Genie Z45 - 25J PDF

Service Manual Part No.
110188
Rev B1
Refer to inside cover for additional serial number information May 2008
Bi-Energy Power
(from serial number 23236)
February 2006
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, Second Edition
maintenance information for the machine owner and (before serial number 23236) ............................ 106488
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 110188 Rev B February 2006

e-mail: [email protected] Third Edition, Second Printing
"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Introduction
INTRODUCTION
Serial Number Legend
Model: Z-45/25
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
Serial label
Redmond, WA 98052 (located under cover)
USA
Serial number
stamped on chassis
PN - 77055
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy iii

February 2006
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iv Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator’s Manual will
result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy v

Section 1 • Safety Rules February 2006
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.
vi Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

May 2008
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

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

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

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
B Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 7
A-2 Perform Function Tests ................................................................................ 3 - 7
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy vii

February 2006
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A-3 Check the Generator Belts and Pulleys ........................................................ 3 - 8
A-4 Perform 30 Day Service ............................................................................... 3 - 9
A-5 Perform Engine Maintenance ..................................................................... 3 - 10
A-6 Perform Engine Maintenance, Z482-E ........................................................ 3 - 10
A-7 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11
A-9 Perform Engine Maintenance, Z482-E ........................................................ 3 - 12
B Checklist B Procedures
B-1 Check the Radiator ..................................................................................... 3 - 13
B-2 Check the Exhaust System ....................................................................... 3 - 13
B-3 Check the Batteries .................................................................................... 3 - 14
B-4 Inspect the Electrical Wiring ....................................................................... 3 - 15
B-5 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 16
B-6 Confirm the Proper Brake Configuration ...................................................... 3 - 16
B-7 Check the Oil Level in the Drive Hubs ........................................................ 3 - 17
B-8 Check and Adjust the Engine RPM ............................................................ 3 - 18
B-9 Test the Ground Control Override ............................................................... 3 - 19
B-10 Test the Platform Self-leveling ................................................................... 3 - 20
B-11 Test the Engine Idle Select ........................................................................ 3 - 20
B-12 Test the Drive Brakes ................................................................................ 3 - 21
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 21
viii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22
B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 22
B-16 Check the Electrical Contactors ................................................................. 3 - 23
B-17 Perform Hydraulic Oil Analysis ................................................................... 3 - 24
B-18 Perform Engine Maintenance ..................................................................... 3 - 24
B Checklist C Procedures
C-1 Perform Engine Maintenance ..................................................................... 3 - 25
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 25
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 26
C-4 Perform Engine Maintenance ..................................................................... 3 - 28
B Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 29
D-2 Check the Free-wheel Configuration ........................................................... 3 - 29
D-3 Replace the Drive Hub Oil .......................................................................... 3 - 30
D-4 Replace the Hydraulic Tank Return Filter ................................................... 3 - 31
D-5 Calibrate the Platform Overload System (if equipped) ................................ 3 - 32
D-6 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 34
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 35
D-8 Perform Engine Maintenance, Z482-E ........................................................ 3 - 37
D-9 Perform Engine Maintenance, Z482-E2B .................................................... 3 - 37
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 38
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 39
E-3 Perform Engine Maintenance, Z482-E ........................................................ 3 - 41
E-4 Perform Engine Maintenance, Z482-E2B .................................................... 3 - 41
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy ix

February 2006
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
A 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
B Kubota Z482-E and Z482-E2B Engine
6-1 Timing Adjustment ..................................................................................... 4 - 27
6-2 RPM Adjustment ........................................................................................ 4 - 27
6-3 Engine Drive Pulley .................................................................................... 4 - 27
x Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

B 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
A Manifolds
9-1 Function Manifold Components .................................................................. 4 - 34
9-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36
9-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 37
9-4 Turntable Rotation Manifold Components ................................................... 4 - 38
9-5 Valve Coils ................................................................................................. 4 - 39
B Turntable Rotation Components
10-1 Turntable Rotation Assembly ..................................................................... 4 - 41
A Motor Controller
11-1 Motor Controller .......................................................................................... 4 - 43
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
A Fault Code Chart .................................................................................................... 5 - 3
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy xi

February 2006
TABLE OF CONTENTS
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
A Power Cable Diagram ............................................................................................. 6 - 5
A Engine Panel Diagram ........................................................................................... 6 - 6
A Electrical Schematic, Z-45/25, ANSI and CSA Models .......................................... 6 - 7
A Electrical Schematic, Z-45/25, CE Models ............................................................. 6 - 9
B Electrical Schematic, Z-45/25J, ANSI and CSA Models ...................................... 6 - 11
B Electrical Schematic, Z-45/25J, CE Models ......................................................... 6 - 13
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
ANSI and CSA Models ........................................................................................ 6 - 15
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 17
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 18
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 21
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 22
A Platform Control Box Wiring Diagram, Z-45/25 ..................................................... 6 - 23
A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option) .................... 6 - 24
B Platform Control Box Wiring Diagram, Z-45/25J ................................................... 6 - 25
A Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option) .................. 6 - 26
B Hydraulic Schematic ............................................................................................ 6 - 27
xii Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

May 2008 Section 2 • Specifications
REV C
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 9 @ 5/8 -18
(including tank) 41.6 liters
Lug nut torque 125 ft-lbs Drive hubs (refer to tag on drive hub to determine type)
169.5 Nm EW1 type 17 fl oz
0.51 liter
Tire size 9-14.5 LT
W1 type 23 fl oz
Tire ply rating Tread 8 0.68 liter
Sidewall 6 Drive hub oil type: EP 80-90W gear oil
API service classification GL5
Tire contact area 43.5 sq in
280 sq cm Batteries
Overall tire diameter 28 in Type 6V DC

71 cm
Quantity 8
Capacity 350 AH
For operational specifications, refer to the
Operator's Manual. Reserve capacity @ 25A rate 750 minutes
Continuous improvement of our products is a

Genie policy. Product specifications are subject
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-1

Section 2 • Specifications May 2008
SPECIFICATIONS REV C
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds, maximum
Jib boom up, Z-45/25J 32 to 40 seconds
Drive speed, stowed 3 mph
4.8 km/h Jib boom down, Z-45/25J 22 to 28 seconds
40 ft/9 sec Primary boom up 31 to 35 seconds
12.2 m/9 sec
Primary boom down 27 to 31 seconds
Drive speed, boom 0.6 mph
raised or extended 1 km/h Secondary boom up 38 to 42 seconds
40 ft/45 sec
12.2 m/45 sec Secondary boom down 32 to 36 seconds
Braking distance, maximum Primary boom extend 14 to 18 seconds
High range on paved surface 5 to 7 ft Primary boom retract 17 to 21 seconds
1.5 to 2 m
Turntable rotate, 355° 99 to 105 seconds
Gradeability See Operator's Manual 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. 110188

REV C SPECIFICATIONS
Hydraulic Specifications Function pump
Hydraulic Oil Specifications Type: Fixed displacement gear pump
Hydraulic oil type Chevron Rykon MV equivalent Displacement 0.183 cu in

Approximate SAE grade 5W-20 3 cc
Viscosity index rating 200 Flow rate 2.1 gpm
Cleanliness level, minimum 15/13 7.9 L/min
Water content, maximum 200 ppm Hydraulic tank 10 micron with

return filter 25 psi / 1.7 bar bypass
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Function manifold
Genie specifications require hydraulic oils which are System relief valve pressure 3200 psi
designed to give maximum protection to hydraulic 220.6 bar
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index Secondary boom down 2000 psi
rating greater than 140. They should provide excellent relief valve pressure 138 bar
antiwear, oxidation, corrosion inhibition, seal
conditioning, and foam and aeration suppression Platform level flow regulator 0.6 gpm
properties. 2.27 L/min
Optional fluids Jib boom/platform rotate flow regulator 0.4 gpm

1.5 L/min
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32 Auxiliary pump
BP Biohyd SE-S
Type: fixed displacement gear pump
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822 Displacement 0.5 gpm
1.9 L/min
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulic

oil when in ambient temperatures
consistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.Function Continuous improvement of our products is a
pump Genie policy. Product specifications are subject

Manifold Component Machine Torque Specifications

Specifications
Platform rotator
Plug torque 3 /4 -10 center bolt, GR 8 380 ft-lbs
515 Nm
SAE No. 2 36 in-lbs / 4 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
SAE No. 4 10 ft-lbs / 13 Nm
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs
SAE No. 10 41 ft-lbs / 55 Nm 244 Nm
SAE No. 12 56 ft-lbs / 76 Nm Drive motor/brake mounting bolts, dry 110 ft-lbs
149 Nm
Drive motor/brake mounting bolts, lubricated 80 ft-lbs

Valve Coil Resistance Specification 108 Nm
Description Specification Drive motor and hubs
Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω Drive hub mounting bolts, lubricated 180 ft-lbs
(schematic items B, C, D, E, F and H) 244 Nm
Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω Drive motor mounting bolts, lubricated 55 ft-lbs
(schematic items A, K, S and AA) 75 Nm
Proportional solenoid valve, 24V DC 17 to 21 Ω

(schematic item I)


Kubota Z482-E Engine Injection system

Kubota Z482-E2B Engine Injection pump make Bosch MD
Displacement 29.23 cu in Injection timing 21° BTDC

0.48 liters
Injection pump pressure 1991 psi
Number of cylinders 2 137 bar
Bore and stroke 2.64 x 2.68 inches Fuel requirement

67 x 68 mm
For fuel requirements, refer to the engine Operator's
Horsepower, gross intermittent 12.5 @ 3600 rpm Manual on your machine.
9.3 kW
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
Lubrication system
Units ship with 10W-40.

Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator's Manual on your machine.


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


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 / 25 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm
-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm
-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm
-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm

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 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-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
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
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 ft - 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

February 2006 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

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

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by 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 disconnected from the
machine

Section 3 • Scheduled Maintenance Procedures February 2006
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-Deliver
Pre-Deliveryy 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. 110188 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 , Z482-E
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 Electrical contactors
performed. A-9 Perform engine B-17 Hydraulic oil analysis
maintenance, Z482-E Perform every 400 hours:
Daily or 8 hour
Inspection: A Perform every 200 hours: B-18 Perform engine
A-10 Perform engine maintenance
Quarterly or 250 hour
Inspection: A+B maintenance
Six Month or 500 hour Checklist C - Rev B Y N R

Inspection: A+B+C C-1 Perform engine
maintenance
Annual or 1000 hours
Inspection: A+B+C+D C-2 Grease platform
overload (if equipped)
2 Year or 2000 hour
Inspection: A+B+C+D+E C-3 Test platform
overload (if equipped)
· Place a check in the appropriate box Perform every 800 hours:
after each inspection procedure is
C-4 Perform engine
completed.
maintenance
· 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 Free-wheel
Date configuration
D-3 Drive hub oil
Hour meter D-4 Hydraulic return filter
D-5 Calibrate platform
Machine owner overload system
(if equipped)
Inspected by (print)
D-6 Turntable bearing bolts
Inspector signature D-7 Turntable bearing wear
Inspector title D-8 Perform engine
maintenance, Z482-E
Inspector company
Instructions D-9 Perform engine
· Make copies of this page to use for maintenance,
each inspection. Z482-E2B
· Select the appropriate checklist(s) for
the type of inspection to be Checklist E - Rev B Y N R
performed. E-1 Hydraulic oil
Daily or 8 hour E-2 Wheel bearings
Inspection: A E-3 Perform engine
Quarterly or 250 hour maintenance, Z482-E
Inspection: A+B E-4 Perform engine
maintenance,
Six Month or 500 hour
Z482-E2B
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 Operator's Manual on your
Complete information to perform this procedure is machine.
available in the 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-4 Replace the Hydraulic Tank Return
Filter
a · D-6 Check the Turnable Rotation Bearing
Bolts
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,
Z482-E Engine
Engine specifications require that

this procedure be performed every Engine specifications require that
50 hours. this procedure be performed
Proper engine maintenance, following the engine every 75 hours.
manufacturer's maintenance schedule, is essential Proper engine maintenance, following the engine
to good engine performance and service life. manufacturer's maintenance schedule, is essential
Failure to perform the maintenance procedures to good engine performance and service life.
can lead to poor engine performance and Failure to perform the maintenance procedures
component damage. can lead to poor engine performance and
Required maintenance procedures and additional component damage.
engine information are available in the Required maintenance procedures and additional
Kubota Z482-E Operator's Manual engine information are available in the
(Kubota part number 16676-89167). Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
To access the engine:
1 Remove the engine pivot plate latch retainer. To access the engine:
2 Open the engine pivot plate latch and swing the 1 Remove the engine pivot plate latch retainer.
engine out away from the machine. 2 Open the engine pivot plate latch and swing the
engine out away from the machine.
3 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

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

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 Before serial number 27001: Locate the Kubota Z482-E Operator's Manual
grease fitting on the front turntable cover. (Kubota part number 16676-89167).
After serial number 27000: Locate the grease Kubota Z482-E Operator's Manual
fitting near the ground control box. Genie part number 52958
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat To access the engine:
this step until the entire bearing has been
1 Remove the engine pivot plate latch retainer.
greased.
2 Open the engine pivot plate latch and swing the
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 11

A-9 A-10
Perform Engine Maintenance, Perform Engine Maintenance
Z482-E Engine

Engine specifications require that this procedure be performed
this procedure be performed every 200 hours.
every 150 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 16676-89167).

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.

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 Check each battery pack and verify that the
all rings, watches and other batteries are wired correctly. Refer to the
jewelry. Battery Connection Diagram decal on the
machine.
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 5 Open the ground controls side turntable cover.

Inspect the Electrical Wiring 6 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Inside of the ground control box
· Hydraulic manifold wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 7 Inspect for a liberal coating of dielectric grease
performance. Failure to find and replace burnt, at the following location:
chafed, corroded or pinched wires could result in · All wire harness connectors to the ground
unsafe operating conditions and may cause control box
component damage.
8 Raise the secondary boom until the mid-pivot is
Electrocution hazard. Contact approximately 10 feet / 3 m off the ground.
9 Remove the center turntable cover.
in death or serious injury. Remove
all rings, watches and other 10 Inspect the turntable center area for burnt,
jewelry. chafed and pinched cables.
1 Open the engine side turntable cover. 11 Install the center turntable cover.
2 Remove the safety pin from the engine pivot 12 Lower the boom to the stowed position and turn
plate latch. the machine off.
The engine pivot plate latch is 13 Inspect the following areas for burnt, chafed,
located under the engine turntable corroded, pinched and loose wires:
pivot plate at the counterweight
end of the machine. · Cable track on the primary, jib and
secondary booms
· Jib boom to platform cable harness
engine pivot plate out and away from the
machine. · Inside of the platform control box
4 Inspect the following areas for burnt, chafed, 14 Inspect for a liberal coating of dielectric grease
corroded and loose wires: at the following location:
· Power units · All wire harness connectors to the platform

control box
· Inside of the ground control box
· Generator and power units
· Engine wiring harness

B-5 B-6
Check the Tires, Wheels and Confirm the Proper
Lug Nut Torque Brake Configuration
Maintaining the tires and wheels in good Proper brake configuration is essential to safe
condition, including proper wheel fastener torque, operation and good machine performance.
is essential to safe operation and good Hydraulically-released, spring-applied individual
performance. Tire and/or wheel failure could result wheel brakes can appear to operate normally when
in a machine tip-over. Component damage may they are actually not fully operational.
also result if problems are not discovered and
repaired in a timely fashion. 1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
Tip over hazard. The tires on this
machine are foam-filled and are brake disengaged position
essential to machine stability and
safe machine operation. Using an
air-filled tire on this machine can
compromise machine stability and
brake engaged position
will cause the machine to tip over.
The tires on this machine are
foam-filled and do not need air
added to them.
1 Check the tire surface and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.

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. 2 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.
3 Turn the key switch to platform controls.
Result: The platform should remain level at
4 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.
5 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine should change to low idle.
6 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
7 Press down the foot switch.
Result: The engine should change to high idle.

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-6, 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
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 Check the Electrical Contactors
moment and then release it.
Maintaining the electrical contactors in good
5 Turn the key switch to platform control. condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor
Result: The flashing beacon should be on
could result in an unsafe working condition and
and flashing.
component damage.
6 Press down the foot switch. Activate the
1 Remove the drive chassis cover from the
primary boom toggle switch in the down
non-steer end of the machine and locate the
position, hold for a moment and then release it.
electrical contactors mounted on the
Result: The descent alarm should sound when component mounting panel.
the control handle is held down.
2 Visually inspect the contact points of each
7 Press down the foot switch. Activate the contactor for the following items:
secondary boom toggle switch in the down
· Excessive burns
position, hold for a moment and then release it.
· Excessive arcs
the control handle is held down. · Excessive pitting
Electrocution hazard. Contact
8 Z-45/25J: Press down the foot switch. Activate
the jib boom toggle switch in the down position,
in death or serious injury. Remove
hold for a moment and then release it.
all rings, watches and other
Result: The descent alarm should sound when jewelry.
Replace the contactors if any
9 Press down the foot switch. Move the drive damage is found.
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
Perform Hydraulic Oil Analysis Perform Engine Maintenance
Replacement or testing of the hydraulic oil is Engine specifications require that

essential for good machine performance and this procedure be performed
service life. Dirty oil and suction strainers may every 400 hours.
cause the machine to perform poorly and
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
Extremely dirty conditions may require oil changes
to good engine performance and service life.
to be performed more often.
Failure to perform the maintenance procedures
Before replacing the hydraulic oil, can lead to poor engine performance and
the oil may be tested by an oil component damage.
distributor for specific levels of
Required maintenance procedures and additional
contamination to verify that
engine information are available in the
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test. See E-1, Kubota Z482-E Operator's Manual
Test or Replace the Hydraulic Oil. Genie part number 52958


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

this procedure be performed
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.
can lead to poor engine performance and
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 16676-89167). 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

CHECKLIST C PROCEDURES REV B
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-5, Calibrate the
Platform Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.

REV B CHECKLIST C PROCEDURES
7 Carefully move the test weights to each 11 Lift the test weights off the platform floor using a
remaining location in the platform. suitable lifting device.
Result: The alarm should be sounding. Result: The platform overload indicator light and
The platform overload indicator light should be alarm should turn off at both the ground and
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-5, 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-5,
9 Turn the key switch to ground control. Calibrate the Platform Overload
System.
10 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.

CHECKLIST C PROCEDURES REV B
C-4
Perform Engine Maintenance

this procedure be performed
every 800 hours.
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.
engine information are available in the



REV B
Checklist D Procedures
D-1 D-2
Check the Primary Boom Check the Free-wheel
Wear Pads Configuration
Maintaining the boom wear pads in good condition Proper use of the free-wheel configuration is
is essential to safe machine operation. Wear pads essential to safe machine operation. The
are placed on boom tube surfaces to provide a low free-wheel configuration is used primarily for
friction, replaceable wear pad between moving towing. A machine configured to free-wheel without
parts. Improperly shimmed wear pads or continued operator knowledge could result in death or serious
use of extremely worn wear pads may result in injury and property damage.
component damage and unsafe operating
conditions. Collision hazard. Select a work
site that is firm and level.
1 Measure each wear pad. Replace the wear pad
Component damage hazard. If the
once it reaches the minimum allowable
machine must be towed, do not
thickness. If the wear pad is still within
exceed 2 mph / 3.2 km/h.
specification, shim as necessary to obtain
minimum clearance with zero binding. 1 Chock the steer wheels to prevent the machine
from rolling.
2 Extend and retract the primary boom through
the entire range of motion to check for tight 2 Center a lifting jack of ample capacity
spots that may cause binding or scraping of the (20,000 lbs / 10,000 kg) under the drive chassis
boom. between the non-steer tires.
Always maintain squareness 3 Lift the wheels off the ground and then place
between the outer and inner jack stands under the drive chassis for support.
boom tubes.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each non-steer
Primary boom wear wheel hub.
pad specifications New Minimum
3 /4 5/8 brake disengaged position

Top, bottom and side wear pads inch 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
brake engaged position
Top wear pads 3 /4

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

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

Result: Each non-steer wheel should rotate with Replace the Drive Hub Oil
minimum effort.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and Replacing the drive hub oil is essential for good
remove the jack stands. machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
Collision hazard. Failure to cause the machine to perform poorly and
engage the drive hubs could result continued use may cause component damage.
in death or serious injury and
property damage. 1 Select the drive hub to be serviced. Then drive
the machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
models with pipe plugs
a models with o-ring plugs

REV B CHECKLIST D PROCEDURES
3 Drive the machine to rotate the hub until one of D-4

the plugs is located on top and the other one is
at 90 degrees. Replace the Hydraulic Tank
4 Fill the hub with oil from the top hole until the oil
Return Filter
level is even with the bottom of the side plug
hole. Refer to Section 2, Specifications.
5 Models with pipe plugs: Apply pipe thread Replacement of the hydraulic tank return filter is
sealant to the plugs and install the plugs. essential for good machine performance and
Models with O-ring plugs: Install the plugs service life. A dirty or clogged filter may cause the
into the drive hub. machine to perform poorly and continued use may
cause component damage. Extremely dirty
6 Repeat steps 1 through 5 for the other drive conditions may require that the filter be replaced
hub. more often.

hot oil. Contact with hot oil may
cause severe burns.
1 Locate the hydraulic return filter next to the
hydraulic tank.
2 Place a suitable container under the hydraulic
filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of oil to the new oil filter
gasket.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls.
7 Activate any boom function and inspect the filter
and related components to be sure that there
are no leaks.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.

D-5 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.
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: 10 Turn the key switch to ground control.

5 Turn the key switch to platform control. 11 Test all machine functions from the ground
controls.
6 Lift the test weight off the platform floor using a
suitable lifting device. Result: All ground control functions should not
operate.
7 Place the test weight back onto the center of
the platform floor using a suitable lifting device. If the platform overload system is
not operating properly, repeat
Result: The alarm should be off. The platform steps 1 through 4.
overload indicator light should be off at both the
ground and platform controls.
indicator light and alarm turn off.
8 Add an additional 10 lb / 4.5 kg test weight to
the original test weight to overload the platform.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at both the ground and platform
controls.
alarm sounds.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.

D-6 2 Check to be sure that each turntable mounting

bolt is torqued in sequence to specification.
Check the Turntable Rotation Refer to Section 2, Specifications.
Bearing Bolts
18 1
9 11
6 7
Maintaining proper torque on the turntable bearing 16 13

bolts is essential to safe machine operation.
3 20
Improper bolt torque could result in an unsafe
operating condition and component damage. 19 4
1 Raise the primary boom and place a safety 14 15
chock on the lift cylinder rod. Carefully lower
the boom onto the lift cylinder safety chock. 8 5
12 10
Crushing hazard. Keep hands 2 17
away from cylinder and all moving Bolt torque sequence
parts when lowering the boom. (from serial number 23236 to 26999)
A lift cylinder safety chock is

available through Genie Service
Parts (Genie part number 33484). Counterweight
18 6 13
3 10
11 1
8 15
16 7
2 12
9 4
14 5 17
Bolt torque sequence
(after serial number 26999)

3 Lower the boom to the stowed position. D-7

4 Remove drive chassis covers from both the Inspect for Turntable Bearing
steer end and the non-steer end of the
machine.
Wear
5 Check to be sure that each bearing mounting
bolt under the drive chassis is torqued in
sequence to specification. Refer to Section 2,
Periodic inspection of turntable bearing wear is
Specifications.
essential to safe machine operation, good machine
performance and service life. Continued use of a
9 1 worn turntable bearing could create an unsafe
11
6 operating condition, resulting in death or serious
7
injury and component damage.
16 13 Perform this procedure with the
machine on a firm, level surface
3 4 and the boom in the stowed
position.
14 15 1 Grease the turntable bearing. See A-7, Grease
the Turntable Bearing and Rotate Gear.
8 5
12 10 2 Torque the turntable bearing bolts to
2 specification. See D-6, Check the Turntable
Bolt torque sequence Rotation Bearing Bolts.
(from serial number 23236)
3 Start the machine from the ground controls and
raise the primary and secondary booms to full
height. Do not extend the primary boom.

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-8 D-9
Perform Engine Maintenance, Perform Engine Maintenance,
Z482-E Engine Z482-E2B Engine
Engine specifications require that Engine specifications require that

this procedure be performed this procedure be performed
every 1000 hours or annually, every 1500 hours.
whichever comes first.
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 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 16676-89167).
Kubota Z482-E Operator's Manual Genie part number 52958

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

Checklist E Procedures REV B
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.
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.
Perform this procedure with the
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.
or spray.

REV B CHECKLIST E PROCEDURES
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.

CHECKLIST E PROCEDURES REV B
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.

REV B CHECKLIST E PROCEDURES
E-3 E-4
Perform Engine Maintenance, Perform Engine Maintenance,
Z482-E Engine Z482-E2B Engine
Engine specifications require that Engine specifications require that

this procedure be performed this procedure be performed
every 2000 hours or every two every 3000 hours or every two
years, whichever comes first. years, whichever comes first.
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 16676-89167). (Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual Kubota Z482-E Operator's Manual

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.


February 2006 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 Operator’s which, if not avoided, will result in
Manual on your machine. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of a
available and ready for use. potentially hazardous situation
Read each procedure completely and adhere which, if not avoided, could result
to the instructions. Attempting shortcuts may in death or serious injury.
produce hazardous conditions. With safety alert symbol—used to
indicate the presence of a
Unless otherwise specified, perform each
potentially hazardous situation
repair procedure with the machine in the
which, if not avoided, may cause
following configuration:
minor or moderate injury.
· Machine parked on a firm, level surface
Without safety alert symbol—used
· Boom in stowed position to indicate the presence of a
· Turntable rotated with the boom between potentially hazardous situation
the non-steer wheels which, if not avoided, may result in
· Turntable secured with the turntable property damage.
rotation lock Used to indicate operation or
· Key switch in the off position with the maintenance information.
key removed
Indicates that a specific result is expected after
· Wheels chocked performing a series of steps.
· All external AC power supply disconnected
Indicates that an incorrect result has occurred
from the machine after performing a series of steps.

Section 4 • Repair Procedures February 2006
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. Refer to Section 5, Fault Codes result in death or serious injury.
for a list of fault codes and additional information. Remove all rings, watches and
There are no adjustments needed on the drive other jewelry.
joystick controller. For further information or
assistance, consult the Genie Industries Service 1 Turn the key switch to platform control and pull
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
3 Disconnect the blk/red wire of the boom

function speed controller from the wht/red wire.
4 Connect the red (+) lead from an amp meter to
the blk/red wire. Connect the black (-) lead to
the wht/red wire.
5 Turn the boom function speed controller to the
CREEP position.
6 Set the threshold: With the boom in the stowed

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

controller specifications
Threshold 0.17 to 0.18A
Max-out 0.54 to 0.55A

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. Before serial number 24304:
How to Bleed the Slave Cylinder 2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
1 Raise the primary boom to a horizontal position. to collect any drainage. Secure the container to
2 Move the platform level switch up and down the boom.
through two platform leveling cycles to remove 3 Open the top bleed valve on the rotator, but do
any air that might be in the system. not remove it.
a
d c b
a top bleed valve

b bottom bleed valve
c container
d clear hose

PLATFORM COMPONENTS REV B
4 Move the function enable toggle switch to either 4 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch side and hold the platform rotate toggle switch
to the left position until the platform is fully to the left position until the platform is fully
rotated to the left. Continue holding the toggle rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed switch until air stops coming out of the bleed
valve. Close the bleed valve. screw. Close the bleed screw.
Crushing hazard. Keep clear of Crushing hazard. Keep clear of
the platform during rotation. the platform during rotation.
5 Connect the clear hose to the bottom bleed 5 Open the bottom bleed screw on the rotator, but
valve and open the valve. Do not remove the do not remove it.
bleed valve.
6 Move the function enable toggle switch to either hydraulic oil can penetrate and
side and hold the platform rotate toggle switch burn skin. Loosen hydraulic
to the right position until the platform is fully connections very slowly to allow
rotated to the right. Continue holding the toggle the oil pressure to dissipate
switch until air stops coming out of the bleed gradually. Do not allow oil to
valve. Close the bleed valve. squirt or spray.
Crushing hazard. Keep clear of 6 Move the function enable toggle switch to either
the platform during rotation. side and hold the platform rotate toggle switch
to the right position until the platform is fully
7 Remove the hose from the bleed valve and
rotated to the right. Continue holding the toggle
clean up any hydraulic oil that may have spilled.
switch until air stops coming out of the bleed
8 Rotate the platform fully in both directions and screw. Close the bleed screw.
inspect the bleed valves for leaks.
Crushing hazard. Keep clear of
After serial number 24303: the platform during rotation.
2 Place a suitable container underneath the 7 Clean up any hydraulic oil that may have
platform rotator. spilled.
3 Open the top bleed screw on the rotator, but do 8 Rotate the platform fully in both directions and
not remove it. inspect the bleed screws for leaks.

hydraulic oil can penetrate and
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.

REV A
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
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
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.
squirt or spray.

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

boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a suitable
lifting device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not properly
supported by the overhead crane.
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 of the
counterbalance valve manifold at the platform
When removing a hose assembly rotator. Cap the fittings on the manifold.
and/or hose end must be replaced Bodily injury hazard. Spraying
and then torqued to specification hydraulic oil can penetrate and
during installation. burn skin. Loosen hydraulic
Refer to Section 2, Hydraulic Hose connections very slowly to allow
and Fitting Torque Specifications. the oil pressure to dissipate
1 Locate the cables from the primary boom cable squirt or spray.
track to the platform control box. Number each
cable and its entry location at the platform 7 Tag, disconnect and plug the hydraulic hoses
control box. from the platform leveling master cylinder. Cap
the fittings on the cylinder.
2 Disconnect the cables from the platform control
box. Bodily injury hazard. Spraying
3 Pull all of the electrical cables out of the plastic burn skin. Loosen hydraulic
cable track. Do not pull out the hydraulic hoses. connections very slowly to allow
4 Raise the primary boom to a horizontal position. the oil pressure to dissipate
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 of the
counterbalance valve manifold at the platform
rotator. Cap the fittings on the manifold.
Bodily injury hazard. Spraying 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.
squirt or spray. Bodily injury hazard. Spraying
7 Tag and disconnect the hydraulic hoses from
the platform leveling slave cylinder at the union
and connect them together using a connector.
Connect the hoses from the cylinder together
using a connector.
squirt or spray.
from the platform leveling master cylinder. Cap
the fittings on the cylinder.
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
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.
Perform this procedure with the
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 to be platform mounting weldment.
removed.
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 Platform Leveling 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 4-2, 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 B
Kubota Z482-E and Z482-E2B 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 B
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 How to Remove
the Engine Drive Pulley.

REV B
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 B
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.
engine out away from the machine to access
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 B 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 B
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 other fasteners to specification. Refer
a white wires (#10 nuts) to 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 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.

REV B
Hydraulic Pumps
8-1 2 Remove the engine pivot plate latch retainer.
Auxiliary Pump 3 Open the engine pivot plate latch and swing the
How to Remove the Auxiliary 4 Tag, disconnect and plug the hydraulic hoses
Pump from the auxiliary pump.
during installation. Refer to
Section 2, Hydraulic Hose and
or spray.
Fitting Torque Specifications.
5 Remove the auxiliary pump mounting bolts.
1 Models with hydraulic tank shut-off valves:
Carefully remove the pump.
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
open closed

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

HYDRAULIC PUMPS REV B

Function Pump 5 Open the engine pivot plate latch and swing the
How to Remove the Function 6 Tag, disconnect and plug the hydraulic hoses
Pump from the pump.
during installation. Refer to
Section 2, Hydraulic Hose and
or spray.
Fitting Torque Specifications.
7 Remove the function pump mounting bolts.
1 Models with hydraulic tank shut-off valves:
Carefully remove the pump.
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
open closed

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

REV B

Manifolds REV A
9-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ....... A ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... B ........... Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... C ........... Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... D ........... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... E ........... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ....... F ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Shuttle valve ...................................... G ........... Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm
8 Solenoid valve, 3 position 4 way ....... H ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm
9 Proportional solenoid valve ............... I ............ Controls flow to functions ............................. 27 ft-lbs / 37 Nm
10 Pressure switch ................................. J ............ Brake circuit
11 Solenoid valve, 2 position 3 way ....... K ........... Primary boom extend ................................... 20 ft-lbs / 27 Nm
12 Flow regulator valve,
0.4 gpm / 1.5 L/min ............................ L ........... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
13 Needle valve ...................................... M .......... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar ......... N ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar ...... O ........... System relief ................................................ 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar ............... P ........... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... Q ........... Steer circuit
18 Orifice, 0.030 inch / 0.76 mm ............. R ........... Proportional valve circuit
19 Solenoid valve, 2 position 3 way ....... S ........... Brake circuit ................................................. 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm
(from serial number 22566 to 22628
and after serial number 23235)
(located under item S) ....................... T ........... Brake circuit
20 Orifice, 0.037 inch / 0.94 mm ............ U
21 Check valve, pilot operated ............... V ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar ......... W .......... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm

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

MANIFOLDS REV A
9-2 How to Adjust the Secondary

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

REV A MANIFOLDS
9-3
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to platform support.

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

MANIFOLDS REV A
9-4
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 ............ X ......... Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ......................... Y ......... Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve ......................... Z .......... Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm
1 2 3

REV A MANIFOLDS
9-5 How to Test a Coil Diode

Valve Coils Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
How to Test a Coil Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
A properly functioning coil provides an to a coil. Faulty diodes can fail to protect the
electromotive force which operates the solenoid electrical system, resulting in a tripped circuit
valve. Critical to normal operation is continuity breaker or component damage.
within the coil that provides this force field.
Electrocution hazard. Contact with electrically charged circuits could
electrically charged circuits could result in death or serious injury.
result in death or serious injury. Remove all rings, watches and
Remove all rings, watches and other jewelry.
other jewelry.
1 Test the coil for resistance. See How to Test a
1 Tag and disconnect the wiring from the coil to Coil.
be tested.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Valve Coil Resistance Specification
Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω

(schematic items B, C, D, E, F and H)
Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω

(schematic items A, K, S and AA)
Proportional solenoid valve, 24V DC 17 to 21 Ω

(schematic item I)

MANIFOLDS REV A
2 Connect a 10Ω resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the
5 Momentarily connect the positive lead from the
coil.
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
Ω
Resistor, 10Ω
Genie part number 27287 6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
The battery should read 9V DC or
Result: Both current readings are greater than
more when measured across the
0 mA and are different by a minimum of 20%.
terminals.
The coil is good.
COIL
Result: If one or both of the current readings are
a 0 mA, or if the two current readings do not differ
MULTI
d METER by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
- replaced.
c
+
b
10 W 9V
RESISTOR BATTERY
+
c - b
a multimeter
b 9V DC battery
c 10Ω resistor
d coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6
3 Set a multimeter to read DC current.

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

REV B
Turntable Rotation Components
Turntable Rotation Assembly 4 Open the engine pivot plate latch and swing the
engine out and away from the machine to
access the turntable rotation assembly.
How to Remove the Turntable
Rotation Assembly 5 Remove the retaining fasteners from the center
turntable cover. Remove the cover from the
When removing a hose assembly machine.
6 Disconnect the battery backs from the machine.
and then torqued to specification Electrocution hazard. Contact with
during installation. Refer to electrically charged circuits could
Section 2, Hydraulic Hose and result in death or serious injury.
Fitting Torque Specifications. Remove all rings, watches and
other jewelry.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine 7 Place a suitable container under the engine
off. plate.
2 Secure the turntable from rotating with the 8 Tag and disconnect the fuel hose from the fuel
turntable rotation lock. filter and drain the fuel tank into a suitable
container. Refer to Section 2, Specifications.
Crushing hazard. The machine
could tip over when the turntable 9 Tag, disconnect and plug the fuel hoses from
rotation assembly is removed if the fuel tank.
the turntable rotation lock is not in
the locked position. 10 Remove the fuel tank strap fasteners and
remove the tank strap.
11 Remove the fuel tank from the machine.
from the turntable rotation motor manifold. Cap
the fittings on the manifold.
Unlocked position
or spray.
Locked position

TURNTABLE ROTATION COMPONENTS REV B
13 Attach a lifting strap from and overhead crane

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

REV A
Motor Controller
11-1 4 Press the release tab on the motor controller
harness connector and remove the motor
Motor Controller controller harness connector from the motor
controller.
The drive motor controller is located under the non-
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.


February 2006 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Operator’s Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine. Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
with electrically charged circuits
· Machine parked on a firm, level surface
may result in death or serious
· Boom in stowed position injury. Remove all rings, watches
· Turntable rotated with the boom between and other jewelry.
the non-steer wheels
· Key switch in the off position with the hydraulic oil can penetrate and
key removed burn skin. Loosen hydraulic
· Wheels chocked connections very slowly to allow
· All external AC power supply disconnected
from the machine
squirt or spray.
Perform all troubleshooting on a
firm level surface.

Section 5 • Fault Codes February 2006
FAULT CODES
Tip-over hazard. When adjusting The controller status indicator light will flash a fault
the raised drive speed settings, code to aid in troubleshooting. This indicator light
the maximum raised drive speed is mounted on the left side of the ground control
must not exceed specification. box.
Refer to Section 2, Specifications.
If the machine is allowed to drive Fault codes are two digits. The controller status
faster than specification, the indicator light will blink the first digit of a two digit
machine could become unstable code, pause for 1 second, and then blink the
and will tip over. second digit. There will be a 2 second pause
between codes.
Additional troubleshooting of the
fault codes may by accomplished
by using the hand-held pendant For example: the indicator light blinks 4
motor controller programmer consecutive times, pauses for 1 second, and then
(Genie part number 56303-S). blinks 1 time. That would indicate Fault Code 41.
When using the hand-held

pendant motor controller
programmer, the M1 MAX SPEED
needs to be set to 33. If needed,
adjust the M1 MAX SPEED higher
or lower to achieve the maximum
raised drive speed. Refer to

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.


February 2006 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

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.
Operator's Manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics February 2006
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
(before serial number 22566)
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
TO ENGINE PANEL TO GROUND CONTROL BOX
CONNECTOR C6B
1 LEFT SIDE
AC POWER CABLE
DC AMMETER CABLE
BATTERY PACK
RD-2GA RIGHT SIDE
- BATTERY PACK
48V DC -
+ ALTERNATOR
FUNCTION HARNESS
D1 +
AC A2
2 BATTERY
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
33 PLUG
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
RD-2GA
6 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
BK-2GA
RD-10GA
RD-10GA
F1 F2
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

REV A Engine Panel Diagram
N M L K J I H G F E D C B A
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
BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4
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
CR16 CR11 CR12 CR13 CR14 CR15

FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG
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

Engine Panel Diagram

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
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
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
F1 M- B+ F2 B- 87 86 85 10 ENGINE FAULT
+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.
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
+
+ BL
(PRI)
BK
+
LS1 AP2
2 STARTER
PUMP PUMP
ALTERNATOR CHARGER (EXT) AUXILIARY
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
2 SWITCH SHOWN WITH BOOM EXTENDED.

NOTES: 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 7 ANSI/CSA

1
8
Section 6 • Schematics
Electrical Schematic, Z-45/25, ANSI and CSA Models
6-8
ENABLE
SWITCH
3
DRIVE
ENABLE
LIMIT
LED L1
DRIVE
A
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
86
85
B
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH
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
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C
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
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
C1P-1 C27AUX RD C1B-1

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

LVI/BCI OPTION
GR/WH RELAY COIL PR2

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

SET TO "N"
1
Part No. 110188
RELAY COIL CR3

TS51
TB27
CR20
33
February 2006
PR3
OR
3
OR/RD AUXILIARY LIFT

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

OR/BK
4
RD
TB19
PR3
87
BCI
SET TO "B"
6
RESET
30
C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86
GR/WH CONTACTOR RELAY

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
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
PLATFORM
G
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
C6B-15 OR/BK
LEVEL
PLATFORM LEVEL
TS59
I
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
RETRACT RETRACT COIL
TB8
C17-1 C18-2
J
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
BOOM
K
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)
+
87
30
C3P-11 C11SBD BL/BK C3B-11

TS10
L
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
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
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
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
C5B-5 C33STR BK
3
POT. HI

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

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

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.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

1
8
Electrical Schematic, Z-45/25, CE Models
6 - 10
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
R41DRE OR/BK C2B-3 C6B-35 RD/WH
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. 110188

87
30

LVI/BCI OPTION
February 2006

BCI
BK
AUXILIARY
F
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

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
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
PLATFORM
ROTATE
RIGHT C4P-6 C18PRR GR/BK C4B-6 GR/BK

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, ANSI and CSA Models REV B
1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
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
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
C5B-5 C33STR BK
3
POT. HI

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
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-45/25J, ANSI and CSA Models
6 - 12
A
3
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

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

B

TB12
14
13

86
85
BRN
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
C2P-3 RD/WH N.C. COIL
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
10
C29JSH RD/WH
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
Part No. 110188
87
30

LVI/BCI OPTION
February 2006

BCI
BK
F
CR3
+
OR/RD
AUX
85
ON
86
DISCHARGE

BCI OPTION
SET TO "N"
1
RELAY COIL CR3

F
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4

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
BRN
GR/WH
COIL
RD
86
TB18
G

CONTROL
DOWN
CR19B
C6B-18 GR/BK ROTATE RIGHT /

ROTARY
JIB DOWN
FLOW
OEM
C6B-17 GR PLATFORM
BOOM
BP1
TS58
UP ROTATE LEFT /
TB17
C22-1 C22-2
86
85
JIB
JIB UP
TB44
C2P-6 C44JDA GR/BK C2B-6

BOOM
JIB
DOWN C4P-6 C18PRR GR/BK C4B-6 GR/BK

TS8
UP
H
RIGHT
BK C44DA C6B-33
PLATFORM
87a
ROTATE
TS57
LEFT
CR7
30
85
86
PLATFORM
ROTATE
WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
I
LEFT C2P-7 C45JSV GR/WH C2B-7

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
PRIMARY EXTEND COIL
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
K
RETRACT C12-1 C12-2

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 C3P-11 C11SBD BL/BK C3B-11
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
REV B
C40LS OR
N
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
Electrical Schematic, Z-45/25J, ANSI and CSA Models

Electrical Schematic, Z-45/25J, CE Models REV B
1 C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
C31REV WH/BK
C40LS OR
FS1
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
INTERLOCK
+
BK-4
WH-4
BK-5
WH-5
POT. LOW
REVERSE
FORWARD
C5B-5 C33STR BK
3
POT. HI

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

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

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.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

1
8
Electrical Schematic, Z-45/25J, CE Models
6 - 14
A
3
ENABLE
SWITCH
DRIVE
ENABLE
LIMIT
LED L1
DRIVE

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

B

TB12
14
13

86
85
BRN
A2
86
85
RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6
+
CR5
CR8
C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
C2P-3 RD/WH N.C. COIL
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
10
C29JSH RD/WH
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
Part No. 110188
87
30

LVI/BCI OPTION
February 2006

BCI
BK
F
CR3
+
OR/RD
AUX
85
ON
86
DISCHARGE

BCI OPTION
SET TO "N"
1
RELAY COIL CR3

F
TS51
TB27
CR20
33
2
PR3
OR
3

5
L.V.I.
4

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
BRN
GR/WH
COIL
RD
86
TB18
G

CONTROL
DOWN
CR19B
C6B-18 GR/BK ROTATE RIGHT /

ROTARY
JIB DOWN
FLOW
OEM
C6B-17 GR PLATFORM
BOOM
BP1
TS58
UP ROTATE LEFT /
TB17
C22-1 C22-2
86
85
JIB
JIB UP
TB44
C2P-6 C44JDA GR/BK C2B-6

BOOM
JIB
DOWN C4P-6 C18PRR GR/BK C4B-6 GR/BK

TS8
UP
H
RIGHT
BK C44DA C6B-33
PLATFORM
87a
ROTATE
TS57
LEFT
CR7
30
85
86
PLATFORM
ROTATE
WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
I
LEFT C2P-7 C45JSV GR/WH C2B-7

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 C6B-8 BK/WH PRIMARY BOOM
BOOM
TS63
TB8
C17-1 C18-2
PRIMARY
BOOM

TS13
TB1
K
RETRACT C12-1 C12-2

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
P24BAT WH LEFT
FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
REV B
C40LS OR
N
TS55
(GND)
PR2
PR3
CR5
BK
RD
RD
Electrical Schematic, Z-45/25J, CE Models

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

ANSI and CSA Models
8
7
6
5
4
3
2
1
6 - 15
C23
A
1 3 4 5 6 7 8 12
RD H6
BK 22B
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)

BRN GND
GR/BK H6
P20BAT RD
BL/WH C1-12
D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK BK-ALARM
B
C3B-2 C2PBD RD/BK RD/BK-TS61

2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
ANSI and CSA Models
C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6
H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
(CE OPTION ONLY)

C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6
C
8 PRIMARY BOOM RETRACT 8

C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK BK ALARM
C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C3B-12 C12DRE BL/WH
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
D
17 PLATFORM ROTATE LEFT 17

C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM
18 PLATFORM ROTATE RIGHT 18

C6B-38 C19PSW GR/WH GR/WH
C4B-7 C19LPMP GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 C22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22
C7B-2 P23SWBAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
E
C1B-1 C27AUX RD RD-TS51

27 AUXILIARY PUMP SELECT 27
C5B-5 C33STR BK
C1B-7 C33STR BK BK-TS52
33 START ENGINE 33
C7B-3
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C1B-9 C35HRPM BK/RD BK/RD-TS54
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
F
February 2006
C6B-24 C40LS OR
Part No. 110188

C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C23ALARM RD RD H6
C2B-5 C134PWR RD RD KS1
134 KEYSWEITCH POWER 134
FAULT C5B-3 C23PWR WH
STATUS
C5B-1 P20BAT RD GROUND
LED
BK C6B-25 C5B-11 C21IGN2 WH CONTROL
G
OR/RD-42A OR/RD HARNESS

C2B-7 C45JSV GR/WH GR/WH
BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
H
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK
C6B-19 R19LPMP GR/WH

C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
C6B-35 R48BRK RD/WH

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

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

48V DC 48V DC CR3 CR20
I
POWER POWER AUXILIARY CONTROL LIFT PUMP

RELAY RELAY RELAY RELAY
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
J
C2B-3 C41DRE OR/BK
C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
C5B-2
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
K
30
CR4 CR5
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

ANSI and CSA Models
BK/RD BK/RD-35A C45JSV GR/WH (C2B-7)
BK-7A GR/BK-18A 1
BK/WH-8A GR-17A
HIGH/LOW
BK WH/BK-5A
TS54
RPM
RD
PLATFORM
ROTATE
WH-4A GR
TS57
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A
AUXILIARY
PUMP
RD
BK
TS51
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
PRIMARY
BOOM
TS61
WH
RD
RD
RD
RD
RD C23-6
RD
BK
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
P20BAT RD (C5B-1) RD
BOOM
TS60
RD 134A
RD RD
RD
RD
RD C23-7 RD 6
D2
RD
GR/BK H6
RD
ENGINE
START
TS52
WH 23A
BK-33A
EMERGENCY
1
WH 7
STOP
P1
C21IGN2 (C5B-11)
RD
RD
RD
NC
BRN
2
BRN-HM
FUNCTION
ENABLE
GLOW
PLUG
TS56
TS55
RD
BASE BOX HARNESS

BK/WH-34A
HOUR METER
H.M.
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

ANSI and CSA Models

CE Models
8
7
6
5
4
3
2
1
6 - 17
U33
1 3 4 5 6 7 8 12
A
CE Models
RD H6
BK 22B
BK C7-1
RD TS51
TERMINAL BASE (TB) RD TS55
BRN GND
GR/BK H6
P20BAT RD
BL/WH C1-12
D C B A
C6B-1 C1PBU RD
1 PRIMARY BOOM UP 1
C6B-4 C4TRL WH
B

C6B-6 C6LFC WH/RD
H6
C6B-7 C7PBE BK
C6B-8 C8PBR BK/WH
GR/BK L45
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
P20BAT RD C7B-4
C

C3B-12 C12DRE BL/WH
C6B-14 C14PLU OR
C6B-15 C15PLD OR/BK
C6B-17 C17PRL GR
17 PLATFORM ROTATE LEFT 17
C6B-18 C18PRR GR/BK
BK-ALARM
D
18 PLATFORM ROTATE RIGHT 18

19 LIFT PUMP 19

GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19

RD-CR3
C5B-5 C33STR BK
E

33 START ENGINE 33
C7B-3
C5B-22 C34SA BK/WH
34 GLOW PLUG 34
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK

37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F
February 2006
Part No. 110188

BK-ALARM
STATUS
LED
G
BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
H
C6B-35 R48BRK RD/WH

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

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

I
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

J
C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
C5B-2
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
HORN BRAKE
K
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

CE Models
BK-7A GR/BK-18A 1
BK/WH-8A GR-17A
HIGH/LOW
BK WH/BK-5A
TS54
RPM
RD
PLATFORM
ROTATE
WH-4A GR
TS57
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A
AUXILIARY
PUMP
RD
BK
TS51
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
PRIMARY
BOOM
TS61
WH
RD
RD
RD
RD
RD C23-6
RD
BK
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
BOOM
TS60
RD 134A
RD RD
RD
RD
RD C23-7 RD 6
D2
RD
GR/BK H6
RD
ENGINE
START
TS52
WH 23A
BK-33A
EMERGENCY
1
WH 7
STOP
P1
C21IGN2 (C5B-11)
RD
RD
RD
NC
BRN
2
BRN-HM
FUNCTION
ENABLE
GLOW
PLUG
TS56
TS55
RD
BASE BOX HARNESS

BK/WH-34A
HOUR METER
H.M.
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

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

ANSI and CSA Models
8
7
6
5
4
3
2
1
6 - 19
C23 A
1 3 4 5 6 7 8 12
RD H6
BK 22B
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)

BRN GND
GR/BK H6
P20BAT RD
D C B A BL/WH C1-12
C6B-1 C1PBU RD
1 PRIMARY BOOM UP 1
B

C6B-4 C4TRL WH
ANSI and CSA Models

C6B-6 C6LFC WH/RD
H6
C6B-7 C7PBE BK
C6B-8 C8PBR BK/WH
GR/BK L45
(CE OPTION ONLY)

C6B-10 C10SBU BL
C
P20BAT RD C7B-4
C3B-12 C12DRE BL/WH
C6B-14 C14PLU OR
C6B-15 C15PLD OR/BK
C6B-17 C17PRL GR
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
D

BK-ALARM
18 PLATFORM ROTATE RIGHT/JIB DOWN 18


19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19

RD-CR3
E

C5B-5 C33STR BK
33 START ENGINE 33
C7B-3
C5B-22 C34SA BK/WH
34 GLOW PLUG 34
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
BATGND BRN
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J,
36 STEER LEFT 36
C6B-37 C37STC BL/BK
37 STEER RIGHT 37
C6B-24 C40LS OR
F
February 2006
C2B-2 C40LS OR
Part No. 110188

BK-ALARM
STATUS
LED
G

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-27 R27AUX
C30FWD WH
H
C28TTA RD/BK

C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
C6B-35 R48BRK RD/WH

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

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

POWER POWER LIFT PUMP
I
AUXILIARY CONTROL
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

J
C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
C5B-2
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
K
CR4 CR5
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

ANSI and CSA Models
BK-7A GR/BK-18A 1
BK
BK/WH-8A GR-17A
HIGH/LOW
BK WH/BK-5A GR/BK
TS54
RPM
RD
PLATFORM
ROTATE
WH-4A GR
TS57
GR
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
GR/BK
RD RD-27A
AUXILIARY
PUMP
RD
GR
BK
TS51
BK
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
GR/BK-44A
PRIMARY
BOOM
TS61
JIB BOOM
WH
RD
RD
RD
TS58
RD
BK
RD C23-6
RD
BK
RD
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
BOOM
TS60
RD 134A
RD RD
RD
RD
RD C23-7 RD 6
D2
RD
GR/BK H6
RD
ENGINE
START
TS52
WH 23A
BK-33A
EMERGENCY
1
WH 7
STOP
P1
C21IGN2 (C5B-11)
RD
RD
RD
RD
NC
BRN
2
BRN-HM
FUNCTION
ENABLE
GLOW
PLUG
TS56
TS55
RD
BASE BOX HARNESS

BK/WH-34A
HOUR METER
H.M.
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

ANSI and CSA Models

CE Models
8
7
6
5
4
3
2
1
6 - 21
U33
1 3 4 5 6 7 8 12
A
CE Models
RD H6
BK 22B
BK C7-1
RD TS51
TERMINAL BASE (TB) RD TS55
BRN GND
GR/BK H6
P20BAT RD
BL/WH C1-12
D C B A
C6B-1 C1PBU RD
1 PRIMARY BOOM UP 1
C6B-4 C4TRL WH
B

C6B-6 C6LFC WH/RD
H6
C6B-7 C7PBE BK
C6B-8 C8PBR BK/WH
GR/BK L45
C6B-10 C10SBU BL
P20BAT RD C7B-4
C

C3B-12 C12DRE BL/WH
C6B-14 C14PLU OR
C6B-15 C15PLD OR/BK
C6B-17 C17PRL GR
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
BK-ALARM
D
18 PLATFORM ROTATE RIGHT/JIB DOWN 18

19 LIFT PUMP 19

GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19

RD-CR3
C5B-5 C33STR BK
E

33 START ENGINE 33
C7B-3
C5B-22 C34SA BK/WH
34 GLOW PLUG 34
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK

37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F
February 2006
Part No. 110188

BK-ALARM
STATUS
LED
G
BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)
BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13
C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C32JSL WH/RD
C29JSH RD/WH
C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
H
C6B-35 R48BRK RD/WH

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

RD
C4B-4
C4B-1
C6B-9 R9HRN
RD/WH
GR/WH
GR/WH
C3B-3 C3BAT RD/WH
RD/WH OR/RD
CR1 CR2 BRN BRN

I
30 30 30 30
BRN
87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2
86 85 86 85 86 85
87 87 87 87
BRN
OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
C2B-3 C41DRE OR/BK

J
C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH
C5B-2
BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
HORN BRAKE
K
RELAY RELEASE
RELAY
L
M
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

CE Models
BK-7A GR/BK-18A 1
BK
BK/WH-8A GR-17A
HIGH/LOW
BK WH/BK-5A GR/BK
TS54
RPM
RD
PLATFORM
ROTATE
WH-4A GR
TS57
GR
ROTATE
TABLE
TURN
TS62
BK
RETRACT
PRIMARY
EXTEND/
BOOM
TS63
RD
BK 2
RD
GR/BK
RD RD-27A
AUXILIARY
PUMP
RD
GR
BK
TS51
BK
RD
BK
OR/BK-15A OR/BK
RD/BK-2A OR-14A OR
RD-1A
PLATFORM
3
LEVEL
TS59
GR/BK-44A
PRIMARY
BOOM
TS61
JIB BOOM
WH
RD
RD
RD
TS58
RD
BK
RD C23-6
RD
BK
RD
4
BK-22A
P20BAT RD (C7B-4)
RD
BL-10A RD
OVERLOAD
PLATFORM
(CE ONLY)
+
KS1
BREAKER 1
BL/BK-11A
CIRCUIT
-
CB1
L45
GR/WH-19A BK 5
SECONDARY
BOOM
TS60
RD 134A
RD RD
RD
RD
RD C23-7 RD 6
D2
RD
GR/BK H6
RD
ENGINE
START
TS52
WH 23A
BK-33A
EMERGENCY
1
WH 7
STOP
P1
C21IGN2 (C5B-11)
RD
RD
RD
RD
NC
BRN
2
BRN-HM
FUNCTION
ENABLE
GLOW
PLUG
TS56
TS55
RD
BASE BOX HARNESS

BK/WH-34A
HOUR METER
H.M.
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

CE Models
Platform Control Box Wiring Diagram, Z-45/25

Platform Control Box Wiring Diagram, Z-45/25 REV A
1
BRN-RELAY
OR/BK-R6
OR/BK
RD/BK-R6
CR6
2
C134PWR RD
C27AUX RD
C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C33STR BK
C34SA BK/WH
C35HRPM BK/RD
C36STCC BL
C37STC BL/BK
R41DRE OR/BK
R42BAT OR/RD
C1PBU RD
C2PBD RD/BK
C3BAT RD/WH
C4TRL WH
C5TRR WH/BK
C6LFC WH/RD
C7PBE BK
C8PBR BK/WH
C9HRN BK/RD
C10SBU BL
C11SBD BL/BK
C12DRE BL/WH
C13DREL BL/RD
C14PLU OR
C15PLD OR/BK
C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH
P22BAT BK
P23SWBAT WH
BRN-BATGND
P26BAT BK
P24BAT WH
P25BAT RD
C16DRE OR/RD
RD/BK L48
BRN-J1
1
BRN-BATGND
C2P-5
C1P-1
C1P-3
C1P-4
C1P-5
C1P-6
C1P-7
C1P-8
C1P-9
C1P-10
C1P-11
C2P-3
C2P-4
C3P-1
C3P-2
C3P-3
C3P-4
C3P-5
C3P-6
C3P-7
C3P-8
C3P-9
C3P-10
C3P-11
C3P-12
C4P-1
C4P-2
C4P-3
C4P-4
C4P-5
C4P-6
C4P-7
C7P-1
C7P-2
C7P-3
C9P-1
C9P-2
C9P-3
3
C1P-2
C28TTA RD/BK
C1P(GY)
C3P(GR)
C4P(BR)
C2P(BK)
4 C7P C9P JIB LS18 OPT.
D40
A1
FOOT
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY SWITCH
GR-LFC DP1
GR C29JSH RD/WH
20k 1 NOTES:
GR OR C32JSL WH/RD
2 1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
TS11 RD
TS12 TS10 PRIMARY TS13 WH C30FWD WH
EXTEND/ BK/RD 3
TURNTABLE SECONDARY BOOM FWD
ROTATE BOOM RETRACT BK
4
C31REV WH/BK COMPONENT INDEX
6 REV
RD
OR/BK-R6
RD-DRE BCI BATTERY CHARGE INDICATOR
5 P24BAT WH 1
WH/GR
- + C12DRE BL/WH BP1 ROTARY FLOW CONTROL DIAL
YL 6
RD-RPM
PRPL RD-J7
DP1 DRIVE JOYSTICK
LIFT
7 RD-SW L1 DRIVE ENABLE LED
BP1 BL RD/BK-R6
DRIVE 8 LVI LOW VOLTAGE INTERRUPT MODULE
R42BAT OR/RD
BK/WH-DRE
BRN-BCI
BCI C37STC BL/BK

C5TRR WH/BK
C4TRL WH
C10SBU BL 1
C11SBD BL/BK
C1PBU RD
C2PBD RD/BK
C8PBR BK/WH
C7PBE BK
RD-SW
C19LPMP GR/WH P25BAT RD
C6LFC WH/RD
BRN-BCI
BRN-J1
RIGHT
WH/YL
9 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
OPTION
WH/RD C36STCC BL P2 EMERGENCY STOP BUTTON
LEFT 10
P3 HORN
P26FS BK C9P-1
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C3BAT RD/WH C3-3

7 TS1 AUXILIARY TOGGLE SWITCH
1
1
TS2 ENGINE START TOGGLE SWITCH
RD-HRN
RD/BK H1
C9HRN BK/RD
RD-HRN
C27AUX RD
RD-AUX
RD-DRE
BK/WH-DRE
C13DREL BL/RD
C34SA BK/WH
C33STR BK
RD-AUX
RD-RPM
C35HRPM BK/RD
C18PRR GR/BK
C17PRL GR
C15PLD OR/BK
C14PLU OR
TS4 HIGH / LOW RPM TOGGLE SWITCH

TS6 GLOW PLUG TOGGLE SWITCH
RD TS7 PLATFORM ROTATE TOGGLE SWITCH
P3
TS9 PLATFORM LEVEL TOGGLE SWITCH
TS10 SECONDARY BOOM TOGGLE SWITCH
3
2
4
TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH

NO
NC NC NC
1
8
1
TS12 TURNTABLE ROTATE TOGGLE SWITCH
RD L48
2
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
1
TS15
P3 DRIVE ENABLE
TS2 TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS6 TS4
ENGINE P2
GLOW PLUG RPM H1 TITL ALARM
TS1 L1 TS7 TS9 START EMERGENCY
AUXILIARY PLATFORM PLATFORM STOP LS18 PLATFORM OVERLOAD LIMIT SWITCH
POWER ROTATE LEVEL L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

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

with LVI/BCI Option
WH
1
1
OR/RD
1
LVI
2
OR
CR8 3
OR/BK
4
OR/RD
5
WH WH RESET IS SET TO "B",
6
BRN-RELAY DISCHARGE IS SET TO "N"
7
8
CR6 CR7 CR19A CR19B 2
C40LS OR
RD-LR19B
RD-LVI
BL-L10
BL-LR19A
R42BAT OR/RD
P24BAT WH
RD-J7
OR-LVI
OR/BK-LVI
OR/RD-LVI
P24BAT WH
BRN-LVI
RD-P2
RD-H1
BK LS CABLE C1P-12
3
GR/BK C133PLA
RD LS18
GR/BK L4
C2P-2
C2P-4
C3P-1
C3P-10
C9P-2
RD
4
C2P-6
C1P(GY)
C3P(GR)
C4P(BR)
C2P(BK)
C7P C9P JIB LS18 OPT.
D39
1
A1
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH
5
NOTES:
1. LOAD SENSE WIRES SHOWN WITH DASHED LINES

DP1
20k
GR
1 1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN
TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
GR OR
2
TS12 TS11 TS13 RD
TS10
LVI/BCI TURNTABLE SECONDARY PRIMARY EXTEND/ BK/RD
WH
3 COMPONENT INDEX
ROTATE BOOM BOOM RETRACT FWD
BK
4 BCI BATTERY CHARGE INDICATOR
6
REV
RD
5 BP1 ROTARY FLOW CONTROL DIAL
WH/GR
3 5 4 6 P24BAT WH DP1 DRIVE JOYSTICK
YL
PRPL
1 RD-J7 L1 DRIVE ENABLE LED
LIFT
7 L2 LOAD SENSE LED
BP1 BL
DRIVE 8 LVI LOW VOLTAGE INTERRUPT MODULE
WH/YL
RIGHT 9 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
OR-LVI
OR/RD-LVI
OR/BK-LVI
BL-LR19A
RD-LR19B
LEFT
WH/RD
10
P2 EMERGENCY STOP BUTTON
P3 HORN 7
TS1 AUXILIARY TOGGLE SWITCH
TS2 START ENGINE TOGGLE SWITCH
GR/BK-H1 (D39)
RD-LS18
TS7 PLATFORM ROTATE TOGGLE SWITCH
1
8
3
2
NO
NC NC NC
1
4
1
RD
1
L4
2
TS15
P3 DRIVE ENABLE TS6 TS2 P2
TS1 TS7 TS9 GLOW PLUG ENGINE START
TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS4 EMERGENCY STOP
AUXILIARY PLATFORM PLATFORM RPM A1 TILT ALARM
POWER L1 ROTATE LEVEL
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

Platform Control Box Wiring Diagram, Z-45/25

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

Platform Control Box Wiring Diagram, Z-45/25J REV B
1
BRN-RELAY
GR/WH
GR/WH-45
GR/WH-R7
OR/RD
OR/BK-R6
OR/BK
RD/BK-R6
RD-J7
CR6 CR7
2
C134PWR RD
C27AUX RD
C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C33STR BK
C34SA BK/WH
C35HRPM BK/RD
C36STCC BL
C37STC BL/BK
R41DRE OR/BK
R42BAT OR/RD
C44JDA GR/BK
C45JSV GR/WH
C1PBU RD
C2PBD RD/BK
C3BAT RD/WH
C4TRL WH
C5TRR WH/BK
C6LFC WH/RD
C7PBE BK
C8PBR BK/WH
C9HRN BK/RD
C10SBU BL
C11SBD BL/BK
C12DRE BL/WH
C13DREL BL/RD
C14PLU OR
C15PLD OR/BK
C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH
P22BAT BK
P23SWBAT WH
BRN-BATGND
P26BAT BK
P24BAT WH
P25BAT RD
BK-JIBGND
GR/WH-45
GR/WH-45
C16DRE OR/RD
RD/BK L48
BRN-J1
1
BRN-BATGND
C2P-5
C1P-1
C1P-3
C1P-4
C1P-5
C1P-6
C1P-7
C1P-8
C1P-9
C1P-10
C1P-11
C2P-3
C2P-4
C2P-6
C2P-7
C3P-1
C3P-2
C3P-3
C3P-4
C3P-5
C3P-6
C3P-7
C3P-8
C3P-9
C3P-10
C3P-11
C3P-12
C4P-1
C4P-2
C4P-3
C4P-4
C4P-5
C4P-6
C4P-7
C7P-1
C7P-2
C7P-3
C9P-1
C9P-2
C9P-3
3 BRN-JIBGND
BK
WH
C1P-2
C28TTA RD/BK
C1P(GY)
C3P(GR)
C4P(BR)
C2P(BK)
4 C7P C9P JIB LS18 OPT.
D40
A1
FOOT
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY SWITCH
GR-LFC DP1 NOTES:

GR C29JSH RD/WH
20k 1 1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
GR OR C32JSL WH/RD
TS11 2
RD
TS10 TS13
TS12
TURNTABLE SECONDARY
PRIMARY
BOOM EXTEND/ BK/RD
FWD
WH
3
C30FWD WH
COMPONENT INDEX
ROTATE BOOM RETRACT BK C31REV WH/BK
BCI BATTERY CHARGE INDICATOR
6 REV
RD
4
OR/BK-R6
RD-DRE BP1 ROTARY FLOW CONTROL DIAL
5 P24BAT WH 1
WH/GR
- +
6 C12DRE BL/WH DP1 DRIVE JOYSTICK
YL
RD-RPM
L1 DRIVE ENABLE LED
LIFT
PRPL RD-J7
7 RD-SW LVI LOW VOLTAGE INTERRUPT MODULE
BP1 BL RD/BK-R6
DRIVE 8 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
R42BAT OR/RD
BK/WH-DRE
BRN-BCI
BCI C37STC BL/BK

C5TRR WH/BK
C4TRL WH
C10SBU BL 1
C11SBD BL/BK
C1PBU RD
C2PBD RD/BK
C8PBR BK/WH
C7PBE BK
RD-SW
C19LPMP GR/WH P25BAT RD
C6LFC WH/RD
BRN-BCI
BRN-J1
WH/YL
RIGHT 9 P2 EMERGENCY STOP BUTTON
OPTION
WH/RD C36STCC BL P3 HORN
LEFT 10
TS1 AUXILIARY TOGGLE SWITCH
P26FS BK C9P-1
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C3BAT RD/WH C3-3

7 TS2 ENGINE START TOGGLE SWITCH
1
1
RD-HRN
RD/BK H1
C9HRN BK/RD
RD-HRN
C27AUX RD
RD-AUX
RD-DRE
BK/WH-DRE
C13DREL BL/RD
C44JDA GR/BK
GR/WH- R7
C34SA BK/WH
C33STR BK
RD-AUX
RD-RPM
C35HRPM BK/RD
C18PRR GR/BK
C17PRL GR
GR/WH-45
C15PLD OR/BK
C14PLU OR

RD TS8 JIB BOOM UP / DOWN SWITCH
P3
TS15
3
2
4
NO
NC NC NC
1
8
1
RD L48
1
P3 DRIVE ENABLE
HORN TS2 TS15 DRIVE ENABLE TOGGLE SWITCH
TS6 TS4
ENGINE P2
GLOW PLUG RPM EMERGENCY
H1 TITL ALARM
TS1 TS8 TS7 TS9 START
AUXILIARY L1 JIB BOOM PLATFORM PLATFORM STOP LS18 PLATFORM OVERLOAD LIMIT SWITCH
POWER ROTATE LEVEL L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

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

with LVI/BCI Option
WH
1 1
OR/RD
1
LVI
2
OR
CR8 3
OR/BK
4
OR/RD
5
WH WH RESET IS SET TO "B",
6
BRN-RELAY DISCHARGE IS SET TO "N"
7
8
CR6 CR7 CR19A CR19B 2
C40LS OR
RD-LR19B
RD-LVI
BL-L10
BL-LR19A
R42BAT OR/RD
P24BAT WH
RD-J7
OR-LVI
OR/BK-LVI
OR/RD-LVI
P24BAT WH
BRN-LVI
RD-P2
RD-H1
BK LS CABLE C1P-12
3
GR/BK C133PLA
RD LS18
GR/BK L4
C2P-2
C2P-4
C3P-1
C3P-10
C9P-2
RD
4
C2P-6
C1P(GY)
C3P(GR)
C4P(BR)
C2P(BK)
C7P C9P JIB LS18 OPT.
D39
1
A1
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH
5
NOTES:
1. LOAD SENSE WIRES SHOWN WITH DASHED LINES
DP1 1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN

TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
GR
20k 1
GR OR
TS12 TS10 TS11 TS13 RD

2 COMPONENT INDEX
WH
LVI/BCI TURNTABLE SECONDARY PRIMARY EXTEND/ BK/RD 3 BCI BATTERY CHARGE INDICATOR
ROTATE BOOM BOOM RETRACT FWD
BK
4 BP1 ROTARY FLOW CONTROL DIAL
6
REV
RD
5 DP1 DRIVE JOYSTICK
WH/GR
3 5 4 P24BAT WH L1 DRIVE ENABLE LED
YL 6
PRPL
1 RD-J7
L2 LOAD SENSE LED
LIFT
7 LVI LOW VOLTAGE INTERRUPT MODULE
BP1 BL
DRIVE 8 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
WH/YL
RIGHT 9 P2 EMERGENCY STOP BUTTON
OR-LVI
OR/RD-LVI
OR/BK-LVI
BL-LR19A
RD-LR19B
WH/RD P3 HORN
LEFT 10
TS1 AUXILIARY TOGGLE SWITCH 7
TS2 START ENGINE TOGGLE SWITCH
GR/BK-H1 (D39)
RD-LS18
TS8 JIB UP / DOWN TOGGLE SWITCH
1
8
3
2
NO
NC NC NC
1
4
1
RD
1
L4
2
TS15
P3 DRIVE ENABLE TS6 TS2 P2
TS1 TS8 TS7 GLOW PLUG ENGINE START
TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS9 TS4 EMERGENCY STOP
AUXILIARY JIB BOOM PLATFORM PLATFORM RPM A1 TILT ALARM
POWER L1 ROTATE LEVEL
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

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

with LVI/BCI Option
REV B Hydraulic Schematic
JIB BOOM PLATFORM ROTATE 1

L R
1.5:1 3:1
3800 psi 3000 psi
262 bar 207 bar
PR2
E R PR1
2
J1 J2 PR2 PR1
JIB BOOM / PLATFORM

ROTATE MANIFOLD
AA
3
V2 V1
PLATFORM LEVEL
SLAVE CYLINDER
TURNTABLE ROTATE PRIMARY LIFT CYLINDER EXTENSION CYLINDER
SECONDARY LIFT CYLINDERS
BRAKES STEER CYLINDERS
M M
Z
3:1
3000 psi
Y
4
207 bar
1:1
ATMOS. 3:1
3:1
3500 psi ATMOS.
1000 psi
241 bar 1500 psi
3:1 69 bar
103 bar
3500 psi
241 bar 3:1
0.030 inch 3800 psi
0.76 mm X 262 bar
S1
MASTER
V2 V1 5
N.O.
COM
N.C.
TEST
P PS ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2 SEC1 SEC2 P1 P2 EXT RET
BRAKE
3200 psi G
221 bar 0.037 inch
AUXILIARY S U 0.94 mm
PRIMARY N
PUMP
0.5 gpm
M PUMP
2.1 gpm
M 6
1.9L/min 2500 psi V
7.9 L/min W
O 172 bar
P H
A
Q 2000 psi
138 bar
0.060 inch
E
F
1.5 mm
R K
D C B
0.030 inch
I 0.030 inch T 0.76 mm 0.4 gpm
0.76 mm L
(from serial number 22566 to 22628 1.5 L/min
RESERVOIR and after serial number 23235) M
7
FUNCTION MANIFOLD

Hydraulic Schematic
California Proposition 65
WARNING
The exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia Genie China

Phone +46 31 575100 Phone +86 21 53852570
Fax +46 31 579020 Fax +86 21 53852569
Genie France Genie Malaysia

Phone +33 (0)2 37 26 09 99 Phone +65 98 480 775
Fax +33 (0)2 37 26 09 98 Fax +65 67 533 544
Genie Iberica Genie Japan

Phone +34 93 579 5042 Phone +81 3 3453 6082
Fax +34 93 579 5059 Fax +81 3 3453 6083
Genie Germany Genie Korea

Phone +49 (0)4202 88520 Phone +82 25 587 267
Fax +49 (0)4202 8852-20 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566

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Service Manual Part No.

Important Serial Number Information

Contact Us: Copyright © 1999 by Genie Industries

http://www.genieindustries.com 110188 Rev B February 2006

"Genie" and "Z" are registered trademarks of

Printed on recycled paper

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

Serial Number Legend

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

Part No. 110188 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. 110188

Do Not Perform Maintenance

Part No. 110188 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. 110188

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 110188 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. 110188

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 110188 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. 110188

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

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

Section 6 Rev Schematics

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

Tires and wheels Fuel tank 9 gallons

Overall tire diameter 28 in Type 6V DC

Continuous improvement of our products is a

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-1

Performance Specifications Boom function speeds, maximum

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

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

Continuous improvement of our products is a

2-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type: Fixed displacement gear pump

Hydraulic oil type Chevron Rykon MV equivalent Displacement 0.183 cu in

Water content, maximum 200 ppm Hydraulic tank 10 micron with

Optional fluids Jib boom/platform rotate flow regulator 0.4 gpm

Use Chevron Aviation A hydraulic

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-3

Manifold Component Machine Torque Specifications

Drive motor/brake mounting bolts, lubricated 80 ft-lbs

Description Specification Drive motor and hubs

Proportional solenoid valve, 24V DC 17 to 21 Ω

Continuous improvement of our products is a

2-4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

Kubota Z482-E Engine Injection system

Displacement 29.23 cu in Injection timing 21° BTDC

Bore and stroke 2.64 x 2.68 inches Fuel requirement

Compression pressure 412 to 469 psi Brush length, minimum 0.3346 in

Low idle 2000 rpm Battery

High idle 3000 rpm Type 12V DC, Group 70