Genie Z-45/25 Bi-Energy Service Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Lifting Systems
  5. Z-45/25
  6. Service manual

Genie Z-45/25 Bi-Energy Service Manual

Hide thumbs Also See for Z-45/25 Bi-Energy:
Table of Contents

Advertisement

Quick Links

See also: Service & Repair Manual , Service Manual
Service Manual
Part No. 106488
Rev A2
Refer to inside cover for serial number information
March 2005

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Z-45/25 Bi-Energy and is the answer not in the manual?

Questions and answers

Related Manuals for Genie Z-45/25 Bi-Energy

Summary of Contents for Genie Z-45/25 Bi-Energy

  • Page 1 Service Manual Part No. 106488 Rev A2 Refer to inside cover for serial number information March 2005...

  • Page 2: Introduction

    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.
  • Page 3 July 2004 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...
  • Page 4 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 . Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 5: Table Of Contents

    Maintenance Inspection Report ................3 - 5 Checklist A Procedures Perform Pre-operation Inspection ..............3 - 7 Check for Fuel Leaks ................... 3 - 7 Check for Hydraulic Leaks ................3 - 8 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 6 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 - 22 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 7 Checklist E Procedures Test or Replace the Hydraulic Oil ............... 3 - 37 Perform Engine Maintenance ..............3 - 38 Grease the Steer Axle Wheel Bearings ............3 - 39 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 8 Secondary Boom Lift Cylinders ..............4 - 25 Kubota Z482-E Engine Timing Adjustment ..................4 - 27 RPM Adjustment ..................4 - 27 Engine Drive Pulley ..................4 - 27 viii Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 9 10-1 Rotation Hydraulic Motor (before serial number 18367) ....... 4 - 48 10-2 Turntable Rotation Assembly (after serial number 18366) ......4 - 50 Motor Controller 11-1 Motor Controller ..................4 - 52 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 10 Engine Panel Diagram (from serial number 17975 to 21180) ........ 6 - 14 Engine Panel Diagram (from serial number 21181 to 22050) ........ 6 - 15 Engine Panel Diagram (after serial number 22050) ..........6 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 11 Electrical Schematic, Z-45/25J (from serial number 21181 to 22050) ....6 - 47 Electrical Schematic, Z-45/25J, ANSI and CSA Models (after serial number 22050) .................. 6 - 49 Electrical Schematic, Z-45/25J, CE Models (after serial number 22050) .................. 6 - 51 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 12 Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 17975 to 21180) ..............6 - 64 Ground Control Box Terminal Srip Wiring Diagram, Z-45/25 (from serial number 21181 to 22050) ..............6 - 65 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 13 Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J (from serial number 16840 to 17974) ..............6 - 79 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 16840 to 17974) ..............6 - 80 xiii Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 14 (from serial number 14079 to 14650) ..............6 - 93 Platform Control Box Wiring Diagram, Z-45/25 (with platform load sense and LVI/BCI option) (from serial number 14079 to 14650) ..............6 - 94 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 15 (from serial number 13361 to 14078) ..............6 - 107 Platform Control Box Wiring Diagram, Z-45/25J (with platform load sense and LVI/BCI option) (from serial number 13361 to 14078) ..............6 - 108 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy...
  • Page 16 Hydraulic Schematic (from serial number 16962 to 20379) ........6 - 122 Hydraulic Schematic (from serial number 20380 to 22565) ........6 - 123 Hydraulic Schematic (after serial number 22565) ..........6 - 124 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 17: Machine Specifications

    Continuous improvement of our products is a 6.89 bar Genie policy. Product specifications are subject to change without notice. For operational specifications, refer to the Performance Specifications Operator's Manual. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 1...
  • Page 18 Platform rotate, 180°, Z-45/25 6 to 10 seconds Platform rotate, 160°, Z-45/25J 6 to 10 seconds Platform level up 50 to 55 seconds Platform level down 35 to 45 seconds 2 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 19: Hydraulic Specifications

    Consult (after serial number 22565) 1.5 L/min the Genie Industries Service Department before use. Auxiliary pump Type: fixed displacement gear pump Displacement 0.5 gpm 1.9 L/min Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 3...

  • Page 20: Manifold Component Specifications

    Solenoid valve, N.C. poppet, 20V DC (schematic items F, LL and BI) 25 to 28 Ω Solenoid valve, N.O. poppet, 20V DC (schematic items B, VV and BT) 2 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 21: A Kubota Z482-E Engine Specifications

    2.48 to 4.41 bar Oil capacity 2.6 quarts (including filter) 2.5 liters Oil viscosity 10W-30 requirements Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 5...

  • Page 22: Generator

    12.2 Nm #10 screw 25 in-lbs 2.8 Nm #10 nut 25 in-lbs 2.8 Nm #4 nut 8-10 in-lbs 0.9-1.1 Nm Voltage regulator 25 in-lbs mounting fasteners 2.8 Nm 2 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    210 ft-lbs / 284.7 Nm 120 ft-lbs / 162.7 Nm 260 ft-lbs / 352.5 Nm 140 ft-lbs / 190 Nm 315 ft-lbs / 427.1 Nm 165 ft-lbs / 223.7 Nm Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 7...
  • Page 24 Section 2 • Specifications July 2004 This page intentionally left blank. 2 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 25 · Turntable secured with the turntable performing a series of steps. rotation lock · Key switch in the off position with the key removed · Wheels chocked Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 1...
  • Page 26 Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. Indicates that dealer service will be required to perform this procedure. 3 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 27: Pre-Delivery Preparation

    Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 3 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 28 Section 3 • Scheduled Maintenance Procedures July 2004 This page intentionally left blank. 3 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 29: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 5...
  • Page 30 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 31: Checklist A Procedures

    Always have an Complete information to perform this procedure is approved fire extinguisher within available in the Genie Z-45/25 Bi-Energy and easy reach. Genie Z-45/25J Bi-Energy Operator's Manual on 1 Perform a visual inspection around the areas your machine.

  • Page 32: Check For Hydraulic Leaks

    1 Be sure that all fasteners and cables on the generator are tight. 2 Be sure that the pulley mounting fasteners are tight and that the pulleys show no signs of damage or unusual wear. 3 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 33 Engine Drive Pulley to adjust the generator pulley pulley alignment. 7 Check the torque of the pulley retaining nut on the generator. Refer to Section 2, S pecifications . Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 9...

  • Page 34: Perform Function Tests

    Complete information to perform this procedure is to good engine performance and service life. available in the Genie Z-45/25 Bi-Energy and Failure to perform the maintenance procedures Genie Z-45/25J Bi-Energy Operator's Manual on can lead to poor engine performance and your machine.

  • Page 35: Perform Engine Maintenance

    1 Remove the engine pivot plate latch retainer. located under the turntable. 2 Open the engine pivot plate latch and swing the engine out away from the machine. Grease type Multipurpose grease Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 11...

  • Page 36: Perform Engine Maintenance

    2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the engine out away from the machine. engine out away from the machine. 3 - 12 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 37: Perform Engine Maintenance

    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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 13...

  • Page 38: Checklist B Procedures

    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. 3 - 14 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 39: Check The Batteries

    1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 15...

  • Page 40: Inspect The Electrical Wiring

    · Cable track on the primary, jib and Refer to Section 2, Specifications. secondary booms · Jib boom to platform cable harness · Inside of the platform control box 3 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 41: Confirm The Proper Brake Configuration

    1 Check each drive hub disconnect cap to be at 90 degrees. sure it is in the engaged position. brake disengaged position brake engaged position models with pipe plugs models with o-ring plugs Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 17...

  • Page 42: Check And Adjust The Engine Rpm

    3 Connect an rpm gauge to the engine, and then start the engine from the ground controls. Result: Low idle should be 2000 rpm. Skip to step 5 if the low idle rpm is correct. 3 - 18 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 43: Test The Ground Control Override

    Skip to step 7 if the high idle rpm is correct. 3 Operate each boom function through a partial cycle at the ground controls. Result: All boom functions should operate. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 19...

  • Page 44: Test The Platform Self-Leveling

    5 At the platform controls, move the engine idle all times to within ±5 degrees. select toggle switch to high idle (rabbit symbol). Result: The engine should change to high idle. 3 - 20 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 45: Test The Drive Brakes

    Refer to Section 2, Specifications . The brakes must be able to hold the machine on any slope it is able to climb. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 21...

  • Page 46: Test The Drive Speed - Stowed Position

    Refer to Section 2, Specifications . finish line. Refer to Section 2, Specifications . 3 - 22 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 47: Test The Alarm Package (If Equipped)

    Z-45/25J: Move the jib boom toggle switch to the down position, hold for a moment and then release it. Result: The descent alarm should sound when each toggle switch is held down. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 23...

  • Page 48: Test The Turntable Rotation Stop

    Result: Movement should stop when the all rings, watches and other primary boom reaches mid-point between the jewelry. steer tires. Replace the contactors if any damage is found. 3 - 24 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 49: Replace The Hydraulic Tank Return Filter

    6 Turn the key switch to ground controls and pull Test or Replace the Hydraulic Oil. out the red Emergency Stop button out to the on position at both the ground and platform controls. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 25...

  • Page 50: Perform Engine Maintenance

    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. 3 - 26 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 51: Checklist C Procedures

    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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 27...
  • Page 52 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. 3 - 28 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 53 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 29...

  • Page 54: Perform Engine Maintenance

    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. 3 - 30 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 55: Checklist D Procedures

    Always maintain squareness between the outer and inner boom tubes. Wear pad specifications All wear pads inch 14.3 mm Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 31...
  • Page 56 Bolt torque sequence (before serial number 23332) Bolt torque sequence (before serial number 23332) Bolt torque sequence (after serial number 23331) Bolt torque sequence (after serial number 23331) 3 - 32 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 57: Check The Free-Wheel Configuration

    4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub. brake disengaged position brake engaged position Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 33...

  • Page 58: Replace The Drive Hub Oil

    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. models with o-ring plugs 3 - 34 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 59 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 35...

  • Page 60: Perform Engine Maintenance

    2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the engine out away from the machine. engine out away from the machine. 3 - 36 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 61: Checklist E Procedures

    Fitting Torque Specifications. the oil pressure to dissipate gradually. Do not allow oil to squirt 1 Place a suitable container under the hydraulic or spray. tank. See capacity specifications. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 37...

  • Page 62: Perform Engine Maintenance

    2 Open the engine pivot plate latch and swing the engine out away from the machine. 17 Operate all machine functions through a full cycle and check for leaks. 3 - 38 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 63: Grease The Steer Axle Wheel Bearings

    Result: There should be no side to side or up rear bearing. and down movement. 14 Pack both bearings with clean, fresh grease. Skip to step 10 if there is no movement. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 39...
  • Page 64 23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 3 - 40 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 65 · Key switch in the off position with the Indicates that a specific result is expected after key removed performing a series of steps. · Wheels chocked Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 1...

  • Page 66: Platform Controls

    2 Open the platform control box lid and locate the boom function speed controller. threshold adjustable trimpot max-out adjustable trimpot white/red wire to TP6 boom function speed controller boom function speed controller drive joystick 4 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 67 9 Before serial number 21180: Remove the temporary wire from TP6 and install the wht/red wire into TP6. Boom function speed controller specifications Threshold 0.17 to 0.18A Max-out 0.54 to 0.55A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 3...

  • Page 68: Platform Components

    5 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not remove the pin. 4 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 69 10 Use a soft metal drift to remove the rod-end pivot pin. 11 Use a soft metal drift to remove the barrel-end pivot pin. 12 Carefully pull the cylinder out of the primary boom. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 5...

  • Page 70: Platform Rotator

    8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. top bleed valve bottom bleed valve container clear hose 4 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 71: A Jib Boom Components, Z-45/25J Models

    Do not allow oil to and fall when removed from the squirt or spray. machine if not properly attached to the overhead crane. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 7...

  • Page 72: Jib Boom Lift Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 73: Primary Boom Components

    4 Raise the primary boom to a horizontal position. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 9...
  • Page 74 3 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 4 - 10 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 75 Do not allow oil to secured together, the cable track squirt or spray. could become unbalanced and fall when removed from the machine. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 11...
  • Page 76 Install the pin retaining fastener. 22 Attach a strap from an overhead crane to the cable track. 4 - 12 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 77: Primary Boom

    3 Z-45/25: Remove the platform leveling slave cylinder. See 2-1, How to Remove the Platform Leveling Slave Cylinder. Z-45/25J: Remove the jib boom. See 3-1, How to Remove the Jib Boom. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 13...
  • Page 78 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 14 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 79 During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 15...

  • Page 80: Primary Boom Lift Cylinder

    Do not lift the boom. cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. 4 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 81: Primary Boom Extension Cylinder

    Note the length of the cylinder after removal. The cylinder must be at the same length for installation. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 17...

  • Page 82: Platform Leveling Master Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 18 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 83 July 2004 Section 4 • Repair Procedures REV A PRIMARY BOOM COMPONENTS This page intentionally left blank. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 19...

  • Page 84: Secondary Boom Components

    (number 2 arm) lower tension link (number 3 arm) mid-pivot compression link secondary boom lift cylinder (2) lower secondary boom (number 4 arm) turntable pivot boom rest upper pivot 4 - 20 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 85: Secondary Boom

    3 Remove the primary boom. See 3-2, How to connections very slowly to allow Remove the Primary Boom . the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 21...
  • Page 86 30 cm block. 16 Attach a lifting strap from an overhead crane to the upper pivot for support. Do not lift it. 4 - 22 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 87 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch / 10 x 10 x 30 cm block. 30 Lower the number 2 arm onto the boom rest pad. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 23...
  • Page 88 51 Remove the number 3 arm from the machine. pinched. Crushing hazard. The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 4 - 24 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 89: Secondary Boom Lift Cylinders

    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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 25...
  • Page 90 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. 4 - 26 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 91: Kubota Z482-E Engine

    3 Loosen the tension adjustment bolt on the generator. shaft set screw engine drive pulley engine drive pulley bolt shaft bushing woodruff key Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 27...
  • Page 92 If the pulley alignment is not within generator specification, remove the engine pulley and repeat steps 2 through 6. See 6-4, How to Remove the Engine Drive Pulley. 4 - 28 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 93: Generator

    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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 29...

  • Page 94: Generator Belts

    4 and 5 and re-check the belt tension. electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. engine pulley generator belts generator pulley 4 - 30 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 95 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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 31...
  • Page 96 When the voltage regulator is replaced, the voltage regulator must be adjusted. See 7-3, How to Adjust the Voltage Regulator. 4 - 32 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 97: Hydraulic Pumps

    Do not allow oil to squirt or spray. or spray. 7 Remove the pump mounting bolts. Carefully 7 Remove the pump mounting bolts. Carefully remove the pump. remove the pump. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 33...

  • Page 98: Manifolds

    0.6 gpm / 2.27 L/min ......S ... Turntable rotate left/right (prevents overflowing the proportional valve) ......10-12 ft-lbs / 14-6 Nm This list continues. Please turn the page 4 - 34 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 99 August 2004 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 35...
  • Page 100 Diagnostic nipple ....... W ..Testing Check valve ........X ... Pressure switch circuit ......10-12 ft-lbs / 14-6 Nm Pressure switch ......... Y ... Brake circuit 4 - 36 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 101 August 2004 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 37...

  • Page 102: Function Manifold Components (From Serial Number 17841 To 20379)

    Orifice, 0.30 inch / 0.76 mm (located under item VV) ..... AW ..Brake circuit Orifice, 0.46 inch / 1.17 mm ....AX ..Secondary boom up 4 - 38 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 103 August 2004 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 39...

  • Page 104: Function Manifold Components (From Serial Number 20380 To 22565)

    Counterbalance valve ......BW ..Platform level up ....... 20-25 ft-lbs / 27-34 Nm Relief valve, 1800 psi / 124 bar ..BX ..Secondary boom down ........ 20 ft-lbs / 27 Nm 4 - 40 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 105 August 2004 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 41...

  • Page 106: Function Manifold Components (After Serial Number 22565)

    Check valve, pilot operated ....CV ..Platform level circuit ........20 ft-lbs / 27 Nm Relief valve, 2100 psi / 145 bar ..CW ..Secondary boom down circuit ...... 20 ft-lbs / 27 Nm 4 - 42 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 107 August 2004 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 43...

  • Page 108: Valve Adjustments - Function Manifold

    5 Repeat steps 2 through 4 and recheck relief Tip-over hazard. Do not adjust valve pressure. the relief valve higher than specified. 5 Repeat steps 2 through 4 and recheck relief valve pressure. 4 - 44 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 109 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. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 45...

  • Page 110: Jib Boom / Platform Rotate Manifold Components

    Solenoid valve, 2 position 3 way ..DC ..Jib boom / platform rotate select ....20 ft-lbs / 27 Nm From serial number Before serial number 16963 16963 to 22565 After serial number 22565 4 - 46 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 111: Turntable Rotation Manifold Components

    Counterbalance valve ......CY ..Turntable rotate right ......30-35 ft-lbs / 41-47 Nm Counterbalance valve ......CZ ..Turntable rotate left ......30-35 ft-lbs / 41-47 Nm Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 47...

  • Page 112: Turntable Rotation Components

    13 Remove the turntable rotation motor mounting fasteners. Remove the motor from the brake. 14 Remove the turntable rotation motor from the machine. Locked position 4 - 48 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 113 4 Open the engine pivot plate latch and swing the the turntable rotation lock is not in engine out away from the machine to access the locked position. the turntable rotation motor and brake. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 49...

  • Page 114: Turntable Rotation Assembly (After Serial Number 18366)

    Unlocked position 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 4 - 50 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 115 Crushing hazard. The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 51...

  • Page 116: Motor Controller

    500kΩ or more electrically charged circuits could result in death or serious injury. Pin 20 to B- 500kΩ or more Remove all rings, watches and other jewelry. 4 - 52 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 117 Do not allow oil to squirt or spray. Perform all troubleshooting on a firm level surface. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 5 - 1...
  • Page 118 M1 MAX SPEED higher or lower to achieve the maximum raised drive speed of 0.6 mph / 1Km/h or 40 feet / 45 seconds / 12.2 meters / 45 seconds. 5 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 119: Fault Code Chart

    Replace the motor ARM SENSOR Machine will not drive. controller. controller. Defective motor Replace the motor FLD SENSOR Machine will not drive. controller. controller. Continued on next page Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 5 - 3...
  • Page 120 Machine will not drive. controller and ground Note: Short can be on OR motor controller is any part of circuit defective. connected to the B+ terminal on the motor controller. 5 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 121 OR check for OR motor controller is mechanical restrictions not being cooled causing excessive load sufficently. on the machine. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 5 - 5...
  • Page 122 Section 5 • Fault Codes July 2004 This page intentionally left blank. 5 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 123 Be sure that all necessary tools and test Identify Malfunction Troubleshoot equipment are available and ready for use. discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 1...

  • Page 124: Electrical Symbols Legend

    Horn button normally open Circuits crossing no connection Red Emergency Stop button Relay panel Diode normally closed contactor Battery Relay contact Toggle switch SPDT normally open 6 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 125: Hydraulic Symbols Legend

    Priority flow regulator N.C. Bi-directional motor 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. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 3...
  • Page 126 Section 6 • Schematics July 2004 6 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 127: Power Cable Diagrams

    Section 6 • Schematics July 2004 Power Cable Diagram (before serial number 16839)

  • Page 128: Power Cable Diagram (From Serial Number 16840 To 21179)

    BLACK-FROM CHARGER RIGHT SIDE DRIVE MOTOR RED-10GA BLK-2GA BRN-J8 BLK-2GA BLK-2GA BLACK-2GA RED-2GA NOTES: MOTOR CONTROLLER CHASSIS GROUND 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED 6 - 5 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 129 BLACK-FROM CHARGER RIGHT SIDE DRIVE MOTOR RED-10GA BLK-2GA BRN-J8 BLK-2GA BLK-2GA BLACK-2GA RED-2GA NOTES: MOTOR CONTROLLER CHASSIS GROUND 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 6...
  • Page 130 July 2004 Section 6 • Schematics Power Cable Diagram (from serial number 16840 to 21179)

  • Page 131: Power Cable Diagram (From Serial Number 21180 To 22050)

    Section 6 • Schematics July 2004 Power Cable Diagram (from serial number 21180 to 22050)
  • Page 132 DRIVE MOTOR BK-FROM CHARGER RD-10GA DRIVE MOTOR BK-2GA BRN-J8 BK-2GA BK-2GA BK-2GA RD-2GA NOTES: CHASSIS 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED. GROUND MOTOR CONTROLLER 6 - 7 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 133: Power Cable Diagram (After Serial Number 22050)

    DRIVE MOTOR BK-FROM CHARGER RD-10GA DRIVE MOTOR BK-2GA RD-10GA BRN-J8 BK-2GA BK-2GA BK-2GA NOTES: RD-2GA 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED. CHASSIS GROUND MOTOR CONTROLLER Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 8...
  • Page 134 July 2004 Section 6 • Schematics Power Cable Diagram (after serial number 22050)

  • Page 135: Engine Panel Diagrams

    Section 6 • Schematics July 2004 Engine Panel Diagram (before serial number 13361)
  • Page 136 MODULE 12/24V DC ENGINE HARNESS (TO CHASSIS HARNESS) 12V VOLTAGE ENGINE HARNESS MALE DEUTSCH (TO ENGINE) 9 10 11 12 CONNECTOR REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS 6 - 9 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 137: Engine Panel Diagram (From Serial Number 13361 To 14078)

    RED-ISM6 WHITE-23 GRN/BLK-BATT. WHT-ISM10 ENGINE HARNESS (TO CHASSIS HARNESS) ENGINE HARNESS (TO ENGINE) MALE DEUTSCH 11 12 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 10...
  • Page 138 July 2004 Section 6 • Schematics Engine Panel Diagram (from serial number 13361 to 14078)

  • Page 139: Engine Panel Diagram (From Serial Number 14079 To 14650)

    Section 6 • Schematics July 2004 Engine Panel Diagram (from serial number 14079 to 14650)
  • Page 140 RED-ISM6 WHITE-23 GRN/BLK-BATT. WHT-ISM10 ENGINE HARNESS (TO CHASSIS HARNESS) ENGINE HARNESS (TO ENGINE) MALE DEUTSCH 11 12 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS 6 - 11 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 141: Engine Panel Diagram (From Serial Number 14651 To 16839)

    RED-ISM6 WHT-23 GRN/BLK-BATT. WHT-ISM10 ENGINE HARNESS (TO CHASSIS HARNESS) ENGINE HARNESS (TO ENGINE) MALE DEUTSCH 11 12 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 12...
  • Page 142 July 2004 Section 6 • Schematics Engine Panel Diagram (from serial number 14651 to 16839)

  • Page 143: Engine Panel Diagram (From Serial Number 16840 To 17974)

    Section 6 • Schematics July 2004 Engine Panel Diagram (from serial number 16840 to 17974)
  • Page 144 RED-ISM6 WHT-23 GRN/BLK-BATT. WHT-ISM10 ENGINE HARNESS (TO CHASSIS HARNESS) ENGINE HARNESS (TO ENGINE) MALE DEUTSCH 11 12 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS 6 - 13 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 145: Engine Panel Diagram (From Serial Number 17975 To 21180)

    RED-ISM6 WHT-23 GRN/BLK-BATT. WHT-ISM10 ENGINE HARNESS (TO CHASSIS HARNESS) ENGINE HARNESS (TO ENGINE) MALE DEUTSCH 11 12 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR CHASSIS HARNESS Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 14...
  • Page 146 July 2004 Section 6 • Schematics Engine Panel Diagram (from serial number 17975 to 21180)

  • Page 147: Engine Panel Diagram (From Serial Number 21181 To 22050)

    Section 6 • Schematics July 2004 Engine Panel Diagram (from serial number 21181 to 22050)
  • Page 148 P20BAT RD C23PWR WH ENGINE HARNESS (TO DRIVE CHASSIS) GR/BK-BATT ENGINE HARNESS (TO ENGINE) WH-ISM10 ENGINE HARNESS (TO GROUND CONTROL BOX) 12V DC VOLTAGE REGULATOR MALE DEUTSCH CONNECTOR 6 - 15 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 149: Engine Panel Diagram (After Serial Number 22050)

    P20BAT RD C23PWR WH ENGINE HARNESS (TO DRIVE CHASSIS) GR/BK-BATT ENGINE HARNESS (TO ENGINE) WH-ISM10 ENGINE HARNESS (TO GROUND CONTROL BOX) 12V DC VOLTAGE REGULATOR MALE DEUTSCH CONNECTOR Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 16...
  • Page 150 July 2004 Section 6 • Schematics Engine Panel Diagram (after serial number 22050)
  • Page 152 1. ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT AS NOTED. 2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED. 6 - 17 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 153 LS3* PLATFORM LEVEL CUTOUT (CE VERSION ONLY) SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL CR10B CR10A TB16 FUNCTION MANIFOLD BRAKE/STEER (GND) GROUND MANIFOLD GROUND (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 18...

  • Page 154: Electrical Schematic, Z-45/25 (Before Serial Number 13361)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (before serial number 13361)
  • Page 156 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 19 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 157 ENABLE (CE MODELS ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD BRAKE/STEER (GND) GROUND MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 20...

  • Page 158: Electrical Schematic, Z-45/25 (From Serial Number 13361 To 14078)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 13361 to 14078)
  • Page 160 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 21 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 161 TB11 TB17 TB36 WHT/RED-6 TB14 TB15 DRIVE PLATFORM LEVEL CUTOUT ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 22...

  • Page 162: Electrical Schematic, Z-45/25 (From Serial Number 14079 To 14650)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 14079 to 14650)
  • Page 164 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 23 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 165 TB11 TB17 TB36 WHT/RED-6 TB14 TB15 DRIVE PLATFORM LEVEL CUTOUT ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 24...

  • Page 166: Electrical Schematic, Z-45/25 (From Serial Number 14651 To 16839)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 14651 to 16839)
  • Page 168 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 25 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 169 TB11 TB17 TB36 WHT/RED-6 TB14 TB15 DRIVE PLATFORM LEVEL CUTOUT ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 26...

  • Page 170: Electrical Schematic, Z-45/25 (From Serial Number 16840 To 17974)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 16840 to 17974)
  • Page 172 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 27 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 173 TB10 TB17 TB36 WHT/RED-6 TB14 TB15 DRIVE PLATFORM LEVEL CUTOUT ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD BRAKE/STEER GROUND (GND) MANIFOLD GROUND (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 28...

  • Page 174: Electrical Schematic, Z-45/25 (From Serial Number 17975 To 21180)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 17975 to 21180)
  • Page 176 RIGHT ALT. (12V DC) MOTOR (PRI) STARTER PUMP PUMP AUXILIARY ALTERNATOR CHARGER (EXT) WH-BATT AC POWER (12V DC) OR-GEN NEG CR16 GROUND ENGINE OR-GEN POS GROUND (GND) 6 - 29 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 177 JACK TS62 TS60 TS61 TS59 TS57 TS63 TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB11 TB10 TB15 TB14 TB17 TB36 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 30...

  • Page 178: Electrical Schematic, Z-45/25 (From Serial Number 21181 To 22050)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25 (from serial number 21181 to 22050)

  • Page 180: Electrical Schematic, Z-45/25, Ansi And Csa Models (After Serial Number 22050)

    ADD D40 ONLY IF UNIT HAS L4 AND L48. 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. ANSI/CSA 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 31 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 181 ROTATE TS60 TS62 TS61 TS63 TS59 TS57 TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB10 TB11 TB15 TB14 TB17 TB36 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 32...
  • Page 182 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25, ANSI and CSA Models (after serial number 22050)

  • Page 184: Electrical Schematic, Z-45/25, Ce Models (After Serial Number 22050)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. ADD D40 ONLY IF UNIT HAS L4 AND L48. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 33 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 185 BOOM TS62 TS60 TS61 TS59 TS57 TS63 TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB11 TB10 TB15 TB14 TB17 TB36 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 34...
  • Page 186 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25, CE Models (after serial number 22050)

  • Page 188: Electrical Schematic, Z-45/25J (Before Serial Number 13361)

    1. ALL LIMIT SWITCHES ARE SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT WHERE NOTED. 2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED. 6 - 35 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 189 *SWITCH SHOWN TB15 LS3* WITH BOOM ROTATED PLATFORM LEVEL CUTOUT PAST EITHER (CE VERSION ONLY) NON-STEER WHEEL. CR10B CR10A TB16 FUNCTION MANIFOLD BRAKE/STEER GROUND (GND) MANIFOLD GROUND (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 36...
  • Page 190 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (before serial number 13361)

  • Page 192: Electrical Schematic, Z-45/25J (From Serial Number 13361 To 14078)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 37 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 193 ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD BRAKE/STEER (GND) GROUND MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 38...
  • Page 194 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 13361 to 14078)

  • Page 196: Electrical Schematic, Z-45/25J (From Serial Number 14079 To 14650)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 39 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 197 ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 40...
  • Page 198 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 14079 to 14650)

  • Page 200: Electrical Schematic, Z-45/25J (From Serial Number 14651 To 16839)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 41 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 201 ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 42...
  • Page 202 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 14651 to 16839)

  • Page 204: Electrical Schematic, Z-45/25J (From Serial Number 16840 To 17974)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 43 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 205 ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 44...
  • Page 206 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 16840 to 17974)

  • Page 208: Electrical Schematic, Z-45/25J (From Serial Number 17975 To 21180)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 2 SWITCH SHOWN WITH BOOM EXTENDED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 45 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 209 ENABLE (CE VERSION ONLY) LIMIT SWITCH CR10B CR10A TB16 FUNCTION MANIFOLD GROUND BRAKE/STEER (GND) MANIFOLD (GND) GROUND NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 46...
  • Page 210 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 17975 to 21180)
  • Page 212 RIGHT ALT. (12V DC) MOTOR (PRI) STARTER PUMP PUMP AUXILIARY ALTERNATOR CHARGER (EXT) WH-BATT AC POWER (12V DC) OR-GEN NEG CR16 GROUND ENGINE OR-GEN POS GROUND (GND) 6 - 47 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 213 TS59 TS57 TS58 GR/WH TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB11 TB10 TB15 TB14 TB17 TB36 BK C44DA C6B-33 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 48...

  • Page 214: Electrical Schematic, Z-45/25J (From Serial Number 21181 To 22050)

    July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J (from serial number 21181 to 22050)

  • Page 216: Electrical Schematic, Z-45/25J, Ansi And Csa Models (After Serial Number 22050)

    ADD D40 ONLY IF UNIT HAS L4 AND L48. 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. ANSI/CSA 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 49 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 217 TS59 TS57 TS58 GR/WH TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB10 TB11 TB15 TB14 TB17 TB36 BK C44DA C6B-33 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 50...
  • Page 218 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J, ANSI and CSA Models (after serial number 22050)

  • Page 220: Electrical Schematic, Z-45/25J, Ce Models (After Serial Number 22050)

    1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. ADD D40 ONLY IF UNIT HAS L4 AND L48. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 6 - 51 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 221 TS59 TS57 TS58 GR/WH TB27 GR/WH GR/WH C6B-38 GR/WH TB19 TB18 TB37 TB11 TB10 TB15 TB14 TB17 TB36 BK C44DA C6B-33 DRIVE ENABLE LIMIT SWITCH CR20 (GND) Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 52...
  • Page 222 July 2004 Section 6 • Schematics Electrical Schematic, Z-45/25J, CE Models (after serial number 22050)
  • Page 223 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (before serial number 13361)
  • Page 224 HARNESS SECONDARY BOOM PRIMARY BOOM FAULT BOOM BOOM BOOM HARNESS LIMIT SWITCH (LS4) LIMIT SWITCH (LS2) STATUS CABLE #1 CABLE #3 CABLE #2 CABLE #4 CABLE #5 6 - 53 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 225: A Ground Control Box Switch Panel Wiring Diagram

    (before serial number 13361) GRN/BLK-18 ORG/BLK GRN/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 54...
  • Page 226 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (before serial number 13361)
  • Page 227 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)
  • Page 228 MANIFOLD HARNESS PRIMARY BOOM BOOM BOOM SECONDARY BOOM BOOM STATUS HARNESS LIMIT SWITCH (LS2) CABLE #2 CABLE #1 LIMIT SWITCH (LS4) CABLE #3 CABLE #5 CABLE #4 6 - 55 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 229 (from serial number 13361 to 14078) GRN/BLK-18 ORG/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 56...
  • Page 230 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)
  • Page 231 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)
  • Page 232 EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 57 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 233 (from serial number 14079 to 14650) GRN/BLK-18 ORG/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 58...
  • Page 234 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)
  • Page 235 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)
  • Page 236 EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 59 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 237 (from serial number 14651 to 16839) GRN/BLK-18 ORG/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 60...
  • Page 238 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)
  • Page 239 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)
  • Page 240 EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 61 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 241 GRN/BLK-18 ORG/BLK GRN/WHT-R3 GRN-17 WHT-40 GRN/WHT ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 62...
  • Page 242 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)
  • Page 243 Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)
  • Page 244 M.H. EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 63 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 245 (from serial number 17975 to 21180) GRN/BLK-18 GRN/WHT-R3 GRN-17 GRN/WHT RED-27P WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 64...
  • Page 246 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)

  • Page 247: (From Serial Number 21181 To 22050)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)
  • Page 248 C6B-28 C28TTA RD/BK C29JSH RD/WH C1B-3 C6B-29 C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 6 - 65 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 249 BK-7A BK/WH-8A GR-17A WH/BK-5A WH-4A RD-27A OR/BK-15A OR/BK RD/BK-2A OR-14A RD-1A P20BAT RD (C6B-23) P20BAT RD (C7B-4) BL-10A BK-22A BL/BK-11A WH-23A GR/WH-19A P20BAT RD (C5B-1) BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 66...
  • Page 250 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)

  • Page 251: Ansi And Csa Models (After Serial Number 22050)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 ANSI and CSA Models (after serial number 22050)
  • Page 252 C1B-3 C6B-29 C29JSH RD/WH C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 (CE OPTION ONLY) 6 - 67 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 253: Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ansi And Csa Models (After Serial Number 22050)

    OR/BK-15A OR/BK RD/BK-2A OR-14A RD-1A RD C23-6 BK-22A P20BAT RD (C7B-4) BL-10A BL/BK-11A GR/WH-19A P20BAT RD (C5B-1) RD 134A RD C23-7 GR/BK H6 WH 23A BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 68...
  • Page 254 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25, ANSI and CSA Models (after serial number 22050)

  • Page 255: A Ground Control Box Terminal Srip Wiring Diagram

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models (after serial number 22050)
  • Page 256 C28TTA RD/BK C1B-2 C6B-28 C1B-3 C6B-29 C29JSH RD/WH C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 6 - 69 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 257: Ground Control Box Switch Panel Wiring Diagram, Z-45/25 Ce Models (After Serial Number 22050)

    OR/BK-15A OR/BK RD/BK-2A OR-14A RD-1A RD C23-6 BK-22A P20BAT RD (C7B-4) BL-10A BL/BK-11A GR/WH-19A P20BAT RD (C5B-1) RD 134A RD C23-7 GR/BK H6 WH 23A BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 70...
  • Page 258 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE Models (after serial number 22050)

  • Page 259: (Before Serial Number 13361)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (before serial number 13361)

  • Page 260: (Before Serial Number 13361)

    MANIFOLD HARNESS SECONDARY BOOM PRIMARY BOOM BOOM BOOM BOOM STATUS HARNESS LIMIT SWITCH (LS4) LIMIT SWITCH (LS2) CABLE #2 CABLE #1 CABLE #3 CABLE #4 CABLE #5 6 - 71 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 261 (before serial number 13361) GRN/BLK-18 ORG/BLK GRN/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 72...
  • Page 262 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (before serial number 13361)

  • Page 263: (From Serial Number 13361 To 14078)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 13361 to 14078)

  • Page 264: (From Serial Number 13361 To 14078)

    MANIFOLD HARNESS SECONDARY BOOM PRIMARY BOOM BOOM BOOM BOOM STATUS HARNESS LIMIT SWITCH (LS4) LIMIT SWITCH (LS2) CABLE #2 CABLE #1 CABLE #3 CABLE #4 CABLE #5 6 - 73 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 265 (from serial number 13361 to 14078) GRN/BLK-18 ORG/BLK GRN/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 74...
  • Page 266 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 13361 to 14078)

  • Page 267: (From Serial Number 14079 To 14650)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14079 to 14650)

  • Page 268: (From Serial Number 14079 To 14650)

    EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 75 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 269 (from serial number 14079 to 14650) GRN/BLK-18 ORG/BLK GRN/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 76...
  • Page 270 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14079 to 14650)

  • Page 271: (From Serial Number 14651 To 16839)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 14651 to 16839)

  • Page 272: (From Serial Number 14651 To 16839)

    EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 77 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 273 (from serial number 14651 to 16839) GRN/BLK-18 ORG/BLK GRN/BLK GRN-17 WHT-40 ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 78...
  • Page 274 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 14651 to 16839)

  • Page 275: (From Serial Number 16840 To 17974)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 16840 to 17974)

  • Page 276: (From Serial Number 16840 To 17974)

    EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOT USED FOR PLATFORM LEVEL CUTOUT OPTION 6 - 79 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 277 ORG/BLK GRN/BLK GRN/WHT-R3 GRN-17 WHT-40 GRN/WHT ORG/BLK ORG/BLK RED-27P GRN/WHT-R3 WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 WHT-23 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 80...
  • Page 278 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 16840 to 17974)

  • Page 279: (From Serial Number 17975 To 21180)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 17975 to 21180)

  • Page 280: (From Serial Number 17975 To 21180)

    M.H. EXTENTION EXT. EXT. EXTENTION PRIMARY PRIMARY PRIMARY PRI. SECONDARY SECONDARY SECONDARY SEC. ENABLE ENABLE ENABLE ENA. GRN/WHT-19 GRN/WHT-19 ORG/RED-42 LED NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 81 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 281 (from serial number 17975 to 21180) GRN/BLK-18 GRN/BLK GRN/WHT-R3 GRN-17 GRN-17 GRN/WHT RED-27P WIRE GOES TO T.B. 27A RED-27 GRN/WHT-19 RED/WHT-48 ORG/RED ORG/BLK-41 RED/BLK-R5 BLK/RED-9 BLK/RED-R4 BLK-22 BLK-22 BLK-22 Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 82...
  • Page 282 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 17975 to 21180)

  • Page 283: (From Serial Number 21181 To 22050)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J (from serial number 21181 to 22050)

  • Page 284: (From Serial Number 21181 To 22050)

    C6B-28 C28TTA RD/BK C29JSH RD/WH C1B-3 C6B-29 C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 6 - 83 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 285 GR-17A WH/BK-5A GR/BK WH-4A RD-27A OR/BK-15A OR/BK RD/BK-2A OR-14A RD-1A GR/BK-44A P20BAT RD (C6B-23) P20BAT RD (C7B-4) BL-10A BK-22A BL/BK-11A WH-23A GR/WH-19A P20BAT RD (C5B-1) BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 84...
  • Page 286 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J (from serial number 21181 to 22050)

  • Page 287: Ansi And Csa Models (After Serial Number 22050)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ANSI and CSA Models (after serial number 22050)
  • Page 288 C1B-3 C6B-29 C29JSH RD/WH C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 (CE OPTION ONLY) 6 - 85 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 289: A Ground Control Box Switch Panel Wiring Diagram

    OR/BK RD/BK-2A OR-14A RD-1A GR/BK-44A RD C23-6 BK-22A P20BAT RD (C7B-4) BL-10A BL/BK-11A GR/WH-19A P20BAT RD (C5B-1) RD 134A RD C23-7 GR/BK H6 WH 23A BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 86...
  • Page 290 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, ANSI and CSA Models (after serial number 22050)

  • Page 291: Ce Models (After Serial Number 22050)

    Section 6 • Schematics July 2004 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models (after serial number 22050)
  • Page 292 C28TTA RD/BK C1B-2 C6B-28 C1B-3 C6B-29 C29JSH RD/WH C6B-30 C30FWD WH C1B-4 C6B-31 C31REV WH/BK C1B-5 C6B-32 C32JSL WH/RD C1B-6 C6B-21 P20BAT RD C7B-4 C7B-3 BATGND BRN C5B-2 6 - 87 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 293: A Ground Control Box Switch Panel Wiring Diagram

    OR/BK RD/BK-2A OR-14A RD-1A GR/BK-44A RD C23-6 BK-22A P20BAT RD (C7B-4) BL-10A BL/BK-11A GR/WH-19A P20BAT RD (C5B-1) RD 134A RD C23-7 GR/BK H6 WH 23A BK-33A BK/WH-34A Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 88...
  • Page 294 July 2004 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models (after serial number 22050)

  • Page 295: (Before Serial Number 13361)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (before serial number 13361)
  • Page 296 PRIMARY BOOM UP / DOWN SWITCH EMERG/STOP TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW SWITCH TS15 DRIVE ENABLE SWITCH 6 - 89 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 297 PRIMARY BOOM UP / DOWN SWITCH EMERGENCY STOP TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW SWITCH TS15 DRIVE ENABLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 90...
  • Page 298 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)
  • Page 299 Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 13361 to 14078)
  • Page 300 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 91 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 301 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH ORG/RED-42 TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 92...
  • Page 302 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with Platform Load Sense and LVI/BCI Option (from serial number 13361 to 14078)
  • Page 303 Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14079 to 14650)
  • Page 304 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 93 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 305 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 94...
  • Page 306 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with Platform Load Sense and LVI/BCI Option (from serial number 14079 to 14650)

  • Page 307: (From Serial Number 14651 To 16839)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 14651 to 16839)
  • Page 308 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 95 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 309 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 96...

  • Page 310: Platform Control Box Wiring Diagram, Z-45/25 With Lvi/Bci Option (From Serial Number 14651 To 16839)

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 14651 to 16839)

  • Page 311: (From Serial Number 16840 To 17974)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 16840 to 17974)
  • Page 312 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 97 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 313 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 98...

  • Page 314: Platform Control Box Wiring Diagram, Z-45/25 With Lvi/Bci Option (From Serial Number 16840 To 17974)

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 16840 to 17974)

  • Page 315: (From Serial Number 17975 To 21180)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 17975 to 21180)
  • Page 316 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 99 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 317 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 100...

  • Page 318: Platform Control Box Wiring Diagram, Z-45/25 With Lvi/Bci Option (From Serial Number 17975 To 21180)

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 17975 to 21180)

  • Page 319: (From Serial Number 21181 To 22050)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (from serial number 21181 to 22050)
  • Page 320 EMERGENCY START TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP PLATFORM AUXILIARY PLATFORM ROTATE LEVEL TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH POWER TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 101 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 321 PRIMARY BOOM UP / DOWN TOGGLE SWITCH AUXILIARY PLATFORM LEVEL STOP POWER ROTATE TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 102...

  • Page 322: Platform Control Box Wiring Diagram, Z-45/25 With Lvi/Bci Option (From Serial Number 21181 To 22050)

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (from serial number 21181 to 22050)

  • Page 323: (After Serial Number 22050)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25 (after serial number 22050)
  • Page 324 DRIVE ENABLE TOGGLE SWITCH HORN ENGINE TITL ALARM GLOW PLUG EMERGENCY START LS18 PLATFORM OVERLOAD LIMIT SWITCH STOP PLATFORM AUXILIARY PLATFORM ROTATE LEVEL PLATFORM OVERLOAD LED POWER TILT ALARM LED 6 - 103 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 325 DRIVE ENABLE TOGGLE SWITCH GLOW PLUG ENGINE START HORN EMERGENCY STOP AUXILIARY PLATFORM TILT ALARM PLATFORM POWER ROTATE LEVEL LS18 PLATFORM OVERLOAD LIMIT SWITCH PLATFORM OVERLOAD LED TILT ALARM LED Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 104...

  • Page 326: Platform Control Box Wiring Diagram, Z-45/25 With Lvi/Bci Option (After Serial Number 22050)

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25 with LVI/BCI Option (after serial number 22050)

  • Page 327: Platform Control Box Wiring Diagram, Z-45/25J (Before Serial Number 13361)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (before serial number 13361)
  • Page 328 PLATFORM ROTATE EMERGENCY STOP TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW SWITCH TS15 DRIVE ENABLE SWITCH 6 - 105 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 329 PRIMARY BOOM UP / DOWN SWITCH EMERGENCY STOP TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW SWITCH TS15 DRIVE ENABLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 106...
  • Page 330 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J (with Platform Load Sense and LVI/BCI Option) (before serial number 13361)

  • Page 331: (From Serial Number 13361 To 14078)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 13361 to 14078)
  • Page 332 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 107 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 333 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH ORG/RED-42 TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 108...

  • Page 334: With Platform Load Sense And Lvi/Bci Option

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with Platform Load Sense and LVI/BCI Option (from serial number 13361 to 14078)

  • Page 335: (From Serial Number 14079 To 14650)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14079 to 14650)
  • Page 336 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 109 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 337 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 110...

  • Page 338: With Platform Load Sense And Lvi/Bci Option

    July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with Platform Load Sense and LVI/BCI Option (from serial number 14079 to 14650)

  • Page 339: (From Serial Number 14651 To 16839)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 14651 to 16839)
  • Page 340 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH ORG/RED-42 TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 111 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 341 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 112...
  • Page 342 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 14651 to 16839)

  • Page 343: (From Serial Number 16840 To 17974)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 16840 to 17974)
  • Page 344 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 113 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 345 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH STOP TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 114...
  • Page 346 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 16840 to 17974)

  • Page 347: (From Serial Number 17975 To 21180)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 17975 to 21180)
  • Page 348 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 115 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 349 TS12 TURNTABLE ROTATE TOGGLE SWITCH STOP TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH / LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 116...
  • Page 350 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 17975 to 21180)

  • Page 351: (From Serial Number 21181 To 22050)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (from serial number 21181 to 22050)
  • Page 352 STOP AUXILIARY JIB BOOM PLATFORM PLATFORM TS12 TURNTABLE ROTATE TOGGLE SWITCH POWER ROTATE LEVEL TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 - 117 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 353 START AUXILIARY JIB BOOM PLATFORM LEVEL STOP POWER ROTATE TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 118...
  • Page 354 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (from serial number 21181 to 22050)

  • Page 355: (After Serial Number 22050)

    Section 6 • Schematics July 2004 Platform Control Box Wiring Diagram, Z-45/25J (after serial number 22050)
  • Page 356 ENGINE TITL ALARM GLOW PLUG EMERGENCY START LS18 PLATFORM OVERLOAD LIMIT SWITCH STOP JIB BOOM PLATFORM AUXILIARY PLATFORM ROTATE LEVEL POWER PLATFORM OVERLOAD LED TILT ALARM LED 6 - 119 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 357 GLOW PLUG ENGINE START HORN EMERGENCY STOP AUXILIARY JIB BOOM PLATFORM TILT ALARM PLATFORM POWER ROTATE LEVEL LS18 PLATFORM OVERLOAD LIMIT SWITCH PLATFORM OVERLOAD LED TILT ALARM LED Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 120...
  • Page 358 July 2004 Section 6 • Schematics Platform Control Box Wiring Diagram, Z-45/25J with LVI/BCI Option (after serial number 22050)

  • Page 359: Hydraulic Schematic (Before Serial Number 16962)

    Section 6 • Schematics August 2004 Hydraulic Schematic (before serial number 16962)

  • Page 360: Hydraulic Schematic (From Serial Number 20380 To 22565)

    1800 psi 159 bar 1.9 L/min 7.9 L/min 124 bar 3500 psi 241 bar 4.5:1 0.060 inch 1.52 mm 0.6 gpm 0.6 gpm 2.3 L/min 2.3 L/min RESERVOIR 6 - 121 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...

  • Page 361: Hydraulic Schematic (After Serial Number 22565)

    4.5:1 124 bar 3500 psi 241 bar ATMOS 0.060 inch 1.5 mm 0.6 gpm 2.27 L/min 0.030 inch 0.1 gpm RESERVOIR 0.76 mm 0.38 L/min FUNCTION MANIFOLD Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 122...
  • Page 362 August 2004 Section 6 • Schematics Hydraulic Schematic (from serial number 16962 to 20379)
  • Page 363 Section 6 • Schematics August 2004 Hydraulic Schematic (from serial number 20380 to 22565)
  • Page 364 7.9 L/min 1800 psi 4.5:1 124 bar 3500 psi 241 bar ATMOS 0.060 inch 1.5 mm 0.6 gpm 2.27 L/min 0.030 inch RESERVOIR 0.76 mm FUNCTION MANIFOLD 6 - 123 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488...
  • Page 365 1.5 mm 0.030 inch 0.030 inch 0.76 mm 0.4 gpm 0.76 mm (from serial number 22566 to 22628 1.5 L/min RESERVOIR and after serial number 23235) FUNCTION MANIFOLD Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 6 - 124...
  • Page 366 August 2004 Section 6 • Schematics Hydraulic Schematic (after serial number 22565)
  • Page 367 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Holland Genie Australia Pty Ltd. Phone + Phone + 31 70 51 78836 61 7 3375 1660 Fax + Fax + 31 70 51 13993 61 7 3375 1002...

This manual is also suitable for:

Z45/25j

Table of Contents