platform rotate 1.5 gpm
flow 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 psi
12 bar
Drive motors, 4WD and 2WD models(before serial number 4551)
Displacement per revolution 1.71 cu in
high speed 28 cc
Displacement per revolution .87 cu in
low speed 14.2 cc
Drive motors, 4WD models(after serial number 4550)
Displacement per revolution, 0.79 cu in
high speed 13 cc
Displacement per revolution, 1.83 cu in
low speed 30 cc
Drive motors, 2WD models(after serial number 4550)
Displacement per revolution, 1.28 cu in
high speed 20.9 cc
Displacement per revolution, 2.14 cu in
low speed 35 cc
Hydraulic filters
High pressure filter Beta 3 ≥ 200
High pressure filter 102 psi
bypass pressure 7 bar
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter 51 psi
bypass pressure 3.5 bar
Hydraulic tank 10 micron with
return filter 25 psi / 1.7 bar bypass
Drive motor case drain Beta 10 ≥ 2
return filter
SPECIFICATIONS
Section 2 • Specifications June 2015
2 - 6 Z-60/34 Part No. 75861
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
SAE No. 8 38 ft-lbs / 51.5 Nm
SAE No. 10 41 ft-lbs / 55.6 Nm
SAE No. 12 56 ft-lbs / 75.9 Nm
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 7
Ford LRG-425 EFI Engine
Displacement 153 cu in
2.5 liters
Number of cylinders 4
Bore & stroke 3.78 x 3.4 in
96.01 x 86.36 mm
HorsepowerGross intermittent 70 @ 2500 rpm
Continuous 60 @ 2500 rpm
Gross intermittent 52 kW @ 2500 rpm
Continuous 44.7 kW @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1600 rpm
Frequency 396.8 Hz
High idle 2500 rpm
Frequency 620 Hz
Compression ratio 9.4:1
Compression pressure (approx.)Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances - 0.035 to 0.055 in
collapsed 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 of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Oil pressure switch specifications
Torque 8-18 ft-lbs
11-24 Nm
Oil pressure switch point 3-5 psi
0.21-0.34 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 DC
while starting (normal temperature)
Brush length, new 0.66 in
16.8 mm
Brush length wear limit 0.25 in
6.35 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 psi
4.4 bar
Fuel flow rate 0.58 gpm
2.18 L/min
SPECIFICATIONS
Section 2 • Specifications June 2015
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 inches
1.07 to 1.17 mm
Spark plug torque 5-10 ft-lbs
7-14 Nm
Engine coolant
Capacity 11.5 quarts
10.9 liters
Coolant temperature switch
Torque 8-18 ft-lbs
11-24 Nm
Temperature switch point 230° F
112° C
Alternator
Output 95A, 13.8V DC
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 9
Ford DSG-423 EFI Engine
Displacement 140.4 cu in
2.3 liters
Number of cylinders 4
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm
HorsepowerContinuous horsepower 59 @ 2500 rpm
Peak horsepower 69 @ 2500 rpm
Continuous horsepower 44 kW @ 2500 rpm
Peak horsepower 51 kW @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Low function idle (computer controlled) 1600 rpm
Frequency 53.3 Hz
High function idle (computer controlled) 2500 rpm
Frequency 83.3 Hz
Compression ratio 9.7:1
Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must be
at 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
Oil viscosity requirements
Unit ships with 5-W20 oil.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type Motorcraft AGSF-32-FEC
Spark plug gap 0.049 to 0.053 inches
1.244 to 1.346 mm
Engine coolant
Capacity 10 quarts
9.5 liters
Cylinder head temperature sending unit
Fault code set temperature 280°F
138°C
Engine shut-down temperature 300°F
149°C
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Current draw, maximum load 800A
Alternator
Output 95A, 13.8V DC
Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes
Torque
Flywheel bolts 83 ft-lbs
Electronic fuel pump
Fuel pressure, static 64 psi
4.4 bar
Fuel flow rate 0.43 gpm
1.6 L/min
SPECIFICATIONS
Section 2 • Specifications June 2015
2 - 10 Z-60/34 Part No. 75861
Ford MSG-425 EFI Engine
Displacement 152.5 cu in
2.5 liters
Number of cylinders 4
Bore & stroke 3.50 x 3.94 inches
89 x 100 mm
HorsepowerContinuous horsepower 60 @ 2500 rpm
Continuous horsepower 44.7 kW @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Idle speed (computer controlled) 1000 rpm
Low function idle (computer controlled) 1600 rpm
High function idle (computer controlled) 2500 rpm
Governor Electronic
Compression ratio 9.7:1
Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must be
at 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 6.7 quarts
(including filter) 6.4 liters
Oil switch pressure point 7-9 psi
0.48 to 0.62 bar
Electronic fuel pump
Fuel pressure, static 60 psi
4.14 bar
Fuel flow rate 0.43 gpm
1.6 L/min
Ignition system
Spark plug type Motorcraft AGSF-32-FEC
Spark plug gap 0.049 to 0.053 inches
1.244 to 1.346 mm
Engine coolant
Capacity 10 quarts
9.5 liters
Operating pressure 13-18 psi
Normal operating temperature 205° F
Cylinder head temperature sending unit
Fault code set temperature 280°F
138°C
Engine shut-down temperature 300°F
149°C
SPECIFICATIONS
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 11
Ford MSG-425 Engine, continued
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Current draw, maximum load 800A
Alternator
Output 95A, 13.8V DC
Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes
SPECIFICATIONS
Section 2 • Specifications June 2015
2 - 12 Z-60/34 Part No. 75861
SPECIFICATIONS
Deutz Engine F4L 1011F
Displacement 166.7 cu in
2.732 liters
Number of cylinders 4
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 56 @ 3000 rpm
42 kW @ 3000 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1500 rpm
Frequency 313 Hz
High idle 2300 rpm
Frequency 479.9 Hz
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure (hot @ 2000 rpm) 60 to 70 psi
4.1 to 4.8 bar
Oil capacity 11 quarts
(including filter) 10.5 liters
Oil viscosity requirements
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Injection system
Injection pump make OMAP
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Alternator output 60A, 14V
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in
19mm
Brush length, minimum 0.5 in
12.7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 13
Injection system
Injection pump make OMAP
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Alternator output 55A, 14V
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in
19 mm
Brush length, minimum 0.5 in
12.7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
Deutz F3L 1011F Engine
Displacement 125 cu in
2.05 liters
Number of cylinders 3
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 43 @ 2800 rpm
32 kW @ 2800 rpm
Firing order 1 - 2 - 3
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1500 rpm
Frequency 313 Hz
High idle 2300 rpm
Frequency 479.9 Hz
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 26 to 87 psi
1.8 to 6.0 bar
Oil capacity 8.5 quarts
(including filter) 8 liters
Oil viscosity requirements
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
SPECIFICATIONS
Section 2 • Specifications June 2015
2 - 14 Z-60/34 Part No. 75861
SPECIFICATIONS
Deutz F3L 2011 EngineDeutz D2011L03i Engine
Displacement 142 cu in
2.33 liters
Number of cylinders 3
Bore and stroke 3.7 x 4.4 inches
94 x 112 mm
Horsepower
Net intermittent 48.7 @ 2800 rpm
Net continuous 46.2 @ 2800 rpm
Net intermittent 36 kW @ 2800 rpm
Net continuous 34.5 kW @ 2800 rpm
Firing order 1 - 2 - 3
Low idle 1500 rpm
Frequency 313 Hz
High idle 2500 rpm
Frequency 521.7 Hz
Compression ratio 19:1
Compression pressure 362 to 435 psi
25 to 30 bar
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure, hot @ 2000 rpm 40-60 psi
2.8 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 viscosity requirements
Unit ships with 15-W40 oil.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Oil temperature switch
Torque 8-18 ft-lbs
11-24 Nm
Temperature switch point 220° F
104° C
Oil pressure switch
Torque 8-18 ft-lbs
11-24 Nm
Oil pressure switch point 7 psi
(Deutz F3L2011 Engine) .5 bar
Oil pressure switch point 22 psi
(Deutz D2011L03i Engine) 1.5 bar
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 15
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi
1034 bar
Injector opening pressure 3046 psi
210 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, normal load 140-200A
Brush length, new 0.72 in
18.5 mm
Brush length, minimum 0.27 in
7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator output 60A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
SPECIFICATIONS
Section 2 • Specifications June 2015
2 - 16 Z-60/34 Part No. 75861
Perkins 404-22 Engine
Displacement 134 cu in
2.2 liters
Number of cylinders 4
Bore and stroke 3.31 x 3.94 inches
84 x 100 mm
Horsepower
gross intermittent 50 @ 2800 rpm
continuous 41 @ 2800 rpm
gross intermittent 37.3 kW @ 2800 rpm
continuous 31 kW @ 2800 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1300 rpm
Frequency 200.4 Hz
Low idle with generator option 1500 rpm
Frequency 231.3 Hz
High idle 2500 rpm
Frquency 385.4 Hz
Compression ratio 22.4:1
Compression pressure 426 psi
29.4 bar
Pressure (psi) of lowest cylinder must
be within 50 psi / 3.45 bar of highest cylinder
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.008 in
0.2 mm
Exhaust 0.008 in
0.2 mm
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 viscosity requirements
Unit ships with 15-W40 oil.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Oil pressure sending unit
Torque 8-18 ft-lbs
11-24 Nm
Oil pressure switch point 14.2 psi
1 bar
Fuel injection system
Injection pump make Zexel
Injection pressure 2133 psi
147 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Alternator output 65A @ 13.8V DC
Fan belt deflection 3/8 to ½ in
9 to 12 mm
Starter motor
Current draw, normal load 140-200A
Brush length, new 0.7480 in
19 mm
Brush length, minimum 0.5 in
12.7 mm
SPECIFICATIONS
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 17
SPECIFICATIONS
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Coolant temperature sending unit
Torque 8-18 ft-lbs
11-24 Nm
Temperature switch point 221° F
105° C
Machine Torque Specifications
Platform rotator
1-8 center bolt, dry 640 ft-lbs
868 Nm
1-8 center bolt, Gr 5, lubricated 480 ft-lbs
651 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-lbs
244 Nm
Turntable rotate assembly
Turntable motor mounting bolts 160 ft-lbs*
*(use blue thread-locking compound) 217 Nm
Section 2 • Specifications June 2015
2 - 18 Z-60/34 Part No. 75861
SPECIFICATIONS
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.
Seal-Lok™ Fittings(hose end - ORFS)
SAE Dash size Torque
-4 10 ft-lbs / 13.6 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 / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
(all types)
SAE Dash size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Adjustablefitting (Adj)
Non-adjustablefitting (Non-adj)
Jamb nut
Section 2 • SpecificationsJune 2015
Part No. 75861 Z-60/34 2 - 19
Figure 1
a hex nutb reference markc body hex fitting
3 Working clockwise on the body hex fitting, makea second mark with a permanent ink marker toindicate the proper tightening position. Refer toFigure 2.
Note: Use the JIC 37° Fittings table on the previouspage to determine the correct number of flats forthe proper tightening position.
Note: The marks indicate that the correct tighteningpositions have been determined. Use the secondmark on the body hex fitting to properly tighten thejoint after it has been loosened.
Figure 2
a body hex fittingb reference markc second mark
4 Tighten the hex nut until the mark on the hex nutis aligned with the second mark on the body hexfitting.
5 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
Torque ProcedureSeal-Lok™ fittings
1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok™fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field 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.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose ofthe fitting body (body hex fitting) and tighten thehex nut to the body hex fitting to hand-tight,approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of thehex nut, and continue it on to the body hexfitting with a permanent ink marker. Refer toFigure 1.
a
bc
a
b
c
b
Section 2 • Specifications June 2015
2 - 20 Z-60/34 Part No. 75861
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 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
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 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
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 Nm20 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 Nm18 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 5DRYLUBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 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
Part No. 75861 Z-60/34 3 - 1
June 2015 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall be
completed 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 a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a
period longer than three months must completethe quarterly inspection.
Unless otherwise specified, perform each
maintenance 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
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.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Note: Used to indicate operation or maintenanceinformation
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
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June 2015Section 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 a minimum of 4 years or in compliance with youremployer, jobsite and governmental regulations andrequirements.
SCHEDULED MAINTENANCE PROCEDURES
Terex Spouth Dakota, Inc. USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc.133192 Rev D
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.
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Part No. 75861 Z-60/34 3 - 5
June 2015 Section 3 • Scheduled Maintenance Procedures
Checklist A Y N R
A-1 Inspect the manuals
and decals
A-2 Pre-operation
inspection
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
Perform every 50 hours:
A-8 Engine maintenance-
Perkins models
Perform every 100 hours:
A-9 Fuel filter/water
separator -
Deutz models
A-10 Engine maintenance -
Ford models
A-11 Rotation bearing
Perform after first 125 hours:
A-12 Engine maintenance -
Deutz 1011F models
Perform after first 150 hours:
A-13 Drive hub oil
Perform every 200 hours:
A-14 Engine maintenance -
Ford models
Checklist B 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 Perkins
models
B-6 Exhaust system
B-7 Oil cooler and fins-
Deutz models
B-8 Tires, wheels and lug
nut torque
B-9 Drive hub maintenance
B-10 Brake configuration
B-11 Engine idle select
B-12 Fuel select -
Ford models
B-13 Ground control
B-14 Directional
valve linkage
B-15 Platform
self-leveling
B-16 Drive brakes
B-17 Drive speed -
stowed position
B-18 Drive speed -
raised position
B-19 Hydraulic oil analysis
B-20 Alarm package
B-21 Fuel and hydraulic cap
venting systems
Perform every 400 hours:
B-22 Engine maintenance -
Ford models
Maintenance Inspection Report
Instructions• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
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 box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
LegendY = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Comments
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June 2015Section 3 • Scheduled Maintenance Procedures
Checklist C Y N R
C-1 Engine maintenance -
Deutz and Perkins
models
C-2 Platform overload
(if equipped)
C-3 Platform overload
(if equipped)
C-4 Air filter element -
Deutz and Perkins
models
C-5 Fuel inline strainer -
Deutz models
C-6 Check engine rpm
Perform every 800 hours:
C-7 Engine maintenance -
Ford models
Checklist D Y N R
D-1 Boom wear pads
D-2 Turntable bearing bolts
D-3 Free-wheel
configuration
D-4 Drive hub oil
D-5 Engine maintenance-
Deutz and Perkins
models
D-6 Hydraulic filters
D-7 Turntable bearing wear
MAINTENANCE INSPECTION REPORT
Checklist E Y N R
E-1 Hydraulic oil
E-2 Steer axle
wheel bearings,
2WD models
Perform every 2000 hours:
E-3 Engine maintenance -
Deutz and
Perkins models
Perform every 3000 hours:
E-4 Engine maintenance -
Deutz and
Perkins models
Perform every 4 years:
E-5 Engine maintenance -
Ford models
Perform every 5000 hours:
E-6 Engine maintenance -
Deutz models
Perform every 6000 hours:
E-7 Engine maintenance -
Deutz
Perform every 12,000 hours:
E-8 Engine maintenance -
Deutz models
Comments
Instructions• Make copies of both pages to use for
each inspection.
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
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 box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
LegendY = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Part No. 75861 Z-60/34 3 - 7
June 2015 Section 3 • Scheduled Maintenance Procedures
Checklist A ProceduresA-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 for
the 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 all
required 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 if replacement manuals or decals areneeded.
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June 2015Section 3 • Scheduled Maintenance Procedures
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
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June 2015 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-4Perform Engine Maintenance
Engine specifications require that this procedure beperformed every 8 hours or daily, whichever comesfirst.
Deutz models
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683) orthe Deutz 2011 Operation Manual (Deutz partnumber 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 the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
Ford models
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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.
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June 2015Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
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 be
operating 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. Refer to Maintenance Procedure,Replace the Hydraulic Filter Elements.
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 and
Rotate Gear
• B-8 Inspect the Tires, Wheels and Lug Nut
Torque
• B-9 Check the Drive Hub Oil Level and
Fastener Torque
• D-2 Check the Turnable Rotation Bearing
Bolts
• D-6 Replace the Hydraulic Filter Elements
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June 2015 Section 3 • Scheduled Maintenance Procedures
A-7Perform Engine Maintenance -Deutz and Ford Models
Engine specifications require that this procedure beperformed after the first 50 hours of operation.
Deutz models
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683) orthe Deutz 2011 Operation Manual (Deutz partnumber 0297 9929).
Deutz 1011F Operation ManualGenie part number 52883
Deutz 2011 Operation ManualGenie part number 84794
CHECKLIST A PROCEDURES
Ford models
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
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June 2015Section 3 • Scheduled Maintenance Procedures
CHECKLIST 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 engine performance.Failure to perform this procedure can lead to poorengine performance and/or hard starting, andcontinued use may result in component damge.Extremely dirty conditions may require thisprocedure 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 procedure beperformed every 50 hours.
Perkins models
Required maintenance procedures and additionalengine information are available in the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
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
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June 2015 Section 3 • Scheduled Maintenance Procedures
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.
CHECKLIST A PROCEDURES
A-10Perform Engine Maintenance -Ford Models
Engine specifications require that this procedure beperformed every 100 hours.
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
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June 2015Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-12Perform Engine Maintenance -Deutz 1011F Models
Engine specifications require that this procedure beperformed after the first 125 hours.
Deutz models
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683).
Deutz 1011F Operation ManualGenie part number 52883
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
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
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June 2015 Section 3 • Scheduled Maintenance Procedures
aa
bb
CHECKLIST A PROCEDURES
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 Specifications, Machine 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.
2 Remove both plugs and drain the oil into asuitable container.
3 Drive the machine until one plug (a) is justabove horizontal. See illustration B.
4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Specifications, Machine Specifications.
5 Apply pipe thread sealant to the plugs. Installthe plugs.
6 Repeat steps 1 through 4 for all the other drivehubs.
Illustration A Illustration B
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June 2015Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-14Perform Engine Maintenance -Ford Models
Engine specifications require that this procedure beperformed every 200 hours.
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
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June 2015 Section 3 • Scheduled Maintenance Procedures
Checklist 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/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.
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 adjusted
specific 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 gravity
of 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.
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June 2015Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-2Inspect the Electrical Wiring
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.
Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.
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.
Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.
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.
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June 2015 Section 3 • Scheduled Maintenance Procedures
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.
Note: Perform this procedure with the engine off.
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 PROCEDURES
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CHECKLIST B PROCEDURES
B-5Perform Engine Maintenance -Deutz and Perkins Models
Engine specifications require that this procedure beperformed quarterly or every 250 hours, whichevercomes first.
Deutz models
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683).
Deutz 1011F Operation ManualGenie part number 52883
Perkins models
Required maintenance procedures and additionalengine information are available in the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
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
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 no
functions should operate.
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B-7Check the Oil Cooler and CoolingFins - Deutz Models
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.
Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.
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
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.
1 Remove the engine tray retaining fastenerslocated under the engine tray. Swing the enginetray out and away from the machine and secureit from moving.
Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.
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.
Crushing hazard. Failure to installthe fasteners into the engine trayto secure it from moving couldresult in death or serious injury.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
B-8Inspect the Tires, Wheelsand Lug Nut Torque
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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 toSpecifications, Machine Torque Specifications.
Models with air-filled tires:
4 Check pressure in each air-filled tire. Add air asnecessary. Refer to Specifications, MachineSpecifications.
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.
Crushing hazard. Failure to installthe fasteners into the engine trayto secure it from moving couldresult in death or serious injury.
cba
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aa
bb
B-9Check the Drive Hub Oil Leveland Fastener Torque
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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 the
bottom 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 Specifications, MachineSpecifications.
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 Specifications, MachineTorque Specifications.
6 Repeat this procedure for each drive hub.
models with pipe plugs a drive hub plugs
a
Drive Hub (after serial number 4550)
1 Drive the machine until one plug is just abovehorizontal. See illustration B.
2 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Specifications, Machine Specifications.
3 Apply pipe thread sealant to the plugs. Installthe plugs.
4 Check the torque of the drive hub mountingfasteners. Refer to Specifications, MachineTorque Specifications.
5 Repeat this procedure for each drive hub.
Illustration A Illustration B
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
brake disengaged position
brake engaged position
a
d
c
b
B-10Confirm the ProperBrake Configuration
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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 the bottomof the drive pump.
a drive pumpb screwdriverc lift pumpd free-wheel valve
Note: The free-wheel valve should always remainclosed.
a
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 Specifications,Machine Torque Specifications.
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CHECKLIST B PROCEDURES
B-11Test 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.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
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 to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
7 Move the engine idle control switch to footswitch activated low idle (turtle symbol).
Result: The engine should change to low idle.
aa
B-12Test the Fuel Select Operation -Ford Models
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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).
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.
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CHECKLIST B PROCEDURES
B-13Test 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.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boomfunction through a partial cycle.
Result: All boom functions should operate.
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B-14Check the Directional ValveLinkage
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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 clevis
pins
• Linkage is properly attached to
directional valve
CHECKLIST B PROCEDURES
B-15Test the Platform Self-leveling
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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 at
all times to within ±5 degrees.
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CHECKLIST B PROCEDURES
B-17Test the Drive Speed -Stowed Position
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.
Note: Select a test area that is firm, level and freeof obstructions.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch symbol), then lower the boom into thestowed position.
4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
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 Specifications, PerformanceSpecifications.
B-16Test the Drive Brakes
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.Refer to Maintenance Procedure,Confirm the Proper BrakeConfiguration.
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 toSpecifications, Performance Specifications.
Note: The brakes must be able to hold the machineon any slope it is able to climb.
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B-18Test the Drive Speed -Raised or Extended Position
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.
Note: Select a test area that is firm, level and freeof obstructions.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Move the engine idle select switch to foot 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.
CHECKLIST B PROCEDURES
6 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Specifications, PeformanceSpecifications.
8 Lower the boom to the stowed position andextend the boom 1 foot / 30 cm.
9 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
10 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Specifications, PerformanceSpecifications.
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CHECKLIST B PROCEDURES
B-20Test 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 and
flashing.
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 when
the toggle switch is held down.
B-19Perform Hydraulic Oil Analysis
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
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.Refer to Maintenance Procedure, Test or Replacethe Hydraulic Oil.
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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 when
the toggle switch is held down.
4 Turn the key switch to platform controls.
Result: The flashing beacons should be on
and 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 when
the 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 when
the 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 the
drive controller is moved off center in eitherdirection.
CHECKLIST B PROCEDURES
B-21Inspect 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.
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.
Gasoline/LPG models (before serialnumber 7924) and Diesel models (all):
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Note: When checking for positive fuel tank capventing, air should pass freely through the cap.
Result: Air should pass through the fuel tank
cap. Proceed to step 4.
Result: Air is not passing through the fuel tankcap. Clean or replace the cap. Proceed to step3.
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B-22Perform Engine Maintenance -Ford Models
Engine specifications require that this procedure beperformed every 400 hours.
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
CHECKLIST B PROCEDURES
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.
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Checklist C Procedures
C-1Perform Engine Maintenance -Deutz and Perkins Models
Engine specifications require that this procedure beperformed every 500 hours.
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 the Deutz 1011FOperation Manual (Deutz part number 0297 9683) orthe Deutz 2011 Operation Manual (Deutz partnumber 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 the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
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
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CHECKLIST 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
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June 2015 Section 3 • Scheduled Maintenance Procedures
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 lights
should 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, 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 lights
should 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, 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, 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, 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 PROCEDURES
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CHECKLIST C PROCEDURES
8 Test all machine functions from the platformcontrols.
Result: All platform control functions should not
operate.
9 Turn the key switch to ground control.
10 Test all machine functions from the groundcontrols.
Result: All ground control functions should not
operate.
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 should
operate.
13 Using a suitable lifting device, lift the additionaltest weight from the platform.
Result: The platform overload indicator lights
should 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 should
operate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platformcontrols.
Result: All platform control functions should
operate.
Note: If the platform overload system is notoperating properly, Refer to Repair Procedure, Howto Calibrate the Platform Overload System (ifequipped).
17 Using a suitable lifting device, remove theremaining test weights from the platform.
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C-5Replace the In-line Fuel Strainer -Deutz Models
Engine specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes 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.
Explosion/burn and fire hazard.Engine fuels are combustible.Perform this procedure in an open,well-ventilated area away fromheaters, sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
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 PROCEDURES
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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, disregard adjustmentstep 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 toSpecifications, Engine Specifications.
CHECKLIST C PROCEDURES
C-6Check and Adjust theEngine RPM
Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first.
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 Product Support OR yourlocal Ford dealer.
Deutz Models
1 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSpecifications, Engine Specifications.
Skip to step 3 if the low idle rpm is correct.
2 Loosen the low idle lock nut and turn the low idleadjustment screw clockwise to increase the rpmor 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 Specifications,Engine Specifications.
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a b c d
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 toSpecifications , Engine Specifications.
If high idle rpm is correct, disregard adjustmentstep 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.
C-7Perform Engine Maintenance -Ford Models
Engine specifications require that this procedure beperformed every 800 hours.
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.
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
CHECKLIST C PROCEDURES
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CHECKLIST C PROCEDURES
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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.
2 Start the engine from the ground controls.
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 Procedures
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CHECKLIST D PROCEDURES
1
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9
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Bolt torque sequence
3 Be sure that each turntable mounting bolt istorqued in sequence to specifications. Refer toSpecifications, Machine Torque Specifications.
4 Start the engine from the ground controls.
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 toSpecifications, Machine Torque Specifications.
Bolt torque sequence
D-2
Check the Turntable RotationBearing Bolts
Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever comes first.
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 primary boom and place safetychocks on the secondary 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.
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June 2015 Section 3 • Scheduled Maintenance Procedures
disengaged position
engaged position
D-3
Check the Free-wheelConfiguration
Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever comes first.
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 PROCEDURES
5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate with
minimum 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.
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D-4Replace the Drive Hub Oil
Genie specifications requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
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.
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 Specifications, Machine 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
CHECKLIST D PROCEDURES
a
d
c
b
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
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aa
bb
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.
2 Remove both plugs and drain the oil into asuitable container.
3 Drive the machine until one plug is just abovehorizontal. See illustration B.
4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Specifications, Machine Specifications.
5 Apply pipe thread sealant to the plugs. Installthe plugs.
6 Repeat steps 1 through 4 for all the other drivehubs.
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 Specifications, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the secondary boom until the platform endof the lower secondary boom arm isapproximately 8 feet / 2.4 m off the ground.
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
4 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.
unlocked locked
a
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D-5Perform Engine Maintenance -Deutz and Perkins Models
Engine specifications require that this procedure beperformed every 1000 hours.
Deutz models
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683) orthe Deutz 2011 Operation Manual (Deutz partnumber 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 the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
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
CHECKLIST D PROCEDURES
5 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.Illustration AIllustration B
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 the machine.Torque the drive hub mounting bolts tospecification. Refer to Specifications, MachineTorque 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.
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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.
Note: Perform this procedure with the engine off.
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 PROCEDURES
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.
18 Start the engine from the ground controls.
19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.
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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
CHECKLIST D PROCEDURES
D-7Inspect for Turntable BearingWear
Genie specifications requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
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. Refer toMaintenance Procedure, Grease the TurntableBearing and Rotate Gear.
2 Torque the turntable bearing bolts tospecification. Refer to Maintenance Procedure,Check the Turntable Rotation Bearing Bolts.
3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.
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7 Note the reading on the dial indicator.
Result: The measurement is less than
0.047 inch / 1.2 mm. The bearing is good.
Result: The measurement is more 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.
CHECKLIST D PROCEDURES
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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 toSpecifications, Machine 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
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CHECKLIST E PROCEDURES
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 Procedure,How to Prime the Pump.
Note: Always use pipe thread sealant wheninstalling the suction hose fittings and the drainplug.
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CHECKLIST E PROCEDURES
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 and
down 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.
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15 Place the large inner bearing into the rear of thehub.
16 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease seal whenremoving 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.
Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.
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 Specifications, MachineSpecifications.
E-3Perform Engine Maintenance -Deutz 1011F and Perkins Models
Engine specifications require that this procedure beperformed every 2000 hours.
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 1011F models
Required maintenance procedures and additionalengine information is available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683).
Deutz 1011F Operation ManualGenie part number 52883
Perkins models
Required maintenance procedures and additionalengine information are available in the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
To access the engine:
1 Remove the engine tray retaining fastenerslocated under the engine tray. Swing the enginetray out and away from the machine and secureit from moving.
Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.
CHECKLIST E PROCEDURES
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Perkins models
Required maintenance procedures and additionalengine information are available in the Perkins404C-22 Operation Manual (Perkins part numberTPD 1443S).
Perkins 404C-22 Operation ManualGenie part number 94890
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
CHECKLIST E PROCEDURES
E-4Perform Engine Maintenance -Deutz and Perkins Models
Engine specifications require that this procedure beperformed every 3000 hours.
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.
Required maintenance procedures and additionalengine information are available in the Deutz 1011FOperation Manual (Deutz part number 0297 9683) orthe Deutz 2011 Operation Manual (Deutz partnumber 0297 9929).
Deutz 1011F Operation ManualGenie part number 52883
Deutz 2011 Operation ManualGenie part number 84794
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
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E-6Perform Engine Maintenance -Deutz 2011 Models
Engine specifications require that this procedure beperformed every 5000 hours.
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.
Required maintenance procedures and additionalengine information are available in the Deutz 2011Operation Manual (Deutz part number 0297 9929).
Deutz 2011 Operation ManualGenie part number 84794
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
CHECKLIST E PROCEDURES
E-5Perform Engine Maintenance -Ford Models
Engine specifications require that this procedure beperformed every 4 years.
Required maintenance procedures and additionalengine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP194-302) or the Ford DSG-423 EFI OperatorHandbook (EDI part number 1060020) or the FordMSG-425 EFI Operator Handbook (Ford partnumber 1020010).
Ford LRG 425 EFI Operation ManualGenie part number 84792
Ford DSG 423 EFI Operator HandbookGenie part number 119488
Ford MSG-425 EFI Operator HandbookGenie part number 215322
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
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CHECKLIST E PROCEDURES
E-8Perform Engine Maintenance -Deutz 2011 Models
Engine specifications require that this procedure beperformed every 12,000 hours.
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.
Required maintenance procedures and additionalengine information are available in the Deutz 2011Operation Manual (Deutz part number 0297 9929).
Deutz 2011 Operation ManualGenie part number 84794
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
E-7Perform Engine Maintenance -2011 Deutz Models
Engine specifications require that this procedure beperformed every 6000 hours.
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.
Required maintenance procedures and additionalengine information are available in the Deutz 2011Operation Manual (Deutz part number 0297 9929).
Deutz 2011 Operation ManualGenie part number 84794
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
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June 2015 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
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.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Indicates that a specific result is expected after
performing 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 a
person trained and qualified on the repair of thismachine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:Read, understand and obey the safety rules
and operating instructions in the Genie Z-60/34Operator’s Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform each
repair 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
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June 2015Section 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. Refer toRepair Procedure, 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.Refer to Repair Procedure, How to Calibrate aJoystick.
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.
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 from thecircuit board.
6 Remove the ALC-500 circuit board mountingfasteners.
7 Carefully remove the ALC-500 circuit board fromthe platform control box.
Platform Controls
bcd
a
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June 2015 Section 4 • Repair Procedures
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.
Note: Perform this procedure with the engine off.
1 Open the platform control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Turn the key switch to platform control. Do notstart the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.
6 Move the joystick full stroke in either directionand hold for 5 seconds.
7 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds.
Result: The alarm should sound indicating
successful joystick calibration.
Result: The alarm does not sound. Check theelectrical connections or replace the joystick.
8 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
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.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
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.
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June 2015Section 4 • Repair Procedures
PLATFORM CONTROLS
7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.
Result: There should be a pause and the alarm
should 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 Specifications, PerformanceSpecifications to determine whether the functiontime needs to increase or decrease.
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 right to increase the time ormomentarily move the drive enable toggleswitch to the left 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 that
the settings have been saved in memory.
Note: Do not operate any machine function duringthe 10 second waiting time.
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.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
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 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that themachine is in ramp rate calibration mode.
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June 2015 Section 4 • Repair Procedures
PLATFORM CONTROLS
8 Start the engine from the platform controls andpress down the foot switch.
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.
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Note: Do not operate any machine function duringthe 10 second waiting time.
Ramp rate (factory settings)
Primary boom up/downaccelerate 3 seconds
decelerate 1 second
Secondary boom up/downaccelerate 2 seconds
decelerate 1 second
Turntable rotateaccelerate 2 seconds
decelerate 0.5 second
Driveaccelerate 2 seconds
decelerate to neutral 0.5 second
decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
decelerate, braking 1.5 seconds
decelerate, shift from low to high speed
2WD and 4WD models 1.75 seconds
decelerate, shift from high to low speed
2WD models 1 second
decelerate, shift from high to low speed
4WD models 3.5 seconds
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June 2015Section 4 • Repair Procedures
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.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
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 8 times.
Result: There should be a pause and the alarm
should sound 8 times indicating that themachine is in threshold calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
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 a
successful calibration.
12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntablerotate).
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.
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June 2015 Section 4 • Repair Procedures
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.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
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.
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June 2015Section 4 • Repair Procedures
PLATFORM 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 Specifications, 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
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June 2015 Section 4 • Repair Procedures
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.
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.
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
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June 2015Section 4 • Repair Procedures
PLATFORM 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.
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.
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.
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June 2015 Section 4 • Repair Procedures
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.
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 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 and
the 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.
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June 2015Section 4 • Repair Procedures
8 Add an additional 10 lb / 4.5 kg test weight tothe platform.
Result: The overload indicator light is flashing at
both 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.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
9 Test all machine functions from the platformcontrols.
Result: All platform control functions should not
operate.
10 Turn the key switch to ground control.
11 Test all machine functions from the groundcontrols.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weightoff the platform floor.
Result: The platform overload indicator light
should 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.
13 Test all machine functions from the groundcontrols.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platformcontrols.
Result: All platform control functions should
operate normally.
6 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 at
the 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.
7 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 and
the 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.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
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June 2015 Section 4 • Repair Procedures
c d
h gm l jk iin
dba e f
a jib boom
b extension boom
c primary boom
d lower tension link
e upper secondary boom
f upper pivot
g turntable bulkhead
h primary boom lift cylinder
i lower leveling link
j lower secondary boom
k secondary boom lift cylinder
l mid-pivot
m connecting link
n jib boom leveling link
Boom Components
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Jib Boom Components
3-1Jib Boom
How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform. Refer to RepairProcedure, How to Remove the Platform.
2 Remove the platform mounting weldment,the platform leveling slave cylinder and theplatform rotator. Refer to Repair Procedure, Howto Remove the Platform Leveling SlaveCylinder.
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.
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.
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.
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.
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.
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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.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
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.
Note: Do not rest the entire weight of the boom onthe 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.
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June 2015Section 4 • Repair Procedures
5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
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.
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
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Primary 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 Specifications, 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.
Note: Do not rest the entire weight of the boom onthe blocks.
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.
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 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.
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.
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 primary
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PRIMARY BOOM COMPONENTS
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
extension 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.
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June 2015 Section 4 • Repair Procedures
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.
Note: Perform this procedure with the boom in thestowed position.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform.Refer to Repair Procedure, How to Remove thePlatform.
2 Remove the platform rotator and platformmounting weldment.
3 Remove the jib boom.Refer to Repair Procedure, How to Remove theJib Boom.
4 Remove cable track.See Repair Procedure, How to Remove theCable Track.
PRIMARY BOOM COMPONENTS
5 Remove the hose and cable clamp from theupper mid-pivot.
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.
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.
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.
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June 2015Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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. Refer to Repair Procedure, Howto Remove the Primary Boom Extension Cylinder.
1 Remove the primary boom. Refer to RepairProcedure, 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.
4 Use a soft metal drift to remove the 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.
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.
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June 2015 Section 4 • Repair Procedures
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.
Note: Pay careful attention to the location andamount of shims used with each wear pad.
PRIMARY BOOM COMPONENTS
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.
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 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.
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June 2015Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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.
Note: Perform this procedure with the boom in thestowed position.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform.Refer to Repair Procedure, How to Remove thePlatform.
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.
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.
11 Place another 24 inch / 60 cm long block ofwood across the lower secondary boomleveling links to support the primary boom liftcylinder.
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.
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June 2015 Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
2 Remove the jib boom. Refer Repair Procedure,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.
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 cotter pin from the extensioncylinder barrel-end pivot pin.
6 Remove the pin using a soft metal drift.
7 Support the extension boom and remove thewear pads from the primary boom.
Note: Pay careful attention to the location andamount of shims used with each wear pad.
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.
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June 2015Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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.
4 Remove the cotter pin from the extensioncylinder barrel-end pivot pin.
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.
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June 2015 Section 4 • Repair Procedures
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.
Note: Perform this procedure with the boom in thestowed position.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
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.
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.
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.
PRIMARY BOOM COMPONENTS
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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.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
Remove the primary boom. Refer to RepairProcedure, 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.
Secondary Boom Components
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.
7 Remove the pin using a soft metal drift.
8 Attach a securing strap from the upper pivot totension link pivot pin mounting tube on theturntable bulkhead, to prevent the upper pivotfrom moving.
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 pivot pins.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.
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SECONDARY BOOM COMPONENTS
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.
Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.
16 Disconnect the battery cables.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
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 of theturntable bulkhead covers, and remove bothturntable bulkhead covers.
20 Remove the hydraulic tank. Refer toMaintenance Procedure, Test or Replace theHydraulic 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.
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.
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SECONDARY BOOM COMPONENTS
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.
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.
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 the 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.
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.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
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.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
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June 2015 Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
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.
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.
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SECONDARY BOOM COMPONENTS
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.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
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.
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.
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.
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June 2015 Section 4 • Repair Procedures
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.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
5 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
6-1RPM Adjustment
Refer to Maintenance Procedure, Check and Adjustthe Engine RPM.
Engines
a b c d e
f
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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.
11 Support the drive pump assembly with anappropriate lifting device.
12 Remove all of the engine bell housing fasteners.
13 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
14 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
Ford DSG-423 and MSG-425 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.
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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.
10 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
11 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
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.
3 Support the drive pump assembly with anappropriate lifting device.
4 Remove all of the engine bell housing fasteners.
5 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
6 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
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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 and MSG-425 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.
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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 Fault Codes Section, How to RetrieveEngine Fault Codes. Use the Fault Code Charts toaid in identifying the fault.
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 modelsFord MSG 425 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 - 36 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
Hydraulic 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 to Specifications, Hydraulic Hose and FittingTorque Specifications.
1 Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. Refer toSpecifications, Machine Specifications.
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.
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.
2 Tag, disconnect and plug the function pumphydraulic hoses. Cap the fittings on the pump.
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.
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 - 37
June 2015 Section 4 • Repair Procedures
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 Product Support tolocate your local authorized service center.
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 to Specifications, Hydraulic Hose and FittingTorque Specifications.
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.
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.
3 Tag and disconnect and plug the hydraulichoses from the drive and function pumps.Cap the fittings on the pumps.
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.
open closed
4 - 38 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
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 - 39
June 2015 Section 4 • Repair Procedures
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 - 40 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
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
and motion control ............................30-35 ft-lbs / 41-47 Nm
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 - 41
June 2015 Section 4 • Repair Procedures
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 - 42 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
8-2Function Manifold Components - View 2(before serial number 4461)
The function manifold is located behind the ground control box.
Index SchematicNo. Description Item Function Torque
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 - 43
June 2015 Section 4 • Repair Procedures
MANIFOLDS
1
Z
AA
AB
AC
AD
AE
AF
AG
AH
AI
AJ
AK
AM
AL
X
Y
4 - 44 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
8-3Function Manifold Componentsfrom 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 ....... 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
and motion control ............................30-35 ft-lbs / 41-47 Nm
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
and motion control ............................30-35 ft-lbs / 41-47 Nm
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 - 45
June 2015 Section 4 • Repair Procedures
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 - 46 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
8-3Function Manifold Components, continued(from serial number 4461)
The function manifold is located behind the ground control box.
Index SchematicNo. Description Item Function Torque
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 - 47
June 2015 Section 4 • Repair Procedures
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
June 2015Section 4 • Repair Procedures
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)
2 Start the engine from the ground controls.
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 Specifications, HydraulicComponent 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)
2 Start the engine from the ground controls.
3 Hold the function enable switch to the high rpmposition and activate and hold the primaryboom down switch with the primary boom fullylowered.
4 Observe the pressure reading on the pressuregauge. Refer to Specifications, HydraulicComponent Specifications.
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)
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.
MANIFOLDS
Part No. 75861 Z-60/34 4 - 49
June 2015 Section 4 • Repair Procedures
MANIFOLDS
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.
2 Start the engine from the ground controls.
3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.
4 Observe the pressure reading on the pressuregauge. Refer to Specifications, HydraulicComponent Specifications.
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)
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.
4 - 50 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
8-5Jib Boom / Platform Rotate Manifold Components(before serial number 4461)
Index SchematicNo. Description Item Function Torque
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 - 51
June 2015 Section 4 • Repair Procedures
8-6Jib Boom / Platform Rotate Manifold Components(from serial number 4461 to serial number 10425)
Index SchematicNo. Description Item Function Torque
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
5 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 - 52 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
MANIFOLDS
8-7Jib Boom / Platform Rotate Manifold Components(from serial number 10426 to serial number 11003)
Index SchematicNo. Description Item Function Torque
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
5 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
1
2BN
BM
Part No. 75861 Z-60/34 4 - 53
June 2015 Section 4 • Repair Procedures
8-8Jib Boom / Platform Rotate Manifold Components(from serial number 11004 to serial number 11477)
Index SchematicNo. Description Item Function Torque
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 - 54 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
8-9Jib Boom / Platform Rotate Manifold Components(from serial number 11478)
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 2 way ..... BW ......... Jib boom up/down ................... 19-21 ft-lbs / 25.8 - 28.6 Nm
2 Check valve ...................................... BV ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
3 Check valve ...................................... BQ ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
4 Flow control valve ............................ BO ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
5 Flow control valve ............................ BK ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
5BK
4BO
3BQ
2BV
1BW
MANIFOLDS
Part No. 75861 Z-60/34 4 - 55
June 2015 Section 4 • Repair Procedures
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MANIFOLDS
4 - 56 Z-60/34 Part No. 75861
June 2015Section 4 • Repair Procedures
MANIFOLDS
8-10Brake / Two Speed Manifold Components(before serial number 4461)
The brake / Two speed manifold is mounted on the engine side bulkhead..
Index SchematicNo. Description Item Function Torque
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
June 2015 Section 4 • Repair Procedures
8-11Brake / Two Speed Manifold Components(from serial number 4461)
The brake / Two speed manifold is mounted on the engine side bulkhead.
Index SchematicNo. Description Item Function Torque
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
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-12Traction Manifold Components, 2WD(before serial number 4551)
The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index SchematicNo. Description Item Function Torque
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
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June 2015 Section 4 • Repair Procedures
MANIFOLDS
6
6
71
4
1
2
3
3
5
5
FA
FB
FC
FD
FE
FF
FG
FH
FI
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June 2015Section 4 • Repair Procedures
8-13Traction Manifold Components, 2WD(from serial number 4551)
The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index SchematicNo. Description Item Function Torque
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
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June 2015 Section 4 • Repair Procedures
TT
WW
SS
XX
UU
VV
1
6
2
5
3
4
MANIFOLDS
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MANIFOLDS
8-14Traction Manifold Components, 4WD(before serial number 10154)
The 4WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index SchematicNo. Description Item Function Torque
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
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June 2015 Section 4 • Repair Procedures
MANIFOLDS
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
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-15Traction Manifold Components, 4WD(from serial number 10154)
The 4WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index SchematicNo. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar ......... HA ........ Charge pressure circuit .................... 55-60 ft-lbs / 74-81 Nm
2 Flow divider/combiner valve ............. HB ........ Controls flow to non-steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm
3 Check valve ....................................... HC ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 74-81 Nm
4 Check valve ....................................... HD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
5 Check valve ....................................... HE ........ Non-steer end drive motor circuit . 80-90 ft-lbs / 108-122 Nm
6 Flow divider/combiner valve ............. HF ......... Controls flow to flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
7 Orifice, 0.040 inch / 1 mm HG Equalizes pressure on both sides
of flow divider/combiner valve 6
8 Shuttle valve, 3 position 3 way ......... HH ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump .......................... 55-60 ft-lbs / 95-100 Nm
9 Check valve ....................................... HI .......... Steer end drive motor circuit .......... 55-60 ft-lbs / 95-100 Nm
10 Check valve ....................................... HJ ......... Steer end drive motor circuit ........ 80-90 ft-lbs / 108-122 Nm
11 Orifice, 0.040 inch / 1 mm .................. HK ........ Equalizes pressure on both sidesof flow divider/combiner valve 13
12 Flow divider/combiner valve ............. HL ......... Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm
13 Check valve ....................................... HM ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
14 Orifice, 0.040 inch / 1 mm .................. HN ........ Equalizes pressure on both sidesof flow divider/combiner valve 2
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June 2015 Section 4 • Repair Procedures
MANIFOLDS
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-16Valve 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.
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June 2015 Section 4 • Repair Procedures
8-17Directional 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
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-18Directional 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.
4 Remove the drive chassis cover from the non-steer end of the drive chassis.
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.
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June 2015 Section 4 • Repair Procedures
a
8-19Valve Adjustments - OscillateRelief Valve
How to Adjust the Oscillate ReliefValve PressureNote: The following procedure will require twopeople.
1 Remove the drive chassis cover from the non-steer end of the drive chassis.
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 toSpecifications, Hydraulic ComponentSpecifications.
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
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-20Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.
Index SchematicNo. Description Item Function Torque
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
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June 2015 Section 4 • Repair Procedures
8-21Oil Diverter Manifold Components (welder option)The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index SchematicNo. Description Item Function Torque
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
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June 2015Section 4 • Repair Procedures
MANIFOLDS
8-22Valve 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/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other 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 (Ω). 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 Ω(schematic items AB, AC and AG)
Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 Ω(schematic items H, I)
Solenoid valve, 3 Position, 4 Way, 10V DC 6.3 Ω(schematic items A, B, C, F, J, AK)
Proportional solenoid valve, 12V DC 3.7 Ω(schematic items HM, HO and HR)
Solenoid valve, 2 Position, 3 Way 10V DC 6.3 Ω(schematic items IJ, IK)
Solenoid valve, 3 Position, 4 Way 10V DC 5 Ω(schematic items HA, HC, HD, HE, HU)
Solenoid valve, 3 Position, 4 Way 10V DC 6.3 Ω(schematic items HF)
Solenoid valve, 2 Position, 3 Way, 10V DC 6.3 Ω(schematic items BA, BB, DA, DB)
Solenoid valve, 2 Position, 3 Way, 10V DC 5 Ω(schematic items BE, EA, EB)
Solenoid valve, 2 Position, 3 Way, 12V DC 8 Ω(schematic items BP, BW)
Part No. 75861 Z-60/34 4 - 73
June 2015 Section 4 • Repair Procedures
9VBATTERY
10
RESISTOR
�
AMMETERCOIL
+
-
+
-
e
b
a
c
c
d
d
a multimeter or ammeterb diodec 9V DC batteryd 10ΩΩΩΩΩ 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.
Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of 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 than
0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not 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.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Test the coil for resistance. See How to Test aCoil.
2 Connect a 10ΩΩΩΩΩ resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.
Resistor, 10ΩΩΩΩΩGenie part number 27287
Note: The battery should read 9V DC or morewhen measured across the terminals.
3 Set a multimeter to read DC current.
Note:The multimeter, when set to read DC current,should be capable of reading up to 800 mA.
MANIFOLDS
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June 2015Section 4 • Repair Procedures
Turntable 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 Specifications, Hydraulic Hose and FittingTorque Specifications.
Note: Perform this procedure with the machine on afirm 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
June 2015 Section 4 • Repair Procedures
Axle 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.
Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.
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 Sepecifications, MachineSpecifications.
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June 2015Section 4 • Repair Procedures
AXLE 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.
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 Specifications, Hydraulic Hose and FittingTorque Specifications.
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.
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 Remove the pin retaining fasteners from therod-end pivot pin.
5 Use a soft metal drift to remove the 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.
8 Use a soft metal drift to remove the 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.
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June 2015 Section 4 • Repair Procedures
a
Generators
11-1Adjustments - HydraulicGenerator
How to Adjust the 3000/3500WGenerator Voltage (prior to serialnumber 10283)
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.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Note: Perform this procedure with the machine on afirm, level surface.
1 Disconnect all electrical tools from the machine.
2 Start the engine from the platform controls.
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 be
112 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.
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June 2015Section 4 • Repair Procedures
How to Purge the Hydraulic Lineon the MTE Generator (fromserial number 10283)
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
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
June 2015 Section 5 • Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie Z-60/34 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardousconditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
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.
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 be
completed by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair 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
June 2015Section 5 • Fault Codes
FAULT CODES
Fault Code Chart -Control System
How to Retrieve ControlSystem Fault 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.
Electrocution/burn hazard.Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platformcontrol box. Do not touch the circuit board.
Component damage hazard.Electrostatic discharge (ESD)can damage printed circuit boardcomponents. If the circuit boarddoes need to be handled,maintain firm contact with ametal part of the machine that isgrounded at all times whenhandling the printed circuit boardOR use a grounded wrist strap.
3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 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 indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 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 followingpages to aid in troubleshooting the machineby pinpointing the area or componentaffected.
Part No. 75861 Z-60/34 5 - 3
June 2015 Section 5 • Fault Codes
Continued on next page
FAULT CODES
Error Source Error TypeID Name ID Name
Condition Solution11121516
Value at 5VValue too highValue too lowValue at 0V
Function is inoperativeuntil joystick iscalibrated. Alarmsounds indicatingfault.
Cycle power off,then on andproblem should becorrected.
17 Not calibratedFunction is inoperativeuntil joystick iscalibrated.
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
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
1215
Value too highValue too low
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
17 Not calibrated Calibrate valvethresholds
23 Boom 1 flowcontrol valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
11121516
Value at 5VValue too highValue too lowValue at 0V
Joystick is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
17 Not calibratedFunction is inoperativeuntil joystick iscalibrated.
Calibrate joystick
31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)
18 Just calibratedInitiate 1 second beepof alarm.
Self-clearing.(transient)
32 Boom 2 directionalvalves
21 Fault
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
5 - 4 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
FAULT CODES
Error Source Error TypeID Name ID Name
Condition Solution
1215
Value too highValue too low
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
17 Not calibrated Calibrate valvethresholds
33 Boom 2 flowcontrol valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
11121516
Value at 5VValue too highValue too lowValue at 0V
Joystick is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
17 Not calibratedFunction is inoperativeuntil joystick iscalibrated.
Calibrate joystick
41 Turntable rotatejoystick
18 Just calibrated Initiate 1-second beepof alarm.
Self-clearing.(transient)
42 Turntable rotatedirectional valves 21 Fault
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
1215
Value too highValue too low
Valve is operatingoutside of operationallimits. Alarm soundsindicating fault.
Cycle power off,then on andproblem should becorrected.
17 Not calibratedCalibrate valvethresholds.
43 Turntable rotateflow control valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
44 Drive enabletoggle switch
21 Fault
Drive enable functionis inoperative.
Cycle power off,then on andproblem should becorrected.
Part No. 75861 Z-60/34 5 - 5
June 2015 Section 5 • Fault Codes
FAULT CODES
Error Source Error TypeID Name ID Name
Condition Solution
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Power up
controller with
problem corrected.
17 Not calibrated
Joystick speed and
direction frozen at
zero and neutral.
Calibrate joystick
51 Drive joystick
18 Just calibratedInitiate 1-second beep
of alarm.
Self-clearing.
(transient)
12
15
Value too high
Value too low
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Power up
controller with
problem corrected.
17 Not calibratedCalibrate valve
thresholds
53 Drive flow valve
(EDC)
18 Just calibrated
Normal function
except threshold for
one or both directions
is zero.
Self-clearing.
(transient)
54 Drive brake valve
21 Fault
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Power up
controller with
problem corrected.
55 High speed drive
motor Valve21 Fault
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Power up
controller with
problem corrected.
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Power up
controller with
problem corrected.
17 Not calibrated
Joystick speed and
direction frozen at
zero and neutral.
Calibrate Joystick
61 Steer joystick
18 Just calibratedInitiate 1-second beep
of alarm.
Self-clearing.
(transient)
62 Steer directional
valves
21 Fault
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Power up
controller with
problem corrected.
5 - 6 Z-60/34 Part No. 75861
June 2015Section 5 • Fault 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 alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highest efficiencywhile at the same time keeping exhaustemissions to a minimum. When a sensor fails orreturns signals that are outside of setparameters, the ECM will store a fault code inmemory that relates to the appropriate sensorand will turn on the Check Engine Light.
Note: Perform this procedure with the key switchin the off position.
1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Quickly activate and release the start toggleswitch/button. Do not start the engine.
4 Move and hold the run/test toggle switch tothe test 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 inthe test position and count the blinks.
Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 threetimes. After the fault codes, the check enginelight will blink a code 123 three times againindicating the end 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 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.
Note: Once a fault code has been retrieved andthe repair has been completed, the ECM memorymust be reset to clear the fault code from theECM. Refer to, How to Clear Engine Fault Codesfrom 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 andlocate the battery.
2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.
Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.
3 Connect the negative battery cable to thebattery.
FORD LRG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 7
June 2015 Section 5 • 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.
FORD LRG-425 FAULT CODES
5 - 8 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Code Problem Cause Solution
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.
FORD LRG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 9
June 2015 Section 5 • Fault Codes
Code Problem Cause Solution
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
Injector Driver #2 OpenOpen wiring and/or connections to fuel injector #2OR fuel injector #2 is faulty OR ECM is faulty.313
Repair wiring and/or connections to fuel injector #2OR replace fuel injector #2 OR replace the ECM.
Injector Driver #2 ShortedWiring and/or connections to fuel injector #2 isshorted OR fuel injector #2 is faulty ORECM is faulty.
314
Injector Driver #3 OpenOpen wiring and/or connections to fuel injector #3OR fuel injector #3 is faulty OR ECM is faulty.315
Repair wiring and/or connections to fuel injector #3OR replace fuel injector #3 OR replace the ECM.
Injector Driver #3 ShortedWiring and/or connections to fuel injector #3 isshorted OR fuel injector #3 is faulty ORECM is faulty.
316
Injector Driver #4 OpenOpen wiring and/or connections to fuel injector #4OR fuel injector #4 is faulty OR ECM is faulty.321
Repair wiring and/or connections to fuel injector #4OR replace fuel injector #4 OR replace the ECM.
Injector Driver #4 ShortedWiring and/or connections to fuel injector #4 isshorted OR fuel injector #4 is faulty ORECM is faulty.
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
FORD LRG-425 FAULT CODES
5 - 10 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Code Problem Cause Solution
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.
FORD LRG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 11
June 2015 Section 5 • Fault Codes
Code Problem Cause Solution
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.
FORD LRG-425 FAULT CODES
5 - 12 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
FORD DSG-423 FAULT 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 alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highest efficiencywhile at the same time keeping exhaustemissions to a minimum. When a sensor fails orreturns signals that are outside of setparameters, the ECM will store a fault code inmemory that relates to the appropriate sensorand will turn on the Check Engine Light.
Note: Perform this procedure with the key switchin the off position.
1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Quickly activate and release the start toggleswitch/button. Do not start the engine.
4 Move and hold the run/test toggle switch tothe test 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 inthe test position and count the blinks.
Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 threetimes. After the fault codes, the check enginelight will blink a code 123 three times againindicating the end 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 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.
Note: Once a fault code has been retrieved andthe repair has been completed, the ECM memorymust be reset to clear the fault code from theECM. Refer to, How to Clear Engine Fault Codesfrom 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 andlocate the battery.
2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.
Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.
3 Connect the negative battery cable to thebattery.
Part No. 75861 Z-60/34 5 - 13
June 2015 Section 5 • Fault Codes
FORD DSG-423 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 high
AUX analog PUD2 low
173
174
181
182
AUX analog PUD3 high
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
June 2015Section 5 • Fault 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 loop open OR low-side short to ground 2
Injector coil shorted 2
Injector loop open OR low-side short to ground 3
Injector coil shorted 3
321
322
351
352
FPump motor loop open OR high-side shorted to ground
Injector loop open OR low-side short to ground 4
Injector coil shorted 4
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
Primary loop open OR low-side short to ground 2
414
415
416
421
422 Primary coil shorted 4
Primary coil shorted 2
Primary loop open OR low-side short to ground 3
Primary coil shorted 3
Primary loop open OR low-side short to ground 4
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
Injector coil shorted 1
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
FORD DSG-423 FAULT CODES
Part No. 75861 Z-60/34 5 - 15
June 2015 Section 5 • 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.
Ford DSG 423 EFI Operator HandbookGenie part number 119488
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
PWM2-gauge2 open / ground short
PWM2-gauge2 short to power
PWM3-gauge3 open / ground short
PWM3-gauge3 short to power
PWM4 open / ground short
PWM4 short to power
PWM5 open / ground short
FORD DSG-423 FAULT CODES
5 - 16 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Ford MSG-425 Engine FaultCodes
How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highest efficiencywhile at the same time keeping exhaustemissions to a minimum. When a sensor fails orreturns signals that are outside of setparameters, the ECM will store a fault code inmemory that relates to the appropriate sensorand will turn on the Check Engine Light.
Note: Perform this procedure with the key switchin the off position.
1 Locate the run/test toggle switch on the sideof the ground control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Quickly activate and release the start toggleswitch/button. Do not start the engine.
4 Move and hold the run/test toggle switch tothe test 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 inthe test position and count the blinks.
Note: Before the fault codes are displayed, thecheck engine light will blink a code 1-6-5-4 threetimes. After the fault codes, the check enginelight will blink a code 1-6-5-4 three times againindicating the end 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 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.
Note: Once a fault code has been retrieved andthe repair has been completed, the ECM memorymust be reset to clear the fault code from theECM. Refer to, How to Clear Engine Fault Codesfrom 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 andlocate the battery.
2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.
Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.
3 Connect the negative battery cable to thebattery.
FORD MSG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 17
June 2015 Section 5 • Fault Codes
Code Description
16 Never crank synced at start
91 FP low voltage
92 FP high voltage
107 MAP Low Voltage
108 MAP High Pressure
111 IAT higher than expected 1
112 IAT low voltage
113 IAT high voltage
116 ECT higher than expected 1
117 ECT/CHT Low Voltage
118 ECT/CHT High Voltage
121 TPS1 lower than TPS2
122 TPS1 low voltage
123 TPS1 high voltage
127 IAT higher than expected 2
129 BP low pressure
134 EGO open/lazy pre-cat 1
140 EGO open/lazy post-cat 1
154 EGO open/lazy pre-cat 2/post-cat 1
160 EGO open/lazy post-cat 2
171 AL high gasoline bank1
172 AL low gasoline bank1
Code Description
174 AL high gasoline bank2
175 AL low gasoline bank2
182 FT Gasoline Low Voltage
183 FT Gasoline High Voltage
187 FT Gaseaous fuel low voltage
188 FT Gaseaous fuel high voltage
217 ECT higher than expected 2
219 Max govern speed override
221 TPS1 higher than TPS2
222 TPS2 low voltage
223 TPS2 high voltage
236 TIP Active
237 TIP Low Voltage
238 TIP High Voltage
261 Injector Loop Open or Low-sideshort to Ground
262 Injector Coil Shorted
264 Injector Loop Open or Low-sideshort to Ground
265 Injector Coil Shorted
267 Injector Loop Open or Low-sideshort to Ground
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
5 - 18 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Code Description
268 Injector Coil Shorted
270 Injector Loop Open or Low-sideshort to Ground
271 Injector Coil Shorted
273 Injector Loop Open or Low-sideshort to Ground
274 Injector Coil Shorted
276 Injector Loop Open or Low-sideshort to Ground
277 Injector Coil Shorted
279 Injector Loop Open or Low-sideshort to Ground
280 Injector Coil Shorted
282 Injector Loop Open or Low-side short to Ground
283 Injector Coil Shorted
285 Injector Loop Open or Low-sideshort to Ground
286 Injector Coil Shorted
288 Injector Loop Open or Low-sideshort to Ground
289 Injector Coil Shorted
Code Description
301 Emissions/catalyst damaging misfire
302 Emissions/catalyst damaging misfire
303 Emissions/catalyst damaging misfire
304 Emissions/catalyst damaging misfire
305 Emissions/catalyst damaging misfire
306 Emissions/catalyst damaging misfire
307 Emissions/catalyst damaging misfire
308 Emissions/catalyst damaging misfire
326 Knock 1 Excessive Signal
327 Knock 1 sensor Open
331 Knock 2 Excessive Signal
332 Knock 2 sensor Open
336 Crank sync noise
337 Crank loss
341 Cam sync noise
342 Cam loss
420 Gasoline cat monitor
430 Gasoline cat monitor
524 Oil pressure low
562 Battery Voltage Low
563 Battery Voltage High
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 19
June 2015 Section 5 • Fault Codes
Code Description
601 Flash checksum invalid
604 RAM failure
606 COP failure
615 Start relay coil open
616 Start relay control ground short
617 Start relay coil short to power
627 Fpump relay coil open
628 FPump motor loop open or high-sideshorted to ground
628 Fpump relay control ground short
629 FPump motor high-side shorted to power
629 Fpump relay coil short to power
642 5VE1 low voltage
643 5VE1 high voltage
650 MIL open
652 5VE2 low voltage
653 5VE2 high voltage
685 Relay Coil Open
686 Relay Control ground short
687 Relay coil short to power
1111 Fuel rev limit
1112 Spark rev limit
1121 FPP1/2 simultaneous voltages out ofrange
Code Description
1122 FPP1/2 do not match each other or theIVS
1151 CL high LPG
1152 CL low LPG
1153 CL high NG
1154 CL low NG
1155 CL high gasoline bank1
1156 CL low gasoline bank1
1157 CL high gasoline bank2
1158 CL low gasoline bank2
1161 AL high LPG
1162 AL low LPG
1163 AL high NG
1164 AL low NG
1165 LPG cat monitor
1166 NG cat monitor
1171 Megajector delivery pressurehigher than expected
1172 Megajector delivery pressurelower than expected
1173 Megajector comm lost
1174 Megajector voltage supply high
1175 Megajector voltage supply low
1176 Megajector internal actuator faultdetection
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
5 - 20 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Code Description
1177 Megajector internal circuitry faultdetection
1178 Megajector internal comm fault detection
1311 Misfire detected
1312 Misfire detected
1313 Misfire detected
1314 Misfire detected
1315 Misfire detected
1316 Misfire detected
1317 Misfire detected
1318 Misfire detected
1511 AUX analog PU1 high
1512 AUX analog PU1 low
1513 AUX analog PU2 high
1514 AUX analog PU2 low
1515 AUX analog PD1 high
1516 AUX analog PD1 low
1517 AUX analog PU3 high
1518 AUX analog PU3 low
1521 CHT higher than expected 1
1522 CHT higher than expected 2
1531 IVS/Brake/Trans-Park interlock failure
Code Description
1541 AUX analog PUD1 high
1542 AUX analog PUD1 low
1543 AUX analog PUD2 high
1544 AUX analog PUD2 low
1545 AUX analog PUD3 high
1551 AUX DIG1 high
1552 AUX DIG1 low
1553 AUX DIG2 high
1554 AUX DIG2 low
1555 AUX DIG3 high
1556 AUX DIG3 low
1561 AUX analog PD2 high
1562 AUX analog PD2 low
1563 AUX analog PD3 high
1564 AUX analog PD3 low
1611 5VE 1/2 simultaneous out of range
1612 RTI 1 loss
1613 RTI 2 loss
1614 RTI 3 loss
1615 A/D loss
1616 Invalid interrupt
1621 Rx Inactive
1622 Rx Noise
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
Part No. 75861 Z-60/34 5 - 21
June 2015 Section 5 • Fault Codes
Code Description
1623 Invalid Packet Format
1624 Shutdown Request
1625 Shutdown Request
1626 CAN Tx failure
1627 CAN Rx failure
1628 CAN addresss conflict failure
1629 J1939 TSC1 message receipt lost
1630 J1939 ETC message receipt lost
1631 PWM1-Gauge1 open / ground short
1632 PWM1-Gauge1 short to power
1633 PWM2-Gauge2 open /ground short
1634 PWM2-Gauge2 short to power
1635 PWM3-Gauge3 open / ground short
1636 PWM3-Gauge3 short to power
1641 Buzzer control ground short
1642 Buzzer open
1643 Buzzer control short to power
1644 MIL control ground short
1645 MIL control short to power
2111 Unable to reach lower TPS
2112 Unable to reach higher TPS
2115 FPP1 higher than IVS limit
2116 FPP2 higher than IVS limit
Code Description
2120 FPP1 invalid voltage and FPP2disagrees with IVS
2121 FPP1 lower than FPP2
2122 FPP1 high voltage
2123 FPP1 low voltage
2125 FPP2 invalid voltage and FPP1disagrees with IVS
2126 FPP1 higher than FPP2
2127 FPP2 low voltage
2128 FPP2 high voltage
2130 IVS stuck at-idle, FPP1/2 match
2131 IVS stuck off-idle, FPP1/2 match
2135 TPS1/2 simultaneous voltages out ofrange
2139 FPP1 lower than IVS limit
2140 FPP2 lower than IVS limit
2229 BP high pressure
2300 Primary Loop Open or Low-sideShort to Ground
2301 Primary Coil Shorted
2303 Primary Loop Open or Low-side Short to Ground
2304 Primary Coil Shorted
2306 Primary Loop Open or Low-sideShort to Ground
2307 Primary Coil Shorted
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
5 - 22 Z-60/34 Part No. 75861
June 2015Section 5 • Fault Codes
Code Description
2309 Primary Loop Open or Low-sideShort to Ground
2310 Primary Coil Shorted
2312 Primary Loop Open or Low-sideShort to Ground
2313 Primary Coil Shorted
2315 Primary Loop Open or Low-sideShort to Ground
2316 Primary Coil Shorted
2318 Primary Loop Open or Low-sideShort to Ground
2319 Primary Coil Shorted
2321 Primary Loop Open or Low-sideShort to Ground
2322 Primary Coil Shorted
2618 Tach output ground short
2619 Tach output short to power
For further engine fault code troubleshooting anddiagnostic information, refer to the Ford MSG-425/Ford DSG-423 EFI Diagnostic Manual (EDIpart number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic ManualGenie part number
162067
FORD MSG-425 FAULT CODES
Part No. 75861 Z-60/34 6 - 1
June 2015 Section 6 • Schematics
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.
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
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Hydraulic Schematics
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.
6 - 2 Z-60/34 Part No. 75861
June 2015Section 6 • Schematics
Wire Connector Legend
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
June 2015 Section 6 • Schematics
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
Electrical Symbols Legend
6 - 4 Z-60/34 Part No. 75861
June 2015Section 6 • Schematics
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
Part No. 75861 Z-60/34 6 - 5
June 2015 Section 6 • Schematics
Electrical Abbreviations Legend
Item Description
B BatteryB1 Engine Start - 12V DC
C ConnectorC7 Power to platform, 12v cable
connector
C9 Footswitch input connector
C54 Options connector
CB Circuit BreakerCB1 Circuit breaker, engine, 15a
CB2 Circuit breaker, controls, 15a
CB7 Circuit breaker, controls, 10aEngine throttle solenoid
CR Control RelayCR1 Start relay
CR2 Ingition power relay
CR4 High idle relay
CR5 Horn relay
CR13 Jib relay (jib option)
CR14 Jib relay (jib option)
CR17 Hydraulic oil cooling fan (option)
CR23 Drive light enable
CR27 Brake circuit relay (lift/drive option)
CR30 Limit switch relay (lift/drive option)
CR76 Load sense aux recovery (AS models)
CR51 Aircraft package (option)
G GaugeG1 Battery Charge Indicator
G2 Engine oil pressure
G3 Engine coolant temp.
G4 Engine oil temp.
G6 Hour meter
Item Description
H Horn or AlarmH1 Tilt/load sense alarm
H4 Descent (ground)
H6 Load sense (ground)
JC JoystickJC1 Boom proportional joystick:
secondary boom up/down
JC2 Boom proportional joystick:primary up/down, turntable rotate
JC3 Drive proportional joystick
KS KeyswitchKS1 Key switch
L LED or LightL1 Drive enable led
L2 Check engine led
L4 Platform overload led (ce only)
L29 Drive lights
L48 Tilt alarm led (ansi/csa only)
LS Limit SwitchLS1 Primary boom extend
LS2 Primary boom up
LS3 Drive enable
LS4 Secondary boom up
LS18 CE limit switch
6 - 6 Z-60/34 Part No. 75861
June 2015Section 6 • Schematics
Electrical Abbreviations Legend
Item Description
M MotorM2 Auxiliary pump
M3 Engine starter
M4 Fuel pump
P ButtonP1 Red emergency stop button
P2 Emergency stop button
P3 Horn Button
P4 Function enable button
PR Power RelayPR1 Auxiliary pump (m2)
PR2 Engine starter (m3)
PR3 Starting aid / glow plugs
PR4 Function pump (m5)
R ResistorR4 Speed limiting variable resistor 20 ohms
R14 Up/down speed resister 7.5 ohms
SW SwitchSW2 Engine oil pressure
SW3 Engine oil tempurature
Item Description
TS Toggle SwitchTS1 Auxiliary pump switch
TS2 Start engine switch
TS3 Fuel select switch (ford efi only)
TS4 Hi/low rpm switch
TS6 Glow plug switch
TS7 Platform rotate switch
TS8 Jib rotate switch (jib option)
TS9 Platform level switch
TS13 Primary boom extend/retract switch
TS14 Drive speed switch
TS15 Drive enable switch
TS43 Heater switch (option)
TS46 Proximity kill switch (option)
TS47 Generator switch (option)
TS51 Auxiliary pump toggle switch
TS52 Engine start toggle switch
TS53 Fuel select toggle switch
TS54 Rpm select toggle switch
TS56 Glow plug toggle switch
TS57 Platform rotate toggle switch
TS58 Jib boom up/down toggle switch (option)
TS59 Platform level up/down toggle switch
TS60 Secondary boom up/down toggle switch
TS61 Primary boom up/down toggle switch
TS62 Turntable rotate toggle switch
TS63 Primary boom extend/retract toggle switch
TS64 Run/test toggle switch (Ford)
TS74 Run/test toggle switch (Deutz)
Part No. 75861 Z-60/34 6 - 7
June 2015 Section 6 • Schematics
Item Description
U ModuleU1 Ignition start module
U4 EDC - drive pump
U13 Alc 500 joystick controller card
U18 Control module
U33 Load sense module
U34 Time delay relay - 2 seconds, 10A
U35 Time delay relay
U38 Time delay relay
U39 J1939 Ground Control Box Display
X ALC500 connectorsX101 ALC500 power connector
X101 ALC500 input/out connectors
X102 ALC500 input/out connectors
X103 ALC500 input/out connectors
X104 ALC500 input/out connectors
X105 ALC500 input/out connectors
X106 ALC500 input/out connectors
X107 ALC500 input/out connectors
X108 ALC500 input/out connectors
X109 ALC500 input/out connectors
X1-4 Circuit splice
Wire Color Legend
Item ................................ DescriptionBL ........................................... Blue
BK .......................................... Black
BR .......................................... Brown
GN .......................................... Green
OR .......................................... Orange
PP .......................................... Purple
RD .......................................... Red
WH.......................................... White
YL ........................................... Yellow
BL/RD ..................................... Blue/Red
BL/WH .................................... Blue/White
BK/RD .................................... Black/Red
OR/WH ................................... Orange/White
RD/BK .................................... Red/Black
RD/WH.................................... Red/White
WH/BL .................................... White/Blue
WH/BK.................................... White/Black
WH/RD.................................... White/Red
WH/YL .................................... White/Yellow
YL/BK ..................................... Yellow/Black
Electrical Abbreviations Legend
6 - 8 Z-60/34 Part No. 75861
June 2015Section 6 • Schematics
Power
Relay
Starter
Relay
Fuel
Pump
Relay
F5-15A
F4-15AF3-10A
F2-5AF1-10A
Empty
Ford Engine Relay Layout
F6-10A
Power
Relay
Fuel
Pump
Relay
F5-15A
F4-15AF3-10A
F2-5AF1-10A
Empty
Ford MSG-425 EFI
F6-10A
Starter
20A
Empty
Empty
F1 Battery voltage to EPR
F2 Ignition voltage to GCP and relays
F3 Battery voltage to GCP
F4 Fuel pump
F5 Battery voltage out of Power Relay
F6 Alternator
Ford DSG-423
June 2015 Section 6 • Schematics
6 - 9
Diesel Electrical Schematic - View 1(before serial number 4496)
6 - 10
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 10 Z-60/34 Part No. 75861
Diesel 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
NO
WA
TE
RT
EM
P
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
HNC
OTS
NO
FL
AS
HIN
GB
EA
CO
NS
OP
TIO
N
OP
TIO
N
GE
NE
RA
TO
R
BK
-33
+W
H-2
4
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
D39F
UN
CT
ION
EN
A.
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
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 11
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 TB30C
1P
BU
RD
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
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
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
June 2015Section 6 • Schematics
6 - 126 - 11
Diesel Electrical Schematic - View 2(before serial number 4496)
June 2015 Section 6 • Schematics
6 - 13
Diesel Electrical Schematic - View 1(from serial number 4496 to serial number 5325)
6 - 14
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 14 Z-60/34 Part No. 75861
Diesel 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 BYPASSIGN./FUEL ON
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
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
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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 15
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
TIO
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
LVE
TR
AV
EL
AL
AR
MO
PT
I ON
DR
IVE
ED
CR
EV
ER
SE
DR
I VE
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
JOYSTICK CONTROL CARD
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
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 B
RN
C2
P- 3
RD
BK
BR
N
OR
J2
6
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
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
POSITION EXCEPT AS NOTED.
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
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
Diesel Electrical Schematic - View 2(from serial number 4496 to serial number 5325)
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
June 2015Section 6 • Schematics
6 - 166 - 15
Diesel Electrical Schematic - View 2(from serial number 4496 to serial number 5325)
June 2015 Section 6 • Schematics
6 - 176 - 18
Diesel Electrical Schematic - View 1(from serial number 5326 to serial number 9798)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 18 Z-60/34 Part No. 75861
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 BYPASSIGN./FUEL ON
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
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
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
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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
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
FUSE 10A
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
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
Diesel Electrical Schematic - View 1(from serial number 5326 to serial number 9798)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 19
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
13B
KW
H22 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
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
June 2015Section 6 • Schematics
6 - 206 - 19
Diesel Electrical Schematic - View 2(from serial number 5326 to serial number 9798)
June 2015 Section 6 • Schematics
6 - 216 - 22
Diesel Electrical Schematic, ANSI / CSA - View 1(from serial number 9799 to serial number 10387)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 22 Z-60/34 Part No. 75861
Diesel 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 BYPASSIGN./FUEL ON
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
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
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 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
NO CR4
NOCR3
HIG
HR
PM
SO
LE
NO
ID
HIG
HID
LE
RE
LA
Y
FAN
IN THE STOWED POSITION AND KEYSWITCH "OFF".
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
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
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 23
Diesel Electrical Schematic, ANSI / CSA - View 2(from serial number 9799 to serial number 10387)
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
June 2015Section 6 • Schematics
6 - 246 - 23
Diesel Electrical Schematic, ANSI / CSA - View 2(from serial number 9799 to serial number 10387)
June 2015 Section 6 • Schematics
6 - 25
Diesel Electrical Schematic ANSI / CSA - View 1(from serial number 10388)
6 - 26
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 26 Z-60/34 Part No. 75861
Diesel 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 BYPASSIGN./FUEL ON
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
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
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 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
NO CR4
NOCR3
HIG
HR
PM
SO
LE
NO
ID
HIG
HID
LE
RE
LA
Y
FAN
IN THE STOWED POSITION AND KEYSWITCH "OFF".
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
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
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
NOCR45
CR45
WO
RK
LIG
HT
SR
EL
AY
(OP
TIO
N)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 27
Diesel Electrical Schematic ANSI / CSA - View 2(from serial number 10388)
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
NC
CR13
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
Y B
OO
M
DE
SC
EN
T A
LA
RM
N
PLA
TF
OR
M R
OTA
TE
CC
W / J
IB D
OW
N
PLA
TF
OR
M R
OTA
TE
CW
/ JIB
UP
BR
PLA
T L
EV
EL U
P
PLA
T L
EV
EL D
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
E R
ELE
AS
E V
ALV
E
TR
AV
EL A
LA
RM
OP
TIO
N
DR
IVE
ED
C R
EV
ER
SE
DR
IVE
ED
C F
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
W C
ON
TR
OL
PR
IMA
RY
BO
OM
PR
IMA
RY
BO
OM
UP
FLO
W C
ON
TR
OL
ST
EE
R C
W
ST
EE
R C
CW
H3
TS59
TB19
TB17
TB18
TB15
C1
9JS
V G
R/W
H
RD
RD
C4
-7
TS57
C4
-5
C4
-6
C3
PB
F R
D/W
H
C2
PB
D R
D/B
K
C1
4P
LU
OR
C1
5P
LD
OR
/BK
TB14
TB8
TB7
TB13TB40
C7
PB
E B
K
C8
PB
R B
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
JOYSTICK CONTROL CARD
TS13
CE
OPTION
LIFT/DRIVE 4
NOCR30
CR27NC
P2
4F
S W
H
P2
4F
S W
H
P2
6E
ST
P B
K
3
J3
13 4 2
8 7
C4
1R
PM
OR
/BK
16
15
19
20
17
1811
10
C3
0E
DC
+ W
H
C3
2B
RK
WH
/RD
C6
TR
F W
H/R
D
C3
6S
TC
BL
C3
7S
TC
C B
L/B
K
C3
1E
DC
- WH
/BK
C5
TR
R W
H/B
K
TB6TB3
TB1
TB2TB5 TB4
TB32TB37TB36 TB31 TB30
C1
PB
U R
D
TS61
C4
TR
L W
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
E A
BL/W
H
DR
E B
BL/B
KBR
OR
BL/W
H
WH
/RD
DR
E L
ED
BL/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
- WH
/BK
C3
0E
DC
+ W
H
C3
2B
RK
WH
/RD
C3
7S
TC
C B
L/B
K
C3
6S
TC
BL
C6
TR
F W
H/R
D
C5
TR
R W
H/B
K
C4
TR
L W
H
C1
PB
U R
D
C2
PB
D R
D/B
K
C3
PB
F R
D/W
H
C7
PB
E B
K
C8
PB
R B
K/W
H
C4
0LS
1 O
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
5R5
DO
WN
SE
CO
ND
AR
Y B
OO
MU
P
C1
2S
BF
BL/W
H
C1
1S
BD
BL/B
K
C1
0S
BU
BL
SE
CO
ND
AR
Y B
OO
M U
P
SE
CO
ND
AR
Y B
OO
M D
OW
N
SE
CO
ND
AR
Y B
OO
MF
LO
W C
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
SECONDARY BOOM UP/DN
6
3910
ORBR
WH
/BK
J1
C2
9M
S R
D/W
H
TS14
C5
-21
C5
-20
C5
-23
MO
TO
R S
TR
OK
EC
1-3
C2
9M
S R
D/W
HC
5-2
4
Y27
BL/WH
RIG
HT
LE
FT
PLA
TR
OTA
TE
UP
DO
WN P
LA
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
TB
OO
M
DO
WN
UP
JIB
BO
OM
EX
TE
ND
RE
TR
AC
TB
OO
M
UP
DO
WN
PR
IMA
RY
BO
OM
DR
IVE
EN
AB
LE
DR
IVE
MO
DE
C7
-3
C3
-9
TB9
C5
-7
EDCRETURN
9
9 EDC GROUND MOVED TO TB9 AT SERIAL NUMBER 11904
POSITION EXCEPT AS NOTED.
ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
NOTE:
1.
RD
CR14
_
+
D29 D30
14
NO13
BK
WH
22 21NC
NO13NC
14
WH
2122
BK
34
NO13NC
14
WH
2122
BK
12
14
NO13
BK
WH
22 21NC
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
June 2015Section 6 • Schematics
6 - 28
Diesel Electrical Schematic ANSI/CSA - View 2(from serial number 10388)
6 - 27
June 2015 Section 6 • Schematics
6 - 29
Diesel Electrical Schematic, CE - View 1(from serial number 9799 to serial number 10387)
6 - 30
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 30 Z-60/34 Part No. 75861
Diesel 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 BYPASSIGN./FUEL ON
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
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
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
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 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
NO CR4
NOCR3
HIG
HR
PM
SO
LE
NO
ID
HIG
HID
LE
RE
LA
Y
FAN
IN THE STOWED POSITION AND KEYSWITCH "OFF".
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
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
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
2 DIODE ADDED BETWEEN AND AT SERIAL NUMBER 10283.TB35 TB45
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 31
Diesel Electrical Schematic, CE - View 2(from serial number 9799 to serial number 10387)
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
June 2015Section 6 • Schematics
6 - 32
Diesel Electrical Schematic, CE - View 2(from serial number 9799 to serial number 10387)
6 - 31
June 2015 Section 6 • Schematics
6 - 33
Diesel Electrical Schematic, CE - View 1(from serial number 10388)
6 - 34
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 34 Z-60/34 Part No. 75861
Diesel 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 BYPASSIGN./FUEL ON
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
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
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 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 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
NO CR4
NOCR3
HIG
HR
PM
SO
LE
NO
ID
HIG
HID
LE
RE
LA
Y
FAN
IN THE STOWED POSITION AND KEYSWITCH "OFF".
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
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
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
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 35
Diesel Electrical Schematic, CE - View 2(from serial number 10388)
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
NC
CR13
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
Y B
OO
M
DE
SC
EN
T A
LA
RM
N
PLA
TF
OR
M R
OTA
TE
CC
W / J
IB D
OW
N
PLA
TF
OR
M R
OTA
TE
CW
/ JIB
UP
BR
PLA
T L
EV
EL U
P
PLA
T L
EV
EL D
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
E R
ELE
AS
E V
ALV
E
TR
AV
EL A
LA
RM
OP
TIO
N
DR
IVE
ED
C R
EV
ER
SE
DR
IVE
ED
C F
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
W C
ON
TR
OL
PR
IMA
RY
BO
OM
PR
IMA
RY
BO
OM
UP
FLO
W C
ON
TR
OL
ST
EE
R C
W
ST
EE
R C
CW
H3
TS59
TB19
TB17
TB18
TB15
C1
9JS
V G
R/W
H
RD
RD
C4
-7
TS57
C4
-5
C4
-6
C3
PB
F R
D/W
H
C2
PB
D R
D/B
K
C1
4P
LU
OR
C1
5P
LD
OR
/BK
TB14
TB8
TB7
TB13TB40
C7
PB
E B
K
C8
PB
R B
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
JOYSTICK CONTROL CARD
TS13
CE
OPTION
LIFT/DRIVE 4
NOCR30
CR27NC
P2
4F
S W
H
P2
4F
S W
H
P2
6E
ST
P B
K
3
J3
13 4 2
8 7
C4
1R
PM
OR
/BK
16
15
19
20
17
1811
10
C3
0E
DC
+ W
H
C3
2B
RK
WH
/RD
C6
TR
F W
H/R
D
C3
6S
TC
BL
C3
7S
TC
C B
L/B
K
C3
1E
DC
- WH
/BK
C5
TR
R W
H/B
K
TB6TB3
TB1
TB2TB5 TB4
TB32TB37TB36 TB31 TB30
C1
PB
U R
D
TS61
C4
TR
L W
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
E A
BL/W
H
DR
E B
BL/B
KBR
OR
BL/W
H
WH
/RD
DR
E L
ED
BL/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
- WH
/BK
C3
0E
DC
+ W
H
C3
2B
RK
WH
/RD
C3
7S
TC
C B
L/B
K
C3
6S
TC
BL
C6
TR
F W
H/R
D
C5
TR
R W
H/B
K
C4
TR
L W
H
C1
PB
U R
D
C2
PB
D R
D/B
K
C3
PB
F R
D/W
H
C7
PB
E B
K
C8
PB
R B
K/W
H
C4
0LS
1 O
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
5R5
DO
WN
SE
CO
ND
AR
Y B
OO
MU
P
C1
2S
BF
BL/W
H
C1
1S
BD
BL/B
K
C1
0S
BU
BL
SE
CO
ND
AR
Y B
OO
M U
P
SE
CO
ND
AR
Y B
OO
M D
OW
N
SE
CO
ND
AR
Y B
OO
MF
LO
W C
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
SECONDARY BOOM UP/DN
6
3910
ORBR
WH
/BK
J1
C2
9M
S R
D/W
H
TS14
C5
-21
C5
-20
C5
-23
MO
TO
R S
TR
OK
EC
1-3
C2
9M
S R
D/W
HC
5-2
4
Y27
BL/WH
RIG
HT
LE
FT
PLA
TR
OTA
TE
UP
DO
WN P
LA
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
TB
OO
M
DO
WN
UP
JIB
BO
OM
EX
TE
ND
RE
TR
AC
TB
OO
M
UP
DO
WN
PR
IMA
RY
BO
OM
DR
IVE
EN
AB
LE
DR
IVE
MO
DE
C7
-3
C3
-9
TB9
C5
-7
EDCRETURN
9
9 EDC GROUND MOVED TO TB9 AT SERIAL NUMBER 11904
POSITION EXCEPT AS NOTED.
ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
NOTE:
1.
RD
CR14
_
+
D29 D30
14
NO13
BK
WH
22 21NC
NO13NC
14
WH
2122
BK
34
NO13NC
14
WH
2122
BK
12
14
NO13
BK
WH
22 21NC
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
June 2015Section 6 • Schematics
6 - 36
Diesel Electrical Schematic, CE - View 2(from serial number 10388)
6 - 35
June 2015 Section 6 • Schematics
6 - 37
Diesel Ground Control Box Wiring Diagram(before serial number 5716)
6 - 38
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 38 Z-60/34 Part No. 75861
Diesel 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
TO PLATFORM C-BOX, TERMINAL 22-23
TO PLATFORM C-BOX, TERMINAL 27-46
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 39
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
TURNTABLE ROTATE F.C.
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
TURNTABLE ROTATE SWITCH
BOOM EXTEND/RETRACT 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
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 ENABLE SWITCH
JIB BOOM SWITCH
AUXILIARY SWITCH
KEY SWITCH
RESISTOR, 7.5 OHM, TURN. ROT. FUNC.R4
TO PLATFORM C-BOX, TERMINAL 13-19C4B
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
PR2
PR1
TO PLATFORM C-BOX, TERMINAL 1-12
TO PLATFORM C-BOX, TERMINAL 39-45
TO PLATFORM C-BOX, TERMINAL 27-38
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
HYDRAULIC COOLER FAN RELAY
HIGH IDLE (RPM) CUTOUT RELAY
CB3 CIRCUIT BREAKER, OPTION, 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
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
TACHOMETERSTART INPUT
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
DRIVE LIGHT OPTION RELAY
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
June 2015Section 6 • Schematics
6 - 40
Diesel Ground Control Box Wiring Diagram(from serial number 5716 to serial number 9798)
6 - 39
June 2015 Section 6 • Schematics
6 - 416 - 42
Diesel Ground Control Box Wiring Diagram(from serial number 9799)
A B C D E F G H I J K L M N
June 2015Section 6 • Schematics
6 - 42 Z-60/34 Part No. 75861
1
2
3
4
5
6
7
8
Diesel Ground Control Box Wiring Diagram(from serial number 9799)
WH S.P.23 KEYSWITCH POWERWH-C7B-2
RD-4 RD-C3B-1 1 RD S.P.
D C B A
WH/RD-C3B-6WH/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-4RD/WH-4RD/BK-4
WH/BK-4WH/RD-4
BL/BK-4
RD/BK-C3B-2
WH-C3B-4
BK-C3B-7
BL/BK-C3B-11BL-C3B-10
GR-4
RD-4 (12V)WH-CR2#87 +D.L.CR23#86
GR/BK-4
OR-4OR/BK-4
GR-C4B-5
OR-C4B-2
BK - C23-4
12
32
456
87
1011
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
1314
17
1516
RD-S.P.(CB2)
BK-CR5#30
181920
2221
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 RTURNTABLE ROTATE L
PRIMARY BOOM DOWN
SECONDARY BOOM UPSECONDARY BOOM DOWN
TURNTABLE ROTATE F.C.
PRIMARY BOOM F.C.
BOOM RETRACTBOOM EXTEND
POWER TO PLATFORM
PLATFORM ROTATE RPLATFORM ROTATE L
PLATFORM LEVEL DOWNPLATFORM LEVEL UP
12V BATTERY SUPPLYIGNITION 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-2RD-C1B-1
WH/RD-C1B-6
WH-C1B-4WH/BK-C1B-5
BK-C1B-7
GR/WH-4
OR/BK-C5-2
BK/RD-C1B-9BL-C1B-10BL/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
2425
2827
313029
3332
RD S.P.
RD CB1
BK S.P.
40
37
3536
39
132
OR/BK-ISM#241134
434445
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 RIGHTSTEER LEFT
RPM
L.P./GAS
GENERATOR OPTION
PULSE PICKUP DEUTZ ONLY
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
V T
O P
LA
T
C1
B
FU
NC
TIO
NS
4C
3B
19
/18
CA
BLE
S
C2
BC
4B
3
2
C7
B
1
HC
(BK
)(G
Y)
(BR
)(G
R)
7.5
5
WH/RD -4
PRIMARY BOOM UP/DOWN SWITCH
TURNTABLE ROTATE SWITCH
BOOM EXTEND/RETRACT SWITCH
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
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 ENABLE SWITCH
JIB BOOM SWITCH
AUXILIARY SWITCH
KEY SWITCH
RESISTOR, 7.5 OHM, TURN. ROT. FUNC.R4
TO PLATFORM C-BOX, TERMINAL 13-19C4B
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
PR2
PR1
TO PLATFORM C-BOX, TERMINAL 1-12
TO PLATFORM C-BOX, TERMINAL 39-45
TO PLATFORM C-BOX, TERMINAL 27-38
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
HYDRAULIC COOLER FAN RELAY
HIGH IDLE (RPM) CUTOUT RELAY
CB3 CIRCUIT BREAKER, OPTION, 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
U33 PLATFORM OVERLOAD MODULE
C5 ENGINE HARNESS
IGN./STARTMODULEAUX. 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
TACHOMETERSTART INPUT
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. SENDEROIL PRESSURE SENDER
WH/RD S.P.WH/BK S.P.
WH/RD-C5-14WH/BK-C5-16
RD-24D
DRIVE LIGHT OPTION RELAY
CR23
BR
RD-C4B-12
WH - 21B
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-134BRD-TS51 - C32-6
BR - GND - C32-12
RD-H6+ - C32-1
RD-TS55 - C32-7 GR/BK-L45GR/BK-133A
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
REPLACE WIRE WITH THIS WIRING DIAGRAM
LOAD SENSE OPTION - TIMER RELAY
WORK LIGHTS OPTION RELAY
30
87A85 86
87
RD-CB3 SP
CR45
WH - W.L.
WH-C21IGN
BR GND
D4
D27
1TERMINAL 9 BEFORE SERIAL NUMBER 10388
1
1
TERMINAL 9 FROM SERIAL NUMBER 10388 TO SERIAL NUMBER 11903
BK/RD-C3B-9 9 DRIVE LIGHT OPTIONBK/RD-CR23#86
9 SPARE
BR C3B-9 9 EDC RETURNTERMINAL 9 FROM SERIAL NUMBER 11904 BR C5-7
BR C3B-9 9 EDC RETURNBR C5-7
September 2013 Section 6 • Schematics
6 - 43
Diesel Platform Control Box Wiring Diagram(before serial number 7227)
6 - 44
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 44 Z-60/34 Part No. 75861
Diesel Platform Control Box Wiring Diagram(before serial number 7227)
TS48
HI/L0 RPM SWITCH
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
GENERATOR OPTION
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL 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
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
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
NOTE:DASHED LINES INDICATE OPTION WIRES
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
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
1 10A FUSE ADDED AT SERIAL NUMBER 4496.
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 45
Diesel Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)
TS48
HI/L0 RPM SWITCH
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
GENERATOR OPTION
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL 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
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
+
+
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
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-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
-1 1
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
DETAIL A: LIFT/DRIVE OPTION
CR27
(SPLICE TO R40LS1)
CP2-2 OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
June 2015Section 6 • Schematics
6 - 46
Diesel Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)
6 - 45
June 2015 Section 6 • Schematics
6 - 47
Diesel Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9696)
6 - 48
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 48 Z-60/34 Part No. 75861
Diesel Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9696)
TS48
HI/L0 RPM SWITCH
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
GENERATOR OPTION
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL 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
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
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 CABLEW
HBK
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
DRIVE SPEED SWITCHTS14
TILT ALARM LEDL48
EMERGENCY STOP BUTTONP2
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
+
+
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
1
6
1
6
1
6
TURNTABLE ROTATESECONDARY BOOM
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
DETAIL A: LIFT/DRIVE OPTION
CR27
(SPLICE TO R40LS1)
CP2-2 OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 49
Diesel Platform Control Box Wiring Diagram(from serial number 9697)
CR30
TS48
HI/L0 RPM SWITCH
DETAIL A: LIFT/DRIVE OPTION
CR27
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
GENERATOR OPTION
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL 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
(SPLICE TO R40LS1)
CP2-2 OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
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-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
LT
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
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
DRIVE SPEED SWITCHTS14
TILT ALARM LEDL48
EMERGENCY STOP BUTTONP2
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
+
+
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
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
1
1 WORK LIGHT OPTION REMOVED FROMPLATFORM BOX AT SERIAL NUMBER 10388
June 2015Section 6 • Schematics
6 - 50
Diesel Platform Control Box Wiring Diagram(from serial number 9697)
6 - 49
June 2015 Section 6 • Schematics
6 - 51
Ford Electrical Schematic - View 1(before serial number 4546)
6 - 52
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 52 Z-60/34 Part No. 75861
Ford Electrical Schematic - View 1(before serial number 4546)
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:
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
ILTA
LA
RM
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
_
SW
ITC
H
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
+W
H-2
4
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
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
TS17
TS4
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
NOOTS
CR17NO
CR17
CB3
20AMP.
TB134P1
RD
TB22
PLATGRD
KS1
RD
C1
34
PW
RO
R/R
DC
2-4
P2
2B
AT
BK
HORN
C7
-1
H1P3
RD
P2
C28TTA RD/BK
RD/BK
C1
33
PL
AO
R/R
DC
4-4
C2-3
TB133
D40
D39F
UN
CT
ION
EN
A.
WH
/BK
WH
/RD
L2
C4
1R
PM
OR
/BK
M1
S7
M2
PR2NO
PR2
G6S2 S1
Y29
CR5NO
PR1
WH
-21
L4L48
STARTER
AUXHM
STA
RT EN
GIN
E
FAN
SEE NOTE 2
SEE NOTE 2
DG
RN
(FE
H2
42
)
RD
(FE
H3
61
A)
ENGINEHARNESS
FORD
FU
EL
PU
MP
FORD42 PIN PLUG
C3
8E
SL
C2
11G
N2
C3
9L
P
C3
5R
PM
2
TS
W
P24BATTB24
OR
/RD
(FE
H3
07
A)
PIN
23
WH
(FE
H1
6A
)P
IN1
BL
(FE
H6
58
)P
IN6
WH
(FE
H3
06
)P
IN2
4
BK
/RD
(FE
H4
58
)P
IN3
BK
/WH
(FE
H7
2)
PIN
7
PUMPFUEL
BR
(FE
H5
70
C)
PIN
34
BL
/WH
(FE
H7
87
)P
IN5
RD
(FE
H3
61
)P
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 BYPASSIGN./FUEL ON
KEY PWR.
43
5
21
AUX. ONGROUND
TACHOMETERSTART INPUT
IGN./STARTMODULE
START RELAY
U1
TB 132 IS WAGO TERMINAL BLOCK 38TB 133 IS WAGO TERMINAL BLOCK 16TB 134 IS WAGO TERMINAL BLOCK 42
December 2011
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 53
WH WH
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
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
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
TB14TB8
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
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
/BK1
6
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
TB2 TB5
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
J2
6
J1
12 1
11 2
9
7
PRI UP/DN & TT ROTATE
YO
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
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
TB10TB11
TB12
TS60
C3
P-1
0
C3
P-11
C3
P-1
2
12
13
14
R4
7.55 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
CA
BL
E#
6
LS
3D
RIV
EE
NA
BL
E
Y17 Y16 Y19 Y20 Y26 Y25 Y14 Y52 Y53H4
Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2
H3
Y51
NOHC NOHC NCHO NCHO
BK
WH
BK
WH
BK
WH
WH
BK
TB44
C4
6P
WR
WH
CA
BL
E#
8
TB46
CA
BL
E#
7
CA
BL
E#
7
CA
BL
E#
6
TB43
C4
6P
WR
WH
TB46
TS15 L1
RIG
HT
LE
FT
PL
AT
RO
TA
TE
UP
DO
WN P
LA
TF
OR
ML
EV
EL
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
TBO
OM
DO
WN
UP
JIB
BO
OM
EX
TE
ND
RE
TR
AC
TBO
OM
UP
DO
WN P
RIM
AR
YB
OO
M
DR
IVE
EN
AB
LE
JIB
VA
LVE
S
C19JSV GR/WH
JD
AL
AR
MG
R/B
K
C1
7JU
GR
C1
8JD
GR
/BK
TS58
TB44
C2
P-6
BRN
JIB
VA
LVE
S
CR13
TS8
GR
/BK
-44
NCCR13
C1
7JU
GR
C1
8JD
GR
/BK
Y18
Ford Electrical Schematic - View 2(before serial number 4546)
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
JC1
PW
R
653 421
GN
D
OU
T
SECONDARY BOOM UP/DN
7
39
10
OR
BR
N
YE
L
J1
June 2015Section 6 • Schematics
6 - 546 - 53
Ford Electrical Schematic - View 2(before serial number 4546)
June 2015 Section 6 • Schematics
6 - 55
Ford Electrical Schematic - View 2(from serial number 4546 to serial number 5715)
6 - 56
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 56 Z-60/34 Part No. 75861
Ford Electrical Schematic - View 1(from serial number 4546 to serial number 5715)
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
R
TILT
ALA
RM
PUMP
BK
12 VDC
+
+BAT.
STA.
BAT.-
ALTERNATOR
EXCT.
RD
-23
RD
-27
RD
/BK
-28B
K-4
3
CR5NO CR5
PR1
RD
WH
NO
PR1
STA
RT
RE
LA
Y
HO
UR
ME
TE
R
_
OTS
FLA
SH
ING
BE
AC
ON
S
OP
TIO
N
OP
TIO
N
GE
NE
RA
TO
R
BK
-33
+
OPS
TB25 TB26
WH
-21
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
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
TS17
TS4
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
OLIN
GFA
N
TE
MP.
SW
ITC
HH
YD
RA
ULIC
OIL
NO
OTS
CR17NO CR17
CB3
20AMP.
TB134P1
RD
TB22
PLAT
GRD
KS1
RD
C1
34
PW
RO
R/R
DC
2-4
P2
2B
AT
BK
HORN
C7
-1
P3
RD
P2
C28TTA RD/BK
RD/BK
C2-3
L48
D40
FU
NC
TIO
NE
NA
.
WH
/BK
WH
/RD
L2
C4
1R
PM
OR
/BK
M1
S7
M2
PR2
NO
PR2
G6
Y29
OHM510
BL/WH
STARTERAUX
HM
STA
RT
EN
GIN
E
FAN
DG
RN
(FE
H2
42
)
RD
(FE
H3
61
A)
ENGINEHARNESS
FORD
FU
EL
PU
MP
LP
G
SO
LE
NO
ID
LO
CK
OU
T
BL/W
HP
IN5
FUELPUMP
BK
PIN
13
BK
PIN
15
C3
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:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 57
Ford Electrical Schematic - View 2(from serial number 4546 to serial number 5715)
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
TIO
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
LVE
TR
AV
EL
AL
AR
MO
PT
ION
DR
IVE
ED
CR
EV
ER
SE
DR
I VE
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
JOYSTICK CONTROL CARD
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
TB32TB37TB36 TB31 TB30C
1P
BU
RD
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
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
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
POSITION EXCEPT AS NOTED.
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
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
June 2015Section 6 • Schematics
6 - 586 - 57
Ford Electrical Schematic - View 2(from serial number 4546 to serial number 5715)
June 2015 Section 6 • Schematics
6 - 59
Ford Electrical Schematic - View 1(from serial number 5716 to serial number 6315)
6 - 60
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 60 Z-60/34 Part No. 75861
Ford Electrical Schematic - View 1(from serial number 5716 to serial number 6315)
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
R
TILT
ALA
RM
PUMP
BK
12 VDC
+
+BAT.
STA.
BAT.-
ALTERNATOR
EXCT.
RD
-23
RD
-27
RD
/BK
-28B
K-4
3
CR5NO CR5
PR1
RD
WH
NO
PR1
STA
RT
RE
LA
Y
HO
UR
ME
TE
R
_
OTS
FLA
SH
ING
BE
AC
ON
S
OP
TIO
N
OP
TIO
N
GE
NE
RA
TO
R
BK
-33
+
OPS
TB25 TB26
WH
-21
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
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
TS17
TS4
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
OLIN
GFA
N
TE
MP.
SW
ITC
HH
YD
RA
ULIC
OIL
NO
OTS
CR17NO CR17
CB3
20AMP.
TB134P1
RD
TB22
PLAT
GRD
KS1
RD
C1
34
PW
RO
R/R
DC
2-4
P2
2B
AT
BK
HORN
C7
-1
P3
RD
P2
C28TTA RD/BK
RD/BK
C2-3
L48
D40
FU
NC
TIO
NE
NA
.
WH
/BK
WH
/RD
L2
C4
1R
PM
OR
/BK
M1
S7
M2
PR2
NO
PR2
G6
Y29
OHM510
BL/WH
STARTERAUX
HM
STA
RT
EN
GIN
E
FAN
DG
RN
(FE
H2
42
)
RD
(FE
H3
61
A)
ENGINEHARNESS
FORD
FU
EL
PU
MP
LP
G
SO
LE
NO
ID
LO
CK
OU
T
BL/W
HP
IN5
FUELPUMP
BK
PIN
13
BK
PIN
15
C3
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
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
FUSE 10A
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 61
Ford Electrical Schematic - View 2(from serial number 5716 to serial number 6315)
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
TIO
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
LVE
TR
AV
EL
AL
AR
MO
PT
ION
DR
IVE
ED
CR
EV
ER
SE
DR
I VE
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
I MA
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
JOYSTICK CONTROL CARD
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
TB32TB37TB36 TB31 TB30C
1P
BU
RD
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
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
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
POSITION EXCEPT AS NOTED.
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
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
June 2015Section 6 • Schematics
6 - 62
Ford Electrical Schematic - View 2(from serial number 5716 to serial number 6315)
6 - 60
June 2015 Section 6 • Schematics
6 - 63
Ford Electrical Schematic - View 1(from serial number 6316 to serial number 7226)
6 - 64
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 64 Z-60/34 Part No. 75861
Ford Electrical Schematic - View 1(from serial number 6316 to serial number 7226)
C5
-16
C5
-14
C5
-3
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
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
P3
C7
-1
HORN
P2
2B
AT
BK
C2
-4C
13
4P
WR
RD
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
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
HTB26 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
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
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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
R4
50
0C
10
7A
FW
HTB 132 IS WAGO TERMINAL BLOCK 38TB 133 IS WAGO TERMINAL BLOCK 16TB 134 IS WAGO TERMINAL BLOCK 42
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 65
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
TIO
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
LVE
TR
AV
EL
AL
AR
MO
PT
I ON
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
JOYSTICK CONTROL CARD
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
TB32TB37TB36 TB31 TB30C
1P
BU
RD
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
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
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
POSITION EXCEPT AS NOTED.
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
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
I VE
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
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
Ford Electrical Schematic - View 2(from serial number 6316 to serial number 7226)
June 2015Section 6 • Schematics
6 - 666 - 65
Ford Electrical Schematic - View 2(from serial number 6316 to serial number 7226)
June 2015 Section 6 • Schematics
6 - 67
Ford Electrical Schematic - View 1(from serial number 7227 to serial number 10387)
6 - 68
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 68 Z-60/34 Part No. 75861
Ford Electrical Schematic - View 1(from serial number 7227 to serial number 10387)
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
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
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
TI O
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
TI O
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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 69
Ford Electrical Schematic - View 2(from serial number 7227 to serial number 10387)
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
June 2015Section 6 • Schematics
6 - 70
Ford Electrical Schematic - View 2(from serial number 7227 to serial number 10387)
6 - 69
June 2015 Section 6 • Schematics
6 - 716 - 72
Ford Electrical Schematic, ANSI / CSA - View 1(from serial number 10388 to serial number 11788)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 72 Z-60/34 Part No. 75861
Ford Electrical Schematic, ANSI / CSA - View 1(from serial number 10388 to 11788)
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
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
HTB26 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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
GIN
ES
PE
ED
D12
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 73
Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 10388 to 11788)
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
June 2015Section 6 • Schematics
6 - 746 - 73
Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 10388 to serial number 11788)
June 2015 Section 6 • Schematics
6 - 75
Ford Electrical Schematic, ANSI / CSA - View 1(from serial number 11789)
6 -76
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 76 Z-60/34 Part No. 75861
Ford Electrical Schematic, ANSI / CSA - View 1(from serial number 11789)
C5
- 16
C5
-14
TB39
C2
6T
SR
WH
/RD
PIN
39
DIAGNOSTIC
WH
/BK
LP
G L
OC
KO
UT
FORD ENGINEHARNESS
RD
/GNB
L/W
H P
IN 5
FUEL PUMP
FUELPUMP
BK
PIN
15
C3
9LP
BL/R
D P
IN 7
WH
PIN
1
C3
8E
SL
BL/W
H P
IN 6
TS22
GR
PIN
3C
12
7T
SW
BK
/RD
PIN
23
C3
5R
PM
42
PIN
PLU
GF
OR
D
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
H P
IN 2
4C
5-8
ABCDB
K/B
L
RD
GY
/YL
GY
/ RD
GA
SO
LIN
E S
EN
SO
R
BL P
IN 1
8
C1
35
FP
C1
35
RE
T
FO
RD
EN
GIN
E H
AR
NE
SS
C4
1R
PM
OR
/BK
PIN
24
2 P
IN F
OR
D C
ON
NE
CT
OR
TB21
BLU
E/P
INK
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
N E
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. S
WIT
CH
CO
OLIN
G F
AN
(OP
TIO
N)
FAN
TB43
WA
TE
R T
EM
P G
AU
GE
OIL
PR
ES
SU
RE
GA
UG
E
VO
LT M
ET
ER
G1
G3 G2
HIG
H R
PM
(FS
)
GE
NE
RA
TO
R
C1
-9
TS4
TS17
OR/BK
BK
WH
RD
RD
TS55
TB35
LO
W R
PM
HIG
H R
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
N W
H
TB26 TB25
OPS
+
GE
NE
RA
TO
R
OP
TIO
N
OP
TIO
N
FLA
SH
ING
BE
AC
ON
S
_
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
ALA
RM
LE
VE
L S
EN
SO
R
RE
LA
Y
SE
RV
ICE
HO
RN
SE
RV
ICE
HO
RN
RE
LA
Y
AU
XIL
IAR
Y P
OW
ER
AU
XIL
IAR
Y P
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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
D39
D40
RD
TB132
C2
-4
C1
-12
P1
34
PW
R R
D
C1
32
PLI1
BL/W
H
GBOX GND
D10
D3
D4
D2
D13
D14
WO
RK
LIG
HT
SO
PT
ION
CR45NOCR45
WO
RK
LIG
HT
S R
ELA
Y (O
PT
ION
)
EN
GIN
E S
PE
ED
D12
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 77
Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 11789)
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
Y B
OO
M
DE
SC
EN
T A
LA
RM
N
PLA
TF
OR
M R
OTA
TE
CC
W / J
IB D
OW
N
PLA
TF
OR
M R
OTA
TE
CW
/ JIB
UP
BR
PLA
T L
EV
EL U
P
PLA
T L
EV
EL D
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
E R
ELE
AS
E V
ALV
E
TR
AV
EL A
LA
RM
OP
TIO
N
DR
IVE
ED
C R
EV
ER
SE
DR
IVE
ED
C F
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
W C
ON
TR
OL
PR
IMA
RY
BO
OM
PR
IMA
RY
BO
OM
UP
FLO
W C
ON
TR
OL
ST
EE
R C
W
ST
EE
R C
CW
H3
TS59
TB19
TB17
TB18
TB15
C1
9JS
V G
R/W
H
RD
RD
C4
-7
TS57
C4
-5
C4
-6
C3
PB
F R
D/W
H
C2
PB
D R
D/B
K
C1
4P
LU
OR
C1
5P
LD
OR
/BK
TB14
TB8
TB7
TB13TB40
C7
PB
E B
K
C8
PB
R B
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
JOYSTICK CONTROL CARD
TS13
CE
OPTION
LIFT/DRIVE 4
NOCR30
CR27NC
P2
4F
S W
H
P2
4F
S W
H
P2
6E
ST
P B
K
3
J3
13 4 2
8 7
C4
1R
PM
OR
/BK16
15
19
20
17
1811
10
C3
2B
RK
WH
/RD
C6
TR
F W
H/R
D
C3
6S
TC
BL
C3
7S
TC
C B
L/B
K
C5
TR
R W
H/B
K
TB6TB3
TB1
TB2TB5 TB4
TB32TB37TB36
C1
PB
U R
D
TS61
C4
TR
L W
H
TS62
C3
-1
C3
-6
C3
-4
C3
-5
C1
-6
C1
-11
C1
-10
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
E A
BL/W
H
DR
E B
BL/B
K
BR
OR
BL/W
H
WH
/RD
DR
E L
ED
BL/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
2B
RK
WH
/RD
C3
7S
TC
C B
L/B
K
C3
6S
TC
BL
C6
TR
F W
H/R
D
C5
TR
R W
H/B
K
C4
TR
L W
H
C1
PB
U R
D
C2
PB
D R
D/B
K
C3
PB
F R
D/W
H
C7
PB
E B
K
C8
PB
R B
K/W
H
C4
0LS
1 O
R
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
5R5
DO
WN
SE
CO
ND
AR
Y B
OO
M
UP
C1
2S
BF
BL/W
H
C1
1S
BD
BL/B
K
C1
0S
BU
BL
SE
CO
ND
AR
Y B
OO
M U
P
SE
CO
ND
AR
Y B
OO
M D
OW
N
SE
CO
ND
AR
Y B
OO
MF
LO
W C
ON
TR
OL
P2
3P
WR
RD
LS
3D
RIV
E E
NA
BLE
Y17 Y16 Y20Y19 Y25Y26 Y53Y52 Y12Y14 Y22Y21 Y23Y29Y13 Y3Y4 Y2
SJ1 WH
SJ2 WH
XO
UT
JC1
PW
R
542 31G
ND
OU
T
SECONDARY BOOM UP/DN
6
3910
ORBR
WH
/BK
J1
C2
9M
S R
D/W
H
TS14
C5
-23
MO
TO
R S
TR
OK
EC
1-3
C2
9M
S R
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
T
BO
OM
DO
WN
UP
JIB
BO
OM
EX
TE
ND
RE
TR
AC
T
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
DR
IVE
EN
AB
LE
DR
IVE
MO
DE
C3
0E
DC
+ W
H
C3
1E
DC
- WH
/BK
TB31 TB30
C1
-4
C1
-5
BR
-2
C3
1E
DC
- WH
/BK
C3
0E
DC
+ W
HA
B
DC
Y51
C5
-21
C5
-20
C7
-3
C3
-9
TB9
C5
-7
EDCRETURN
8
8 EDC GROUND MOVED TO TB9 AT SERIAL NUMBER 11904
POSITION EXCEPT AS NOTED.
ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
NOTE:
1.
RD
CR14
_
+
D29 D30
14NO13
BK
WH
22 21NC
NO13NC
14
WH
2122
BK
34
NO13NC
14
WH
2122
BK
12
14NO13
BK
WH
22 21NC
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
June 2015Section 6 • Schematics
6 - 78
Ford Electrical Schematic, ANSI / CSA - View 2(from serial number 11789)
6 - 77
June 2015 Section 6 • Schematics
6 - 796 - 80
Ford Electrical Schematic, CE - View 1(from serial number 10388 to serial number 11788)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 80 Z-60/34 Part No. 75861
Ford Electrical Schematic, CE - View 1(from serial number 10388 to serial number 11788)
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
HTB26 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
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
I ON
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)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 81
Ford Electrical Schematic, CE - View 2(from serial number 10388 to serial number 11789)
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
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
/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
TB32TB37TB36 TB31 TB30
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
SECONDARY BOOM UP/DN
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
POSITION EXCEPT AS NOTED.
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
June 2015Section 6 • Schematics
6 - 826 - 81
Ford Electrical Schematic, CE - View 2(from serial number 10388 to serial number 11788)
June 2015 Section 6 • Schematics
6 - 83
Ford Electrical Schematic, CE - View 1(from serial number 11789)
6 - 84
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 84 Z-60/34 Part No. 75861
Ford Electrical Schematic, CE - View 1(from serial number 11789)
C5
-16
C5
-14
TB39
C2
6T
SR
WH
/RD
PIN
39
DIAGNOSTIC
WH
/BK
LP
G L
OC
KO
UT
FORD ENGINEHARNESS
RD
/GN
BL/W
H P
IN 5
FUEL PUMP
FUELPUMP
BK
PIN
15
C3
9LP
BL/R
D P
IN 7
WH
PIN
1
C3
8E
SL
BL/W
H P
IN 6
TS22
GR
PIN
3C
12
7T
SW
BK
/RD
PIN
23
C3
5R
PM
42
PIN
PLU
GF
OR
D
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
H P
IN 2
4C
5-8
ABCDB
K/B
L
RD
GY
/YL
GY
/ RD
GA
SO
LIN
E S
EN
SO
R
BL P
IN 1
8
C1
35
FP
C1
35
RE
T
FO
RD
EN
GIN
E H
AR
NE
SS
C4
1R
PM
OR
/BK
PIN
24
2 P
IN F
OR
D C
ON
NE
CT
OR
TB21
BLU
E/P
INK
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. S
WIT
CH
CO
OLIN
G F
AN
(OP
TIO
N)
FAN
TB43
WA
TE
R T
EM
P G
AU
GE
OIL
PR
ES
SU
RE
GA
UG
E
VO
LT M
ET
ER
G1
G3 G2
P26ESTP BK
P25FS RD
P24FS WH
TS2
C1
-7
TS52
TB33
C3
3S
TR
BK
C9-3
C9-2
FS1
BKC9-1
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.P
20
BA
T R
D
CB
2
TB20 15AMP.
TB41
FB
R2
1IG
N W
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
CR5
NOCR5
R3
4H
RN
BK
RD
/BK
RD
RD
+
DC12 V
BK PUMP
TILT
ALA
RM
LE
VE
L S
EN
SO
R
RE
LA
Y
SE
RV
ICE
HO
RN
SE
RV
ICE
HO
RN
RE
LA
Y
AU
XIL
IAR
Y P
OW
ER
AU
XIL
IAR
Y P
UM
P
-
H2
STA
RT
ER
MO
TO
R
BR
N
IN THE STOWED POSITION AND KEYSWITCH "OFF".
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
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
R R
D
C1
32
PLI1
BL/W
H
GBOX GND
D10
D3
D4
D2
C1
-2
C4
-4
D40
H1L4
D39
PBOXGND
R204.7 K
LS18
LS18A
D88
D89
2 SEC
U34
NO10A
P2
4P
WRGN
/BK
2 SEC
U35
NO30A
C28TTA RD/BK
GR
/BK
C1
33
PLA
OR
/RD
PBOXGND
C132PLI2 BK
C4
-10
L45H6
BL/WH
Y29
FU
NC
TIO
N E
NA
.
RD/BK
HIG
H R
PM
(FS
)
GE
NE
RA
TO
R
C1
-9
TS4
TS17
OR/BK
BK
WH
RD
RD
TS55
TB35
LO
W R
PM
HIG
H R
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
TI O
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
LI G
HT
S
OP
TI O
N
EN
GIN
E S
PE
ED
D12
CR45
NO
CR45
WO
RK
LIG
HT
S R
ELA
Y (O
PT
ION
)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 85
Ford Electrical Schematic, CE - View 2(from serial number 11789)
June 2015Section 6 • Schematics
6 - 86
Ford Electrical Schematic, CE - View 2(from serial number 11789)
6 - 85
June 2015 Section 6 • Schematics
6 - 87
Ford Ground Control Box Wiring Diagram(before serial number 4546)
6 - 88
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 88 Z-60/34 Part No. 75861
Ford Ground Control Box Wiring Diagram(before serial number 4546)
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
TO PLATFORM C-BOX, TERMINAL 22-23
TO PLATFORM C-BOX, TERMINAL 27-46
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 89
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.-
GLOW PLUG/CHECK ENGINE
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.
TURNTABLE ROTATE F.C.
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM DOWN
TURNTABLE ROTATE RTURNTABLE ROTATE L
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
BOOM EXTEND/RETRACT SWITCH
TURNTABLE ROTATE SWITCH
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
PRIMARY BOOM UP/DOWN 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
TS22 RUN/TEST SWITCH
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
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
HYDRAULIC COOLER FAN 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
U33 PLATFORM OVERLOAD MODULE
L2
TS53 LP/GAS SWITCH
TO FUNCTION MANIFOLD(CABLE#4)
TO PLATFORM C-BOX, TERMINAL 1-19
TO PLATFORM C-BOX, TERMINAL 22-23
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
DRIVE LIGHT OPTION RELAY
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
June 2015Section 6 • Schematics
6 - 90
Ford Ground Control Box Wiring Diagram(from serial number 4545 to serial number 5715)
6 - 89
June 2015 Section 6 • Schematics
6 - 916 - 92
Ford Ground Control Box Wiring Diagram(from serial number 5716 to serial number 7226)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 92 Z-60/34 Part No. 75861
Ford 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
BOOM EXTEND/RETRACT SWITCH
TURNTABLE ROTATE SWITCH
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
PRIMARY BOOM UP/DOWN SWITCH
TS63
TS62
CB1
CB2
HMHOUR METER
KS1
TS51
TS52
TS57
TS55
P1
LABEL
TS60
TS59
TS61
TS58
FUNCTION ENABLE SWITCH
JIB BOOM SWITCH
AUXILIARY SWITCH
KEY SWITCH
RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
TO PLATFORM C-BOX, TERMINAL 13-19 C4B
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
PR2
PR1
TO PLATFORM C-BOX, TERMINAL 1-12
TO PLATFORM C-BOX, TERMINAL 39-45
TO PLATFORM C-BOX, TERMINAL 27-38
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
HYDRAULIC COOLER FAN RELAY
HIGH IDLE (RPM) CUTOUT RELAY
CB3CIRCUIT BREAKER, OPTION, 20A
RESISTOR, 5 OHM, TURN. AUX. FUNC.
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
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-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
TURNTABLE ROTATE F.C.
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
MOTOR SPEEDRD/WH -C5-24 RD/WH-C1B-3
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)
DRIVE LIGHT OPTIONBK/RD-CR23#86
RD-24D
DRIVE LIGHT OPTION RELAY
CR23
BR
RD-C4B-12
BK/RD-9B
RD-C4B-10
HYDRAULIC OIL COOLER OPTION RELAY
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 93
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
R3RESISTOR, 1K OHM/2W, #104333
DRIVE LIGHT OPTION RELAY CR23
CHECK ENGINE LED/INCANDESCENT LAMP L2
AUX FUNCTION CR39
RUN/TEST SWITCH TS22
LP/GAS SWITCH TS53
BOOM EXTEND/RETRACT SWITCH
TURNTABLE ROTATE SWITCH
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
PRIMARY BOOM UP/DOWN SWITCH
TS63
TS62
CB1
CB2
HMHOUR METER
KS1
TS51
TS52
TS57
TS55
P1
LABEL
TS60
TS59
TS61
TS58
FUNCTION ENABLE SWITCH
JIB BOOM SWITCH
AUXILIARY SWITCH
KEY SWITCH
RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
TO PLATFORM C-BOX, TERMINAL 13-19 C4B
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
PR2
PR1
TO PLATFORM C-BOX, TERMINAL 1-12
TO PLATFORM C-BOX, TERMINAL 39-45
TO PLATFORM C-BOX, TERMINAL 27-38
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
HYDRAULIC COOLER FAN RELAY
HIGH IDLE (RPM) CUTOUT RELAY
CB3CIRCUIT BREAKER, OPTION, 20A
RESISTOR, 5 OHM, TURN. AUX. FUNC.
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
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-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
TURNTABLE ROTATE F.C.
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
MOTOR SPEEDRD/WH -C5-24 RD/WH-C1B-3
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)
DRIVE LIGHT OPTIONBK/RD-CR23#86
RD-24D
DRIVE LIGHT OPTION RELAY
CR23
BR
RD-C4B-12
BK/RD-9B
RD-C4B-10
HYDRAULIC OIL COOLER OPTION RELAY
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
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
DRIVE LIGHT OPTION RELAY
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
REPLACE WIRE WITH THIS WIRING DIAGRAM
LOAD SENSE OPTION - TIMER RELAY
U34
WL
June 2015Section 6 • Schematics
6 - 946 - 93
Ford Ground Control Box Wiring Diagram(from serial number 7227 to serial number 9798)
June 2015 Section 6 • Schematics
6 - 956 - 96
Ford Ground Control Box Wiring Diagram(from serial number 9799)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 96 Z-60/34 Part No. 75861
Ford 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-33ATS58
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-3ARD/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 LIGHT L2
AUX FUNCTION CR39
RUN/TEST SWITCH TS22
LP/GAS SWITCH TS53
BOOM EXTEND/RETRACT SWITCH
TURNTABLE ROTATE SWITCH
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
PRIMARY BOOM UP/DOWN SWITCH
TS63
TS62
CB1
CB2
HMHOUR METER
KS1
TS51
TS52
TS57
TS55
P1
LABEL
TS60
TS59
TS61
TS58
FUNCTION ENABLE SWITCH
JIB BOOM SWITCH
AUXILIARY SWITCH
KEY SWITCH
RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
TO PLATFORM C-BOX, TERMINAL 13-19 C4B
GLOW PLUG POWER RELAY
AUXILARY POWER RELAY
PR2
PR1
TO PLATFORM C-BOX, TERMINAL 1-12
TO PLATFORM C-BOX, TERMINAL 39-45
TO PLATFORM C-BOX, TERMINAL 27-38
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
HYDRAULIC COOLER FAN RELAY
HIGH IDLE (RPM) CUTOUT RELAY
CB3CIRCUIT BREAKER, OPTION, 20A
RESISTOR, 5 OHM, TURN. AUX. FUNC.
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
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-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
BR-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
TURNTABLE ROTATE F.C.
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
MOTOR SPEEDRD/WH -C5-24 RD/WH-C1B-3
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
V T
O P
LA
T
C1
B
FU
NC
TIO
NS
C3
B
19
/18
CA
BLE
S C2
BC
4B
3
2
C7
B 1
HC
(BK
)(G
Y)
(BR
)(G
R)
EDC RETURN
RD-24D
DRIVE LIGHT OPTION RELAY
CR23
BR
RD-C4B-12
BK/RD-9B
RD-C4B-10
HYDRAULIC OIL COOLER OPTION RELAY
FUSE 10A
BR-C4B-11
GNDBR-C4B-9
FUNCTIONENABLE
LP/GAS
ENGINESTART
PLATFORMROTATE
JIB BOOM
PLATFORMLEVEL
SECONDARYBOOMUP/DOWN
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
RD-TS55 - C32-7 GR/BK-L45GR/BK-133A
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
REPLACE WIRE WITH THIS WIRING DIAGRAM
LOAD SENSE OPTION - TIMER RELAY
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
1 BK/WH S.P.
1TERMINAL 9 BEFORE SERIAL NUMBER 10388
TERMINAL 9 NOT USED FROM SERIAL NUMBER 10388 TO SERIAL NUMBER 11903
BK/RD-C3B-9 9 DRIVE LIGHT OPTIONBK/RD-CR23#86
9 SPARE
BR C3B-9 9 EDC RETURNTERMINAL 9 FROM SERIAL NUMBER 11904 BR C5-7
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 97
Ford Platform Control Box Wiring Diagram(before serial number 7227)
CR30
TS48-9
HI/L0 RPM SWITCH
DETAIL A: LIFT/DRIVE OPTION
CR27
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
SWITCH TOGGLE SPDT 2POS MNT
CHASSIS TILT LED
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
TS15
TS17
TS13
TS9
TS8
L4
TS7
27378
56457
13037
13037
56298
13037
13037
16397
66813, 66816
66812, 94506
PART NUMBER
BOOM SECONDARY JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
EMERGENCY STOP BUTTON
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
P2
JC3
COMPONENT INDEX
JC1
JC2
56457
13038
13037
42730
75565
56298
62391
62390
(SPLICE TO R40LS1)
OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
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
7
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
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
I VE
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
WH
J1
-5B
K-2
2
WH
J1
-5B
LJ1
-4
BR
NJ1
-14
OR
J1
-13
WH
- 23
RD
-TIL T
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-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
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
June 2015Section 6 • Schematics
6 - 98
Ford Platform Control Box Wiring Diagram(before serial number 7227)
6 - 97
June 2015 Section 6 • Schematics
6 - 99
Ford Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)
6 - 100
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 100 Z-60/34 Part No. 75861
Ford Platform Control Box Wiring Diagram(from serial number 7227 to serial number 9065)
TS48-9
HI/L0 RPM SWITCH
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
SWITCH TOGGLE SPDT 2POS MNT
CHASSIS TILT LED
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
TS15
TS17
TS13
TS9
TS8
L4
TS7
27378
56457
13037
13037
56298
13037
13037
16397
66813, 66816
66812, 94506
PART NUMBER
BOOM SECONDARY JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
EMERGENCY STOP BUTTON
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
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
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
-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
PRIMARY BOOMUP / DOWN
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
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
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
DETAIL A: LIFT/DRIVE OPTION
CR27
(SPLICE TO R40LS1)
OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 101
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
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
SWITCH TOGGLE SPDT 2POS MNT
CHASSIS TILT LED
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
TS15
TS17
TS13
TS9
TS8
L4
TS7
27378
56457
13037
13037
56298
13037
13037
16397
66813, 66816
66812, 94506
PART NUMBER
BOOM SECONDARY JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
EMERGENCY STOP BUTTON
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
P2
JC3
COMPONENT INDEX
JC1
JC2
56457
13038
13037
42730
75565
56298
62391
62390
(SPLICE TO R40LS1)
OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
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
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
PRIMARY BOOMUP / DOWN
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
LT
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
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
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
June 2015Section 6 • Schematics
6 - 1026 - 101
Ford Platform Control Box Wiring Diagram(from serial number 9066 to serial number 9798)
June 2015 Section 6 • Schematics
6 - 103
Ford Platform Control Box Wiring Diagram(from serial number 9799 to 11788)
December 2011
6 - 104
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 104 Z-60/34 Part No. 75861
Ford PlatformControl Box Wiring Diagram(from serial number 9799 to 11788)
CR30
TS48-9
HI/L0 RPM SWITCH
DETAIL A: LIFT/DRIVE OPTION
CR27
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
SWITCH TOGGLE SPDT 2POS MNT
CHASSIS TILT LED
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
TS15
TS17
TS13
TS9
TS8
L4
TS7
27378
56457
13037
13037
56298
13037
13037
16397
66813, 66816
66812, 94506
PART NUMBER
BOOM SECONDARY JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
EMERGENCY STOP BUTTON
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
P2
JC3
COMPONENT INDEX
JC1
JC2
56457
13038
13037
42730
75565
56298
62391
62390
(SPLICE TO R40LS1)
OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
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
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
-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
PRIMARY BOOMUP / DOWN
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-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 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/
BK
C2
P-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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 105
Ford PlatformControl Box Wiring Diagram(from serial number 11789)
CR30
TS48-9
HI/L0 RPM SWITCH
DETAIL A: LIFT/DRIVE OPTION
CR27
WORK/DRIVE LIGHT ( OPTION )
PRIMARY BOOM EXTEND/RETRACT SWITCH
PLATFORM ROTATE SWITCH
SWITCH TOGGLE SPDT 2POS MNT
CHASSIS TILT LED
DRIVE ENABLE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
TS15
TS17
TS13
TS9
TS8
L4
TS7
BOOM SECONDARY JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
EMERGENCY STOP BUTTON
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
P2
JC3
COMPONENT INDEX
JC1
JC2
(SPLICE TO R40LS1)
OR R40LS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
WH/RD C32BRK
(SPLICE TO C32BRK)
WH TS7WH TS1
BRN BATGND
(GND STUD)
CE SEE DETAIL A
+
C2
9M
S R
D/W
H J
1-8
C2
7A
UX
RD
C1
P-1
C1
7JU
GR
C4
P-5
C1
9JS
V G
R/W
H J
IB
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
K J
1-2
BR
N J
1-1
2O
R J
1-1
1
JC2
BK
-7
BK
/WH
-8
BR
N J
1-1
0W
H-2
4
TS13JC1
RETRACTEXTEND/
BOOMPRIMARY
WH
-24
OR
J1
-9
WH
/BK
J1
- 3
BK
- 22
BL/B
K-D
E2
J1
-7
BL/W
H-D
E1
J1
-6
BL/R
D-D
E3
J1
-16
WH
-24
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
GR
/BK
H1
WH
- 24
BK
/ RD
-35
RD
-P2
L4
JC3
BK
-22
WH
-23
RD
- TIL T
C1
9JS
V G
R/W
H
JD
ALA
RM
GR
/BK
-44
C2
P-6
GR/BK
GR
JIB
TS8
WH
-JIB
WH
-JIB
BR
N
WH
-24
CR13
GR
/WH
-45
TS17
(OPTION)GENERATOR
RD
RD
WL1
BL/ R
D-3
9
FUEL SELECTTS3
RD
DRIVE / STEERPRIMARY BOOM
UP / DOWN
TURNTABLEROTATE
JC21
6
JC11
6
1
6
BL/W
H J
1-5
BL/W
H J
1-5
WH
/RD
J1
-4
BR
N J
1-1
4O
R J
1-1
3
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
S R
D/W
HC
13
LE
D B
L/R
DD
RE
B B
L/B
K
DR
E A
BL/W
HC
28
TTA
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
,6 W
HJC
3-2
BR
N
C2
7A
UX
RD
C1
P-1
C3
4S
A B
K/W
H C
1P-8
C3
5R
PM
BK
/RD
C1
P-9
C3
3S
TR
BK
C1
P-7
C1
34
PW
R R
D C
2P-4
C1P
C2P
9
1
J1
RD
/BK
L4
C6
TR
F W
H/R
D C
3P-6
C1
0S
BU
BL C
3P-1
0C
13
DR
E B
L/R
D C
4P-1
C1
1S
BD
BL/B
K C
3P-1
1C
40
LS
1 O
R C
2P-2
C1
2S
BF
BL/W
H C
3P-1
2C
41
RP
M O
R/B
K C
2P-3
C3
0E
DC
+ W
H C
1P-4
C1
PB
U R
D C
3P-1
C3
1E
DC
- WH
/BK
C1
P-5
C2
PB
D R
D/B
K C
3P-2
C3
7S
TC
C B
L/B
K C
1P-1
1C
3P
BF
RD
/WH
C3
P-3
C3
6S
TC
BL C
1P-1
0
C4
TR
L W
H C
3P-4
C3
2B
RK
WH
/RD
C1
P-6
C5
TR
R W
H/B
K C
3P-5
C2
9M
S R
D/W
H C
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
S W
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
S W
H C
9P-2
P2
5F
S R
D C
9P-3
P2
6B
AT
BK
C9
P-1
C7
PB
E B
K C
3P-7
C8
PB
R B
K/W
H C
3P-8
C4
3 H
RN
GR
C2
P-5
JD
ALA
RM
GR
/ BK
C2
P-6
C1
9JS
V G
R/W
H J
IB
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
ALA
RM
GR
/BK
C2
P-6
TS
48
- WL2
RD
C2
P- 1
1T
S4
8- W
L1
RD
C2
P- 1
2
C3
9LP
BL/R
D C
2P-1
47
00
R2
0
P1
34
PW
R R
D-H
1+
RD
-E-S
TO
P
BR
JC
3B
R G
ND
C1
9JS
V G
R/W
H C
4P-7
C1
9JS
V G
R/W
H T
S7
LOAD SENSE OPTION
P1
34
PW
R R
D
RD
-H1
+
BR
GN
D
P2
6E
ST
P B
K E
-ST
OP
U35
R2
6E
ST
P B
K C
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
6 G
R/W
H
P1
34
PW
R R
D
GR/WHCR14
C1
RD
BR
BR
JIB
HARNESSPBOX WIRING
DR
IVE
LT B
K/R
D C
3P-9
CR14 JIB TIME DELAY RELAYJIB TIME DELAY
TILT ALARMH1
C1
COMPONENT INDEX P2
4F
S W
H
D12 D11
+
L48
RD
/BK
H1
June 2015Section 6 • Schematics
6 - 106
Ford PlatformControl Box Wiring Diagram(from serial number 11789)
6 - 105
June 2015 Section 6 • Schematics
6 - 107
Engine Wire HarnessFord LRG-425 EFI Models
6 - 108
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 108 Z-60/34 Part No. 75861
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 109
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
June 2015Section 6 • Schematics
6 - 110
Engine Wire HarnessFord DSG-423 EFI Models (before serial number 6810)
6 - 109
June 2015 Section 6 • Schematics
6 - 111
Engine Wire HarnessFord DSG-423 Models (from serial number 6810 to serial number 11788)
6 - 112
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 112 Z-60/34 Part No. 75861
Engine Wire HarnessFord DSG-423 Models (from serial number 6810 to serial number 11788)
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 113
Engine Wire HarnessFord MSG-425 Models (from serial number 11789)
June 2015Section 6 • Schematics
6 - 114
Engine Wire HarnessFord MSG-425 Models (from serial number 11789)
6 - 113
June 2015 Section 6 • Schematics
6 - 1156 - 116
Electrical Schematic - CTE Option(before serial number 9697)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 116 Z-60/34 Part No. 75861
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)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 117
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
June 2015Section 6 • Schematics
6 - 1186 - 117
Electrical Schematic - CTE Option(from serial number 9697)
June 2015 Section 6 • Schematics
6 - 119
Joystick Connector Diagram
6 - 120
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 120 Z-60/34 Part No. 75861
Joystick Connector Diagram
JOYSTICK CONTROL CARD
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
PRI UP/DN & TT ROTATE
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/STEER
J1
-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
Joystick Adaptor Harness
8 7 20
17
181110
RD
BK
BR
N
OR
J2
6
J1
12 1
11 2
9
7
PRI UP/DN & TT ROTATE
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
SECONDARY BOOM UP/DN
7
39
10
OR
BR
N
YE
L
J1
JOYSTICK CONTROL CARD
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 121
Hydraulic Generator Options(from serial number 10283)
SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONS
C4
5G
EN
-GR
/WH
-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
June 2015Section 6 • Schematics
6 - 1226 - 121
Hydraulic Generator Options(from serial number 10283)
June 2015 Section 6 • Schematics
6 - 1236 - 124
Electrical Schematic - Welder Option
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 124 Z-60/34 Part No. 75861
Electrical 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
RS232TxDC
R4
HIG
HID
LE
RE
LA
Y
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
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 125
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.
June 2015Section 6 • Schematics
6 - 1266 - 125
Hydraulic Schematic - Welder Option
June 2015 Section 6 • Schematics
6 - 127
Hydraulic Schematic - 2WD Models(before serial number 4461)
6 - 128
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 128 Z-60/34 Part No. 75861
Hydraulic 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 psiat
at serial number11003
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 129
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
COUNTERBALANCE VALVE
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)
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
June 2015Section 6 • Schematics
6 - 1306 - 129
Hydraulic Schematic - 2WD Models(from serial number 4461 to serial number 10282)
June 2015 Section 6 • Schematics
6 - 131
Hydraulic Schematic - 2WD Models(from serial number 10283 to serial number 11003)
6 - 132
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 132 Z-60/34 Part No. 75861
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
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
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
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
COUNTERBALANCE VALVE
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
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)
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 133
Hydraulic Schematic - 2WD Models(from serial number 11004 to 11477)
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
SECONDARY LIFT4.1 gpm
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
SET @ .6 GPM2.3 L/min
X
X
X
MANIFOLD2 SPEED
X BRAKE/
3 psi0.20 bar
F
E
D
C
B
A
G
PRESSRATIO
COUNTERBALANCE VALVE
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
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
P -12
F -12
RELIEF VALVESET @ 2700 PSI
HYDRAULIC GENERATOR OPTION
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
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
June 2015Section 6 • Schematics
6 - 134
Hydraulic Schematic - 2WD Models(from serial number 11004 to 11477)
6 - 133
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 135
Hydraulic Schematic - 2WD Models(from serial number 11478)
FILTER
PRESSUREMEDIUM
FUNCTIONPUMP
DRIVE PUMP
RESERVOIR
X
X
2.2 gpm3.8 L/min
PRIMARY LIFT
AUX. PUMP
LEVELPLATFORM
MASTERSLAVE
TURNTABLEROTATE1 gpm
3.8 L/min
OIL COOLER
FILTERRETURN
SECONDARY LIFT4.1 gpm
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 gpm5.7 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 psi2.1 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
SET @ .6 GPM2.3 L/min
X
X
X
MANIFOLD2 SPEED
X BRAKE/
3 psi0.20 bar
F
E
D
C
B
A
G
PRESSRATIO
COUNTERBALANCE VALVE
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
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
P -12
F -12
HYDRAULIC GENERATOR OPTION
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
BW
BQ
BK
B0
BV
June 2015Section 6 • Schematics
6 - 136
Hydraulic Schematic - 2WD Models(from serial number 11478)
6 - 135
June 2015 Section 6 • Schematics
6 - 137
Hydraulic Schematic - 4WD Models(before serial number 4461)
6 - 138
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 138 Z-60/34 Part No. 75861
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
SECONDARY LIFT4.1 gpm
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
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
COUNTERBALANCE VALVE
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
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
Hydraulic Schematic - 4WD Models(before serial number 4461)
Changed to 750 psiat
at serial number11003
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 139
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
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
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
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
COUNTERBALANCE VALVE
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
CYLINDERSSTEERINGLEFT
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
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
June 2015Section 6 • Schematics
6 - 1406 - 139
Hydraulic Schematic - 4WD Models(from serial number 4461 to serial number 10282)
June 2015 Section 6 • Schematics
6 - 1416 - 142
Hydraulic Schematic - 4WD Models(from serial number 10283 to serial number 11003)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
June 2015Section 6 • Schematics
6 - 142 Z-60/34 Part No. 75861
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
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
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
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
COUNTERBALANCE VALVE
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
CYLINDERSSTEERINGLEFT
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
RELIEF VALVESET @ 2700 PSI
HYDRAULIC GENERATOR OPTION
V1
V2
JIB SELECTMANIFOLD
J2
J1
PR1
PR2
MANIFOLD CHANGEDAT SN 10426
X X
XX
XX
Hydraulic Schematic - 4WD Models(from serial number 10283 to serial number 11003)
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 143
Hydraulic Schematic - 4WD Models(from serial number 11004 to 11477)
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
SET @ .6 GPM2.3 L/min
2.2 gpm3.8 L/min
PRIMARY LIFT
C
X
X
X
MANIFOLD2 SPEED
X BRAKE/
SECONDARY LIFT4.1 gpm
15.5 L/min
C
3 psi0.20 bar
F
E
D
C
B
A
G
PRESSRATIO
COUNTERBALANCE VALVE
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
CYLINDERSSTEERINGLEFT
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
RELIEF VALVESET @ 2700 PSI
HYDRAULIC GENERATOR OPTION
X X
XX
XX
V2
PR2
PR1
V1
J1
J2
X
X
LEVELPLATFORM
SLAVE
E
E JIB SELECTMANIFOLD
BP
BS
BTBU
BR
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
June 2015Section 6 • Schematics
6 - 1446 - 143
Hydraulic Schematic - 4WD Models(from serial number 11004 to 11477)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
June 2015 Section 6 • Schematics
Part No. 75861 Z-60/34 6 - 145
PLATFORM ROTATE
ROTARYHYDRAULIC
COUPLER
FILTER
PRESSUREMEDIUM
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 gpm5.7 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 psi2.1 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
SET @ .6 GPM2.3 L/min
2.2 gpm3.8 L/min
PRIMARY LIFT
C
X
X
X
MANIFOLD2 SPEED
X BRAKE/
SECONDARY LIFT4.1 gpm
15.5 L/min
C
3 psi0.20 bar
F
E
D
C
B
A
G
PRESSRATIO
COUNTERBALANCE VALVE
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
CYLINDERSSTEERINGLEFT
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
RELIEF VALVE
HYDRAULIC GENERATOR OPTION
X X
XX
XX
V2
V1
X
X
LEVELPLATFORM
SLAVE
E
EPR2
PR1
J1
J2
JIB SELECTMANIFOLD
BW
BQ
BK
B0
BV
Hydraulic Schematic - 4WD Models(from serial number 11478)
June 2015Section 6 • Schematics
6 - 1466 - 145
Hydraulic Schematic - 4WD Models(from serial number 11478)
Dis
trib
ute
d B
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