Genie Z45 - 25J PDF [PDF]

Zitiervorschau

Service Manual

Rev B1

Refer to inside cover for additional serial number information

May 2008

Bi-Energy Power (from serial number 23236)

Part No. 110188

February 2006

Introduction Important

Serial Number Information

Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Operator's Manual before attempting any maintenance or repair procedure.

Genie Industries offers the following Service Manuals for these models:

This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals.

Title

Part No.

Z-45/25 Bi-Energy and Z-45/25J Bi-Energy Service Manual, Second Edition (before serial number 23236) ............................ 106488

Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.

Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Contact Us:

Copyright © 1999 by Genie Industries

http://www.genieindustries.com e-mail: [email protected]

110188 Rev B February 2006 Third 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.

ii

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

February 2006

Introduction

INTRODUCTION

Serial Number Legend

Model: Z-45/25 Z452505-12345 Serial number: Model year: 2005 Manufacture date: 04/12/05 Electrical schematic number: ES0274 Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg Maximum number of platfrm occupants: 2 Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 45 ft 6 in/ 13.8 m Maximum platform reach : 25 ft 3 in/ 7.7 m Gradeability: N/A Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4

Z4525 05 - 12345 Model

Sequence number Model year

Genie Industries 18340 NE 76th Street

Serial label (located under cover)

Redmond, WA 98052 USA

Serial number stamped on chassis

PN - 77055

Part No. 110188

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Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

February 2006

Section 1 • Safety Rules

Safety Rules

Danger Failure to obey the instructions and safety rules in this manual and the Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Operator’s Manual will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.

Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.

Part No. 110188

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v

February 2006

Section 1 • Safety Rules

SAFETY RULES

Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Used to indicate operation or maintenance information.

vi

Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

May 2008

Table of Contents Introduction Important Information ................................................................................................... ii Serial Number Information ............................................................................................ ii Serial Number Legend ................................................................................................. iii Section 1

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

Section 2

Rev C

Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 2 Hydraulic Specifications ........................................................................................ 2 - 3 Manifold Component Specifications ....................................................................... 2 - 4 Machine Torque Specifications .............................................................................. 2 - 4 Kubota Z482-E and Z482-E2B Engine Specifications ............................................. 2 - 5 Generator ............................................................................................................... 2 - 6 Generator Torque Specifications ............................................................................ 2 - 6 Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 7 SAE and Metric Fasteners Torque Charts .............................................................. 2 - 8

Section 3

Rev

Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-delivery Preparation ......................................................................................... 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5

B

Part No. 110188

Checklist A Procedures A-1

Perform Pre-operation Inspection ................................................................. 3 - 7

A-2

Perform Function Tests ................................................................................ 3 - 7

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

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February 2006

TABLE OF CONTENTS

Section 3

Rev

Scheduled Maintenance Procedures, continued A-3

Check the Generator Belts and Pulleys ........................................................ 3 - 8

A-4

Perform 30 Day Service ............................................................................... 3 - 9

A-5

Perform Engine Maintenance ..................................................................... 3 - 10

A-6

Perform Engine Maintenance, Z482-E ........................................................ 3 - 10

A-7

Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11

A-8

Perform Engine Maintenance ..................................................................... 3 - 11

A-9

Perform Engine Maintenance, Z482-E ........................................................ 3 - 12

A-10 Perform Engine Maintenance ..................................................................... 3 - 12 B

Checklist B Procedures B-1

Check the Radiator ..................................................................................... 3 - 13

B-2

Check the Exhaust System ....................................................................... 3 - 13

B-3

Check the Batteries .................................................................................... 3 - 14

B-4

Inspect the Electrical Wiring ....................................................................... 3 - 15

B-5

Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 16

B-6

Confirm the Proper Brake Configuration ...................................................... 3 - 16

B-7

Check the Oil Level in the Drive Hubs ........................................................ 3 - 17

B-8

Check and Adjust the Engine RPM ............................................................ 3 - 18

B-9

Test the Ground Control Override ............................................................... 3 - 19

B-10 Test the Platform Self-leveling ................................................................... 3 - 20 B-11 Test the Engine Idle Select ........................................................................ 3 - 20 B-12 Test the Drive Brakes ................................................................................ 3 - 21 B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 21

viii

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

February 2006

TABLE OF CONTENTS

Section 3

Rev

Scheduled Maintenance Procedures, continued B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22 B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 22 B-16 Check the Electrical Contactors ................................................................. 3 - 23 B-17 Perform Hydraulic Oil Analysis ................................................................... 3 - 24 B-18 Perform Engine Maintenance ..................................................................... 3 - 24

B

B

B

Part No. 110188

Checklist C Procedures C-1

Perform Engine Maintenance ..................................................................... 3 - 25

C-2

Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 25

C-3

Test the Platform Overload Mechanism (if equipped) ................................. 3 - 26

C-4

Perform Engine Maintenance ..................................................................... 3 - 28

Checklist D Procedures D-1

Check the Primary Boom Wear Pads ......................................................... 3 - 29

D-2

Check the Free-wheel Configuration ........................................................... 3 - 29

D-3

Replace the Drive Hub Oil .......................................................................... 3 - 30

D-4

Replace the Hydraulic Tank Return Filter ................................................... 3 - 31

D-5

Calibrate the Platform Overload System (if equipped) ................................ 3 - 32

D-6

Check the Turntable Rotation Bearing Bolts ............................................... 3 - 34

D-7

Inspect for Turntable Bearing Wear ............................................................ 3 - 35

D-8

Perform Engine Maintenance, Z482-E ........................................................ 3 - 37

D-9

Perform Engine Maintenance, Z482-E2B .................................................... 3 - 37

Checklist E Procedures E-1

Test or Replace the Hydraulic Oil ............................................................... 3 - 38

E-2

Grease the Steer Axle Wheel Bearings ...................................................... 3 - 39

E-3

Perform Engine Maintenance, Z482-E ........................................................ 3 - 41

E-4

Perform Engine Maintenance, Z482-E2B .................................................... 3 - 41

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February 2006

TABLE OF CONTENTS

Section 4

Rev

Repair Procedures Introduction ............................................................................................................ 4 - 1

B

Platform Controls 1-1

B

A

B

B

B

x

Controllers .................................................................................................... 4 - 2

Platform Components 2-1

Platform Leveling Slave Cylinder .................................................................. 4 - 4

2-2

Platform Rotator ........................................................................................... 4 - 5

Jib Boom Components, Z-45/25J Models 3-1

Jib Boom ...................................................................................................... 4 - 7

3-2

Jib Boom Lift Cylinder .................................................................................. 4 - 8

Primary Boom Components 4-1

Cable Track ................................................................................................ 4 - 10

4-2

Primary Boom ............................................................................................ 4 - 14

4-3

Primary Boom Lift Cylinder ......................................................................... 4 - 17

4-4

Primary Boom Extension Cylinder .............................................................. 4 - 18

4-5

Platform Leveling Master Cylinder .............................................................. 4 - 19

Secondary Boom Components 5-1

Secondary Boom ........................................................................................ 4 - 21

5-2

Secondary Boom Lift Cylinders .................................................................. 4 - 26

Kubota Z482-E and Z482-E2B Engine 6-1

Timing Adjustment ..................................................................................... 4 - 27

6-2

RPM Adjustment ........................................................................................ 4 - 27

6-3

Engine Drive Pulley .................................................................................... 4 - 27

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

February 2006

TABLE OF CONTENTS

Section 4

Rev B

B

A

B

Repair Procedures, continued Generator 7-1

Generator Pulley ........................................................................................ 4 - 29

7-2

Generator Belts .......................................................................................... 4 - 30

7-3

Generator Voltage Regulator ...................................................................... 4 - 30

Hydraulic Pumps 8-1

Auxiliary Pump ........................................................................................... 4 - 33

8-2

Function Pump ........................................................................................... 4 - 33

Manifolds 9-1

Function Manifold Components .................................................................. 4 - 34

9-2

Valve Adjustments - Function Manifold ...................................................... 4 - 36

9-3

Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 37

9-4

Turntable Rotation Manifold Components ................................................... 4 - 38

9-5

Valve Coils ................................................................................................. 4 - 39

Turntable Rotation Components 10-1 Turntable Rotation Assembly ..................................................................... 4 - 41

A

Motor Controller 11-1 Motor Controller .......................................................................................... 4 - 43

Section 5

Rev

Fault Codes Introduction ............................................................................................................ 5 - 1

A

Part No. 110188

Fault Code Chart .................................................................................................... 5 - 3

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February 2006

TABLE OF CONTENTS

Section 6

Rev

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

xii

A

Electrical Symbols Legend .................................................................................... 6 - 2

A

Hydraulic Symbols Legend .................................................................................... 6 - 3

A

Power Cable Diagram ............................................................................................. 6 - 5

A

Engine Panel Diagram ........................................................................................... 6 - 6

A

Electrical Schematic, Z-45/25, ANSI and CSA Models .......................................... 6 - 7

A

Electrical Schematic, Z-45/25, CE Models ............................................................. 6 - 9

B

Electrical Schematic, Z-45/25J, ANSI and CSA Models ...................................... 6 - 11

B

Electrical Schematic, Z-45/25J, CE Models ......................................................... 6 - 13

A

Ground Control Box Terminal Srip Wiring Diagram, Z-45/25 ANSI and CSA Models ........................................................................................ 6 - 15

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ANSI and CSA Models ........................................................................................ 6 - 16

A

Ground Control Box Terminal Srip Wiring Diagram, Z-45/25 CE Models ........................................................................................................... 6 - 17

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 CE Models ........................................................................................................... 6 - 18

A

Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J ANSI and CSA Models ........................................................................................ 6 - 19

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J ANSI and CSA Models ........................................................................................ 6 - 20

A

Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J CE Models ........................................................................................................... 6 - 21

A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J CE Models ........................................................................................................... 6 - 22

A

Platform Control Box Wiring Diagram, Z-45/25 ..................................................... 6 - 23

A

Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option) .................... 6 - 24

B

Platform Control Box Wiring Diagram, Z-45/25J ................................................... 6 - 25

A

Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option) .................. 6 - 26

B

Hydraulic Schematic ............................................................................................ 6 - 27

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

May 2008

Section 2 • Specifications

Specifications

REV C

Machine Specifications

Fluid capacities

Tires and wheels

Fuel tank

9 gallons 34.1 liters

Hydraulic tank

8 gallons 30.3 liters

Hydraulic system (including tank)

11 gallons 41.6 liters

Wheel diameter Wheel width Wheel lugs

14.5 inches 7 inches 9 @ 5/8 -18

Lug nut torque

125 ft-lbs 169.5 Nm

Tire size

9-14.5 LT

Tire ply rating Tire contact area

Tread 8 Sidewall 6 43.5 sq in 280 sq cm

Overall tire diameter

28 in 71 cm

For operational specifications, refer to the Operator's Manual.

Drive hubs (refer to tag on drive hub to determine type) EW1 type 17 fl oz 0.51 liter W1 type 23 fl oz 0.68 liter Drive hub oil type:

EP 80-90W gear oil API service classification GL5

Batteries Type

6V DC

Quantity

8

Capacity

350 AH

Reserve capacity @ 25A rate

750 minutes

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 110188

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2-1

Section 2 • Specifications

May 2008

SPECIFICATIONS

REV C

Performance Specifications Drive speeds, maximum Drive speed, stowed

Drive speed, boom raised or extended

3 mph 4.8 km/h 40 ft/9 sec 12.2 m/9 sec 0.6 mph 1 km/h 40 ft/45 sec 12.2 m/45 sec

Braking distance, maximum High range on paved surface Gradeability

5 to 7 ft 1.5 to 2 m See Operator's Manual

Boom function speeds, maximum from platform controls Jib boom up, Z-45/25J

32 to 40 seconds

Jib boom down, Z-45/25J

22 to 28 seconds

Primary boom up

31 to 35 seconds

Primary boom down

27 to 31 seconds

Secondary boom up

38 to 42 seconds

Secondary boom down

32 to 36 seconds

Primary boom extend

14 to 18 seconds

Primary boom retract

17 to 21 seconds

Turntable rotate, 355° primary boom retracted

99 to 105 seconds

Platform rotate, 180°, Z-45/25

6 to 10 seconds

Platform rotate, 160°, Z-45/25J

6 to 10 seconds

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2-2

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Part No. 110188

May 2008

Section 2 • Specifications

REV C

SPECIFICATIONS

Hydraulic Specifications

Function pump

Hydraulic Oil Specifications

Type:

Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W-20 Viscosity index rating 200

Displacement

Cleanliness level, minimum Water content, maximum

Fixed displacement gear pump 0.183 cu in 3 cc

Flow rate

2.1 gpm 7.9 L/min

15/13 200 ppm

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 greater than 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Hydraulic tank return filter

10 micron with 25 psi / 1.7 bar bypass

Function manifold System relief valve pressure Secondary boom down relief valve pressure

2000 psi 138 bar

Platform level flow regulator Jib boom/platform rotate flow regulator

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

3200 psi 220.6 bar

0.6 gpm 2.27 L/min 0.4 gpm 1.5 L/min

Auxiliary pump Type: Displacement

fixed displacement gear pump 0.5 gpm 1.9 L/min

Shell Tellus T32 Shell Tellus T46 Chevron Aviation A

Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0°F / -18°C. Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C. Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use.Function pump

Part No. 110188

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

2-3

Section 2 • Specifications

May 2008

SPECIFICATIONS

REV C

Manifold Component Specifications

Machine Torque Specifications

Plug torque

3 /4

-10 center bolt, GR 8

3 /8

-16 bolts, GR 8

Platform rotator

SAE No. 2

36 in-lbs / 4 Nm

SAE No. 4

10 ft-lbs / 13 Nm

SAE No. 6

14 ft-lbs / 19 Nm

SAE No. 8

38 ft-lbs / 51 Nm

SAE No. 10

41 ft-lbs / 55 Nm

SAE No. 12

56 ft-lbs / 76 Nm

380 ft-lbs 515 Nm 44 ft-lbs 60 Nm

Turntable rotate assembly Rotate bearing mounting bolts, lubricated

180 ft-lbs 244 Nm

Drive motor/brake mounting bolts, dry

110 ft-lbs 149 Nm

Drive motor/brake mounting bolts, lubricated Valve Coil Resistance Specification Description

Specification

80 ft-lbs 108 Nm

Drive motor and hubs

Solenoid valve, 3 position 4 way, 20V DC (schematic items B, C, D, E, F and H)

25 to 29 Ω

Drive hub mounting bolts, lubricated

Solenoid valve, 2 position 3 way, 20V DC (schematic items A, K, S and AA)

25 to 29 Ω

Drive motor mounting bolts, lubricated

Proportional solenoid valve, 24V DC (schematic item I)

17 to 21 Ω

180 ft-lbs 244 Nm 55 ft-lbs 75 Nm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Part No. 110188

May 2008

Section 2 • Specifications

REV C

SPECIFICATIONS

Kubota Z482-E Engine Kubota Z482-E2B Engine Displacement Number of cylinders Bore and stroke Horsepower, gross intermittent

Injection system

29.23 cu in 0.48 liters

Bosch MD

Injection timing

21° BTDC

Injection pump pressure

2.64 x 2.68 inches 67 x 68 mm 12.5 @ 3600 rpm 9.3 kW 1-2

Compression ratio

23:1 412 to 469 psi 28.4 to 32.3 bar

Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Starter motor Brush length, new

0.5188 in 13 mm

Brush length, minimum

0.3346 in 8.5 mm

Low idle

2000 rpm

Battery

High idle

3000 rpm

Type

Governor

centrifugal mechanical

Valve clearance, cold

0.0057 to 0.0072 in 0.145 to 0.185 mm

Engine coolant Capacity

2.9 quarts 2.8 liters

Oil capacity (including filter)

12V DC, Group 70

Quantity

1

Cold cranking ampere Reserve capacity @ 25A rate Alternator Output Fan belt deflection

Lubrication system Oil pressure

1991 psi 137 bar

2

Firing order

Compression pressure

Injection pump make

450A 125 minutes 12V DC, 150 watts 1

/4 to 3/8 inch 7 to 9 mm

36 to 64 psi 2.48 to 4.41 bar 2.6 quarts 2.5 liters

Lubrication system Units ship with 10W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator's Manual on your machine.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 110188

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

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Section 2 • Specifications

May 2008

SPECIFICATIONS

REV C

Generator Generator output with engine @ 3000 rpm

54V DC, 100A 1/16

Generator pulley to engine pulley offset, maximum

inch 1.6 mm 1 /4 inch 6.5 mm

Belt deflection, maximum

Generator Torque Specifications Generator pulley retaining nut torque Engine pulley retaining bolts

80-90 ft-lbs 108-122 Nm 108 in-lbs 12.2 Nm

#10 screw

25 in-lbs 2.8 Nm

#10 nut

25 in-lbs 2.8 Nm

#4 nut Voltage regulator mounting fasteners

8-10 in-lbs 0.9-1.1 Nm 25 in-lbs 2.8 Nm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Part No. 110188

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Section 2 • Specifications

REV C

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.

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. 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).

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

Torque

-4

11 ft-lbs / 14.9 Nm

2 Lubricate the O-ring before installation.

-6

23 ft-lbs / 31.2 Nm

-8

40 ft-lbs / 54.2 Nm

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

-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

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

-4

16 ft-lbs / 21.7 Nm

-4

18 ft-lbs / 25 Nm

-6

35 ft-lbs / 47.5 Nm

-6

30 ft-lbs / 40 Nm

-8

60 ft-lbs / 81.3 Nm

-8

40 ft-lbs / 55 Nm

-10

105 ft-lbs / 142.4 Nm

-10

60 ft-lbs / 80 Nm

-12

140 ft-lbs / 190 Nm

-12

85 ft-lbs / 115 Nm

-16

210 ft-lbs / 284.7 Nm

-16

110 ft-lbs / 150 Nm

-20

260 ft-lbs / 352.5 Nm

-20

140 ft-lbs / 190 Nm

-24

315 ft-lbs / 427.1 Nm

-24

180 ft-lbs / 245 Nm

Part No. 110188

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Torque

2-7

Section 2 • Specifications

May 2008

SPECIFICATIONS

REV C

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

SIZE

Grade 5

THREAD LUBED 20 28

1/4

DRY

18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12

3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 1 1/8 1 1/4 1 1/2

LUBED

DRY

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

80 90

9 10.1

100 120

11.3 13.5

110 120

12.4 13.5

140 160

15.8 18

130 140

14.7 15.8

LUBED 5/16

A574 High Strength Black Oxide Bolts LUBED

Grade 8

DRY

LUBED

DRY

LUBED

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640

17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223

17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190

23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969

18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670

24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620

25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560

33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826

21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000

28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067

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

Class 4.6

Size (m m ) 5 6 7

LUBED

2-8

DRY

LUBED

Class 10.9

8.8

DRY

DRY

LUBED

Class 12.9

10.9

LUBED

12.9

DRY

in- lbs

Nm

in-lbs

Nm

in- lbs

Nm

in- lbs

Nm

in- lbs

Nm

in- lbs

Nm

in- lbs

Nm

in- lbs

Nm

16 19 45

1.8 3.05 5.12

21 36 60

2.4 4.07 6.83

41 69 116

4.63 7.87 13.2

54 93 155

6.18 10.5 17.6

58 100 167

6.63 11.3 18.9

78 132 223

8.84 15 25.2

68 116 1.95

7.75 13.2 22.1

91 155 260

10.3 17.6 29.4

LUBED 8 10 12 14 16 18 20 22 24

Class 8.8

4.6

DRY

LUBED

DRY

LUBED

DRY

LUBED

DRY

f t - lbs

Nm

f t -lbs

Nm

f t - lbs

Nm

f t - lbs

Nm

f t - lbs

Nm

ft - lbs

Nm

f t - lbs

Nm

f t - lbs

Nm

5.4 10.8 18.9 30.1 46.9 64.5 91 124 157

7.41 14.7 25.6 40.8 63.6 87.5 124 169 214

7.2 14.4 25.1 40 62.5 86.2 121 166 210

9.88 19.6 34.1 54.3 84.8 117 165 225 285

14 27.9 48.6 77.4 125 171 243 331 420

19.1 37.8 66 105 170 233 330 450 570

18.8 37.2 64.9 103 166 229 325 442 562

25.5 50.5 88 140 226 311 441 600 762

20.1 39.9 69.7 110 173 238 337 458 583

27.3 54.1 94.5 150 235 323 458 622 791

26.9 53.2 92.2 147 230 317 450 612 778

36.5 72.2 125 200 313 430 610 830 1055

23.6 46.7 81 129 202 278 394 536 682

32 63.3 110 175 274 377 535 727 925

31.4 62.3 108 172 269 371 525 715 909

42.6 84.4 147 234 365 503 713 970 1233

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Part No. 110188

February 2006

Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions.

Observe and Obey:

Symbols Legend

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, six months, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each procedure with the machine in the following configuration: · 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 · Key switch in the off position with the key removed

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps.

· Wheels chocked · All external AC power disconnected from the machine

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Section 3 • Scheduled Maintenance Procedures

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SCHEDULED MAINTENANCE PROCEDURES

Maintenance Schedule

Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

Indicates that tools will be required to perform this procedure.

There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two year. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection

Checklist

Daily or every 8 hours

Indicates that new parts will be required to perform this procedure.

Quarterly or every 250 hours Six months or every 500 hours Annual or every 1000 hours

Indicates that a cold motor, pump or engine will be required to perform this procedure.

Two year or every 2000 hours

A A+B A+B+C A+B+C+D A+B+C+D+E

Maintenance Inspection Report Indicates that a warm motor or pump will be required to perform this procedure.

Indicates that dealer service will be required to perform this procedure.

3-2

The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years.

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Part No. 110188

Pre-Deliver Pre-Deliveryy Preparation February 2006

Section 3 • Scheduled Maintenance Procedures

Fundamentals

Instructions

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

Use the operator’s manual on your machine.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual. If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments

Pre-Delivery Preparation

Y

N

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 Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond, WA 98073-9730 (425) 881-1800

Part No. 110188

Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333

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

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February 2006

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Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report Model

Checklist A - Rev B

Serial number

A-1 Pre-operation inspection

B-1 Radiator

Date

A-2 Function tests

B-3 Batteries B-4 Electrical wiring

Hour meter

A-3 Generator belts and pulleys

Y N R

Perform after 50 hours: Machine owner

A-4 30 Day Service

Inspected by (print)

Perform every 50 hours:

Inspector signature

A-5 Perform engine maintenance Perform every 75 hours:

Inspector title

A-6 Perform engine maintenance , Z482-E

Inspector company

Perform every 100 hours: A-7 Grease rotation bearing

Instructions · Make copies of this page to use for each inspection. · Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection:

A A+B

Checklist B - Rev B B-2 Exhaust system

B-5 Lug nut torque B-6 Brake configuration B-7 Drive hub oil level B-8 Engine RPM B-9 Ground control override B-10 Platform leveling B-11 Engine idle select B-12 Drive brakes B-13 Drive speed - stowed B-14 Drive speed - raised

A-8 Perform engine maintenance

B-15 Alarm package (if equipped)

Perform every 150 hours:

B-16 Electrical contactors

A-9 Perform engine maintenance, Z482-E

B-17 Hydraulic oil analysis

Perform every 200 hours:

B-18 Perform engine maintenance

A-10 Perform engine maintenance

Perform every 400 hours:

Checklist C - Rev B

Six Month or 500 hour Inspection: A+B+C

Y N R

Y N R

C-1 Perform engine maintenance

Annual or 1000 hours Inspection: A+B+C+D

C-2 Grease platform overload (if equipped)

2 Year or 2000 hour Inspection: A+B+C+D+E

C-3 Test platform overload (if equipped)

· Place a check in the appropriate box after each inspection procedure is completed. · 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.

Perform every 800 hours: C-4 Perform engine maintenance

Legend Y = yes, acceptable N = no, remove from service R = repaired Comments

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Section 3 • Scheduled Maintenance Procedures

February 2006

MAINTENANCE INSPECTION REPORT

Model

Checklist D - Rev B

Y N R

D-1 Boom wear pads

Serial number

D-2 Free-wheel configuration

Date

D-3 Drive hub oil Hour meter

D-4 Hydraulic return filter

Machine owner

D-5 Calibrate platform overload system (if equipped)

Inspected by (print)

D-6 Turntable bearing bolts D-7 Turntable bearing wear

Inspector signature

Perform every 1000 hours: Inspector title

D-8 Perform engine maintenance, Z482-E

Inspector company

Perform every 1500 hours:

Instructions · Make copies of this page to use for each inspection.

D-9 Perform engine maintenance, Z482-E2B

· Select the appropriate checklist(s) for the type of inspection to be performed.

Checklist E - Rev B

Daily or 8 hour Inspection: Quarterly or 250 hour Inspection:

Y N R

E-1 Hydraulic oil E-2 Wheel bearings A

A+B

Six Month or 500 hour Inspection: A+B+C

E-3 Perform engine maintenance, Z482-E E-4 Perform engine maintenance, Z482-E2B

Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E · Place a check in the appropriate box after each inspection procedure is completed. · If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments

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Part No. 110188

February 2006

REV B

Section 3 • Scheduled Maintenance Procedures

Checklist A Procedures

A-1 Perform Pre-operation Inspection

A-2 Perform Function Tests

Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required.

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.

Complete information to perform this procedure is available in the Operator's Manual on your machine.

Part No. 110188

Complete information to perform this procedure is available in the Operator's Manual on your machine.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST A

February 2006

PROCEDURES

A-3 Check the Generator Belts and Pulleys

REV B

3 Check to be sure the engine pulley and the generator pulley are aligned within specification using a straightedge. Refer to Section 2, Specifications. a

Maintaining the generator belts and the pulleys is essential to good engine performance and service life. The generator will not operate properly with loose or defective belts and continued use may cause component damage. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns. Charging the batteries with the engine does not fully charge the batteries. Periodically, use the AC battery charger to fully charge the batteries. 1 Be sure that all fasteners and cables on the generator are tight.

b

d

c a b c d

engine pulley straightedge maximum pulley offset generator pulley

If alignment does not meet specification, refer to Repair Procedure 6-3, How to Install the Engine Drive Pulley to adjust the pulley alignment.

2 Be sure that the pulley mounting fasteners are tight and that the pulleys show no signs of damage or unusual wear.

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Part No. 110188

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST A

REV B

4 Inspect the generator belts for:

PROCEDURES

A-4 Perform 30 Day Service

· Cracking · Glazing · Separation · Breaks

The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.

5 Replace both belts if any damage is found. 6 Check the generator belts for proper tension. Refer to Section 2, Specifications. If the belt deflection is not within specification, see repair procedure 7-2, How to Adjust the Generator Belts.

a b

1 Perform the following maintenance procedures: · B-5

Check the Lug Nut Torque (including tires and wheels) · D-4 Replace the Hydraulic Tank Return Filter · D-6 Check the Turnable Rotation Bearing Bolts

c

a b c

engine pulley generator belts generator pulley

7 Check the torque of the pulley retaining nut on the generator. Refer to Section 2, Specifications.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST A

February 2006

PROCEDURES

REV B

A-5 Perform Engine Maintenance

A-6 Perform Engine Maintenance, Z482-E Engine

Engine specifications require that this procedure be performed every 50 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

Engine specifications require that this procedure be performed every 75 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

To access the engine: 1 Remove the engine pivot plate latch retainer.

To access the engine:

2 Open the engine pivot plate latch and swing the engine out away from the machine.

1 Remove the engine pivot plate latch retainer.

3 - 10

2 Open the engine pivot plate latch and swing the engine out away from the machine.

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Part No. 110188

February 2006

Section 3 • Scheduled Maintenance Procedures

REV B

CHECKLIST A

A-7 Grease the Turntable Rotation Bearing and Rotate Gear

Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Before serial number 27001: Locate the grease fitting on the front turntable cover. After serial number 27000: Locate the grease fitting near the ground control box. 2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased. 3 Apply grease to each tooth of the drive gear, located under the turntable.

PROCEDURES

A-8 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 100 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

To access the engine: 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine.

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

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST A

February 2006

PROCEDURES

REV B

A-9 Perform Engine Maintenance, Z482-E Engine

A-10 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 150 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

Engine specifications require that this procedure be performed every 200 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

52958

To access the engine: To access the engine:

1 Remove the engine pivot plate latch retainer.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the engine out away from the machine.

2 Open the engine pivot plate latch and swing the engine out away from the machine.

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Part No. 110188

February 2006

Section 3 • Scheduled Maintenance Procedures

Checklist B Procedures

REV B

B-1 Check the Radiator

B-2 Check the Exhaust System

Maintaining the radiator in good condition is essential for good engine performance. Operating a machine with a damaged or leaking radiator may result in engine damage. Also, restricting air flow through the radiator (i.e., dirt or debris) will affect the performance of the cooling system. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems.

Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions.

Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns. 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine to access the radiator. 3 Inspect the radiator for leaks and physical damage.

Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns. 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine to access the exhaust system. 3 Be sure that all nuts and bolts are tight. 4 Inspect all welds for cracks. 5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints.

4 Clean the radiator fins of debris and foreign materials. 5 Swing the engine back to its original position and close the engine pivot plate latch. 6 Install the engine pivot plate latch retainer.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

REV B

3 Be sure that the cable connections are tight.

B-3 Check the Batteries

4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer.

Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

Result: If any battery cell displays a specific gravity of less than 1.026, the battery must be replaced. 5 Check the battery acid level of the battery. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill. 6 Install the battery vent caps. 7 Check each battery pack and verify that the batteries are wired correctly. Refer to the Battery Connection Diagram decal on the machine.

Perform this procedure after fully charging the batteries. Charging the batteries with the engine does not fully charge the batteries. Periodically, use the AC battery charger to fully charge the batteries. The engine battery is a maintenance free battery and does not require the replenishing of electrolyte. For a more accurate determination of battery condition, fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize. 1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

REV B

B-4 Inspect the Electrical Wiring

PROCEDURES

5 Open the ground controls side turntable cover. 6 Inspect the following areas for burnt, chafed, corroded and loose wires: · Inside of the ground control box

Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

· Hydraulic manifold wiring 7 Inspect for a liberal coating of dielectric grease at the following location: · All wire harness connectors to the ground control box 8 Raise the secondary boom until the mid-pivot is approximately 10 feet / 3 m off the ground. 9 Remove the center turntable cover. 10 Inspect the turntable center area for burnt, chafed and pinched cables.

1 Open the engine side turntable cover.

11 Install the center turntable cover.

2 Remove the safety pin from the engine pivot plate latch.

12 Lower the boom to the stowed position and turn the machine off.

The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Inspect the following areas for burnt, chafed, corroded and loose wires: · Power units · Inside of the ground control box

13 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: · Cable track on the primary, jib and secondary booms · Jib boom to platform cable harness · Inside of the platform control box 14 Inspect for a liberal coating of dielectric grease at the following location: · All wire harness connectors to the platform control box

· Generator and power units · Engine wiring harness

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

REV B

B-5 Check the Tires, Wheels and Lug Nut Torque

B-6 Confirm the Proper Brake Configuration

Maintaining the tires and wheels in good condition, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.

Proper brake configuration is essential to safe operation and good machine performance. Hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. 1 Check each drive hub disconnect cap to be sure it is in the engaged position.

Tip over hazard. The tires on this machine are foam-filled and are essential to machine stability and safe machine operation. Using an air-filled tire on this machine can compromise machine stability and will cause the machine to tip over.

brake disengaged position

brake engaged position

The tires on this machine are foam-filled and do not need air added to them. 1 Check the tire surface and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications.

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Section 3 • Scheduled Maintenance Procedures

REV B

CHECKLIST B

PROCEDURES

2 Remove the plug located at 90 degrees and check the oil level.

B-7 Check the Oil Level in the Drive Hubs

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

Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees.

3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. 4 Models with pipe plugs: Apply pipe thread sealant to the plugs and install the plugs. Models with O-ring plugs: Install the plugs into the drive hub. 5 Repeat steps 1 through 4 for the other drive hub. 6 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications.

models with pipe plugs

a

a

Part No. 110188

models with o-ring plugs

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

REV B

4 Loosen the lock nut, then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the lock nut and recheck the rpm.

B-8 Check and Adjust the Engine RPM

a

Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. 1 Remove the engine pivot plate latch retainer.

b

2 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine.

c

3 Connect an rpm gauge to the engine, and then start the engine from the ground controls.

d

Result: Low idle should be 2000 rpm. Skip to step 5 if the low idle rpm is correct. a b c d

low idle adjustment screw (not shown) high idle adjustment nut rpm solenoid fuel shut off solenoid

5 Move the engine idle control switch to high idle (rabbit symbol) from the ground controls. Result: High idle should be 3000 rpm. Skip to step 7 if the high idle rpm is correct.

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Section 3 • Scheduled Maintenance Procedures

REV B

CHECKLIST B

6 Loosen the lock nut on the solenoid, then turn the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the lock nut and recheck the rpm. Be sure the solenoid fully retracts when activating high idle. 7 Swing the engine back to its original position and close the engine pivot plate latch. 8 Install the engine pivot plate latch retainer.

PROCEDURES

B-9 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the ON or OFF position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the platform red Emergency Stop button to the off position. 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position. 3 Operate each boom function through a partial cycle at the ground controls. Result: All boom functions should operate.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

B-10 Test the Platform Self-leveling

Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom. A platform self-leveling failure creates an unsafe working condition. 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position. 2 Lower the boom to the stowed position. 3 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch. 4 Raise and lower the primary boom through a full cycle. Result: The platform should remain level at all times to within ±5 degrees.

REV B

B-11 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol): Low idle and slow battery charging. High idle (rabbit symbol): High idle and quickest battery charging. Foot switch activated high idle (rabbit and foot switch symbols): Activates high idle only when the foot switch is pressed down. 1 Start the engine from the ground controls. Move the engine idle select toggle switch to high idle (rabbit symbol). Result: The engine should change to high idle. 2 Release the engine idle select toggle switch. Result: The engine should return to low idle. 3 Turn the key switch to platform controls. 4 At the platform controls, move the engine idle select toggle switch to high idle (rabbit symbol). Result: The engine should change to high idle. 5 Move the engine idle select toggle switch to low idle (turtle symbol). Result: The engine should change to low idle. 6 Move the engine idle select toggle switch to foot switch activated high idle (rabbit and foot switch symbol). Result: The engine should not change to high idle. 7 Press down the foot switch. Result: The engine should change to high idle.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

REV B

B-12 Test the Drive Brakes

PROCEDURES

B-13 Test the Drive Speed Stowed Position

Proper brake action is essential to safe machine operation. The machine uses drive motor regenerative braking to stop the machine. Hydraulically-released individual wheel brakes hold the machine once it has stopped. The drive motor regenerative braking should operate smoothly, free of hesitation and jerking. Hydraulically-released individual wheel brakes can appear to operate normally when not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to B-6, Confirm the Proper Brake Configuration. Select a test area that is firm, level and free of obstructions. 1 Mark a test line on the ground for reference. 2 Lower the boom into the stowed position. 3 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. 4 Bring the machine to maximum drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line.

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Lower the boom into the stowed position. 3 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 4 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 5 Continue at full speed and note the time when the machine reference point passes over the finish line. Refer to Section 2, Specifications.

5 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

B-14 Test the Drive Speed - Raised or Extended Position

REV B

B-15 Test the Alarm Package (if equipped) The alarm package includes: · Travel alarm

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Raise the platform more than 5 feet / 1.5 m. 3 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 4 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 5 Continue at full speed and note the time when the machine reference point passes over the finish line. Refer to Section 2, Specifications.

· Descent alarm · Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the turntable covers. The alarms and beacon will operate with the engine running or not running. 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Result: The flashing beacon should be on and flashing. 2 Move the function enable switch to either side and activate the primary boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. 3 Move the function enable switch to either side and activate the secondary boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

REV B

4 Z-45/25J: Move the function enable toggle switch to either side and activate the jib boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. 5 Turn the key switch to platform control. Result: The flashing beacon should be on and flashing. 6 Press down the foot switch. Activate the primary boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 7 Press down the foot switch. Activate the secondary boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 8 Z-45/25J: Press down the foot switch. Activate the jib boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down. 9 Press down the foot switch. Move the drive control handle off center, hold for a moment and then release it. Move the drive control handle off center in the opposite direction, hold for a moment and then release it.

PROCEDURES

B-16 Check the Electrical Contactors

Maintaining the electrical contactors in good condition is essential to safe machine operation. Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage. 1 Remove the drive chassis cover from the non-steer end of the machine and locate the electrical contactors mounted on the component mounting panel. 2 Visually inspect the contact points of each contactor for the following items: · Excessive burns · Excessive arcs · Excessive pitting Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Replace the contactors if any damage is found.

Result: The travel alarm should sound when the drive control handle is moved off center in either direction.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST B

February 2006

PROCEDURES

B-17 Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil.

REV B

B-18 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 400 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

To access the engine: 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine.

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Section 3 • Scheduled Maintenance Procedures

Checklist C Procedures

REV B

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

C-1 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 500 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52957

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist. Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage. 1 Locate the grease fittings on each pivot pin of the platform overload assembly. 2 Thoroughly pump grease into each grease fitting.

To access the engine: Grease Specification

1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine.

Part No. 110188

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

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST

C

February 2006

PROCEDURES

C-3 Test the Platform Overload System (if equipped)

REV B

4 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown.

Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over. Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. 2 Level the platform from the platform controls. 3 Determine the maximum platform capacity. Refer to the machine serial plate.

Result: The platform overload indicator light should be off at both the ground and platform controls. 5 Carefully move the test weight to each remaining location. Result: The platform overload indicator light should be off at both the ground and platform controls. 6 Add an additional 10 lbs / 4.5 kg of weight to overload the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at both the ground and platform controls. Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. See D-5, Calibrate the Platform Overload System. There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

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CHECKLIST

REV B

7 Carefully move the test weights to each remaining location in the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at both the ground and platform controls. Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. See D-5, Calibrate the Platform Overload System. There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 10 Test all machine functions from the ground controls.

C PROCEDURES

11 Lift the test weights off the platform floor using a suitable lifting device. Result: The platform overload indicator light and alarm should turn off at both the ground and platform controls. There may be an approximate 2 second delay before the overload indicator light and alarm turn off. 12 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 13 Turn the key switch to platform control. 14 Test all machine functions from the platform controls. Result: All platform control functions should operate. If the platform overload system is not operating properly, see D-5, Calibrate the Platform Overload System.

Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls.

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CHECKLIST

C

February 2006

REV B

PROCEDURES

C-4 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 800 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

To access the engine: 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine.

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Section 3 • Scheduled Maintenance Procedures

Checklist D Procedures

REV B

D-1 Check the Primary Boom Wear Pads

D-2 Check the Free-wheel Configuration

Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions.

Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge could result in death or serious injury and property damage.

1 Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness. If the wear pad is still within specification, shim as necessary to obtain minimum clearance with zero binding. 2 Extend and retract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom. Always maintain squareness between the outer and inner boom tubes. Primary boom wear pad specifications Top, bottom and side wear pads (platform end of boom) Side and bottom wear pads (pivot end of boom) Top wear pads (pivot end of boom)

Part No. 110188

New 3 /4

Minimum inch 15.9 mm

5/8 inch 15.9 mm

1/2 inch 12.7 mm

inch 19 mm

Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. 1 Chock the steer wheels to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the non-steer tires. 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support. 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub.

5/8

inch 19 mm

3 /4

Collision hazard. Select a work site that is firm and level.

brake disengaged position

brake engaged position

5/8 inch 15.9 mm

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CHECKLIST

D

February 2006

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 over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the jack stands. Collision hazard. Failure to engage the drive hubs could result in death or serious injury and property damage.

REV B

D-3 Replace the Drive Hub Oil

Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. 1 Select the drive hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil.

models with pipe plugs

a

a

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Section 3 • Scheduled Maintenance Procedures

REV B

CHECKLIST

3 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees. 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole. Refer to Section 2, Specifications. 5 Models with pipe plugs: Apply pipe thread sealant to the plugs and install the plugs. Models with O-ring plugs: Install the plugs into the drive hub. 6 Repeat steps 1 through 5 for the other drive hub.

D PROCEDURES

D-4 Replace the Hydraulic Tank Return Filter

Replacement of the hydraulic tank return filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 1 Locate the hydraulic return filter next to the hydraulic tank. 2 Place a suitable container under the hydraulic filter. 3 Remove the filter with an oil filter wrench. 4 Apply a thin layer of oil to the new oil filter gasket. 5 Install the new filter and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. 6 Turn the key switch to ground controls and pull out the red Emergency Stop button out to the on position at both the ground and platform controls. 7 Activate any boom function and inspect the filter and related components to be sure that there are no leaks. 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST

D

PROCEDURES

D-5 Calibrate the Platform Overload System (if equipped)

Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Yearly calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over. Perform this procedure with the machine on a firm, level surface. 1 Level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor.

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February 2006

REV B

Determine the limit switch trigger point: 4 Gently move the platform up and down by hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle. Result: The overload indicator light and the alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off. The platform will need to be moved up and down and allowed to settle in between adjustments. There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. Result: The overload indicator light and alarm is off. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on. There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. The platform will need to be moved up and down and allowed to settle in between adjustments.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST

REV B

D PROCEDURES

Confirm the setting:

10 Turn the key switch to ground control.

5 Turn the key switch to platform control.

11 Test all machine functions from the ground controls.

6 Lift the test weight off the platform floor using a suitable lifting device. 7 Place the test weight back onto the center of the platform floor using a suitable lifting device. Result: The alarm should be off. The platform overload indicator light should be off at both the ground and platform controls.

Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4.

There may be an approximate 2 second delay before the overload indicator light and alarm turn off. 8 Add an additional 10 lb / 4.5 kg test weight to the original test weight to overload the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at both the ground and platform controls. There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate.

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CHECKLIST

D

February 2006

PROCEDURES

D-6 Check the Turntable Rotation Bearing Bolts

REV B

2 Check to be sure that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications. 9

18

1

11 7

6

Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the primary boom and place a safety chock on the lift cylinder rod. Carefully lower the boom onto the lift cylinder safety chock.

16

13

3

20

19

4

14

15 8

5 12

Crushing hazard. Keep hands away from cylinder and all moving parts when lowering the boom.

2

17

10

Bolt torque sequence (from serial number 23236 to 26999)

A lift cylinder safety chock is available through Genie Service Parts (Genie part number 33484).

Counterweight

11

3

18 6 13

10 1

8

15 7 12

16 2 9

14 5

17

4

Bolt torque sequence (after serial number 26999)

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST

REV B

3 Lower the boom to the stowed position. 4 Remove drive chassis covers from both the steer end and the non-steer end of the machine. 5 Check to be sure that each bearing mounting bolt under the drive chassis is torqued in sequence to specification. Refer to Section 2, Specifications. 9

1

11

6

7

16

13 4

3

15

14 8

5 12

2

10

Bolt torque sequence (from serial number 23236)

D PROCEDURES

D-7 Inspect for Turntable Bearing Wear

Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage. Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 1 Grease the turntable bearing. See A-7, Grease the Turntable Bearing and Rotate Gear. 2 Torque the turntable bearing bolts to specification. See D-6, Check the Turntable Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the primary and secondary booms to full height. Do not extend the primary boom.

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CHECKLIST

D

February 2006

PROCEDURES

4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing. To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing.

a

REV B

7 Note the reading on the dial indicator. Result: The measurement is less than 0.055 inch / 1.4 mm. The bearing is good. Result: The measurement is more than 0.055 inch / 1.4 mm. The bearing is worn and needs to be replaced. 8 Fully retract the primary boom. Raise the primary and secondary booms to full height. Visually inspect the the dial indicator to be sure the needle returns to the "zero" position. 9 Remove the dial indicator and rotate the turntable 90°.

b

10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart.

c

11 Lower the primary and secondary booms to the stowed position and turn the machine off. 12 Remove the dial indicator from the machine.

d

a b c d

turntable dial indicator drive chassis turntable rotation bearing

5 At the dial indicator, adjust it to "zero" the indicator. 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom.

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Section 3 • Scheduled Maintenance Procedures

REV B

CHECKLIST

D-9 Perform Engine Maintenance, Z482-E2B Engine

D-8 Perform Engine Maintenance, Z482-E Engine

Engine specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

D PROCEDURES

Engine specifications require that this procedure be performed every 1500 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167). Kubota Z482-E Operator's Manual Genie part number

52958

52958

To access the engine:

To access the engine:

1 Remove the engine pivot plate latch retainer.

1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine.

Part No. 110188

2 Open the engine pivot plate latch and swing the engine out away from the machine.

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February 2006

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

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. Perform this procedure with the boom in the stowed position. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Place a suitable container under the hydraulic tank.

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REV B

2 Remove the drain plug from the hydraulic tank. 3 Completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 4 Tag, disconnect and plug the hydraulic hose from the hydraulic tank filter at the tank. 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. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 5 Remove the hydraulic tank mounting fasteners. 6 Pull the hydraulic tank out slightly to access the two suction hoses. 7 Tag, disconnect and plug the two suction hoses on the back of the hydraulic tank. 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.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST E

REV B

8 Remove the hydraulic tank from the machine. Component damage hazard. The hydraulic tank is plastic and may become damaged if allowed to fall.

PROCEDURES

E-2 Grease the Steer Axle Wheel Bearings

9 Remove the suction strainer from the tank and clean it using a mild solvent. 10 Rinse out the inside of the tank using a mild solvent. 11 Install the suction strainer and drain plug using a thread sealer on the threads. 12 Place the hydraulic tank onto the machine. 13 Install the hydraulic hoses. 14 Install the hydraulic tank retaining strap. Component damage hazard. The hydraulic tank may become damaged if the tank strap fasteners are over tightened. 15 Fill the tank with hydraulic oil until the fluid is within the FULL and ADD marks on the hydraulic tank. Do not overfill. 16 Clean up any oil that may have spilled. Properly discard of oil. 17 Operate all machine functions through a full cycle and check for leaks.

Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often. 1 Loosen the wheel lug nuts. Do not remove them. 2 Block the non-steer wheels, then center a lifting jack under the steer axle. 3 Raise the machine 6 inches / 15 cm and place blocks under the drive chassis for support. 4 Remove the lug nuts. Remove the tire and wheel assembly. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: There should be no side to side or up and down movement. Skip to step 10 if there is no movement.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST E

February 2006

PROCEDURES

6 Remove the dust cap from the hub. Remove the cotter pin from the castle nut. 7 Tighten the castle nut to 35 ft-lbs / 47 Nm to seat the bearings. 8 Loosen the castle nut and re-tighten to 8 ft-lbs / 11 Nm. 9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: If there is no side to side or up and down movement, continue with step 10 and grease the wheel bearings. Result: If there is side to side or up and down movement, continue to step 10 and replace the wheel bearings with new ones. When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced. 10 Remove the castle nut. 11 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub. 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing.

REV B

15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush. Always replace the bearing grease seal when removing the hub. 16 Slide the hub onto the yoke spindle. Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur. 17 Place the outer bearing into the hub. 18 Install the washer and castle nut. 19 Tighten the castle nut to 35 ft-lbs / 47 Nm to seat the bearings. 20 Loosen the castle nut and re-tighten to 8 ft-lbs / 11 Nm. 21 Install a new cotter pin. Bend the cotter pin to lock it in. Always use a new cotter pin when installing a castle nut. 22 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications.

13 Pack both bearings with clean, fresh grease. 14 Place the large inner bearing into the rear of the hub.

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Section 3 • Scheduled Maintenance Procedures

CHECKLIST E

REV B

PROCEDURES

E-4 Perform Engine Maintenance, Z482-E2B Engine

E-3 Perform Engine Maintenance, Z482-E Engine

Engine specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first.

Engine specifications require that this procedure be performed every 3000 hours or every two years, whichever comes first.

Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage.

Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage.

Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167).

Required maintenance procedures and additional engine information are available in the Kubota Z482-E Operator's Manual (Kubota part number 16676-89167).

Kubota Z482-E Operator's Manual Genie part number

Kubota Z482-E Operator's Manual Genie part number

52958

52958

To access the engine:

To access the engine:

1 Remove the engine pivot plate latch retainer.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the engine out away from the machine.

2 Open the engine pivot plate latch and swing the engine out away from the machine.

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Section 4 • Repair Procedures

Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Observe and Obey: 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. 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 Operator’s Manual on your machine. 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. Unless otherwise specified, perform each repair procedure with the machine in the following 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

Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Used to indicate operation or maintenance information.

· Wheels chocked

Indicates that a specific result is expected after performing a series of steps.

· All external AC power supply disconnected from the machine

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

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Platform Controls 1-1 Controllers

REV B

Boom Function Speed Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC at the platform red Emergency Stop button.

Platform Controls The drive joystick is connected to the drive motor controller located under the non-steer end drive chassis cover. The drive motor controller can also recognize machine drive malfunctions and display controller fault codes by flashing an LED at the ground controls. Refer to Section 5, Fault Codes for a list of fault codes and additional information. There are no adjustments needed on the drive joystick controller. For further information or assistance, consult the Genie Industries Service Department.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 Open the platform control box lid and locate the boom function speed controller. b a c

d

a b c d b a b

4-2

threshold adjustable trimpot max-out adjustable trimpot white/red wire to TP6 boom function speed controller

a

boom function speed controller drive joystick

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REV B

PLATFORM CONTROLS

3 Disconnect the blk/red wire of the boom function speed controller from the wht/red wire. 4 Connect the red (+) lead from an amp meter to the blk/red wire. Connect the black (-) lead to the wht/red wire. 5 Turn the boom function speed controller to the CREEP position. 6 Set the threshold: With the boom in the stowed position, press down the foot switch and move the primary boom toggle switch in the down position until the amperage reading appears. Adjust the amperage to 0.17 to 0.18A. Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. 7 Turn the boom function speed controller to the 9 position. 8 Set the max-out: Press down the foot switch, then move the primary boom toggle switch in the down position. Adjust the amperage to 0.54 to 0.55A. Turn the max-out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. Boom function speed controller specifications Threshold

0.17 to 0.18A

Max-out

0.54 to 0.55A

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Platform Components 2-1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Z-45/25J: Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the primary boom slightly and place blocks under the platform for support.

4-4

REV B

3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks. 4 Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector. Connect the hoses from the cylinder together using a connector. 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. 5 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not remove the pin. 6 Z-45/25J: Remove the external snap rings from the slave cylinder barrel-end pivot pin. Do not remove the pin. Z-45/25: Remove the pin retaining fastener from the slave cylinder barrel-end pivot pin. Do not remove the pin. 7 Place a block under the slave cylinder for support. Protect the cylinder rod from damage.

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REV B

PLATFORM COMPONENTS

8 Use a soft metal drift to drive the rod-end pivot pin out. Crushing hazard. The platform could fall when the slave cylinder rod-end pivot pin is removed if not properly supported. Component damage hazard. The slave cylinder rod may become damaged if it is allowed to fall if not properly supported by the lifting device. 9 Use a soft metal drift and drive the barrel-end pin out. 10 Carefully pull the cylinder out of the primary boom.

How to Bleed the Slave Cylinder 1 Raise the primary boom to a horizontal position. 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system.

2-2 Platform Rotator How to Bleed the Platform Rotator This procedure will require two people. 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right. Before serial number 24304: 2 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container to collect any drainage. Secure the container to the boom. 3 Open the top bleed valve on the rotator, but do not remove it. a

d

c a b c d

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top bleed valve bottom bleed valve container clear hose

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REV B

PLATFORM COMPONENTS

4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 5 Connect the clear hose to the bottom bleed valve and open the valve. Do not remove the bleed valve. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. After serial number 24303:

4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. 5 Open the bottom bleed screw on the rotator, but do not remove it. 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. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation.

2 Place a suitable container underneath the platform rotator.

7 Clean up any hydraulic oil that may have spilled.

3 Open the top bleed screw on the rotator, but do not remove it.

8 Rotate the platform fully in both directions and inspect the bleed screws for leaks.

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.

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REV A

Section 4 • Repair Procedures

Jib Boom Components, Z-45/25J

3-1 Jib Boom

5 Attach a lifting strap from an overhead crane to the platform rotator for support.

How to Remove the Jib Boom

6 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

Perform this procedure with the boom in the stowed position. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. 2 Tag and disconnect the electrical connectors from the jib boom/platform rotate select manifold mounted to the platform support. 3 Tag, disconnect and plug all of the hydraulic hoses from the jib boom/platform rotate select valve manifold. Cap the fittings on the manifold and pull the hoses out through the platform rotator. 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. 4 Remove the platform mounting weldment.

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7 Remove the pin retaining fasteners from both platform rotator pivot pins. Do not remove the pins. 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down. 9 Use a soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the machine. 10 Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. 11 Remove the hose and cable cover from the side of the jib boom. Remove the hose and cable separators. 12 Attach a lifting strap from an overhead crane to the jib boom. 13 Support the barrel end of the jib boom lift cylinder with a suitable lifting device. 14 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. 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.

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JIB BOOM COMPONENTS, Z-45/25J

15 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. 16 Use a soft metal drift to remove the pin and let the cylinder hang down. Crushing hazard. The jib boom could fall when when the barrelend pivot pin is removed if not properly supported by the overhead crane. 17 Remove the pin retaining fastener from the jib boom pivot pin. Use a soft metal drift to remove the pin, then remove the jib boom from the bellcrank. Crushing hazard. The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 18 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 19 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the bellcrank. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

4-8

REV A

3-2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks. 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. 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.

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Section 4 • Repair Procedures

REV A

JIB BOOM COMPONENTS, Z-45/25J

3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 5 Support the jib boom lift cylinder with a suitable lifting device. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down. Crushing hazard. The jib boom could fall when the barrel-end pivot pin is removed if not properly supported by the overhead crane. 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

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Primary Boom Components 4-1 Cable Track The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom.

How to Remove the Cable Track, Z-45/25 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 2 Disconnect the cables from the platform control box. 3 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 4 Raise the primary boom to a horizontal position.

4 - 10

REV B

5 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. 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. 6 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports of the counterbalance valve manifold at the platform rotator. Cap the fittings on the manifold. 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. 7 Tag, disconnect and plug the hydraulic hoses from the platform leveling master 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.

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Section 4 • Repair Procedures

REV B

PRIMARY BOOM COMPONENTS

8 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder and connect them together using a connector. 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. 9 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder. 10 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 11 Remove all hose and cable clamps from the underside of the primary boom. 12 Attach a strap from an overhead crane to the cable track. 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom.

14 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 15 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

How to Remove the Cable Track, Z-45/25J 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 2 Disconnect the cables from the platform control box. 3 Remove the hose and cable cover from the side of the jib boom. Remove the hose and cable separators.

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REV B

PRIMARY BOOM COMPONENTS

4 Remove the hose clamp on the primary boom bellcrank. 5 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 6 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports of the counterbalance valve manifold at the platform rotator. Cap the fittings on the manifold. 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. 7 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder at the union and connect them together using a connector. Connect the hoses from the cylinder together using a connector. 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.

4 - 12

8 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate manifold. Cap the fittings on the manifold. 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. 9 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. 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. 10 Tag, disconnect and plug the hydraulic hoses from the platform leveling master 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.

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REV B

PRIMARY BOOM COMPONENTS

11 Raise the boom to a horizontal position. 12 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 13 Attach a lifting strap from an overhead 5 ton / 5,000 kg capacity crane to the platform end of the primary boom for support. Do not lift it.

20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder. 21 Raise the rod end of the primary boom lift cylinder back into position and install the rodend pivot pin. Install the pin retaining fasteners. 22 Attach a strap from an overhead crane to the cable track. 23 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom.

14 Remove all hose and cable clamps from the underside of the primary boom.

24 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom.

15 Support the rod end of the primary boom lift cylinder with a suitable lifting device.

25 Remove the cable track from the machine and place it on a structure capable of supporting it.

16 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Do not remove the pin. 17 Raise the primary boom slightly with the overhead crane to relieve the pressure on the primary boom lift cylinder rod-end pivot pin. 18 Use a soft metal drift to remove the primary boom lift cylinder rod-end pivot pin.

Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device. 19 Lower the rod end of the primary boom lift cylinder approximately 12 inches / 30 cm.

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PRIMARY BOOM COMPONENTS

REV B

How to Repair the Primary Boom Cable Track Component damage hazard. The primary boom cable track can be damaged if it is twisted. A 7 link repair section of cable track is available through the Genie Industries Service Parts Department.

a b

a b

link separation point lower clip

1 Use a slotted screwdriver to pry down on the lower clip. 2 To remove a single link, open the lower clip and then use a screw driver to pry the link to the side. 3 Repeat steps 1 and 2 for each link to be removed.

4-2 Primary Boom How to Remove the Primary Boom Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Perform this procedure with the boom in the stowed position. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. 2 Z-45/25: Remove the platform rotator and platform mounting weldment. Z-45/25J: Remove the jib boom. See 3-1, How to Remove the Jib Boom. 3 Remove the cable track. See 4-1, How to Remove the Cable Track. 4 Raise the primary boom to a horizontal position.

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Section 4 • Repair Procedures

REV B

PRIMARY BOOM COMPONENTS

5 Remove the hose and cable cover from the upper pivot.

13 Remove the hose clamp at the pivot end of the boom.

6 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. Then lower the cylinder and let it hang down.

14 Attach a 5 ton / 5,000 kg overhead crane to the center point of the primary boom.

Component damage hazard. When lowering the master cylinder down, be sure not to damage the master cylinder hoses or fittings. 7 Locate the primary boom drive speed limit switch inside of the upper pivot. 8 Remove the primary boom drive speed limit switch mounting fasteners. Do not disconnect the wiring.

15 Attach a similar lifting device to the primary boom lift cylinder. 16 Place support blocks under the primary boom lift cylinder. 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom lift cylinder and primary boom will fall if not properly supported.

9 Locate the primary extension boom drive speed limit switch inside of the extension boom.

18 Lower the rod end of the primary boom lift cylinder onto support blocks. Protect the cylinder rod from damage.

10 Remove the primary extension boom drive speed limit switch mounting fasteners. Do not disconnect the wiring.

19 Remove the pin retaining fasteners from the primary boom pivot pin.

11 Pull the limit switch and the wiring out of the extension tube and move it out of the way. 12 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. 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.

Part No. 110188

20 Remove the primary boom pivot pin with a soft metal drift, then carefully remove the primary boom from the machine and place it on a structure capable of supporting it. Crushing hazard. The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

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REV B

PRIMARY BOOM COMPONENTS

How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Primary Boom Extension Cylinder. 1 Remove the primary boom. See How to Remove the Primary Boom. 2 Place blocks under the barrel end of the primary boom extension cylinder for support.

6 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin. 7 Support and slide the extension cylinder out of the base end of the extension tube. Place the extension cylinder on blocks for support. Crushing hazard. The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

3 Remove the pin retaining fastener from the extension cylinder barrel-end pivot pin at the pivot end of the primary boom. Use a soft metal drift to remove the pin. 4 Remove and label the location of the wear pads from the platform end of the primary boom. Pay careful attention to the location and amount of shims used with each wear pad. 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube. Crushing hazard. The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

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REV B

PRIMARY BOOM COMPONENTS

4-3 Primary Boom Lift Cylinder

5 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device.

The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

6 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.

How to Remove the Primary Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to a horizontal position. 2 Raise the secondary boom until the primary boom lift cylinder barrel-end pivot pin is above the turntable covers. 3 Attach a 5 ton / 5000 kg overhead crane to the primary boom for support. 4 Raise the primary boom with the overhead crane slightly to take the pressure off the primary boom lift cylinder pivot pins.

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. 7 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The primary boom will fall if not properly supported when the primary boom rod-end pivot pin is removed. 8 Place a support block across both turntable covers under the primary boom lift cylinder. 9 Lower the rod end of the lift cylinder onto the block. Protect the cylinder rod from damage. Crushing hazard. The primary boom lift cylinder could fall if not properly supported. 10 Support the barrel end of the primary boom lift cylinder with an overhead crane or similar lifting device. 11 Remove the primary boom lift cylinder barrelend pivot pin retaining fasteners. Use a slide hammer to remove the barrel-end pivot pin. Carefully remove the primary boom lift cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device.

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PRIMARY BOOM COMPONENTS

4-4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Primary Boom Extension Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to a horizontal position. 2 Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube.

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3 Remove the hose and cable guard from the upper pivot. 4 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. 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. 5 At the platform end of the boom, remove the external snap rings from the extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 6 Remove the barrel-end pivot pin retaining fasteners. 7 Place a rod through the barrel-end pivot pin and twist to remove the pin. 8 Support and slide the extension cylinder out of the upper pivot. Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported. Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom. Component damage hazard. Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them. Note the length of the cylinder after removal. The cylinder must be at the same length for installation.

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Section 4 • Repair Procedures

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PRIMARY BOOM COMPONENTS

4-5 Platform Leveling Master Cylinder

3 Attach overhead crane or similar lifting device to the master cylinder.

The master cylinder acts as a pump for the slave cylinder. It’s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. The master cylinder is located at the base of the primary boom.

5 Place a rod through the barrel-end pivot pin and twist to remove the pin.

4 Remove the pin retaining fasteners from the master cylinder barrel-end pivot pin.

How to Remove the Platform Leveling Master Cylinder 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 2, Hydraulic Hose and Fitting Torque Specifications.

6 Remove the pin retaining fastener from the rodend pivot pin. 7 Place a rod through the rod-end pivot pin and twist to remove the pin. 8 Remove the master cylinder from the machine. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane.

1 Raise the secondary boom until both the rodend and barrel-end pivot pins on the master cylinder are accessible. 2 Tag, disconnect and plug the master cylinder hydraulic hoses. 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.

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Secondary Boom Components a

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f Secondary Boom components a upper secondary boom (number 1 arm) b upper tension link (number 2 arm) c lower tension link (number 3 arm) d mid-pivot e compression link f secondary boom lift cylinder (2) g lower secondary boom (number 4 arm) h turntable pivot i boom rest j upper pivot

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Section 4 • Repair Procedures

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SECONDARY BOOM COMPONENTS

4 Remove the master cylinder. See 4-5, How to Remove the Platform Leveling Master Cylinder.

5-1 Secondary Boom How to Disassemble the Secondary Boom Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required. Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. 2 Z-45/25J: Remove the jib boom. See 3-1, How to Remove the Jib Boom. 3 Remove the primary boom. See 4-2, How to Remove the Primary Boom.

Part No. 110188

5 Attach a lifting strap from an overhead crane to to the lug on the rod end of the primary boom lift cylinder. Then raise the primary boom lift cylinder with the crane, to a vertical position. 6 Tag, disconnect and plug the hydraulic hoses at the primary boom lift 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. 7 Remove the pin retaining fastener from the primary boom lift cylinder barrel-end pivot pin. 8 Use a slide hammer to remove the pin. Remove the primary boom lift cylinder from the machine. Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not properly supported by the overhead crane. 9 Tag, disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders. Cap the fittings on the cylinders. 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.

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SECONDARY BOOM COMPONENTS

10 Remove the pin retaining fasteners from both sides of the secondary boom lift cylinder rodend pivot pin and barrel-end pivot pin. Do not remove the pins. 11 Attach a strap from an overhead crane to the lug on the rod end of one of the secondary boom lift cylinders for support. Do not apply any lifting pressure. 12 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 13 Use a soft metal drift to drive the rod-end pivot pin half way out. 14 Remove the secondary boom lift cylinder from the machine. 15 Repeat steps 11 through 14 for the other secondary boom lift cylinder. Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder.

17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid-point between the upper pivot and mid-pivot. 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid-pivot and the upper pivot. Do not remove the pins. 19 Use a soft metal drift to drive both pins out. 20 Remove the number 1 arm from the machine. Crushing hazard. The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Crushing hazard. The upper pivot could fall when the number 1 arm is removed from the machine if not properly supported by the overhead crane. 21 Using the overhead crane attached to the upper pivot, raise the secondary boom assembly approximately 30 inches / 76 cm. 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block between the number 2 arm and the boom rest. Then lower the secondary boom assembly onto the block. Crushing hazard. The secondary boom assembly could fall if not properly supported by the 4 x 4 x 11 inch / 10 x 10 x 28 cm block.

16 Attach a lifting strap from an overhead crane to the upper pivot for support. Do not lift it.

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SECONDARY BOOM COMPONENTS

23 Pull all of the cables and hoses out through the upper pivot. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid-pivot end. 32 Attach a lifting strap from the overhead crane to the mid-pivot for support. Do not lift it.

24 Remove the hose and cable covers from the top of the number 2 arm.

33 Remove the pin retaining fasteners from the number 2, 3 and 4 arm pivot pins at the mid-pivot. Do not remove the pins.

25 Pull all of the hoses and cables out of the upper pivot and out through the mid-pivot. Lay the hoses and cables on the ground.

34 Use a soft metal drift to drive each pin out. Then remove the mid-pivot from the secondary boom assembly.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 26 Remove the pin retaining fastener from the number 2 arm pivot pin at the upper pivot. Use a soft metal drift to remove the pin. 27 Remove the upper pivot from the machine. Crushing hazard. The upper pivot could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 28 Attach the lifting strap from an overhead crane to the number 2 arm at the upper pivot end. 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch / 10 x 10 x 28 cm block.

Crushing hazard. The mid-pivot could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane. 35 Attach the lifting strap from an overhead crane to the center point of the number 2 arm for support. Do not lift it. 36 Remove the pin retaining fasteners from both compression link pivot pins. Do not remove the pins. 37 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm. 38 Support the compression link with an appropriate lifting device.

30 Lower the number 2 arm onto the boom rest pad.

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SECONDARY BOOM COMPONENTS

39 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm. Remove the compression link from the machine. Crushing hazard. The number 2 arm could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane. Crushing hazard. The compression link may fall if not properly supported when removed from the secondary boom assembly. 40 Remove the number 2 arm from the machine. Crushing hazard. The number 2 arm could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane. 41 Remove the upper and lower hose and cable covers from the number 3 arm. 42 Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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43 Open the ground controls side turntable cover. 44 Remove the fuel tank filler cap. 45 Using an approved hand-operated pump, drain the fuel tank into a container of suitable capacity. Refer to Section 2, Specifications. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or contrainer. Be sure to only use a handoperated pump suitable for use with gasoline and diesel fuel. 46 Tag, disconnect and plug the fuel hoses from the fuel tank. Clean up any fuel that may have spilled. 47 Remove the fuel tank mounting fasteners. Carefully remove the fuel tank from the machine. Component damage hazard. The fuel tank is plastic and may become damaged if allowed to fall. Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine.

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SECONDARY BOOM COMPONENTS

48 Remove the retaining fastener from the ground control box and function manifold pivot plate. 49 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin. 50 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support. Do not lift it. 51 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser. 52 Remove the pin retaining fasteners from the number 3 arm at the turntable riser. Do not remove the pin.

57 Remove the pin retaining fasteners from the number 4 arm at the turntable riser. Do not remove the pin. 58 Attach a lifting strap from the overhead crane to the center point of the number 4 arm. Do not lift it. 59 Use a slide hammer to remove the number 4 arm from the turntable riser through the ground controls side bulkhead. 60 Remove the number 4 arm from the machine. Crushing hazard. The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

53 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box. 54 Remove the number 3 arm from the machine. Crushing hazard. The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 55 Remove the upper and lower hose and cable covers from the number 3 arm. 56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid-pivot end. Do not disconnect the wiring.

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SECONDARY BOOM COMPONENTS

5-2 Secondary Boom Lift Cylinders There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly. These cylinders operate in parallel and require hydraulic pressure to extend and retract. Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

How to Remove a Secondary Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Lower the secondary boom to the stowed position. 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod-end pivot pin.

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3 Tag, disconnect and plug the hydraulic hoses on the secondary boom lift 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. 4 Remove the pin retaining fasteners from the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do not remove the pins. 5 Attach a strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder for support. Do not apply any lifting pressure. 6 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 7 Use a soft metal drift to drive the rod-end pivot pin half way out. 8 Remove the secondary boom lift cylinder from the machine. Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder.

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Section 4 • Repair Procedures

Kubota Z482-E and Z482-E2B Engine 4 Pull the generator away from the machine and remove the belts from the generator pulley.

6-1 Timing Adjustment Complete information to perform this procedure is available in the Kubota Z482-E Workshop Manual (Kubota part number 97897-01165). Kubota Z482-E Workshop Manual Genie part number

52956

5 Remove the 3 bolts that attach the engine drive pulley to the shaft bushing. 6 Install the same 3 bolts that were removed in step 5 into the threaded holes of the engine drive pulley. 7 Carefully tighten each bolt evenly until the engine drive pulley slides off the shaft. Component damage hazard. The engine drive pulley and/or shaft can be damaged if the bolts are not tightened evenly.

6-2 RPM Adjustment See the scheduled maintenance procedure B-8, Check and Adjust the Engine RPM.

8 Loosen the set screw on the pulley bushing, then slide the pulley bushing off of the engine shaft. a

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6-3 Engine Drive Pulley How to Remove the Engine Drive Pulley 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine to access the engine drive pulley. 3 Loosen the tension adjustment bolt on the generator.

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gap shaft set screw engine drive pulley engine drive pulley bolt shaft bushing woodruff key

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REV B

KUBOTA Z482-E ENGINE

How to Install the Engine Drive Pulley

3 Tighten the set screw on the pulley bushing hand tight. 4 Slide the engine pulley onto the pulley bushing.

The generator pulley must already be installed before performing this procedure. See 7-1, How to Install the Generator Pulley.

5 Install the pulley mounting bolts and tighten them to specification. Refer to Section 2, Specifications. Component damage hazard. Do not overtighten the pulley mounting bolts. There must be a gap visible between the engine drive pulley and the pulley bushing.

1 Align the woodruff key on the engine shaft with the slot in the pulley bushing and slide the pulley bushing onto the engine shaft. Do not tighten the set screw. 2 Align the flywheel side of the pulley bushing on the engine shaft with the outer face of the generator pulley using a straightedge. a

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pulley shaft pulley bushing engine flywheel straightedge generator pulley generator

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gap shaft set screw engine drive pulley pulley mounting bolt pulley bushing woodruff key

6 Check the alignment between the engine drive pulley and the generator pulley using a straightedge. Refer to Section 2, Specifications. If the pulley alignment is not within specification, remove the engine pulley and repeat steps 2 through 6. See How to Remove the Engine Drive Pulley.

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Generator

REV B

7-1 Generator Pulley

How to Install the Generator Pulley

How to Remove the Generator Pulley 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator pulley. 3 Loosen the tension adjustment bolt on the generator. 4 Pull the generator away from the machine and remove the belts from the generator pulley.

The pulley on the generator must be installed before installing the engine drive pulley. 1 Align the woodruff key on the generator shaft with the slot in the pulley and slide the pulley all the way onto the generator shaft. 2 Install the flat washer and pulley retaining nut onto the generator shaft, then torque the nut to specification. Refer to Section 2, Specifications. 3 Adjust the tension of the generator belts. See 7-2, How to Adjust the Generator Belts.

5 Disconnect the battery cables from the engine battery. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 6 Remove the engine battery hold down, then remove the battery from the machine. 7 Remove the generator pulley retaining nut from the generator shaft. 8 Slide the pulley off of the generator shaft.

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GENERATOR

7-2 Generator Belts

7-3 Generator Voltage Regulator

How to Adjust the Generator Belts

How to Adjust the Generator Voltage Regulator

1 Disconnect the battery packs.

The voltage regulator regulates the output voltage of the generator. A properly adjusted voltage regulator is essential to good generator performance and service life. A defective or improperly adjusted voltage regulator could result in component damage.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Remove the engine pivot plate latch retainer. 3 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator belts.

Be sure the batteries are fully charged before performing this procedure. 1 Remove the engine pivot plate latch retainer. 2 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator.

4 Loosen the tension adjustment bolt on the generator. 5 Push the generator towards the machine and tighten the adjustment bolt.

3 Connect the positive lead of a voltmeter to the POS terminal on the generator and the negative lead of the voltmeter to the NEG terminal on the generator.

6 Check the generator belts for proper tension. Refer to Section 2, Specifications. If the belt deflection is not within specification, perform steps 4 and 5 and re-check the belt tension.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

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engine pulley generator belts generator pulley

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GENERATOR

4 Start the engine from the ground controls and move the rpm select toggle switch to the maintained high idle position. Check the voltage on the generator. Result: The voltage should be 54V DC. 5 If the voltage reading is not 54V DC, insert a small flat blade screwdriver into the potentiometer located inside of the generator. Use the access hole on the back of the generator labeled VOLT ADJ. Component damage hazard. Be sure that the screwdriver is properly inserted into the potentiometer or the generator and/or voltage regulator may become damaged. 6 Carefully adjust the potentiometer to obtain a 54V DC voltage reading. Turn the potentiometer clockwise to increase the voltage or counterclockwise to decrease the voltage. Do not rotate the potentiometer past the internal stops. Component damage hazard. The voltage regulator inside the generator will become damaged if the potentiometer is rotated past the internal stops.

How to Replace the Voltage Regulator 1 Disconnect the battery packs from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Remove the engine pivot plate latch retainer. 3 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator. 4 Tag and disconnect the positive and negative battery cables from the generator. 5 Loosen the tension adjustment bolt on the generator. 6 Pull the generator away from the machine and remove the belts from the generator pulley. 7 Remove the generator mounting fasteners then remove the generator from the machine. 8 Remove the 3 nuts from the battery cable terminal posts. 9 Remove the 3 screws that hold the plastic cover onto the generator. Carefully remove the cover.

The maximum range of motion of the potentiometer on the voltage regulator is 280° and the maximum allowed torque is 5 oz-in / 0.035 Nm.

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GENERATOR

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12 Locate the red wire that leads from the voltage regulator to the positive rectifier assembly.

10 Locate the 3 white wires that lead from the voltage regulator to the negative rectifier assembly.

13 Remove the screw that attaches the red wire to the positive recitfier assembly.

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14 Remove the #4 nut that attaches the black wire to the voltage regulator.

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15 Remove the voltage regulator mounting screws. 16 Remove the voltage regulator while carefully guiding the red and black wires from underneath the bottom support of the positive and negative rectifier assembly.

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17 Install the new voltage regulator by following the previous steps in reverse order.

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18 Apply Loctite® removable thread sealant onto the voltage regulator mounting fasteners and torque to specification. Refer to Section 2, Specifications.

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white wires (#10 nuts) negative rectifier assembly black wire (#10 screw) black wire (#4 nut) voltage regulator mounting fastener (#8 screw) voltage regulator red wire (#10 screw) positive rectifier assembly

11 Remove the nuts on those 3 wires from the negative rectifier assembly, then remove the wires. Do not remove the spacers from the underneath the wires on the negative rectifier assembly.

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19 Torque all other fasteners to specification. Refer to Section 2, Specifications. 20 Install the plastic cover onto the generator then install the generator onto the machine. 21 Adjust the generator belts. See 7-2, How to Adjust the Generator Belts. 22 Adjust the voltage regulator. See How to Adjust the Voltage Regulator. Component damage hazard. The voltage regulator and/or generator may become damaged if the voltage regulator is not properly adjusted after replacement.

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Hydraulic Pumps

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8-1 Auxiliary Pump

2 Remove the engine pivot plate latch retainer.

How to Remove the Auxiliary Pump

4 Tag, disconnect and plug the hydraulic hoses from the auxiliary pump.

3 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine.

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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves.

open

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. 5 Remove the auxiliary pump mounting bolts. Carefully remove the pump.

closed

Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Models without hydraulic tank shut-off valves: Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

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HYDRAULIC PUMPS

8-2 Function Pump

4 Remove the engine pivot plate latch retainer.

How to Remove the Function Pump

6 Tag, disconnect and plug the hydraulic hoses from the pump.

5 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine.

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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves.

open

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. 7 Remove the function pump mounting bolts. Carefully remove the pump.

closed

Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Models without hydraulic tank shut-off valves: Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

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Manifolds

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9-1 Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index No.

Description

Schematic Item

1

Solenoid valve, 2 position 3 way ....... A ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm

Function

Torque

2

Solenoid valve, 3 position 4 way ....... B ........... Primary boom up/down ................................ 25 ft-lbs / 34 Nm

3

Solenoid valve, 3 position 4 way ....... C ........... Secondary boom up/down ........................... 25 ft-lbs / 34 Nm

4

Solenoid valve, 3 position 4 way ....... D ........... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm

5

Solenoid valve, 3 position 4 way ....... E ........... Platform rotate left/right and jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm

6

Solenoid valve, 3 position 4 way ....... F ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm

7

Shuttle valve ...................................... G ........... Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm

8

Solenoid valve, 3 position 4 way ....... H ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm

9

Proportional solenoid valve ............... I ............ Controls flow to functions ............................. 27 ft-lbs / 37 Nm

10

Pressure switch ................................. J ............ Brake circuit

11

Solenoid valve, 2 position 3 way ....... K ........... Primary boom extend ................................... 20 ft-lbs / 27 Nm

12

Flow regulator valve, 0.4 gpm / 1.5 L/min ............................ L ........... Platform rotate and turntable rotate circuits ................................................ 20 ft-lbs / 27 Nm

13

Needle valve ...................................... M .......... Platform level circuit ..................................... 20 ft-lbs / 27 Nm

14

Relief valve, 2500 psi / 172 bar ......... N ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm

15

Relief valve, 3200 psi / 220.6 bar ...... O ........... System relief ................................................ 20 ft-lbs / 27 Nm

16

Check valve, 5 psi / 0.3 bar ............... P ........... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm

17

Orifice, 0.060 inch / 1.5 mm ............... Q ........... Steer circuit

18

Orifice, 0.030 inch / 0.76 mm ............. R ........... Proportional valve circuit

19

Solenoid valve, 2 position 3 way ....... S ........... Brake circuit ................................................. 20 ft-lbs / 27 Nm

—

Orifice, 0.030 inch / 0.76 mm (from serial number 22566 to 22628 and after serial number 23235) (located under item S) ....................... T ........... Brake circuit

20

Orifice, 0.037 inch / 0.94 mm ............ U

21

Check valve, pilot operated ............... V ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm

22

Relief valve, 2100 psi / 145 bar ......... W .......... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm

4 - 36

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Part No. 110188

February 2006

Section 4 • Repair Procedures

REV A

MANIFOLDS

1

2

3

4

5

6

7

8

9 22 10 21

20

19 18

17

16

11

15

Part No. 110188

14

13

12

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Section 4 • Repair Procedures

February 2006

MANIFOLDS

REV A

9-2 Valve Adjustments Function Manifold

How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position.

How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. 2 Move and hold the function enable toggle switch to either side and hold the primary boom extend/retract toggle switch in the retract direction with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 3 Turn the machine off. Hold the system relief valve with a wrench and remove the cap (item O). 4 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold. 2 Move and hold the function enable toggle switch to either side and hold the secondary boom up/down toggle switch in the down direction with the secondary boom fully lowered. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 3 Turn the machine off. Hold the secondary boom down relief valve with a wrench and remove the cap (item W). 4 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 5 Repeat steps 2 through 4 and recheck relief valve pressure.

5 Repeat steps 2 through 4 and recheck relief valve pressure.

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Part No. 110188

February 2006

Section 4 • Repair Procedures

REV A

MANIFOLDS

9-3 Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to platform support. Index No.

Description

Schematic Item Function

1

Solenoid valve, 2 position 3 way ...... AA ........ Jib boom / platform rotate select .................. 20 ft-lbs / 27 Nm

Torque

1

Part No. 110188

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Section 4 • Repair Procedures

February 2006

REV A

MANIFOLDS

9-4 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No.

Description

Schematic Item Function

1

Shuttle valve 2 position 3 way ............ X ......... Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm

2

Counterbalance valve ......................... Y ......... Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm

3

Counterbalance valve ......................... Z .......... Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm 1

4 - 40

2

Torque

3

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Part No. 110188

February 2006

Section 4 • Repair Procedures

REV A

MANIFOLDS

9-5 Valve Coils

How to Test a Coil Diode

How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Tag and disconnect the wiring from the coil to be tested.

Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Test the coil for resistance. See How to Test a Coil.

2 Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Valve Coil Resistance Specification Solenoid valve, 3 position 4 way, 20V DC (schematic items B, C, D, E, F and H)

25 to 29 Ω

Solenoid valve, 2 position 3 way, 20V DC (schematic items A, K, S and AA)

25 to 29 Ω

Proportional solenoid valve, 24V DC (schematic item I)

17 to 21 Ω

Part No. 110188

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Section 4 • Repair Procedures

February 2006

REV A

MANIFOLDS

2 Connect a 10Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. Ω Resistor, 10Ω Genie part number

27287

The battery should read 9V DC or more when measured across the terminals. COIL MULTI METER

d

a

+

c

10 W RESISTOR

4 Connect the negative lead to the other terminal on the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. 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 differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced.

b

9V BATTERY

+

c

a b c d

b

multimeter 9V DC battery 10Ω resistor coil

Note: Dotted lines in illustration indicate a reversed connection as specified in step 6

3 Set a multimeter to read DC current. The multimeter, when set to read DC current, should be capable of reading up to 800 mA.

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Part No. 110188

February 2006

REV B

Section 4 • Repair Procedures

Turntable Rotation Components

10-1 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly 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 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the secondary boom until the upper pivot is above the turntable covers. Turn the machine off. 2 Secure the turntable from rotating with the turntable rotation lock. Crushing hazard. The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position.

3 Remove the engine pivot plate latch retainer. 4 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation assembly. 5 Remove the retaining fasteners from the center turntable cover. Remove the cover from the machine. 6 Disconnect the battery backs from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 7 Place a suitable container under the engine plate. 8 Tag and disconnect the fuel hose from the fuel filter and drain the fuel tank into a suitable container. Refer to Section 2, Specifications. 9 Tag, disconnect and plug the fuel hoses from the fuel tank. 10 Remove the fuel tank strap fasteners and remove the tank strap. 11 Remove the fuel tank from the machine. 12 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor manifold. Cap the fittings on the manifold.

Unlocked position

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.

Locked position

Part No. 110188

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Section 4 • Repair Procedures

February 2006

TURNTABLE ROTATION COMPONENTS

REV B

13 Attach a lifting strap from and overhead crane or other suitable lifting device to the turntable rotation assembly. 14 Remove the turntable rotation assembly mounting fasteners. 15 Carefully remove the turntable rotation assembly from the machine. Crushing hazard. The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position. Crushing hazard. The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

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Part No. 110188

February 2006

Section 4 • Repair Procedures

Motor Controller

REV A

11-1 Motor Controller The drive motor controller is located under the nonsteer end drive chassis cover. The drive motor controller can recognize machine drive malfunctions and display controller fault codes by flashing a LED at the ground controls and on the motor controller. See the Troubleshooting section of this manual for a list of fault codes and additional information. There are no adjustments needed on the drive joystick controller. For further information or assistance, consult the Genie Industries Service Department.

How to Test the Motor Controller Use the following procedure to test the motor controller. If the motor controller is found to be faulty, note which test failed and which fault code (if any) was present at the time of failure.

4 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller. 5 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below and check for resistance. Result: All desired results must be 500 kilohms or more. If any test has a result less than 500 kilohms, replace the motor controller. Test

Desired result (in kilohms)

F1 to F2

500kΩ or more

F1 to B-

500kΩ or more

F1 to M-

500kΩ or more

F1 to B+

500kΩ or more

F2 to B-

500kΩ or more

1 Turn the key switch to the off position and disconnect the battery packs from the machine.

F2 to M-

500kΩ or more

2 Remove the chassis cover from the non-steer end of the machine.

F2 to B+

500kΩ or more

3 Tag and disconnect all power cables from the motor controller.

B- to M-

500kΩ or more

M- to B+

500kΩ or more

Pin 17 to B-

500kΩ or more

Pin 20 to B-

500kΩ or more

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Part No. 110188

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Section 4 • Repair Procedures

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Part No. 110188

February 2006

Section 5 • Fault Codes

Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Operator’s Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.

Observe and Obey: Troubleshooting and 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. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Boom in stowed position · Turntable rotated with the boom between the non-steer wheels · Key switch in the off position with the key removed · Wheels chocked · All external AC power supply disconnected from the machine

Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Electrocution hazard. Contact with electrically charged circuits may result in death or serious injury. Remove all rings, watches and other jewelry. 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. Perform all troubleshooting on a firm level surface.

Part No. 110188

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5-1

Section 5 • Fault Codes

February 2006

FAULT CODES

Tip-over hazard. When adjusting the raised drive speed settings, the maximum raised drive speed must not exceed specification. Refer to Section 2, Specifications. If the machine is allowed to drive faster than specification, the machine could become unstable and will tip over. Additional troubleshooting of the fault codes may by accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303-S).

The controller status indicator light will flash a fault code to aid in troubleshooting. This indicator light is mounted on the left side of the ground control box. Fault codes are two digits. The controller status indicator light will blink the first digit of a two digit code, pause for 1 second, and then blink the second digit. There will be a 2 second pause between codes. For example: the indicator light blinks 4 consecutive times, pauses for 1 second, and then blinks 1 time. That would indicate Fault Code 41.

When using the hand-held pendant motor controller programmer, the M1 MAX SPEED needs to be set to 33. If needed, adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed. Refer to Section 2, Specifications.

5-2

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Part No. 110188

February 2006

Section 5 • Fault Codes

Fault Code Chart

REV A

Fault Code

Controller status indicator light is OFF or is ON but not blinking

01 12 13

Programmer Diagnostic Display

COMMUNICATION ERROR

Condition

Possible Causes

Solution

The key switch or red Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Push in the ground control red Emergency Stop button to the OFF position and wait for 5 seconds. Pull out the ground control red Emergency Stop button out to the ON position. If problem persists, replace the motor controller.

Machine will not drive.

The motor controller failed self test.

Replace the motor controller.

Machine will not drive.

The motor controller has a internal short between M- and Bterminals.

Test the motor controller, see the Repair Section.

Motor wiring is loose OR motor is defective OR motor controller has an internal short.

Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See the Repair Section.

Defective motor controller. Defective motor controller.

Replace the motor controller. Replace the motor controller.

Machine will not drive.

Normal operation. HW FAILSAFE 1-2-3

M- SHORTED

FIELD OPEN

Machine will not drive.

ARM SENSOR

Machine will not drive.

FLD SENSOR

Machine will not drive.

Continued on next page

Part No. 110188

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5-3

Section 5 • Fault Codes

February 2006

FAULT CODE CHART

Fault Code

21

REV A

Code Scanner Display

THROTTLE FAULT 1

THROTTLE FAULT 2

31

32

33

5-4

CONT DRVR OC

MAIN CONT WELDED

PRECHARGE FAULT

Condition

Possible Causes

Solution

Machine will not drive.

Open in wht/red wire #32 at pin 14 or red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick defective.

Consult Genie Industries Service Department.

Machine will not drive.

Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective.

Consult Genie Industries Service Department.

Machine will not drive.

Main contactor (PR1) coil defective OR brake release relay CR5 defective.

Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller.

Machine will not drive.

Main contactor (PR1) contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has a internal short to ground.

Consult Genie Industries Service Department.

External short between B+ terminal on motor controller and ground OR motor controller is defective.

Repair short between B+ terminal on motor controller and ground OR replace motor controller. Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller.

Machine will not drive.

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Part No. 110188

February 2006

Section 5 • Fault Codes

REV A

FAULT CODE CHART

Fault Code

34

Code Scanner Display MISSING CONTACTOR

MAIN CONT DNC

41

42

43

Part No. 110188

LOW BATTERY VOLTAGE

OVERVOLTAGE

THERMAL CUTBACK

Condition

Possible Causes

Machine will not drive.

Motor controller does not detect the main contactor PR1 or brake release relay CR5.

Consult Genie Industries Service Department.

Machine will not drive.

Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective.

Consult Genie Industries Service Department.

Machine will not drive.

Battery supply voltage to motor controller less than 32V DC.

Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller.

Machine will not drive.

Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in.

Be sure the battery charger is disconnected OR check for loose battery cables or poor connections

Machine will not drive.

Machine being operated outside of temperature range of -13°F to 185°F / -25°C to 85°C OR machine being driven under excessive load OR motor controller is not being cooled sufficently.

Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine.

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Solution

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Section 5 • Fault Codes

February 2006

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Part No. 110188

February 2006

Section 6 • Schematics

Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics

Observe and Obey:

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Troubleshooting and 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.

Hydraulic Schematics 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.

Repair any machine damage or malfunction before operating the machine.

Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Operator's Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.

General Repair Process

Identify symptoms

Malfunction discovered

Troubleshoot

problem still exists

Return to service

Part No. 110188

problem solved

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Inspect and test

Perform repair

6-1

Section 6 • Schematics

February 2006

Electrical Symbols Legend REV A

TB17

15AMP.

TS6 RIGHT

LEFT

GRN/BLK

ORG/BLK-1

Circuit breaker

Toggle switch DPDT

Wire color with cable number

GRN

WHT

TB20

RED

Ground supression circuit BP1

Terminal

Boom function speed controller

Horn

NC

NO

LS3

TP29

Quick disconnect terminal

Limit switch

L1 FB

Light BLK #21

BLK/RED

Solenoid or relay coil

LS1 NO

TB21

Limit switch normally open held closed

T-circuits connect at terminal

PLAT KS1

T-circuits connect

Connection no terminal

Tilt sensor

GRND

Key switch

LS2 NC

Limit switch normally closed held open

HORN

P4

Horn button normally open

Circuits crossing no connection P1

Diode

PR4

Red Emergency Stop button normally closed

Relay panel contactor

+

TS3

Relay contact normally open

PLAT. UP PLAT. DWN

-

6-2

CR4

Battery

Toggle switch SPDT

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

February 2006

Section 6 • Schematics

Hydraulic Symbols Legend REV A

0.035”

Orifice with size Pressure gauge Differential sensing valve

3 position 4 way directional solenoid valve

Variable orifice or shut-off valve

Solenoid operated proportional valve (before serial number 22566)

Filter

Shuttle valve

Check valve

Check valve, pilot operated

Fixed displacement pump

Relief valve Solenoid operated proportional valve (after serial number 22565)

Spring applied, hydraulically released brake Priority flow regulator

N.O. COM N.C.

Bi-directional motor

M

Pressure switch

2 position 2 way solenoid valve

Pump prime mover (motor) Solenoid operated 2 pos., 3 way, directional valve Cylinder Counterbalance valve

Part No. 110188

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Section 6 • Schematics

6-4

February 2006

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Part No. 110188

Section 6 • Schematics

February 2006

Power Cable Diagram

Section 6 • Schematics

February 2006 REV A

Power Cable Diagram A

B

C

D

TO ENGINE PANEL

1

E

F

G

H

I

TO GROUND CONTROL BOX CONNECTOR C6B

J

K

L

RIGHT SIDE BATTERY PACK

RD-2GA -

48V DC ALTERNATOR

-

A1

POS

RD-2GA

+

AUXILIARY LIFT PUMP

-

BK-2GA BK-2GA

+

3

RD-2GA

GR/BK-BATT ISM-9 WH-BATT R12

NEG

PRIMARY LIFT PUMP

D1

-

FUNCTION HARNESS

+

D1

A2

+

+

AC BATTERY CHARGER

-

_

RD-2GA RD-20-12GA

+

+

-

-

WH-FROM CHARGER

+

WH-BATT WH-BATT

P42BAT OR/RD BK-2GA BK-2GA

BK WH

BK-2GA BK-2GA

DIODE

GR/WH-19

PR-2

PR-1

R42BAT OR/RD R42BAT OR/RD BRN-J8 R27AUX RD BK

BK

BRN-J8 RD BK

2

+

7

RD-2GA RD-10GA

RD-2GA RD-20-12GA

24V DC

C32JSL WH/RD

F1

C12DRE BL/WH

R42BAT OR/RD

C40LS OR

CFIL BK

C30FWD WH

R42BAT OR/RD

OR/RD BRN-J8

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

A1

OR/RD RD-2GA

A2

GR

CR5 RD/BK

RD-10GA RD-2GA F2

C29JSH RD/WH

F2 200A

F1 200A

BK-2GA BK-2GA BK-FROM CHARGER BK-2GA BRN-J8 BK-2GA

33

AC CHARGER PLUG

PR-3

BK

48V DC

8

+

6

R42BAT OR/RD

RD-2GA RD-10GA

6

DIODE

CONTROLLER

PR-1

LIFT CONTACTOR

BRN-J8

F4 500A

P42BAT OR/RD BK-2GA BK-2GA BK-FROM CHARGER BK-2GA

RD-2GA

5

LEFT SIDE DRIVE MOTOR

-

5

9

DIODE

33

F1

-

4

AMMETER

AP-2

7

3

AP-1

BATTERY

-

-

+

AUXILIARY POWER UNIT CONTACTOR

8

-

TOP VIEW OF DRIVE CONTACTOR

DRIVE CONTACTOR

1

+

BK-2GA RD-2GA

+

F5 10A

RD-2GA

4

N

AC POWER CABLE DC AMMETER CABLE

LEFT SIDE BATTERY PACK

2

M

F2 A2

RIGHT SIDE DRIVE MOTOR

RD-10GA F2

F1

RD-10GA

BK-2GA BK-2GA RD-2GA B-

CHASSIS GROUND

6-5

M-

MOTOR CONTROLLER

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Part No. 110188

B+

NOTES: 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.

February 2006

Section 6 • Schematics

REV A

Engine Panel Diagram

N

M

L

K

J

I

H

G

F

E

D

C

NOTE: RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.

B

RD-CB

A CIRCUT BREAKER CB3

RD-CB (12V+)

BRN-J4 WH-J6

WH-J4

87

87a

86

85

BRN-J4

BRN-J4 BK/RD

86

85

87a

85

86

BRN-J4

BRN-J4

BRN-J4

87

87

87a

BRN-J4 BK/RD

87

87a

86

85

87

87a

86

85

87a

GND BRN

86

1 3 4 7 10 9 2

87 85

WH-J5 BRN-J4 WH-J4

BRN-J4

RD-CB

BRN-VOLT

KEYSWITCH PWR. 7

ENGINE FAULT

24V BATTERY + 6

10

GROUND 5

(NOT USED)

(NOT USED) 4

IGN./FUEL ON

START INPUT 3

9

TACH. INPUT 2

C33STR BK

3

4 GR/BK-BATT

BL-ISM2

P20BAT RD

BK-ISM1

BL-ISM2

BRN-J5 BRN-ISM5

BK-ISM1

START RELAY BK-ISM-1

WH-BATT

WH-R14

C33STR BK

WH-BATT

BL-ISM2

RD-J6

1

C34SA BK/WH

WH-J6

C23PWR WH

CR15 GLOW PLUG RELAY

CR14 RPM RELAY

CR13 RPM CUTOUT RELAY

8

30

RD-CB (12V+)

WH-J4 WH-J6 RD-J6

30

RD-J10

BK-START BK-ISM-1 WH-R11

30

BK/WH-34

CR12 ENGINE POWER RELAY WH-J4

CR11 START RELAY

OR-GEN NEG BRN-VOLT

5

BRN-J5 BRN-ISM5

WH-R14

BRN-VOLT BRN-ISM5 BL-E.H. BL-ISM2 RD-J10

BL-E.H.

WH-BATT

BRN-ISM5

P20BAT RD C23PWR WH

6

ENGINE HARNESS (TO DRIVE CHASSIS)

GR/BK-BATT

ENGINE HARNESS (TO ENGINE)

WH-ISM10

C5B-22 C34SA BK/WH

C5B-18 C35HRPM BK/RD

C5B-5 C33STR BK

C5B-11 C21IGN2 WH

C5B-3 C23PWR WH

12V DC VOLTAGE REGULATOR

C5B-2 GND BRN

7 C5B-1 P20BAT RD

YEL

GR

RD

BL

BK

ENGINE HARNESS (TO GROUND CONTROL BOX) BL

WH-BATT

OR-GEN POS

CR16 FIELD RELAY

30

BK/RD-35

30

WH-R14

30

2

WH-ISM10

BRN-J4

C21IGN2 WH C35HRPM BK/RD

RD-CB

WH-J5

12V, 15A

IGNITION/START MODULE 12/24V DC

C21IGN2 WH C35HRPM BK/RD

1

8

C5B MALE DEUTSCH CONNECTOR

Part No. 110188

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

6-6

February 2006

Section 6 • Schematics

Engine Panel Diagram

Section 6 • Schematics

February 2006 REV A

Electrical Schematic, Z-45/25, ANSI and CSA Models A

B

C

D

E

F

G

H

I

J

K

L

M

N

1

C29JSH RD/WH C32JSL WH/RD C30FWD WH C31REV WH/BK C40LS OR

BK

2

C132 PLI BL/WH C1B-12

TS2 ENGINE START

LOW RPM

HIGH RPM

FOOTSWITCH HIGH RPM

TS4 RPM

L48 C1P-8

C1P-7

C1P-9

R42BAT OR/RD

C34SA BK/WH

C33STR BK

C35HRPM BK/RD

C2B-4

C1B-8

C1B-7

C1B-9

D40

C7B-2

GR/BK

TS6 GLOW PLUGS

C2P-4

8

P24BAT WH

C3B-3

12

7

P24BAT WH

P23BAT WH

5

C9P-2

C3BAT RD/WH

C1B-2

6

WH-(FS)

C7P-2

C2B-5

5 C32

P25BAT RD

C3P-3

C28TTA RD/BK

C6B-29

C134PWR GR

C2B-2

C6B-32

C2P-5

C1B-3

C6B-31

C1P-2

C40LS OR

C1B-6

C6B-30

C3B-9

C29JSH RD/WH

C1B-5

C9HRN BK/RD

C3P-9

4

6

C7B-2

C32JSL WH/RD

C1B-4

OR

3

P23BAT WH

C2P-2

C1P-3

C1P-6

C31REV WH/BK

C7B-4

C30FWD WH

P20BAT RD

4

C1P-5

C1P-4

3

1

C7B-1

TB22 GROUND

C9P-3

7 A1 TILT ALARM

+ P3 HORN

PLATFORM

KS1

P1

P20BAT RD

LS18

RD-(FS)

R42BAT OR/RD

RD

C1P-12 RD

CB1 10 A

BK-(FS)

C9P-1 BK P26BAT RD

P22BAT

TB134

FS1

P2

C7P-1

RD

OR

TB40

CR5 C12DRE BL/WH

P42BAT OR/RD C6B-3

P42BAT OR/RD C6B-22

+

-

+ +

3

START INPUT

4

(NOT USED)

5

GROUND

6

BATTERY

7

KEY SWITCH POWER

8

(NOT USED)

86

IGNITION ON

10

ENGINE FAULT

CR16 86

86

87

BRN

BRN

BRN

GR/BK BATT

BK

-

WH-BATT

WH AP2 AUXILIARY

(12V DC) C5B-2

BRN

A2

9

85

CR14

BRN

86

85

87 85

CR15 BK/RD

ALT. BL

WH

CR13

BRN

87

BL

VR1

85

BK/WH

YEL

(12V DC)

30

30

30 RD

+12V DC

WH-J4

BRN

-

87

86

WH

-

CR12

BRN

+

TACH. INPUT

BK

+

C5B-1 P20BAT RD

C34SA BK/WH

30

85

STARTER

OR-GEN POS

ENGINE GROUND

(GND) BK

PR2

PR2

PR3

PR3 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

Part No. 110188

ENGINE RUN SOLENOID

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

STARTER RELAY CR11

ANSI/CSA

48V DC POWER RELAY CR2

ADD D40 ONLY IF UNIT HAS L4 AND L48.

7

48V DC POWER RELAY CR1

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

FLASHING BEACON OPTION

6

TILT SENSOR

SWITCH SHOWN WITH BOOM EXTENDED.

NOTES:

HOUR METER

HORN RELAY

HORN

BASE CONTROL BOX GROUND

CHASSIS GROUND

BRAKE RELEASE RELAY CR5

MOTOR MAIN CONTACTOR RELAY PR1

48V DC CHARGER

48V DC ALTERNATOR

PRIMARY LIFT PUMP

2

6-7

2

BK

AUXILIARY LIFT PUMP

8

START RELAY

BL-ISM2

C5B-18 C35HRPM

C5B-22

CR11

BK

C8-C WH

RD

+

87

86

87

AP1

ENGINE START

GLOW PLUGS

BRN

RD/WH

RD

RD/BK

30 CR16

14

85

C8-B

AC POWER

22

30

(12V DC)

2

1

C5B-3 C23PWR WH

+

13 LS1 (EXT)

RD-J10 (12GA)

FB

BRN

BK

OR-GEN NEG

GROUND

C5B-11 C21IGN2 WH

IGNITION / START MODULE

BK-ISM1 C5B-5 C33STR BK

85

87

HIGH

TB35

87

BRN

C6B-34

86

C6B-9 BK/RD

-

-

WH-6

CHARGER

C11-2

LS2 21 (PRI)

BK-6

F1

RIGHT MOTOR

C11-1

F2

BK-7

A1

WH-7

A2

A1

BK 2 GA

7

ALTERNATOR

A2

C11-4

PUMP

+

F1

C11-3

-

WH

+

PUMP

LEFT MOTOR

F2

85

LOW

TB33

TB34

30

CR1

15 A

PR2

+

87

+

C8-A

B-

F2

RD-5

B+

HM

CR4

-

+

RIGHT BOX

M-

F1

86

C6B-28

WH-5

BK-5

30

BK

85

CB3

MOTOR CONTROLLER

PR3

RD/BK

BK

C10-2

C10-1

WH-4

BK-4

+24V DC

F1 200A

30

TS54 RPM

TS52

C23PWR WH

_

BK-5

AP1

D2

21 LS4 (SEC) 22

5

20

17

6

86

TS56

TB23

U6A 24V DC

CR2

OR/RD

BK/RD

C6B-20 RD

BK

C10-4

C6B-25 CFIL BK

C6B-39 CR5 RD/BK

GR

3

16

2

11

14

10

1

9

AP2

C10-3

CONTROLLER FAULT INDICATOR LED L2

85

CR5

COIL-PR1

POT. HI

INTERLOCK

OFF-LMT SPD INP

BL/WH

POT. LOW

FORWARD

REVERSE

+48V INPUT

-

+

DIODE RETURN

RD 20

F2 200A

C6B-40 OR

OR/RD

OR/RD 86

-

+

5

RD

TB42

OR/RD

C6B-24

C6B-12

RD/WH

WH/RD

PR1

+48V DC

LEFT BOX

WH/BK

F4 500A

48V DC

WH

AP2

OR/RD

F5 10A

Electrical Schematic, Z-45/25, ANSI and CSA Models REV A

C29JSH RD/WH C32JSL WH/RD

P24BAT WH P24BAT WH

C13DREL BL/RD

C4B-4

C3B-12

C4B-1 BL/WH

BL/RD

R41DRE OR/BK C2P-3

C1B-10

C2B-3

C7P-3 BATGND BRN C6B-13 C13DREL

C6B-26 C12DRE C6B-16 C16DRE

C6B-35 RD/WH

PS1

OR/RD

RD

BK-8

RD/WH

RD/WH

WH-8

3 C6B-4 WH

C6B-5 WH/BK

C6B-11 BL/BK

C6B-10 BL

C6B-2 RD/BK

C6B-1 RD

C6B-8 BK/WH

C6B-7 BK

C6B-15 OR/BK

C6B-14 OR

C6B-17 GR

C6B-18 GR/BK

C6B-6 WH/RD

GR/WH

C6B-27 RD

C6B-37 BL/BK

C6B-36 BL

21 14

BRN C4P-1

C12DRE BL/WH

C36STCC BL C1P-10 C1B-11

OR/RD

C16DRE OR/RD

C37STC BL/BK C1P-11

C1B-1

BRN

C27AUX RD

C4B-6 GR/BK

LEFT

RIGHT

C3B-6 WH/RD

C4B-7 GR/WH

RD

5 C4B-5 GR

UP

DOWN

EXTEND

RETRACT

UP

DOWN

UP

33

BRN-8

RD-8

C7B-3 BATGND BRN C6B-21 DREGND BRN

C26-2

C24-2

C25-2

C19-1

C18-1

C13-1

C12-1

C17-1

C16-1

C21-1

C20-1

C22-1

C23-1

C19-2

C18-2

C13-2

C12-2

C18-2

C16-2

C21-2

C20-2

C22-2

C23-2

C6B-19 GR/WH

C25-1

C24-1

C26-1

+

DRIVE ENABLE LIMIT SWITCH LS3

22 13

6 TB36 CR3

C4P-4

C1P-1

C19LPMP GR/WH

C6LFC WH/RD

C18PRR GR/BK C17PRL GR

C4B-2 C4B-3

C3B-7 C3B-8

C3B-1

TB27

C3P-12

CR5 CR5 C12DRE BL/WH

C15-1

C14-1

C15-2

C14-2

TURNTABLE ROTATE LEFT 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 LEFT

PLATFORM ROTATE RIGHT

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

BRAKE RELEASE N.C. COIL

BRAKE RELEASE TRAVEL ALARM (A2)

8 BK BK PR2

RD

AUXILIARY PUMP

C4P-7

C3P-6

C4P-5

C4P-6

C14PLU OR C15PLD OR/BK

C7PBE BK C8PBR BK/WH

C1PBU RD C3B-2

DOWN

RIGHT

LEFT

PR2

6-8 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

RD-AUX

OR/RD

C4P-2 C4P-3

C3P-7 C3P-8

C3P-1 C2PBD RD/BK

C3B-10 C3B-11

C3B-5 C3B-4

CR5 RD

7 87

CR20 85

30

PR3 86

OR OR/RD OR/BK

WH

RIGHT

LEFT

UP

DOWN

EXTEND

RETRACT

UP C3P-2

C10SBU BL

C4TRL WH

C4TRR WH/BK

C11SBD BL/BK

C3P-10 C3P-11

C3P-5

PR3

BCI OPTION

A2

33 A3

F

C6B-38 GR/WH GR/WH GR/WH

3 87

C3P-4

+

DOWN

UP

DOWN

TS51 RD

85 87 87a

86 30

TB6 TB17 TB14 TB15 TB7 TB8 TB1 TB2 TB10 TB11 TB5

+

9

85

RIGHT

LEFT

TB19

TB12 OR/RD P42BAT OR/RD

BCI E

TB37 TB18 TB4

TS57 TS59 TS63 TS61 TS60 TS62

87

PLATFORM ROTATE PLATFORM LEVEL PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM TURNTABLE ROTATE

SET TO "N"

85

RD

8 DRIVE

10 L R STEER BP1

BK/RD

86

CR6 RD/BK-R6 TS15 DRIVE 30 ENABLE 7

SET TO "B" 85 BRN 87

BRN ROTARY OEM FLOW CONTROL

DRIVE ENABLE LED L1 LIFT

6

L.V.I. 86 85

CR19A 30

CR19B 87

3 FWD

OR/BK-R6 5

TS1 1 2 3 4 5 6 7

DISCHARGE

86

CR8 2

BK

4

8

CR19B

20K

3 5 4

REV

86

RESET

CR19A 30

2 DP1 BCI

PLATFORM ROTATE

30 AUXILIARY POWER

FUNCTION ENABLE TS55

C40LS OR C40LS OR

4 RD

C31REV WH/BK C31REV WH/BK

CE VERSION: REMOVE JUMPER 30 AND ADD RELAY 87 1

TS7 PLATFORM LEVEL TS9 PRIMARY BOOM TS13 PRIMARY BOOM TS11 SECONDARY BOOM TS10 TURNTABLE ROTATE TS12

C30FWD WH

LVI/BCI OPTION C30FWD WH

1 C29JSH RD/WH C32JSL WH/RD

A B C D E F G H I J K L M N

Section 6 • Schematics February 2006

R42BAT OR/RD

(GND)

February 2006

Section 6 • Schematics

Electrical Schematic, Z-45/25, ANSI and CSA Models

Section 6 • Schematics

February 2006 REV A

Electrical Schematic, Z-45/25, CE Models A

B

C

D

E

F

G

H

I

J

K

L

M

N

1

C29JSH RD/WH C32JSL WH/RD C30FWD WH C31REV WH/BK C40LS OR C7P-1

BK

2

C132PLI BL/WH

C1B-12

A1 TILT ALARM

LOW RPM

HIGH RPM

FOOT SWITCH HIGH RPM

C2P-4

C1P-8

C1P-7

C1P-9

R42BAT OR/RD

C34SA BK/WH

C33STR BK

C35HRPM BK/RD

C3B-3

C2B-4

C1B-8

C1B-7

C1B-9

C7B-2

C3BAT RD/WH

P23BAT WH

C3P-3

C7P-2

C1B-2

C6B-29

C2B-5

C6B-32

C28TTA RD/BK

C1B-3

C6B-31

C134PWR GR

C1B-6

C6B-30

C2B-2

C1B-5

C7B-4

C1B-4

GR/BK

C2P-5

P20BAT RD

L45

D40

C1P-2

8

6

TS2 ENGINE START

TS4 RPM

C3B-9

7

P24BAT WH

TS6 GLOW PLUGS

C9HRN BK/RD

5

P24BAT WH

C3P-9

C40LS OR

C29JSH RD/WH

C32JSL WH/RD

C31REV WH/BK

C30FWD WH

6 12

C9P-2

C7B-2

5 U33

WH-(FS)

P23BAT WH

3

P25BAT RD

C7P-2

C7B-1

C2P-2

C1P-3

C1P-6

C1P-5

C1P-4

1 4

A6

OR

+

D39

GROUND

C9P-3

R42BAT OR/RD

L4 5

P3 HORN

TB22

3

4

LS18

PLATFORM

KS1

P1

P20BAT RD

RD-(FS)

RD

C1P-12 RD

CB1 10A

BK-(FS)

C9P-1 BK P26BAT RD

P22BAT

TB134

FS1

P2

RD

OR

TB40

CR5 C12DRE BL/WH

P42BAT OR/RD C6B-3

P42BAT OR/RD C6B-22

GROUND

6

BATTERY

7

KEY SWITCH POWER

8

(NOT USED)

9

IGNITION ON

10

ENGINE FAULT

CR16

GR/BK BATT

BRN

+12V DC

-

(NOT USED)

5

86

BRN

-

+

START INPUT

4

86

87

BRN

-

+

+

3

WH-BATT

WH AP2 AUXILIARY

C5B-2

ENGINE GROUND

(GND) BK

PR2

PR2

PR3

PR3 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

ENGINE RUN SOLENOID

Part No. 110188

STARTER RELAY CR11

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

48V DC POWER RELAY CR2

ADD D40 ONLY IF UNIT HAS L4 AND L48.

48V DC POWER RELAY CR1

6

FLASHING BEACON OPTION

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

CE & PLATFORM LOAD SENSE OPT.

TILT SENSOR

SWITCH SHOWN WITH BOOM EXTENDED.

5

HOUR METER

2 NOTES:

HORN RELAY

HORN

BASE CONTROL BOX GROUND

CHASSIS GROUND

BRAKE RELEASE RELAY CR5

MOTOR MAIN CONTACTOR RELAY PR1

48V DC CHARGER

48V DC ALTERNATOR

PRIMARY LIFT PUMP

6-9

TACH. INPUT

(12V DC) BRN

A2

OR-GEN POS

START RELAY

2

85

BK

AUXILIARY LIFT PUMP

8

86

CR14

BRN

BK

STARTER

85

87 85

CR15 BK/RD

ALT. BL

86

WH

IGNITION / START MODULE 1

CR13

BRN

87

BL

VR1

85

BK/WH

YEL

(12V)

30

30

30 RD

-

WH-J4

BRN

+

87

86

(12V DC)

WH

+

CR12

BRN

+

86

30

85

BK

14

CR11

+

2

C34SA BK/WH

WH

RD

LS1 (EXT)

85

BK

C8-C

87

13

C5B-1 P20BAT RD

C5B-22

30

87

AP1

ENGINE START

GLOW PLUGS

BRN

RD/WH

RD

RD/BK

30 CR16

C5B-18 C35HRPM C5B-3 C23PWR WH

15 A

C8-B

AC POWER

C5B-5 C33STR BK

FB

BRN

BK OR-GEN NEG

GROUND

22

BL-ISM2

85

87

C6B-9 BK/RD

-

-

WH-6

CHARGER

C11-2

LS2 21 (PRI)

BK-6

RIGHT MOTOR

C11-1

A1

BK-7

A1

F1

BK 2 GA

7

ALTERNATOR

F1

F2

WH-7

PUMP

F2

+

A2

BK-ISM1

C5B-11 C21IGN2 WH

C8-A

BK

C11-4

-

WH

+

PUMP

86

HIGH

TB35

CB3

C11-3

-

+

+

A2

LOW

87

RD-J10 (12GA)

PR2

LEFT MOTOR

85

TS54 RPM

TB33

TB34

30

_

RD-5

B-

87

+

CR4

F2

85

TS52

C23PWR WH HM

BK-5

B+

30

CR1

BRN

C6B-34

WH-5

BK-5

WH-4

BK-4

5

20

17

M-

F1 PR3

86

C6B-28

C10-2

C10-1

C10-4

C10-3

C6B-25 CFIL BK

C6B-39 CR5 RD/BK

GR

2

3

16

F1 200A

RD/BK

BK

D2

21 LS4 (SEC) 22

U6A MOTOR CONTROLLER

86

OR/RD

BK/RD

C6B-20 RD

C6B-40 OR

CONTROLLER FAULT INDICATOR LED L2

CR5

COIL-PR1

POT. HI

INTERLOCK

OFF-LMT SPD INP

BL/WH

11

14

10

AP1

85

BK

CR2

TS56

TB23

30

24V DC

+24V DC

POT. LOW

FORWARD

1

9

6

REVERSE

+48V DC INPUT

DIODE RETURN

RD 20

-

+

AP2

RIGHT BOX

OR/RD

-

+

LEFT BOX

OR/RD 86

F2 200 A

5

RD

TB42

OR/RD

PR1

+48V DC

C6B-24

C6B-12

RD/WH

WH/RD

WH/BK

WH

F4 500 A

48V DC

AP2

OR/RD

F5 10 A

C29JSH RD/WH C32JSL WH/RD

C40LS OR C40LS OR

P24BAT WH P24BAT WH

RD-AUX

OR/RD

RD

6 C6B-13 C13DREL

C7P-3 BATGND BRN

BL/RD

OR/RD

RD

BK-8

RD/WH

RD/WH

WH-8

3 C6B-4 WH

C6B-5 WH/BK

C6B-11 BL/BK

C6B-10 BL

C6B-2 RD/BK

C6B-1 RD

C6B-8 BK/WH

C6B-7 BK

C6B-15 OR/BK

C6B-14 OR

C6B-17 GR

C6B-18 GR/BK

C6B-6 WH/RD

GR/WH

C6B-27 RD

C6B-37 BL/BK

C6B-36 BL

21 14

BRN C4B-1

C13DREL BL/RD

C6B-26 C12DRE

C4P-1 BL/WH

C12DRE BL/WH C4B-4

PS1

C6B-35 RD/WH

C3B-12

C3P-12 C16DRE OR/RD

C2B-3

C6B-16 C16DRE

R41DRE OR/BK C2P-3

C1B-10

OR/RD

C36STCC BL C1P-10 C1B-11

RD

C4B-7 GR/WH

C3B-6 WH/RD

RIGHT

LEFT

C4B-6 GR/BK

33

BRN-8

RD-8

C7B-3 BATGND BRN

C15-1

C14-1

C25-2

C24-2

C26-2

C6B-21 DREGND BRN

C19-1

C18-1

C13-1

C12-1

C17-1

C16-1

C21-1

C20-1

C22-1

C23-1

C6B-19 GR/WH

C25-1

C24-1

C26-1

+

DRIVE ENABLE LIMIT SWITCH LS3

22 13

5 C4B-5 GR

UP

DOWN

UP

DOWN

UP

RETRACT

EXTEND

TB27

BRN

C4P-4

C37STC BL/BK C1P-11

C19LPMP GR/WH

C6LFC WH/RD

C18PRR GR/BK C17PRL GR

C4B-2 C4B-3

C3B-7 C3B-8

C3B-1

CR5

C23-2

C22-2

C20-2

C21-2

C16-2

C18-2

C12-2

C13-2

C18-2

C19-2

C15-2

C14-2

BRAKE RELEASE TRAVEL ALARM (A2) BRAKE RELEASE N.C. COIL

STEER LEFT COIL

BRAKE RELEASE PRESSURE SWITCH PS1

STEER RIGHT COIL

PRIMARY LIFT PUMP RELAY COIL PR2

AUXILIARY CONTROL RELAY COIL CR3

AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT

PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL

PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B

PRIMARY BOOM RETRACT COIL

PRIMARY BOOM EXTEND COIL

PRIMARY BOOM DOWN COIL

PRIMARY BOOM UP COIL

SECONDARY BOOM DOWN COIL

SECONDARY BOOM UP COIL

DESCENT ALARM OPTION (A3)

TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL

6 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

C1B-1

C1P-1

C4P-7

C3P-6

C4P-5

C4P-6

C14PLU OR C15PLD OR/BK

C7PBE BK C8PBR BK/WH

C1PBU RD

C3B-2

DOWN

RIGHT

LEFT

PR2

C6B-38 GR/WH GR/WH GR/WH

C27AUX RD

AUXILIARY PUMP

C4P-2 C4P-3

C3P-7 C3P-8

C3P-1

C2PBD RD/BK

C3B-10 C3B-11

C3B-5 C3B-4

TB19

TB36 CR3

4 BCI OPTION

9

A B

8 BK BK PR2

30

RD

7 87

CR20 85

OR OR/RD OR/BK

WH

RIGHT

LEFT

UP

DOWN

EXTEND

RETRACT

UP C3P-2

C10SBU BL C11SBD BL/BK

C3P-10 C3P-11

C4TRL WH

C4TRR WH/BK

CR5 CR5 C12DRE BL/WH

3 C3P-5

PR3

F

87

C3P-4

TS51 RD

30

PR3 86

TB12 OR/RD P42BAT OR/RD

BCI E

A2

33 A3

DOWN

UP

DOWN

RIGHT

+

85 87 87a

86 30

TB6

+ BK/RD

TB37 TB18 TB17 TB14 TB15 TB7 TB8 TB1 TB2 TB10 TB11 TB5 TB4

TS57 TS59 TS63 TS61 TS60 TS62

87

PLATFORM ROTATE PLATFORM LEVEL PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM TURNTABLE ROTATE

85 BRN

85

RD

8 DRIVE

10 L R STEER BP1

SET TO "N" 87

BRN

86

CR6 RD/BK-R6 TS15 DRIVE 30 ENABLE 7

CR19A 30

CR19B 87

ROTARY OEM FLOW CONTROL

DRIVE ENABLE LED L1 LIFT

L.V.I. 86 85

SET TO "B"

6

85

OR/BK-R6 5

TS1 1 2 3 4 5 6 7

3 FWD

4

8

CR19B

DISCHARGE

86

CR8 2

BK

REV

86

RESET

CR19A 30

20K

3 5 4

1 C29JSH RD/WH C32JSL WH/RD

CE VERSION: REMOVE JUMPER 30 AND ADD RELAY 87 LEFT

RD

C31REV WH/BK C31REV WH/BK

2 DP1 BCI

PLATFORM ROTATE

C30FWD WH

LVI/BCI OPTION C30FWD WH

1

TS7 PLATFORM LEVEL TS9 PRIMARY BOOM TS13 PRIMARY BOOM TS11 SECONDARY BOOM TS10 TURNTABLE ROTATE TS12

AUXILIARY POWER

FUNCTION ENABLE TS55

Electrical Schematic, Z-45/25, CE Models REV A

C D E F G H I J K L M N

Section 6 • Schematics February 2006

R42BAT OR/RD

(GND)

February 2006

Section 6 • Schematics

Electrical Schematic, Z-45/25, CE Models

Section 6 • Schematics

February 2006 REV B

Electrical Schematic, Z-45/25J, ANSI and CSA Models A

B

C

D

E

F

G

H

I

J

K

L

M

N

1

C29JSH RD/WH C32JSL WH/RD C30FWD WH C31REV WH/BK C40LS OR

BK

2

C132 PLI BL/WH C1B-12

TS2 ENGINE START

LOW RPM

HIGH RPM

FOOTSWITCH HIGH RPM

TS4 RPM

L48 C1P-8

C1P-7

C1P-9

R42BAT OR/RD

C34SA BK/WH

C33STR BK

C35HRPM BK/RD

C2B-4

C1B-8

C1B-7

C1B-9

D40

C7B-2

GR/BK

TS6 GLOW PLUGS

C2P-4

8

P24BAT WH

C3B-3

12

7

P24BAT WH

P23BAT WH

5

C9P-2

C3BAT RD/WH

C1B-2

6

WH-(FS)

C7P-2

C2B-5

5 C32

P25BAT RD

C3P-3

C28TTA RD/BK

C6B-29

C134PWR GR

C2B-2

C6B-32

C2P-5

C1B-3

C6B-31

C1P-2

C40LS OR

C1B-6

C6B-30

C3B-9

C29JSH RD/WH

C1B-5

C9HRN BK/RD

C3P-9

4

6

C7B-2

C32JSL WH/RD

C1B-4

OR

3

P23BAT WH

C2P-2

C1P-3

C1P-6

C31REV WH/BK

C7B-4

C30FWD WH

P20BAT RD

4

C1P-5

C1P-4

3

1

C7B-1

TB22 GROUND

C9P-3

7 A1 TILT ALARM

+ P3 HORN

PLATFORM

KS1

P1

P20BAT RD

LS18

RD-(FS)

R42BAT OR/RD

RD

C1P-12 RD

CB1 10 A

BK-(FS)

C9P-1 BK P26BAT RD

P22BAT

TB134

FS1

P2

C7P-1

RD

OR

TB40

CR5 C12DRE BL/WH

P42BAT OR/RD C6B-3

P42BAT OR/RD C6B-22

+

-

+ +

3

START INPUT

4

(NOT USED)

5

GROUND

6

BATTERY

7

KEY SWITCH POWER

8

(NOT USED)

86

IGNITION ON

10

ENGINE FAULT

CR16 86

86

87

BRN

BRN

BRN

GR/BK BATT

BK

-

WH-BATT

WH AP2 AUXILIARY

(12V DC) C5B-2

BRN

A2

9

85

CR14

BRN

86

85

87 85

CR15 BK/RD

ALT. BL

WH

CR13

BRN

87

BL

VR1

85

BK/WH

YEL

(12V DC)

30

30

30 RD

+12V DC

WH-J4

BRN

-

87

86

WH

-

CR12

BRN

+

TACH. INPUT

BK

+

C5B-1 P20BAT RD

C34SA BK/WH

30

85

STARTER

OR-GEN POS

ENGINE GROUND

(GND) BK

PR2

PR2

PR3

PR3 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

Part No. 110188

ENGINE RUN SOLENOID

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

STARTER RELAY CR11

ANSI/CSA

48V DC POWER RELAY CR2

ADD D40 ONLY IF UNIT HAS L4 AND L48.

7

48V DC POWER RELAY CR1

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

FLASHING BEACON OPTION

6

TILT SENSOR

SWITCH SHOWN WITH BOOM EXTENDED.

NOTES:

HOUR METER

HORN RELAY

HORN

BASE CONTROL BOX GROUND

CHASSIS GROUND

BRAKE RELEASE RELAY CR5

MOTOR MAIN CONTACTOR RELAY PR1

48V DC CHARGER

48V DC ALTERNATOR

PRIMARY LIFT PUMP

2

6 - 11

2

BK

AUXILIARY LIFT PUMP

8

START RELAY

BL-ISM2

C5B-18 C35HRPM

C5B-22

CR11

BK

C8-C WH

RD

+

87

86

87

AP1

ENGINE START

GLOW PLUGS

BRN

RD/WH

RD

RD/BK

30 CR16

14

85

C8-B

AC POWER

22

30

(12V DC)

2

1

C5B-3 C23PWR WH

+

13 LS1 (EXT)

RD-J10 (12GA)

FB

BRN

BK

OR-GEN NEG

GROUND

C5B-11 C21IGN2 WH

IGNITION / START MODULE

BK-ISM1 C5B-5 C33STR BK

85

87

HIGH

TB35

87

BRN

C6B-34

86

C6B-9 BK/RD

-

-

WH-6

CHARGER

C11-2

LS2 21 (PRI)

BK-6

F1

RIGHT MOTOR

C11-1

F2

BK-7

A1

WH-7

A2

A1

BK 2 GA

7

ALTERNATOR

A2

C11-4

PUMP

+

F1

C11-3

-

WH

+

PUMP

LEFT MOTOR

F2

85

LOW

TB33

TB34

30

CR1

15 A

PR2

+

87

+

C8-A

B-

F2

RD-5

B+

HM

CR4

-

+

RIGHT BOX

M-

F1

86

C6B-28

WH-5

BK-5

30

BK

85

CB3

MOTOR CONTROLLER

PR3

RD/BK

BK

C10-2

C10-1

WH-4

BK-4

+24V DC

F1 200A

30

TS54 RPM

TS52

C23PWR WH

_

BK-5

AP1

D2

21 LS4 (SEC) 22

5

20

17

6

86

TS56

TB23

U6A 24V DC

CR2

OR/RD

BK/RD

C6B-20 RD

BK

C10-4

C6B-25 CFIL BK

C6B-39 CR5 RD/BK

GR

3

16

2

11

14

10

1

9

AP2

C10-3

CONTROLLER FAULT INDICATOR LED L2

85

CR5

COIL-PR1

POT. HI

INTERLOCK

OFF-LMT SPD INP

BL/WH

POT. LOW

FORWARD

REVERSE

+48V INPUT

-

+

DIODE RETURN

RD 20

F2 200A

C6B-40 OR

OR/RD

OR/RD 86

-

+

5

RD

TB42

OR/RD

C6B-24

C6B-12

RD/WH

WH/RD

PR1

+48V DC

LEFT BOX

WH/BK

F4 500A

48V DC

WH

AP2

OR/RD

F5 10A

C29JSH RD/WH C32JSL WH/RD

C40LS OR C40LS OR

RD-AUX

RD

C3P-12

C4P-1

C36STCC BL C1P-10

R41DRE OR/BK C2P-3

C16DRE OR/RD

C12DRE BL/WH

C13DREL BL/RD

C1B-11

C1B-10

C2B-3

C4B-4

C3B-12

C4B-1

BRN

C4P-4

C37STC BL/BK C1P-11

C1B-1

C1P-1

C7P-3 BATGND BRN C6B-13 C13DREL

C6B-26 C12DRE

BL/RD

BRN

BL/WH C6B-16 C16DRE

PS1

C6B-35 RD/WH

OR/RD

RD

C4B-7 GR/WH

C3B-6 WH/RD

DOWN

UP

C4B-6 GR/BK

RIGHT

C4B-5 GR

LEFT

OR/RD

RD

BK-8

WH-8

RD/WH RD/WH

C6B-36 BL

C6B-37 BL/BK

C6B-27 RD GR/WH C6B-6 WH/RD

C6B-18 GR/BK C6B-17 GR

C6B-14 OR C6B-15 OR/BK

C6B-7 BK C6B-8 BK/WH

C6B-1 RD C6B-2 RD/BK

C6B-10 BL C6B-11 BL/BK

C6B-5 WH/BK C6B-4 WH

BRN-8

RD-8

C7B-3 BATGND BRN

C15-1

C14-1

C25-2

C24-2

C26-2

C6B-21 DREGND BRN

C19-1

C18-1

C13-1

C12-1

C17-1

C16-1

C21-1

C20-1

C22-1

C23-1

C6B-19 GR/WH

C25-1

C24-1

C26-1

+

21 14

C23-2

C22-2

C20-2

C21-2

C16-2

C18-2

C12-2

C13-2

C18-2

C19-2

C15-2

C14-2

BRAKE RELEASE TRAVEL ALARM (A2) BRAKE RELEASE N.C. COIL

STEER LEFT COIL

BRAKE RELEASE PRESSURE SWITCH PS1

STEER RIGHT COIL

PRIMARY LIFT PUMP RELAY COIL PR2

AUXILIARY CONTROL RELAY COIL CR3

AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL PLATFORM ROTATE RIGHT / JIB DOWN PLATFORM ROTATE LEFT / JIB UP

PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL

PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B

PRIMARY BOOM RETRACT COIL

PRIMARY BOOM EXTEND COIL

PRIMARY BOOM DOWN COIL

PRIMARY BOOM UP COIL

SECONDARY BOOM DOWN COIL

SECONDARY BOOM UP COIL

DESCENT ALARM OPTION (A3)

TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL

6 - 12 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

LS3

22 13

3 DRIVE ENABLE LIMIT SWITCH

33

5 C2B-7

UP

DOWN

EXTEND

TB27 RETRACT

UP

DOWN

UP

DOWN

RIGHT

LEFT

PR2

C27AUX RD

AUXILIARY PUMP

C19LPMP GR/WH

C2B-6

C6LFC WH/RD

BK JIB MANIFOLD

C45JSV GR/WH

C4B-2 C4B-3

C3B-7 C3B-8

CR5

8 BK BK PR2

7 87

CR20 85

OR/RD

C4P-7

C3P-6

C17PRL GR

C18PRR GR/BK

C44JDA GR/BK C4P-6 C4P-5

WH

C2P-7

C14PLU OR C15PLD OR/BK

C7PBE BK C8PBR BK/WH

C3B-1 C3B-2

87

6 TB36 CR3 BK C44DA C6B-33

C6B-38 GR/WH GR/WH GR/WH

TB37 TB18

30

PR3 86

OR

C2P-6

C4P-2 C4P-3

C3P-7 C3P-8

C1PBU RD C2PBD RD/BK

C3P-1 C3P-2

C3B-10 C3B-11

C3B-5 C3B-4

PR3

OR/RD OR/BK

WH

DOWN

UP

RIGHT

LEFT

UP

DOWN

EXTEND

RETRACT

UP

DOWN

C10SBU BL C11SBD BL/BK

C4TRR WH/BK C4TRL WH

CR5 CR5 C12DRE BL/WH

4 BCI OPTION

A2

33 A3

85 87 87a

86 30

TB6

F

C3P-10 C3P-11

C3P-5

TB19

BCI E

A B C

3 87

C3P-4

+

GR/WH

TB17 TB14 TB15 TB7 TB8 TB1 TB2 TB10 TB11 TB5 TB4

UP

DOWN

RIGHT

TS51 RD

TB12 OR/RD P42BAT OR/RD

30

RD

TS58 TS57 TS59 TS63 TS61 TS60 TS62

86

JIB BOOM PLATFORM ROTATE PLATFORM LEVEL PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM TURNTABLE ROTATE

CR7 85

+ BK/RD

86 9

85

RD BP1

DRIVE

10 L R STEER

8

SET TO "N" SET TO "B" 85 BRN 87

BRN ROTARY OEM FLOW CONTROL

CR6 RD/BK-R6 TS15 DRIVE 30 ENABLE 7

L.V.I. 86 85

1

DRIVE ENABLE LED L1 LIFT

6

85

OR/BK-R6 5

TS1 1 2 3 4 5 6 7

3 FWD

4

8

CR19B

DISCHARGE 30

86

CR8 2

BK

REV

86

RESET

CR19A CR19A 30

CR19B 87

AUX ON

FUNCTION ENABLE

P24BAT WH P24BAT WH

CE VERSION: REMOVE JUMPER 30 AND ADD RELAY 87 LEFT

RD

C31REV WH/BK C31REV WH/BK

1 C29JSH RD/WH C32JSL WH/RD

2 DP1 BCI 87a

C30FWD WH

LVI/BCI OPTION C30FWD WH

20K

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

TB44 TS55

Electrical Schematic, Z-45/25J, ANSI and CSA Models REV B

D E F G H I J K L M N

Section 6 • Schematics February 2006

R42BAT OR/RD

(GND)

February 2006

Section 6 • Schematics

Electrical Schematic, Z-45/25J, ANSI and CSA Models

Section 6 • Schematics

February 2006 REV B

Electrical Schematic, Z-45/25J, CE Models A

B

C

D

E

F

G

H

I

J

K

L

M

N

1

C29JSH RD/WH C32JSL WH/RD C30FWD WH C31REV WH/BK C40LS OR C7P-1

BK

2

C132PLI BL/WH

C1B-12

A1 TILT ALARM

LOW RPM

HIGH RPM

FOOT SWITCH HIGH RPM

C2P-4

C1P-8

C1P-7

C1P-9

R42BAT OR/RD

C34SA BK/WH

C33STR BK

C35HRPM BK/RD

C3B-3

C2B-4

C1B-8

C1B-7

C1B-9

C7B-2

C3BAT RD/WH

P23BAT WH

C3P-3

C7P-2

C1B-2

C6B-29

C2B-5

C6B-32

C28TTA RD/BK

C1B-3

C6B-31

C134PWR GR

C1B-6

C6B-30

C2B-2

C1B-5

C7B-4

C1B-4

GR/BK

C2P-5

P20BAT RD

L45

D40

C1P-2

8

6

TS2 ENGINE START

TS4 RPM

C3B-9

7

P24BAT WH

TS6 GLOW PLUGS

C9HRN BK/RD

5

P24BAT WH

C3P-9

C40LS OR

C29JSH RD/WH

C32JSL WH/RD

C31REV WH/BK

C30FWD WH

6 12

C9P-2

C7B-2

5 U33

WH-(FS)

P23BAT WH

3

P25BAT RD

C7P-2

C7B-1

C2P-2

C1P-3

C1P-6

C1P-5

C1P-4

1 4

A6

OR

+

D39

GROUND

C9P-3

R42BAT OR/RD

L4 5

P3 HORN

TB22

3

4

LS18

PLATFORM

KS1

P1

P20BAT RD

RD-(FS)

RD

C1P-12 RD

CB1 10A

BK-(FS)

C9P-1 BK P26BAT RD

P22BAT

TB134

FS1

P2

RD

OR

TB40

CR5 C12DRE BL/WH

P42BAT OR/RD C6B-3

P42BAT OR/RD C6B-22

GROUND

6

BATTERY

7

KEY SWITCH POWER

8

(NOT USED)

9

IGNITION ON

10

ENGINE FAULT

CR16

GR/BK BATT

BRN

+12V DC

-

(NOT USED)

5

86

BRN

-

+

START INPUT

4

86

87

BRN

-

+

+

3

WH-BATT

WH AP2 AUXILIARY

C5B-2

ENGINE GROUND

(GND) BK

PR2

PR2

PR3

PR3 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

ENGINE RUN SOLENOID

Part No. 110188

STARTER RELAY CR11

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

48V DC POWER RELAY CR2

ADD D40 ONLY IF UNIT HAS L4 AND L48.

48V DC POWER RELAY CR1

6

FLASHING BEACON OPTION

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

CE & PLATFORM LOAD SENSE OPT.

TILT SENSOR

SWITCH SHOWN WITH BOOM EXTENDED.

5

HOUR METER

2 NOTES:

HORN RELAY

HORN

BASE CONTROL BOX GROUND

CHASSIS GROUND

BRAKE RELEASE RELAY CR5

MOTOR MAIN CONTACTOR RELAY PR1

48V DC CHARGER

48V DC ALTERNATOR

PRIMARY LIFT PUMP

6 - 13

TACH. INPUT

(12V DC) BRN

A2

OR-GEN POS

START RELAY

2

85

BK

AUXILIARY LIFT PUMP

8

86

CR14

BRN

BK

STARTER

85

87 85

CR15 BK/RD

ALT. BL

86

WH

IGNITION / START MODULE 1

CR13

BRN

87

BL

VR1

85

BK/WH

YEL

(12V)

30

30

30 RD

-

WH-J4

BRN

+

87

86

(12V DC)

WH

+

CR12

BRN

+

86

30

85

BK

14

CR11

+

2

C34SA BK/WH

WH

RD

LS1 (EXT)

85

BK

C8-C

87

13

C5B-1 P20BAT RD

C5B-22

30

87

AP1

ENGINE START

GLOW PLUGS

BRN

RD/WH

RD

RD/BK

30 CR16

C5B-18 C35HRPM C5B-3 C23PWR WH

15 A

C8-B

AC POWER

C5B-5 C33STR BK

FB

BRN

BK OR-GEN NEG

GROUND

22

BL-ISM2

85

87

C6B-9 BK/RD

-

-

WH-6

CHARGER

C11-2

LS2 21 (PRI)

BK-6

RIGHT MOTOR

C11-1

A1

BK-7

A1

F1

BK 2 GA

7

ALTERNATOR

F1

F2

WH-7

PUMP

F2

+

A2

BK-ISM1

C5B-11 C21IGN2 WH

C8-A

BK

C11-4

-

WH

+

PUMP

86

HIGH

TB35

CB3

C11-3

-

+

+

A2

LOW

87

RD-J10 (12GA)

PR2

LEFT MOTOR

85

TS54 RPM

TB33

TB34

30

_

RD-5

B-

87

+

CR4

F2

85

TS52

C23PWR WH HM

BK-5

B+

30

CR1

BRN

C6B-34

WH-5

BK-5

WH-4

BK-4

5

20

17

M-

F1 PR3

86

C6B-28

C10-2

C10-1

C10-4

C10-3

C6B-25 CFIL BK

C6B-39 CR5 RD/BK

GR

2

3

16

F1 200A

RD/BK

BK

D2

21 LS4 (SEC) 22

U6A MOTOR CONTROLLER

86

OR/RD

BK/RD

C6B-20 RD

C6B-40 OR

CONTROLLER FAULT INDICATOR LED L2

CR5

COIL-PR1

POT. HI

INTERLOCK

OFF-LMT SPD INP

BL/WH

11

14

10

AP1

85

BK

CR2

TS56

TB23

30

24V DC

+24V DC

POT. LOW

FORWARD

1

9

6

REVERSE

+48V DC INPUT

DIODE RETURN

RD 20

-

+

AP2

RIGHT BOX

OR/RD

-

+

LEFT BOX

OR/RD 86

F2 200 A

5

RD

TB42

OR/RD

PR1

+48V DC

C6B-24

C6B-12

RD/WH

WH/RD

WH/BK

WH

F4 500 A

48V DC

AP2

OR/RD

F5 10 A

C40LS OR C40LS OR

C29JSH RD/WH C29JSH RD/WH

P24BAT WH P24BAT WH

RD-AUX

OR/RD

RD

C3P-12

C4P-1

R41DRE OR/BK C2P-3

C16DRE OR/RD

C12DRE BL/WH

C13DREL BL/RD

C1B-10

C2B-3

C4B-4

C3B-12

C4B-1

BL/RD

BRN

BL/WH OR/RD

C7P-3 BATGND BRN C6B-13 C13DREL

C6B-26 C12DRE C6B-16 C16DRE

BK-8

WH-8

RD/WH RD/WH

C6B-27 RD GR/WH C6B-6 WH/RD

C6B-18 GR/BK C6B-17 GR

C6B-14 OR C6B-15 OR/BK

C6B-7 BK C6B-8 BK/WH

C6B-1 RD C6B-2 RD/BK

C6B-10 BL C6B-11 BL/BK

C6B-5 WH/BK C6B-4 WH

BRN-8

RD-8

C7B-3 BATGND BRN C6B-21 DREGND BRN

C26-2

C24-2

C25-2

C19-1

C18-1

C13-1

C12-1

C17-1

C16-1

C21-1

C20-1

C22-1

C23-1

C19-2

C18-2

C13-2

C12-2

C18-2

C16-2

C21-2

C20-2

C22-2

C23-2

C6B-19 GR/WH

C25-1

C24-1

C26-1

+

21 14

C6B-37 BL/BK

C6B-36 BL

LS3

22 13

3 DRIVE ENABLE LIMIT SWITCH

33

C6B-35 RD/WH

PS1

OR/RD

TB37 RD

86

BRN

C4P-4

C36STCC BL C1P-10 C1B-11

RD

C4B-7 GR/WH

C3B-6 WH/RD

DOWN

UP

C4B-6 GR/BK

LEFT

RIGHT

C4B-5 GR

C2B-7

UP

DOWN

DOWN

UP

RETRACT

EXTEND

TB27

C15-1

C14-1

C15-2

C14-2

BRAKE RELEASE TRAVEL ALARM (A2) BRAKE RELEASE N.C. COIL

STEER LEFT COIL

BRAKE RELEASE PRESSURE SWITCH PS1

STEER RIGHT COIL

PRIMARY LIFT PUMP RELAY COIL PR2

AUXILIARY CONTROL RELAY COIL CR3

AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL PLATFORM ROTATE RIGHT / JIB DOWN PLATFORM ROTATE LEFT / JIB UP

PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL

PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B

PRIMARY BOOM RETRACT COIL

PRIMARY BOOM EXTEND COIL

PRIMARY BOOM DOWN COIL

PRIMARY BOOM UP COIL

SECONDARY BOOM DOWN COIL

SECONDARY BOOM UP COIL

DESCENT ALARM OPTION (A3)

TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL

6 - 14 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

C37STC BL/BK C1P-11

C19LPMP GR/WH

C2B-6

C6LFC WH/RD

BK JIB MANIFOLD

C45JSV GR/WH

C4B-2 C4B-3

C3B-7 C3B-8

CR5

8 BK BK PR2

C1B-1

C1P-1

C4P-7

C3P-6

C17PRL GR

C18PRR GR/BK

C44JDA GR/BK C4P-6 C4P-5

WH

C2P-7

C14PLU OR C15PLD OR/BK

C7PBE BK C8PBR BK/WH

C3B-1

UP

DOWN

RIGHT

LEFT

PR2

C6B-38 GR/WH GR/WH GR/WH

C27AUX RD

AUXILIARY PUMP

C2P-6

C4P-2 C4P-3

C3P-7 C3P-8

C1PBU RD

C3B-2

87

A B

7 87

CR20 85

30

PR3 86

OR OR/RD OR/BK

WH

DOWN

UP

RIGHT

LEFT

UP

DOWN

EXTEND

RETRACT

C3P-1

C2PBD RD/BK

C3B-10 C3B-11

C3B-5 C3B-4

PR3

BCI OPTION

A2

33 A3

UP C3P-2

C10SBU BL C11SBD BL/BK

C4TRR WH/BK C4TRL WH

+

F

86 9

6 85 87 87a

TB36 CR3 BK C44DA C6B-33

BCI E

C3P-10 C3P-11

C3P-5

CR5 CR5 C12DRE BL/WH

3 C3P-4

TB19

5 TS58

30

TB6 TB17 TB14 TB15 TB7 TB8 TB1 TB2 TB10 TB11 TB5

DOWN

UP

DOWN

RIGHT

LEFT

TS51 RD

TB12 OR/RD P42BAT OR/RD

30 AUX ON

RD

TB18 TB4

GR/WH

TS57 TS59 TS63 TS61 TS60 TS62

86

JIB BOOM PLATFORM ROTATE PLATFORM LEVEL PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM TURNTABLE ROTATE

CR7 85

+ BK/RD

87

BRN ROTARY OEM FLOW CONTROL

3

85

RD BP1

DRIVE

10 L R STEER

8

SET TO "N" SET TO "B" 85 BRN 87

2

CR6 RD/BK-R6 TS15 DRIVE 30 ENABLE 7

L.V.I. 86 85

CR19A 30

CR19B 87

1

DRIVE ENABLE LED L1 LIFT

6

85

OR/BK-R6 5

TS1

CR8

86 FWD

4 REV

1 2 3 4 5 6 7 8

CR19B

DISCHARGE RESET

CR19A 30

2 20K

4 RD

C31REV WH/BK C31REV WH/BK

1 C32JSL WH/RD C32JSL WH/RD

CE VERSION: REMOVE JUMPER 30 AND ADD RELAY 87 86

C30FWD WH

LVI/BCI OPTION C30FWD WH

DP1 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

TB44 FUNCTION ENABLE TS55

Electrical Schematic, Z-45/25J, CE Models REV B

C D E F G H I J K L M N

Section 6 • Schematics February 2006

R42BAT OR/RD

(GND)

February 2006

Section 6 • Schematics

Electrical Schematic, Z-45/25J, CE Models

Section 6 • Schematics

February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 ANSI and CSA Models

GROUND STUD

8

6 - 15 P20BAT RD C7B-4

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy C7B-3

Part No. 110188 BK

BATGND BRN

H6 (CE OPTION ONLY) C6B-13 C13DREL BL/RD C4B-1

C6B-16 C16DRE OR/RD C4B-4

C6B-28 C28TTA RD/BK C1B-2

C6B-29 C29JSH RD/WH C1B-3

C6B-30 C30FWD WH C1B-4

C6B-31 C31REV WH/BK C1B-5

C6B-32 C32JSL WH/RD C1B-6

BRN C5B-2

CR4 HORN RELAY

30

86

87

30

87a

86

CR5 BRAKE RELEASE RELAY

85

86 87

87a 85

30

BRN CR3 AUXILIARY CONTROL RELAY

OR/RD

GR/WH-J19

RD KS1

GR/BK-TS58 RD H6

OR/RD-CR1 OR/RD-LED BK-ALARM

GR/WH-J19

GR/WH

GR/WH

86 87

87a 85

30

CR20 LIFT PUMP RELAY

BRN

(TO SWITCH PANEL)

GROUND CONTROL HARNESS

J

BK

87

OR/BK

87a

87

85

30 87a

BRN

85

OR/RD

OR/RD BRN

86

GR/WH RD/WH

BRN

85

CR2 48V DC POWER RELAY

134

44

42

40

37

36

BK/RD-TS54

BRN

C9HRN BK/RD

87

87a

30

RD/WH

KEYSWEITCH POWER

JIB DESCENT ALARM

SWITCH 48 VOLTS

34 35

BK-TS52 BK/WH-TS56

I

C41DRE OR/BK

OR/RD BRN

86

CR1 48V DC POWER RELAY

C3B-3 C3BAT RD/WH

C6B-9 R9HRN

C6B-3 P42BAT OR/RD C6B-39 CR5 RD/BK

C6B-35 R48BRK RD/WH

C6B-27 R27AUX C6B-19 R19LPMP GR/WH

STEER RIGHT OFF-LIMIT SPEED

27 33

WH-KS1 (D2) RD-CR3 RD-TS51

GR/WH-J19 BK-CR4 BK-KS1

GR/BK-TS57 GR/WH GR/WH-TS60

GR-TS57

OR/BK-TS59

OR-TS59

C12DRE BL/WH

H

BRN

C6B-21 BRN BRN

C6B-33 C44DA BK

BK

OR/RD

BRN

GR/WH

OR/RD

134

44

42

40

37

STEER LEFT

HIGH/LOW RPM

GLOW PLUG

START ENGINE

AUXILIARY PUMP SELECT

23

22

19

19

18

BL-TS60 BK ALARM BL/BK-TS60

G

C3B-9

C2B-3

5 C6B-26 C12DRE BL/WH

C6B-40 C40LS OR

C2B-7 C45JSV GR/WH

C5B-1 P20BAT RD C5B-11 C21IGN2 WH

C5B-3 C23PWR WH

C2B-5 C134PWR RD

C2B-6 C44JDA GR/BK C6B-34 C23ALARM RD

C2B-4 R42BAT OR/RD

C2B-2 C40LS OR

36

35

34

33

27

KEYSWITCH POWER

+24V DC TO PLATFORM

LIFT PUMP

LIFT PUMP

PLATFORM ROTATE RIGHT

15 17

BK-TS63 BK/WH-TS63

F

BRN-HM

C6B-25 OR/RD-42A

C6B-22 R42BAT OR/RD

C1B-10 C36STCC BL C1B-11 C37STC BL/BK

22 23

PLATFORM LEVEL DOWN PLATFORM ROTATE LEFT

14

12

11

10

8

7

GR/WH

E

C6B-24 C40LS OR

C6B-37 C37STC BL/BK

C1B-1 C27AUX RD C5B-5 C33STR BK C1B-7 C33STR BK C5B-22 C34SA BK/WH C1B-8 C34SA BK/WH C5B-18 C35HRPM BK/RD C1B-9 C35HRPM BK/RD

C23-4 P22BAT BK

19

19

18

17

15

PLATFORM LEVEL UP

FOOTSWITCH POWER #2

SECONDARY BOOM DOWN

SECONDARY BOOM UP

PRIMARY BOOM RETRACT

PRIMARY BOOM EXTEND

5 6

WH-TS62 WH/BK-TS62

D

C6B-36 C36STCC BL

C7B-2 P23SWBAT WH

C6B-20 C22LS BK

C4B-7 C19LPMP GR/WH GR/WH-CR3

C4B-6 C18PRR GR/BK

C4B-5 C17PRL GR

14

12

11

10

8

7

LIFT FLOW CONTROL

TURNTABLE ROTATE RIGHT

2 4

BRN GND GR/BK H6 RD TS55 RD TS51 BK C7-1 BK 22B BL/WH C1-12 RD H6

C6B-38 C19PSW GR/WH

C4B-2 C14PLU OR C4B-3 C15PLD OR/BK

5 6

PRIMARY BOOM DOWN TURNTABLE ROTATE LEFT

RD-TS61 BK-ALARM RD/BK-TS61

C

C6B-18 C18PRR GR/BK

C6B-17 C17PRL GR

C6B-15 C15PLD OR/BK

C6B-14 C14PLU OR

C3B-12 C12DRE BL/WH

C3B-11 C11SBD BL/BK

C3B-10 C10SBU BL

C3B-8 C8PBR BK/WH

2 4

1

P20BAT RD

2

C6B-12 C12DRE BL/WH

C6B-11 C11SBD BL/BK

C6B-10 C10SBU BL

C6B-8 C8PBR BK/WH

C3B-7 C7PBE BK

C3B-6 C6LFC WH/RD

C3B-5 C5TRR WH/BK

C3B-4 C4TRL WH

PRIMARY BOOM UP

A

B

FAULT STATUS LED

GR/BK C23-8 GR/BK L45 GR/BK C2B-6

C6B-7 C7PBE BK

C6B-6 C6LFC WH/RD

C6B-5 C5TRR WH/BK

C6B-4 C4TRL WH

1

B

A

C3B-2 C2PBD RD/BK

C3B-1 C1PBU RD

6

RD C23-1 RD 134B

7 C6B-1 C1PBU RD

C

3

C6B-2 C2PBD RD/BK

D

4 TERMINAL BASE (TB)

C23

1 1 3 4 5 6 7 8 12

Section 6 • Schematics February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, ANSI and CSA Models REV A

K L

BK-ALARM

GR/WH RD

RD

RD/WH

OR/RD

RD/BK BK/RD

M N

February 2006 REV A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models F

E

D

TS54 HIGH/LOW RPM

BK/RD

C

BK/RD-35A

C45JSV GR/WH (C2B-7)

BK-7A

GR/BK-18A

BK/WH-8A

GR-17A

BK RD

WH/BK-5A

B

1

GR

TS63 PRIMARY BOOM EXTEND/ RETRACT

WH-4A

BK

A

BK RD

2

RD

RD BK

RD

RD

RD-27A

RD/BK-2A

OR/BK-15A

OR/BK

OR-14A

OR

BK

G

TS57 PLATFORM ROTATE

H

TS62 TURN TABLE ROTATE

I

TS59 PLATFORM LEVEL

TS61 PRIMARY BOOM

RD

RD

RD

WH

RD-1A

3

BK

RD C23-6

RD

RD

4

BK-22A

RD

P20BAT RD (C7B-4) RD CB1 CIRCUIT BREAKER 1

L45 PLATFORM OVERLOAD (CE ONLY)

BL-10A

+

KS1

BL/BK-11A

-

GR/WH-19A

BK

TS60 SECONDARY BOOM

P20BAT RD (C5B-1) RD 134A

5

RD

RD

RD

RD RD

6

RD

RD C23-7 RD

TS52 ENGINE START

GR/BK H6 WH 23A

BK-33A 1

Part No. 110188

RD

BK/WH-34A

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

RD TS55 FUNCTION ENABLE

TS56 GLOW PLUG BASE BOX HARNESS

RD

RD

BRN

HOUR METER H.M.

2

7

BRN-HM

NC

WH C21IGN2 (C5B-11)

J

RD

K

TS51 AUXILIARY PUMP

L

D2

M

P1 EMERGENCY STOP

N

Section 6 • Schematics

8

6 - 16

February 2006

Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models

Section 6 • Schematics

February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models

GROUND STUD

8

6 - 17 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy C7B-3

Part No. 110188 BK

BATGND BRN

H6 C6B-13 C13DREL BL/RD C4B-1

C6B-16 C16DRE OR/RD C4B-4

C6B-28 C28TTA RD/BK C1B-2

C6B-29 C29JSH RD/WH C1B-3

C6B-30 C30FWD WH C1B-4

C6B-31 C31REV WH/BK C1B-5

C6B-32 C32JSL WH/RD C1B-6

BRN

87

C5B-2 30

86

87

30

87a

86

CR5 BRAKE RELEASE RELAY

85

OR/BK

87a

85

86 87

87a 85

30

BRN CR3 AUXILIARY CONTROL RELAY

OR/RD

134

44

42

40

RD KS1

GR/BK-TS58 RD H6

OR/RD-CR1 OR/RD-LED BK-ALARM

GR/WH-J19

GR/WH

GR/WH

86 87

87a 85

30

CR20 LIFT PUMP RELAY

BRN

(TO SWITCH PANEL)

GROUND CONTROL HARNESS

J

CR4 HORN RELAY

85

87

BRN

BK

OR/RD

OR/RD BRN

86

GR/WH RD/WH

BRN

85

87a

30

CR2 48V DC POWER RELAY

36 37

BK/RD-TS54 GR/WH-J19

I

C9HRN BK/RD

87

RD/WH

34 35

BK-TS52 BK/WH-TS56

BRN

C41DRE OR/BK

OR/RD BRN

86

87a

30

CR1 48V DC POWER RELAY

C3B-3 C3BAT RD/WH

C6B-9 R9HRN

C6B-3 P42BAT OR/RD C6B-39 CR5 RD/BK

C6B-35 R48BRK RD/WH

C6B-27 R27AUX C6B-19 R19LPMP GR/WH

27 33

WH-KS1 (D2) RD-CR3 RD-TS51

GR/WH-J19 BK-CR4 BK-KS1

H

BRN

C6B-21 BRN BRN

C6B-33 C44DA BK

BK

OR/RD

BRN

GR/WH

OR/RD

KEYSWEITCH POWER

JIB DESCENT ALARM

SWITCH 48 VOLTS

OFF-LIMIT SPEED

STEER RIGHT

STEER LEFT

HIGH/LOW RPM

GLOW PLUG

START ENGINE

AUXILIARY PUMP SELECT

23

22

19

19

18

GR-TS57 GR/BK-TS57 GR/WH GR/WH-TS60

G

C3B-9

C2B-3

5 C6B-26 C12DRE BL/WH

C6B-40 C40LS OR

C2B-7 C45JSV GR/WH

C5B-1 P20BAT RD C5B-11 C21IGN2 WH

134

44

42

40

37

36

35

34

33

27

KEYSWITCH POWER

+24V DC TO PLATFORM

LIFT PUMP

LIFT PUMP

PLATFORM ROTATE RIGHT

15 17

OR-TS59 OR/BK-TS59

F

BRN-HM

C6B-25 OR/RD-42A

C5B-3 C23PWR WH

C2B-5 C134PWR RD

C2B-6 C44JDA GR/BK C6B-34 C23ALARM RD

C2B-4 R42BAT OR/RD

C2B-2 C40LS OR

C1B-11 C37STC BL/BK

C1B-10 C36STCC BL

C1B-1 C27AUX RD C5B-5 C33STR BK C1B-7 C33STR BK C5B-22 C34SA BK/WH C1B-8 C34SA BK/WH C5B-18 C35HRPM BK/RD C1B-9 C35HRPM BK/RD

23

22

19

PLATFORM LEVEL DOWN PLATFORM ROTATE LEFT

14

C12DRE BL/WH

BK ALARM BL/BK-TS60

BL-TS60

BK/WH-TS63

BK-TS63

GR/WH

E

C6B-22 R42BAT OR/RD

C6B-24 C40LS OR

C6B-37 C37STC BL/BK

C6B-36 C36STCC BL

C7B-2 P23SWBAT WH

C23-4 P22BAT BK

19

18

17

15

PLATFORM LEVEL UP

12

11

10

8

7

WH-TS62 WH/BK-TS62

D

FAULT STATUS LED

P20BAT RD C7B-4 C6B-20 C22LS BK

C4B-7 C19LPMP GR/WH GR/WH-CR3

C4B-6 C18PRR GR/BK

C4B-5 C17PRL GR

14

FOOTSWITCH POWER #2

SECONDARY BOOM DOWN

SECONDARY BOOM UP

PRIMARY BOOM RETRACT

PRIMARY BOOM EXTEND

5 6

RD-TS61 BK-ALARM RD/BK-TS61

C

C6B-38 C19PSW GR/WH

C4B-2 C14PLU OR C4B-3 C15PLD OR/BK

12

11

10

8

7

LIFT FLOW CONTROL

TURNTABLE ROTATE RIGHT

4

2

1

BRN GND GR/BK H6 RD TS55 RD TS51 BK C7-1 BK 22B BL/WH C1-12 RD H6

C6B-18 C18PRR GR/BK

C6B-17 C17PRL GR

C6B-15 C15PLD OR/BK

C6B-14 C14PLU OR

C3B-12 C12DRE BL/WH

5 6

TURNTABLE ROTATE LEFT

PRIMARY BOOM DOWN

PRIMARY BOOM UP

P20BAT RD

2

C6B-12 C12DRE BL/WH

C3B-11 C11SBD BL/BK

C3B-10 C10SBU BL

C3B-8 C8PBR BK/WH

C3B-7 C7PBE BK

C3B-6 C6LFC WH/RD

C3B-5 C5TRR WH/BK

4

2

1

A

B

C6B-11 C11SBD BL/BK

C6B-10 C10SBU BL

C6B-8 C8PBR BK/WH

C6B-7 C7PBE BK

C6B-6 C6LFC WH/RD

C6B-5 C5TRR WH/BK

C3B-4 C4TRL WH

C3B-2 C2PBD RD/BK

B

A

GR/BK C23-8 GR/BK L45 GR/BK C2B-6

RD C23-1 RD 134B

7 C6B-4 C4TRL WH

6 C3B-1 C1PBU RD

4

C6B-1 C1PBU RD

C

3

C6B-2 C2PBD RD/BK

D

U33

TERMINAL BASE (TB)

1 1 3 4 5 6 7 8 12

Section 6 • Schematics February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models REV A

K

BK-ALARM

GR/WH RD

RD

RD/WH

OR/RD

RD/BK BK/RD

L M N

February 2006 REV A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models F

E

D

TS54 HIGH/LOW RPM

BK/RD

C

BK/RD-35A

C45JSV GR/WH (C2B-7)

BK-7A

GR/BK-18A

BK/WH-8A

GR-17A

BK RD

WH/BK-5A

B

1

GR

TS63 PRIMARY BOOM EXTEND/ RETRACT

WH-4A

BK

A

TS57 PLATFORM ROTATE

BK RD

2

RD

RD BK

RD

RD

RD-27A

RD/BK-2A

OR/BK-15A

OR/BK

OR-14A

OR

BK

G

TS62 TURN TABLE ROTATE

H

TS59 PLATFORM LEVEL

TS61 PRIMARY BOOM

RD

RD

RD

RD-1A

WH

3

BK

RD C23-6

RD

RD

4

BK-22A

RD

P20BAT RD (C7B-4)

+

RD CB1 CIRCUIT BREAKER 1

BL-10A

L45 PLATFORM OVERLOAD (CE ONLY)

BL/BK-11A

-

GR/WH-19A

BK

TS60 SECONDARY BOOM

P20BAT RD (C5B-1) RD 134A

5

RD

RD

RD

RD RD

6

RD

RD C23-7 RD

TS52 ENGINE START

GR/BK H6 WH 23A

BK-33A 1

Part No. 110188

RD

BK/WH-34A

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

RD TS55 FUNCTION ENABLE

TS56 GLOW PLUG BASE BOX HARNESS

RD

RD

BRN

HOUR METER H.M.

2

7

BRN-HM

NC

WH C21IGN2 (C5B-11)

I

KS1

J

RD

K

TS51 AUXILIARY PUMP

L

D2

M

P1 EMERGENCY STOP

N

Section 6 • Schematics

8

6 - 18

February 2006

Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models

Section 6 • Schematics

February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ANSI and CSA Models

GROUND STUD

8

6 - 19 P20BAT RD C7B-4

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy C7B-3

Part No. 110188 BK

BATGND BRN

H6 (CE OPTION ONLY) C6B-13 C13DREL BL/RD C4B-1

C6B-16 C16DRE OR/RD C4B-4

C6B-28 C28TTA RD/BK C1B-2

C6B-29 C29JSH RD/WH C1B-3

C6B-30 C30FWD WH C1B-4

C6B-31 C31REV WH/BK C1B-5

C6B-32 C32JSL WH/RD C1B-6

BRN C5B-2

BK

87

87

30

87a

86

CR5 BRAKE RELEASE RELAY

85

86 87

87a 85

30

BRN CR3 AUXILIARY CONTROL RELAY

OR/RD

RD KS1

GR/BK-TS58 RD H6

OR/RD-CR1 OR/RD-LED BK-ALARM

GR/WH-J19

GR/WH

GR/WH

86 87

87a 85

30

CR20 LIFT PUMP RELAY

BRN

(TO SWITCH PANEL)

GROUND CONTROL HARNESS

J

CR4 HORN RELAY

30

86

OR/BK

87a

87

85

30 87a

BRN

85

OR/RD

OR/RD BRN

86

GR/WH RD/WH

BRN

85

CR2 48V DC POWER RELAY

BK/RD-TS54 GR/WH-J19

BRN

C9HRN BK/RD

87

87a

30

RD/WH

BK-TS52 BK/WH-TS56

I

C41DRE OR/BK

OR/RD BRN

86

CR1 48V DC POWER RELAY

C3B-3 C3BAT RD/WH

C6B-9 R9HRN

C6B-3 P42BAT OR/RD C6B-39 CR5 RD/BK

C6B-35 R48BRK RD/WH

C6B-27 R27AUX C6B-19 R19LPMP GR/WH

134

44

42

40

37

36

35

34

33

27

WH-KS1 (D2) RD-CR3 RD-TS51

H

BRN

C6B-21 BRN BRN

C6B-33 C44DA BK

BK

OR/RD

BRN

GR/WH

OR/RD

KEYSWEITCH POWER

JIB DESCENT ALARM

SWITCH 48 VOLTS

OFF-LIMIT SPEED

STEER RIGHT

STEER LEFT

HIGH/LOW RPM

GLOW PLUG

START ENGINE

AUXILIARY PUMP SELECT

22 23

GR/WH-J19 BK-CR4 BK-KS1

G

C3B-9

C2B-3

5 C6B-26 C12DRE BL/WH

C6B-40 C40LS OR

C2B-7 C45JSV GR/WH

C5B-1 P20BAT RD C5B-11 C21IGN2 WH

134

44

42

40

37

36

35

34

33

27

KEYSWITCH POWER

+24V DC TO PLATFORM

19 19

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

F

BRN-HM

C6B-25 OR/RD-42A

C5B-3 C23PWR WH

C2B-5 C134PWR RD

C2B-6 C44JDA GR/BK C6B-34 C23ALARM RD

C2B-4 R42BAT OR/RD

C2B-2 C40LS OR

C1B-11 C37STC BL/BK

22 23

LIFT PUMP

LIFT PUMP

18

PLATFORM ROTATE RIGHT/JIB DOWN

15

14

12

11

17

RD

PLATFORM ROTATE LEFT/JIB UP

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

FOOTSWITCH POWER #2

SECONDARY BOOM DOWN

8 10

BK-TS63 BK/WH-TS63

E

C6B-22 R42BAT OR/RD

C6B-24 C40LS OR

C6B-37 C37STC BL/BK

C1B-10 C36STCC BL

C1B-1 C27AUX RD C5B-5 C33STR BK C1B-7 C33STR BK C5B-22 C34SA BK/WH C1B-8 C34SA BK/WH C5B-18 C35HRPM BK/RD C1B-9 C35HRPM BK/RD

C23-4 P22BAT BK

19

19

18

17

15

14

12

11

SECONDARY BOOM UP

PRIMARY BOOM RETRACT

6 7

WH/BK-TS62 GR/WH

D

C6B-36 C36STCC BL

C7B-2 P23SWBAT WH

C6B-20 C22LS BK

C4B-7 C19LPMP GR/WH GR/WH-CR3

C4B-6 C18PRR GR/BK

C4B-5 C17PRL GR

C4B-3 C15PLD OR/BK

8 10

LIFT FLOW CONTROL PRIMARY BOOM EXTEND

5

WH-TS62

BRN GND GR/BK H6 RD TS55 RD TS51 BK C7-1 BK 22B BL/WH C1-12 RD H6

C6B-38 C19PSW GR/WH

C3B-12 C12DRE BL/WH C4B-2 C14PLU OR

6 7

TURNTABLE ROTATE RIGHT

2 4

RD-TS61 BK-ALARM RD/BK-TS61

C

C6B-18 C18PRR GR/BK

C6B-17 C17PRL GR

C6B-15 C15PLD OR/BK

C6B-14 C14PLU OR

C3B-11 C11SBD BL/BK

C3B-10 C10SBU BL

C3B-8 C8PBR BK/WH

C3B-7 C7PBE BK

5

PRIMARY BOOM DOWN TURNTABLE ROTATE LEFT

1

P20BAT RD

2

C6B-12 C12DRE BL/WH

C6B-11 C11SBD BL/BK

C6B-10 C10SBU BL

C6B-8 C8PBR BK/WH

C6B-7 C7PBE BK

C3B-5 C5TRR WH/BK C3B-6 C6LFC WH/RD

2 4

PRIMARY BOOM UP

A

B

FAULT STATUS LED

GR/BK C23-8 GR/BK L45 GR/BK C2B-6

C6B-6 C6LFC WH/RD

C6B-5 C5TRR WH/BK

C3B-4 C4TRL WH

1

B

A

C6B-4 C4TRL WH

C3B-2 C2PBD RD/BK

C3B-1 C1PBU RD

6

C6B-2 C2PBD RD/BK

C

3

RD C23-1 RD 134B

7 C6B-1 C1PBU RD

D

4 TERMINAL BASE (TB)

C23

1 1 3 4 5 6 7 8 12

Section 6 • Schematics February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, ANSI and CSA Models REV A

K

BK-ALARM

GR/WH RD RD/WH

OR/RD

RD/BK BK/RD

L M N

February 2006 REV A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models I

H

G

F

E

D

BK/RD

C

B

A

BK/RD-35A

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

1

BK

TS57 PLATFORM ROTATE

TS62 TURN TABLE ROTATE

TS63 PRIMARY BOOM EXTEND/ RETRACT

TS54 HIGH/LOW RPM

BK

BK RD

2

BK

RD/BK-2A

OR/BK-15A

OR/BK

OR-14A

OR

BK

RD

BK

GR/BK

RD

RD-27A

GR

RD

RD

TS59 PLATFORM LEVEL

GR/BK-44A TS58 JIB BOOM

TS61 PRIMARY BOOM

RD

RD

RD

WH

RD-1A

RD

3

BK

RD

BK RD C23-6

4

RD BK-22A

RD

P20BAT RD (C7B-4) RD CB1 CIRCUIT BREAKER 1

L45 PLATFORM OVERLOAD (CE ONLY)

BL-10A

+

KS1

BL/BK-11A

-

GR/WH-19A

BK

TS60 SECONDARY BOOM

P20BAT RD (C5B-1) RD 134A

5

RD

RD

RD

RD RD

6

RD

RD C23-7 RD

TS52 ENGINE START

GR/BK H6 WH 23A

BK-33A 1

Part No. 110188

RD

BK/WH-34A

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

RD

RD TS55 FUNCTION ENABLE

TS56 GLOW PLUG BASE BOX HARNESS

RD

RD

BRN

HOUR METER H.M.

2

7

BRN-HM

NC

WH C21IGN2 (C5B-11)

J

RD

K

TS51 AUXILIARY PUMP

L

D2

M

P1 EMERGENCY STOP

N

Section 6 • Schematics

8

6 - 20

February 2006

Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models

Section 6 • Schematics

February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models

GROUND STUD

8

6 - 21 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy C7B-3

Part No. 110188 BK

BATGND BRN

H6 C6B-13 C13DREL BL/RD C4B-1

C6B-16 C16DRE OR/RD C4B-4

C6B-28 C28TTA RD/BK C1B-2

C6B-29 C29JSH RD/WH C1B-3

C6B-30 C30FWD WH C1B-4

C6B-31 C31REV WH/BK C1B-5

C6B-32 C32JSL WH/RD C1B-6

BRN

87

C5B-2 30

86

87

30

87a

86

CR5 BRAKE RELEASE RELAY

85

OR/BK

87a

85

86 87

87a 85

30

BRN CR3 AUXILIARY CONTROL RELAY

OR/RD

134

44

42

40

RD KS1

GR/BK-TS58 RD H6

OR/RD-CR1 OR/RD-LED BK-ALARM

GR/WH-J19

GR/WH

GR/WH

86 87

87a 85

30

CR20 LIFT PUMP RELAY

BRN

(TO SWITCH PANEL)

GROUND CONTROL HARNESS

J

CR4 HORN RELAY

85

87

BRN

BK

OR/RD

OR/RD BRN

86

GR/WH RD/WH

BRN

85

87a

30

CR2 48V DC POWER RELAY

36 37

BK/RD-TS54 GR/WH-J19

I

C9HRN BK/RD

87

RD/WH

34 35

BK-TS52 BK/WH-TS56

BRN

C41DRE OR/BK

OR/RD BRN

86

87a

30

CR1 48V DC POWER RELAY

C3B-3 C3BAT RD/WH

C6B-9 R9HRN

C6B-3 P42BAT OR/RD C6B-39 CR5 RD/BK

C6B-35 R48BRK RD/WH

C6B-27 R27AUX C6B-19 R19LPMP GR/WH

27 33

WH-KS1 (D2) RD-CR3 RD-TS51

GR/WH-J19 BK-CR4 BK-KS1

H

BRN

C6B-21 BRN BRN

C6B-33 C44DA BK

BK

OR/RD

BRN

GR/WH

OR/RD

KEYSWEITCH POWER

JIB DESCENT ALARM

SWITCH 48 VOLTS

OFF-LIMIT SPEED

STEER RIGHT

STEER LEFT

HIGH/LOW RPM

GLOW PLUG

START ENGINE

AUXILIARY PUMP SELECT

23

22

19

GR-TS57 GR/BK-TS57 GR/WH GR/WH-TS60

G

C3B-9

C2B-3

5 C6B-26 C12DRE BL/WH

C6B-40 C40LS OR

C2B-7 C45JSV GR/WH

C5B-1 P20BAT RD C5B-11 C21IGN2 WH

134

44

42

40

37

36

35

34

33

27

KEYSWITCH POWER

+24V DC TO PLATFORM

LIFT PUMP

OR-TS59 OR/BK-TS59

F

BRN-HM

C6B-25 OR/RD-42A

C5B-3 C23PWR WH

C2B-5 C134PWR RD

C2B-6 C44JDA GR/BK C6B-34 C23ALARM RD

C2B-4 R42BAT OR/RD

C2B-2 C40LS OR

C1B-11 C37STC BL/BK

C1B-10 C36STCC BL

C1B-1 C27AUX RD C5B-5 C33STR BK C1B-7 C33STR BK C5B-22 C34SA BK/WH C1B-8 C34SA BK/WH C5B-18 C35HRPM BK/RD C1B-9 C35HRPM BK/RD

23

22

19

19

18

LIFT PUMP

PLATFORM ROTATE RIGHT/JIB DOWN

15 17

RD

PLATFORM ROTATE LEFT/JIB UP

PLATFORM LEVEL DOWN

14

C12DRE BL/WH

BK ALARM BL/BK-TS60

BL-TS60

BK/WH-TS63

BK-TS63

GR/WH

E

C6B-22 R42BAT OR/RD

C6B-24 C40LS OR

C6B-37 C37STC BL/BK

C6B-36 C36STCC BL

C7B-2 P23SWBAT WH

C23-4 P22BAT BK

19

18

17

15

PLATFORM LEVEL UP

12

11

10

8

7

WH-TS62 WH/BK-TS62

D

FAULT STATUS LED

P20BAT RD C7B-4 C6B-20 C22LS BK

C4B-7 C19LPMP GR/WH GR/WH-CR3

C4B-6 C18PRR GR/BK

C4B-5 C17PRL GR

14

FOOTSWITCH POWER #2

SECONDARY BOOM DOWN

SECONDARY BOOM UP

PRIMARY BOOM RETRACT

PRIMARY BOOM EXTEND

5 6

RD-TS61 BK-ALARM RD/BK-TS61

C

C6B-38 C19PSW GR/WH

C4B-2 C14PLU OR C4B-3 C15PLD OR/BK

12

11

10

8

7

LIFT FLOW CONTROL

TURNTABLE ROTATE RIGHT

4

2

1

BRN GND GR/BK H6 RD TS55 RD TS51 BK C7-1 BK 22B BL/WH C1-12 RD H6

C6B-18 C18PRR GR/BK

C6B-17 C17PRL GR

C6B-15 C15PLD OR/BK

C6B-14 C14PLU OR

C3B-12 C12DRE BL/WH

5 6

TURNTABLE ROTATE LEFT

PRIMARY BOOM DOWN

PRIMARY BOOM UP

P20BAT RD

2

C6B-12 C12DRE BL/WH

C3B-11 C11SBD BL/BK

C3B-10 C10SBU BL

C3B-8 C8PBR BK/WH

C3B-7 C7PBE BK

C3B-6 C6LFC WH/RD

C3B-5 C5TRR WH/BK

4

2

1

A

B

C6B-11 C11SBD BL/BK

C6B-10 C10SBU BL

C6B-8 C8PBR BK/WH

C6B-7 C7PBE BK

C6B-6 C6LFC WH/RD

C6B-5 C5TRR WH/BK

C3B-4 C4TRL WH

C3B-2 C2PBD RD/BK

B

A

GR/BK C23-8 GR/BK L45 GR/BK C2B-6

RD C23-1 RD 134B

7 C6B-4 C4TRL WH

6 C3B-1 C1PBU RD

4

C6B-1 C1PBU RD

C

3

C6B-2 C2PBD RD/BK

D

U33

TERMINAL BASE (TB)

1 1 3 4 5 6 7 8 12

Section 6 • Schematics February 2006

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models REV A

K

BK-ALARM

GR/WH RD RD/WH

OR/RD

RD/BK BK/RD

L M N

February 2006 REV A

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models I

H

G

F

E

D

BK/RD

C

B

A

BK/RD-35A

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

1

BK

TS57 PLATFORM ROTATE

TS62 TURN TABLE ROTATE

TS63 PRIMARY BOOM EXTEND/ RETRACT

TS54 HIGH/LOW RPM

BK

BK RD

2

BK

RD

RD/BK-2A

OR/BK-15A

OR/BK

OR-14A

OR

BK

RD

GR

RD-27A

BK

GR/BK

RD

RD

TS59 PLATFORM LEVEL

GR/BK-44A TS58 JIB BOOM

TS61 PRIMARY BOOM

RD

RD

RD

WH

RD-1A

RD

3

BK

RD

BK RD C23-6

4

RD BK-22A

RD

P20BAT RD (C7B-4) RD CB1 CIRCUIT BREAKER 1

L45 PLATFORM OVERLOAD (CE ONLY)

BL-10A

+

KS1

BL/BK-11A

-

GR/WH-19A

BK

TS60 SECONDARY BOOM

P20BAT RD (C5B-1) RD 134A

5

RD

RD

RD

RD RD

6

RD

RD C23-7 RD

TS52 ENGINE START

GR/BK H6 WH 23A

BK-33A 1

Part No. 110188

RD

BK/WH-34A

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

RD

RD TS55 FUNCTION ENABLE

TS56 GLOW PLUG BASE BOX HARNESS

RD

RD

BRN

HOUR METER H.M.

2

7

BRN-HM

NC

WH C21IGN2 (C5B-11)

J

RD

K

TS51 AUXILIARY PUMP

L

D2

M

P1 EMERGENCY STOP

N

Section 6 • Schematics

8

6 - 22

February 2006

Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models

Section 6 • Schematics

February 2006

Platform Control Box Wiring Diagram, Z-45/25

Section 6 • Schematics

February 2006 REV A

Platform Control Box Wiring Diagram, Z-45/25 A

B

C

D

E

F

G

H

I

J

K

L

M

N

1 BRN-RELAY

RD/BK-R6

OR/BK OR/BK-R6

CR6

2 P25BAT RD P24BAT WH P26BAT BK

BRN-BATGND P23SWBAT WH P22BAT BK

C19LPMP GR/WH C18PRR GR/BK C17PRL GR C16DRE OR/RD

1

1

1

C9P-3 C9P-2 C9P-1

C7P-3 C7P-2 C7P-1

C4P-7 C4P-6 C4P-5 C4P-4 C4P-3 C4P-2 C4P-1

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-4 C2P-3

C1P-11 C1P-10 C1P-9 C1P-8 C1P-7 C1P-6 C1P-5 C1P-4 C1P-3

3

C15PLD OR/BK C14PLU OR C13DREL BL/RD

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

1

C1P-1

R42BAT OR/RD R41DRE OR/BK

C27AUX RD RD/BK L48

C2P-5

C37STC BL/BK C36STCC BL C35HRPM BK/RD C34SA BK/WH C33STR BK C32JSL WH/RD C31REV WH/BK C30FWD WH C29JSH RD/WH

C134PWR RD

BRN-J1 BRN-BATGND

C1P-2

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

C28TTA RD/BK

4

C7P

C9P

JIB

LS18

OPT.

D40

A1 TILT ALARM

19/18 CONTROL CABLE

FOOT SWITCH

12V DC BATTERY

5 GR-LFC

DP1 GR

20k

TS12 TURNTABLE ROTATE

6

TS11 PRIMARY BOOM

TS10 SECONDARY BOOM

GR RD BK/RD

TS13 EXTEND/ RETRACT

OR WH

FWD REV

-

YL

LIFT DRIVE RIGHT LEFT

BL WH/YL WH/RD

2

C32JSL WH/RD

3 4 5 6 7 8 9

COMPONENT INDEX

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

1

C36STCC BL

P3

TS4 RPM

1

Part No. 110188

TS6 GLOW PLUG

1

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

TS9 PLATFORM LEVEL

2

TS7 PLATFORM ROTATE

1

2

L1

NC NC NC

2

TS1 AUXILIARY POWER

TS2 ENGINE START

P2 EMERGENCY STOP

C3BAT RD/WH C3-3

RD-HRN

RD/BK H1

C35HRPM BK/RD

RD-RPM RD-AUX

C33STR BK

NO

L48

TS15 DRIVE ENABLE

P23SWBAT WH C7P-2

1

RD

P22BAT BK C7P-1

10

NOTES: 1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.

C30FWD WH

3

4

RD P3 HORN

6 - 23

PRPL

C29JSH RD/WH

P26FS BK C9P-1

BRN-J1 BRN-BCI

C34SA BK/WH

C14PLU OR C15PLD OR/BK

C17PRL GR

C18PRR GR/BK

C13DREL BL/RD

BK/WH-DRE RD-DRE

RD-AUX

C27AUX RD

RD-HRN

C9HRN BK/RD

C6LFC WH/RD C19LPMP GR/WH P25BAT RD RD-SW

C7PBE BK C8PBR BK/WH

C2PBD RD/BK 1 C1PBU RD

C11SBD BL/BK C10SBU BL 1 C4TRL WH

C5TRR WH/BK

1

1

8

BP1

R42BAT OR/RD

BRN-BCI

7

RD WH/GR

+

BCI OPTION

BK

1

BCI BP1

BATTERY CHARGE INDICATOR ROTARY FLOW CONTROL DIAL

DP1 L1 LVI LVI/BCI P2 P3 TS1 TS2 TS4 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS15 H1 LS18 L4 L48

DRIVE JOYSTICK DRIVE ENABLE LED LOW VOLTAGE INTERRUPT MODULE BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP BUTTON HORN AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH / LOW RPM TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH PLATFORM ROTATE 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 TITL ALARM PLATFORM OVERLOAD LIMIT SWITCH PLATFORM OVERLOAD LED TILT ALARM LED

February 2006

Section 6 • Schematics

REV A

Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option

N

M

L

K

J

I

H

G

F

E

D

C

B

A

WH

1

1 OR/RD OR OR/BK OR/RD WH

CR8

WH BRN-RELAY

CR6

CR7

CR19A

LVI

1 2 3 4 5 6 7 8

RESET IS SET TO "B", DISCHARGE IS SET TO "N"

2

CR19B BRN-LVI P24BAT WH OR/RD-LVI OR/BK-LVI OR-LVI

RD-J7 P24BAT WH R42BAT OR/RD BL-LR19A

BL-L10 RD-LVI

RD-LR19B C40LS OR

C9P-2

C3P-10 C3P-1

C2P-4 C2P-2

GR/BK C133PLA

GR/BK L4

RD LS18

BK LS CABLE C1P-12

RD-H1

RD-P2

3

RD

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

C2P-6

D39

C7P

C9P

JIB

4

LS18

OPT.

1

A1 TILT ALARM

19/18 CONTROL CABLE

12V DC BATTERY

FOOT SWITCH

5 NOTES: 1. LOAD SENSE WIRES SHOWN WITH DASHED LINES

DP1 20k TS12 TURNTABLE ROTATE

LVI/BCI

TS11 PRIMARY BOOM

TS10 SECONDARY BOOM

TS13 EXTEND/ RETRACT

GR RD BK/RD

5

2

WH

FWD

4

RD

5

LIFT DRIVE

RD-LR19B

BL-LR19A

OR/BK-LVI

OR/RD-LVI

OR-LVI

RIGHT LEFT

P24BAT WH

6

YL

BP1

COMPONENT INDEX

3

BK

WH/GR

4

1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.

1

OR

REV

3

GR

1

PRPL

7

BL

RD-J7

8

WH/YL WH/RD

9 10

RD-LS18

GR/BK-H1 (D39)

1

TS6 GLOW PLUG

TS2 ENGINE START

1

TS9 PLATFORM LEVEL

1

L1

TS7 PLATFORM ROTATE

2

TS15 DRIVE ENABLE

1

2

TS1 AUXILIARY POWER

RD

NC NC NC

2

3

4

NO

P3 HORN

L4

P2 EMERGENCY STOP

TS4 RPM

Part No. 110188

6

BCI BP1

BATTERY CHARGE INDICATOR ROTARY FLOW CONTROL DIAL

DP1 L1 L2 LVI LVI/BCI P2 P3 TS1 TS2 TS4 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS15 A1 LS18 L4 L48

DRIVE JOYSTICK DRIVE ENABLE LED LOAD SENSE LED LOW VOLTAGE INTERRUPT MODULE BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP BUTTON HORN AUXILIARY TOGGLE SWITCH START ENGINE TOGGLE SWITCH HIGH / LOW RPM TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH PLATFORM ROTATE 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

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

7

8

6 - 24

February 2006

Section 6 • Schematics

Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option

Section 6 • Schematics

February 2006

Platform Control Box Wiring Diagram, Z-45/25J

Section 6 • Schematics

February 2006 REV B

Platform Control Box Wiring Diagram, Z-45/25J A

B

C

D

E

F

G

H

I

J

K

L

M

N

1 BRN-RELAY

OR/RD GR/WH-R7 GR/WH-45 GR/WH

CR7

RD-J7

RD/BK-R6

OR/BK OR/BK-R6

CR6

2

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

C28TTA RD/BK

C7P

C9P

WH

BK

C1P-2

4

GR/WH-45 GR/WH-45 BK-JIBGND

C9P-3 C9P-2 C9P-1

1

P25BAT RD P24BAT WH P26BAT BK

C7P-3 C7P-2 C7P-1

C4P-7 C4P-6 C4P-5 C4P-4 C4P-3 C4P-2 C4P-1

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

BRN-BATGND P23SWBAT WH P22BAT BK

C19LPMP GR/WH C18PRR GR/BK C17PRL GR C16DRE OR/RD

C15PLD OR/BK C14PLU OR C13DREL BL/RD

1

C1P-11 C1P-10 C1P-9 C1P-8 C1P-7 C1P-6 C1P-5 C1P-4 C1P-3

1

C1P-1

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

C37STC BL/BK C36STCC BL C35HRPM BK/RD C34SA BK/WH C33STR BK C32JSL WH/RD C31REV WH/BK C30FWD WH C29JSH RD/WH

1

C27AUX RD RD/BK L48

C2P-5

C45JSV GR/WH C44JDA GR/BK R42BAT OR/RD R41DRE OR/BK

C134PWR RD

3

BRN-J1 BRN-BATGND BRN-JIBGND

JIB

LS18

OPT.

D40

A1 TILT ALARM

19/18 CONTROL CABLE

FOOT SWITCH

12V DC BATTERY

5 GR-LFC

DP1

NOTES: GR

20k

6

TS11 PRIMARY BOOM

TS10 SECONDARY BOOM

TS12 TURNTABLE ROTATE

GR RD BK/RD

TS13 EXTEND/ RETRACT

OR WH

FWD REV

-

YL

LIFT DRIVE

LEFT

PRPL BL WH/YL WH/RD

C29JSH RD/WH

2

C32JSL WH/RD

3 4 5 6 7 8 9

COMPONENT INDEX

C30FWD WH 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

1

C36STCC BL

P3

TS4 RPM

1

Part No. 110188

TS6 GLOW PLUG

1

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

TS9 PLATFORM LEVEL

2

TS7 PLATFORM ROTATE

1

2

L1

TS8 JIB BOOM

NC NC NC

2

TS1 AUXILIARY POWER

L48

TS2 ENGINE START

P2 EMERGENCY STOP

C3BAT RD/WH C3-3

RD-HRN

RD/BK H1

C35HRPM BK/RD

RD-RPM RD-AUX

C33STR BK

NO

3

4

RD DRIVE ENABLE

P23SWBAT WH C7P-2

1

RD

P22BAT BK C7P-1

10

1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.

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

C13DREL BL/RD

BK/WH-DRE RD-DRE

RD-AUX

C27AUX RD

RD-HRN

C9HRN BK/RD

C44JDA GR/BK

RIGHT

TS15

P3 HORN

6 - 25

C5TRR WH/BK

1

1

8

BP1

R42BAT OR/RD

BRN-BCI

7

RD WH/GR

+

BCI OPTION

BK

1

BCI BP1

BATTERY CHARGE INDICATOR ROTARY FLOW CONTROL DIAL

DP1 L1 LVI LVI/BCI P2 P3 TS1 TS2 TS4 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS15 H1 LS18 L4 L48

DRIVE JOYSTICK DRIVE ENABLE LED LOW VOLTAGE INTERRUPT MODULE BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP BUTTON 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 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

February 2006

Section 6 • Schematics

REV A

Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option

N

M

L

K

J

I

H

G

F

E

D

C

B

A

WH

1

1 OR/RD OR OR/BK OR/RD WH

CR8

WH BRN-RELAY

CR6

CR7

CR19A

LVI

1 2 3 4 5 6 7 8

RESET IS SET TO "B", DISCHARGE IS SET TO "N"

2

CR19B

BRN-LVI P24BAT WH OR/RD-LVI OR/BK-LVI OR-LVI

RD-J7 P24BAT WH R42BAT OR/RD BL-LR19A

BL-L10 RD-LVI

RD-LR19B C40LS OR

C9P-2

C3P-10 C3P-1

C2P-4 C2P-2

GR/BK C133PLA

GR/BK L4

RD LS18

BK LS CABLE C1P-12

RD-H1

RD-P2

3

RD

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

C2P-6 D39

C7P

C9P

JIB

4

LS18

OPT.

1

A1 TILT ALARM

19/18 CONTROL CABLE

12V DC BATTERY

FOOT SWITCH

5 NOTES: 1. LOAD SENSE WIRES SHOWN WITH DASHED LINES 1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.

DP1 20k TS12 TURNTABLE ROTATE

LVI/BCI

TS11 PRIMARY BOOM

TS10 SECONDARY BOOM

TS13 EXTEND/ RETRACT

GR RD BK/RD

5

1

OR

FWD

3

BK

4

RD

5

WH/GR

4

BP1

DRIVE

RD-LR19B

BL-LR19A

OR/BK-LVI

OR/RD-LVI

OR-LVI

RIGHT LEFT

P24BAT WH

6

YL

LIFT

COMPONENT INDEX

2

WH

REV

3

GR

1

PRPL

7

BL

RD-J7

8

WH/YL WH/RD

9 10

RD-LS18

GR/BK-H1 (D39)

1

TS9 PLATFORM LEVEL

TS6 GLOW PLUG

TS2 ENGINE START

1

TS7 PLATFORM ROTATE

1

L1

TS8 JIB BOOM

2

TS15 DRIVE ENABLE

1

2

TS1 AUXILIARY POWER

RD

NC NC NC

2

3

4

NO

P3 HORN

L4

P2 EMERGENCY STOP

TS4 RPM

Part No. 110188

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

DRIVE JOYSTICK DRIVE ENABLE LED LOAD SENSE LED LOW VOLTAGE INTERRUPT MODULE BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP BUTTON HORN AUXILIARY TOGGLE SWITCH START ENGINE TOGGLE SWITCH HIGH / LOW RPM TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH JIB 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

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

6

7

8

6 - 26

February 2006

Section 6 • Schematics

Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option

February 2006

Section 6 • Schematics

REV B

Hydraulic Schematic

N

M

L

K

J

I

H

G

F

D

C

B

A

1

PLATFORM ROTATE

JIB BOOM

L

R

3:1 3000 psi 207 bar

1.5:1 3800 psi 262 bar

E

R

PR2

PR1

J1

J2

PR2

PR1

2

JIB BOOM / PLATFORM ROTATE MANIFOLD

AA

3

V1

V2

PLATFORM LEVEL SLAVE CYLINDER BRAKES

E

TURNTABLE ROTATE

PRIMARY LIFT CYLINDER

SECONDARY LIFT CYLINDERS

EXTENSION CYLINDER

STEER CYLINDERS M

M

Z

3:1 3000 psi 207 bar

4

Y 1:1 ATMOS. 3500 psi 241 bar

3:1 3500 psi 241 bar S1

0.030 inch 0.76 mm

3:1 ATMOS. 1500 psi 103 bar

3:1 1000 psi 69 bar 3:1 3800 psi 262 bar

X

MASTER V2

5

V1

J

COM TEST P

AUXILIARY PUMP M 0.5 gpm 1.9L/min

BRAKE

ST2

ST1

PS

PR1

PR2

PL2

PL1

SW2

SW1

S

U

N

M

O

2500 psi 172 bar

H

P

SEC2

SEC1

G

3200 psi 221 bar PRIMARY PUMP 2.1 gpm 7.9 L/min

N.O. N.C.

V

0.030 inch 0.76 mm

RESERVOIR

T

0.030 inch 0.76 mm (from serial number 22566 to 22628 and after serial number 23235)

EXT

6 A

F D

0.4 gpm 1.5 L/min

RET

W 2000 psi 138 bar

E

R I

P2

0.037 inch 0.94 mm

Q 0.060 inch 1.5 mm

P1

C

B

K

L

7

M

T

FUNCTION MANIFOLD

8

Part No. 110188

Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

6 - 27

February 2006

Section 6 • Schematics

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.

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