Terex Genie Z-45/25 Bi-Energy Service Manual
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Terex Genie Z-45/25 Bi-Energy Service Manual

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  • Page 2: Introduction

    237062 Rev B September 2015 future printings of this and all other manuals. Fifth Edition, Second Printing "Genie" and "Z" are registered trademarks of Contact Us: Terex South Dakota, Inc. in the USA and many other countries. http://www.genielift.com Printed on recycled paper e-mail: awp.techpub@terex.com Printed in U.S.A.

  • Page 3: Revision History

    September 2015 Revision History Revision Date Section Procedure / Schematic Page / Description 12/2012 New release 11/2014 3 - Maint. B-18 9/2015 Added ending serial break to front cover. REFERENCE EXAMPLES: Electronic Version Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure.
  • Page 4 September 2015 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. Electronic Version A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5.

  • Page 5: Serial Number Legend

    Country of manufacture: USA number This machine complies with: Facility code (used only for models manufactured in multiple facilities) Terex South Dakota, Inc. 18340 NE 76th St. Serial label PO Box 97030 (located under cover) Redmond, WA 98052 Serial number...

  • Page 6: Safety Rules

    September 2015 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. Danger Read each procedure thoroughly. This manual and the decals on the machine, Failure to obey the instructions and safety rules use signal words to identify the following:...
  • Page 7 September 2015 SAFETY RULES 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.

  • Page 8: Table Of Contents

    September 2015 Table of Contents Introduction Important Information ....................ii Serial Number Information .................... ii Revision History ......................iii Serial Number Legend ....................v Section 1 Safety Rules General Safety Rules ....................vi Section 2 Specifications Machine Specifications ..................2 - 1 Performance Specifications ...................
  • Page 9 September 2015 TABLE OF CONTENTS Scheduled Maintenance Procedures, continued Section 3 Checklist A Procedures Inspect the Manuals and Decals ..............3 - 7 Perform Pre-operation Inspection ..............3 - 8 Perform Function Tests ................3 - 8 Check the Generator Belts and Pulleys ............3 - 9 Perform 30 Day Service ................
  • Page 10 September 2015 TABLE OF CONTENTS Scheduled Maintenance Procedures, continued Section 3 B-13 Test the Drive Speed - Stowed Position ............. 3 - 23 B-14 Test the Drive Speed - Raised or Extended Position ........3 - 24 B-15 Test the Alarm Package (if equipped) ............3 - 24 B-16 Check the Electrical Contactors ..............
  • Page 11 September 2015 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ......................4 - 1 Platform Controls Controllers ....................4 - 2 Platform Components Platform Leveling Slave Cylinder ..............4 - 4 Platform Rotator ................... 4 - 5 Jib Boom Components, Z-45/25J Models Jib Boom ......................
  • Page 12 September 2015 TABLE OF CONTENTS Repair Procedures, continued Section 4 Generator Generator Pulley ..................4 - 29 Generator Belts ..................4 - 30 Generator Voltage Regulator ..............4 - 30 Hydraulic Pumps Auxiliary Pump ................... 4 - 33 Function Pump ................... 4 - 34 Manifolds Function Manifold Components ..............
  • Page 13 September 2015 TABLE OF CONTENTS Section 6 Schematics Introduction ......................6 - 1 Electrical Symbols Legend ..................6 - 2 Hydraulic Symbols Legend ..................6 - 3 Electrical Schematics - ANSI / CSA Electrical Schematic (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) ......6 - 6 Ground Control Box Terminal Strip Wiring Diagram (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) ......
  • Page 14 September 2015 TABLE OF CONTENTS Schematics, continued Section 6 Electrical Schematics - CE Electrical Schematic (CE) (from serial number Z452510A-39314 to Z452513A-45734) ......6 - 26 Ground Control Box Terminal Strip Wiring Diagram (CE) (from serial number Z452510A-39314 to Z452513A-45734) ......6 - 30 Ground Control Box Switch Panel Wiring Diagram (CE) (from serial number Z452510A-39314 to Z452513A-45734) ......
  • Page 15 September 2015 TABLE OF CONTENTS Schematics, continued Section 6 Electrical Schematics - AS Electrical Schematic (AS) (from serial number Z452511A-40560 to Z452513A-45734) ......6 - 56 Ground Control Box Terminal Strip Wiring Diagram (AS) (from serial number Z452511A-40560 to Z452513A-45734) ......6 - 60 Ground Control Box Switch Panel Wiring Diagram (AS) (from serial number Z452511A-40560 to Z452513A-45734) ......
  • Page 16 September 2015 This page intentionally left blank. Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 17: Specifications

    September 2015 Section 2 • Specifications Specifications Machine Specifications Fluid capacities Fuel tank 9 gallons Tires and wheels 34.1 liters Wheel diameter 14.5 inches Hydraulic tank 8 gallons 30.3 liters Wheel width 7 inches Hydraulic system 11 gallons Wheel lugs (including tank) 41.6 liters Lug nut torque...

  • Page 18: Performance Specifications

    Section 2 • Specifications September 2015 SPECIFICATIONS Performance Specifications Boom function speeds, maximum from platform controls Drive speeds, maximum Jib boom up, Z-45/25J 33 to 39 seconds Drive speed, stowed 3 mph Jib boom down, Z-45/25J 22 to 28 seconds 4.8 km/h 40 ft/9 sec Primary boom up...

  • Page 19: Hydraulic Specifications

    September 2015 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently Hydraulic Oil Specifications above 32°F / 0°C may result in Hydraulic oil type Chevron Rando HD MV equivalent component damage.

  • Page 20: Manifold Component Specifications

    Section 2 • Specifications September 2015 SPECIFICATIONS Manifold Component Machine Torque Specifications Specifications Platform rotator Plug torque -10 center bolt, GR 8 380 ft-lbs 515 Nm SAE No. 2 36 in-lbs / 4 Nm -16 bolts, GR 8 44 ft-lbs SAE No.
  • Page 21 September 2015 Section 2 • Specifications SPECIFICATIONS Kubota Z482-E2B Engine Lubrication system Kubota Z482-E3B Engine Units ship with 10W-40. Extreme operating temperatures may require the use of Displacement 29.23 cu in alternative engine oils. For oil requirements, refer to the 0.48 liters Engine Operator's Manual on your machine.

  • Page 22: Generator

    Section 2 • Specifications September 2015 SPECIFICATIONS Generator Generator output with engine @ 3000 rpm 54V DC, 100A inch Generator pulley to engine pulley offset, maximum 1.6 mm Belt deflection, maximum inch 6.5 mm Generator Torque Specifications 80-90 ft-lbs Generator pulley retaining nut torque 108-122 Nm Engine pulley retaining bolts 108 in-lbs...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    September 2015 Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port (tube fitting - installed into Aluminum) Torque Specifications (all types) Your machine is equipped with Parker Seal-Lok ™ SAE Dash size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose 14 ft-lbs / 19 Nm ends be torqued to specification when they are...
  • Page 24 Section 2 • Specifications September 2015 SPECIFICATIONS Torque Procedure Seal-Lok™ fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-rings used in the Parker Seal Lok™...
  • Page 25 September 2015 Section 2 • Specifications SPECIFICATIONS 10.9 12.9 Part No. 237062 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2 - 9...
  • Page 26 Section 2 • Specifications September 2015 This page intentionally left blank. 2 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 27: Scheduled Maintenance Procedures

    September 2015 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 Safety alert symbol—used to alert Maintenance inspections shall be completed by personnel to potential personal a person trained and qualified on the...
  • Page 28 Section 3 • Scheduled Maintenance Procedures September 2015 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Maintenance Schedule The following symbols have been used in this There are five types of maintenance inspections manual to help communicate the intent of the that must be performed according to a schedule— instructions.

  • Page 29: Pre-Delivery Preparation

    Genie UK 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc.
  • Page 30 Section 3 • Scheduled Maintenance Procedures September 2015 This page intentionally left blank. 3 - 4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 31: Maintenance Inspection Report

    September 2015 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B Y N R A-1 Manuals and Decals B-1 Radiator Serial number A-2 Pre-operation B-2 Exhaust system inspection B-3 Batteries Date A-3 Function tests B-4 Electrical wiring Hour meter A-4 Generator belts and...
  • Page 32 Section 3 • Scheduled Maintenance Procedures September 2015 MAINTENANCE INSPECTION REPORT Model Checklist D 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 D-5 Calibrate platform Machine owner overload system (if equipped)

  • Page 33: Checklist A Procedures

    September 2015 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes Result: The machine is equipped with all first.

  • Page 34: Perform Pre-Operation Inspection

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES Perform Pre-operation Perform Function Tests Inspection Completing the function tests is essential to safe machine operation. Function tests are designed to Completing a pre-operation inspection is essential discover any malfunctions before the machine is to safe machine operation.

  • Page 35: Check The Generator Belts And Pulleys

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 3 Check to be sure the engine pulley and the generator pulley are aligned within specification Check the Generator Belts and using a straightedge. Refer to Section 2, Pulleys Specifications .

  • Page 36: Perform 30 Day Service

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES 4 Inspect the generator belts for: Perform 30 Day Service • Cracking • Glazing • Separation • Breaks The 30 day maintenance procedure is a one time 5 Replace both belts if any damage is found. sequence of procedures to be performed after the first 30 days or 50 hours of usage.

  • Page 37: Perform Engine Maintenance

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Engine Maintenance Perform Engine Maintenance Note: Engine specifications require that this Note: Engine specifications require that this procedure be performed after the first 50 hours. procedure be performed every 75 hours. •...

  • Page 38: Grease The Turntable Rotation Bearing And Rotate Gear

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES Grease the Turntable Rotation Perform Engine Maintenance Bearing and Rotate Gear Note: Engine specifications require that this procedure be performed every 100 hours. Note: Genie specifications require that this procedure be performed every 100 hours of •...

  • Page 39: Perform Engine Maintenance

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-10 A-11 Perform Engine Maintenance Perform Engine Maintenance Note: Engine specifications require that this Note: Engine specifications require that this procedure be performed every 150 hours. procedure be performed every 200 hours. •...

  • Page 40: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures September 2015 Checklist B Procedures Check the Radiator Check the Exhaust System Maintaining the radiator in good condition is Maintaining the exhaust system is essential to essential for good engine performance. Operating good engine performance and service life. Running a machine with a damaged or leaking radiator may the engine with a damaged or leaking exhaust result in engine damage.

  • Page 41: Check The Batteries

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 3 Be sure that the battery retainers and cable connections are tight. Check the Batteries 4 Fully charge the battery. Allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize.

  • Page 42: Inspect The Electrical Wiring

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES 8 Remove the battery vent caps and check the specific gravity of each battery cell with a Inspect the Electrical Wiring hydrometer. Note the results. 9 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Maintaining electrical wiring in good condition is...

  • Page 43: Check The Tires, Wheels And Lug Nut Torque

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 5 Open the ground controls side turntable cover. Check the Tires, Wheels and 6 Inspect the following areas for burnt, chafed, corroded and loose wires: Lug Nut Torque • Inside of the ground control box •...

  • Page 44: Confirm The Proper Brake Configuration

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES Confirm the Proper Check the Oil Level Brake Configuration in the Drive Hubs Proper brake configuration is essential to safe Failure to maintain proper drive hub oil levels may operation and good machine performance.

  • Page 45: Check And Adjust The Engine Rpm

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 2 Remove the plug located at 90 degrees and check the oil level. Check and Adjust the Result: The oil level should be even with the Engine RPM bottom of the side plug hole. 3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole.
  • Page 46 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES Skip to step 5 if the low idle rpm is correct. Skip to step 7 if the high idle rpm is correct. 4 Loosen the lock nut, then turn the low idle 6 Loosen the lock nut on the solenoid, then turn adjustment screw clockwise to increase the rpm the solenoid boot counterclockwise to increase...

  • Page 47: Test The Ground Control Override

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-10 Test the Ground Control Test the Platform Self-leveling Override A properly functioning ground control override is essential to safe machine operation. The ground Automatic platform self-leveling throughout control override function is intended to allow the full cycle of boom raising and lowering is ground personnel to operate the machine from the essential for safe machine operation.

  • Page 48: Test The Engine Idle Select

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B-11 6 Move the engine idle select toggle switch to foot switch activated high idle (rabbit and foot switch Test the Engine Idle Select symbol). A properly operating engine idle select switch Result: The engine should not change to is essential to good engine performance and safe high idle.

  • Page 49: Test The Drive Brakes

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-12 B-13 Test the Drive Brakes Test the Drive Speed - Stowed Position Proper brake action is essential to safe machine operation. The machine uses drive motor Proper drive function movement is essential to safe regenerative braking to stop the machine.

  • Page 50: Test The Drive Speed - Raised Or Extended Position

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B-14 B-15 Test the Drive Speed - Raised or Test the Alarm Package Extended Position (if equipped) The alarm package includes: • Travel alarm Proper drive function movement is essential to safe •...
  • Page 51 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 3 Move the function enable switch to either side 7 Press down the foot switch. Activate the and activate the secondary boom toggle switch secondary boom toggle switch in the down in the down position, hold for a moment and position, hold for a moment and then release it.

  • Page 52: Check The Electrical Contactors

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B-16 B-17 Check the Electrical Contactors Perform Hydraulic Oil Analysis Maintaining the electrical contactors in good Replacement or testing of the hydraulic oil is condition is essential to safe machine operation. essential for good machine performance and Failure to locate a worn or damaged contactor service life.

  • Page 53: Test The Emergency Power System

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-18 5 Turn the key switch to platform controls. Test the Emergency Power 6 At the platform controls, break the security tie and lift the emergency power switch cover (if System equipped).

  • Page 54: Perform Engine Maintenance

    Section 3 • Scheduled Maintenance Procedures September 2015 B-19 Perform Engine Maintenance Note: Engine specifications require that this procedure be performed every 400 hours. • Fuel filter Required maintenance procedures and additional engine information are available in the Kubota Z482-E2B Operator's Manual (Kubota part number 16676-89167).

  • Page 55: Checklist C Procedures

    September 2015 Section 3 • Scheduled Maintenance Procedures Checklist C Procedures Perform Engine Maintenance Grease the Platform Overload Mechanism (if equipped) Note: Engine specifications require that this procedure be performed every 500 hours. Note: Genie specifications require that this procedure be performed every 500 hours or 6 •...
  • Page 56 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 4 Using a suitable lifting device, place an appropriate test weight equal to that of the Test the Platform Overload maximum platform capacity in one of the System (if equipped) locations shown.
  • Page 57 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 7 Carefully move the test weights to each 11 Lift the test weights off the platform floor using a remaining location in the platform. suitable lifting device. Result: The alarm should be sounding. Result: The platform overload indicator light and The platform overload indicator light should be alarm should turn off at both the ground and...

  • Page 58: Perform Engine Maintenance

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES Perform Engine Maintenance Note: Engine specifications require that this procedure be performed every 800 hours. • Valve clearance Required maintenance procedures and additional engine information are available in the Kubota Z482-E2B Operator's Manual (Kubota part number 16676-89167).

  • Page 59: Checklist D Procedures

    September 2015 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures Check the Primary Boom Check the Free-wheel Wear Pads Configuration Proper use of the free-wheel configuration is Maintaining the boom wear pads in good condition essential to safe machine operation. The is essential to safe machine operation.

  • Page 60: Replace The Drive Hub Oil

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 5 Manually rotate each non-steer wheel. Replace the Drive Hub Oil 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 Replacing the drive hub oil is essential for good check for engagement.

  • Page 61: Replace The Hydraulic Tank Return Filter

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 3 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is Replace the Hydraulic Tank at 90 degrees. Return Filter 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug...

  • Page 62: Calibrate The Platform Overload System (If Equipped)

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES Determine the limit switch trigger point: Calibrate the Platform Overload 4 Gently move the platform up and down by hand, so it bounces approximately 1 to 2 inches / System (if equipped) 2.5 to 5 cm.
  • Page 63 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Confirm the setting: 10 Turn the key switch to ground control. 11 Test all machine functions from the ground 5 Turn the key switch to platform control. controls. 6 Lift the test weight off the platform floor using a Result: All ground control functions should not suitable lifting device.

  • Page 64: Check The Turntable Rotation Bearing Bolts

    Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 2 Check to be sure that each turntable mounting bolt is torqued in sequence to specification. Check the Turntable Rotation Refer to Section 2, Specifications . Bearing Bolts Counterweight Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation.

  • Page 65: Inspect For Turntable Bearing Wear

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 3 Lower the boom to the stowed position. Inspect for Turntable Bearing 4 Remove drive chassis covers from both the steer end and the non-steer end of the machine. Wear 5 Check to be sure that each bearing mounting bolt under the drive chassis is torqued in...
  • Page 66 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator. and the turntable at a point that is directly Result: The measurement is less than under, or in-line with, the boom and no more 0.055 inch / 1.4 mm.

  • Page 67: Perform Engine Maintenance

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Perform Engine Maintenance Note: Engine specifications require that this procedure be performed every 1500 hours. • Fuel injectors Required maintenance procedures and additional engine information are available in the Kubota Z482-E2B Operator's Manual (Kubota part number 16676-89167).

  • Page 68: Checklist E Procedures

    Section 3 • Scheduled Maintenance Procedures September 2015 Checklist E Procedures 3 Completely drain the tank into a container of suitable capacity. Refer to Section 2, Test or Replace the Hydraulic Oil Specifications . Bodily injury hazard. Beware of hot oil.

  • Page 69: Grease The Steer Axle Wheel Bearings

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES 8 Remove the hydraulic tank from the machine. Grease the Steer Axle Component damage hazard. The hydraulic tank is plastic and may Wheel Bearings become damaged if allowed to fall. 9 Remove the suction strainer from the tank and clean it using a mild solvent.
  • Page 70 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST E PROCEDURES 6 Remove the dust cap from the hub. Remove the 15 Install a new bearing grease seal into the hub by cotter pin from the castle nut. pressing it evenly into the hub until it is flush. 7 Tighten the castle nut to 150 ft-lbs / 203 Nm to Note: Always replace the bearing grease seal when seat the bearings.

  • Page 71: Perform Engine Maintenance

    September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES Perform Engine Maintenance Perform Engine Maintenance Note: Engine specifications require that this Note: Engine specifications require that this procedure be performed every 2000 hours or every procedure be performed every 3000 hours. two years, whichever comes first.
  • Page 72 Section 3 • Scheduled Maintenance Procedures September 2015 This page intentionally left blank. 3 - 46 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 73: Repair Procedures

    September 2015 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.

  • Page 74: Platform Controls

    Section 4 • Repair Procedures September 2015 Platform Controls Boom Function Speed Controllers Controller Adjustments Note: Do not adjust the controllers unless the static Platform Controls battery supply voltage is above 24V DC at the platform red Emergency Stop button. The drive joystick is connected to the drive motor controller located under the non-steer end drive Electrocution/burn hazard.
  • Page 75 September 2015 Section 4 • Repair Procedures PLATFORM CONTROLS 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 position.

  • Page 76: Platform Components

    Section 4 • Repair Procedures September 2015 Platform Components 4 Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the unions and Platform Leveling Slave Cylinder connect them together using a connector. Connect the hoses from the cylinder together The slave cylinder and the rotator pivot are the using a connector.

  • Page 77: Platform Rotator

    September 2015 Section 4 • Repair Procedures PLATFORM COMPONENTS 8 Use a soft metal drift to drive the rod-end pivot pin out. Platform Rotator Crushing hazard. The platform could fall when the slave cylinder How to Bleed the Platform rod-end pivot pin is removed if not Rotator properly supported.
  • Page 78 Section 4 • Repair Procedures September 2015 PLATFORM COMPONENTS 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.

  • Page 79: Jib Boom Components, Z-45/25J Models

    September 2015 Section 4 • Repair Procedures Jib Boom Components, Z-45/25J 5 Attach a lifting strap from an overhead crane to the platform rotator for support. Jib Boom 6 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not How to Remove the Jib Boom remove the pin.

  • Page 80: Jib Boom Lift Cylinder

    Section 4 • Repair Procedures September 2015 JIB BOOM COMPONENTS, Z-45/25J 15 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Jib Boom Lift Cylinder 16 Use a soft metal drift to remove the pin and let the cylinder hang down.
  • Page 81 September 2015 Section 4 • Repair Procedures 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.

  • Page 82: Primary Boom Components

    Section 4 • Repair Procedures September 2015 Primary Boom Components 5 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the Cable Track primary boom lift cylinder. Cap the fittings on the unions. The primary boom cable track guides the cables Bodily injury hazard.
  • Page 83 September 2015 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS 8 Tag and disconnect the hydraulic hoses from 14 Remove the cable track mounting fasteners that the platform leveling slave cylinder and connect attach the lower cable track to the primary them together using a connector.
  • Page 84 Section 4 • Repair Procedures September 2015 PRIMARY BOOM COMPONENTS 4 Remove the hose clamp on the primary boom 8 Tag, disconnect and plug the hydraulic hoses bellcrank. from the jib boom/platform rotate manifold. Cap the fittings on the manifold. 5 Pull all of the electrical cables out of the plastic cable track.
  • Page 85 September 2015 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS 11 Raise the boom to a horizontal position. 20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the 12 Place blocks between the upper and lower cable primary boom lift cylinder.

  • Page 86: Primary Boom

    Section 4 • Repair Procedures September 2015 PRIMARY BOOM COMPONENTS How to Repair the Primary Boom Cable Track Primary Boom Component damage hazard. The How to Remove the Primary primary boom cable track can be Boom damaged if it is twisted. Note: A 7 link repair section of cable track is Bodily injury hazard.
  • Page 87 September 2015 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS 5 Remove the hose and cable cover from the 13 Remove the hose clamp at the pivot end of the upper pivot. boom. 6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead crane to the master cylinder barrel-end pivot pin.
  • Page 88 Section 4 • Repair Procedures September 2015 PRIMARY BOOM COMPONENTS How to Disassemble the Primary 6 Remove the external snap rings from the extension cylinder rod-end pivot pin at the Boom platform end of the extension tube. Use a soft metal drift to remove the pin.

  • Page 89: Primary Boom Lift Cylinder

    September 2015 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS 5 Support the rod end and the barrel end of the primary boom lift cylinder with a second Primary Boom Lift Cylinder overhead crane or similar lifting device. 6 Tag, disconnect and plug the primary boom lift The primary boom lift cylinder raises and lowers the cylinder hydraulic hoses.

  • Page 90: Primary Boom Extension Cylinder

    Section 4 • Repair Procedures September 2015 PRIMARY BOOM COMPONENTS 3 Remove the hose and cable guard from the upper pivot. Primary Boom Extension 4 Tag, disconnect and plug the primary boom Cylinder extension cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom extension cylinder extends and Bodily injury hazard.

  • Page 91: Platform Leveling Master Cylinder

    September 2015 Section 4 • Repair Procedures PRIMARY BOOM COMPONENTS 3 Attach overhead crane or similar lifting device to the master cylinder. Platform Leveling 4 Remove the pin retaining fasteners from the Master Cylinder master cylinder barrel-end pivot pin. 5 Place a rod through the barrel-end pivot pin and The master cylinder acts as a pump for the slave twist to remove the pin.

  • Page 92: Secondary Boom Components

    Section 4 • Repair Procedures September 2015 Secondary Boom Components Secondary Boom components upper secondary boom (number 1 arm) upper tension link (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...

  • Page 93: Secondary Boom

    September 2015 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS 4 Remove the master cylinder. See 4-5, How to Remove the Platform Leveling Master Cylinder . Secondary Boom 5 Attach a lifting strap from an overhead crane to the lug on the rod end of the primary boom lift How to Disassemble the cylinder.
  • Page 94 Section 4 • Repair Procedures September 2015 SECONDARY BOOM COMPONENTS 10 Remove the pin retaining fasteners from both 17 Attach a lifting strap from a second overhead sides of the secondary boom lift cylinder rod- crane to the number 1 arm at the midpoint end pivot pin and barrel-end pivot pin.
  • Page 95 September 2015 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS 23 Pull all of the cables and hoses out through the 31 Insert a 4 x 4 x 8 inch / 10 x 10 x 22 cm upper pivot. block between the number 3 arm and the number 4 arm at the mid-pivot end.
  • Page 96 Section 4 • Repair Procedures September 2015 SECONDARY BOOM COMPONENTS 39 Use a soft metal drift to remove the upper 43 Open the ground controls side turntable cover. compression link pivot pin from the number 2 44 Remove the fuel tank filler cap. arm.
  • Page 97 September 2015 Section 4 • Repair Procedures SECONDARY BOOM COMPONENTS 48 Remove the retaining fastener from the ground 57 Remove the pin retaining fasteners from the control box and function manifold pivot plate. number 4 arm at the turntable riser. Do not remove the pin.

  • Page 98: Secondary Boom Lift Cylinders

    Section 4 • Repair Procedures September 2015 SECONDARY BOOM COMPONENTS 3 Tag, disconnect and plug the hydraulic hoses on the secondary boom lift cylinder. Secondary Boom Lift Cylinders Bodily injury hazard. Spraying hydraulic oil can penetrate and There are two secondary boom lift cylinders burn skin.

  • Page 99: Timing Adjustment

    September 2015 Section 4 • Repair Procedures Kubota Z482-E2B and Z482-E3B Engines 3 Loosen the tension adjustment bolt on the generator. Timing Adjustment 4 Pull the generator away from the machine and remove the belts from the generator pulley. Complete information to perform this procedure is available in the Kubota Z482-E2B Workshop 5 Remove the 3 bolts that attach the engine drive Manual (Kubota part number 97897-01165).
  • Page 100 Section 4 • Repair Procedures September 2015 KUBOTA Z482-E2B AND Z482-E3B ENGINES How to Install the Engine Drive 3 Tighten the set screw on the pulley bushing hand tight. Pulley 4 Slide the engine pulley onto the pulley bushing. Note: The generator pulley must already be 5 Install the pulley mounting bolts and tighten installed before performing this procedure.

  • Page 101: Generator

    September 2015 Section 4 • Repair Procedures Generator How to Install the Generator Generator Pulley Pulley Note: The pulley on the generator must be installed How to Remove the Generator before installing the engine drive pulley. Pulley 1 Align the woodruff key on the generator shaft with the slot in the pulley and slide the pulley all 1 Remove the engine pivot plate latch retainer.

  • Page 102: Generator Belts

    Section 4 • Repair Procedures September 2015 GENERATOR Generator Belts Generator Voltage Regulator How to Adjust the Generator How to Adjust the Generator Belts Voltage Regulator 1 Disconnect the battery packs. The voltage regulator regulates the output voltage of the generator. A properly adjusted voltage Electrocution/burn hazard.
  • Page 103 September 2015 Section 4 • Repair Procedures GENERATOR 4 Start the engine from the ground controls and How to Replace the Voltage move the rpm select toggle switch to the Regulator maintained high idle position. Check the voltage on the generator. 1 Disconnect the battery packs from the machine.
  • Page 104 Section 4 • Repair Procedures September 2015 GENERATOR 10 Locate the 3 white wires that lead from the 12 Locate the red wire that leads from the voltage voltage regulator to the negative rectifier regulator to the positive rectifier assembly. assembly.

  • Page 105: Hydraulic Pumps

    September 2015 Section 4 • Repair Procedures Hydraulic Pumps 2 Remove the engine pivot plate latch retainer. Auxiliary Pump 3 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine. How to Remove the Auxiliary 4 Tag, disconnect and plug the hydraulic hoses from the auxiliary pump.

  • Page 106: Function Pump

    Section 4 • Repair Procedures September 2015 HYDRAULIC PUMPS 2 Remove the engine pivot plate latch retainer. Function Pump 3 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine. How to Remove the Function 4 Tag, disconnect and plug the hydraulic hoses from the pump.
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  • Page 108: Function Manifold Components

    Section 4 • Repair Procedures September 2015 Manifolds Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..A ... Primary boom retract ........20 ft-lbs / 27 Nm Solenoid valve, 3 position 4 way ..
  • Page 109 September 2015 Section 4 • Repair Procedures MANIFOLDS Part No. 237062 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 37...

  • Page 110: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures September 2015 MANIFOLDS How to Adjust the Secondary Valve Adjustments - Boom Down Relief Valve Function Manifold Note: Perform this procedure with the boom in the stowed position. How to Adjust the System 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure Relief Valve gauge to the test port on the function manifold.

  • Page 111: Jib Boom / Platform Rotate Manifold Components

    September 2015 Section 4 • Repair Procedures MANIFOLDS Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to platform support. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..AA ..Jib boom / platform rotate select ....20 ft-lbs / 27 Nm Part No.

  • Page 112: Turntable Rotation Manifold Components

    Section 4 • Repair Procedures September 2015 MANIFOLDS Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index Schematic Description Item Function Torque Shuttle valve 2 position 3 way .... X ..Turntable rotation brake release ..10-13 ft-lbs / 14-18 Nm Counterbalance valve ......

  • Page 113: Valve Coils

    September 2015 Section 4 • Repair Procedures MANIFOLDS How to Test a Coil Diode Valve Coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. How to Test a Coil Voltage spikes naturally occur within a function circuit following the interruption of electrical current A properly functioning coil provides an to a coil.
  • Page 114 Section 4 • Repair Procedures September 2015 MANIFOLDS 2 Connect a 10Ω resistor to the negative terminal 4 Connect the negative lead to the other terminal of a known good 9V DC battery. Connect the on the coil. other end of the resistor to a terminal on the 5 Momentarily connect the positive lead from the coil.

  • Page 115: Turntable Rotation Components

    September 2015 Section 4 • Repair Procedures Turntable Rotation Components 10-1 3 Remove the engine pivot plate latch retainer. Turntable Rotation Assembly 4 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation assembly.
  • Page 116 Section 4 • Repair Procedures September 2015 TURNTABLE ROTATION COMPONENTS 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.

  • Page 117: Motor Controller

    September 2015 Section 4 • Repair Procedures Motor Controller 11-1 4 Press the release tab on the motor controller harness connector and remove the motor Motor Controller controller harness connector from the motor controller. The drive motor controller is located under the non- 5 Connect the leads from an ohmmeter to test steer end drive chassis cover.
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  • Page 119: Fault Codes

    September 2015 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate Operator’s Manual on your machine before attempting any maintenance or repair procedure. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
  • Page 120 Section 5 • Fault Codes September 2015 FAULT CODES Tip-over hazard. When adjusting The controller status indicator light will flash a fault the raised drive speed settings, code to aid in troubleshooting. This indicator light the maximum raised drive speed is mounted on the left side of the ground control must not exceed specification.

  • Page 121: Fault Code Chart

    September 2015 Section 5 • Fault Codes Fault Code Chart Fault Code Programmer Condition Possible Causes Solution Indicator The key switch or red Push in the ground control LED is Communication Machine will Emergency Stop button(s) red Emergency Stop button OFF or is Error not drive...
  • Page 122 Section 5 • Fault Codes September 2015 FAULT CODE CHART Fault Code Programmer Condition Possible Causes Solution Throttle Machine will Open in the WH/RD wire #32, Consult the Genie service fault 1 not drive pin 14 OR the RD/WH wire department.
  • Page 123 September 2015 Section 5 • Fault Codes FAULT CODE CHART Fault Code Programmer Condition Possible Causes Solution Missing Machine will Motor controller does not Consult the Genie service contactor not drive detect the main contactor department. PR1 OR the brake release relay CR5.
  • Page 124 Section 5 • Fault Codes September 2015 This page intentionally left blank. 5 - 6 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...
  • Page 125 September 2015 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 126: Electrical Symbols Legend

    Section 6 • Schematics September 2015 Electrical Symbols Legend TB20 2 SEC Circuit breaker 200A Boom function Wire color with speed controller Fuse cable number Solenoid with Time delay capacitor ground suppresion 4.7K W TB20 Resistor Relay normally open Terminal Solenoid without ground suppresion PLATFORM...

  • Page 127: Hydraulic Symbols Legend

    September 2015 Section 6 • Schematics Hydraulic Symbols Legend 0.035” Orifice with size Pressure gauge 3 position, 4 way Differrential sensing valve solenoid operate directional valve Variable orfice or shut-off valve Shuttle valve Filter Check valve Solenoid operated proportional valve Fixed displacement Check valve, pilot operated N.O.
  • Page 128 Section 6 • Schematics September 2015 This page intentionally left blank. 6 - 4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 129: Electrical Schematic (Ansi / Csa)

    Section 6 • Schematics September 2015 Electrical Schematic, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) 6 - 5 6 - 6...

  • Page 130: (From Serial Number Z452510A-39314 To Z452513A-45734)

    Section 6 • Schematics September 2015 Electrical Schematic, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) WH-(FS) C9-2 P24BAT WH P24BAT WH R42BAT OR/RD C1P-12 BL/WH TS49...
  • Page 131 September 2015 Section 6 • Schematics Electrical Schematic, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH P24BAT WH P24BAT WH R42PWR OR/RD BOOM TURNTABLE SECONDARY...
  • Page 132 September 2015 Section 6 • Schematics Electrical Schematic, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) 6 - 7 6 - 8...

  • Page 133: Ground Control Box Terminal Strip Wiring Diagram (Ansi / Csa)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA), (from serial number Z452510A-39314 to Z452513A-45734) 6 - 9 6 - 10...

  • Page 134: Ground Control Box Terminal Strip Wiring Diagram (Ansi / Csa From Serial Number Z452510A-39314 To Z452513A-45734)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) (from serial number Z452510A-39314 to Z452513A-45734) BRN GND RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D C129DA-BK GR/WH GR/WH RD/WH RD/WH OR/RD OR/BK...

  • Page 135: Ground Control Box Switch Panel Wiring Diagram (Ansi / Csa From Serial Number Z452510A-39314 To Z452513A-45734)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA), (from serial number Z452510A-39314 to Z452513A-45734) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK WH-4A COMPONENT INDEX - GROUND CONTROLS LABEL DESCRIPTION CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY 48V DC POWER RELAY...

  • Page 136: Ground Control Box Switch Panel Wiring Diagram (Ansi / Csa)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA), (from serial number Z452510A-39314 to Z452513A-45734) 6 - 11 6 - 12...

  • Page 137: (From Serial Number Z452510A-39314 To Z452513A-45734)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (ANSI / CSA), from serial number Z452510A-39314 to Z452513A-45734) GR/WH + RD OUTPUT BRN - CR14 GR/WH COMPONENT INDEX - PLATFORM CONTROLS BR-RELAY LABEL DESCRIPTION BATTERY CHARGE INDICATOR (OPTION) ROTARY FLOW CONTROL DIAL TIME DELAY CAPACITOR (OPTION) DRIVE ENABLE RELAY...
  • Page 138 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (ANSI / CSA), from serial number Z452510A-39314 to Z452513A-45734) 6 - 13 6 - 14...

  • Page 139: Electrical Schematic (Ansi / Csa)

    Section 6 • Schematics September 2015 Electrical Schematic, (ANSI / CSA) (from serial number Z452513A-45735) 6 - 15 6 - 16...

  • Page 140: Electrical Schematic (Ansi / Csa From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Electrical Schematic, (ANSI / CSA) (from serial number Z452513A-45735) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) WH-(FS) C9-2 P24BAT WH P24BAT WH R42BAT OR/RD C1P-12 BL/WH TS49 TS48...

  • Page 141: (From Serial Number Z452513A-45735)

    September 2015 Section 6 • Schematics Electrical Schematic, (ANSI / CSA) (from serial number Z452513A-45735) C31REV WH/BK C31REV WH/BK C30FWD WH C29JSH RD/WH LVI/BCI OPTION C32JSL WH/RD C30FWD WH C29JSH RD/WH C32JSL WH/RD P24BAT WH P24BAT WH R42PWR OR/RD BOOM TURNTABLE SECONDARY PRIMARY...
  • Page 142 September 2015 Section 6 • Schematics Electrical Schematic, (ANSI / CSA) (from serial number Z452513A-45735) 6 - 17 6 - 18...

  • Page 143: Ground Control Box Terminal Strip Wiring Diagram (Ansi / Csa)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735) 6 - 19 6 - 20...

  • Page 144: (From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735) BRN GND HARNESS TO RD TS55 SWITCH PANEL RD TS51 BK C7B-1 BK 22D C129DA-BK GR/WH GR/WH RD/WH RD/WH OR/RD OR/BK RD/BK BK/RD...

  • Page 145: Ground Control Box Switch Panel Wiring Diagram (Ansi / Csa)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK COMPONENT INDEX - GROUND CONTROLS WH-4A LABEL DESCRIPTION CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY 48V DC POWER RELAY AUXILIARY PUMP RELAY...
  • Page 146 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA) (from serial number Z452513A-45735) 6 - 21 6 - 22...

  • Page 147: Platform Control Box Wiring Diagram (Ansi / Csa)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (ANSI / CSA) from serial number Z452513A-45735) GR/WH + RD OUTPUT BRN - C134PWR RD CR14 GR/WH C54-2 P24BAT RD C54-3 P41DE RD/BK COMPONENT INDEX - PLATFORM CONTROLS C54-5 C10SBU BL BR-RELAY C54-6 C1PBU RD LABEL...
  • Page 148 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (ANSI / CSA) from serial number Z452513A-45735) 6 - 23 6 - 24...

  • Page 149: Electrical Schematics - Ce

    Section 6 • Schematics September 2015 Electrical Schematic, (CE) (from serial number Z452510A-39314 to Z4525Z452513A-45734) 6 - 25 6 - 26...

  • Page 150: (From Serial Number Z452510A-39314 To Z452513A-45734)

    Section 6 • Schematics September 2015 Electrical Schematic, (CE) (from serial number Z452510A-39314 to Z452513A-45734) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C40LS OR RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) LS18B WH-(FS) C9-2 P24BAT WH P24BAT WH LS18A R42BAT OR/RD C132PLI2 GR...
  • Page 151 September 2015 Section 6 • Schematics Electrical Schematic, (CE) (from serial number Z452510A-39314 to Z452513A-45734) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C40LS OR C40LS OR P24BAT WH P24BAT WH R42PWR OR/RD BOOM TURNTABLE...
  • Page 152 September 2015 Section 6 • Schematics Electrical Schematic, (CE) (from serial number Z452510A-39314 to Z452513A-45734) 6 - 27 6 - 28...

  • Page 153: Ground Control Box Terminal Strip Wiring Diagram (Ce)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (CE), (from serial number Z452510A-39314 to Z452513A-45734) 6 - 29 6 - 30...

  • Page 154: Ground Control Box Terminal Strip Wiring Diagram (Ce From Serial Number Z452510A-39314 To Z452513A-45734)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (CE), (from serial number Z452510A-39314 to Z452513A-45734) BRN GND GR/BK H6 RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D BL/WH C1-12 RD H6 C129DA-BK GR/WH GR/WH...

  • Page 155: (From Serial Number Z452510A-39314 To Z452513A-45734)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (CE), (from serial number Z452510A-39314 to Z452513A-45734) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK COMPONENT INDEX - GROUND CONTROLS WH-4A LABEL DESCRIPTION CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY 48V DC POWER RELAY AUXILIARY PUMP RELAY...

  • Page 156: Ground Control Box Switch Panel Wiring Diagram (Ce)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (CE), (from serial number Z452510A-39314 to Z452513A-45734) 6 - 32 6 - 31...

  • Page 157: (From Serial Number Z452510A-39314 To Z452513A-45734)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (CE) from serial number Z452510A-39314 to Z4525013A-45734) P26BAT BK GR/WH + RD OUTPUT BRN - CR14 GR/WH COMPONENT INDEX - PLATFORM CONTROLS BR-RELAY BR-GND LABEL DESCRIPTION BATTERY CHARGE INDICATOR (OPTION) ROTARY FLOW CONTROL DIAL TIME DELAY CAPACITOR (OPTION) DRIVE ENABLE RELAY...
  • Page 158 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (CE) from serial number Z452510A-39314 to Z452513A-45734) 6 - 33 6 - 34...

  • Page 159: (From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Electrical Schematic, (CE) (from serial number Z452513A-45735) 6 - 35 6 - 36...

  • Page 160: (From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Electrical Schematic, (CE) (from serial number Z452513A-45735) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C40LS OR RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) LS18B WH-(FS) C9-2 P24BAT WH P24BAT WH LS18A R42BAT OR/RD C132PLI2 GR C1P-12 BL/WH...
  • Page 161 September 2015 Section 6 • Schematics Electrical Schematic, (CE) (from serial number Z452513A-45735) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C40LS OR C40LS OR P24BAT WH P24BAT WH R42PWR OR/RD TURNTABLE SECONDARY PRIMARY...
  • Page 162 September 2015 Section 6 • Schematics Electrical Schematic, (CE) (from serial number Z452513A-45735) 6 - 38 6 - 37...

  • Page 163: Ground Control Box Terminal Strip Wiring Diagram (Ce)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452513A-45735) 6 - 39 6 - 40...

  • Page 164: Ground Control Box Terminal Strip Wiring Diagram (Ce From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (CE) (from serial number Z452513A-45735) BRN GND GR/BK H6 RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D BL/WH C1-12 RD H6 C129DA-BK GR/WH GR/WH RD/WH RD/WH...

  • Page 165: Ground Control Box Switch Panel Wiring Diagram (Ce)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452513A-45735) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK COMPONENT INDEX - GROUND CONTROLS WH-4A LABEL DESCRIPTION CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY 48V DC POWER RELAY AUXILIARY PUMP RELAY...
  • Page 166 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (CE) (from serial number Z452513A-45735) 6 - 41 6 - 42...

  • Page 167: Platform Control Box Wiring Diagram (Ce)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (CE) from serial number Z452513A-45735) C134PWR RD P26BAT BK GR/WH + RD OUTPUT BRN - CR14 C134PWR RD GR/WH C54-2 P24BAT RD C54-3 P41DE RD/BK C54-5 C10SBU BL COMPONENT INDEX - PLATFORM CONTROLS BR-RELAY C54-6 C1PBU RD BR-GND...
  • Page 168 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (CE) from serial number Z452513A-45735) 6 - 43 6 - 44...

  • Page 169: Electrical Schematic (As)

    Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452510A-39314 to Z452511A-40559) 6 - 45 6 - 46...

  • Page 170: (From Serial Number Z452510A-39314 To Z452511A-40559)

    Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452510A-39314 to Z452511A-40559) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) WH-(FS) C9-2 P24BAT WH P24BAT WH R42BAT OR/RD C1P-12 BL/WH TS49 TS48...

  • Page 171: (From Serial Number Z452510A-39314 To Z452511A-40559)

    September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452510A-39314 to Z452511A-40559) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH P24BAT WH P24BAT WH R42PWR OR/RD BOOM TURNTABLE SECONDARY PRIMARY...
  • Page 172 September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452510A-39314 to Z452511A-40559) 6 - 47 6 - 48...

  • Page 173: Ground Control Box Terminal Strip Wiring Diagram (As)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559) 6 - 50 6 - 49...

  • Page 174: Ground Control Box Terminal Strip Wiring Diagram (As From Serial Number Z452510A-39314 To Z452511A-40559)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559) BRN GND RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D C129DA-BK GR/WH GR/WH RD/WH RD/WH OR/RD OR/BK RD/BK BK/RD...

  • Page 175: Ground Control Box Switch Panel Wiring Diagram (As)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK WH-4A COMPONENT INDEX - GROUND CONTROLS LABEL DESCRIPTION CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY RD-27A 48V DC POWER RELAY...
  • Page 176 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452510A-39314 to Z452511A-40559) 6 - 51 6 - 52...

  • Page 177: Platform Control Box Wiring Diagram (As)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452510A-39314 to Z452511A-40559) GR/WH + RD OUTPUT BRN - CR14 GR/WH COMPONENT INDEX - PLATFORM CONTROLS BR-RELAY LABEL DESCRIPTION BATTERY CHARGE INDICATOR (OPTION) ROTARY FLOW CONTROL DIAL TIME DELAY CAPACITOR (OPTION) DRIVE ENABLE RELAY JIB SELECT RELAY (OPTION)
  • Page 178 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452510A-39314 to Z452511A-40559) 6 - 53 6 - 54...

  • Page 179: (From Serial Number Z452511A-40560 To Z452513A-45734)

    Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452511A-40560 to Z452513A-45734) 6 - 55 6 - 56...

  • Page 180: (From Serial Number Z452511A-40560 To Z452513A-45734)

    Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452511A-40560 to Z452513A-45734) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C40LS OR RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) LS18B WH-(FS) C9-2 P24BAT WH P24BAT WH LS18A R42BAT OR/RD C132PLI2 GR...
  • Page 181 September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452511A-40560 to Z452513A-45734) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C40LS OR C40LS OR P24BAT WH P24BAT WH R42PWR OR/RD TURNTABLE SECONDARY...
  • Page 182 September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452511A-40560 to Z452513A-45734) 6 - 57 6 - 58...

  • Page 183: Ground Control Box Terminal Strip Wiring Diagram (As)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734) 6 - 59 6 - 60...

  • Page 184: (From Serial Number Z452511A-40560 To Z452513A-45734)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734) BRN GND GR/BK H6 RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D BL/WH C1-12 RD H6 C129DA-BK GR/WH GR/WH...

  • Page 185: (From Serial Number Z452511A-40560 To Z452513A-45734)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK WH-4A RD-27A COMPONENT INDEX - GROUND CONTROLS LABEL DESCRIPTION OR/BK-15A OR/BK CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY...

  • Page 186: Ground Control Box Switch Panel Wiring Diagram (As)

    September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452511A-40560 to Z452513A-45734) 6 - 61 6 - 62...

  • Page 187: Platform Control Box Wiring Diagram (As)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452511A-40560 to Z452513A-45734) P26BAT BK GR/WH + CR76 RD OUTPUT BRN - CR14 WH/BK GR/WH CR76A COMPONENT INDEX - PLATFORM CONTROLS BR-RELAY LABEL DESCRIPTION BR-GND BATTERY CHARGE INDICATOR (OPTION) C171LS WH/BK ROTARY FLOW CONTROL DIAL...
  • Page 188 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452511A-40560 to Z452513A-45734) 6 - 63 6 - 64...
  • Page 189 Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452513A-45735) 6 - 65 6 - 66...

  • Page 190: (From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Electrical Schematic, (AS) (from serial number Z452513A-45735) C31REV WH/BK C30FWD WH C32JSL WH/RD C29JSH RD/WH C40LS OR RD-(FS) C9-3 P25BAT RD C7P-1 P26BAT C9-1 BK BK-(FS) LS18B WH-(FS) C9-2 P24BAT WH P24BAT WH LS18A R42BAT OR/RD C132PLI2 GR C1P-12 BL/WH...
  • Page 191 September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452513A-45735) C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH LVI/BCI OPTION C32JSL WH/RD C32JSL WH/RD C29JSH RD/WH C29JSH RD/WH C40LS OR C40LS OR P24BAT WH P24BAT WH R42PWR OR/RD BOOM TURNTABLE SECONDARY...
  • Page 192 September 2015 Section 6 • Schematics Electrical Schematic, (AS) (from serial number Z452513A-45735) 6 - 67 6 - 68...
  • Page 193 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452513A-45735) 6 - 69 6 - 70...

  • Page 194: Ground Control Box Terminal Strip Wiring Diagram (As From Serial Number Z452513A-45735)

    Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, (AS) (from serial number Z452513A-45735) BRN GND GR/BK H6 RD TS55 HARNESS TO SWITCH PANEL RD TS51 BK C7B-1 BK 22D BL/WH C1-12 RD H6 C129DA-BK GR/WH GR/WH RD/WH RD/WH...
  • Page 195 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452513A-45735) BK/RD-35A C45JSV GR/WH (C2B-7) BK-7A GR/BK-18A BK/WH-8A GR-17A WH/BK-5A GR/BK WH-4A RD-27A OR/BK-15A OR/BK COMPONENT INDEX - GROUND CONTROLS LABEL DESCRIPTION RD/BK-2A OR-14A CONTROLS CIRCUIT BREAKER, 15A 48V DC POWER RELAY...
  • Page 196 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, (AS) (from serial number Z452513A-45735) 6 - 71 6 - 72...

  • Page 197: Platform Control Box Wiring Diagram (As From Serial Number Z452513A-45735)

    September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452513A-45735) P26BAT BK GR/WH + CR76 RD OUTPUT BRN - CR14 C134PWR RD WH/BK GR/WH CR76A C54-2 P24BAT RD C54-3 P41DE RD/BK C54-5 C10SBU BL BR-RELAY COMPONENT INDEX - PLATFORM CONTROLS C54-6 C1PBU RD...
  • Page 198 September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, (AS) from serial number Z452513A-45735) 6 - 73 6 - 74...

  • Page 199: Platform Options Wiring Diagram

    Section 6 • Schematics September 2015 Platform Options Wiring Diagram (from serial number Z452510A-39314 to Z452513A-45734) 6 - 75 6 - 76...

  • Page 200: Platform Options Wiring Diagram

    Section 6 • Schematics September 2015 Platform Options Wiring Diagram (from serial number Z452510A-39314 to Z452513A-45734) CR45 BR-GND CR19A CR19B BR-GND COMPONENT INDEX - PLATFORM CONTROLS TS48 LABEL DESCRIPTION BATTERY CHARGE INDICATOR CR19A PRIMARY BOOM UP CUTOUT RELAY CR19B SECONDARY BOOM UP CUTOUT RELAY CR45 WORK LIGHTS RELAY LOW VOLTAGE INTERUPT MODULE...
  • Page 201 September 2015 Section 6 • Schematics Platform Options Wiring Diagram (from serial number Z452513A-45735) CR14 CR45 BR-GND C54-1 P24BAT WH C54-4 LVI#3 BK C54-5 C10SBU BL C54-6 C1PBU RD C54-7 C1PBU RD C54-8 C10SBU BL CR19A CR19B BR-GND LVI#4 BR COMPONENT INDEX - PLATFORM CONTROLS LABEL DESCRIPTION...
  • Page 202 September 2015 Section 6 • Schematics Platform Options Wiring Diagram (from serial number Z452513A-45735) 6 - 77 6 - 78...

  • Page 203: Engine Panel Wiring Diagram

    Section 6 • Schematics September 2015 Engine Panel Wiring Diagram 6 - 79 6 - 80...
  • Page 204 Section 6 • Schematics September 2015 Engine Panel Wiring Diagram CB3-RD CB3-RD (+12V DC) RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE C21ING2 WH C35HRPM BK/RD WH/J5 BR-J4 BR-J4 BR-J4 BR-J4 BR-J4 WH-J4 BK/RD BR-GND CB3 RD CR16 CR11 CR12 CR13 CR14...

  • Page 205: Power Panel Wiring Diagram

    September 2015 Section 6 • Schematics Power Panel Wiring Diagram TO ENGINE PANEL TO GROUND CONTROL BOX CONNECTOR C6B AC POWER CABLE LEFT SIDE DC AMMETER CABLE BATTERY PACK RD-2GA RIGHT SIDE BATTERY PACK 48V DC ALTERNATOR BATTERY CHARGER PRIMARY LIFT PUMP RD-2GA AUXILIARY LIFT...
  • Page 206 September 2015 Section 6 • Schematics Power Panel Wiring Diagram 6 - 81 6 - 82...

  • Page 207: Cte Option Wiring Diagram, (Ce)

    Section 6 • Schematics September 2015 CTE Option Wiring Diagram, (CE) 6 - 83 6 - 84...
  • Page 208 Section 6 • Schematics September 2015 CTE Option Wiring Diagram, (CE) P22LS BK TB134 FUNCTION HARNESS TB15 TB14 TB40 CR21 CR20 BR - GROUND PLATFORM LEVEL CUTOUT WIRING DIAGRAM ES0276N 6 - 84 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 237062...

  • Page 209: Charger Interlock Option

    September 2015 Section 6 • Schematics Charger Interlock Option C49-10 CHARGER INDICATOR C56-1 BK (N.O.) BATTERY BATTERY CHARGER CHARGER C56-1 BK (NO) C56-2 WH (COM) CHARGER ECU C56-2 WH (COM) SUPPLY BATTERY CONTACT OPEN COIL CONNECT CLOSED CONNECT CONNECT OPEN CONNECT OPEN P42BAT OR/RD...
  • Page 210 September 2015 Section 6 • Schematics Charger Interlock Option 6 - 85 6 - 86...

  • Page 211: Hydraulic Schematic

    September 2015 Section 6 • Schematics Hydraulic Schematic JIB BOOM PLATFORM ROTATE 1.5:1 3800 psi 3000 psi 262 bar 207 bar JIB BOOM / PLATFORM ROTATE MANIFOLD PLATFORM LEVEL SLAVE CYLINDER TURNTABLE ROTATE PRIMARY LIFT CYLINDER EXTENSION CYLINDER SECONDARY LIFT CYLINDERS BRAKES STEER CYLINDERS 3000 psi...
  • Page 212 September 2015 Section 6 • Schematics Hydraulic Schematic 6 - 87 6 - 88...

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