Genie 45 25J

Service Manual
Refer to inside cover for additional serial number information

Part No. 106488
Rev B
June 2005
Bi-Energy Power
(from serial number 9996 to 23235)
Introduction June 2005
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie Z-45/25 Manuals for these models:
Bi-Energy and Genie Z-45/25J Bi-Energy Operator's
Manual before attempting any maintenance or Title Part No.
repair procedure.
Z-45/25 Bi-Energy and Z-45/25J Bi-Energy
This manual provides detailed scheduled Service Manual
maintenance information for the machine owner and (after serial number 23235) ................................ 110188
user. It also provides troubleshooting fault codes
and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are subject
to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 1999 by Genie Industries
http://www.genieindustries.com 106488 Rev B June 2005

e-mail: techsup@genieind.com Second Edition, Second Printing
"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

June 2005
INTRODUCTION
Serial Number Legend
Model: Z-45/25
Serial number: Z452505-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0274
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg Z4525 05 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 45 ft 6 in/ 13.8 m
Model Sequence
Maximum platform reach : 25 ft 3 in/ 7.7 m
number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
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iv Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

June 2005
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator’s Manual will
result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy v

June 2005
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
Read each procedure thoroughly. This placing loads. Always wear approved steel-toed
manual and the decals on the machine, shoes.
use signal words to identify the following:
Workplace Safety
Safety alert symbol—used to alert
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Used to indicate the presence of
an imminently hazardous situation Be sure that all tools and working areas
which, if not avoided, will result in are properly maintained and ready for use.
death or serious injury. Keep work surfaces clean and free of
Used to indicate the presence of a debris that could get into machine components and
potentially hazardous situation cause damage.
which, if not avoided, could result Be sure any forklift, overhead crane or
in death or serious injury. other lifting or supporting device is fully
With safety alert symbol—used to capable of supporting and stabilizing the
indicate the presence of a weight to be lifted. Use only chains or straps that
potentially hazardous situation are in good condition and of ample capacity.
which, if not avoided, may cause Be sure that fasteners intended for one
minor or moderate injury. time use (i.e., cotter pins and self-locking
Without safety alert symbol—used nuts) are not reused. These components
to indicate the presence of a may fail if they are used a second time.
potentially hazardous situation
Be sure to properly dispose of old oil or
which, if not avoided, may result in
other fluids. Use an approved container.
property damage.
Please be environmentally safe.
Used to indicate operation or
maintenance information. Be sure that your workshop or work area is
properly ventilated and well lit.
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June 2005
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

A Machine Specifications .......................................................................................... 2 - 1
B Performance Specifications ................................................................................... 2 - 2
B Hydraulic Specifications ........................................................................................ 2 - 3
B Manifold Component Specifications ....................................................................... 2 - 4
B Machine Torque Specifications .............................................................................. 2 - 4
A Kubota Z482-E Engine Specifications .................................................................... 2 - 5
A Generator ............................................................................................................... 2 - 6
A Generator Torque Specifications ............................................................................ 2 - 6
A Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 7
A SAE and Metric Fasteners Torque Charts .............................................................. 2 - 8
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
B Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 7
A-2 Perform Function Tests ................................................................................ 3 - 7
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TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A-3 Check the Generator Belts and Pulleys ........................................................ 3 - 8
A-4 Perform 30 Day Service ............................................................................... 3 - 9
A-5 Perform Engine Maintenance ..................................................................... 3 - 10
A-7 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11
B Checklist B Procedures
B-1 Check the Radiator ..................................................................................... 3 - 13
B-2 Check the Exhaust System ....................................................................... 3 - 13
B-3 Check the Batteries .................................................................................... 3 - 14
B-4 Inspect the Electrical Wiring ....................................................................... 3 - 15
B-5 Check the Lug Nut Torque (including the tires and wheels) ......................... 3 - 16
B-6 Confirm the Proper Brake Configuration ...................................................... 3 - 16
B-7 Check the Oil Level in the Drive Hubs ........................................................ 3 - 17
B-8 Check and Adjust the Engine RPM ............................................................ 3 - 18
B-9 Test the Ground Control Override ............................................................... 3 - 19
B-10 Test the Platform Self-leveling ................................................................... 3 - 20
B-11 Test the Engine Idle Select ........................................................................ 3 - 20
B-12 Test the Drive Brakes ................................................................................ 3 - 21
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 21
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TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22
B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 22
B-16 Test the Turntable Rotation Stop ................................................................ 3 - 23
B-17 Check the Electrical Contactors ................................................................. 3 - 24
B-18 Perform Hydraulic Oil Analysis ................................................................... 3 - 24
B-19 Perform Engine Maintenance ..................................................................... 3 - 25
B Checklist C Procedures
C-1 Perform Engine Maintenance ..................................................................... 3 - 26
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 26
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 27
C-4 Perform Engine Maintenance ..................................................................... 3 - 29
B Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 30
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 30
D-3 Check the Free-wheel Configuration ........................................................... 3 - 32
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 33
D-5 Replace the Hydraulic Tank Return Filter ................................................... 3 - 34
D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 34
D-7 Calibrate the Platform Overload System (if equipped) ................................ 3 - 36
D-8 Perform Engine Maintenance ..................................................................... 3 - 37
D-9 Perform Engine Maintenance ..................................................................... 3 - 38
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 39
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 40
E-3 Perform Engine Maintenance ..................................................................... 3 - 42
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June 2005
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
B Platform Controls
1-1 Controllers .................................................................................................... 4 - 2
B Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2 Platform Rotator ........................................................................................... 4 - 5
B Jib Boom Components, Z-45/25J Models
3-1 Jib Boom ...................................................................................................... 4 - 7
3-2 Jib Boom Lift Cylinder .................................................................................. 4 - 8
B Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 10
4-2 Primary Boom ............................................................................................ 4 - 14
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 17
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 18
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 19
B Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 21
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 26
A Kubota Z482-E Engine
6-1 Timing Adjustment ..................................................................................... 4 - 27
6-2 RPM Adjustment ........................................................................................ 4 - 27
6-3 Engine Drive Pulley .................................................................................... 4 - 27
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TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

A Generator
7-1 Generator Pulley ........................................................................................ 4 - 29
7-2 Generator Belts .......................................................................................... 4 - 30
7-3 Generator Voltage Regulator ...................................................................... 4 - 30
B Hydraulic Pumps
8-1 Auxiliary Pump ........................................................................................... 4 - 33
8-2 Function Pump ........................................................................................... 4 - 33
C Manifolds
9-1 Function Manifold Components (before serial number 17841) ..................... 4 - 34
9-2 Function Manifold Components (from serial number 17841 to 20379) ......... 4 - 38
9-5 Valve Adjustments - Function Manifold ...................................................... 4 - 44
9-6 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 46
9-7 Turntable Rotation Manifold Components ................................................... 4 - 47
B Turntable Rotation Components
10-1 Rotation Hydraulic Motor (before serial number 18367) ............................... 4 - 48
10-2 Turntable Rotation Assembly (after serial number 18366) ........................... 4 - 50
A Motor Controller
11-1 Motor Controller .......................................................................................... 4 - 52
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June 2005
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
A Fault Code Chart .................................................................................................... 5 - 3
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
Power Cable Diagrams
A Power Cable Diagram (before serial number 16839) ............................................... 6 - 5
A Power Cable Diagram (from serial number 16840 to 21179) ................................... 6 - 6
Engine Panel Diagrams
A Engine Panel Diagram (before serial number 13361) .............................................. 6 - 9
A Engine Panel Diagram (from serial number 13361 to 14078) ................................ 6 - 10
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TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Electrical Schematics, Z-45/25
A Electrical Schematic, Z-45/25 (before serial number 13361) ................................. 6 - 17
A Electrical Schematic, Z-45/25 (from serial number 13361 to 14078) ..................... 6 - 19
A Electrical Schematic, Z-45/25, ANSI and CSA Models
(from serial number 22051 to 23235) .................................................................... 6 - 31
A Electrical Schematic, Z-45/25, CE Models
Electrical Schematics, Z-45/25J
A Electrical Schematic, Z-45/25J (before serial number 13361) ............................... 6 - 35
A Electrical Schematic, Z-45/25J (from serial number 13361 to 14078) ................... 6 - 37
A Electrical Schematic, Z-45/25J, ANSI and CSA Models
A Electrical Schematic, Z-45/25J, CE Models
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June 2005
TABLE OF CONTENTS

Ground Control Box Wiring Diagrams, Z-45/25
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(before serial number 13361) ................................................................................ 6 - 53
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
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TABLE OF CONTENTS

ANSI and CSA Models (from serial number 22051 to 23235) ............................... 6 - 67
ANSI and CSA Models (after serial number 22050) .............................................. 6 - 68
CE Models (from serial number 22051 to 23235) .................................................. 6 - 69
Ground Control Box Wiring Diagrams, Z-45/25J
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
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June 2005
TABLE OF CONTENTS

Platform Control Box Wiring Diagrams, Z-45/25
A Platform Control Box Wiring Diagram, Z-45/25
(with platform load sense and LVI/BCI option)
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TABLE OF CONTENTS

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 17975 to 21180) ................................................................... 6 - 100
Platform Control Box Wiring Diagrams, Z-45/25J
A Platform Control Box Wiring Diagram, Z-45/25J
(before serial number 13361) ............................................................................... 6 - 105
(before serial number 13361) ............................................................................... 6 - 106
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June 2005
TABLE OF CONTENTS

A Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
Hydraulic Schematics
B Hydraulic Schematic (before serial number 16962) .............................................. 6 - 121
B Hydraulic Schematic (from serial number 16962 to 20379) .................................. 6 - 122
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June 2005 Section 2 • Specifications
REV A
Specifications
Machine Specifications Fluid capacities
Tires and wheels Fuel tank 9 gallons

34.1 liters
Wheel diameter 14.5 inches
Hydraulic tank 8 gallons
Wheel width 7 inches 30.3 liters
Hydraulic system 11 gallons
Wheel lugs (before serial number 16128)
(including tank) 41.6 liters
Front 8 @ 5/8 -18
Rear 9 @ 5/8 -18 Drive hubs (refer to tag on drive hub to determine type)
EW1 type 17 fl oz
Wheel lugs (from serial number 16127 to 23235) 0.51 liter
Front 9 @ 5/8 -18 W1 type 23 fl oz
Rear 9 @ 5/8 -18 0.68 liter
Lug nut torque 125 ft-lbs Drive hub oil type: SAE 90 multipurpose hypoid gear oil
169.5 Nm API service classification GL5
Tire size 9-14.5 LT Batteries
Tire ply rating Tread 8 Type 6V DC

Sidewall 6 Quantity 8
Tire contact area 43.5 sq in Capacity 350 AH
280 sq cm
Reserve capacity @ 25A rate 750 minutes
Overall tire diameter 28 in
71 cm
Tire pressure 100 psi

6.89 bar Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
For operational specifications, refer to the
Operator's Manual.
Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-1

Section 2 • Specifications June 2005
SPECIFICATIONS REV B
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds, maximum
Jib boom up, Z-45/25J 30 to 40 seconds
Drive speed, stowed 3 mph
All models 4.8 km/h Jib boom down, Z-45/25J 18 to 23 seconds
40 ft/9 sec Primary boom up 30 to 36 seconds
12.2 m/9 sec
Primary boom down 26 to 32 seconds
Drive speed, boom 0.6 mph
raised or extended, 1 km/h Secondary boom up 38 to 42 seconds
all models 40 ft/45 sec
12.2 m/45 sec Secondary boom down 32 to 36 seconds
Braking distance, maximum Primary boom extend, Z-45/25 25 to 30 seconds
High range on paved surface 5 to 7 ft Primary boom extend, Z-45/25J 16 to 24 seconds
1.5 to 2 m
Primary boom retract, Z-45/25 21 to 30 seconds
Gradeability (boom stowed) 30%
Primary boom retract, Z-45/25J 13 to 23 seconds
Turntable rotate, 359° 76 to 82 seconds

primary boom retracted
Platform rotate, 180°, Z-45/25 6 to 10 seconds
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
2-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

REV B SPECIFICATIONS
Hydraulic Specifications Function pump
Before serial number 20926 Type: Fixed displacement gear pump

Hydraulic oil type Shell Donax TG (Dexron III) Displacement 0.183 cu in
After serial number 20925 3 cc
Hydraulic oil type Chevron Rykon MV equivalent Flow rate 2.1 gpm
Approximate SAE grade 5W-20 7.9 L/min
Viscosity index rating 200
Hydraulic tank 10 micron with
Cleanliness level, minimum 15/13 return filter 25 psi / 1.7 bar bypass
Water content, maximum 200 ppm Function manifold
Chevron Rykon MV oil is fully compatible and Function relief valve pressure 3200 psi
mixable with Shell Donax TG (Dexron III) oils. 220.6 bar
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic Primary boom down 2300 psi
systems, have the ability to perform over a wide relief valve pressure 158.6 bar
temperature range, and have a minimum viscosity index (before serial number 11819)
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and Secondary boom down 1800 psi
foam and aeration suppression properties. relief valve pressure 124 bar
(before serial number 22566)
Optional fluids
Secondary boom down 2000 psi
Biodegradable Petro Canada Premium ECO 46 relief valve pressure 138 bar
Statoil Hydra Way Bio Pa 32 (from serial number 22566 to 23235)
BP Biohyd SE-S
Platform level flow regulator 0.1 gpm
Fire resistant UCON Hydrolube HP-5046 (before serial number 20380) 0.38 L/min
Quintolubric 822
Platform level flow regulator 0.6 gpm
Mineral based Shell Tellus T32 (from serial number 20380 to 23235) 2.27 L/min
Shell Tellus T46
Chevron Aviation A Jib boom/platform rotate flow regulator 0.6 gpm
(before serial number 22566) 2.27 L/min
Jib boom/platform rotate flow regulator 0.4 gpm

Use Chevron Aviation A hydraulic
(from serial number 22566 to 23235) 1.5 L/min
oil when in ambient temperatures
consistently below 0°F / -18°C. Auxiliary pump
Use Shell Tellus T46 hydraulic oil Type: fixed displacement gear pump
when oil temperatures consistently
exceed 205°F / 96°C. Displacement 0.5 gpm
1.9 L/min
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.Function
pump

SPECIFICATIONS REV B
Manifold Component Machine Torque Specifications

Specifications
Platform rotator
Plug torque 1 -8 center bolt (grade 2) 200 ft-lbs
271 Nm
SAE No. 2 36 in-lbs / 4 Nm
1 -8 center bolt (grade 8) 480 ft-lbs
SAE No. 4 10 ft-lbs / 13 Nm 651 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
SAE No. 6 14 ft-lbs / 19 Nm
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs
SAE No. 12 56 ft-lbs / 76 Nm 244 Nm
Drive motor/brake mounting bolts, dry 110 ft-lbs

149 Nm
Valve Coil Resistance Specification
Drive motor/brake mounting bolts, lubricated 80 ft-lbs
Description Specification 108 Nm
Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω Drive motor and hubs
(schematic items E, H, J, K, L, M, CC, DD,
EE, FF, HH, II, BB, BC, BD, BE, BF, BG, CB, Drive hub mounting bolts, lubricated 180 ft-lbs
CD, CE, CF and CH) 244 Nm
Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω Drive motor mounting bolts, lubricated 55 ft-lbs
(schematic items N, P, AA, BB, BA, BJ, 75 Nm
CA, CK and CR)
Solenoid valve, 2 position 3 way, 20V DC 17 to 21 Ω

(schematic item CR)

(schematic item DC)

(schematic items DA and DB)
Proportional solenoid valve, 24V DC 17 to 21 Ω

(schematic items G, JJ, BH and CI)
Solenoid valve, N.C. poppet, 20V DC 25 to 28 Ω

(schematic items F, LL and BI)
Solenoid valve, N.O. poppet, 20V DC 25 to 28 Ω

(schematic items B, VV and BT)

REV A SPECIFICATIONS
Kubota Z482-E Engine Injection system
Displacement 29.23 cu in Injection pump make Bosch MD

0.48 liters Injection timing 21° BTDC
Number of cylinders 2 Injection pump pressure 1991 psi
Bore and stroke 2.64 x 2.68 inches 137 bar
67 x 68 mm Fuel requirement diesel number 2-D
Horsepower
Gross intermitent 12.5 @ 3600 rpm
Starter motor
Firing order 1-2
Brush length, new 0.5188 in
Compression ratio 23:1 13 mm
Compression pressure 412 to 469 psi Brush length, minimum 0.3346 in
28.4 to 32.3 bar 8.5 mm
Low idle 2000 rpm Battery
High idle 3000 rpm Type 12V DC, Group 70
Governor centrifugal mechanical Quantity 1
Valve clearance, cold 0.0057 to 0.0072 in Cold cranking ampere 450A
0.145 to 0.185 mm
Reserve capacity @ 25A rate 125 minutes
Engine coolant
Alternator
Capacity 2.9 quarts Output 12V DC, 150 watts
2.8 liters
1
Fan belt deflection /4 to 3/8 inch
Lubrication system 7 to 9 mm
Oil pressure 36 to 64 psi
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.

SPECIFICATIONS REV A
Generator
Generator output
with engine @ 3000 rpm 54V DC, 100A
Generator pulley to engine 1/16inch

pulley offset, maximum 1.6 mm
1
Belt deflection, maximum /4 inch
6.5 mm
Generator Torque Specifications

Generator pulley retaining nut torque 80-90 ft-lbs
108-122 Nm
Engine pulley retaining bolts 108 in-lbs

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

REV A SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
field service kit (Genie part
SAE Dash size Torque
number 49612).
-4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-8 40 ft-lbs / 54.2 Nm
4 Position the tube and nut squarely on the face
-10 69 ft-lbs / 93.6 Nm
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.
-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-20 172 ft-lbs / 233.2 Nm
6 Operate all machine functions and inspect the
-24 208 ft-lbs / 282 Nm hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 24.4 Nm
-6 35 ft-lbs / 47.5 Nm -6 27 ft-lbs / 36.6 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm
-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm
-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm
-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm

SPECIFICATIONS REV A
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 100 11.3 80 9 140 15.8 110 12.4 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
1 8 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
1 1/8 7 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
1 1/4 7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
1 1/2 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

June 2005 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
and every 2 years as specified on the Used to indicate the presence of
Maintenance Inspection Report. an imminently hazardous situation
which, if not avoided, will result in
Failure to properly complete each death or serious injury.
inspection when required may
cause death, serious injury or Used to indicate the presence of a
substantial machine damage. potentially hazardous situation
which, if not avoided, could result
Immediately tag and remove from service a in death or serious injury.
damaged or malfunctioning machine.
With safety alert symbol—used to
Repair any machine damage or malfunction indicate the presence of a
before operating machine. potentially hazardous situation
which, if not avoided, may cause
Keep records on all inspections for three years. minor or moderate injury.
Unless otherwise specified, perform each Without safety alert symbol—used
procedure with the machine in the following to indicate the presence of a
configuration: potentially hazardous situation
· Machine parked on a firm, level surface which, if not avoided, may result in
property damage.
· Boom in the stowed position
Used to indicate operation or
· Turntable rotated with the boom between maintenance information.
the non-steer wheels
Indicates that a specific result is expected after
· Turntable secured with the turntable performing a series of steps.
rotation lock
Indicates that an incorrect result has occurred
· Key switch in the off position with the after performing a series of steps.
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine

Section 3 • Scheduled Maintenance Procedures June 2005
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

The following symbols have been There are five types of maintenance inspections
used in this manual to help that must be performed according to a schedule—
communicate the intent of the daily, quarterly, six months, annual, and two year.
instructions. When one or more of The Scheduled Maintenance Procedures Section
the symbols appear at the and the Maintenance Inspection Report have been
beginning of a maintenance divided into five subsections—A, B, C, D and E.
procedure, it conveys the meaning Use the following chart to determine which
below. group(s) of procedures are required to perform a
scheduled inspection.
Indicates that tools will be required to Inspection Checklist

perform this procedure.
Daily or every 8 hours A
Indicates that new parts will be required Quarterly or every 250 hours A+B
to perform this procedure.
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that a cold motor, pump or
engine will be required to perform this Two year or every 2000 hours A+B+C+D+E
procedure.
Maintenance Inspection Report

Indicates that a warm motor or pump The maintenance inspection report contains
will be required to perform this checklists for each type of scheduled inspection.
procedure.
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.

Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
3-3

Maintenance Inspection Report

Model Checklist A - Rev B Y N R Checklist B - Rev B Y N R
A-1 Pre-operation B-1 Radiator
Serial number inspection B-2 Exhaust system
Date A-2 Function tests B-3 Batteries
A-3 Generator belts and B-4 Electrical wiring
Hour meter pulleys
B-5 Lug nut torque
Perform after 50 hours:
Machine owner B-6 Brake configuration
A-4 30 Day Service
B-7 Drive hub oil level
Inspected by (print) Perform every 50 hours:
B-8 Engine RPM
A-5 Perform engine
B-9 Ground control
Inspector signature maintenance
override
Perform every 75 hours:
Inspector title B-10 Platform leveling
A-6 Perform engine
B-11 Engine idle select
maintenance
Inspector company B-12 Drive brakes
B-13 Drive speed - stowed
Instructions A-7 Grease rotation
· Make copies of this page to use for bearing B-14 Drive speed - raised
each inspection. A-8 Perform engine B-15 Alarm package
maintenance (if equipped)
· Select the appropriate checklist(s) for
the type of inspection to be Perform every 150 hours: B-16 Turntable rotation stop
performed. A-9 Perform engine B-17 Electrical contactors
maintenance B-18 Hydraulic oil analysis
Daily or 8 hour
Inspection: A Perform every 200 hours:
Quarterly or 250 hour A-10 Perform engine Checklist C - Rev B Y N R

Inspection: A+B maintenance C-1 Perform engine
Six Month or 500 hour maintenance
Inspection: A+B+C C-2 Grease platform
overload (if equipped)
Annual or 1000 hours
Inspection: A+B+C+D C-3 Test platform
overload (if equipped)
2 Year or 2000 hour
Inspection: A+B+C+D+E Perform every 800 hours:
C-4 Perform engine
· Place a check in the appropriate box maintenance
after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

MAINTENANCE INSPECTION REPORT
Model Checklist D - Rev B Y N R

D-1 Boom wear pads
Serial number
D-2 Turntable bearing bolts
Date D-3 Free-wheel
configuration
Hour meter D-4 Drive hub oil
D-5 Hydraulic return filter
Machine owner
D-6 Turntable bearing wear
Inspected by (print) D-7 Calibrate platform
overload system
Inspector signature (if equipped)
Inspector title D-8 Perform engine
maintenance
Inspector company
Instructions D-9 Perform engine
· Make copies of this page to use for maintenance
each inspection.
· Select the appropriate checklist(s) for Checklist E - Rev B Y N R
the type of inspection to be E-1 Hydraulic oil
performed.
E-2 Wheel bearings
Daily or 8 hour E-3 Perform engine
Inspection: A maintenance
Quarterly or 250 hour
Inspection: A+B
Six Month or 500 hour
Inspection: A+B+C
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
· Place a check in the appropriate box

after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

REV B
Checklist A Procedures
A-1 A-2
Perform Pre-operation Inspection Perform Function Tests
Completing a pre-operation inspection is essential Completing the function tests is essential to safe
to safe machine operation. The pre-operation machine operation. Function tests are designed to
inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The pre-operation inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the Genie Z-45/25 Bi-Energy and
Complete information to perform this procedure is Genie Z-45/25J Bi-Energy Operator's Manual on
available in the Genie Z-45/25 Bi-Energy and your machine.
Genie Z-45/25J Bi-Energy Operator's Manual on
your machine.

CHECKLIST A PROCEDURES REV B
A-3 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.
Maintaining the generator belts and the pulleys is

essential to good engine performance and service b
life. The generator will not operate properly with
loose or defective belts and continued use may
cause component damage.
Bodily injury hazard. Do not

inspect while the engine d
is running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
c
hot engine components. Contact
with hot engine components may a engine pulley
cause severe burns. b straightedge
c maximum pulley offset
Charging the batteries with the d generator pulley
engine does not fully charge the
batteries. Periodically, use the AC If alignment does not meet
battery charger to fully charge the specification, refer to Repair
batteries. Procedure 6-3, How to Install the
Engine Drive Pulley to adjust the
1 Be sure that all fasteners and cables on the pulley alignment.
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.

REV B CHECKLIST A PROCEDURES
4 Inspect the generator belts for: A-4

· Cracking Perform 30 Day Service
· 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. After this
6 Check the generator belts for proper tension.
interval, refer to the maintenance tables for
Refer to Section 2, Specifications.
continued scheduled maintenance.
If the belt deflection is not within
specification, see repair procedure 1 Perform the following maintenance procedures:
7-2, How to Adjust the Generator · B-5 Check the Lug Nut Torque
Belts. (including tires and wheels)
· D-2 Check the Turnable Rotation Bearing
Bolts
a · D-5 Replace the Hydraulic Tank Return
Filter
b
a engine pulley
b generator belts
c generator pulley
7 Check the torque of the pulley retaining nut on

the generator. Refer to Section 2,
Specifications.

A-5 A-6
Perform Engine Maintenance Perform Engine Maintenance
Engine specifications require that Engine specifications require that

this procedure be performed every this procedure be performed
50 hours. every 75 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. to good engine performance and service life.
Failure to perform the maintenance procedures Failure to perform the maintenance procedures
can lead to poor engine performance and can lead to poor engine performance and
component damage. component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Kubota Z482-E Operator's Manual Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163). (Kubota part number 16676-89163).

Genie part number 52958 Genie part number 52958
To access the engine: To access the engine:
1 Remove the engine pivot plate latch retainer. 1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the 2 Open the engine pivot plate latch and swing the
engine out away from the machine. engine out away from the machine.
3 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

REV B CHECKLIST A PROCEDURES
A-7 A-8
Grease the Turntable Rotation Perform Engine Maintenance
Bearing and Rotate Gear
Engine specifications require that

Genie specifications require that this procedure be performed
this procedure be performed every every 100 hours.
100 hours of operation. Perform Proper engine maintenance, following the engine
this procedure more often if dusty manufacturer's maintenance schedule, is essential
conditions exist. to good engine performance and service life.
Frequent application of lubrication to the turntable Failure to perform the maintenance procedures
bearing and rotate gear is essential to good can lead to poor engine performance and
machine performance and service life. Continued component damage.
use of an improperly greased bearing and gear will Required maintenance procedures and additional
result in component damage. engine information are available in the
1 Locate the grease fitting on the front turntable Kubota Z482-E Operator's Manual
cover. (Kubota part number 16676-89163).
2 Pump grease into the turntable rotation bearing. Kubota Z482-E Operator's Manual
Rotate the turntable in increments of Genie part number 52958
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.
To access the engine:
3 Apply grease to each tooth of the drive gear,
1 Remove the engine pivot plate latch retainer.
located under the turntable.
2 Open the engine pivot plate latch and swing the
Grease Specification engine out away from the machine.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 11

A-9 A-10
Perform Engine Maintenance Perform Engine Maintenance
Engine specifications require that Engine specifications require that

this procedure be performed this procedure be performed
every 150 hours. every 200 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. to good engine performance and service life.
Failure to perform the maintenance procedures Failure to perform the maintenance procedures
can lead to poor engine performance and can lead to poor engine performance and
component damage. component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
(Kubota part number 16676-89163). (Kubota part number 16676-89163).

Genie part number 52958 Genie part number 52958
To access the engine: To access the engine:
engine out away from the machine. engine out away from the machine.

REV B
Checklist B Procedures
B-1 B-2
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. Also, restricting air flow system can cause component damage and unsafe
through the radiator (i.e., dirt or debris) will affect operating conditions.
the performance of the cooling system. A frequent
check allows the inspector to identify changes in Bodily injury hazard. Do not
the condition of the radiator that might indicate inspect while the engine
cooling system problems. is running. Remove the key to
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
with hot engine components may
cause severe burns.
with hot engine components may 2 Open the engine pivot plate latch and swing the
cause severe burns. engine pivot plate out away from the machine to
access the exhaust system.
3 Be sure that all nuts and bolts are tight.
engine pivot plate out away from the machine to 4 Inspect all welds for cracks.
access the radiator.
5 Inspect for exhaust leaks; i.e., carbon buildup
3 Inspect the radiator for leaks and physical around seams and joints.
damage.
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.

CHECKLIST B PROCEDURES REV B
B-3 3 Be sure that the cable connections are tight.

Check the Batteries 4 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Result: If any battery cell displays a specific
Proper battery condition is essential to good gravity of less than 1.026, the battery must be
machine performance and operational safety. replaced.
Improper fluid levels or damaged cables and
connections can result in engine component 5 Check the battery acid level of the battery. If
damage and hazardous conditions. needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
Electrocution hazard. Contact
6 Install the battery vent caps.
with hot or live circuits could result
in death or serious injury. Remove 7 Be sure the battery packs are wired correctly.
all rings, watches and other
jewelry. + + + +
Bodily injury hazard. Batteries +
-
contain acid. Avoid spilling or
contacting battery acid. Neutralize - - - -
battery acid spills with baking soda
and water.
Perform this procedure after fully
charging the batteries.
Charging the batteries with the
engine does not fully charge the
batteries. Periodically, use the AC
battery charger to fully charge the
batteries.
The engine battery is a
maintenance free battery and
does not require the replenishing
of electrolyte.
For a more accurate determination
of battery condition, fully charge
the batteries and allow the
batteries to rest 24 hours before
performing this procedure to allow
the battery cells to equalize.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.

REV B CHECKLIST B PROCEDURES
B-4 6 Install the center turntable cover.

Inspect the Electrical Wiring 7 Lower the boom to the stowed position and turn
the machine off.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 8 Inspect the following areas for burnt, chafed,
performance. Failure to find and replace burnt, corroded, pinched and loose wires:
chafed, corroded or pinched wires could result in · Cable track on the primary, jib and
unsafe operating conditions and may cause secondary booms
component damage.
· Jib boom to platform cable harness
Electrocution hazard. Contact · Inside of the platform control box
in death or serious injury. Remove 9 After serial number 21180: Inspect for a liberal
all rings, watches and other coating of dielectric grease at the following
jewelry. location:
1 Inspect the following areas for burnt, chafed, · All wire harness connectors to the platform
corroded and loose wires: control box
· Power units
· Inside of the ground control box
· Turntable manifold wiring
· Generator and power units
· Engine wiring harness
2 After serial number 21180: Inspect for a liberal
coating of dielectric grease at the following
location:
· All wire harness connectors to the ground
control box
3 Raise the secondary boom until the mid-pivot is
approximately 10 feet / 3 m off the ground.
4 Remove the center turntable cover.
5 Inspect the turntable center area for burnt,
chafed and pinched cables.

B-5 B-6
Check the Lug Nut Torque Confirm the Proper
(including the tires and wheels) Brake Configuration
Maintaining the tires and wheels in good Proper brake configuration is essential to safe
condition is essential to safe operation and good operation and good machine performance.
performance. Tire and/or wheel failure could result Hydraulically-released, spring-applied individual
in a machine tip-over. Component damage may wheel brakes can appear to operate normally when
also result if problems are not discovered and they are actually not fully operational.
repaired in a timely fashion.
1 Check each drive hub disconnect cap to be
Tip over hazard. An over-inflated sure it is in the engaged position.
tire can explode which will
compromise machine stability and brake disengaged position
and cause the machine to tip over.
Bodily injury hazard. An over-
inflated tire can explode and could
result in death or serious injury. brake engaged position
Tip-over hazard. Do not use

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

B-7 2 Remove the plug located at 90 degrees and

check the oil level.
Check the Oil Level
Result: The oil level should be even with the
in the Drive Hubs
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
Failure to maintain proper drive hub oil levels may side plug hole.
cause the machine to perform poorly and 4 Models with pipe plugs: Apply pipe thread
continued use may cause component damage. sealant to the plugs and install the plugs.
1 Drive the machine to rotate the hub until one of Models with O-ring plugs: Install the plugs
the plugs is located on top and the other one is into the drive hub.
at 90 degrees.
5 Repeat steps 1 through 4 for the other drive
hub.
6 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
models with pipe plugs
a models with o-ring plugs

B-8 4 Loosen the lock nut, then turn the low idle
adjustment screw clockwise to increase the rpm
Check and Adjust the or counterclockwise to decrease the rpm.
Engine RPM Tighten the lock nut and recheck the rpm.
a
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.

b
engine pivot plate out away from the machine.
c
3 Connect an rpm gauge to the engine, and then
start the engine from the ground controls. d
Result: Low idle should be 2000 rpm.

Skip to step 5 if the low idle rpm is correct.
a low idle adjustment screw
(not shown)
b high idle adjustment nut
c rpm solenoid
d fuel shut off solenoid
5 Move the engine idle control switch to high idle

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

6 Loosen the lock nut on the solenoid, then turn B-9

the solenoid boot counterclockwise to increase
the rpm or clockwise to decrease the rpm. Test the Ground Control Override
Tighten the lock nut and recheck the rpm. A properly functioning ground control override is
Be sure the solenoid fully retracts essential to safe machine operation. The ground
when activating high idle. control override function is intended to allow
ground personnel to operate the machine from the
7 Swing the engine back to its original position ground controls whether or not the Emergency
and close the engine pivot plate latch. Stop button on the platform controls is in the ON or
8 Install the engine pivot plate latch retainer. OFF position. This function is particularly useful if
the operator at the platform controls cannot return
the boom to the stowed position.
1 Push in the platform red Emergency Stop

button to the off position.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
3 Operate each boom function through a
partial cycle at the ground controls.
Result: All boom functions should operate.

B-10 B-11
Test the Platform Self-leveling Test the Engine Idle Select
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are three settings.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is Low idle (turtle symbol): Low idle and slow battery
essential for safe machine operation. The charging.
platform is maintained at level by the platform
leveling slave cylinder which is controlled by the High idle (rabbit symbol): High idle and quickest
master cylinder located at the base of the primary battery charging.
boom. A platform self-leveling failure creates an Foot switch activated high idle (rabbit and foot
unsafe working condition. switch symbols): Activates high idle only when the
1 Turn the key switch to ground control and pull foot switch is pressed down.
out the red Emergency Stop button to the on 1 Start the engine from the ground controls. Move
position. the engine idle select toggle switch to high idle
2 Lower the boom to the stowed position. (rabbit symbol).
3 Hold the function enable toggle switch to either Result: The engine should change to high idle.
side and adjust the platform to a level position
using the platform level toggle switch. 3 Release the engine idle select toggle switch.
4 Raise and lower the primary boom through Result: The engine should return to low idle.
a full cycle.
4 Turn the key switch to platform controls.
Result: The platform should remain level at
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.
6 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine should change to low idle.
7 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
8 Press down the foot switch.
Result: The engine should change to high idle.

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
regenerative braking to stop the machine. safe machine operation. The drive function should
Hydraulically-released individual wheel brakes hold respond quickly and smoothly to operator control.
the machine once it has stopped. The drive motor Drive performance should also be free of
regenerative braking should operate smoothly, free hesitation, jerking and unusual noise over the
of hesitation and jerking. Hydraulically-released entire proportionally controlled speed range.
individual wheel brakes can appear to operate
normally when not fully operational. Select a test area that is firm, level
and free of obstructions.
Collision hazard. Be sure that the
machine is not in free-wheel or 1 Create start and finish lines by marking two
partial free-wheel configuration. lines on the ground 40 feet / 12.2 m apart.
Refer to B-4, Confirm the Proper
2 Lower the boom into the stowed position.
Brake Configuration.
3 Choose a point on the machine; i.e., contact
Select a test area that is firm, level
patch of a tire, as a visual reference for use
and free of obstructions.
when crossing the start and finish lines.
1 Mark a test line on the ground for reference.
4 Bring the machine to maximum drive speed
2 Lower the boom into the stowed position. before reaching the start line. Begin timing
when your reference point on the machine
3 Choose a point on the machine; i.e., contact crosses the start line.
patch of a tire, as a visual reference for use
when crossing the test line. 5 Continue at full speed and note the time when
the machine reference point passes over the
4 Bring the machine to maximum drive speed finish line. Refer to Section 2, Specifications.
before reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
5 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
The brakes must be able to hold
the machine on any slope it is able
to climb.

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 · Descent alarm
safe machine operation. The drive function should
respond quickly and smoothly to operator control. · Flashing beacon
Drive performance should also be free of Alarms and a beacon are installed to alert
hesitation, jerking and unusual noise over the operators and ground personnel of machine
entire proportionally controlled speed range. proximity and motion. The alarm package is
installed on the turntable covers.
Select a test area that is firm, level
and free of obstructions. The alarms and beacon will
operate with the engine
1 Create start and finish lines by marking two
running or not running.
lines on the ground 40 feet / 12.2 m apart.
1 Turn the key switch to ground control and pull
2 Raise the platform more than 5 feet / 1.5 m.
out the red Emergency Stop button to the on
3 Choose a point on the machine; i.e., contact position at both the ground and platform
patch of a tire, as a visual reference for use controls.
when crossing the start and finish lines.
Result: The flashing beacon should be on and
4 Bring the machine to maximum drive speed flashing.
before reaching the start line. Begin timing
2 Move the function enable switch to either side
when your reference point on the machine
and activate the primary boom toggle switch in
crosses the start line.
the down position, hold for a moment and then
5 Continue at full speed and note the time when release it.
the machine reference point passes over the
Result: The descent alarm should sound when
finish line. Refer to Section 2, Specifications.
the switch is held down.
3 Move the function enable switch to either side
and activate the secondary boom toggle switch
in the down position, hold for a moment and
then release it.

4 Z-45/25J: Move the function enable toggle B-16

switch to either side and activate the jib boom
toggle switch in the down position, hold for a Test the Turntable Rotation Stop
moment and then release it. The turntable is capable of rotating the boom 355
Result: The descent alarm should sound when degrees and is stopped midpoint between the steer
the switch is held down. wheels by the rotation stop. Detecting a rotation
stop malfunction is essential to safe operation and
5 Turn the key switch to platform control. good machine performance. If the turntable rotates
Result: The flashing beacon should be on past the rotation stop, component damage may
and flashing. result.
6 Press down the foot switch. Activate the 1 Turn the key switch to platform control and pull
primary boom toggle switch in the down out the red Emergency Stop button to the on
position, hold for a moment and then release it. position at both the ground and platform
controls.
the control handle is held down. 2 Rotate the turntable to the left as far as it
will go.
7 Press down the foot switch. Activate the
secondary boom toggle switch in the down Result: Movement should stop when the
position, hold for a moment and then release it. primary boom reaches mid-point between the
steer tires.
the control handle is held down. 3 Rotate the turntable to the right full circle as far
as it will go.
8 Z-45/25J: Press down the foot switch. Activate
the jib boom toggle switch in the down position, Result: Movement should stop when the
hold for a moment and then release it. primary boom reaches mid-point between the
Result: The descent alarm should sound when steer tires.
9 Press down the foot switch. Move the drive
control handle off center, hold for a moment
and then release it. Move the drive control
handle off center in the opposite direction, hold
for a moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in
either direction.

B-17 B-18
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. Dirty oil and suction strainers may
could result in an unsafe working condition and cause the machine to perform poorly and
component damage. continued use may cause component damage.
Extremely dirty conditions may require oil changes
1 Remove the drive chassis cover from the to be performed more often.
non-steer end of the machine and locate the
electrical contactors mounted on the Before replacing the hydraulic oil,
component mounting panel. the oil may be tested by an oil
distributor for specific levels of
2 Visually inspect the contact points of each
contamination to verify that
contactor for the following items:
changing the oil is necessary. If
· Excessive burns the hydraulic oil is not replaced
at the two year inspection, test
· Excessive arcs
the oil quarterly. Replace the oil
· Excessive pitting when it fails the test. See E-1,
Electrocution hazard. Contact Test or Replace the Hydraulic Oil.
in death or serious injury. Remove
all rings, watches and other
jewelry.
Replace the contactors if any
damage is found.

B-19
Perform Engine Maintenance

this procedure be performed
every 400 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional

engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).

Genie part number 52958

engine out away from the machine.

Checklist C Procedures REV B
C-1 C-2
Perform Engine Maintenance Grease the Platform Overload
Mechanism (if equipped)

Genie specifications require
every 500 hours.
that this procedure be performed
Proper engine maintenance, following the engine every 500 hours or 6 months,
manufacturer's maintenance schedule, is essential whichever comes first. Perform
to good engine performance and service life. this procedure more often if dusty
Failure to perform the maintenance procedures conditions exist.
Application of lubrication to the platform overload
component damage.
mechanism is essential to safe machine operation.
Required maintenance procedures and additional Continued use of an improperly greased platform
engine information are available in the overload mechanism could result in the system not
Kubota Z482-E Operator's Manual sensing an overloaded platform condition and will
(Kubota part number 16676-89163). result in component damage.
1 Locate the grease fittings on each pivot pin of
Kubota Z482-E Operator's Manual the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent

REV B CHECKLIST C PROCEDURES
C-3 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.
Genie specifications require that

this procedure be performed every
500 hours or six months,
whichever comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an Result: The platform overload indicator light
overloaded platform condition. Machine stablity should be off at both the ground and platform
could be compromised resulting in the machine controls.
tipping over.
5 Carefully move the test weight to each
Perform this procedure with the remaining location.
machine on a firm, level surface.
Result: The platform overload indicator light
1 Turn the key switch to platform control. should be off at both the ground and platform
controls.
2 Level the platform from the platform controls.
6 Add an additional 10 lbs / 4.5 kg of weight to
3 Determine the maximum platform capacity.
overload the platform.
Refer to the machine serial plate.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at both the ground and platform
controls.
Result: If the alarm does not sound and the
platform overload indicator light does not come
on with the test weights in any of the platform
locations, the platform overload system needs
to be calibrated. See D-6, Calibrate the
Platform Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.

CHECKLIST C PROCEDURES REV B
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
flashing at both the ground and platform platform controls.
controls.
Result: If the alarm does not sound and the second delay before the overload
platform overload indicator light does not come indicator light and alarm turn off.
on with the test weights in any of the platform
12 Test all machine functions from the ground
locations, the platform overload system needs
controls.
to be calibrated. See D-6, Calibrate the
Platform Overload System. Result: All ground control functions should
operate normally.
second delay before the overload 13 Turn the key switch to platform control.
alarm sounds. 14 Test all machine functions from the platform
controls.
8 Test all machine functions from the platform
controls. Result: All platform control functions should
operate.
Result: All platform control functions should not
operate. If the platform overload system is
not operating properly, see D-6,
9 Turn the key switch to ground control. Calibrate the Platform Overload
System.
controls.
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.

REV B CHECKLIST C PROCEDURES
C-4

every 800 hours.
component damage.



Checklist D Procedures REV B
D-1 D-2
Check the Primary Boom Check the Turntable Rotation
Wear Pads Bearing Bolts
Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing
is essential to safe machine operation. Wear pads bolts is essential to safe machine operation.
are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe
friction, replaceable wear pad between moving operating condition and component damage.
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in 1 Raise the primary boom and place a safety
component damage and unsafe operating chock on the lift cylinder rod. Carefully lower
conditions. the boom onto the lift cylinder safety chock.
Crushing hazard. Keep hands
1 Measure each wear pad. Replace the wear pad
away from cylinder and all moving
once it reaches the minimum allowable
parts when lowering the boom.
thickness. If the wear pad is still within
specification, shim as necessary to obtain A lift cylinder safety chock is
minimum clearance with zero binding. available through Genie
(part number 33484).
2 Extend and retract the primary boom through
the entire range of motion to check for tight
spots that may cause binding or scraping of the
boom.
Always maintain squareness
between the outer and inner
boom tubes.
Primary boom wear

pad specifications New Minimum
Top, bottom and side wear pads 3 /4

inch 5/8 inch
(platform end of boom) 19 mm 15.9 mm
Side and bottom wear pads 5/8 inch 1/2 inch

(pivot end of boom) 15.9 mm 12.7 mm
Top wear pads 3 /4

inch 5/8 inch
(pivot end of boom) 19 mm 15.9 mm

REV B CHECKLIST D PROCEDURES
2 Check to be sure that each turntable mounting 3 Lower the boom to the stowed position.
bolt is torqued in sequence to specification.
4 Remove drive chassis covers from both the
steer end and the non-steer end of the
9 machine.
5 1
5 Check to be sure that each bearing mounting
bolt under the drive chassis is torqued in
3 11 sequence to specification. Refer to Section 2,
Specifications.
1
8 7
9
7
12 4
2 6 5 4
10
Bolt torque sequence
3 6
18 1
9 11
8 2
6 7
16 13 (before serial number 23332)
3 20 1
9 11
19 4 6 7
14 15 16 13
8 5
3 4
12 10
2 17
14 15
(after serial number 23331)
8 5
12 10
2
(after serial number 23331)

CHECKLIST D PROCEDURES REV B
D-3 5 Manually rotate each non-steer wheel.

Check the Free-wheel Result: Each non-steer wheel should rotate with
minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
Proper use of the free-wheel configuration is the hub disconnect caps. Rotate each wheel to
essential to safe machine operation. The check for engagement. Lift the machine and
free-wheel configuration is used primarily for remove the jack stands.
towing. A machine configured to free-wheel without
operator knowledge could result in death or serious Collision hazard. Failure to
injury and property damage. engage the drive hubs could result
in death or serious injury and
Collision hazard. Select a work property damage.
site that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each non-steer
wheel hub.
brake disengaged position
brake engaged position

D-4 4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
Replace the Drive Hub Oil hole.
Replacing the drive hub oil is essential for good 5 Models with pipe plugs: Apply pipe thread
machine performance and service life. Failure to sealant to the plugs and install the plugs.
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and Models with O-ring plugs: Install the plugs
continued use may cause component damage. into the drive hub.
1 Select the drive hub to be serviced. Then drive 6 Repeat steps 1 through 5 for the other drive
the machine until one of the two plugs is at the hub.
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
models with pipe plugs
a models with o-ring plugs

D-5 D-6
Replace the Hydraulic Tank Inspect for Turntable Bearing
Return Filter Wear
Replacement of the hydraulic tank return filter is Periodic inspection of turntable bearing wear is
essential for good machine performance and essential to safe machine operation, good machine
service life. A dirty or clogged filter may cause the performance and service life. Continued use of a
machine to perform poorly and continued use may worn turntable bearing could create an unsafe
cause component damage. Extremely dirty operating condition, resulting in death or serious
conditions may require that the filter be replaced injury and component damage.
more often.
Perform this procedure with the
Bodily injury hazard. Beware of machine on a firm, level surface
hot oil. Contact with hot oil may and the boom in the stowed
cause severe burns. position.
1 Locate the hydraulic return filter next to the 1 Grease the turntable bearing. See A-7, Grease
hydraulic tank. the Turntable Bearing and Rotate Gear.
2 Place a suitable container under the hydraulic 2 Torque the turntable bearing bolts to
filter. specification. See D-2, Check the Turntable
3 Remove the filter with an oil filter wrench.
Rotation Bearing Bolts.
4 Apply a thin layer of oil to the new oil filter 3 Start the machine from the ground controls and
gasket. raise the primary and secondary booms to full
height. Do not extend the primary boom.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls.
7 Activate any boom function and inspect the filter
and related components to be sure that there
are no leaks.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.

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 inline with, the boom and no more
0.055 inch / 1.4 mm. The bearing is good.
than 1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
To obtain an accurate
0.055 inch / 1.4 mm. The bearing is worn and
measurement, place the dial
needs to be replaced.
indicator no more than 1 inch /
2.5 cm from the turntable rotation 8 Fully retract the primary boom. Raise the
bearing. primary and secondary booms to full height.
Visually inspect the the dial indicator to be sure
the needle returns to the "zero" position.
a
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
b
bearing has been checked in at least four
equally spaced areas 90° apart.
c 11 Lower the primary and secondary booms to the

stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
d
a turntable
b dial indicator
c drive chassis
d turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the

indicator.
6 Lower the secondary boom to the stowed
position and lower the primary boom to a
horizontal position. Fully extend the primary
boom.

D-7 Determine the limit switch trigger point:

Calibrate the Platform Overload 4 Gently move the platform up and down by hand,
System (if equipped) so it bounces approximately 1 to 2 inches /
2.5 to 5 cm. Allow the platform to settle.
Result: The overload indicator light and the
alarm is on. Slowly tighten the load spring
Genie specifications require that adjustment nut by turning it clockwise just until
this procedure be performed every the overload indicator light and alarm turns off.
1000 hours or annually, whichever The platform will need to be
comes first. moved up and down and allowed
Yearly calibration of the platform overload system to settle in between adjustments.
is essential to safe machine operation. Continued There may be an approximate 2
use of an improperly calibrated platform overload second delay before the overload
system could result in the system failing to sense indicator light turns on and the
an overloaded platform. The stability of the alarm sounds.
machine is compromised and it could tip over.
Result: The overload indicator light and
Perform this procedure with the alarm is off. Slowly loosen the load spring
machine on a firm, level surface. adjustment nut by turning it counterclockwise
just until the overload indicator light and alarm
1 Level the platform.
turn on.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
second delay before the overload
3 Using a suitable lifting device, place an indicator light turns on and the
appropriate test weight equal to that of the alarm sounds.
maximum platform capacity at the center of the
The platform will need to be
platform floor.
moved up and down and allowed
to settle in between adjustments.

Confirm the setting: D-8

5 Turn the key switch to platform control. Perform Engine Maintenance
6 Lift the test weight off the platform floor using a
suitable lifting device.
7 Place the test weight back onto the center of Engine specifications require that
the platform floor using a suitable lifting device. this procedure be performed
Result: The alarm should be off. The platform every 1000 hours or annually,
overload indicator light should be off at both the whichever comes first.
ground and platform controls. Proper engine maintenance, following the engine
There may be an approximate 2 manufacturer's maintenance schedule, is essential
second delay before the overload to good engine performance and service life.
indicator light and alarm turn off. Failure to perform the maintenance procedures
8 Add an additional 10 lb / 4.5 kg test weight to component damage.
the original test weight to overload the platform.
Result: The alarm should be sounding. engine information are available in the
The platform overload indicator light should be Kubota Z482-E Operator's Manual
flashing at both the ground and platform (Kubota part number 16676-89163).
controls.
There may be an approximate 2 Kubota Z482-E Operator's Manual
second delay before the overload Genie part number 52958
alarm sounds.
9 Test all machine functions from the platform To access the engine:
controls. 1 Remove the engine pivot plate latch retainer.
Result: All platform control functions should not 2 Open the engine pivot plate latch and swing the
operate. engine out away from the machine.
10 Turn the key switch to ground control.
controls.
Result: All ground control functions should not
operate.
If the platform overload system is
not operating properly, repeat
steps 1 through 4.

D-9

every 1500 hours.
component damage.




REV B
Checklist E Procedures
E-1 2 Remove the drain plug from the hydraulic tank.
Test or Replace the Hydraulic Oil 3 Completely drain the tank into a container of
suitable capacity. Refer to Section 2,
Specifications.
Replacement or testing of the hydraulic oil is hot oil. Contact with hot oil may
essential for good machine performance and cause severe burns.
service life. Dirty oil and suction strainers may
4 Tag, disconnect and plug the hydraulic hose
cause the machine to perform poorly and
from the hydraulic tank filter at the tank.
continued use may cause component damage.
Extremely dirty conditions may require oil changes Bodily injury hazard. Spraying
to be performed more often. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Before replacing the hydraulic oil, connections very slowly to allow
the oil may be tested by an oil the oil pressure to dissipate
distributor for specific levels of gradually. Do not allow oil to squirt
contamination to verify that or spray.
changing the oil is necessary. If
the hydraulic oil is not replaced Bodily injury hazard. Beware of
at the two year inspection, test hot oil. Contact with hot oil may
the oil quarterly. Replace the oil cause severe burns.
when it fails the test.
5 Remove the hydraulic tank mounting fasteners.
6 Pull the hydraulic tank out slightly to access the
boom in the stowed position.
two suction hoses.
When removing a hose assembly
7 Tag, disconnect and plug the two suction hoses
or fitting, the O-ring on the fitting
on the back of the hydraulic tank.
and/or hose end must be replaced
and then torqued to specification Bodily injury hazard. Spraying
during installation. Refer to hydraulic oil can penetrate and
Section 2, Hydraulic Hose and burn skin. Loosen hydraulic
Fitting Torque Specifications. connections very slowly to allow
the oil pressure to dissipate
1 Place a suitable container under the hydraulic
gradually. Do not allow oil to squirt
tank. See capacity specifications.
or spray.

CHECKLIST E PROCEDURES REV B
8 Remove the hydraulic tank from the machine. E-2

Component damage hazard. The Grease the Steer Axle
hydraulic tank is plastic and may
become damaged if allowed to fall.
Wheel Bearings
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Rinse out the inside of the tank using a mild Maintaining the steer axle wheel bearings is
solvent. essential for safe machine operation and service
life. Operating the machine with loose or worn
11 Install the suction strainer and drain plug using
wheel bearings may cause an unsafe operating
a thread sealer on the threads.
condition and continued use may result in
12 Place the hydraulic tank onto the machine. component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
13 Install the hydraulic hoses. washing of the machine may require that this
14 Install the hydraulic tank retaining strap. procedure be performed more often.
Component damage hazard. The 1 Loosen the wheel lug nuts. Do not remove
hydraulic tank may become them.
damaged if the tank strap
2 Block the non-steer wheels, then center a lifting
fasteners are over tightened.
jack under the steer axle.
15 Fill the tank with hydraulic oil until the fluid is
3 Raise the machine 6 inches / 15 cm and place
within the FULL and ADD marks on the hydraulic
blocks under the drive chassis for support.
tank. Do not overfill.
4 Remove the lug nuts. Remove the tire and
16 Clean up any oil that may have spilled. Properly
wheel assembly.
discard of oil.
5 Check for wheel bearing wear by attempting to
17 Operate all machine functions through a full
move the wheel hub side to side, then up and
cycle and check for leaks.
down.
Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.

REV B CHECKLIST E PROCEDURES
6 Remove the dust cap from the hub. Remove the 15 Install a new bearing grease seal into the hub
cotter pin from the castle nut. by pressing it evenly into the hub until it is flush.
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to Always replace the bearing grease
seat the bearings. seal when removing the hub.
8 Loosen the castle nut and re-tighten to 16 Slide the hub onto the yoke spindle.
8 ft-lbs / 11 Nm.
Component damage hazard. Do
9 Check for wheel bearing wear by attempting to not apply excessive force or
move the wheel hub side to side, then up and damage to the lip of the seal may
down. occur.
Result: If there is no side to side or up and 17 Place the outer bearing into the hub.
down movement, continue with step 10 and
18 Install the washer and castle nut.
grease the wheel bearings.
19 Tighten the castle nut to 35 ft-lbs / 47 Nm to
Result: If there is side to side or up and down
seat the bearings.
movement, continue to step 10 and replace the
wheel bearings with new ones. 20 Loosen the castle nut and re-tighten to
8 ft-lbs / 11 Nm.
When replacing a wheel bearing,
both the inner and outer bearings, 21 Install a new cotter pin. Bend the cotter pin
including the pressed-in races, to lock it in.
must be replaced.
Always use a new cotter pin when
10 Remove the castle nut. installing a castle nut.
11 Pull the hub off of the spindle. The washer and 22 Install the dust cap, then the tire and wheel
outer bearing should fall loose from the hub. assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
12 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of the
hub.

CHECKLIST E PROCEDURES REV B
E-3

every 2000 hours or every two
years, whichever comes first.
component damage.




June 2005 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
personnel to potential personal
Repair any machine damage or malfunction
injury hazards. Obey all safety
before operating the machine.
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Used to indicate the presence of
Read, understand and obey the safety rules
an imminently hazardous situation
and operating instructions in the which, if not avoided, will result in
Genie Z-45/25 Bi-Energy and Genie Z-45/25J death or serious injury.
Bi-Energy Operator’s Manual on your machine.
Used to indicate the presence of a
Be sure that all necessary tools and parts are potentially hazardous situation
available and ready for use. which, if not avoided, could result
Read each procedure completely and adhere in death or serious injury.
to the instructions. Attempting shortcuts may With safety alert symbol—used to
produce hazardous conditions. indicate the presence of a
potentially hazardous situation
Unless otherwise specified, perform each
which, if not avoided, may cause
repair procedure with the machine in the
minor or moderate injury.
following configuration:
· Machine parked on a firm, level surface Without safety alert symbol—used
to indicate the presence of a
· Boom in stowed position potentially hazardous situation
· Turntable rotated with the boom between which, if not avoided, may result in
the non-steer wheels property damage.
· Turntable secured with the turntable Used to indicate operation or
rotation lock maintenance information.
· 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
Indicates that an incorrect result has occurred
· All external AC power supply disconnected after performing a series of steps.
from the machine

Section 4 • Repair Procedures June 2005
Platform Controls REV B
1-1 Boom Function Speed

Controllers Controller Adjustments
Do not adjust the controllers
Platform Controls unless the static battery supply
The drive joystick is connected to the drive motor voltage is above 24V DC at the
controller located under the non-steer end drive platform red Emergency Stop
chassis cover. The drive motor controller can also button.
recognize machine drive malfunctions and display Electrocution hazard. Contact with
controller fault codes by flashing an LED at the electrically charged circuits could
ground controls. See the Troubleshooting section result in death or serious injury.
of this manual for a list of fault codes and Remove all rings, watches and
additional information. There are no adjustments other jewelry.
needed on the drive joystick controller. For further
information or assistance, consult the Genie 1 Turn the key switch to platform control and pull
Industries Service Department. out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
a threshold adjustable trimpot

b max-out adjustable trimpot
c white/red wire to TP6
d boom function speed controller
b a
a boom function speed controller

b drive joystick

REV B PLATFORM CONTROLS
Before serial number 21180:

3 Remove the wht/red wire from TP6. Temporarily
insert a short piece of stripped wire into TP6.
4 Connect the red (+) lead from an amp meter to
the wht/red wire. Connect the black (-) lead to
the piece of wire at TP6.
From serial number 21180 to 23235:
3 Disconnect the blk/red wire of the boom
function speed controller from the wht/red wire.
4 Connect the red (+) lead from an amp meter to
the blk/red wire. Connect the black (-) lead to
the wht/red wire.
All models:
5 Turn the boom function speed controller to the
CREEP position.
6 Set the threshold: With the boom in the stowed

position, press down the foot switch and move
the primary boom toggle switch in the down
position until the amperage reading appears.
Adjust the amperage to 0.17 to 0.18A. Turn the
threshold trimpot adjustment screw clockwise to
increase the amperage or counterclockwise to
decrease the amperage.
7 Turn the boom function speed controller to
the 9 position.
8 Set the max-out: Press down the foot switch,
then move the primary boom toggle switch in
the down position. Adjust the amperage to 0.54
to 0.55A. Turn the max-out trimpot adjustment
screw clockwise to increase the amperage or
counterclockwise to decrease the amperage.
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

Platform Components REV B
2-1 3 Lower the primary boom until the platform is

resting on the blocks just enough to support the
Platform Leveling Slave Cylinder platform.
The slave cylinder and the rotator pivot are the Do not rest the entire weight of the
two primary supports for the platform. The slave boom on the blocks.
cylinder keeps the platform level through the 4 Tag, disconnect and plug the hydraulic hoses
entire range of boom motion. It operates in a from the slave cylinder at the unions and
closed-circuit hydraulic loop with the master connect them together using a connector.
cylinder. The slave cylinder is equipped with Connect the hoses from the cylinder together
counterbalance valves to prevent movement in using a connector.
the event of a hydraulic line failure.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
Leveling Slave Cylinder connections very slowly to allow
Before cylinder removal is the oil pressure to dissipate
considered, bleed the slave gradually. Do not allow oil to
cylinder to be sure there is no squirt or spray.
air in the closed loop. 5 Remove the pin retaining fastener from the
When removing a hose assembly slave cylinder rod-end pivot pin. Do not remove
or fitting, the O-ring on the fitting the pin.
and/or hose end must be replaced 6 Z-45/25J: Remove the external snap rings from
and then torqued to specification the slave cylinder barrel-end pivot pin. Do not
during installation. remove the pin.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications. Z-45/25: Remove the pin retaining fastener
from the slave cylinder barrel-end pivot pin. Do
1 Z-45/25J: Extend the primary boom until the not remove the pin.
slave cylinder barrel-end pivot pin is accessible.
7 Place a block under the slave cylinder for
2 Raise the primary boom slightly and place
support. Protect the cylinder rod from damage.
blocks under the platform for support.

REV B PLATFORM COMPONENTS
8 Use a soft metal drift to drive the rod-end pivot 2-2

pin out.
Platform Rotator
Crushing hazard. The platform
could fall when the slave cylinder
rod-end pivot pin is removed if not
How to Bleed the Platform
properly supported. Rotator
Component damage hazard. The This procedure will require two
slave cylinder rod may become people.
damaged if it is allowed to fall if
1 Move the function enable toggle switch to either
not properly supported by the
side and activate the platform rotate toggle
lifting device.
switch to the right then the left through two
9 Use a soft metal drift and drive the barrel-end platform rotation cycles, then hold the switch to
pin out. the right position until the platform is fully
rotated to the right.
10 Carefully pull the cylinder out of the primary
boom. 2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
How to Bleed the Slave Cylinder to collect any drainage. Secure the container to
the boom.
1 Raise the primary boom to a horizontal position.
3 Open the top bleed valve on the rotator, but do
2 Move the platform level switch up and down
not remove it.
through two platform leveling cycles to remove
a
any air that might be in the system.
d c b
a top bleed valve

b bottom bleed valve
c container
d clear hose

PLATFORM COMPONENTS REV B

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

REV B
Jib Boom Components, Z-45/25J
3-1 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.
Perform this procedure with the 7 Remove the pin retaining fasteners from both
boom in the stowed position. platform rotator pivot pins. Do not remove the
When removing a hose assembly pins.
or fitting, the O-ring on the fitting 8 Use a soft metal drift to remove the leveling arm
and/or hose end must be replaced pivot pin and let the leveling arms hang down.
and then torqued to specification
during installation. 9 Use a soft metal drift to remove the platform
Refer to Section 2, Hydraulic Hose rotator pivot pin and remove the platform rotator
and Fitting Torque Specifications. from the machine.
1 Remove the platform. 10 Slide both of the jib boom leveling arms off of
the jib boom cylinder rod-end pivot pin.
2 Tag and disconnect the electrical connectors
from the jib boom/platform rotate select 11 Remove the hose and cable cover from the side
manifold mounted to the platform support. of the jib boom. Remove the hose and cable
separators.
3 Tag, disconnect and plug all of the hydraulic
hoses from the jib boom/platform rotate select 12 Attach a lifting strap from an overhead crane to
valve manifold. Cap the fittings on the manifold the jib boom.
and pull the hoses out through the platform
13 Support the barrel end of the jib boom lift
rotator.
cylinder with a suitable lifting device.
14 Tag, disconnect and plug the jib boom lift
hydraulic oil can penetrate and
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
connections very slowly to allow
the oil pressure to dissipate Bodily injury hazard. Spraying
gradually. Do not allow oil to hydraulic oil can penetrate and
squirt or spray. burn skin. Loosen hydraulic
4 Remove the platform mounting weldment.
gradually. Do not allow oil to
squirt or spray.

JIB BOOM COMPONENTS, Z-45/25J REV B
15 Remove the pin retaining fastener from the jib 3-2

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.
How to Remove the Jib Boom
Crushing hazard. The jib boom Lift Cylinder
could fall when when the barrel-
end pivot pin is removed if not Perform this procedure with the
properly supported by the boom in the stowed position.
overhead crane.
17 Remove the pin retaining fastener from the jib or fitting, the O-ring on the fitting
boom pivot pin. Use a soft metal drift to remove and/or hose end must be replaced
the pin, then remove the jib boom from the and then torqued to specification
bellcrank. during installation.
Crushing hazard. The jib boom
and Fitting Torque Specifications.
could become unbalanced and fall
when removed from the machine if 1 Raise the jib boom slightly and place blocks
not properly attached to the under the platform mounting weldment. Then
overhead crane. lower the jib boom until the platform is resting
on the blocks just enough to support the
18 Attach a lifting strap from an overhead crane to
platform.
the lug on the rod end of the jib boom lift
cylinder. Do not rest the entire weight of the
boom on the blocks.
19 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib 2 Tag, disconnect and plug the jib boom lift
boom lift cylinder from the bellcrank. cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Crushing hazard. The jib boom lift
cylinder could become unbalanced Bodily injury hazard. Spraying
and fall when removed from the hydraulic oil can penetrate and
machine if not properly attached to burn skin. Loosen hydraulic
the overhead crane. connections very slowly to allow
squirt or spray.

REV B JIB BOOM COMPONENTS, Z-45/25J
3 Remove the pin retaining fasteners from the jib

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

Primary Boom Components REV B
4-1 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
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
Z-45/25 from the "V1" and "V2" ports on the
counterbalance valve manifold located on the
When removing a hose assembly platform rotator. Cap the fittings on the
or fitting, the O-ring on the fitting manifold.
and/or hose end must be replaced
and then torqued to specification Bodily injury hazard. Spraying
during installation. hydraulic oil can penetrate and
Refer to Section 2, Hydraulic Hose burn skin. Loosen hydraulic
and Fitting Torque Specifications. connections very slowly to allow
1 Locate the cables from the primary boom cable gradually. Do not allow oil to
track to the platform control box. Number each squirt or spray.
cable and its entry location at the platform
control box. 7 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master cylinder. Cap
2 Disconnect the cables from the platform control the fittings on the cylinder.
box.
3 Pull all of the electrical cables out of the plastic hydraulic oil can penetrate and
cable track. Do not pull out the hydraulic hoses. burn skin. Loosen hydraulic
4 Raise the primary boom to a horizontal position. connections very slowly to allow
squirt or spray.

REV B 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. Cap the boom.
fittings on the cylinder.
15 Remove the cable track from the machine and
Bodily injury hazard. Spraying place it on a structure capable of supporting it.
Crushing hazard. The cable track
if not properly attached to the
overhead crane.
squirt or spray. Component damage hazard.
Cables and hoses can be
9 Pull the four hydraulic hoses toward the
damaged if they are kinked or
platform to clear the rod end of the primary
pinched.
boom lift cylinder.
10 Place blocks in between the upper and lower How to Remove the Cable Track,
cable tracks and secure the upper and lower Z-45/25J
tracks together.
Crushing hazard. If the upper and or fitting, the O-ring on the fitting
lower cable tracks are not properly and/or hose end must be replaced
secured together, the cable track and then torqued to specification
could become unbalanced and fall during installation. Refer to
when removed from the machine. Section 2, Hydraulic Hose and
11 Remove all hose and cable clamps from the Fitting Torque Specifications.
underside of the primary boom. 1 Locate the cables from the primary boom cable
12 Attach a strap from an overhead crane to the track to the platform control box. Number each
cable track. cable and its entry location at the platform
control box.
13 Remove the mounting fasteners from the upper
cable track at the platform end of the extension 2 Disconnect the cables from the platform control
boom. box.
3 Remove the hose and cable cover from the side
of the jib boom. Remove the hose and cable
separators.

PRIMARY BOOM COMPONENTS REV B
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. Do not pull out the hydraulic hoses. Bodily injury hazard. Spraying
6 Tag, disconnect and plug the hydraulic hoses
from the "V1" and "V2" ports on the
counterbalance valve manifold located on the
platform rotator. Cap the fittings on the
manifold.
squirt or spray.
9 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located above the
primary boom lift cylinder. Cap the fittings on
the unions.
gradually. Do not allow oil to Bodily injury hazard. Spraying
squirt or spray. hydraulic oil can penetrate and
7 Tag and disconnect the hydraulic hoses from
the platform leveling slave cylinder at the union
and connect them together using a connector.
Connect the hoses from the cylinder together
squirt or spray.
using a connector.
from the platform leveling master cylinder. Cap
the fittings on the cylinder.
connections very slowly to allow Bodily injury hazard. Spraying
the oil pressure to dissipate hydraulic oil can penetrate and
gradually. Do not allow oil to burn skin. Loosen hydraulic
squirt or spray. connections very slowly to allow
squirt or spray.

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
primary boom lift cylinder.
cable tracks and secure the upper and lower
tracks together. 21 Raise the rod end of the primary boom lift
cylinder back into position and install the rod-
Crushing hazard. If the upper and
end pivot pin. Install the pin retaining fasteners.
lower cable tracks are not properly
secured together, the cable track 22 Attach a strap from an overhead crane to the
could become unbalanced and fall cable track.
when removed from the machine.
23 Remove the mounting fasteners from the upper
13 Attach a lifting strap from an overhead 5 ton / cable track at the platform end of the extension
5,000 kg capacity crane to the platform end of boom.
the primary boom for support. Do not lift it.
24 Remove the cable track mounting fasteners that
14 Remove all hose and cable clamps from the attach the lower cable track to the primary
underside of the primary boom. boom.
15 Support the rod end of the primary boom lift 25 Remove the cable track from the machine and
cylinder with a suitable lifting device. place it on a structure capable of supporting it.
16 Remove the pin retaining fasteners from the Crushing hazard. The cable track
primary boom lift cylinder rod-end pivot pin. Do could become unbalanced and fall
not remove the pin. if not properly attached to the
overhead crane.
17 Raise the primary boom slightly with the
overhead crane to relieve the pressure on the Component damage hazard.
primary boom lift cylinder rod-end pivot pin. Cables and hoses can be
18 Use a soft metal drift to remove the primary
pinched.
boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the lifting device.
19 Lower the rod end of the primary boom lift
cylinder approximately 12 inches / 30 cm.

How to Repair the Primary Boom 4-2

Cable Track Primary Boom
Component damage hazard. The
primary boom cable track can be How to Remove the Primary
damaged if it is twisted. Boom
A 7 link repair section of cable Bodily injury hazard. This
track is available through the procedure requires specific repair
Genie Industries Service Parts skills, lifting equipment and a
Department. suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
a
service is strongly recommended.
b boom in the stowed position.
a link separation point and/or hose end must be replaced
b lower clip
1 Use a slotted screwdriver to pry down on the during installation.
lower clip. Refer to Section 2, Hydraulic Hose
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to 1 Remove the platform.
the side.
2 Z-45/25: Remove the platform rotator and
3 Repeat steps 1 and 2 for each link. platform mounting weldment.
Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
3 Remove the cable track. See 4-1, How to
Remove the Cable Track.
4 Raise the primary boom to a horizontal position.

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. Use a soft center point of the primary boom.
metal drift to remove the pin. Then lower the
15 Attach a similar lifting device to the primary
cylinder and let it hang down.
boom lift cylinder.
Component damage hazard.
16 Place support blocks under the primary boom
When lowering the master cylinder
lift cylinder.
down, be sure not to damage the
master cylinder hoses or fittings. 17 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
7 Locate the primary boom drive speed limit
a soft metal drift to remove the pin.
switch inside of the upper pivot.
Crushing hazard. The boom lift
8 Remove the primary boom drive speed limit
cylinder and primary boom will fall
switch mounting fasteners. Do not disconnect
if not properly supported.
the wiring.
18 Lower the rod end of the primary boom lift
9 Locate the primary extension boom drive speed
cylinder onto support blocks. Protect the
limit switch inside of the extension boom.
cylinder rod from damage.
10 Remove the primary extension boom drive
19 Remove the pin retaining fasteners from the
speed limit switch mounting fasteners. Do not
primary boom pivot pin.
disconnect the wiring.
20 Remove the primary boom pivot pin with a soft
11 Pull the limit switch and the wiring out of the
metal drift, then carefully remove the primary
extension tube and move it out of the way.
boom from the machine and place it on a
12 Tag, disconnect and plug the primary boom structure capable of supporting it.
extension cylinder hydraulic hoses. Cap the
boom could become unbalanced
Bodily injury hazard. Spraying and fall when removed from the
hydraulic oil can penetrate and machine if not properly attached to
burn skin. Loosen hydraulic the overhead crane.
squirt or spray.

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
Complete disassembly of the metal drift to remove the pin.
boom is only necessary 7 Support and slide the extension cylinder out of
if the outer or inner boom tube the base end of the extension tube. Place the
must be replaced. The extension extension cylinder on blocks for support.
cylinder can be removed without
completely disassembling the Crushing hazard. The extension
boom. See 4-4, How to Remove cylinder could become unbalanced
the Primary Boom Extension and fall when removed from
Cylinder. primary boom extension tube if not
properly supported.
1 Remove the primary boom. See How to
Remove the Primary Boom. During removal, the overhead
crane strap will need to be
2 Place blocks under the barrel end of the primary carefully adjusted for proper
boom extension cylinder for support. balancing.
3 Remove the pin retaining fastener from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom. Use a soft metal
drift to remove the pin.
4 Remove and label the location of the wear pads
from the platform end of the primary boom.
Pay careful attention to the
location and amount of shims
used with each wear pad.
5 Support and slide the extension tube and
extension cylinder assembly out of the boom
tube.
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.

4-3 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.
The primary boom lift cylinder raises and lowers 6 Tag, disconnect and plug the primary boom lift
the primary boom. The primary boom lift cylinder is cylinder hydraulic hoses. Cap the fittings on the
equipped with a counterbalance valve to prevent cylinder.
movement in the event of a hydraulic line failure. Bodily injury hazard. Spraying
How to Remove the Primary burn skin. Loosen hydraulic
Boom Lift Cylinder connections very slowly to allow
Bodily injury hazard. This gradually. Do not allow oil to
procedure requires specific repair squirt or spray.
skills, lifting equipment and a
suitable workshop. Attempting this 7 Remove the pin retaining fasteners from the
procedure without these skills and primary boom lift cylinder rod-end pivot pin. Use
tools could result in death or a soft metal drift to remove the pin.
serious injury and significant Crushing hazard. The primary
component damage. Dealer boom will fall if not properly
service is strongly recommended. supported when the primary boom
When removing a hose assembly rod-end pivot pin is removed.
or fitting, the O-ring on the fitting 8 Place a support block across both turntable
and/or hose end must be replaced covers under the primary boom lift cylinder.
during installation. 9 Lower the rod end of the lift cylinder onto the
Refer to Section 2, Hydraulic Hose block. Protect the cylinder rod from damage.
1 Raise the primary boom to a horizontal position. boom lift cylinder could fall if not
properly supported.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above 10 Support the barrel end of the primary boom lift
the turntable covers. cylinder with an overhead crane or similar lifting
device.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support. 11 Remove the primary boom lift cylinder barrel-
end pivot pin retaining fasteners. Use a slide
4 Raise the primary boom with the overhead hammer to remove the barrel-end pivot pin.
crane slightly to take the pressure off the Carefully remove the primary boom lift cylinder
primary boom lift cylinder pivot pins. from the machine.
Crushing hazard. The lift cylinder
if not properly supported and
secured to the lifting device.

4-4 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
The primary boom extension cylinder extends and
retracts the primary boom extension tube.The Bodily injury hazard. Spraying
primary boom extension cylinder is equipped with hydraulic oil can penetrate and
counterbalance valves to prevent movement in the burn skin. Loosen hydraulic
event of a hydraulic line failure. connections very slowly to allow
How to Remove the Primary gradually. Do not allow oil to
squirt or spray.
Boom Extension Cylinder
5 At the platform end of the boom, remove the
Bodily injury hazard. This
external snap rings from the extension cylinder
procedure requires specific repair
rod-end pivot pin. Use a soft metal drift to
skills, lifting equipment and a
remove the pin.
suitable workshop. Attempting this
procedure without these skills and 6 Remove the barrel-end pivot pin retaining
tools could result in death or fasteners.
7 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
8 Support and slide the extension cylinder out of
the upper pivot.
and/or hose end must be replaced Crushing hazard. The extension
and then torqued to specification cylinder could fall when removed
during installation. from the extension boom if not
Refer to Section 2, Hydraulic Hose properly supported.
Component damage hazard. Be
1 Raise the primary boom to a horizontal position. careful not to damage the
counterbalance valves on the
2 Extend the primary boom until the primary
primary boom extension cylinder
boom extension cylinder rod-end pivot pin is
when removing the cylinder from
accessible in the primary boom extension tube.
the primary boom.
Hoses and cables can be
damaged if the primary boom
extension cylinder is dragged
across them.
Note the length of the cylinder
after removal. The cylinder must
be at the same length for
installation.

4-5 3 Attach overhead crane or similar lifting device to

the master cylinder.
Platform Leveling
Master Cylinder master cylinder barrel-end pivot pin.
The master cylinder acts as a pump for the slave 5 Place a rod through the barrel-end pivot pin and
cylinder. It’s part of the closed circuit hydraulic loop twist to remove the pin.
that keeps the platform level through the entire
6 Remove the pin retaining fastener from the rod-
range of boom motion. The master cylinder is
end pivot pin.
located at the base of the primary boom.
7 Place a rod through the rod-end pivot pin and
How to Remove the Platform twist to remove the pin.
Leveling Master Cylinder 8 Remove the master cylinder from the machine.
When removing a hose assembly Crushing hazard. The master
or fitting, the O-ring on the fitting cylinder could become unbalanced
and/or hose end must be replaced and fall if not properly attached to
and then torqued to specification the overhead crane.
during installation.
1 Raise the secondary boom until both the rod-
end and barrel-end pivot pins on the master
cylinder are accessible.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.

Secondary Boom Components REV B
a b c
h d
Secondary Boom components

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

REV B SECONDARY BOOM COMPONENTS
5-1 4 Remove the master cylinder. See 4-5, How to

Remove the Master Cylinder.
Secondary Boom
to the lug on the rod end of the primary boom
How to Disassemble the lift cylinder. Then raise the primary boom lift
Secondary Boom cylinder with the crane, to a vertical position.
Bodily injury hazard. The 6 Tag, disconnect and plug the hydraulic hoses at
procedures in this section require the primary boom lift cylinder. Cap the fittings
specific repair skills, lifting on the cylinder.
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools could result in death or
service is required.
or spray.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
primary boom lift cylinder barrel-end pivot pin.
secondary boom by following the disassembly
steps in reverse order. 8 Use a slide hammer to remove the pin. Remove
the primary boom lift cylinder from the machine.
or fitting, the O-ring on the fitting Crushing hazard. The primary
and/or hose end must be replaced boom lift cylinder could become
and then torqued to specification unbalanced and fall if not properly
during installation. supported by the overhead crane.
on both of the secondary boom lift cylinders.
1 Remove the platform. Cap the fittings on the cylinders.
2 Z-45/25J: Remove the jib boom. Bodily injury hazard. Spraying
See 3-1, How to Remove the Jib Boom. hydraulic oil can penetrate and
3 Remove the primary boom. See 3-2, How to connections very slowly to allow
Remove the Primary Boom. the oil pressure to dissipate
or spray.

SECONDARY BOOM COMPONENTS REV B
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 mid-point
end pivot pin and barrel-end pivot pin. Do not between the upper pivot and mid-pivot.
remove the pins.
11 Attach a strap from an overhead crane to the number 1 arm pivot pins at the mid-pivot and
lug on the rod end of one of the secondary the upper pivot. Do not remove the pins.
boom lift cylinders for support. Do not apply any
19 Use a soft metal drift to drive both pins out.
lifting pressure.
20 Remove the number 1 arm from the machine.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of Crushing hazard. The number 1
the secondary boom lift cylinder and let it hang arm could become unbalanced
down. and fall when removed from the
machine if not properly attached to
13 Use a soft metal drift to drive the rod-end pivot
the overhead crane.
pin half way out.
Crushing hazard. The upper pivot
14 Remove the secondary boom lift cylinder from
could fall when the number 1 arm
the machine.
is removed from the machine if not
15 Repeat steps 11 through 14 for the other properly supported by the
secondary boom lift cylinder. overhead crane.
Crushing hazard. The secondary 21 Using the overhead crane attached to the upper
boom lift cylinder could become pivot, raise the secondary boom assembly
unbalanced and fall when approximately 30 inches / 76 cm.
removed from the machine if not
22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
properly attached to the overhead
between the number 2 arm and the boom rest.
crane.
Then lower the secondary boom assembly onto
Component damage hazard. the block.
When removing a secondary
Crushing hazard. The secondary
boom lift cylinder from the
boom assembly could fall if not
machine, be careful not to damage
properly supported by the
the counterbalance valve at the
4 x 4 x 11 inch / 10 x 10 x
barrel end of the cylinder.
28 cm block.
the upper pivot for support. Do not lift it.

23 Pull all of the cables and hoses out through the 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm block
upper pivot. between the number 3 arm and the number 4
arm at the mid-pivot end.
Cables and hoses can be 32 Attach a lifting strap from the overhead crane to
damaged if they are kinked or the mid-pivot for support. Do not lift it.
pinched.
24 Remove the hose and cable covers from the top number 2, 3 and 4 arm pivot pins at the
of the number 2 arm. mid-pivot. Do not remove the pins.
25 Pull all of the hoses and cables out of the upper 34 Use a soft metal drift to drive each pin out. Then
pivot and out through the mid-pivot. Lay the remove the mid-pivot from the secondary boom
hoses and cables on the ground. assembly.
Component damage hazard. Crushing hazard. The mid-pivot
Cables and hoses can be could become unbalanced and fall
damaged if they are kinked or when removed from the
pinched. secondary boom assembly if not
overhead crane.
number 2 arm pivot pin at the upper pivot. Use
a soft metal drift to remove the pin. 35 Attach the lifting strap from an overhead crane
to the center point of the number 2 arm for
27 Remove the upper pivot from the machine.
support. Do not lift it.
Crushing hazard. The upper pivot
36 Remove the pin retaining fasteners from both
compression link pivot pins. Do not remove the
when removed from the machine if
pins.
not properly attached to the
overhead crane. 37 Use a soft metal drift to remove the lower
compression link pivot pin at the number 3 arm.
28 Attach the lifting strap from an overhead crane
to the number 2 arm at the upper pivot end. 38 Support the compression link with an
appropriate lifting device.
29 Raise the number 2 arm slightly and remove the
4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest
pad.

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. Remove the compression link from the
machine. 45 Using an approved hand-operated pump, drain
the fuel tank into a container of suitable
Crushing hazard. The number 2
capacity. Refer to Section 2, Specifications.
arm could fall when the
compression link is disconnected Explosion and fire hazard. Engine
from the number 2 arm if not fuels are combustible. Perform this
properly supported by the procedure in an open, well-
overhead crane. ventilated area away from heaters,
sparks, flames and lighted
Crushing hazard. The
tobacco. Always have an
compression link may fall if not
approved fire extinguisher within
properly supported when removed
easy reach.
from the secondary boom
assembly. Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
Crushing hazard. The number 2 machine and pump or contrainer.
arm could become unbalanced
Be sure to only use a hand-
operated pump suitable for use
secondary boom assembly if not
with gasoline and diesel fuel.
overhead crane. 46 Tag, disconnect and plug the fuel hoses from
the fuel tank. Clean up any fuel that may have
41 Remove the upper and lower hose and cable
spilled.
covers from the number 3 arm.
47 Remove the fuel tank mounting fasteners.
42 Pull all of the cables and hoses from the
Carefully remove the fuel tank from the
number 3 arm and lay them over the turntable
machine.
counterweight.
fuel tank is plastic and may
Cables and hoses can be
become damaged if allowed to fall.
pinched. Clean the fuel tank and inspect for
cracks and other damage before
installing it onto the machine.

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.
49 Lower the ground control box and function
manifold pivot plate to access the number 3 58 Attach a lifting strap from the overhead crane to
arm pivot pin. the center point of the number 4 arm. Do not
lift it.
50 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for 59 Use a slide hammer to remove the number 4
support. Do not lift it. arm from the turntable riser through the ground
controls side bulkhead.
51 Remove the mounting fasteners from the cover
located in the boom storage area to access the 60 Remove the number 4 arm from the machine.
number 3 and number 4 arm pivot pin retaining
fasteners at the turntable riser.
52 Remove the pin retaining fasteners from the and fall when removed from the
number 3 arm at the turntable riser. Do not machine if not properly supported
remove the pin. by the overhead crane.
53 Use a slide hammer to remove the number 3
arm pivot pin from the turntable pivot through
the access hole behind the ground control box.
machine if not properly supported
by the overhead crane.
55 Remove the upper and lower hose and cable
covers from the number 3 arm.
56 Remove the secondary boom drive speed limit
switch mounting fasteners from the number 4
arm at the mid-pivot end. Do not disconnect the
wiring.

5-2 3 Tag, disconnect and plug the hydraulic hoses

on the secondary boom lift cylinder.
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders hydraulic oil can penetrate and
incorporated in the structure of the secondary burn skin. Loosen hydraulic
boom assembly. These cylinders operate in connections very slowly to allow
parallel and require hydraulic pressure to extend the oil pressure to dissipate
and retract. Each secondary boom lift cylinder is gradually. Do not allow oil to squirt
equipped with a counterbalance valve to prevent or spray.
movement in the event of a hydraulic line failure. 4 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin
How to Remove a Secondary and barrel-end pivot pin. Do not remove the
Boom Lift Cylinder pins.
Bodily injury hazard. This 5 Attach a strap from an overhead crane to the
procedure requires specific repair lug on the rod end of the secondary boom lift
skills, lifting equipment and a cylinder for support. Do not apply any lifting
suitable workshop. Attempting this pressure.
procedure without these skills and 6 Use a soft metal drift to drive the barrel-end
tools could result in death or pivot pin half way out. Lower the barrel end of
serious injury and significant the secondary boom lift cylinder and let it hang
component damage. Dealer down.
7 Use a soft metal drift to drive the rod-end pivot
When removing a hose assembly pin half way out.
and/or hose end must be replaced 8 Remove the secondary boom lift cylinder from
and then torqued to specification the machine.
during installation.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
1 Lower the secondary boom to the stowed removed from the machine if not
position. properly attached to the overhead
crane.
2 Raise the primary boom so that it is above the
secondary boom lift cylinder rod-end pivot pin. 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.

REV A
Kubota Z482-E Engine
6-1 4 Pull the generator away from the machine and
remove the belts from the generator pulley.
Timing Adjustment
5 Remove the 3 bolts that attach the engine drive
Complete information to perform this procedure is pulley to the shaft bushing.
available in the Kubota Z482-E Workshop Manual 6 Install the same 3 bolts that were removed in
(Kubota part number 97897-01165). step 5 into the threaded holes of the engine
drive pulley.
Kubota Z482-E Workshop Manual
7 Carefully tighten each bolt evenly until the
engine drive pulley slides off the shaft.
engine drive pulley and/or shaft
can be damaged if the bolts are
not tightened evenly.
6-2
RPM Adjustment 8 Loosen the set screw on the pulley bushing,
then slide the pulley bushing off of the engine
See the scheduled maintenance procedure B-8, shaft.
Check and Adjust the Engine RPM.
a b c a
6-3
Engine Drive Pulley
How to Remove the Engine Drive

Pulley
engine out away from the machine to access d e f g f e d
the engine drive pulley.
3 Loosen the tension adjustment bolt on the a gap
generator. b shaft
c set screw
d engine drive pulley
e engine drive pulley bolt
f shaft bushing
g woodruff key

KUBOTA Z482-E ENGINE REV A
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.
The generator pulley must already
be installed before performing this 5 Install the pulley mounting bolts and tighten
procedure. See 7-1, How to Install them to specification. Refer to Section 2,
the Generator Pulley. Specifications.
1 Align the woodruff key on the engine shaft with Component damage hazard. Do
the slot in the pulley bushing and slide the not overtighten the pulley
pulley bushing onto the engine shaft. Do not mounting bolts. There must be a
tighten the set screw. gap visible between the engine
drive pulley and the pulley
2 Align the flywheel side of the pulley bushing on bushing.
the engine shaft with the outer face of the
generator pulley using a straightedge. a b c a
a b c
d e f g f e d
a gap
b shaft
c set screw
d engine drive pulley
e pulley mounting bolt
f pulley bushing
f e d g woodruff key
a pulley shaft 6 Check the alignment between the engine drive

b pulley bushing pulley and the generator pulley using a
c engine flywheel
d straightedge
straightedge. Refer to Section 2, Specifications.
e generator pulley
f generator
If the pulley alignment is not within
specification, remove the engine
pulley and repeat steps 2
through 6. See 6-4, How to
Remove the Engine Drive Pulley.

REV A
Generator
7-1 How to Install the Generator
Generator Pulley Pulley
The pulley on the generator must
How to Remove the Generator be installed before installing the
Pulley engine drive pulley.
1 Remove the engine pivot plate latch retainer. 1 Align the woodruff key on the generator shaft
with the slot in the pulley and slide the pulley all
2 Open the engine pivot plate latch and swing the the way onto the generator shaft.
engine out away from the machine to access
the generator pulley. 2 Install the flat washer and pulley retaining nut
onto the generator shaft, then torque the nut to
3 Loosen the tension adjustment bolt on the specification. Refer to Section 2, Specifications.
generator.
3 Adjust the tension of the generator belts.
4 Pull the generator away from the machine and See 7-2, How to Adjust the Generator Belts.
remove the belts from the generator pulley.
5 Disconnect the battery cables from the engine
battery.
Electrocution hazard. Contact with
electrically charged circuits could
Remove all rings, watches and
other jewelry.
6 Remove the engine battery hold down, then
remove the battery from the machine.
7 Remove the generator pulley retaining nut from
the generator shaft.
8 Slide the pulley off of the generator shaft.

GENERATOR REV A
7-2 7-3
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
regulator is essential to good generator
performance and service life. A defective or
improperly adjusted voltage regulator could result
in component damage.
other jewelry.
Be sure the batteries are fully
charged before performing this
3 Open the engine pivot plate latch and swing the procedure.
the generator belts. 1 Remove the engine pivot plate latch retainer.
4 Loosen the tension adjustment bolt on the 2 Open the engine pivot plate latch and swing the
generator. engine out away from the machine to access
the generator.
5 Push the generator towards the machine and
3 Connect the positive lead of a voltmeter to the
tighten the adjustment bolt.
POS terminal on the generator and the negative
6 Check the generator belts for proper tension. lead of the voltmeter to the NEG terminal on the
Refer to Section 2, Specifications. If the belt generator.
deflection is not within specification, perform
steps 4 and 5 and re-check the belt tension.
a other jewelry.
b
a engine pulley
b generator belts
c generator pulley

REV A GENERATOR
4 Start the engine from the ground controls and How to Replace the Voltage
move the rpm select toggle switch to the
maintained high idle position. Check the voltage Regulator
on the generator. 1 Disconnect the battery packs from the machine.
Result: The voltage should be 54V DC. Electrocution hazard. Contact with
5 If the voltage reading is not 54V DC, insert a electrically charged circuits could
small flat blade screwdriver into the result in death or serious injury.
potentiometer located inside of the generator. Remove all rings, watches and
Use the access hole on the back of the other jewelry.
generator labeled VOLT ADJ. 2 Remove the engine pivot plate latch retainer.
Component damage hazard. Be 3 Open the engine pivot plate latch and swing the
sure that the screwdriver is engine out away from the machine to access
properly inserted into the the generator.
potentiometer or the generator
and/or voltage regulator may 4 Tag and disconnect the positive and negative
become damaged. battery cables from the generator.
6 Carefully adjust the potentiometer to obtain a 5 Loosen the tension adjustment bolt on the
54V DC voltage reading. Turn the generator.
potentiometer clockwise to increase the voltage 6 Pull the generator away from the machine and
or counterclockwise to decrease the voltage. remove the belts from the generator pulley.
Do not rotate the potentiometer past the internal
7 Remove the generator mounting fasteners then
stops.
remove the generator from the machine.
8 Remove the 3 nuts from the battery cable
voltage regulator inside the
terminal posts.
generator will become damaged if
the potentiometer is rotated past 9 Remove the 3 screws that hold the plastic cover
the internal stops. onto the generator. Carefully remove the cover.
The maximum range of motion of
the potentiometer on the voltage
regulator is 280° and the
maximum allowed torque is
5 oz-in / 0.035 Nm.

GENERATOR REV A
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.
13 Remove the screw that attaches the red wire to
the positive recitfier assembly.
a g 14 Remove the #4 nut that attaches the black wire
to the voltage regulator.
b h 15 Remove the voltage regulator mounting screws.
16 Remove the voltage regulator while carefully
c guiding the red and black wires from
underneath the bottom support of the positive
and negative rectifier assembly.
d 17 Install the new voltage regulator by following the
previous steps in reverse order.
e
18 Apply Loctite® removable thread sealant onto
the voltage regulator mounting fasteners and
f torque to specification. Refer to Section 2,
Specifications.
19 Torque all fasteners to specification. Refer to
a white wires (#10 nuts) Section 2, Specifications.
b negative rectifier assembly
c black wire (#10 screw) 20 Install the plastic cover onto the generator then
d black wire (#4 nut) install the generator onto the machine.
e voltage regulator
mounting fastener (#8 screw) 21 Adjust the generator belts. See 7-2, How to
f voltage regulator Adjust the Generator Belts.
g red wire (#10 screw)
h positive rectifier assembly 22 Adjust the voltage regulator. See 7-3, How to
Adjust the Voltage Regulator.
11 Remove the nuts on those 3 wires from the
negative rectifier assembly, then remove the Component damage hazard. The
wires. voltage regulator and/or generator
may become damaged if the
Do not remove the spacers from
voltage regulator is not properly
the underneath the wires on the
adjusted after replacement.
negative rectifier assembly.
When the voltage regulator is
replaced, the voltage regulator
must be adjusted. See 7-3, How to
Adjust the Voltage Regulator.

REV B
Hydraulic Pumps
8-1 8-2
Auxiliary Pump Function Pump
How to Remove the Auxiliary How to Remove the Function

Pump Pump
When removing a hose assembly When removing a hose assembly
or fitting, the O-ring on the fitting or fitting, the O-ring on the fitting
and/or hose end must be replaced and/or hose end must be replaced
and then torqued to specification and then torqued to specification
during installation. Refer to during installation. Refer to
Section 2, Hydraulic Hose and Section 2, Hydraulic Hose and
Fitting Torque Specifications. Fitting Torque Specifications.
1 Place a suitable container under the hydraulic 1 Place a suitable container under the hydraulic
tank. tank.
2 Remove the drain plug from the hydraulic tank. 2 Remove the drain plug from the hydraulic tank.
3 Completely drain the hydraulic tank into a 3 Completely drain the hydraulic tank into a
container of suitable capacity. Refer to container of suitable capacity. Refer to
Section 2, Specifications. Section 2, Specifications.
Bodily injury hazard. Beware of Bodily injury hazard. Beware of
hot oil. Contact with hot oil may hot oil. Contact with hot oil may
cause severe burns. cause severe burns.
engine pivot plate out away from the machine. engine pivot plate out away from the machine.
6 Tag, disconnect and plug the hydraulic hoses 6 Tag, disconnect and plug the hydraulic hoses
from the auxiliary pump. from the pump.
Bodily injury hazard. Spraying Bodily injury hazard. Spraying
hydraulic oil can penetrate and hydraulic oil can penetrate and
burn skin. Loosen hydraulic burn skin. Loosen hydraulic
connections very slowly to allow connections very slowly to allow
the oil pressure to dissipate the oil pressure to dissipate
gradually. Do not allow oil to squirt gradually. Do not allow oil to squirt
or spray. or spray.
7 Remove the auxiliary pump mounting bolts. 7 Remove the function pump mounting bolts.
Carefully remove the pump. Carefully remove the pump.

Manifolds REV C
9-1
Function Manifold Components (before serial number 17841)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque
1 Differential sensing valve .................. A ........... All functions ....................................... 20-25 ft-lbs / 27-34 Nm
2 Solenoid valve, N.O. poppet .............. B ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
3 Orifice, 0.050 inch / 1.27 mm ............. C ........... Brake circuit
4 Orifice, 0.060 inch / 1.5 mm ............... D ........... Steer circuit
5 Solenoid valve, 3 position 4 way ....... E ........... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
6 Solenoid valve, N.C. poppet .............. F ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
7 Proportional solenoid valve ............... G ........... All functions ....................................... 25-30 ft-lbs / 34-41 Nm
8 Solenoid valve, 3 position 4 way ....... H ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
9 Counterbalance valve ........................ I ............ Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
10 Solenoid valve, 3 position 4 way ....... J ............ Jib boom up/down and
Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm
11 Solenoid valve, 3 position 4 way ....... K ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
12 Solenoid valve, 3 position 4 way ....... L ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
13 Solenoid valve, 3 position 4 way ....... M .......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
14 Solenoid valve, 2 position 3 way ....... N ........... Primary boom extend ........................ 20-25 ft-lbs / 27-34 Nm
15 Orifice, 0.037 inch / 0.94 mm ............. O ........... Secondary boom up
16 Solenoid valve, 2 position 3 way ....... P ........... Primary boom retract ........................ 20-25 ft-lbs / 27-34 Nm
17 Relief valve, 2300 psi / 158.7 bar
(before serial number 11819) ............ Q ........... Primary boom down ........................... 25-30 ft-lbs / 34-41 Nm
18 Relief valve, 1800 psi / 124.1 bar ...... R ........... Secondary boom down ...................... 25-30 ft-lbs / 34-41 Nm
19 Flow regulator valve,
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

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
25
24
15
23
16
22 21 20 19 18 17

MANIFOLDS REV C
Function Manifold Components (before serial number 17841), continued

Index Schematic

0.6 gpm / 2.27 L/min .......................... T ........... Jib boom up/down,
platform rotate left/right and
platform level up/down
(prevents overflowing
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
21 Counterbalance valve ........................ U ........... Platform level down ........................... 35-40 ft-lbs / 47-54 Nm
22 Relief valve, 3200 psi / 220.6 bar ...... V ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
23 Diagnostic nipple ............................... W .......... Testing
24 Check valve ....................................... X ........... Pressure switch circuit ........................ 10-12 ft-lbs / 14-6 Nm
25 Pressure switch ................................. Y ........... Brake circuit

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
25
24
15
23
16
22 21 20 19 18 17

MANIFOLDS REV C
9-2
Function Manifold Components (from serial number 17841 to 20379)
Index Schematic
1 Solenoid valve, 2 position 3 way ....... AA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 2 position 3 way ....... AB ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ....... AC ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... AD ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... AE ......... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ....... AF ......... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
7 Counterbalance valve ........................ AG ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
8 Solenoid valve, 3 position 4 way ....... AH ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm
9 Solenoid valve, 3 position 4 way ....... AI .......... Steer left/right ............................................... 25 ft-lbs / 34 Nm
10 Proportional solenoid valve ............... AJ ......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
11 Differential sensing valve .................. AK ......... All functions .................................................. 25 ft-lbs / 34 Nm
12 Solenoid valve, 2 position 2 way,
N.C. poppet ....................................... AL ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
13 Relief valve, 1800 psi / 124 bar ......... AM ........ Secondary boom down ................................ 20 ft-lbs / 27 Nm
0.6 gpm / 2.27 L/min .......................... AN ........ Platform rotate, turntable rotate
and jib boom circuits (Z-45/25J) .................. 20 ft-lbs / 27 Nm
15 Flow control valve,
0.1 gpm / 0.38 L/min .......................... AO ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
16 Counterbalance valve ........................ AP ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
17 Relief valve, 3200 psi / 220.6 bar ...... AQ ........ System relief ................................................ 20 ft-lbs / 27 Nm
18 Diagnostic nipple ............................... AR ........ Testing
19 Check valve ....................................... AS ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
20 Orifice, 0.060 inch / 1.5 mm ............... AT ......... Steer circuit
21 Pressure switch ................................. AU ........ Brake circuit
N.O. poppet ....................................... AV ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm
(located under item VV) ..................... AW ........ Brake circuit
23 Orifice, 0.046 inch / 1.17 mm ............. AX ......... Secondary boom up

REV C MANIFOLDS
1 2 3 4 5 6 7 8 9
10
11
12
23
22
21
20
19
18
17 16 15 14 13

MANIFOLDS REV C
9-3
Index Schematic
1 Solenoid valve, 2 position 3 way ....... BA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... BB ......... Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... BC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... BD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... BE ......... Platform rotate left/right and
6 Solenoid valve, 3 position 4 way ....... BF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Solenoid valve, 3 position 4 way ....... BG ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
8 Proportional solenoid valve ............... BH ........ Controls flow to functions ............................. 27 ft-lbs / 37 Nm
N.C. poppet ....................................... BI .......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
10 Solenoid valve, 2 position 3 way ....... BJ ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
0.6 gpm / 2.27 L/min .......................... BK ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
12 Counterbalance valve ........................ BL ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
13 Flow control valve .............................. BM ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
14 Relief valve, 3200 psi / 220.6 bar ...... BN ........ System relief ................................................ 20 ft-lbs / 27 Nm
15 Diagnostic nipple ............................... BO ........ Testing
16 Check valve ....................................... BP ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... BQ ........ Steer circuit
18 Differential sensing valve .................. BR ........ All functions .................................................. 25 ft-lbs / 34 Nm
19 Pressure switch ................................. BS ......... Brake circuit
N.O. poppet ....................................... BT ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
(located under item BT) ..................... BU ........ Brake circuit
21 Orifice, 0.046 inch / 1.17 mm ............. BV ......... Secondary boom up
22 Counterbalance valve ........................ BW ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
23 Relief valve, 1800 psi / 124 bar ......... BX ......... Secondary boom down ................................ 20 ft-lbs / 27 Nm

REV C MANIFOLDS
1 2 3 4 5 6 7
8
23 9
22
21
20
19
18
10
17
16
15
14 13 12 11

MANIFOLDS REV C
9-4
Index Schematic
1 Solenoid valve, 2 position 3 way ....... CA ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... CB ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... CC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... CD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... CE ........ Platform rotate left/right and
6 Solenoid valve, 3 position 4 way ....... CF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Shuttle valve ...................................... CG ........ Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm
8 Solenoid valve, 3 position 4 way ....... CH ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
9 Proportional solenoid valve ............... CI .......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
10 Pressure switch ................................. CJ ......... Brake circuit
11 Solenoid valve, 2 position 3 way ....... CK ........ Primary boom extend ................................... 20 ft-lbs / 27 Nm
0.4 gpm / 1.5 L/min ............................ CL ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
13 Needle valve ...................................... CM ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar ......... CN ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar ...... CO ........ System relief ................................................ 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar ............... CP ........ Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... CQ ........ Steer circuit
18 Orifice, 0.030 inch / 0.76 mm ............. CR ........ Proportional valve circuit
19 Solenoid valve, 2 position 3 way ....... CS ........ Brake circuit ................................................. 20 ft-lbs / 27 Nm
(from serial number 22566 to 22628
and after serial number 23235)
(located under item CS) ..................... CT ......... Brake circuit
20 Orifice, 0.037 inch / 0.94 mm ............. CU
21 Check valve, pilot operated ............... CV ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar ......... CW ....... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm

REV C MANIFOLDS
1 2 3 4 5 6 7 8
22
10
21
20
19
18
17
16
11
15 14 13 12

MANIFOLDS REV C
9-5 How to Adjust the Primary Boom

Valve Adjustments - Down Relief Valve
Function Manifold (before serial number 11819)
How to Adjust the System boom in the stowed position.
Relief Valve 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
Perform this procedure with the gauge to the test port on the function manifold.
boom in the stowed position. 2 Move and hold the function enable toggle switch
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure to either side and hold the primary boom
gauge to the test port on the function manifold. up/down toggle switch in the down direction
with the primary boom fully lowered. Observe
2 Move and hold the function enable toggle switch the pressure reading on the pressure gauge.
to either side and hold the primary boom Refer to Section 2, Specifications.
extend/retract toggle switch in the retract
direction with the primary boom fully retracted. 3 Turn the machine off. Hold the primary boom
Observe the pressure reading on the pressure down relief valve with a wrench and remove
gauge. Refer to Section 2, Specifications. the cap (item Q).
3 Turn the machine off. Hold the system relief 4 Adjust the internal hex socket. Turn it clockwise
valve with a wrench and remove the cap to increase the pressure or counterclockwise to
(item V, AQ, BN or CO). decrease the pressure. Install the relief valve
cap.
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to Tip-over hazard. Do not adjust
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 5 Repeat steps 2 through 4 and recheck relief
the relief valve higher than valve pressure.
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.

REV C MANIFOLDS
How to Adjust the Secondary

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

MANIFOLDS REV C
9-6
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to platform support.

Index Schematic
1 Solenoid valve, 2 position 2 way ...... DA ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
2 Solenoid valve, 2 position 2 way ...... DB ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
3 Solenoid valve, 2 position 3 way ...... DC ........ Jib boom / platform rotate select .................. 20 ft-lbs / 27 Nm
1 2 3 1 2
From serial number

Before serial number 16963
16963 to 22565
From serial number 22566 to 23235

REV C MANIFOLDS
9-7
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
1 Shuttle valve 2 position 3 way ........... CX ........ Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ CY ........ Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve ........................ CZ ........ Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm
1 2 3

Turntable Rotation Components REV B
10-1 3 Remove the engine pivot plate latch retainer.

Rotation Hydraulic Motor 4 Open the engine pivot plate latch and swing the
(before serial number 18367) the turntable rotation motor.
How to Remove the Rotation 5 Remove the retaining fasteners from the center
turntable cover. Remove the cover from the
Hydraulic Motor machine.
When removing a hose assembly 6 Disconnect the battery backs from the machine.
and/or hose end must be replaced Electrocution hazard. Contact with
and then torqued to specification electrically charged circuits could
during installation. Refer to result in death or serious injury.
Section 2, Hydraulic Hose and Remove all rings, watches and
Fitting Torque Specifications. other jewelry.
1 Raise the secondary boom until the upper pivot 7 Place a suitable container under the engine
is above the turntable covers. Turn the machine plate.
off. 8 Tag and disconnect the fuel hose from the fuel
2 Secure the turntable from rotating with the filter and drain the fuel tank into a container of
turntable rotation lock pin. suitable capacity. See capacity specifications.
Crushing hazard. The machine 9 Tag, disconnect and plug the fuel hoses from
could tip over when the turntable the fuel tank.
rotation assembly is removed if 10 Remove the fuel tank strap fasteners and
the turntable rotation lock is not in remove the tank strap.
the locked position.
11 Remove the fuel tank from the machine.
from the turntable rotation motor manifold. Cap
Unlocked position burn skin. Loosen hydraulic
or spray.
13 Remove the turntable rotation motor mounting
fasteners. Remove the motor from the brake.
14 Remove the turntable rotation motor from the
Locked position machine.

REV B TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable 5 Remove the retaining fasteners from the center
Rotation Brake machine.
(before serial number 18367) 6 Disconnect the battery backs from the machine.
When removing a hose assembly Electrocution hazard. Contact with
or fitting, the O-ring on the fitting electrically charged circuits could
and/or hose end must be replaced result in death or serious injury.
and then torqued to specification Remove all rings, watches and
during installation. Refer to other jewelry.
Section 2, Hydraulic Hose and
Fitting Torque Specifications. 7 Place a suitable container under the engine
plate.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine 8 Tag and disconnect the fuel hose from the fuel
off. filter and drain the fuel tank into a suitable
container. See capacity specifications.
2 Secure the turntable from rotating with the
turntable rotation lock pin. 9 Tag, disconnect and plug the fuel hoses from
the fuel tank.
Crushing hazard. The machine
could tip over when the turntable 10 Remove the fuel tank strap fasteners and
rotation assembly is removed if remove the tank strap.
the turntable rotation lock is not in
11 Remove the fuel tank from the machine.
from the turntable rotation motor manifold and
the brake. Cap the fittings on the manifold and
the brake.
Unlocked position burn skin. Loosen hydraulic
or spray.
13 Remove the turntable rotation motor mounting
fasteners. Remove the motor from the brake.
14 Remove the brake mounting bolts. Remove the
turntable rotation brake from the machine.
Locked position
3 Remove the engine pivot plate latch retainer. could tip over when the turntable
4 Open the engine pivot plate latch and swing the rotation assembly is removed if
engine out away from the machine to access the turntable rotation lock is not in
the turntable rotation motor and brake. the locked position.

TURNTABLE ROTATION COMPONENTS REV B
10-2 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
(from serial number 18367 access the turntable rotation assembly.
to 23235)
5 Remove the retaining fasteners from the center
How to Remove the Turntable machine.
Rotation Assembly 6 Disconnect the battery backs from the machine.
When removing a hose assembly Electrocution hazard. Contact with
or fitting, the O-ring on the fitting electrically charged circuits could
and/or hose end must be replaced result in death or serious injury.
and then torqued to specification Remove all rings, watches and
during installation. Refer to other jewelry.
Section 2, Hydraulic Hose and
Fitting Torque Specifications. 7 Place a suitable container under the engine
plate.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine 8 Tag and disconnect the fuel hose from the fuel
off. filter and drain the fuel tank into a suitable
container. See capacity specifications.
2 Secure the turntable from rotating with the
turntable rotation lock pin. 9 Tag, disconnect and plug the fuel hoses from
the fuel tank.
could tip over when the turntable 10 Remove the fuel tank strap fasteners and
rotation assembly is removed if remove the tank strap.
the turntable rotation lock is not in 11 Remove the fuel tank from the machine.
from the turntable rotation motor manifold. Cap
Unlocked position connections very slowly to allow
or spray.
Locked position

REV B 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.
could tip over when the turntable
rotation assembly is removed if
the turntable rotation lock is not in
Crushing hazard. The turntable
rotation assembly could become
unbalanced and fall when
removed from the machine if not
overhead crane.

Motor Controller REV A
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-
steer end drive chassis cover. The drive motor 5 Connect the leads from an ohmmeter to test
controller can recognize machine drive each motor controller terminal combination
malfunctions and display controller fault codes by listed below and check for resistance.
flashing a LED at the ground controls and on the Result: All desired results must be 500 kilohms
motor controller. See the Troubleshooting section
or more. If any test has a result less than
of this manual for a list of fault codes and
500 kilohms, replace the motor controller.
additional information. There are no adjustments
needed on the drive joystick controller. For further
information or assistance, consult the Genie Test Desired result
(in kilohms)
Industries Service Department.
F1 to F2 500kΩ or more
How to Test the Motor Controller
Use the following procedure to test F1 to B- 500kΩ or more
the motor controller. If the motor
controller is found to be faulty, F1 to M- 500kΩ or more
note which test failed and which
F1 to B+ 500kΩ or more
fault code (if any) was present at
the time of failure.
F2 to B- 500kΩ or more
1 Turn the key switch to the off position and
disconnect the battery packs from the machine. F2 to M- 500kΩ or more
2 Remove the chassis cover from the non-steer F2 to B+ 500kΩ or more

end of the machine.
B- to M- 500kΩ or more
3 Tag and disconnect all power cables from the
motor controller.
M- to B+ 500kΩ or more
electrically charged circuits could Pin 17 to B- 500kΩ or more
Remove all rings, watches and Pin 20 to B- 500kΩ or more
other jewelry.

June 2005 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie Z-45/25 Bi-Energy and Genie Z-45/25J
Bi-Energy Operator’s Manual on your machine.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropiate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing

before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
Electrocution hazard. Contact
· Machine parked on a firm, level surface
with electrically charged circuits
· Boom in stowed position may result in death or serious
· Turntable rotated with the boom between injury. Remove all rings, watches
the non-steer wheels and other jewelry.
· Key switch in the off position with the Bodily injury hazard. Spraying
key removed hydraulic oil can penetrate and
· Wheels chocked burn skin. Loosen hydraulic
· All external AC power supply disconnected
from the machine
squirt or spray.
Perform all troubleshooting on a
firm level surface.

Section 5 • Fault Codes June 2005
FAULT CODES REV A
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 0.6 mph / 1Km/h box.
or 40 feet/45 seconds /
12.2 meters / 45 seconds. If the Fault codes are two digits. The controller status
machine is allowed to drive faster indicator light will blink the first digit of a two digit
than specification, the machine code, pause for 1 second, and then blink the
could become unstable and will tip second digit. There will be a 2 second pause
over. between codes.
Additional troubleshooting of the

fault codes may by accomplished For example: the indicator light blinks 4
by using the hand-held pendant consecutive times, pauses for 1 second, and then
motor controller programmer blinks 1 time. That would indicate Fault Code 41.
(Genie part number 56303-S).
When using the hand-held
pendant motor controller
programmer, the M1 MAX SPEED
needs to be set to 33. If needed,
adjust the M1 MAX SPEED higher
or lower to achieve the maximum
raised drive speed of 0.6 mph /
1Km/h or 40 feet / 45 seconds /
12.2 meters / 45 seconds.

REV A
Fault Code Chart
Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display
Push in the ground

control red Emergency
The key switch or red Stop button to the OFF
Controller Emergency Stop position and wait for 5
status indicator button(s) was cycled on seconds. Pull out the
COMMUNICATION
light is OFF or ERROR
Machine will not drive. and off faster than 5 ground control red
is ON but not seconds OR controller Emergency Stop button
sensed an internal error out to the ON position. If
blinking
during start up. problem persists,
replace the motor
controller.
01 Normal operation.
The motor controller Replace the motor
12 HW FAILSAFE 1-2-3 Machine will not drive.
failed self test. controller.
The motor controller
Test the motor
has a internal short
13 M- SHORTED Machine will not drive.
between M- and B-
controller, see the
Repair Section.
terminals.
Check for loose or open

connections at the drive
Motor wiring is loose motors and motor
OR motor is defective controller OR replace
FIELD OPEN Machine will not drive.
OR motor controller has the defective drive
an internal short. motor OR test the motor
controller. See the
Repair Section.
Defective motor 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

FAULT CODE CHART REV A
Code Scanner
Display
Open in wht/red wire

#32 at pin 14 or red/wht
wire #29 at pin 16 on
the motor controller
going from drive joystick
Consult Genie
to pins 14 and 16 at the
21 THROTTLE FAULT 1 Machine will not drive.
motor controller OR pin
Industries Service
Department.
14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick
defective.
Pin 14 (wht/red #32) is

shorted to power or
Consult Genie
ground OR the
THROTTLE FAULT 2 Machine will not drive. Industries Service
potentiometer on the
Department.
drive joystick is
defective.
Main contactor (PR1) Replace main contactor

coil defective OR brake PR1 or brake release
31 CONT DRVR OC Machine will not drive.
release relay CR5 relay CR5 OR replace
defective. the motor controller.
Main contactor (PR1)

contacts stuck closed
OR grn wire at pin 17 on
motor controller shorted Consult Genie
32 MAIN CONT WELDED Machine will not drive. to ground OR open in Industries Service
motor armature wiring Department.
OR motor controller has
a internal short to
ground.
Repair short between

B+ terminal on motor
controller and ground
External short between
OR replace motor
B+ terminal on motor
controller.
33 PRECHARGE FAULT 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.

REV A FAULT CODE CHART
Code Scanner
Display
Motor controller does
Consult Genie
not detect the main
34 MISSING CONTACTOR Machine will not drive.
contactor PR1 or brake
Industries Service
Department.
release relay CR5.
Main contactor PR1 or

brake release relay CR5
did not close OR open
Consult Genie
in org/red wire to PR1
MAIN CONT DNC Machine will not drive. Industries Service
and/or CR5 OR main
Department.
contactor and/or brake
release relay is
defective.
Completely charge
batteries OR check
Battery supply voltage battery cable condition
LOW BATTERY
41 VOLTAGE
Machine will not drive. to motor controller less OR check for corrosion
than 32V DC. or loose connections at
battery terminals and
motor controller.
Battery supply voltage

to motor controller more Be sure the battery
than 55V DC OR charger is disconnected
42 OVERVOLTAGE Machine will not drive. machine is being OR check for loose
operated with the battery cables or poor
battery charger plugged connections
in.
Operate machine within

Machine being operated
specified temperature
outside of temperature
limits OR check for
range of -13°F to
debris around motor
185°F / -25°C to 85°C
controller preventing
43 THERMAL CUTBACK Machine will not drive. OR machine being
proper cooling of the
driven under excessive
controller OR check for
load OR motor
mechanical restrictions
controller is not being
causing excessive load
cooled sufficently.
on the machine.


June 2005 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
Genie Z-45/25 Bi-Energy and Genie Z-45/25J General Repair Process
Bi-Energy Operator's Manual on your machine.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics June 2005
Electrical Symbols Legend

REV A
TB17
15AMP.
TS6
Circuit breaker
GRN/BLK
ORG/BLK-1
LEFT
RIGHT
Toggle switch DPDT
Wire color
with cable
number
RED
Solenoid or Ground GRN
relay coil supression
BLK/RED
WHT
TB20 circuit
BP1
Terminal Boom function

speed controller
Horn NC NO
TP29 LS3
Limit switch
Quick disconnect L1 FB
terminal
Light LS1
NO
BLK #21
TB21
T-circuits connect Limit switch

at terminal normally open
held closed
PLAT
KS1
T-circuits Tilt sensor GRND

connect
Key switch
LS2
NC
Connection
no terminal HORN P4
Limit switch
normally closed
held open
Horn button
normally open
Circuits crossing
no connection
P1 PR4
Red Emergency
Stop button Relay panel
Diode normally closed contactor
TS3
CR4
-
PLAT. DWN
PLAT. UP
Battery Relay contact

normally open Toggle switch SPDT

Hydraulic Symbols Legend

REV A
0.035”
Orifice with size
Pressure gauge
3 position 4 way directional
Differential sensing valve solenoid valve
Variable orifice
or shut-off valve
Filter Solenoid operated Shuttle valve

proportional valve
Check valve
Check valve, pilot operated

Fixed displacement pump
Relief valve
Solenoid operated
Spring applied, proportional valve
hydraulically released (after serial number 22565)
brake
N.O.
Priority flow regulator
COM
N.C.
Bi-directional motor Pressure switch
2 position 2 way
M solenoid valve
Pump prime mover (motor)
Solenoid operated 2 pos.,

3 way, directional valve
Cylinder
Counterbalance valve


Power Cable Diagram

Power Cable Diagram REV A

A B C D E F G H I J K L M N
1 TO BASE CONTROL BOX

AND ENGINE PANEL
AC POWER CABLE
LEFT SIDE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RED-2GA
BATTERY PACK
+
48V DC
ALTERNATOR +
-
2 AC D1
CHASSIS HARNESS
-
GRN/BLK-BATT ISM-9
BATTERY A2
_
CHARGER NEG
WHT-BATT R12
-
+ A1 POS
PRIMARY RED-2GA
LIFT PUMP +
RED-2GA
AUXILIARY LIFT
+ PUMP
BLACK-2GA
D1
BLACK-2GA +
3 - BI-ENERGY
ONLY
RED-2GA
-
RED#20-12GA
-
-
+ WHITE-FROM CHARGER
ORG/RED-R2 +
WHITE-BATT
WHITE-BATT
FUSE-F5, 10A
4 FUSE-F3, 500A BLACK-2GA
BLACK-2GA
BLACK-2GA
BLACK-2GA
FUSE-F4, 500A
RED-2GA
+ -
+ + DIODE
3
4 5 6
7
DIODE
2
AP-1
8
1
9
- - - -
AMMETER
AC
GRN/WHT-19
AP-2 LIFT CONTACTOR DRIVE CONTACTOR

AUXILIARY POWER + + CHARGER
PR-2 PR-1 PR-3 PLUG
5 UNIT CONTACTOR
BLACK-FROM CHARGER
BI-ENERGY
MODELS ONLY
ORG/RED-42
BLACK-2GA
ORG/RED-42 ORG/RED-42
RED-2GA
BLACK-2GA
BLACK-2GA
BLACK-2GA
BRN-J9 BRN-J9
RED-2GA
RED-2GA
RED-2GA
RED-27 RED-27
RED-2GA
BRN-J8 RED#20-12GA
RED-2GA
RED-2GA RED-2GA
RED-10GA RED-10GA 24V DC
48V
F2-200A
F1-200A
WHT/RED-32
RED/WHT-29
RED-10GA RED-10GA
RED/BLK-R5
RED-2GA
GREEN
E2 E1
7 A2
J1
A1
ORG/RED-42
ORG/RED-42
24 23 22 21 20 19 18 17 16 15 14 13
RED-10GA
12 11 10 9 8 7 6 5 4 3 2 1
RED-2GA
RED-2GA
E1 E2
ORG/RED-42
ORG/RED-42
BLU/WHT-12
WHT/BLK-31
BLU/RED-39
ORANGE-40
BLACK-LED
RED-10GA
WHT-30
A1 A2
BI-ENERGY MODELS ONLY
BLK-2GA
BRN-J8
BLK-2GA
8 LEFT SIDE DRIVE MOTOR BLACK-FROM CHARGER RED-10GA RIGHT SIDE DRIVE MOTOR
BLK-2GA F1 F2
BRN-J8
BLK-2GA BLK-2GA
BLACK-2GA
RED-2GA
NOTES:
CHASSIS GROUND B- M- B+ MOTOR CONTROLLER 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED

REV A Power Cable Diagram

N M L K J I H G F E D C B A
1
TO BASE CONTROL BOX
AND ENGINE PANEL
AC POWER CABLE
LEFT SIDE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RED-2GA
BATTERY PACK
+
48V DC
- ALTERNATOR + 2
AC D1
CHASSIS HARNESS
-
GRN/BLK-BATT ISM-9
BATTERY A2
_
CHARGER NEG
WHT-BATT R12
-
+ A1 POS
PRIMARY RED-2GA
LIFT PUMP +
RED-2GA
AUXILIARY LIFT
+ PUMP
BLACK-2GA
D1 3
BLACK-2GA +
- BI-ENERGY
ONLY
RED-2GA
-
RED#20-12GA
-
-
+ WHITE-FROM CHARGER
ORG/RED-R2 +
WHITE-BATT
WHITE-BATT
4
FUSE-F5, 10A
FUSE-F3, 500A BLACK-2GA BLACK-2GA
BLACK-2GA BLACK-2GA
FUSE-F4, 500A
RED-2GA
+ -
+ + DIODE
3
4 5 6
7
DIODE
2
AP-1
8
1
9
- - - -
AMMETER
AC
GRN/WHT-19
AP-2 LIFT CONTACTOR DRIVE CONTACTOR
AUXILIARY POWER + + CHARGER 5
PR-2 PR-1 UNIT CONTACTOR PR-3 PLUG
BLACK-FROM CHARGER
BI-ENERGY
MODELS ONLY
ORG/RED-42
BLACK-2GA
ORG/RED-42 ORG/RED-42
RED-2GA
BLACK-2GA
BLACK-2GA
BLACK-2GA
BRN-J9 BRN-J9
RED-2GA
RED-2GA
RED-2GA
RED-27 RED-27
RED-2GA
BRN-J8 RED#20-12GA 6
RED-2GA
RED-2GA RED-2GA
RED-10GA RED-10GA 24V DC
48V
F2-200A
F1-200A
WHT/RED-32
RED/WHT-29
RED-10GA RED-10GA
RED/BLK-R5
RED-2GA 7
GREEN
E2 E1
A2
J1
A1
ORG/RED-42
ORG/RED-42
24 23 22 21 20 19 18 17 16 15 14 13
RED-10GA
12 11 10 9 8 7 6 5 4 3 2 1
RED-2GA
RED-2GA
E1 E2
ORG/RED-42
ORG/RED-42
BLU/WHT-12
WHT/BLK-31
ORANGE-40
BLACK-LED
RED-10GA
WHT-30
A1 A2
BI-ENERGY MODELS ONLY
BLK-2GA
8
BRN-J8
BLK-2GA
LEFT SIDE DRIVE MOTOR BLACK-FROM CHARGER RED-10GA RIGHT SIDE DRIVE MOTOR
BLK-2GA F1 F2
BRN-J8
BLK-2GA BLK-2GA
BLACK-2GA
RED-2GA
NOTES:
CHASSIS GROUND B- M- B+ MOTOR CONTROLLER 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED

Power Cable Diagram

Power Cable Diagram

Power Cable Diagram REV A

TO ENGINE PANEL TO GROUND CONTROL BOX
CONNECTOR C6B
1 LEFT SIDE
AC POWER CABLE
DC AMMETER CABLE
BATTERY PACK
RIGHT SIDE
RD-2GA
BATTERY PACK
+
48V DC +
- ALTERNATOR
FUNCTION HARNESS
D1
A2 -
AC
2 _ GR/BK-BATT ISM-9
BATTERY PRIMARY NEG
WH-BATT R12
CHARGER LIFT PUMP
-
+ A1 POS
RD-2GA
AUXILIARY LIFT +
RD-2GA
PUMP
+
BK-2GA
D1
BK-2GA +
-
3 RD-2GA
-
RD-20-12GA
-
-
+ WH-FROM CHARGER
P42BAT OR/RD +
WH-BATT
WH-BATT
F3 500A BK-2GA F5 10A BK-2GA

BK-2GA BK-2GA
4
WH
F4 500A
BK
RD-2GA
+ -
TOP VIEW OF
+ + DRIVE CONTACTOR DRIVE CONTACTOR AUXILIARY POWER UNIT 3
4 5 6
7
2
AP-1
8
CONTACTOR
9
BATTERY - -
- -
AMMETER
AP-2 DIODE DIODE AC
33
GR/WH-19
PR-1 DIODE
+ + CHARGER
33 PLUG
5 PR-2 PR-1 CONTROLLER PR-3

BK-FROM CHARGER
LIFT R42BAT OR/RD

CONTACTOR R42BAT OR/RD R42BAT OR/RD
RD-2GA
BK-2GA
BRN-J8 BRN-J8
R27AUX RD RD
RD-2GA
RD-2GA
RD-2GA
BK-2GA
BK-2GA
BK-2GA
BRN-J8
BK BK BK BK RD-2GA
RD-20-12GA
RD-2GA RD-2GA
RD-2GA
6 RD-10GA RD-10GA 24V DC
48V DC
F2
F1-200A 200A
C29JSH RD/WH
C32JSL WH/RD
RD-10GA RD-10GA
CR5 RD/BK
RD-2GA
F2 F1
7
GR
A2 A1
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
RD-10GA
RD-2GA
C31REV WH/BK
C12DRE BL/WH
R42BAT OR/RD
R42BAT OR/RD
OR/RD
OR/RD
RD-2GA
F1 F2
C30FWD WH
RD-10GA J1
C40LS OR
CFIL BK
A1 A2
BK-2GA
BRN-J8
BK-2GA RIGHT SIDE

LEFT SIDE DRIVE MOTOR
8 DRIVE MOTOR
BK-FROM CHARGER
BK-2GA
RD-10GA
F1 F2
BRN-J8
BK-2GA BK-2GA
BK-2GA
RD-2GA
B- M- B+
NOTES:
CHASSIS
GROUND 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
MOTOR CONTROLLER

REV A Power Cable Diagram

TO ENGINE PANEL TO GROUND CONTROL BOX
CONNECTOR C6B
AC POWER CABLE
1
LEFT SIDE DC AMMETER CABLE
BATTERY PACK
RD-2GA RIGHT SIDE
- BATTERY PACK
48V DC -
+ ALTERNATOR
FUNCTION HARNESS
D1 +
AC
BATTERY
A2 2
GR/BK-BATT ISM-9
_
CHARGER NEG
PRIMARY
WH-BATT R12
LIFT PUMP
-
+ A1 POS
RD-2GA
AUXILIARY LIFT +
RD-2GA
- PUMP
BK-2GA
D1 -
+ BK-2GA
3
RD-2GA +
RD-20-12GA
-
-
+ WH-FROM CHARGER
P42BAT OR/RD +
WH-BATT
WH-BATT
F5 10A BK-2GA BK-2GA

BK-2GA BK-2GA 4
WH
BK
+ -
TOP VIEW OF AUXILIARY POWER UNIT
+ + DRIVE CONTACTOR DRIVE CONTACTOR CONTACTOR 3
4 5 6
7
2
AP-1
8
1
9
BATTERY - -
- -
AMMETER
AP-2 DIODE DIODE AC
+ + CHARGER
GR/WH-19
33 PR-1 DIODE
PLUG
33 5
P42BAT OR/RD
PR-2 PR-1 CONTROLLER PR-3

BK-FROM CHARGER
LIFT R42BAT OR/RD

CONTACTOR R42BAT OR/RD R42BAT OR/RD
RD-2GA
BK-2GA
BRN-J8 BRN-J8
F4
R27AUX RD RD
RD-2GA
BK-2GA
BK-2GA
BK-2GA
BRN-J8
500A
BK BK BK BK RD-2GA
RD-20-12GA
RD-2GA RD-2GA
6
RD-2GA
RD-10GA RD-10GA 24V DC
48V DC
F2
F1 200A
200A
C29JSH RD/WH
C32JSL WH/RD
RD-10GA
CR5 RD/BK
RD-2GA
F2 F1 7
GR
A2 A1
24 23 22 21 20 19 18 17 16 15 14 13
A1 12 11 10 9 8 7 6 5 4 3 2 1
RD-2GA
C31REV WH/BK
C12DRE BL/WH
R42BAT OR/RD
R42BAT OR/RD
OR/RD
OR/RD
RD-2GA
F1 F2
C30FWD WH
RD-10GA
C40LS OR
CFIL BK
A2
BK-2GA
BRN-J8
BK-2GA RIGHT SIDE

LEFT SIDE BK-FROM CHARGER DRIVE MOTOR 8
DRIVE MOTOR RD-10GA
BK-2GA F1 F2 RD-10GA
BRN-J8
BK-2GA BK-2GA
BK-2GA
RD-2GA NOTES:
CHASSIS B- M- B+ 1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
GROUND
MOTOR CONTROLLER

Power Cable Diagram

Engine Panel Diagram

Engine Panel Diagram REV A

WHT-BATT.
WHT-21
1
BLK/RED-35
RED-J1 BLK/WHT-34
BRN-VOLT
ENGINE RPM
START POWER CUTOUT RPM GLOW PLUG
CR11 CR12 CR13 CR14 CR15 RED-CB

CIRCUT BREAKER
BROWN-CHH
BLK-ISM-1 CB3
2 24V 24V 24V 24V 24V 12V, 15A
BRN-J1 BRN-J2 BRN-J3 BRN-J4
WHT-J1 BLK/RD
IGNITION/START
WHT-J2 WHT-J3
MODULE
RED-CB (12V+)
12/24V DC
BLK/RED#35
BLK/WHT-34
3
BLK-START
WHT-R11
RED-J2
WHT-R14
BLU-E.H.
BLU-E.H.
KEY SWITCH POWER
IGNITION/FUEL ON
24V BATTERY +
ENGINE FAULT
START RELAY
4
START INPUT
TACH. INPUT
(NOT USED)
(NOT USED)
GROUND
10
1
9
2
8
4
WHT-R14
WHT-ISM10
GRN/BLK-BATT.
BLK-ISM-1
BRN-ISM5
RED-ISM6
WHITE-23
BLU-ISM2
BLK#33B
5
BRN-J5
YEL
GRN
RED
BLU
BLU
BLK
ENGINE HARNESS (TO CHASSIS HARNESS)
GRN/BLK-BATT
WHITE-BATT.
BLK/WHT-34
BLK/RED-35
RED-PISM7
BLACK-33
WHITE-21
WHITE-23
BROWN
7
12V VOLTAGE ENGINE HARNESS

(TO ENGINE)
MALE DEUTSCH
1 2 3 4 5 6 7 8 9 10 11 12
CONNECTOR
REGULATOR
FEMALE DEUTSCH
1 2 3 4 5 6 7 8 9 10 11 12
8 CONNECTOR
GRN/BLK-BATT
WHITE-BATT.
BLK/WHT-34
BLK/RED-35
RED-PISM7
BLACK-33
WHITE-21
WHITE-23
BROWN
CHASSIS HARNESS

REV A Engine Panel Diagram

RED-CB CIRCUT BREAKER
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE. CB3 1
15A
RED-CB (12V+)
WHT-BATT WHT-BATT WHT-BATT

WHT-21 WHT-21
BLK/RED-35 BLK/RED-35
IGNITION/START
WHT-J5 WHT-J5
BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4
12/24V DC
MODULE
1 3 4 7 10 9 2
WHT-J4 WHT-J4 WHT-J6 BLK/RD BLK/RD
RED-CB
2
87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 BROWN-CH H
87a 87a 87a 87a 87a 87a
RED-CB
30 30 30 30 30 30
CR16 CR11 CR12 CR13 CR14 CR15

FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG
RELAY WHT-J4 RELAY RELAY BLK/WHT-34
KEYSWITCH PWR.
WHT-J4 WHT-J6 WHT-J6
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
3
START INPUT
TACH. INPUT
RED-J6 RED-J6
(NOT USED)
(NOT USED)
GROUND
RED-CB (12V+)
ORG-GEN NEG
ORG-GEN POS
BLK/WHT-34
BLK/RED-35
BLK-START
BRN-VOLT
BLK-ISM-1
10
1
WHT-R14
9
2
8
4
6
WHT-R11
RED-J10
4
BLK-ISM-1
GRN/BLK-BATT.
BRN-J5
BRN-ISM5
BLK-33
WHITE-23
RED-ISM6
BLU-ISM2
WHT-ISM10
WHT-R14
BLK-ISM-1 BLK-ISM-1
BRN-VOLT
BLU-ISM2 BLU-ISM2
BLK-33
BRN-J5 5
BRN-ISM5 BRN-ISM5
RED-ISM6
WHITE-23
BRN-VOLT
BRN-ISM5
BLU-ISM2
WHT-R14
BLU-E.H.
BLU-E.H.
RED-J10
GRN/BLK-BATT.
6
WHT-ISM10

YEL
GRN
RED
BLU
BLU
BLK
GRN/BLK-BATT
BROWN-CH H
ENGINE HARNESS
WHITE-BATT
BLK/WHT-34
BLK/RED-35
RED-PISM6
(TO ENGINE)
BLACK-33
WHITE-21
WHITE-23
7
MALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
12V DC
VOLTAGE REGULATOR FEMALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
8
WHITE-21
BLK/RED-35
BROWN-J3
BLACK-33
WHITE-23
BLK/WHT-34
RED-PISM6
WHITE-BATT
GRN/BLK-BATT
CHASSIS HARNESS




NOTE:
CB3
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
1 RED-CB (12V+)
15A

WHT-21 WHT-21
IGNITION/START
WHT-J5 WHT-J5
12/24V DC
MODULE
1 3 4 7 10 9 2
RED-CB
2 87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 BROWN-CH H
87a 87a 87a 87a 87a 87a
RED-CB
30 30 30 30 30 30

KEYSWITCH PWR.
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
START INPUT
TACH. INPUT
RED-J6 RED-J6
(NOT USED)
(NOT USED)
3
GROUND
RED-CB (12V+)
ORG-GEN NEG
ORG-GEN POS
BLK/WHT-34
BLK/RED-35
BLK-START
BRN-VOLT
BLK-ISM-1
10
1
WHT-R14
9
2
8
4
6
WHT-R11
RED-J10
BLK-ISM-1
GRN/BLK-BATT.
BRN-J5
BRN-ISM5
BLK-33
WHITE-23
RED-ISM6
BLU-ISM2
WHT-ISM10
4 WHT-R14
BLK-ISM-1 BLK-ISM-1
BRN-VOLT
BLU-ISM2 BLU-ISM2
BLK-33
BRN-J5
5 BRN-ISM5 BRN-ISM5
RED-ISM6
WHITE-23
BRN-VOLT
BRN-ISM5
BLU-ISM2
WHT-R14
BLU-E.H.
BLU-E.H.
RED-J10
GRN/BLK-BATT.
6 WHT-ISM10

YEL
GRN
RED
BLU
BLU
BLK
GRN/BLK-BATT
BROWN-CH H
ENGINE HARNESS
WHITE-BATT
BLK/WHT-34
BLK/RED-35
RED-PISM6
(TO ENGINE)
BLACK-33
WHITE-21
WHITE-23
7
MALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
12V DC
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
WHITE-21
8
BLK/RED-35
BROWN-J3
BLACK-33
WHITE-23
BLK/WHT-34
RED-PISM6
WHITE-BATT
GRN/BLK-BATT
CHASSIS HARNESS


NOTE:
15A
RED-CB (12V+)

WHT-21 WHT-21
IGNITION/START
WHT-J5 WHT-J5
12/24V DC
MODULE
1 3 4 7 10 9 2
RED-CB
2
87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 BROWN-CH H
87a 87a 87a 87a 87a 87a
RED-CB
30 30 30 30 30 30

KEYSWITCH PWR.
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
3
START INPUT
TACH. INPUT
RED-J6 RED-J6
(NOT USED)
(NOT USED)
GROUND
RED-CB (12V+)
ORG-GEN NEG
ORG-GEN POS
BLK/WHT-34
BLK/RED-35
BLK-START
BRN-VOLT
BLK-ISM-1
10
1
WHT-R14
9
2
8
4
6
WHT-R11
RED-J10
4
BLK-ISM-1
GRN/BLK-BATT.
BRN-J5
BRN-ISM5
BLK-33
WHITE-23
RED-ISM6
BLU-ISM2
WHT-ISM10
WHT-R14
BLK-ISM-1 BLK-ISM-1
BRN-VOLT
BLU-ISM2 BLU-ISM2
BLK-33
BRN-J5 5
BRN-ISM5 BRN-ISM5
RED-ISM6
WHT-23
BRN-VOLT
BRN-ISM5
BLU-ISM2
WHT-R14
BLU-E.H.
BLU-E.H.
RED-J10
GRN/BLK-BATT.
6
WHT-ISM10

YEL
GRN
RED
BLU
BLU
BLK
GRN/BLK-BATT
ENGINE HARNESS
BLK/WHT-34
BLK/RED-35
RED-PISM6
(TO ENGINE)
WHT-BATT
BRN-CH H
WHT-21
WHT-23
BLK-33
7
MALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
12V DC
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
8
WHT-21
BLK/RED-35
BRN-J3
BLK-33
BLK/WHT-34
WHT-23
RED-PISM6
WHT-BATT
GRN/BLK-BATT
CHASSIS HARNESS




NOTE:
CB3
1 RED-CB (12V+)
15A

WHT-21 WHT-21
IGNITION/START
WHT-J5 WHT-J5
12/24V DC
MODULE
1 3 4 7 10 9 2
RED-CB
2 87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 BROWN-CH H
87a 87a 87a 87a 87a 87a
RED-CB
30 30 30 30 30 30

KEYSWITCH PWR.
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
START INPUT
TACH. INPUT
RED-J6 RED-J6
(NOT USED)
(NOT USED)
3
GROUND
RED-CB (12V+)
ORG-GEN NEG
ORG-GEN POS
BLK/WHT-34
BLK/RED-35
BLK-START
BRN-VOLT
BLK-ISM-1
10
1
WHT-R14
9
2
8
4
6
WHT-R11
RED-J10
BLK-ISM-1
GRN/BLK-BATT.
BRN-J5
BRN-ISM5
BLK-33
WHITE-23
RED-ISM6
BLU-ISM2
WHT-ISM10
4 WHT-R14
BLK-ISM-1 BLK-ISM-1
BRN-VOLT
BLU-ISM2 BLU-ISM2
BLK-33
BRN-J5
5 BRN-ISM5 BRN-ISM5
RED-ISM6
WHT-23
BRN-VOLT
BRN-ISM5
BLU-ISM2
WHT-R14
BLU-E.H.
BLU-E.H.
RED-J10
GRN/BLK-BATT.
6 WHT-ISM10

YEL
GRN
RED
BLU
BLU
BLK
GRN/BLK-BATT
ENGINE HARNESS
BLK/WHT-34
BLK/RED-35
RED-PISM6
(TO ENGINE)
WHT-BATT
BRN-CH H
WHT-21
WHT-23
BLK-33
7
MALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
12V DC
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
8
WHT-21
BLK/RED-35
BRN-J3
BLK-33
BLK/WHT-34
WHT-23
RED-PISM6
WHT-BATT
GRN/BLK-BATT
CHASSIS HARNESS


NOTE:
15A
RED-CB (12V+)

WHT-21 WHT-21
IGNITION/START
WHT-J5 WHT-J5
12/24V DC
MODULE
1 3 4 7 10 9 2
RED-CB
2
87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 BROWN-CH H
87a 87a 87a 87a 87a 87a
RED-CB
30 30 30 30 30 30

KEYSWITCH PWR.
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
3
START INPUT
TACH. INPUT
RED-J6 RED-J6
(NOT USED)
(NOT USED)
GROUND
RED-CB (12V+)
ORG-GEN NEG
ORG-GEN POS
BLK/WHT-34
BLK/RED-35
BLK-START
BRN-VOLT
BLK-ISM-1
10
1
WHT-R14
9
2
8
4
6
WHT-R11
RED-J10
4
BLK-ISM-1
GRN/BLK-BATT.
BRN-J5
BRN-ISM5
BLK-33
WHITE-23
RED-ISM6
BLU-ISM2
WHT-ISM10
WHT-R14
BLK-ISM-1 BLK-ISM-1
BRN-VOLT
BLU-ISM2 BLU-ISM2
BLK-33
BRN-J5 5
BRN-ISM5 BRN-ISM5
RED-ISM6
WHT-23
BRN-VOLT
BRN-ISM5
BLU-ISM2
WHT-R14
BLU-E.H.
BLU-E.H.
RED-J10
GRN/BLK-BATT.
6
WHT-ISM10

YEL
GRN
RED
BLU
BLU
BLK
GRN/BLK-BATT
ENGINE HARNESS
BLK/WHT-34
BLK/RED-35
RED-PISM6
(TO ENGINE)
WHT-BATT
BRN-CH H
WHT-21
WHT-23
BLK-33
7
MALE DEUTSCH
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
12V DC
CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12
8
WHT-21
BLK/RED-35
BRN-J3
BLK-33
BLK/WHT-34
WHT-23
RED-PISM6
WHT-BATT
GRN/BLK-BATT
CHASSIS HARNESS




NOTE: RD-CB CIRCUT BREAKER
1 RD-CB (12V+)
CB3
12V, 15A
C21IGN2 WH C21IGN2 WH
C35HRPM BK/RD C35HRPM BK/RD
WH-J5 WH-J5
IGNITION/START
1 3 4 7 10 9 2
12/24V DC
MODULE
WH-J4 WH-J4 WH-J6 BK/RD BK/RD
RD-CB
2 87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 GND BRN
87a 87a 87a 87a 87a 87a
RD-CB
30 30 30 30 30 30

RELAY WH-J4 RELAY C34SA BK/WH
KEYSWITCH PWR.
RELAY
WH-J4 WH-J6 WH-J6
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
3
START INPUT
RD-J6
TACH. INPUT
RD-J6
(NOT USED)
(NOT USED)
GROUND
RD-CB (12V+)
WH-BATT
OR-GEN NEG
OR-GEN POS
BRN-VOLT
BK-START
10
BK/WH-34
1
BK/RD-35
9
2
8
4
BK-ISM-1
6
WH-R14
WH-R11
RD-J10
C23PWR WH
C33STR BK
P20BAT RD
GR/BK-BATT
BRN-ISM5
WH-BATT WH-BATT
WH-ISM10
BK-ISM-1
BL-ISM2
BRN-J5
WH-R14
BK-ISM1 BK-ISM1
BRN-VOLT BL-ISM2 BL-ISM2
C33STR BK
5
BRN-J5
BRN-ISM5 BRN-ISM5
P20BAT RD
WH-BATT
C23PWR WH
BRN-VOLT
BRN-ISM5
BL-ISM2
WH-R14
BL-E.H.
BL-E.H.
RD-J10
6 ENGINE HARNESS (TO DRIVE CHASSIS) GR/BK-BATT
ENGINE HARNESS (TO ENGINE) WH-ISM10
ENGINE HARNESS (TO GROUND CONTROL BOX)

YEL
GR
RD
BK
BL
BL
C5B-18 C35HRPM BK/RD
C5B-22 C34SA BK/WH

C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
C5B-5 C33STR BK
C5B-1 P20BAT RD
C5B-2 GND BRN
12V DC
VOLTAGE REGULATOR
8
C5B
MALE DEUTSCH
CONNECTOR


NOTE: RD-CB CIRCUT BREAKER
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE. 1
CB3
RD-CB (12V+) 12V, 15A
C21IGN2 WH C21IGN2 WH
C35HRPM BK/RD C35HRPM BK/RD
WH-J5 WH-J5
IGNITION/START
1 3 4 7 10 9 2
12/24V DC
MODULE
WH-J4 WH-J4 WH-J6 BK/RD BK/RD
2
RD-CB
87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 GND BRN
87a 87a 87a 87a 87a 87a
RD-CB
30 30 30 30 30 30

RELAY WH-J4 RELAY C34SA BK/WH
KEYSWITCH PWR.
RELAY
WH-J4 WH-J6 WH-J6 3
24V BATTERY +
ENGINE FAULT
START RELAY
IGN./FUEL ON
START INPUT
RD-J6
TACH. INPUT
RD-J6
(NOT USED)
(NOT USED)
GROUND
RD-CB (12V+)
WH-BATT
OR-GEN NEG
OR-GEN POS
BRN-VOLT
BK-START
10
BK/WH-34
1
BK/RD-35
9
2
8
4
BK-ISM-1
6
WH-R14
WH-R11
RD-J10
4
C23PWR WH
C33STR BK
P20BAT RD
GR/BK-BATT
BRN-ISM5
WH-BATT WH-BATT
WH-ISM10
BK-ISM-1
BL-ISM2
BRN-J5
WH-R14
BK-ISM1 BK-ISM1
BRN-VOLT BL-ISM2 BL-ISM2
C33STR BK
5
BRN-J5
BRN-ISM5 BRN-ISM5
P20BAT RD
WH-BATT
C23PWR WH
BRN-VOLT
BRN-ISM5
6
BL-ISM2
WH-R14
BL-E.H.
BL-E.H.
RD-J10
ENGINE HARNESS (TO DRIVE CHASSIS) GR/BK-BATT
ENGINE HARNESS (TO ENGINE) WH-ISM10
ENGINE HARNESS (TO GROUND CONTROL BOX)

YEL
GR
RD
BK
BL
BL
C5B-18 C35HRPM BK/RD
C5B-22 C34SA BK/WH

C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
C5B-5 C33STR BK
C5B-1 P20BAT RD
C5B-2 GND BRN
12V DC
VOLTAGE REGULATOR 8
C5B
MALE DEUTSCH
CONNECTOR


Electrical Schematic, Z-45/25 REV A

LOAD SENSE OPTION RED/WHT #29

1
ORG/RED
WHT/RED #32
L4
1 2 3 4 WHT #30
LOAD SENSE PCB P2 FS1 WHT/BLK #31

87a RED-FS
BLK LSTOP BLK-26 BLK-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7
BRN
86 CR17 LOAD SENSE OPTION (SEE DETAIL ABOVE)

3A CR17 FS1 RED-FS
85 P2 TP25
BLK-2 BLK#26 BLK-FS
RED L1 WHT-FS TP24 WHT-24
TP22 TP26
2 RED
ORG/RED-42
RED
LOW
HIGH FOOTSWITCH
ORG/RED-42
RPM
RED/WHT-3
P3 RED
RPM HIGH RPM
HORN TS6 TS2
PLATFORM CONTROLLER GLOW ENGINE
10 A P1 KS1
BLK/RED-9
RED 20 FAULT LED PLUGS START
TB22 + TS4
L3
CB1 TILT RPM
GROUND
ALARM
A1 TP3
TP32
TP30
TP29
TP31
TP39 TP9 TP23 TP28 TP42
3 TP34 TP33 TP35
BLK/RED-3
BLU/RED-1
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
TB39
TB29 RED
TB31
TB32
TB30
TB20 ORG #40 TB40 RED-8

TB3
4 TB42
CR2
WHT-
RED/
BLU/WHT #12
ORG/RED R2
RED
WHT#30
WHT/BLK#31
WHT/RED#32
RED/WHT#29
BLU/WHT #12
ORG/RED #42
ORG/RED #42
BLU/RED #39
ORG/RED #42
ORG/RED
21
F5 LS4 TS56 TS52 TS54
ORG/RED
10 A 22 (SEC.) RPM
ENGINE
PLUGS
START
GLOW
F4 AP2 48V 86 30
BLK-8
CR2 LOW HIGH
500 A PR1 86 TB23
RED PISM6
+48 V
INDICATOR LED L2
CONTROLLER FAULT
85 87
+
COIL-PR1
CR5
F2 85 TB50 TB28
5 200 A
OFF-LIMIT SPEED INPUT
86 30
CR1 IGNITION / START
BLK #22
RED-6
RED 20
RED/BLK #28
TB34 TB33 TB35 MODULE
BLK ISM1
-
LEFT 85 87 1 START RELAY

DIODE RETURN
BOX 21 BLU ISM2 2 TACH. INPUT

RED/BLK-R5
+
TB9
INTERLOCK
-
+48V INPUT
LS2
FAULT LED
FORWARD
BLK-33
POT. LOW
REVERSE
BLK/WHT
22 (PRI.) WHT #23 3 START INPUT
POT. HI
C1 1
4
BLK-6
(NOT USED)
GRN
0.1 ENABLE WHT #21

BLK
HM TB21 BLK/RED
mF 3 5 GROUND
BLK/RED #CR4
RED/WHT #23
RED/WHT #23
15 A
+
-
2 RED (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49 CB3
AP2 7 KEY SWITCH POWER
CURTIS 1244
RED-7
6 F3 24 V SEPEX CONTROLLER
30 86
WHT WHT
8 (NOT USED)
9 IGNITION ON
13 86 30 WHT
500 A F1
AP1
200 A
F2 M- B+ F1 B- LS1 * 87 85
CR11
CR12
30 86 10 ENGINE FAULT
BRN
+24 V
BLK
PR3 PR2 (EXT.) + CR13
14
85 87 WHT GRN/BLK WHT
BLK-7
+
FB 87 85
RED
WHT
30 86 CR14
(12V) 30 86 AP2
WHT
+12V CR15
AUXILIARY
+ WHT
RED
YEL
*SWITCH 87
WHT
LEFT E2 E1 85
A2 A2 87 85
30 86
BLK/RED
MOTOR SHOWN BLU
BLK/WHT
These items (12V)
-
RIGHT
RIGHT removed after WITH BOOM VR1 ALT.
BOX E2 E1 A1 A1 MOTOR EXTENDED. CR4 -
serial number BLU
+
+ +
7
BLK
10667. 87 85 STARTER
PUMP PUMP ALTERNATOR CHARGER
BLK
+
- - (12V)
+
BLK
-
BRN
GROUND AC POWER ENGINE

GROUND (GND)
10 A HORN
(GND)
AP1 CB2 48V POWER RELAY CR2 BRN
48V POWER RELAY CR1
HOUR METER
HORN RELAY
RELAY CR12
ENGINE POWER
PUMP
PRIMARY LIFT
BOX GROUND
GROUND CONTROL
RPM SOLENOID
RPM RELAY CR14

48V ALTERNATOR
(OPTION)
FLASHING BEACON
12V ALTERNATOR
TILT SENSOR
SWITCH
OIL PRESSURE
SWITCH
WATER TEMPERATURE
ENGINE RUN SOLENOID
RPM CUTOUT RELAY CR13

GLOW PLUGS
PUMP
AUXILIARY LIFT
STARTER RELAY CR11
GLOW PLUG RELAY CR15

VOLTAGE REGULATOR
12V
48V CHARGER
8 BLACK
2 GA.
CHASSIS
GROUND
NOTES:
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.

REV A Electrical Schematic, Z-45/25

RED/WHT #29 NOTES: 1

WHT/RED #32 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
WHT #30
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
WHT/BLK #31
WHT-24 WHT-24
ORG/RED-42
WHT-24 RED 2
TURNTABLE PLATFORM
BLU/WHT#12
SECONDARY PRIMARY PRIMARY PLATFORM
ORG/RED-42 ROTATE BOOM BOOM BOOM JP1 (REMOVE FOR CE VERSION)
LEVEL ROTATE
DP1
RED
TS12 TS10 TS11 TS13 TS9 TS7
1 20K A
LEFT
RIGHT
DOWN
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
2 B
RED/BLK-R6
3 FWD C
ORG/RED-16
TS1 DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
5 L TS15 ENABLE
BP1 STEER
ROTARY RED
ORG/BLK-R6
87
85 3
TP4 TP5 TP11 TP10 TP2 TP1 TP8 TP7 TP15 TP14 TP17 TP18 OEM BRN DRIVE
FLOW + TP27 TP37 TP36 TP41 ENABLE
GRN/BLK-3
GRN-3
BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT3
BLK-3
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
BCI
E
TP19
TP13
TP6
BLU/RED - 3
BLU/WHT - 3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
4
BLU/WHT #12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM
ROTATE BOOM BOOM BOOM LEVEL ROTATE
RED
BRAKE
RELEASE 30
TB41
5
RED
JACK CR5
DOWN
DOWN
DOWN
EXTEND
UP
LEFT
RIGHT
UP
UP
RETRACT
LEFT
RIGHT
J1 87
PS1
TB27
GRN/WHT #19 GRN/WHT#19 TB48 TB13
TB19
BLK-7
BRN-2
ORG/RED - 3
TB18 TB37
WHT-7
TB4 TB5 TB11 TB10 TB2 TB1 TB8 TB7
TB17 TB6
TB36
WHT/RED #6
6
BLU/BLK #37
BLU #36
GRN/WHT
GRN/BLK #18
WHT/RED #6
RED #27
GRN #17
RED/WHT #48
BLU/BLK #11
BLU #10
BLK/WHT # 8
BLK #7
ORG
WHT/BLK #5
RED/BLK #2
RED #1
WHT #4
13
TB14 22
TB15 LS3*
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
30
14 21
86
*
RED-7
86 86 CR3 SWITCH SHOWN WITH
30 30 87a 87 85 BOOM ROTATED PAST
EITHER NON-STEER WHEEL
CR10B 87 87 CR10A 85 7
RED
GRN/WHT
85
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3 13
LS2
FUNCTION 14
MANIFOLD
(GND) GROUND BRAKE/STEER
MANIFOLD
(GND) GROUND
PRESSURE SWITCH (PS1)

BRAKE RELEASE
BRAKE RELEASE N.O.

STEER LEFT
BRAKE RELEASE N.C.
TRAVEL ALARM
BRAKE RELEASE
LIMIT SWITCH
DRIVE ENABLE
RELAY COIL (CR3)
AUXILIARY CONTROL
STEER RIGHT
PUMP RELAY COIL (PR3)
AUXILIARY LIFT
BRN
ROTATE LEFT
PLATFORM
ROTATE RIGHT
PLATFORM
EXTEND
PRIMARY BOOM
UP
PRIMARY BOOM
RELAY COIL (PR2)

LIFT PUMP
BOOM UP
SECONDARY
RETRACT
PRIMARY BOOM
VALVE
PROPORTIONAL
DOWN
PLATFORM LEVEL
DOWN
PRIMARY BOOM
UP
PLATFORM LEVEL
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
TURNTABLE
BOOM DOWN
SECONDARY
(OPTION)
DESCENT ALARM
RELAY (CR10B)
DOWN CUTOUT
PLATFORM LEVEL
(CR10A)
UP CUTOUT RELAY
PLATFORM LEVEL

Electrical Schematic, Z-45/25


LOAD SENSE OPTION RED/WHT-29

1
ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
LOAD SENSE PCB P2 87a FS1
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN
86 LOAD SENSE OPTION (SEE DETAIL)

3A CR17 P2 FS1 RED-FS TP25
85
BLK-2 BLK-26 BLK-FS
TP22 TP26
2 RED
ORG/RED-42
RED
TS4
RPM
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3 TS2
TS6
KS1 PLATFORM CONTROLLER GLOW ENGINE HIGH LOW
BLK/RED-9
10 A P1 FOOTSWITCH
RED-20 FAULT LED PLUGS START RPM RPM HIGH RPM
TB22 +
CB1 A1
GROUND TILT
ALARM
TP32
TP30
TP29
TP31
3 TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30
TB20 ORG-40 TB40 RED-8

TB3
4 TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4 TS56 TS52 TS54
F4
RED PISM6
10A
ORG/RED
22 (SEC.) RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
COIL-PR1
CR5
F2 85 TB50 TB28
5
200 A 30
86
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
DIODE RETURN
LEFT 87 START RELAY
BRN
BRN
BOX BLU-ISM2
RED/BLK-R5
21 2 TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
22 (PRI.) WHT-23 3 START INPUT
POT. HI
1
4
GRN
BLK-6
(NOT USED)
BLK
ENABLE WHT-21 BLK/RED-35

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49
WHT-21
CB3 WHT-23
6
RED-7
MOTOR CONTROLLER 30 85 8 (NOT USED)

F3 24V DC
9 IGNITION ON
13 30 WHT
500A AP1 F1 CR11 85 30
F2 M- B+ F1 B- LS1 87 86 85 10 ENGINE FAULT
200A 2
+24V DC CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
+12V DC
86
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT BATT WHT

RIGHT VR1 ALT.
BOX E2 E1 A1 A1 MOTOR CR4 -
(12V DC)
+
BLU
7 + +
BLK
AP2
PUMP PUMP 87 85 STARTER
ALTERNATOR CHARGER AUXILIARY
WHT-BATT
BLK
+
- -
BRN
AC POWER
CR16 (12V DC)
BLK
+
-
ORG GEN NEG 30

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
PRESSURE SWITCH
OIL
SWITCH
TEMPERATURE
WATER
SOLENOID
ENGINE RUN
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY
RELAY CR11
STARTER
RELAY CR15
GLOW PLUG
REGULATOR
12V DC VOLTAGE
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.

REV A Electrical Schematic, Z-45/25

RED/WHT-29 1
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 WHT-24
ORG/RED-42
WHT-24 RED 2
TURNTABLE PLATFORM
BLU/WHT-12
ORG/RED-42 JP1 (REMOVE FOR CE VERSION)
DP1
RED
1 20K A
LEFT
RIGHT
DOWN
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
2 B
RED/BLK-R6
ORG/RED-16
3 FWD C
TS1 DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
5 L TS15
BP1
RED
STEER ENABLE
87
85 3
ROTARY ORG/BLK-R6
FLOW + TP27 TP37 TP36 TP41 ENABLE
GRN/BLK-3
GRN-3
BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
BCI
E
TP19
TP13
TP6
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
4
BLU/WHT-12
TB12
RED
TS55 FUNCTION
ENABLE RED
TS51
WHT/RED-3
AUXILIARY
RED
POWER
BRAKE
TB41 5
TS62 TS60 TS61 TS63 TS59 TS57 RELEASE 30
RED
JACK CR5
DOWN
DOWN
DOWN
EXTEND
UP
LEFT
RIGHT
UP
UP
RETRACT
LEFT
RIGHT
J1 87
PS1
TB27
GRN/WHT-19 GRN/WHT-19 TB48 TB13
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
WHT/RED-6
TB36
6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
3
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
PLATFORM LEVEL CUTOUT ENABLE
(CE MODELS ONLY) LIMIT
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85 7
RED
GRN/WHT
85
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
ROTATE LEFT
PLATFORM
ROTATE RIGHT
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
COIL
FLOW CONTROL
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
3 SWITCH SHOWN WITH BOOM ROTATED
PAST EITHER NON-STEER WHEEL.



1 LOAD SENSE OPTION RED/WHT-29
ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
TS4
RPM
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3 TS2
TS6
BLK/RED-9
10 A P1 FOOTSWITCH
TB22 +
CB1 A1
GROUND TILT
ALARM
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4 TS56 TS52 TS54
F4
RED PISM6
10A
ORG/RED
22 (SEC.) RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
DIODE RETURN
LEFT 87 START RELAY
BRN
BRN
BOX BLU-ISM2
RED/BLK-R5
21 2 TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
GRN
BLK-6
(NOT USED)
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49
WHT-21
CB3 WHT-23
6 AP2 7 KEY SWITCH POWER
RED-7

F3 24V DC
9 IGNITION ON
13 30 WHT
500A AP1 F1 CR11 85 30
200A 2
+24V DC CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
+12V DC
86
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT BATT WHT

RIGHT VR1 ALT.
7 BOX E2 E1 A1 A1 MOTOR CR4 -
(12V DC)
+
+ + BLU
BLK
AP2
WHT-BATT
BLK
+
- -
BRN
AC POWER
CR16 (12V DC)
BLK
+
-
ORG GEN NEG 30

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
TILT SENSOR
PRESSURE SWITCH
OIL
SWITCH
TEMPERATURE
WATER
SOLENOID
ENGINE RUN
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY
RELAY CR11
STARTER
RELAY CR15
GLOW PLUG
REGULATOR
12V DC VOLTAGE
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:

1
8
Section 6 • Schematics
6 - 22
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22
TP13 BLU/RED-3 BLK-7 BRN-7

LS3
TB16
BLU/WHT-12 TP12 BLU/WHT-3 WHT-7 RED-7

TB12
14
13
B
ORG/RED-16 TP16 ORG/RED-3

A2
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy

JP1 (REMOVE FOR CE VERSION)
86
85
BRN PLATFORM BRAKE RELEASE

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
ORG/BLK-1 RED/WHT-48
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
C
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
BLU/BLK-1 BLU/BLK-37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106488

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
June 2005
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
H
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
UP ORG #14 PLATFORM LEVEL
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15
EXTEND BLK-7 PRIMARY BOOM

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
RETRACT RETRACT COIL
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
RETRACT UP RED-1 PRIMARY BOOM
TP8
UP COIL
PRIMARY
RED/BLK-2 PRIMARY BOOM
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
BLU/BLK-11 SECONDARY BOOM
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
L
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
RIGHT WHT/BLK-5 ROTATE RIGHT
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
LEFT
M
TP4
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
WHT-LOAD WHT-24 WHT-30
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
2 LOAD SENSOR OPTION TP22 TP26
RED
WHT-(FS) TP24 WHT-24
ORG/RED-42
RED
LOW
HIGH RPM FOOT SWITCH
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN L3 TS2
KS1
BLK/RED-9
P1 PLUGS
RED-20 FAULT LED START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
RED-7
CURTIS 1244 30 85 8 (NOT USED)

F3 24V DC
SEPEX CONTROLLER 9 IGNITION ON
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
7 BOX E2 E1 A1 A1 MOTOR CR4 - (12V DC)
+
+ + BLU
BLK
AP2
PUMP 87 85 STARTER
PUMP ALTERNATOR CHARGER AUXILIARY
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:

1
8
6 - 24
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2

86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

C
JACK
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106488

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
June 2005
TP19
87
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
H
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
L
BLU/BLK-3
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
LEFT
M
TP4
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
LOW
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN TS2
PLATFORM GLOW ENGINE
KS1
BLK/RED-9
P1 PLUGS
RED-20 START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
+
+ + BLU
BLK
AP2
PUMP 87 85 STARTER
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM SOLENOID
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:

1
8
6 - 26
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2

86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
C
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106488

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
June 2005
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
H
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86
CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
L
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE
WHT-3
TS12
LEFT
M
TP4
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


P2 RED/WHT-29
FS1 RED-(FS)
1 TP22
BLK-26 BLK-(FS)
WHT-(FS) C
LOAD
SENSOR
WHT/RED-32
TP26
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
LOAD SENSOR OPTION WHT-(FS) TP24 WHT-24
TP22 TP26
2 RED
ORG/RED-42
RED
LOW
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN TS2
KS1
BLK/RED-9
P1 PLUGS
RED-20 START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1
TP32
TP30
TP29
TP31 TP9 TP23 TP28 TP3 TP42
3 TP34 TP33 TP35
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

TB3
4 TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
COIL-PR1
CR5
F2 85 TB50 TB28
5
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
+ 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
-
+
-
RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
6
RED-7

F3 24V DC
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 F2 F1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
BOX F2 F1 A1 A1 MOTOR CR4 - (12V DC)
+
+ + BLU
7
BLK
AP2
PUMP 87 85 STARTER
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM SOLENOID
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
RELAY CR15
GLOW PLUG
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:

1
8
6 - 28
3
A
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
BRN-2
TB13
21
22

LS3
TB16

TB12
14
13
B

A2

86
85

TRAVEL ALARM (A2)
TB48
CONTROL BOX
TB41
+
CR5
CR6
GROUND
DRIVE 30
87
87
30
TP41
BRAKE RELEASE
RED/BLK-R6
N.C. COIL
ENABLE
TS15
RED
BRAKE/STEER
BRAKE RELEASE
N.O. COIL
WHT-24
MANIFOLD
RELEASE
GROUND
J1
BRAKE
PS1 BRAKE RELEASE

JACK
C
TP36
PRESSURE SWITCH PS1

TB36
BLU-1 BLU-36
RED STEER LEFT COIL
TB37
STEER RIGHT COIL
TP37
ORG/BLK-R6
D
10
1
2
3
4
5
7
8
9
GRN/WHT-19
WHT/RED-32
RED/WHT-29
WHT/BLK-31
DRIVE
LIFT
STEER
FWD
WHT-30
WHT-24
REV
20K
L R
DP1
AUXILIARY
E
PUMP
RED - 1
TS1
CR3
AUX
85
ON
86
RED RED RED-27

TP27
AUXILIARY CONTROL
BCI
RELAY COIL CR3

TS51
TB27
Part No. 106488

F
E
+
RED AUXILIARY LIFT

PUMP RELAY COIL PR3
TB19
TP19
87
June 2005
GRN/
30
WHT-3 GRN/WHT
GRN/WHT LIFT PUMP
TP6
RELAY COIL PR2

TB6
87a
F
WHT/RED-3 WHT/RED-6
BLK/RED
FLOW
CONTROL
GRN/WHT-19
RED
BRN
COIL
TB18
PLATFORM
CONTROL
RIGHT GRN/BLK-18
ROTARY
PLATFORM
ROTATE RIGHT
FLOW
ROTATE
OEM
GRN-17 PLATFORM
BP1
TS57
ROTATE LEFT
TB17
LEFT
WHT/RED-6
TP18
G
RIGHT GRN/BLK-3
GRN-3
PLATFORM
TS7
LEFT
TP17
ROTATE
ORG/RED-42
LS2
H
(CE VERSION ONLY)
14
13
WHT-24
WHT-40
RED
PLATFORM LEVEL
CR10A 85
86 CUTOUT UP
RELAY COIL CR10A
TB14
87a
30
PLATFORM
UP COIL
ORG/BLK #15
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL
30
87a
TB15
FUNCTION
MANIFOLD
GROUND
ORG
CR10B
TP14
PLATFORM LEVEL
ORG-3
PLATFORM
UP CUTOUT DOWN
85
86
RELAY COIL CR10B
ORG/BLK-3
LEVEL
TS9
TB7
DOWN
TP15

EXTEND COIL
PRIMARY
BLK/WHT-8
PRIMARY BOOM
BOOM
TS63
TB8
J
TP7
EXTEND BLK-3
PRIMARY
BLK/WHT-3
BOOM
TS13
TB1
TP8
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
TP1
K
UP RED-3
PRIMARY
RED/BLK-3
BOOM
TS11
TB10
DOWN
BLU-10
SECONDARY
UP SECONDARY BOOM
TP2
UP COIL
TS60
BOOM
DOWN DOWN COIL
TB11
TP10
DESCENT
ALARM
SECONDARY
UP BLU-3
A3
OPTION (A3)
+
BLU/BLK-3
L
BOOM
TS10
TB5
DOWN TURNTABLE
TP11
TURNTABLE
COIL
ROTATE
WHT-4 TURNTABLE
TS62
LEFT ROTATE LEFT
TB4
COIL
TP5
RED
RIGHT WHT/BLK-3
TURNTABLE
ROTATE WHT-3
TS12
LEFT
M
TP4
FUNCTION
ENABLE
WHT/RED-32
RED/WHT-29
WHT/BLK-31
BLU/WHT-12
ORG/RED-42
WHT-30
WHT-24
TS55
(GND)
(GND)
BRN
RED
RED
REV A
N


P2 FS1
RD-(FS) C9P-3 LOAD
1 C7P-1 P22BAT BK C9P-1 BK BK-(FS)
P25BAT BK SENSOR
MODULE
C29JSH RD/WH
P26BAT WH-(FS) C9P-2 C
P24BAT WH C32JSL WH/RD
WH-LOAD
BK-26 LOAD B+ GND 8 C30FWD WH
OR-LOAD
BRN
C31REV WH/BK
LOAD SENSOR OPTION LOAD
C40LS OR
CELL
NOTES:
2 SWITCH SHOWN WITH BOOM EXTENDED. LOAD SENSOR OPTION (SEE DETAIL)
2 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
P22BAT C7P-1
P2
C9P-1 BK BK-(FS)
FS1
RD-(FS) C9P-3 P25BAT RD
WH-(FS) C9P-2 P24BAT WH P24BAT WH
BK P26BAT
RD
R42BAT OR/RD
C7B-1
RD
RD TS6 TS2
KS1 PLATFORM HIGH LOW FOOT SWITCH
P1 GLOW ENGINE
P20BAT RD P3 RPM RPM HIGH RPM
+ PLUGS START
TB22 HORN TILT
CB1 TS4
ALARM RPM
10 A GROUND
C1P-4
C1P-5
C1P-6
C1P-3
A1
C2P-2
C3P-9
C7P-2
C1P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
3
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
C33STR BK
C35HRPM BK/RD
C34SA BK/WH
C9HRN BK/RD
P23SWBAT WH
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
P20BAT RD
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
C1B-8
C1B-7
C1B-9
C3B-9
C7B-2
C1B-2
C3B-3
C2B-4
4
C7B-4
C6B-30
C6B-31
C6B-32
C6B-29
OR TB40 OR P20BAT RD
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
F5
OR/RD
F4
OR/RD
10A TS56 TS52 TS54
C6B-12
C6B-24
500 A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30 RPM
START
ENGINE
PLUGS
GLOW
CR2 86
86 LOW HIGH
PR1 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
5 85
C5B-1 P20BAT RD
BK 87
WH
RD/BK
BK
BK/RD
+
COIL-PR1
CR5
BL/WH
F2 85
200 A 30 TB34 TB33 TB35

86
RD 20
MODULE
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
BK-ISM1
C6B-28
C6B-34
+
DIODE RETURN
85 1
-
START RELAY
C6B-25 CFIL BK
LEFT 87
BRN
BRN
BOX BL-ISM2
INTERLOCK
2 TACH. INPUT
+48V INPUT
+
BK-4
WH-4
BK-5
WH-5
FORWARD
POT. LOW
REVERSE
C5B-5 C33STR BK
C23PWR WH 3 START INPUT
POT. HI
C5B-18 4 (NOT USED)

21 + C5B-11 C21IGN2 WH
GR
C5B-22
LS4 HM C35HRPM
_ 15 A
5 GROUND
(SEC)
+
-
RD-J10 (12GA)
6 22 6 BATTERY
1
10
11
14
16
17
20
CB3 C5B-3 C23PWR WH

AP2 30 7 KEY SWITCH POWER
RD/WH
RD/BK
86
RD
C34SA BK/WH
CURTIS 1244 CR4 30 85 8 (NOT USED)
F3 24 V DC
BK-5
RD-5
SEPEX CONTROLLER 87 85 9 IGNITION ON

500 A F1 BK CR11 85 30 WH
AP1 30
C8-A
C8-C
F2 M- B+ F1 B- 87 86 85 10 ENGINE FAULT
+24 V 200A CR12
BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+
87 85
C11-3
C11-4
C11-1
C11-2
+
RD
WH
30 85 CR14
(12V DC) 30 CR16
WH
BRN
BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7
BK-6
86
+12V DC
87
WH
RD
YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK
BK/RD
BRN
BRN
BRN
BRN
BRN
BK/WH
MOTOR
7
+
-
RIGHT WH
RIGHT VR1 ALT. BATT
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
(12V DC)
+
+ + BL
(PRI)
BK
LS1 AP2
PUMP PUMP 2 STARTER
ALTERNATOR CHARGER (EXT) AUXILIARY
22 WH-BATT
BK
14
BK 2 GA
BRN
- -
AC POWER +
C8-B
(12V DC)
BK
+
-
OR-GEN NEG 30 CR16

BRN
GROUND
C5B-2
ENGINE
OR-GEN POS
GROUND
87 (GND)
AP1 BK BK
PR2 PR2
8 PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
RPM RELAY
ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
ALERNATOR
12V DC
SOLENOID
RPM
CR14
TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
SOLENOID
ENGINE RUN
RELAY CR13
RPM CUTOUT
CR16
FIELD RELAY
ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
RELAY CR11
STARTER
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC

1
8
6 - 30
3
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
A
LED L1
DRIVE
BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22
C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3
C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8

TB12
14
13
C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86
85
BRN
A2
B
86
85
BRAKE RELEASE
RD/WH
TRAVEL ALARM
CR6
+
CR5
CR8
(A2)
C27-1 C27-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH
BRAKE RELEASE
C2P-3 RD/WH
DRIVE 30
87
87
30
N.C. COIL
30
87
RD/BK-R6
CE VERSION:
ENABLE
BRAKE RELEASE
TS15
RD C26-1 C26-2
AND ADD
RD/WH N.O. COIL

REMOVE
JUMPER
RELAY
RELEASE
J1
BRAKE
PS1 BRAKE RELEASE

JACK
CR5
PRESSURE SWITCH PS1

TB36
C
C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C1P-10
TB37
C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
C6B-23 P20BAT RD
D
C31REV WH/BK
C29JSH RD/WH
10
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH
C1P-1 C27AUX RD C1B-1

TS1
PR2
RD-AUX
87
30
E
OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION
GR/WH RELAY COIL PR2

BCI
BK
F
CR3
+
Part No. 106488

BCI OPTION
OR/RD
AUX
85
ON
86
DISCHARGE
OR/RD RD RD AUXILIARY CONTROL

SET TO "N"
1
RELAY COIL CR3

TS51
TB27
CR20
33
2
PR3
OR
3
3
June 2005
OR/RD AUXILIARY LIFT

5
L.V.I.
4
C6B-27 PUMP RELAY COIL PR3

OR/BK
4
RD
TB19
87
BCI
SET TO "B"
F
RESET
30
C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86
GR/WH CONTACTOR RELAY

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD FLOW CONTROL

COIL
BK
85 BRN
BK/RD
CR19A
BRN
GR/WH
RD
86
TB18
C23-1 C23-2 PLATFORM

CONTROL
RIGHT
CR19B
C6B-18 GR/BK ROTATE RIGHT

ROTARY
PLATFORM
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
G
PLATFORM
ROTATE
RIGHT C4P-6 C18PRR GR/BK C4B-6 GR/BK

C4P-5 C17PRL GR C4B-5 GR
TS7
LEFT
H
TB14
UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM
UP COIL
I
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL

TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
C4P-3 C15PLD OR/BK C4B-3
TS9
TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY
C6B-8 BK/WH PRIMARY BOOM

BOOM
TS63
J
TB8
C17-1 C18-2
PRIMARY
BOOM
EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13
TB1
RETRACT C12-1 C12-2
UP C6B-1 RD PRIMARY BOOM
UP COIL
PRIMARY
C6B-2 RD/BK PRIMARY BOOM
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
K
BOOM
UP C3P-1 C1PBU RD C3B-1

30
87
C3P-2 C2PBD RD/BK C3B-2

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
UP C3P-10 C10SBU BL C3B-10
A3
OPTION (A3)
+
L
87
30
C3P-11 C11SBD BL/BK C3B-11

TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4
TS12
R42BAT OR/RD
M
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
P20BAT RD
C40LS OR
TS55
(GND)
PR2
PR3
CR5
BK
RD
REV A
N

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

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3 P25BAT RD
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132 PLI BL/WH C1P-12 RD

7 TS6 TS2 HIGH LOW FOOTSWITCH
GLOW
C1B-12
A1 ENGINE RPM RPM HIGH RPM
+
RD
LS18 TILT PLUGS START
L48 TS4
P3 ALARM RPM
CB1 HORN
KS1 PLATFORM
10 A P1
C7P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
P20BAT RD D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C33STR BK
C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH
R42BAT OR/RD
4 5
C32
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C1B-8
C1B-7
C1B-9
C3B-3
C2B-4
P20BAT RD
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5 TS54
BK/RD
F4
OR/RD
10A TS56 TS52 RPM
C6B-12
C6B-24
500A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30
START
ENGINE
PLUGS
GLOW
CR2 86
C5B-1 P20BAT RD
86 TB23 LOW HIGH
PR1
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
TB34 TB33
5 200A 86
CR1
30 TB35
IGNITION / START
RD 20
BL/WH
OFF-LMT SPD INP
MODULE
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
BK-ISM1
C6B-28
+
C6B-34
85 1 START RELAY
-
LEFT 87
+48V INPUT
BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
C5B-5 C33STR BK
3
POT. HI
C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR
C5B-11 C21IGN2 WH
C5B-22
LS4 HM C35HRPM
_ 15 A
5 GROUND
+
(SEC)
-
RD-J10 (12GA)
6 BATTERY
2
9
14
10
11
16
17
20
5
1
22
AP2 CB3 C5B-3 C23PWR WH
30 7 KEY SWITCH POWER
RD/WH
RD/BK
86
RD
U6A
C34SA BK/WH
MOTOR CONTROLLER CR4 30 85 8 (NOT USED)
24V DC
6
BK-5
RD-5
87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30
C8-A
C8-C
+24V DC 200A CR12
BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+
87 85
C11-3
C11-4
C11-1
C11-2
RD
WH
30 85 CR14
(12V DC) 30 CR16
WH
BRN
BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7
BK-6
86
+12V DC
87
WH
RD
YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK
BK/RD
BRN
BRN
BRN
BRN
BRN
BK/WH
MOTOR
+
RIGHT BATT WH
RIGHT (12V DC) VR1 ALT.
+
+ BL
(PRI)
BK
+
LS1 AP2
2 STARTER
PUMP PUMP
22 WH-BATT
BK
14
BK 2 GA
7 -
BRN
-
+
C8-B
BK
+
(12V DC)
-
OR-GEN NEG 30 CR16

BRN
GROUND A2
C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)
AP1 BK BK
PR2 PR2
PR3 PR3
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
ALERNATOR
12V DC
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
RELAY CR15
GLOW PLUG
LIFT PUMP
AUXILIARY
STARTER RELAY CR11

CHARGER
48V DC
REGULATOR
12V DC VOLTAGE
8

NOTES: 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 7 ANSI/CSA

1
8
Electrical Schematic, Z-45/25, ANSI and CSA Models
6 - 32
ENABLE
SWITCH
3
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
A

21
22
LS3
C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8

TB12
14
13

86
85
BRN
A2
86
85
B
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30
87
87
30
30
87
RD/BK-R6
CE VERSION:
ENABLE
TS15
AND ADD
REMOVE
JUMPER
RELAY
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
RD STEER LEFT COIL
C
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
C31REV WH/BK
C29JSH RD/WH
10
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
D
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
PUMP
33
GR/WH

TS1
PR2
RD-AUX
BCI OPTION
87
30

LVI/BCI OPTION

BCI
E
BK
AUXILIARY
F
POWER
CR3
+
OR/RD
85
86
DISCHARGE

SET TO "N"
1
Part No. 106488
RELAY COIL CR3

TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4
C6B-27
June 2005
OR/BK PUMP RELAY COIL

4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30

WH
85
86

7
F
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK
85 BRN
BK/RD
CR19A
COIL
BRN
GR/WH
RD
86
TB18
C23-1 C23-2 PLATFORM

CONTROL
RIGHT
CR19B

ROTARY
PLATFORM
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
PLATFORM
G
ROTATE

TS7
LEFT
H
TB14
UP C20-1 C20-2
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
I
DOWN DOWN COIL

TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
TS9
TB7
DOWN C16-1 C16-2
EXTEND COIL
PRIMARY

BOOM
TS63
TB8
C17-1 C18-2
J
PRIMARY
BOOM

TS13
TB1
RETRACT C12-1 C12-2
UP C6B-1 RD PRIMARY BOOM
UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM
K

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
87
30

TS10
L
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
ROTATE
RD
TS12
R42BAT OR/RD
LEFT
P24BAT WH
FUNCTION
M
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
REV A
N
Electrical Schematic, Z-45/25, ANSI and CSA Models

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

1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH
P22BAT
P26BAT
RD
R42BAT OR/RD
2 C132PLI BL/WH C1P-12 RD TS6 TS2

HIGH LOW FOOT SWITCH
GLOW ENGINE
C1B-12
RPM RPM HIGH RPM
+
RD
A1 PLUGS START
LS18 TILT TS4
P3 L4 ALARM RPM
CB1 HORN 5
10A KS1 PLATFORM
P1
C7P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
P20BAT RD D39 D40
TB22 6
C7B-1
C2P-5
C1P-2
GROUND
C7P-2
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-2
1 3
C33STR BK
C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH
R42BAT OR/RD
4 5
U33
C134PWR GR
C28TTA RD/BK
P23BAT WH
P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
3 6
5
7
12 8
C1B-8
C1B-7
C1B-9
C3B-3
C2B-4
P20BAT RD
A6 L45
C7B-2
C3B-9
C2B-5
C1B-2
C7B-2
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
GR/BK
C7B-4
RD
C6B-30
C6B-31
C6B-32
C6B-29
4 OR TB40 OR
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
OR/RD
F5
BK/RD
F4
OR/RD
10 A TS56 TS52 TS54
C6B-12
C6B-24
500 A
C6B-20 RD
C6B-40 OR
AP2 48V DC 30 RPM
START
ENGINE
PLUGS
GLOW
CR2 86
TB23 LOW HIGH
C5B-1 P20BAT RD
PR1 86
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85 87
BK D2
RD/BK
BK
+
COIL-PR1
CR5
F2 85
200 A
5 86
CR1
30 TB34 TB33 TB35
IGNITION / START
RD 20
BL/WH
OFF-LMT SPD INP
MODULE
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK
C6B-25 CFIL BK
DIODE RETURN
BK-ISM1
C6B-28
+
C6B-34
85 1 START RELAY
-
LEFT 87
+48V DC INPUT
BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
C5B-5 C33STR BK
3
POT. HI
C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR
C5B-11 C21IGN2 WH
C5B-22
LS4 HM C35HRPM
_ 5 GROUND
+
(SEC)
-
RD-J10 (12GA)
6 BATTERY
10
14
16
17
20
11
22
3
9
5
2
1
AP2 CB3 C5B-3 C23PWR WH

30 15 A 7 KEY SWITCH POWER
RD/WH
RD/BK
86
RD
C34SA BK/WH
U6A 30 8 (NOT USED)
CR4 85
6 24V DC MOTOR CONTROLLER
BK-5
RD-5
87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30
C8-A
C8-C
+24V DC 200A CR12
BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+
87 85
C11-3
C11-4
C11-1
C11-2
RD
WH
30 85 CR14
30 CR16
WH
BRN
(12V DC)
BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7
BK-6
+12V DC
86
87
WH
RD
YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK
BK/RD
BRN
BRN
BRN
BRN
BRN
BK/WH
MOTOR
+
(12V)
-
RIGHT BATT WH
RIGHT VR1 ALT.
+
+ BL
(PRI)
BK
+
LS1 AP2
2 STARTER
PUMP PUMP
22 WH-BATT
BK
7 14
BK 2 GA
-
BRN
-
+
C8-B (12V DC)
BK
+
OR-GEN NEG 30 CR16

BRN
GROUND A2
C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)
AP1 BK BK
PR2 PR2
PR3 PR3
48V DC POWER RELAY CR2

48V DC POWER RELAY CR1
HOUR METER
HORN
HORN RELAY
ENGINE POWER RELAY CR12

LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
CHASSIS GROUND
BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC
FLASHING BEACON OPTION
12V DC ALERNATOR
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
12V DC VOLTAGE REGULATOR
CHARGER
48V DC

NOTES: 5 CE & PLATFORM LOAD SENSE OPT.
6 ADD D40 ONLY IF UNIT HAS L4 AND L48.

1
8
Electrical Schematic, Z-45/25, CE Models
6 - 34
A
ENABLE
SWITCH
3
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

21
22
LS3
BL/WH WH-8 RD-8

B
C3P-12 C12DRE BL/WH C3B-12 C6B-26 C12DRE

TB12
14
13

86
85
BRN
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30
87
87
30
30
87
RD/BK-R6
CE VERSION:
ENABLE
C
TS15
AND ADD
REMOVE
JUMPER
RELAY
PS1 BRAKE RELEASE

CR5
PRESSURE SWITCH PS1

TB36
C24-1 C24-2
RD STEER LEFT COIL
C1P-10
TB37

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D
OR/BK-R6
C31REV WH/BK
C29JSH RD/WH
10
C32JSL WH/RD
2
3
4
5
7
8
9
C30FWD WH
P24BAT WH
DRIVE
C40LS OR
LIFT
STEER
FWD
REV
20K
L R
DP1
AUXILIARY
E
PUMP
33
GR/WH

TS1
PR2
RD-AUX
BCI OPTION
Part No. 106488

87
30

LVI/BCI OPTION

BCI
BK
AUXILIARY
June 2005
POWER
CR3
+
OR/RD
85
86
DISCHARGE

SET TO "N"
1
RELAY COIL CR3

F
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4
C6B-27 PUMP RELAY COIL

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30

WH
85
86

7
CR20
TB6
87a
8
C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK
85 BRN
BK/RD
CR19A
COIL
BRN
GR/WH
RD
86
TB18
PLATFORM
G
C23-1 C23-2
CONTROL
RIGHT
CR19B

ROTARY
PLATFORM
FLOW
ROTATE
OEM
C6B-17 GR PLATFORM
BP1
TS57
LEFT ROTATE LEFT

TB17
C22-1 C22-2
86
85
PLATFORM
ROTATE

TS7
LEFT
H
I
TB14
UP C20-1 C20-2
PLATFORM
UP COIL
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
DOWN DOWN COIL
TB15
PLATFORM
C21-1 C21-2
LEVEL
PLATFORM LEVEL
RELAY COIL CR10B
J

TS9
TB7
DOWN C16-1 C16-2
EXTEND COIL
PRIMARY
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
C12-1 C12-2
K
RETRACT UP C6B-1 RD PRIMARY BOOM

UP COIL
PRIMARY
BOOM
TS61
DOWN DOWN COIL
TB2
C13-1 C13-2
PRIMARY
CR19A
BOOM

30
87

TS11
TB10
DOWN C18-1 C18-2
SECONDARY
UP COIL
L
TS60
BOOM
SECONDARY
DOWN DOWN COIL
TB11
C19-1 C19-2
CR19B
DESCENT
BOOM
ALARM
A3
OPTION (A3)
+
87
30
TS10
TB5
DOWN TURNTABLE
C15-1 C15-2
TURNTABLE
COIL
ROTATE
C6B-4 WH TURNTABLE
TS62
LEFT ROTATE LEFT
TURNTABLE
TB4
C14-1 C14-2
COIL
M
ROTATE
RD
TS12
R42BAT OR/RD
LEFT
P24BAT WH
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
C40LS OR
REV A
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
Electrical Schematic, Z-45/25, CE Models

Electrical Schematic, Z-45/25J REV A

RED/WHT #29
1 LOAD SENSE OPTION
ORG/RED
WHT/RED #32
L4
1 2 3 4 WHT #30
P2 FS1 WHT/BLK #31

LOAD SENSE PCB 87a RED-FS
1 2 3 4 5 6 7 8 9 10 1112 WHT-FS
30 87 TP26
RED L7 CR17
BRN
86 LOAD SENSE OPTION (SEE DETAIL BELOW)

3A CR17
85 P2 FS1 RED-FS TP25
BLK-2 BLK#26 BLK-FS
2 TP22 TP26
RED
ORG/RED-42
RED
LOW
RED/WHT-3
P3 RED
ORG/RED-42
RPM HIGH RPM
HORN TS6 TS2
10 A P1 KS1
BLK/RED-9
RED 20 FAULT LED PLUGS START
TB22 + TS4
L3
CB1 TILT RPM
GROUND
ALARM
A1 RED
3 TP3
TP32
TP30
TP29
TP31 TP39 TP9 TP23 TP28 TP42
TP34 TP33 TP35
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
BLU/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
TB39 RED
TB29
TB31
TB32
TB30
TB20 ORG #40 TB40 RED-8

TB3
4
TB42
CR2
WHT-
RED/
BLU/WHT #12
ORG/RED #CR2
RED
WHT#30
WHT/BLK#31
WHT/RED#32
RED/WHT#29
BLU/WHT #12
ORG/RED #42
ORG/RED #42
BLU/RED #39
ORG/RED #42
ORG/RED
21
ORG/RED
10 A 22 (SEC.) RPM
ENGINE
PLUGS
START
GLOW
F4 AP2 48V 86 30
BLK-8
CR2 LOW HIGH
500 A PR1 86 TB23
RED PISM6
+48 V
INDICATOR LED L2
CONTROLLER FAULT
85 87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200 A
86 30
BLK #22
RED-6
RED 20
RED/BLK #28
BLK-ISM 1
+
-
LEFT 85 87 1 START RELAY

DIODE RETURN
BOX 21 BLU-ISM2 2 TACH. INPUT

RED/BLK-R5
-
+
INTERLOCK
TB9
+48V INPUT
LS2
FAULT LED
FORWARD
BLK-33
POT. LOW
REVERSE
BLK/WHT
22 (PRI.) WHT #23 3 START INPUT
POT. HI
C1 1
4
BLK-6
(NOT USED)
GRN
0.1 ENABLE
BLK
WHT #21 TB21 BLK/RED

HM
mF 3 5 GROUND
BLK/RED #CR4
RED/WHT #23
RED/WHT #23
15 A
+
-
2 RED (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49 CB3
6 AP2
CURTIS 1244
7 KEY SWITCH POWER
RED-7
30 86 8 (NOT USED)
F3 24 V SEPEX CONTROLLER WHT WHT
9 IGNITION ON
13 86 30 WHT
500 A AP1 F1 CR11 30 86
F2 M- B+ F1 B- LS1 87 85 10 ENGINE FAULT
200 A CR12
BRN
+24 V
BLK
PR3 PR2 (EXT.)* + CR13
14
85 87 WHT GRN/BLK WHT
BLK-7
-
+
FB 87 85
RED
WHT
30 86 CR14
(12V) 30 86 AP2
WHT
+12V CR15
AUXILIARY
+ WHT
87
WHT
85
RED
YEL
LEFT A2 A2 E2 E1 *SWITCH
These items 30 86 BLU 87 85
BLK/RED
BLK/WHT
+
MOTOR SHOWN (12V)

-
RIGHT removed after

RIGHT VR1 ALT.
7 BOX E2 E1 A1 A1 MOTOR serial number
WITH BOOM CR4 -
-
+
+ + EXTENDED BLU
BLK
10667. 87 85 STARTER
PUMP PUMP ALTERNATOR CHARGER
BLK
+
- - (12V)
+
-
BLK
BRN
GROUND AC POWER ENGINE

GROUND (GND)
10 A HORN
(GND)
AP1 CB2 BRN
8
48V POWER RELAY CR2
48V POWER RELAY CR1
HOUR METER
BLACK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
BOX GROUND
GROUND CONTROL
ALTERNATOR
48V
(OPTION)
FLASHING BEACON
12V ALTERNATOR
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
OIL PRESSURE SWITCH
SWITCH
WATER TEMPERATURE
ENGINE RUN SOLENOID
CR13
RPM CUTOUT RELAY
GLOW PLUGS
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
CR15
GLOW PLUG RELAY
REGULATOR
12V VOLTAGE
CHARGER
48V
2GA.
CHASSIS
GROUND
NOTES:
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.

REV A Electrical Schematic, Z-45/25J

RED/WHT #29
NOTES: 1
WHT/RED #32
WHT #30 2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
WHT/BLK #31
WHT-24 WHT-24
ORG/RED-42
WHT-24
TURNTABLE
RED
PLATFORM JIB BOOM
2
BLU/WHT#12
ORG/RED-42 ROTATE BOOM BOOM BOOM ROTATE CR7A JP1 (REMOVE FOR CE VERSION)
LEVEL
30
87 DP1
RED
TS12 TS10 TS11 TS13 TS9 TS7 TS8
20K
DOWN
1 A
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
2 B
RED/BLK-R6
3 FWD C
TS1
ORG/RED-16
DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
5 L TS15 ENABLE
BP1 STEER
TP45
30 CR7B ROTARY RED
ORG/BLK-R6
87
85
3
T1 FLOW + TP27 TP37 TP36 TP41 ENABLE
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED - 3
BLU/WHT - 3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT #12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
RED
TB41
BRAKE
RELEASE 30
5
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
GRN/WHT#19 TB48 TB13

GRN/WHT #19 TB19
BLK-7
BRN-2
ORG/RED - 3
TB18 TB37
WHT-7
TB17 TB6
CR9
TB36
WHT/RED #6
6
BLU/BLK #37
BLU #36
GRN/WHT
GRN/BLK #18
WHT/RED #6
RED #27
GRN #17
RED/WHT #48
BLU/BLK #11
BLU #10
BLK/WHT # 8
BLK #7
ORG
WHT/BLK #5
RED/BLK #2
RED #1
WHT #4
13
TB14 22 *SWITCH SHOWN
TB15 LS3*
PLATFORM LEVEL CUTOUT WITH BOOM ROTATED
(CE VERSION ONLY) PAST EITHER
14 21 NON-STEER WHEEL.
30 86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B 87 87 CR10A 85 7
RED
GRN/WHT
85
WHT #40
BRN-7
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3 13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
PRESSURE SWITCH PS1

BRAKE RELEASE
BRAKE RELEASE N.O.

STEER LEFT
BRAKE RELEASE N.C.
TRAVEL ALARM
BRAKE RELEASE
LIMIT SWITCH
DRIVE ENABLE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT
PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN JIB BOOM UP
ROTATE LEFT/
PLATFORM
JIB BOOM DOWN
ROTATE RIGHT/
PLATFORM
EXTEND
PRIMARY BOOM
UP
PRIMARY BOOM
COIL PR2
LIFT PUMP RELAY
UP
SECONDARY BOOM
RETRACT
PRIMARY BOOM
VALVE
PROPORTIONAL
RELAY CR10B
DOWN CUTOUT
PLATFORM LEVEL
DOWN
PLATFORM LEVEL
DOWN
PRIMARY BOOM
UP RELAY CR10A
PLATFORM LEVEL
UP
PLATFORM LEVEL
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
TURNTABLE
DOWN
SECONDARY BOOM
(OPTION)
DESCENT ALARM

Electrical Schematic, Z-45/25J


ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
TS4
RPM
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3 TS2
TS6
BLK/RED-9
10 A P1 FOOTSWITCH
TB22 +
CB1 A1
GROUND TILT
ALARM RED
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4 TS56 TS52 TS54
F4
RED PISM6
10A
ORG/RED
22 (SEC.) RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
DIODE RETURN
LEFT 87 START RELAY
BRN
BRN
BOX BLU-ISM2
RED/BLK-R5
21 2 TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
GRN
BLK-6
(NOT USED)
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
9 IGNITION ON
13 30 WHT
500A AP1 F1 CR11 85 30
200A 2
+24V DC CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
+12V DC
86
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT BATT WHT

RIGHT VR1 ALT.
(12V DC)
+
+ + BLU
BLK
AP2
WHT-BATT
BLK
+
- -
BRN
AC POWER
CR16 (12V DC)
BLK
+
-
ORG GEN NEG 30

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
TILT SENSOR
PRESSURE SWITCH
OIL
SWITCH
TEMPERATURE
WATER
SOLENOID
ENGINE RUN
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY
RELAY CR11
STARTER
RELAY CR15
GLOW PLUG
REGULATOR
12V DC VOLTAGE
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:


RED/WHT-29
1
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24 WHT-24
ORG/RED-42
WHT-24 RED
2
TURNTABLE PLATFORM JIB BOOM
BLU/WHT-12
ORG/RED-42 ROTATE CR7A JP1 (REMOVE FOR CE VERSION)
ROTATE BOOM BOOM BOOM LEVEL
30
87a DP1
RED
20K
DOWN
1 A
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
2 B
RED/BLK-R6
ORG/RED-16
3 FWD C
TS1 DRIVE
4 REV R
L R DRIVE 30 CR6 86
PUMP
AUXILIARY
TS15
RED
TP45 BP1
5
STEER
L
ENABLE
85
3
30 ROTARY RED 87
CR7B ORG/BLK-R6
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
TS62 TS60 TS61 TS63 TS59 TS57 TS58 RELEASE 30
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
(CE VERSION ONLY) LIMIT
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40
+
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.



ORG/RED
WHT/RED-32
L4
1 2 3 4 WHT-30
WHT/BLK-31
RED-FS
1 2 3 4 5 6 7 8 9 10 11 12 WHT-FS
30 87 TP26
RED L7 CR17
BRN

85
BLK-2 BLK-26 BLK-FS
2 RED L1
TP22 TP26
WHT-FS
RED
TP24 WHT-24
ORG/RED-42
RED
TS4
RPM
P3 RED
ORG/RED-42
RED/WHT-3
HORN L3 TS2
TS6
BLK/RED-9
10 A P1 FOOTSWITCH
TB22 +
CB1 A1
GROUND TILT
ALARM RED
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
F5 21
LS4 TS56 TS52 TS54
F4
RED PISM6
10A
ORG/RED
22 (SEC.) RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200 A 30
86
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
DIODE RETURN
LEFT 87 START RELAY
BRN
BRN
BOX BLU-ISM2
RED/BLK-R5
21 2 TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
FORWARD
LS2
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
GRN
BLK-6
(NOT USED)
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
2
9
6
14
10
11
16
17
20
5
1
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
9 IGNITION ON
13 30 WHT
500A AP1 F1 CR11 85 30
200A 2
+24V DC CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
+12V DC
86
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT BATT WHT

RIGHT VR1 ALT.
(12V DC)
+
+ + BLU
BLK
AP2
WHT-BATT
BLK
+
- -
BRN
AC POWER
CR16 (12V DC)
BLK
+
-
ORG GEN NEG 30

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
TILT SENSOR
PRESSURE SWITCH
OIL
SWITCH
TEMPERATURE
WATER
SOLENOID
ENGINE RUN
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY
RELAY CR11
STARTER
RELAY CR15
GLOW PLUG
REGULATOR
12V DC VOLTAGE
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:


RED/WHT-29 RED/WHT-29
1
WHT/RED-32 WHT/RED-32
WHT-30 WHT-30
WHT/BLK-31 WHT/BLK-31
WHT-24 WHT-24 WHT-24
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
SECONDARY PRIMARY PRIMARY PLATFORM 2
ORG/RED-42 BOOM ROTATE CR7A
ROTATE BOOM BOOM LEVEL FWD 3
30 JP1 (REMOVE FOR CE VERSION)
87a REV 4
RED
TS12 TS10 TS11 TS13 TS9 TS7 TS8 ORG/BLK-R6
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
LOW
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN L3 TS2
KS1
BLK/RED-9
P1 PLUGS
RED-20 FAULT LED START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
TP39
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
BLU/RED-1
TB39
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
BLU/RED-39
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
FAULT LED
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
+
+ + BLU
BLK
AP2
PUMP 87 85 STARTER
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
RPM RELAY CR14

TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:


1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
LOW
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN TS2
KS1
BLK/RED-9
P1 PLUGS
RED-20 START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
1
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
3 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
+
-
2 RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 E2 E1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
+
+ + BLU
BLK
AP2
PUMP 87 85 STARTER
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
RPM SOLENOID
TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:


1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:



1 TP22
P2
BLK-26
FS1
BLK-(FS)
RED-(FS)
RED/WHT-29
LOAD
WHT-(FS) WHT/RED-32
TP26 C SENSOR
BOX
BLK-26 LOAD B+
GND 8
TP24 WHT/BLK-31
ORG-LOAD
FS1
P2 RED-(FS) TP25
BLK-2 BLK BLK-(FS)
RED
ORG/RED-42
RED
LOW
P3 RED
ORG/RED-42
RED/WHT-3
TS6 RPM HIGH RPM
HORN TS2
KS1
BLK/RED-9
P1 PLUGS
RED-20 START TS4
TB22 +
CB1 TILT RPM
GROUND
10A ALARM
A1 RED
3
TP32
TP30
TP29
TP31
TP34 TP33 TP35
BLK/RED-3
RED/BLK-1
ORG/RED-1
RED/WHT-3
WHT-2
BLK-1
BLK/WHT-1
BLK/RED-1
WHT-1
WHT/BLK-1
WHT/RED-1
RED/WHT-1
RED
TB29
TB31
TB32
TB30

4 TB3
TB42
WHT-3
RED/
BLU/WHT-12
ORG/RED-R2
RED
WHT-30
WHT/BLK-31
WHT/RED-32
RED/WHT-29
BLU/WHT-12
ORG/RED-42
ORG/RED-42
ORG/RED
ORG/RED-42
21
F4
ORG/RED
(SEC.)
RED PISM6
10A 22 RPM
START
ENGINE
PLUGS
GLOW
500 A AP2 48V DC 30
86
BLK-8
CR2 LOW HIGH
PR1 86 TB23
+48V DC
85
INDICATOR LED L2
CONTROLLER FAULT
87
+
5
COIL-PR1
CR5
F2 85 TB50 TB28
200A 86 30
BLK-22
RED-6
RED 20
RED/BLK-28
BLK-ISM1
+
85 1
-
START RELAY
DIODE RETURN
LEFT 87
BRN
BRN
BOX 21 BLU-ISM2 2
RED/BLK-R5
TACH. INPUT
INTERLOCK
+48V INPUT
+
TB9
-
LS2
FORWARD
POT. LOW
REVERSE
BLK-33
BLK/WHT-34
POT. HI
4
BLK-6
(NOT USED)
GRN
BLK

HM TB21
+ 5 GROUND
BLK/RED-9
RED/WHT-23
RED/WHT-23
15 A
-
+
-
RED-J10 (12GA)
6 BATTERY
1
10
11
14
16
17
20
TB49
WHT-21
CB3 WHT-23
RED-7

F3 24V DC
13 30 WHT
500 A AP1 F1 86 CR11 85 30
+24V DC 200A CR12
BLK
14
86 87 WHT-J4 86
BLK-7
+
FB 87 85
RED
WHT
30 85 CR14
(12V DC) 30 CR16
WHT
BRN
BRN
85 CR15
+
86
86
+12V DC
87
WHT
RED
YEL
LEFT A2 A2 F2 F1 86
30 BLU 87 GRN/BLK
BLK/RED
BRN
BRN
BRN
BRN
BRN
BLK/WHT
MOTOR 86
+
-
RIGHT WHT
RIGHT VR1 ALT. BATT
7 BOX F2 F1 A1 A1 MOTOR CR4 - (12V DC)
+
+ + BLU
BLK
AP2
PUMP 87 85 STARTER
WHT-BATT
BLK
+
- -
BRN
AC POWER (12V)
BLK
+
-
ORG GEN NEG 30 CR16

BRN
GROUND ENGINE
(GND)
ORG GEN POS GROUND
HORN
87 (GND)
AP1 BRN
8
RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
BLK
HORN RELAY
RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY
RELAY PR1
CONTACTOR
MOTOR MAIN
RELAY CR5
BRAKE RELEASE
BOX GROUND
BASE CONTROL
RPM SOLENOID
RPM RELAY CR14

ALTERNATOR
48V DC
OPTION
BEACON
FLASHING
12V DC ALERNATOR
TILT SENSOR
SWITCH
PRESSURE
OIL
SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID
RELAY CR13
RPM CUTOUT
FIELD RELAY CR16

ALTERNATOR
PLUGS
GLOW
LIFT PUMP
AUXILIARY
STARTER RELAY CR11
RELAY CR15
GLOW PLUG
REGULATOR
VOLTAGE
12V DC
CHARGER
48V DC
2 GA
CHASSIS
GROUND
NOTES:


1
WHT-30 WHT-30
ORG/RED-42
RED
DP1
WHT-24 20K
2
1
BLU/WHT-12
87a REV 4
RED
5
DOWN
6
UP
DOWN
LEFT
RIGHT
DOWN
LEFT
DOWN
RIGHT
UP
UP
RETRACT
EXTEND
UP
LIFT
RED
7
RED/BLK-R6
ORG/RED-16
8
TS1 DRIVE TS15
9
L R
DRIVE 30 CR6 86
PUMP
AUXILIARY
RED
TP45 BP1 STEER
10 ENABLE
85
3
30 ROTARY RED 87
CR7B
GRN/BLK-3
GRN-3
87 BLK/RED
TP16
TP12
CONTROL F LED L1
BLU/BLK-3
BLU-3
BLK/WHT-3
BLK-3
RED
BLU-1
BLU/BLK-1
BRN
WHT/BLK-3
RED - 1
RED/BLK-3
RED-3
ORG/BLK-3
ORG-3
WHT-3
ORG/BLK-1
CR7A BCI
MANIFOLD
JIB
E
86 86
TP19
TP13
BRN
85 CR7B 85
TP6
GROUND
BLU/RED-3
BLU/WHT-3
RED
GROUND
CONTROL BOX
PLATFORM
WHT-3
GRN/
WHT-1
GRN/
4
BLU/WHT-12
TB12
RED TS51
AUX
TS55 FUNCTION ON
ENABLE RED
WHT/RED-3
JIB BOOM
ROTATE
5
RED
TB41
BRAKE
RED
JACK CR5
DOWN
DOWN
DOWN
DOWN
UP
EXTEND
UP
LEFT
LEFT
RIGHT
UP
UP
RETRACT
RIGHT
J1 87
TB45
PS1
TB27
TB19
BLK-7
BRN-2
ORG/RED-3
TB18 TB37
WHT-7
TB17 TB6
CR9
WHT/RED-6
TB36 6
BLU/BLK-37
BLU-36
GRN/WHT
GRN/BLK-18
WHT/RED-6
RED-27
GRN-17
RED/WHT-48
BLU/BLK-11
BLU-10
BLK/WHT-8
BLK-7
ORG
WHT/BLK-5
RED/BLK-2
RED-1
WHT-4
13
TB14 22
TB15 LS3 DRIVE
3
30
14 21 SWITCH
86
RED-7
86 86 CR3
30 30 87a 87 85
CR10B
87a 87a
CR10A 85
7
RED
GRN/WHT
85
BRN-7
WHT-40 +
+
ORG/BLK #15
ORG #14
A2 TB16
A3
13
LS2
FUNCTION 14
MANIFOLD
MANIFOLD
(GND) GROUND
8
PRESSURE SWITCH PS1

BRAKE RELEASE
N.O. COIL
BRAKE RELEASE
STEER LEFT COIL
N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)

BRAKE RELEASE
RELAY COIL CR3
AUXILIARY CONTROL
STEER RIGHT COIL

PUMP RELAY COIL PR3
AUXILIARY LIFT
BRN
JIB UP
ROTATE LEFT/
PLATFORM
JIB DOWN
ROTATE RIGHT/
PLATFORM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RELAY COIL PR2

LIFT PUMP
UP COIL
SECONDARY BOOM
RETRACT COIL
PRIMARY BOOM
CONTROL COIL
FLOW
RELAY COIL CR10B
CUTOUT DOWN
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
DOWN COIL
PRIMARY BOOM
RELAY COIL CR10A

CUTOUT UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
DOWN COIL
SECONDARY BOOM
OPTION (A3)
ALARM
DESCENT
NOTES:



1 C7P-1 P22BAT BK
P2
C9P-1 BK BK-(FS)
FS1
RD-(FS) C9P-3 LOAD
SENSOR
P25BAT BK C29JSH RD/WH
P26BAT MODULE
WH-(FS) C9P-2 C
P24BAT WH C32JSL WH/RD
WH-LOAD
BK-26 LOAD B+ GND 8 C30FWD WH
OR-LOAD
BRN
C31REV WH/BK
LOAD SENSOR OPTION LOAD
C40LS OR
CELL
NOTES:
2 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
FS1
P22BAT C7P-1 C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH P24BAT WH
BK P26BAT
RD
R42BAT OR/RD
C7B-1
RD
RD TS6 TS2
KS1 PLATFORM HIGH LOW FOOT SWITCH
P1 GLOW ENGINE
P20BAT RD P3 RPM RPM HIGH RPM
+ PLUGS START
TB22 HORN TILT
CB1 TS4
ALARM RPM
10 A GROUND
C1P-4
C1P-5
C1P-6
C1P-3
A1
C2P-2
C3P-9
C7P-2
C1P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
3
C40LS OR
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
C33STR BK
C35HRPM BK/RD
C34SA BK/WH
C9HRN BK/RD
P23SWBAT WH
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
P20BAT RD
C1B-4
C1B-5
C1B-6
C1B-3
C2B-2
C1B-8
C1B-7
C1B-9
C3B-9
C7B-2
C1B-2
C3B-3
C2B-4
4
C7B-4
C6B-30
C6B-31
C6B-32
C6B-29
OR TB40 OR P20BAT RD
CR5
C12DRE BL/WH
C6B-22 TB42 RD
WH
WH/BK
WH/RD
RD/WH
OR/RD
OR/RD
OR/RD
F5
OR/RD
F4
OR/RD
10A TS56 TS52 TS54
C6B-12
C6B-24
500 A
C6B-20 RD
AP2 48V DC C6B-40 OR 30 RPM
START
ENGINE
PLUGS
GLOW
CR2 86
LOW HIGH
5 PR1 86 TB23
INDICATOR LED L2
CONTROLLER FAULT
+48V DC
85
C5B-1 P20BAT RD
BK 87
WH
RD/BK
BK
BK/RD
+
COIL-PR1
CR5
BL/WH
F2 85
200 A 30 TB34 TB33 TB35

86
RD 20
MODULE
C10-3
C10-4
C10-1
C10-2
C6B-39 CR5 RD/BK

Genie 45 25J

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Genie 45 25J

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Service Manual

Refer to inside cover for additional serial number information

Important Serial Number Information

Contact Us: Copyright © 1999 by Genie Industries

http://www.genieindustries.com 106488 Rev B June 2005

"Genie" and "Z" are registered trademarks of

Printed on recycled paper

ii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy iii

This page intentionally left blank.

iv Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Do Not Perform Maintenance

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy v

Personal Safety Be sure to wear protective eye wear and

vi Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy vii

Section 3 Rev Scheduled Maintenance Procedures, continued

viii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy ix

Section 4 Rev Repair Procedures

x Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 4 Rev Repair Procedures, continued

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy xi

Section 5 Rev Fault Codes

Section 6 Rev Schematics

xii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 6 Rev Schematics, continued

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy xiii

Section 6 Rev Schematics, continued

xiv Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 6 Rev Schematics, continued

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy xv

Section 6 Rev Schematics, continued

xvi Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Section 6 Rev Schematics, continued

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy xvii

Section 6 Rev Schematics, continued

xviii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Tires and wheels Fuel tank 9 gallons

Tire size 9-14.5 LT Batteries

Tire ply rating Tread 8 Type 6V DC

Tire pressure 100 psi

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-1

Performance Specifications Boom function speeds, maximum

Turntable rotate, 359° 76 to 82 seconds

Platform rotate, 180°, Z-45/25 6 to 10 seconds

Platform rotate, 160°, Z-45/25J 6 to 10 seconds

2-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 106488

Hydraulic Specifications Function pump

Before serial number 20926 Type: Fixed displacement gear pump

Jib boom/platform rotate flow regulator 0.4 gpm

Part No. 106488 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-3

Manifold Component Machine Torque Specifications

Drive motor/brake mounting bolts, dry 110 ft-lbs

Solenoid valve, 2 position 3 way, 20V DC 17 to 21 Ω

Solenoid valve, 2 position 3 way, 20V DC 25 to 28 Ω

Solenoid valve, 2 position 2 way, 20V DC 22 to 26 Ω

Proportional solenoid valve, 24V DC 17 to 21 Ω