z45-25 pdf2

Service Manual Supplement
Contact Us:
http://www.genieindustries.com
e-mail: awp.techpub@terex.com
July 2011
Copyright 2004 by Genie Industries

107713 Rev B July 2011
First Edition, Second Printing
"Genie" and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
Self-Propelled Servicing Platform
Part No. 107713
Contact Us:
http://www.genielift.com
e-mail: awp.techpub@terex.com
November 2011
Copyright 2011 Terex Corporation

107713 Rev B July 2011
First Edition, Second Printing
"Genie" and "Z" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
Part No. 107713
July 2011
Table of Contents
Machine Specifications ................................................. 4
Scheduled Maintenance Procedure ............................ 9
Maintenance Inspection Report ................................. 10
Maintenance Procedure ............................................. 11
Repair Procedures ..................................................... 16
Steer Axle Components ............................................. 17
Non-steer Axle Components ...................................... 21
Fiberglass Covers ...................................................... 23
Electrical Schematic ................................................... 25
Ground Control Box Terminal Strip Wiring Diagram .. 27
Ground Control Box Switch Panel Wiring Diagram ... 28
Platform Control Box Wiring Diagram ........................ 29
Platform Control Box Switch Panel Wiring Diagram .. 30
Engine Panel Diagram ............................................... 31
Power Cable Diagram ................................................ 32
Hydraulic Schematic .................................................. 33
Part No. 107713
January 2006
REV A
Specifications
Machine Specifications
Performance Specifications
Tires and wheels
Gradeability (boom stowed)
Tire size
Wheel diameter
Wheel width
Wheel lugs
Front
Rear
9-14.5 LT
14.5 inches
7 inches
8 @ 5/8 -18
9 @ 5/8 -18
30%
Boom function speeds, maximum

from platform controls
Jib boom up
35 to 41 seconds
Jib boom down
18 to 24 seconds
Primary boom up
47 to 53 seconds
Primary boom down
34 to 40 seconds
Lug nut torque
125 ft-lbs
169.5 Nm
Secondary boom up
35 to 41 seconds
Tire size
9-14.5 LT
Secondary boom down
22 to 28 seconds
Tire ply rating
Tread 6
Sidewall 6
Primary boom extend
7 to 13 seconds
Primary boom retract
9 to 15 seconds
Tire contact area
43.5 sq in
280 sq cm
Overall tire diameter
28 in
71 cm
Fluid capacities
Fuel tank
9 gallons
34.1 liters
Hydraulic tank
8 gallons
30.3 liters
Hydraulic system
(including tank)
11 gallons
41.6 liters
Drive hubs
Turntable rotate, 357

primary boom retracted
Platform rotate, 160
94 to 100 seconds
3 to 9 seconds
Platform level up
199 to 205 seconds
Platform level down
127 to 133 seconds
23 fl oz
0.68 liter
For operational specifications, refer to the

Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 107713
January 2006
REV A
SPECIFICATIONS
Hydraulic Specifications
Function pump
Hydraulic Oil Specifications
Type: fixed displacement gear pump
Hydraulic oil type

Chevron Rykon MV equivalent
Approximate SAE grade
5W-20
Viscosity index rating
200
Displacement
Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable
Fire resistant
Mineral based
Hydraulic tank circuit

return line filter
0.12 cu in
2 cc
10 micron with
25 psi / 1.7 bar bypass
Function manifold
Function relief valve pressure
3200 psi
220.6 bar
Secondary boom down

relief valve pressure
2000 psi
138 bar
Auxiliary pump
Type: fixed displacement gear pump
Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Displacement
Auxiliary pump
relief pressure
0.5 gallons per minute

1.9 liters per minute
3200 psi
220.6 bar
Shell Tellus T32

Shell Tellus T46
Chevron Aviation A
Note: Genie specifications require additional

equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Part No. 107713
January 2006
SPECIFICATIONS
REV A
Kubota Z482-E Engine

Displacement
Injection system
29.23 cu in
0.48 liters
2
Number of cylinders
Bore and stroke
Horsepower
Gross intermittent
2.64 x 2.68 inches

67 x 68 mm
12.5 @ 3600 rpm
Injection pump make
Bocsh MD
Injection timing
21 BTDC
Injection pump pressure

Fuel requirement
Alternator
Output
1991 psi
137 bar
diesel number 2-D
12V, 150 watts
Firing order
1-2
Starter motor
Compression ratio
23:1
Brush length, new
0.5188 in
13 mm
Brush length, minimum
0.3346 in
8.5 mm
Compression pressure
412 to 469 psi

28.4 to 32.3 bar
Low idle
2000 rpm
High idle
3000 rpm
Governor
Valve clearance, cold
centrifugal mechanical
0.0057 to 0.0072 in
0.145 to 0.185 mm
Engine coolant
Capacity
2.9 quarts
2.8 liters
Battery
Type
12V, Group 70
Quantity
Cold cranking ampere
450A
Reserve capacity @ 25A rate
125 minutes
Fan belt deflection
/4 to 3/8 inch
7 to 9 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
Oil viscosity
requirements
36 to 64 psi
2.48 to 4.41 bar
2.6 quarts
2.5 liters
10W-30
Engine oil should have properties of API classification

CC/SE, CD/SE, CC/SF or CD/SF grades.
Part No. 107713
January 2006
REV A
SPECIFICATIONS
Hydraulic Hose and Fitting

Torque Specifications
Your machine is equipped with Parker Seal-Lok
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
SAE Dash size
Torque
-4
11 ft-lbs / 14.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
139 ft-lbs / 188.5 Nm
-20
172 ft-lbs / 233.2 Nm
-24
208 ft-lbs / 282 Nm
Seal-Lok fittings
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been 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 are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok Fittings
(tube fitting - installed into Steel)
(hose end)
SAE Dash size
Torque
SAE Dash size
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
27 ft-lbs / 36.6 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 54.2 Nm
-10
105 ft-lbs / 142.4 Nm
-10
63 ft-lbs / 85.4 Nm
-12
140 ft-lbs / 190 Nm
-12
90 ft-lbs / 122 Nm
-16
210 ft-lbs / 284.7 Nm
-16
120 ft-lbs / 162.7 Nm
-20
260 ft-lbs / 352.5 Nm
-20
140 ft-lbs / 190 Nm
-24
315 ft-lbs / 427.1 Nm
-24
165 ft-lbs / 223.7 Nm
Part No. 107713
January 2006
This page intentionally left blank.
Part No. 107713
November 2011
Scheduled Maintenance Procedure

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Maintenance inspections shall be completed by a

person trained and qualified on the maintenance
of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every 2
years as specified on the Maintenance
Inspection Report.
Used to indicate the presence of an

imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to properly complete each

inspection when required may
cause death, serious injury or
substantial machine damage.
Used to indicate the presence of a

potentially hazardous situation
which, if not avoided, could result in
Immediately tag and remove from service a

damaged or malfunctioning machine.

which, if not avoided, may cause
minor or moderate injury.
Repair any machine damage or malfunction

before operating machine.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:

which, if not avoided, may result in
property damage.
Machine parked on a firm, level surface

Boom in the stowed position
Turntable rotated with the boom between the
non-steering wheels
Indicates that a specific result is expected after

performing a series of steps.
Turntable secured with the turntable

rotation lock
Key switch in the off position with the key
removed
Wheels chocked
Part No. 107713
November 2011
Maintenance Inspection Report
Hour meter
Refer to the Genie Z-45/25 Bi-Energy & Z-45/25J Bi-Energy Service

Manual for scheduled machine maintenance procedures.
The following scheduled maintenance procedure will need to be
performed every 1000 hours or annually in addition to regularly
scheduled machine maintenance inspections as outlined in the
Service Manual.
Machine owner
Checklist D
Model
Serial number
Date
Y N R
D-6.1 Temperature sensor

Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection. Maintain completed
forms for a minimum of 4 years or in
compliance with employer, jobsite
and governmental regulations and
requirements.
If any inspection receives an N, tag
and remove the machine from
service, repair and reinspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
10
Part No. 107713
July 2011
REV B
Maintenance Procedure
D-6.1
Test the Exhaust Manifold
Temperature Sensor
Note: Genie specifications require that this

procedure be performed every 1000 hours of
operation or yearly.
Yearly calibration of the exhaust manifold
temperature sensor is essential to safe machine
operation. Continued use of an improperly
calibrated temperature sensor could result in
failure to sense an accurate exhaust manifold
temperature. This could create a hazardous
situation.
Component damage hazard. This
procedure requires specific repair
skills and testing equipment.
Dealer service is strongly
recommended.
1 See How to Program the Temperature Display
and access the TYPE menu item.
2 To change the input type, press the
blank (unmarked) button to scroll through the
available choices until L IN is shown on the
display. Press the SEL button to select and
return to the main menu.
3 Press the SEL button until the OFSET menu is
shown on the display. Change the offset value
to zero.
4 Press and hold the SEL button for 3 seconds to
enter the value and return to the main menu.
Part No. 107713
5 Remove the jumper wire from the back of the

temperature display.
Result: The display will show SAVE to indicate the
programming changes are being saved into
memory.
Note: Do not turn the machine off before removing
the jumper from the back of the display. If the
machine is turned off before the jumper wire is
removed, all data may not save completely or
correctly. This could result in a fault display of FR IL
the next time the machine is turned on.
6 Use a precision DC voltage power supply with
an output range of -10 mV DC to 60 mV DC
and an accuracy of 0.03% or better. Connect
the negative lead to the TC - terminal and the
positive lead to the TC+ terminal of the
7 Set the power supply to mV DC and turn the
power supply on.
8 Compare the voltage on the temperature
display to that of the power supply over a range
of -10 mV DC to 60 mV DC.
Result: If the voltage differences between the
temperature display and the power supply are
within 0.02 mV DC at all points over the range
of -10 mV DC to 60 mV DC, the display does
not need to be calibrated.
Result: If the voltage differences between the
temperature display and the power supply are
more than 0.02 mV DC at one or more points
over the range of -10 mV DC to 60 mV DC, the
display will need to be calibrated. See How to
Calibrate the Temperature Sensor Voltage
Input.
11
July 2011
MAINTENANCE PROCEDURE
REV B
How to Program the

Temperature Display
4 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on
position at the ground controls.
There are six items that can be accessed in the

programming mode.
5 Press the SEL button to scroll to the menu item

you want to program.
TYPE - Allows the choice of thermocouple being

used. Genie uses Type K thermocouples.
6 Press the blank (unmarked) button to cycle

through available choices for each menu item.
CJC - Cold Junction Compensation. This feature is

not used on your machine.
7 Press the SEL button to make your choice and

return to the main menu.
DISP - Allows the choice between F or C. Also

allows the choice between whole numbers or
tenths.
8 Repeat steps 5 through 7 for each menu item.
FLTER - Used to help stabilize the display if it is

difficult to read due to small process variations or
noise. Choose "0" for no filtering or up to "3" for
heavy filtering.
RANGE - The range value determines if the filter
will be applied to the new input sample. If the new
input value is within the range of the previous
display, the filter will be applied to the new input.
OFSET - Used to add or subtract a constant
temperature from the display.

Result: The display will show SAVE to indicate
the programming changes are being saved into
memory.
1 Push in the red Emergency Stop buttons to the

off position at both the ground and platform
controls.
2 Open the ground control box and locate the
3 Connect a jumper wire between the PROGRAM
and COMM terminals on the back of the
12
Part No. 107713
July 2011
REV B
How to Calibrate the

Temperature Sensor Voltage
Input
Component damage hazard. This
procedure requires specific repair
skills and testing equipment.
Dealer service is strongly
recommended.
5 Use a precision DC voltage power supply with

an output range of -10 mV DC to 60 mV DC and
an accuracy of 0.03% or better. Connect the
positive and negative leads of the power supply
to the TC + and TC - terminals on the back the
6 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at the ground controls.
Note: Calibration of the exhaust manifold

temperature sensor should only be performed by
individuals experienced in calibrating electronic
equipment.
7 Turn on the power supply and set it to

-10 mV DC.
Note: Allow the temperature sensor to warm up for

30 minutes before performing the calibration
procedure.
9 Press the blank (unmarked) button to

select YES.
Note: The calibration procedure should be

performed at an ambient temperature between 59
to 95 F / 15 to 35 C.
1 Push in the red Emergency Stop buttons to the
off position at both the ground and platform
controls.
2 Open the ground control box and locate the
3 Connect a jumper wire between the PROGRAM and
COMM terminals on the back of the temperature
display.
4 Tag and disconnect the thermocouple wires from
the TC + and TC - terminals of the temperature
display.
Part No. 107713
8 Press the SEL button until CAL is shown on the

display.
Result: The display will show "00000".

10 Press the blank (unmarked) button to increment
the access code until the display shows
"00006".
11 Press and hold the SEL button. After entering the
correct access code, the display will show IN 1.
Follow the table below for the calibration
sequence.
Note: The display will show CALC for approximately 3
seconds after pressing the SEL button before
proceeding to the next input point.
Note: After the calibration sequence is complete,
the display will show CAL.
13
July 2011
REV B
12 Exit the programming mode by removing the

jumper wire from the back of the temperature
display.
memory.
13 Perform procedure Test the Exhaust Manifold
Temperature Display to verify voltage calibration.
14 Repeat the calibration procedure if necessary.
14
Display
Parameter
Action
IN1
-10mV DC
Apply -10mV DC, wait 5 seconds, press SEL button
IN2
0 mV DC
Apply 0 mV DC, wait 5 seconds, press SEL button.
IN3
10 mV DC
IN4
20 mV DC
IN5
30 mV DC
IN6
40 mV DC
IN5
50 mV DC
IN5
60 mV DC
Part No. 107713
July 2011
REV B
How to Program the Temperature

Offset
Note: This procedure will only need to be performed
if the temperature display is being replaced or if the
saved data is corrupted and needs to be reset.
Note: Genie programs a default value of +30 F / 1.1 C for temperature offset.
1 See How to Program the Temperature Display
and access the OFSET menu item.
2 To enter the offset value, press the
blank (unmarked) button to increment the
flashing digit or the sign of the number. To select
a new digit or sign of the number, press the SEL
button.
Note: If no digits are flashing, press the blank button
to toggle the sign of the number or press the SEL
button to wrap around to the LSD.
3 After the desired offset value is on the display,
press and hold the SEL button for 3 seconds to
enter the value and return to the main menu.
memory.
Part No. 107713
15
July 2011
16
Part No. 107713
July 2011
Repair Procedures
REV B
About This Section

Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:

Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Perform disassembly procedures to the point where

repairs can be completed. Then to
reassemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Repair any machine damage or malfunction

before operating the machine.
Before Repairs Start:
Used to indicate the presence of

an imminently hazardous situation
which, if not avoided, will result in
Read, understand and obey the safety rules

and operating instructions in the
Genie Z-45/25 Bi-Energy & Genie Z-45/25J
Bi-Energy Operators Manual on your machine.

which, if not avoided, could result
in death or serious injury.
Be sure that all necessary tools and parts are

available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

which, if not avoided, may cause
minor or moderate injury.
Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:

which, if not avoided, may result in
property damage.
Machine parked on a firm, level surface

Boom in the stowed position
Turntable rotated with the boom between
the non-steer wheels
Turntable secured with the turntable
rotation lock
Indicates that a specific result is expected after

performing a series of steps.
Key switch in the off position with the

key removed
Wheels chocked
Part No. 107713
17
November 2011
Steer Axle Components
2 Loosen the wheel lug nuts. Do not remove them.
Yoke and Hub
3 Block the non-steer wheels, and then center a

lifting jack of ample capacity under the steer
axle.
How to Remove the Yoke

and Hub
The yoke installation utilizes bushings in the axle
and a thrust washer that may require periodic
replacement.
1 Remove the cotter pin from the steer cylinder
rod-end clevis pin and remove the cotter pin
from the tie rod clevis pin. Remove the clevis
pins.
Note: Always use a new cotter pin when installing a
clevis pin.
a
REV B
4 Raise the machine 6 inches / 15 cm and place

blocks under the chassis for support.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
6 Remove the pin retaining fasteners from the
yoke pivot pins. Do not remove the pins.
7 Support and secure the yoke/hub assembly to a
lifting jack.
8 Place a rod through the upper yoke pivot pin
and twist to remove the pin. Use a soft metal
drift to drive the lower yoke pivot pin down and
out.
Crushing hazard. The yoke/hub

assembly may become
unbalanced and fall when the yoke
pivot pins are removed if not
properly supported and secured to
the lifting jack.
g
f
a
b
c
d
e
f
g
18
tie rod
steer axle
yoke pivot pin
yoke
hub
pivot pin
steer cylinder
Torque specifications
Lug nut torque, dry
125 ft-lbs
169.5 Nm
Lug nut torque, lubricated
94 ft-lbs
127.4 Nm
Part No. 107713
November 2011
REV B
STEERING AXLE COMPONENTS
How to Remove the

Hub and Bearings
How to Install the

Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove

them.
Note: When replacing a wheel bearing, both the

inner and outer bearings including the pressed-in
races must be replaced.
2 Block the non-steer wheels and place a lifting

jack of ample capacity under the steering axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Remove the dust cap, cotter pin and castle nut.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
1 Be sure that both bearings are packed

with clean, fresh grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub
until it is flush.
4 Slide the hub onto the yoke spindle.
Component damage. Do not
apply excessive force or damage
to the lip of the seal may occur.
7 Place the hub on a flat surface and gently pry

the bearing seal out of the hub. Remove the
rear bearing.
5 Place the outer bearing into the hub.

6 Install the washer and castle nut.
7 Tighten the castle nut to 150 ft-lbs / 203 Nm to
seat the bearing.
8 Loosen the slotted nut, then retighten to
35 ft-lbs / 48 Nm.
9 Install a new cotter pin. Bend the cotter pin
to lock it in.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
125 ft-lbs / 169.5 Nm.
Part No. 107713
19
November 2011
STEERING AXLE COMPONENTS
REV B
Steer Cylinders
Tie Rod
How to Remove a Steer Cylinder
How to Remove the Tie Rod
There are two identical steer cylinders that

work in parallel. They are part of the same hydraulic
circuit, but move in opposite directions. The tie rod
maintains equal movement of the tires.
1 Remove the cotter pins from the clevis pins at

each end of the tie rod, then remove the clevis
pins.
2 Remove the tie rod.
Note: When removing a hose assembly or fitting,

the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and burn
skin. Loosen hydraulic connections
very slowly to allow the oil pressure
to dissipate gradually. Do not allow
oil to
squirt or spray.
2 Remove the cotter pin from the rod-end clevis pin
of the steer cylinder. Remove the clevis pin.
3 Remove the cotter pin from the barrel-end clevis
pin of the steer cylinder then remove the clevis
pin.
Note: Always use a new cotter pin when installing a
clevis pin.
4 Remove the steer cylinder from the machine.
20
Part No. 107713
July 2011
Non-steer Axle Components
REV B
Drive Motor
Torque Hub
How to Remove a Drive Motor

1 Disconnect the battery packs.
How to Remove a Drive

Torque Hub
2 Remove the fasteners from the cover on the nonsteer axle. Remove the cover.
Note: The drive motor must be removed in order to

access the torque hub mounting bolts.
3 Tag and disconnect the power cables and relay

wiring from the drive motor.
Note: When removing a hose assembly or fitting,

the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.
Electrocution/burn hazard. Contact

with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
4 Remove the drive motor mounting fasteners.
5 Guide the drive motor shaft out of the brake and
then remove the drive motor from the machine.
1 Remove the drive motor. See, How to Remove a

Drive Motor.
2 Disconnect the hydraulic hose from the brake
and plug it. Remove the hydraulic fitting and the
bleed valve.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and burn
skin. Loosen hydraulic connections
very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
3 Chock the steer wheels.
4 Loosen the wheel lug nuts. Do not remove them.
5 Center a lifting jack of ample capacity under the
non-steer axle. Raise the machine approximately
6 inches / 15.2 cm and place blocks under the
chassis for support.
6 Remove the wheel lug nuts, then the tire and
wheel assembly.
Part No. 107713
21
July 2011
NON-STEER AXLE COMPONENTS
REV B
7 Place a second lifting jack under the torque

hub for support. Secure the torque hub to the
lifting jack.
8 Remove the torque hub mounting bolts that
attach the torque hub to the non-steer axle.
9 Remove the torque hub from the machine.
Crushing hazard. The torque
hub may become unbalanced and
fall when the mounting fasteners
are removed if not properly
supported and secured to the
lifting jack.
Torque specifications
Lug nut torque, dry
125 ft-lbs
169.5 Nm
Lug nut torque, lubricated
94 ft-lbs
127.4 Nm
Drive torque hub mounting bolts
210 ft-lbs
285 Nm
22
Part No. 107713
July 2011
Fiberglass Covers
REV A
Repair or Replacement of a
Fiberglass Cover
Repair: Minor damage, including small holes,
cracks and chips in a fiberglass cover may be
repaired by a qualified repair facility.
Replacement: Replacement of a fiberglass cover
when the structural integrity has been compromised
due to excessive damage is required.
Part No. 107713
23
July 2011
24
Part No. 107713
Electrical Schematic
November 2011
November 2011
REV C
A
N
C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
BK
FS1
P2
C7P-1
P22BAT
WH
TS48
WORK
LIGHTS
C1B-9
L30
L30
C2B-4
C2B-5
C35HRPM BK/RD
C1B-7
TS48
DRIVE
LIGHTS
DLITE GN
C1P-9
C33STR BK
C2P-9
C1P-7
AIRCRAFT
PROTECTION
C1B-8
86
PANEL
ILLUM.
C34SA BK/WH
CR51
L49
C1P-8
WH
WH
85
FB2
WH
C1B-12
BK
TS4
RPM
F5
7.5A
F5
7.5A
GROUND
ISOLATOR
RD
CR5
C6B-3
P42BAT OR/RD
+
+
TACH. INPUT
START INPUT
(NOT USED)
GROUND
BATTERY
KEY SWITCH POWER
(NOT USED)
WH
86
IGNITION ON
10
ENGINE FAULT
IGNITION/START MODULE
85
CR14
CR16
86
BRN
BRN
BRN
BRN
GR/BK
BATT
WH-BATT
WH
AP2
AUXILIARY
(12V)
C5-2
BRN
C5-6
BRN
THERMOCOUPLE WIRE
(ENGINE EXHAUST MAINIFOLD)
CR16
START RELAY
85
86
87
BK
L49
OR-GEN POS
BL
86
C8-B
H2
ALT.
VR1
87
85
BK/RD
STARTER
87
BL
BRN
(12V DC)
BL-ISM2
CR13
CR15
85
BK/WH
5 TC-
YEL
RD
1 GND PWR 2
30
30
30
BK
LS1
(EXT)
+
WH-J4
BRN
87
86
CR12
(12V DC)
+12V
FB
30
85
WH
CR11
87
86
C34SA BK/WH
85
L29
BK-ISM1
C5-18
C35HRPM
C5-22
30
BRN
TB35
L29
C5-3 C23PWR WH
BK
C8-C
PGM
WH
3 TC+
RD
TEMPERATURE
DISPLAY (F)
C5-1 P20BAT RD
ENGINE
START
GLOW
PLUGS
CB3
15A
SW33
HIGH
C5-5 C33STR BK
87
87
AP1
RPM
LOW
87
RD-J10 (12GA)
C8-A
30
TS54
TB33
TB34
BRN
C5-11 C21IGN2 WH
C5-4
OR-GEN NEG
AC POWER
RIGHT
BOX
87
30
13
14
TS52
BRN
85
CR4
BRN
GROUND
22
FB2
RD/WH
85
86
HM
RD
86
C6-9 BK/RD
BK
BK 2 GA
BK-6
CHARGER
WH-6
LS2 21
(PRI)
85
RD/BK
CR4
87
C11-2
RIGHT
MOTOR
30
30
CR1
BRN
C6-34
RD-5
A1
F1
WH-7
A1
F2
C11-1
ALTERNATOR
F1
A2
BK-7
F2
A2
C11-4
C11-3
WH
PUMP
LEFT
MOTOR
86
C6-28
WH-5
B-
85
RD/BK
BK
C10-2
18
F2
OR/RD
BK/RD
C6-20 RD
BK-5
BK
86
TS56
C23PWR WH
PR2
+
PUMP
C10-1
B+
WH-4
M-
F1
C10-4
PR3
D2
21
LS4
(SEC)
22
BK-5
SW33
BK-4
20
17
16
11
14
10
+24V DC
F1
200A
C10-3
C6-25 CFIL BK
C6-39 CR5 RD/BK
C39-3 GR
POT. HI
INTERLOCK
POT. LOW
REVERSE
FORWARD
C39-2
C39-1
C39-11
C38-10
C38-9
C39-8
AP1
BK
CR2
TB23
30
U6A
CURTIS 1244
SEPEX CONTROLLER
24V DC
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
85
C6-40 OR
OR/RD
OR/RD
OR/RD
86
OFF-LMT SPD INP
BL/WH
DIODE RETURN
+48V DC INPUT
RD 20
AP2
RD
TB42
C6-24
PR1
F2
200 A
C6-12
RD/WH
WH/RD
WH/BK
F4
500A
48V DC
WH
AP2
AC POWER
ENGINE
GROUND
BK
(GND)
BK
PR2
PR2
PR3
PR3
PR2
WATER TEMPERATURE SWITCH
OIL PRESSURE SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC VOLTAGE REGULATOR
ENGINE POWER RELAY CR12
STARTER RELAY CR11
ENGINE RUN SOLENOID
BLOCK HEATER
BATTERY BLANKET
48V DC POWER
RELAY CR1
Part No. 107713
48V DC POWER
RELAY CR2
RELAY CR24 ADDED PER CAMPAIGN BULLETIN 080008.
FLASHING
BEACON
OPTION
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
TILT SENSOR
SWITCH SHOWN WITH BOOM EXTENDED.
HOUR METER
TEMPERATURE
DISPLAY
GROUND PANEL
ILLUMINATION
HORN RELAY
HORN
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC CHARGER
48V DC ALTERNATOR
PRIMARY LIFT PUMP
AUXILIARY PUMP
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.
25
TS46
FUNCTION
OVERRIDE
FOOTSWITCH
HIGH RPM
TB40
P42BAT OR/RD
OR/RD
F5
10A
+48V DC
P
C2P-8
R42BAT OR/RD
C7B-2
C3B-3
C6-29
C6-32
C6-31
C6-30
C7B-4
C39-12
LEFT
BOX
LOW
RPM
HIGH
RPM
BRN
C6-22
TS2
ENGINE
START
C12DRE BL/WH
TS6
GLOW
PLUGS
TS44
DUAL
BEACON
C2P-4
P23BAT WH
GR/BK
P24BAT WH
87
30
L48
C3BAT RD/WH
C1B-2
C2B-2
C7B-2
C1B-3
C28TTA RD/BK
C40LS OR
C1B-6
P23BAT WH
C29JSH RD/WH
C1B-5
C3B-9
C32JSL WH/RD
C1B-4
12
C9HRN BK/RD
C31REV WH/BK
BK
C30FWD WH
P20BAT RD
OR
TILT
ALARM
H1
C7P-2
5
C32
C7P-2
P24BAT WH
C1P-2
C3P-9
C2P-2
C1P-3
C1P-6
C1P-5
C1P-4
GROUND
C7B-1
TB22
CB1
10A
C9P-2
C3P-3
P1
P20BAT RD
WH-(FS)
R42BAT OR/RD
P3
HORN
PLATFORM
KS1
P25BAT RD
RD
RD
TB134
C9P-3
BK
C132 PLI BL/WH
BK-(FS)
C9P-1 BK
P26BAT
RD
RD-(FS)
GROUND BOX
GROUND
ISOLATOR
REV C
P24BAT WH
P24BAT WH
C31REV WH/BK
C31REV WH/BK
C40LS OR
C40LS OR
C4P-1
C4P-4
C3P-12
C1P-1
C16DRE OR/RD
C12DRE BL/WH
C13DREL BL/RD
C4B-4
C3B-12
C4B-1
C37STC BL/BK
C1P-11
C36STCC BL
C1P-10
R41DRE OR/BK
C2P-3
C1B-1
C1B-11
C1B-10
C2B-3
BRN
C27AUX RD
C19LPMP GR/WH
BRN
BL/RD
BL/WH
OR/RD
RD
C7P-3 BATGND BRN

C6-13 C13DREL
WH-8
BK-8
OR/RD
RD
RD/WH
RD/WH
C6-36 BL
BRN-8
RD-8
C6-37 BL/BK
C6-10 BL
C6-2 RD/BK
C6-1 RD
C6-8 BK/WH
C6-7 BK
C6-15 OR/BK
C6-14 OR
C6-17 GR
C6-18 GR/BK
C6-6 WH/RD
GR/WH
C6-27
RD
C6-26 C12DRE
C6-16 C16DRE
PS1
C6-35
RD/WH
C4B-7 GR/WH
C3B-6 WH/RD
DOWN
UP
C4B-6 GR/BK
RIGHT
C4B-5 GR
LEFT
21
14
C6-11 BL/BK
30
C26-1
C24-1
C25-1
C6-19
GR/WH
C23-1
C22-1
C20-1
C21-1
C16-1
C17-1
C12-1
C13-1
C18-1
C19-1
C15-1
C25-2
C24-2
C26-2
C6-21 DREGND BRN
C7B-3 BATGND BRN
7
33
6
2
22
C23-2
C22-2
C20-2
C21-2
C16-2
C18-2
C12-2
C13-2
C18-2
C19-2
C15-2
BRAKE RELEASE
TRAVEL ALARM
(A2)
BRAKE RELEASE
N.C. COIL
TURNTABLE ROTATE
RIGHT COIL
DESCENT ALARM
OPTION (A3)
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM UP COIL
PRIMARY BOOM DOWN COIL
PRIMARY BOOM UP COIL
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL UP COIL
PLATFORM
ROTATE RIGHT /
JIB BOOM DOWN
PLATFORM
ROTATE LEFT /
JIB BOOM UP
FLOW CONTROL COIL
LIFT PUMP
CONTACTOR RELAY
CR20
AUXILIARY LIFT
PUMP RELAY COIL
PR3
AUXILIARY CONTROL
RELAY COIL CR3
PRIMARY LIFT PUMP

RELAY COIL PR2
STEER RIGHT COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
8
TURNTABLE ROTATE
LEFT COIL
26
Part No. 107713
TB37
13
C6-5 WH/BK
PR3
RD
AUXILIARY
PUMP
C4P-7
C6LFC WH/RD
BK
C2B-7
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
C14-2
PR2
TB36
CR3
+
H2
C14-1
PR2
C6-38 GR/WH
GR/WH
GR/WH
LS3
C39-7
33
C6-4 WH
C39-6
(GND)
RD-AUX
OR
OR/RD
C3P-6
C18PRR GR/BK
C2B-6
C4P-6
C17PRL GR
C44JDA GR/BK
C4P-5
WH
C45JSV GR/WH
JIB BOOM
MANIFOLD
C4B-2
C2P-7
C14PLU OR
C3B-7
C4B-3
C3B-8
C15PLD OR/BK
C7PBE BK
C3B-1
C8PBR BK/WH
C1PBU RD
C3B-2
C3B-10
C2PBD RD/BK
C3B-11
TB27
DRIVE
ENABLE
LIMIT
SWITCH
PR3
86
87
CR20
85
OR/RD
C2P-6
C4P-2
C4P-3
C3P-8
C3P-7
C3P-1
C3P-2
C10SBU BL
CR5
5
LEFT
TB19
C6-33
85
87
87a
86
30
TB6
TB17
OR/BK
WH
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
C11SBD BL/BK
C3B-5
C3B-4
C4TRR WH/BK
TS58
30
TB44
AUX
ON
TS51
RD
TB12
OR/RD
P42BAT OR/RD
4
CR5
CR5
C12DRE BL/WH
3
C4TRL WH
BK
BK
PR2
GR/WH
TS57
TS59
TS63
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
C3P-10
C3P-11
C3P-5
C3P-4
SECONDARY
BOOM
TURNTABLE
ROTATE
TS61
TS60
TS62
87
JIB
BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
CR7
85
TB18
TB4
UP
DOWN
RIGHT
RD
PRIMARY
BOOM
86
LEFT
BRN
BRN
86
9
85
RD
BP1
BK/RD
87
ROTARY
OEM
FLOW
CONTROL
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
10
L R
STEER
8
DRIVE
85 BRN
87
2
3
FWD
DRIVE
ENABLE
LED L1
7
SET TO "N"
85
SET TO "B"
6
LIFT
CR19B
1
20K
OR/BK-R6
5
TS1
1
2
3
4
5
6
7
8
DISCHARGE
CR19B
L.V.I.
RESET
CR19A
30
87
C30FWD WH
LVI/BCI
C30FWD WH
REV
86
86
CR19A
30
DP1 - JOYSTICK
BCI
87a
BK
3
5
4
JIB
BOOM
TS8
30
PLATFORM
ROTATE
TS7
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
RD
FUNCTION
ENABLE
TS55
C29JSH RD/WH
C29JSH RD/WH
1
C32JSL WH/RD
C32JSL WH/RD
A
B
C
D
E
F
G
H
I
J
K
L
M
N

November 2011
R42BAT OR/RD
November 2011
Ground Control Box Terminal Strip Wiring Diagram
November 2011
WH
27
BK
C2B-8
DLITE GN
T.C. WIRE
SWITCH PANEL
TEMPERATURE METER

P20BAT RD C7B-4
C6
C7B-3 BATGND BRN
BK
C6-37 C37STC BL/BK
DRIVE LIGHTS AND

THERMOCOUPLE
Part No. 107713

FAULT
STATUS
LED
C7B
GROUND
ISOLATOR
C4B
C3B
C2B
C6-13
C13DREL BL/RD
C4B-1
C6-16
C16DRE OR/RD
C4B-4
C6-28
C28TTA RD/BK
C1B-2
C6-29
C29JSH RD/WH
C1B-3
C6-30
C30FWD WH
C1B-4
C6-31
C31REV WH/BK
C1B-5
C6-32
C32JSL WH/RD
C1B-6
C6-21
BRN
BRN
C1B
BRN C5-6
BRN C5-2
C5
BK
87
30
86
85
30
87a
87
OR/BK
87a
86
BRN
85
GR/WH
RD/WH
BRN
C9HRN BK/RD
OR/RD
OR/RD
BRN
87
86
87
85
30
87a
GR/WH
GR/WH
86
BRN
87
85
30
87a
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BRN
C3B-9
87
85
30
87a
RD KS1
GR/BK-TS58
RD H6
OR/RD-CR1
OR/RD-LED
BK-ALARM
GR/WH-J19
GR/WH-J19
BK/RD-TS54
BK/WH-TS56
BK-TS52
WH-KS1 (D2)
RD-CR3
RD-TS51
BK-ALARM
GR/WH-J19
BK-CR4
BK-KS1
BRN
C2B-3 C41DRE OR/BK
OR/RD
BRN
CR1
48V DC
POWER
RELAY
86
CR2
48V DC
POWER
RELAY
85
BRN
OR/RD
134
44
42
40
37
36
35
34
33
27
23
22
19
CR20
LIFT
PUMP
RELAY
87a
KEY SWITCH POWER
JIB BOOM DESCENT ALARM
SWITCH 48V DC
OFF-LIMIT SPEED
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
ENGINE START
AUXILIARY PUMP SELECT
KEYS WITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
GR/BK-TS57
GR/WH
GR/WH-TS60
GR-TS57
OR/BK-TS59
OR-TS59
C12DRE BL/WH
BK ALARM
BL/BK-TS60
BL-TS60
BK/WH-TS63
BK-TS63
GR/WH
30
BK
OR/RD
BRN
GR/WH
OR/RD
134
44
18
19
PLATFORM ROTATE RIGHT/JIB DOWN

LIFT PUMP
17
PLATFORM ROTATE LEFT/JIB UP
WH-TS62
WH/BK-TS62
C23
1 3 4 5 6 7 8 12
86
RD/WH
C3B-3 C3BAT RD/WH
C5-4 PANEL ILLUM WH
C6-9 R9HRN
C6-3 P42BAT OR/RD

C6-39 CR5 RD/BK
40
42
14
15
RD-TS61
BK-ALARM
RD/BK-TS61
C6-35 R48BRK RD/WH
C6-33 C44DA BK
C6-27 R27AUX
C6-19 R19LPMP GR/WH
C6-26 C12DRE BL/WH
C6-40 C40LS OR
C2B-7 C45JSV GR/WH
C5-1 P20BAT RD
C5-11 C21IGN2 WH
C5-3 C23PWR WH
C2B-5 C134PWR RD
C6-34 C23ALARM RD
C2B-4 R42BAT OR/RD
37
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
11
12
BRN-HM
C6-25
OR/RD-42A
C6-22 R42BAT OR/RD
C2B-2 C40LS OR
C1B-11 C37STC BL/BK
36
35
34
33
27
23
22
19
19
18
17
15
14
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
8
10
C6-24 C40LS OR
C1B-10 C36STCC BL
C1B-1 C27AUX RD
C5-5 C33STR BK
C1B-7 C33STR BK
C5-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
C23-4 P22BAT BK
C4B-7 C19LPMP GR/WH

GR/WH-CR3
11
12
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
C6-36 C36STCC BL
C7B-2 P23SWBAT WH
C4B-5 C17PRL GR
C4B-6 C18PRR GR/BK
8
10
PRIMARY BOOM EXTEND
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM DOWN
PRIMARY BOOM UP
BRN GND
GR/BK H6
RD TS55
RD TS51
BK C7-1
BK 22B
BL/WH C1-12
RD H6
C6-20 C22LS BK
C6-38 C19PSW GR/WH
C6-18 C18PRR GR/BK
C4B-3 C15PLD OR/BK
C4B-2 C14PLU OR
C3B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C6-17 C17PRL GR
C6-15 C15PLD OR/BK
C6-14 C14PLU OR
C6-12 C12DRE BL/WH
C6-11 C11SBD BL/BK
C6-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
C3B-4 C4TRL WH
C3B-2 C2PBD RD/BK
P20BAT RD
C6-8 C8PBR BK/WH
C6-7 C7PBE BK
C6-6 C6LFC WH/RD
C6-5 C5TRR WH/BK
C6-4 C4TRL WH
C6-2 C2PBD RD/BK
5
D
C3B-1 C1PBU RD
4
TERMINAL BASE (TB)
7A
7
C6-1 C1PBU RD
6
C2B-9 SP. BEACONS OR

November 2011
Ground Control Box Terminal Strip Wiring Diagram

REV C
I
J
BK-ALARM
CR3
AUXILIARY
POWER
RELAY
GR/WH
RD
RD
RD/WH
OR/RD
RD/BK
BK/RD
CR5
BRAKE
RELEASE
RELAY
CR4
HORN
RELAY
K
L
M
N
November 2011
REV C
Ground Control Box Switch Panel Wiring Diagram

E
D
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
GR/BK
WH-4A
GR
GR
BK
1
BK
BK
RD
OR/BK-15A
OR/BK
OR-14A
OR
TS59
PLATFORM
LEVEL
GR/BK-44A
TS58
JIB BOOM
UP/DOWN
TS61
PRIMARY
BOOM
RD
RD
RD
RD-1A
RD
BK
RD
RD-27A
RD/BK-2A
WH
RD
RD
RD
BK
TS57
PLATFORM
ROTATE
PRIMARY
BK/RD-35A
TS63
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
BK/RD
BK
GR/BK
GR
TS62
T.TABLE
ROTATE
BK
RD
BK
RD C23-6
RD
BK-22A
CB1
CIRCUIT
BREAKER
RD
P20BAT RD (C7B-4)
BL-10A
KS1
BL/BK-11A
GR/WH-19A
RD 134A
BK
TS60
SECONDARY
BOOM
P20BAT RD (C5B-1)
RD
RD
RD
PNL ILLUM WH (C5-4)
RD
SP BEACON OR (C2B-9)
RD
RD C23-7
7
RD
BRN
Part No. 107713
RD
TS56
GLOW
PLUG
BASE BOX HARNESS
RD
BK/WH-34A
TS55
FUNCTION
ENABLE
T.C. WIRE
HOUR METER
BRN-TEMP DISP (-)
BRN
BRN-HM
NC
WH
RD
BK-33A
1
1
TEMP.
2 DISPLAY
F
WH 23A
TS52
ENGINE
START
GR/BK H6
RD
C21IGN2 (C5B-11)
RD
TS51
AUXILIARY
PUMP
D2
P1
EMERGENCY
STOP
28
November 2011
Ground Control Box Switch Panel Wiring Diagram
Platform Control Box Wiring Diagram
November 2011
November 2011
REV C
Platform Control Box Wiring Diagram

A
OR/RD
GR/WH-R7
GR/WH-45
GR/WH
P25BAT RD
P24BAT WH
P26BAT BK
C7P-3
C7P-2
C7P-1
C9P-3
C9P-2
C9P-1
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
C28TTA RD/BK
C7P
C9P
WH
BK
C1P-2
GR/WH-45
GR/WH-45
BK-JIBGND
BRN-BATGND
P23SWBAT WH
P22BAT BK
C19LPMP GR/WH
C18PRR GR/BK
C17PRL GR
C16DRE OR/RD
C3P-12
C3P-11
C3P-10
C3P-9
C3P-8
C3P-7
C3P-6
C3P-5
C3P-4
C3P-3
C3P-2
C3P-1
C2P-7
C2P-6
C2P-4
C2P-3
C4P-7
C4P-6
C4P-5
C4P-4
C4P-3
C4P-2
C4P-1
C15PLD OR/BK
C14PLU OR
C13DREL BL/RD
C1P-11
C1P-10
C1P-9
C1P-8
C1P-7
C1P-6
C1P-5
C1P-4
C1P-3
C12DRE BL/WH
C11SBD BL/BK
C10SBU BL
C9HRN BK/RD
C8PBR BK/WH
C7PBE BK
C6LFC WH/RD
C5TRR WH/BK
C4TRL WH
C3BAT RD/WH
C2PBD RD/BK
C1PBU RD
C1P-1
C37STC BL/BK
C36STCC BL
C35HRPM BK/RD
C34SA BK/WH
C33STR BK
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
C29JSH RD/WH
C45JSV GR/WH
C44JDA GR/BK
R42BAT OR/RD
R41DRE OR/BK
C27AUX RD
RD/BK L48
C2P-5
BRN-J1
BRN-BATGND
BRN-JIBGND
C134PWR RD
RD-J7
CR7
RD/BK-R6
OR/BK
OR/BK-R6
CR6
JIB
LS18
12V DC BATTERY
FOOT SWITCH
GR-LFC
DP1
20k
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
GR
RD
BK/RD
TS13
EXTEND/
RETRACT
FWD
REV
GR
C29JSH RD/WH
OR
C32JSL WH/RD
WH
C30FWD WH
BK
C31REV WH/BK
OR/BK-R6
RD-DRE
P24BAT WH
C12DRE BL/WH
RD-RPM
RD-J7
RD-SW
RD/BK-R6
BK/WH-DRE
C37STC BL/BK
RD
WH/GR
YL
LIFT
BP1
DRIVE
RIGHT
LEFT
WH/YL
WH/RD
6
7
8
9
10
C36STCC BL
PLATFORM CONTROL BOX LID
Part No. 107713
TS9
PLATFORM
LEVEL
TS7
PLATFORM
ROTATE
TS8
JIB BOOM
L1
TS4
RPM SELECT
NC NC NC
TS1
AUXILIARY
POWER
TS2
ENGINE
START
P2
EMERGENCY
STOP
C3BAT RD/WH C3-3
P3
L48
TS6
GLOW PLUG
P23SWBAT WH C7P-2
RD-HRN
RD/BK H1
C35HRPM BK/RD
RD-RPM
RD-AUX
C33STR BK
RD
P22BAT BK C7P-1
NO
RD
P3
HORN
29
PRPL
BL
P26FS BK C9P-1
BRN-J1
BRN-BCI
C34SA BK/WH
GR/WH-45
C14PLU OR
C15PLD OR/BK
C6LFC WH/RD
C19LPMP GR/WH P25BAT RD
RD-SW
C7PBE BK
C8PBR BK/WH
C2PBD RD/BK
1
C1PBU RD
C17PRL GR
GR/WH- R7
C18PRR GR/BK
C11SBD BL/BK
C10SBU BL 1
C4TRL WH
C44JDA GR/BK
C13DREL BL/RD
BK/WH-DRE
RD-DRE
RD-AUX
C27AUX RD
RD-HRN
C9HRN BK/RD
TS15
DRIVE
ENABLE
C5TRR WH/BK
DRIVE JOYSTICK
DRIVE ENABLE LED
EMERGENCY STOP
HORN
AUXILIARY SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TITL ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
NOTES:
TS12
TURNTABLE
ROTATE
ROTARY FLOW CONTROL DIAL
DP1
L1
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
H1
LS18
L4
L48
19/18 CONTROL CABLE
H1
BP1
OPT.
D40
TILT ALARM
M
COMPONENT INDEX
PLATFORM CONTROL BOX
BRN-RELAY
GROUND (B-) CONNECTIONS

ISOLATED FROM CHASSIS W/
INSULATING STUD. C17 BOEING
SPECIAL ONLY
November 2011
REV C
Platform Control Box Switch Panel Wiring Diagram

LVI/BCI Options
86
87
2
3
4
5
6
7
8
OR
OR/BK
OR/RD
WH
CR51
WH
BRN-RELAY
86
86
85
85
30
RESET IS SET TO "B",

DISCHARGE IS SET TO "N"
30
CR19A
CR19B
7A
CR7
BRN-LVI
P24BAT WH
OR/RD-LVI
OR/BK-LVI
OR-LVI
R42BAT OR/RD
BL-LR19A
BL-L10
RD-LVI
RD-LR19B
BN
WH TS46
WH P24 BAT
WH AIRCRAFT PROX.
CR6
LVI
OR/RD
WH P24 BAT
87
WH
WH TS44
BK GND
WH CR51 #86
BK TS4
WH TS44
BK GND
C3P-10
C3P-1
C4P(BR)
C3P(GR)
H1
C2P(BK)
D39
19/18 CONTROL CABLE
C7P
C9P
WH
TO LEFT
WORK
LIGHT
BASE
BEACON
C1P(GY)
C2P-6
LEFT
WORK
LIGHT
C2P-4
TO RIGHT
WORK LIGHT
BN
GN DLITE C2P-5
OR TS44 C2P-2
GR/BK C133PLA
GR/BK L4
RD LS18
WH
COMPONENT INDEX
87
PLATFORM CONTROL BOX
30
85
BN
RIGHT
WORK
LIGHT
JIB
BCI
BP1
BATTERY CHARGE INDICATOR

ROTARY FLOW CONTROL DIAL
DP1
L1
L2
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
A1
LS18
L4
L48
CR51
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TILT ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
PROXIMITY KILL RELAY
NOTES:
12V DC BATTERY
AIRCRAFT
PROTECTION
PROXIMITY SENSOR
FOOT SWITCH
PLATFORM
BEACON
TILT ALARM
CUT FOOTSWITCH POWER AND

PLACE RELAY CONTACTS (80 & 37)
IN LINE
GROUND (B-) CONNECTIONS

ISOLATED FROM CHASSIS W/
INSULATING STUD. C17 BOEING
SPECIAL ONLY
DP1
20k
LVI/BCI
TS12
TURNTABLE
ROTATE
TS44
BEACON ON
TS10
SECONDARY
BOOM
TS11
PRIMARY
BOOM
GR
RD
BK/RD
TS13
EXTEND/RETRACT
FWD
REV
GR
OR
WH
BK
RD
WH/GR
YL
PRPL
BP1
DRIVE
RIGHT
RD-LR19B
BL-LR19A
WH - DP1
OR C2P-2
BK/WH DP1
OR/BK-LVI
OR/RD-LVI
LEFT
WH/YL
WH/RD
10
GN DLITE C2P-5
BK
P24BAT WH
BL
WH LVI-1
BK A.C. PROX
WH CR51 #85
RD
OR-LVI
WH - BASE BEACON
WH - PLAT. BEACON
LIFT
TS7
PLATFORM
ROTATE
TS9
PLATFORM LEVEL
TS46
FUNCTION
OVERIDE
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM SELECT
TS46
DRIVE LIGHTS
TS8
JIB BOOM
L1
TS15
DRIVE ENABLE
TS1
AUXILIARY
POWER
NC NC NC
NO
P3
HORN
P2
EMERGENCY STOP
PLATFORM CONTROL BOX LID
Part No. 107713
30
November 2011
Platform Control Box Switch Panel Wiring Diagram

LVI/BCI Options
Engine Panel Diagram
November 2011
November 2011
REV C
Engine Panel Diagram

A
RD-CB
NOTE: RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
C21IGN2 WH
C35HRPM BK/RD
85
86
85
BRN-J4
87
87
87a
BRN-J4
BK/RD
85
86
87a
87
87a
86
85
87
87a
86
85
87a
IGNITION/START
MODULE
12/24V DC
GND BRN
86
1 3 4 7 10 9 2
86
BRN-J4
BK/RD
RD-CB
BL-ISM2
BL-ISM2
C33STR BK
BRN-VOLT
BRN-J5
WH-R14
BL-E.H.
BL-ISM2
RD-J10
STARTER B-
OFF
BRN-VOLT
ON
BL-E.H.
WH-BATT
BRN-ISM5
BRN-ISM5
ENGINE HARNESS (TO DRIVE CHASSIS)
GR/BK-BATT
ENGINE HARNESS (TO ENGINE)
WH-ISM10
GR
YEL
BL
RD
BK
BL
ENGINE HARNESS (TO GROUND CONTROL BOX)
C5
MALE DEUTSCH
CONNECTOR
31
Part No. 107713
C5-22 C34SA BK/WH
C5-11 C21IGN2 WH
C5-18 C35HRPM BK/RD
C5-5 C33STR BK
VOLTAGE REGULATOR
12V DC
C5-2 GND BRN
B+
C5-1 P20BAT RD
STARTER
C5-3 C23PWR WH
P20BAT RD
C23PWR WH
IGN./FUEL ON
(NOT USED)
8
24V BATTERY +
KEYSWITCH PWR.
(NOT USED)
GROUND
START INPUT
TACH. INPUT
9
GR/BK-BATT
BK-ISM1
P20BAT RD
BK-ISM1
BRN-J5
BRN-ISM5
WH-R14
C33STR BK
WH-BATT
WH-BATT
BL-ISM2
RD-J6
START RELAY
C34SA BK/WH
WH-J6
C23PWR WH
CR15
GLOW PLUG
RELAY
CR14
RPM RELAY
WH-R14
WH-J4
WH-J6
RD-J6
CR13
RPM CUTOUT
RELAY
30
RD-J10
BK-START
BK-ISM-1
WH-R11
OR-GEN NEG
BRN-VOLT
WH-BATT
OR-GEN POS
WH-J4
30
BK-ISM-1
CR12
ENGINE POWER
RELAY
CR11
START RELAY
30
RD-CB (12V+)
30
BK/WH-34
CR16
FIELD
RELAY
30
BK/RD-35
30
ENGINE FAULT
87
87a
BRN-J4
10
87
85
BRN-J4
WH-J6
WH-J4
WH-ISM10
BRN-J4
BRN-J4
C21IGN2 WH
C35HRPM BK/RD
RD-CB
WH-J5
BRN-J4
WH-J4
WH-J5
CB3
CIRCUT BREAKER
12V DC, 15A
RD-CB (12V+)
November 2011
REV C
Power Cable Diagram
A
1
TO ENGINE PANEL
TO GROUND CONTROL BOX

CONNECTOR C6
AC POWER CABLE
DC AMMETER CABLE
LEFT SIDE
BATTERY PACK
RIGHT SIDE
BATTERY PACK
RD-2GA
-
48V
NEG
A1
OFF
WH-FROM CHARGER TO BK 12/2
GR/WH-19
AP-2
DIODE
PR-1
R42BAT OR/RD
R42BAT OR/RD
BRN-J8
R27AUX RD
BK
BK
DIODE
CONTROLLER
PR-1
PR-2
33
BRN-J8
RD
BK
BK
RD-2GA
RD-20-12GA
AC
CHARGER
PLUG
24V DC
C32JSL WH/RD
F1
BRN-J8
C12DRE BL/WH
R42BAT OR/RD
C40LS OR
CFIL BK
C30FWD WH
R42BAT OR/RD
OR/RD
RD-2GA
RD-10GA
C31REV WH/BK
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
A1
RD-10GA
F2
F1
F2
A2
BK-2GA
RD-2GA
M-
RIGHT SIDE
DRIVE MOTOR
RD-10GA
BK-2GA
B-
A1
OR/RD
RD-2GA
GR
A2
C108PLP
CR5 RD/BK
F2
C29JSH RD/WH
F2
200A
RD-10GA
RD-2GA
GROUND
ISOLATOR
RD-2GA
RD-10GA
F1
200A
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
BRN-J8
BK-2GA
PR-3
48V DC
LEFT SIDE
DRIVE MOTOR
R42BAT OR/RD
RD-2GA
RD-10GA
F1
AMMETER
DIODE
85
87
LIFT
CONTACTOR
BRN-J8
F4
500A
P42BAT OR/RD
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
RD-2GA
33W
86
87a
AP-1
BATTERY
30
AUXILIARY POWER UNIT

CONTACTOR
TOP VIEW OF
DRIVE CONTACTOR
DRIVE CONTACTOR
CR24
BK-2GA
RD-2GA
BK-2GA
BK-2GA
BK
WH
BK-2GA
BK-2GA
RD-2GA
WH 12/2
WH-BATT
WH-BATT
P42BAT OR/RD
FUSE-F5
10A
WH 12/2
RD-2GA
D1
BK - 12/2
+
ON
RD-2GA
RD-20-12GA
POS
RD-2GA
RD-2GA
AUXILIARY LIFT
PUMP
BK-2GA
BK-2GA
PRIMARY
LIFT
PUMP
GR/BK-BATT ISM-9
WH-BATT R12
A2
D1
FUNCTION HARNESS
ALTERNATOR
AC
BATTERY
CHARGER
B+
NOTES:
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
3. DEUTSCH CONNECTIONS INTO RELAY ENCLOSURE NOT SHOWN.
1
RELAY CR24 ADDED PER CAMPAIGN BULLETIN 080008.
SEP-EX DC MOTOR CONTROLLER
Part No. 107713
32
November 2011
Power Cable Diagram
November 2011
REV C
Hydraulic Schematic
A
1
PLATFORM ROTATE
JIB BOOM
3:1
3000 psi /
207 bar
1.5:1
3800 psi /
262 bar
PR2
PR1
0.020 inch /
0.51 mm
J1
J2
0.020 inch /
0.51 mm
PR2
PR1
V2
V1
JIB BOOM MANIFOLD

SLAVE CYLINDER
BRAKES
TURNTABLE ROTATE
SECONDARY BOOM
LIFT CYLINDERS
PRIMARY BOOM
LIFT CYLINDER
4.25:1
3626 psi /
250 bar
4.5:1
ATMOS.
3500 psi /
241 bar
TOW BAR OPTION
3:1
1000 psi /
69 bar
3:1
3500 psi /
241 bar
MASTER
CYLINDER
COM
TEST
AUXILIARY
PUMP
0.5 gpm /
1.89 L/min
PRIMARY
PUMP (2cc)
1.5 gpm /
5.7 L/min
EXTENSION CYLINDER
STEER
BRAKE
3:1
ATMOS.
1500 psi /
103 bar
3:1
3800 psi /
262 bar
S1
0.030 inch /
0.76 mm
V2
V1
N.O.
N.C.
PS
ST1
ST2
PR1
PR2
PL1
PL2
SW1
SW2
3200 psi /
220.6 bar
SEC2
SEC1
P1
P2
EXT
RET
0.037 inch /
0.94 mm
M
2500 psi /
172 bar
2000 psi /
138 bar
0.060 inch /
1.52 mm
0.030 inch /
0.76 mm
0.030 inch /
0.76 mm
0.4 gpm /
1.5 L/min
RESERVOIR
FUNCTION MANIFOLD
Part No. 107713
33
November 2011
Hydraulic Schematic
California Proposition 65
WARNING
The exhaust from this product contains chemicals

known to the State of California to cause cancer,
birth defects or other reproductive harm.
Genie North America

425.881.1800
USA and Canada
800.536.1800
Fax
Genie Australia Pty Ltd.
Genie Holland
Phone +31 70 51 78836
Fax +31 70 51 13993
Genie Scandinavia
Phone +46 31 3409612
Fax +46 31 3409613
Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Phone +60 4 228 1235

Fax +60 4 226 6872
Genie Japan
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Phone +81 3 3453 6082

Fax +81 3 3453 6083
Genie Korea
Genie Germany
88520
8852-20
Phone +82 2 558 7267

Fax +82 2 558 3910
Genie Africa
Genie U.K.
Phone +44 (0)1476
Fax +44 (0)1476
Phone +61 7 3375 1660

Fax +61 7 3375 1002
Genie Malaysia
Genie France
Phone +49 (0)4202

Fax +49 (0)4202
425.883.3475
584333
584334
Genie Mexico City

Phone +52 55 5666 5242
Fax +52 55 5666 3241
Phone +27 11 455 0373

Fax +27 11 455 0355
Genie Latin America

Phone +55 11 4055 2499
Fax +55 11 4043 1661
Distributed By:
Phone
Toll Free

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Service Manual Supplement

Copyright 2004 by Genie Industries

Self-Propelled Servicing Platform

Part No. 107713

Service Manual Supplement

Copyright 2011 Terex Corporation

Self-Propelled Servicing Platform

Part No. 107713

Service Manual Supplement

Part No. 107713

Self-Propelled Servicing Platform

Service Manual Supplement

Tires and wheels

Gradeability (boom stowed)

Boom function speeds, maximum

Jib boom down

Primary boom down

Lug nut torque

Secondary boom down

Tire ply rating

Primary boom extend

Primary boom retract

Tire contact area

Overall tire diameter

Turntable rotate, 357

199 to 205 seconds

Platform level down

127 to 133 seconds

For operational specifications, refer to the

Self-Propelled Servicing Platform

Part No. 107713

Service Manual Supplement

Hydraulic Oil Specifications

Type: fixed displacement gear pump

Hydraulic oil type

Chevron Rykon MV oil is fully compatible and

Hydraulic tank circuit

Secondary boom down

Petro Canada Premium ECO 46

0.5 gallons per minute

Shell Tellus T32

Note: Genie specifications require additional

Part No. 107713

Self-Propelled Servicing Platform

Service Manual Supplement

Kubota Z482-E Engine

2.64 x 2.68 inches

Injection pump make

Injection pump pressure

Brush length, new

Brush length, minimum

412 to 469 psi

Cold cranking ampere

Reserve capacity @ 25A rate

Fan belt deflection

Engine oil should have properties of API classification

Self-Propelled Servicing Platform

Part No. 107713

Service Manual Supplement

Hydraulic Hose and Fitting

SAE O-ring Boss Port

139 ft-lbs / 188.5 Nm