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Terex Genie Z-45/25 Bi-Energy Service Manual Download Page 78

4 - 6

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

Part No. 237062

September 2015

Section 4 • Repair Procedures

PLATFORM COMPONENTS

5 Open the bottom bleed screw on the rotator, but

do not remove it.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

6 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
screw. Close the bleed screw.

Crushing hazard. Keep clear of the
platform during rotation.

7 Clean up any hydraulic oil that may have

spilled.

8 Rotate the platform fully in both directions and

inspect the bleed screws for leaks.

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

Page 1: ......

Page 2: ...s 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 ht...

Page 3: ... A1 11 2014 3 Maint B 18 B 9 2015 Added ending serial break to front cover REFERENCEEXAMPLES KubotaEngine_Section2_Specifications A 6 B 3 C 7_Section3_MaintenanceProcedure 3 2 6 4 9 1_Section4_RepairProcedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update ...

Page 4: ...dure Schematic Page Description REFERENCEEXAMPLES KubotaEngine_Section2_Specifications A 6 B 3 C 7_Section3_MaintenanceProcedure 3 2 6 4 9 1_Section4_RepairProcedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update ...

Page 5: ...n of the chassis 0 deg Gradeability N A Maximum allowable side force XXX lb XXX N Maximum number of platfrm occupants X Model year Manufacture date 04 12 05 2005 Maximum wind speed XX mph XX m s Maximum platform height XX ft XX m Maximum platform reach XX ft XX m Terex South Dakota Inc 18340 NE 76th St PO Box 97030 Redmond WA 98052 USA Serial Number Legend Model Modelyear Sequence number Serial la...

Page 6: ... or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes vi Danger Failure to obe...

Page 7: ...hat could get into machine components and causedamage Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fai...

Page 8: ...chine Specifications 2 1 PerformanceSpecifications 2 2 Hydraulic Specifications 2 3 ManifoldComponentSpecifications 2 4 Machine Torque Specifications 2 4 Kubota Z482 E and Z482 E2B Engine Specifications 2 5 Generator 2 6 GeneratorTorqueSpecifications 2 6 Hydraulic Hose and Fitting Torque Specifications 2 7 SAE and Metric Fasteners Torque Charts 2 9 Section 3 ScheduledMaintenanceProcedures Introduc...

Page 9: ...table Rotation Bearing and Rotate Gear 3 12 A 9 PerformEngineMaintenance 3 12 A 10 PerformEngineMaintenance 3 13 A 11 PerformEngineMaintenance 3 13 ChecklistBProcedures B 1 Check the Radiator 3 14 B 2 Check the Exhaust System 3 14 B 3 Check the Batteries 3 15 B 4 Inspect the Electrical Wiring 3 16 B 5 Check the Tires Wheels and Lug Nut Torque 3 17 B 6 ConfirmtheProperBrakeConfiguration 3 18 B 7 Ch...

Page 10: ...2 Grease the Platform Overload Mechanism if equipped 3 29 C 3 Test the Platform Overload Mechanism if equipped 3 30 C 4 PerformEngineMaintenance 3 32 ChecklistDProcedures D 1 Check the Primary Boom Wear Pads 3 33 D 2 ChecktheFree wheelConfiguration 3 33 D 3 Replace the Drive Hub Oil 3 34 D 4 Replace the Hydraulic Tank Return Filter 3 35 D 5 Calibrate the Platform Overload System if equipped 3 36 D...

Page 11: ... Components Z 45 25J Models 3 1 Jib Boom 4 7 3 2 Jib Boom Lift Cylinder 4 8 Primary Boom Components 4 1 CableTrack 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 SecondaryBoomComponents 5 1 SecondaryBoom 4 21 5 2 Secondary Boom Lift Cylinders 4 26 Kubota Z482 E and Z482 E2B Engine 6 1 Timing Adjustm...

Page 12: ...mps 8 1 Auxiliary Pump 4 33 8 2 Function Pump 4 34 Manifolds 9 1 FunctionManifoldComponents 4 36 9 2 Valve Adjustments Function Manifold 4 38 9 3 Jib Boom Platform Rotate Manifold Components 4 39 9 4 TurntableRotationManifoldComponents 4 40 9 5 Valve Coils 4 41 Turntable Rotation Components 10 1 Turntable Rotation Assembly 4 43 Motor Controller 11 1 MotorController 4 45 Section 5 Fault Codes Intro...

Page 13: ...452510A 39314toZ452513A 45734 6 10 Ground Control Box Switch Panel Wiring Diagram ANSI CSA fromserialnumberZ452510A 39314toZ452513A 45734 6 11 Platform Control Box Wiring Diagram ANSI CSA fromserialnumberZ452510A 39314toZ452513A 45734 6 13 Electrical Schematic ANSI CSA fromserialnumberZ452513A 45735 6 16 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA fromserialnumberZ452513A 45735 6 20 ...

Page 14: ...atic CE fromserialnumberZ452513A 45735 6 36 Ground Control Box Terminal Strip Wiring Diagram CE fromserialnumberZ452513A 45735 6 40 Ground Control Box Switch Panel Wiring Diagram CE fromserialnumberZ452513A 45735 6 41 Platform Control Box Wiring Diagram CE fromserialnumberZ452513A 45735 6 43 Electrical Schematics AS Electrical Schematic AS fromserialnumberZ452510A 39314toZ452511A 40559 6 46 Ground...

Page 15: ...52511A 40560toZ452513A 45734 6 63 Electrical Schematic AS fromserialnumberZ452513A 45735 6 66 Ground Control Box Terminal Strip Wiring Diagram AS fromserialnumberZ452513A 45735 6 70 Ground Control Box Switch Panel Wiring Diagram AS fromserialnumberZ452513A 45735 6 71 Platform Control Box Wiring Diagram AS fromserialnumberZ452513A 45735 6 73 Platform Options Wiring Diagram fromserialnumberZ452510A ...

Page 16: ...Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 237062 September2015 xvi This page intentionally left blank ...

Page 17: ...ontact area 43 5 sq in 280 sq cm Overall tire diameter 28 in 71 cm For operational specifications refer to the Operator s Manual Fluid capacities Fuel tank 9 gallons 34 1 liters Hydraulic tank 8 gallons 30 3 liters Hydraulic system 11 gallons including tank 41 6 liters Drive hubs refer to tag on drive hub to determine type EW1 type 17 fl oz 0 51 liter W1 type 23 fl oz 0 68 liter Drive hub oil type...

Page 18: ... to 7 ft 1 5 to 2 m Gradeability See Operator s Manual Boom function speeds maximum from platform controls Jib boom up Z 45 25J 33 to 39 seconds Jib boom down Z 45 25J 22 to 28 seconds Primary boom up 32 to 40 seconds Primary boom down 26 to 30 seconds Secondary boom up 38 to 46 seconds Secondary boom down 38 to 46 seconds Primary boom extend 14 to 18 seconds Primary boom retract 17 to 21 seconds ...

Page 19: ...ubric 822 Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A ARNICA 32 Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in componentdamage Note Use Chevron Aviation A hydraulic oil when ambient temperatures consistently below 0 F 18 C Note Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consi...

Page 20: ... 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 SPECIFICATIONS Machine Torque Specifications Platform rotator 3 4 10 center bolt GR 8 380 ft lbs 515 Nm 3 8 16 bolts GR 8 44 ft lbs 60 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Drive motor brake moun...

Page 21: ...64 psi 2 48 to 4 41 bar Oil capacity including filter Z482 E2B 2 2 quarts 2 1 liters Z482 E3B 2 6 quarts 2 5 liters Lubrication system Units ship with 10W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator s Manual on your machine Injection system Injection pump make Bosch MD Injection timing 21 BTDC Injection pump pre...

Page 22: ...engine 1 16 inch pulley offset maximum 1 6 mm Belt deflection maximum 1 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 SPECIFICATIONS ...

Page 23: ... 9 16 18 1 1 4 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAEO ringBossPort tube fitting installed into Aluminum all types SAE Dash size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm SAEO ringBossPort tube fitting installed into Steel ...

Page 24: ...7 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Figure 1 a hex nut b reference mark c body hex fitting 3 Workin...

Page 25: ...PartNo 237062 Z 45 25 Bi Energy Z 45 25J Bi Energy 2 9 Section 2 Specifications September2015 10 9 12 9 8 8 4 6 SPECIFICATIONS ...

Page 26: ...2 10 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 237062 Section 2 Specifications September2015 This page intentionally left blank ...

Page 27: ... incorrect result has occurred after performing a series of steps Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every 2 years as specified on the Maintenance Inspection Report The frequency a...

Page 28: ...There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspectio...

Page 29: ...e box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre deliveryPreparation The Pre delivery Preparation i...

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Page 31: ...ipped B 16 Electrical contactors B 17 Hydraulic oil analysis B 18 Emergency power Perform every 400 hours B 19 Perform engine maintenance Checklist C Y N R C 1 Perform engine maintenance C 2 Grease platform overload if equipped C 3 Test platform overload if equipped Perform every 800 hours C 4 Perform engine maintenance Instructions Make copies of this page to use for each inspection Select the ap...

Page 32: ...opies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed If any i...

Page 33: ...result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in goodcondition Result The operator s manual is not a...

Page 34: ...the appropriate operator s manual Refer to the Operator s Manual on your machine A 2 Perform Pre operation Inspection Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the opera...

Page 35: ...taining the generator belts and the pulleys is essential to good engine performance and service life The generator will not operate properly with loose or defective belts and continued use may causecomponentdamage Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of hot engine components Contact with hot engine compo...

Page 36: ...lley 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 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Performthefo...

Page 37: ...r 139420 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine A 7 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 75 hours Engine oil Requiredmaintenanceproceduresandadditional engine information are available in the KubotaZ482 E2BOperator sManual K...

Page 38: ...is step until the entire bearing has been greased 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 CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 100 hours Air filter Fuel filter Fan belt Requiredmaintenancep...

Page 39: ...ine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine A 11 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 200 hours Radiator hoses and clamps Air intake hose Requiredmaintenanceproceduresandadditional engine information are available in the KubotaZ482 E2BOperator sM...

Page 40: ...out away from the machine to access the radiator 3 Inspect the radiator for leaks and physical 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 B 2 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and ...

Page 41: ...orrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainers and cable connections are tight 4 Fully charge the battery Allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize 5 Remove the battery vent caps and check the specific...

Page 42: ...the specific gravity of one or more cells is 1 172 or less Replace the battery 10 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled B 4 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential ...

Page 43: ...r 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 5 Open the ground controls side turntable cover 6 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manifold wiring 7 Inspect for a liberal coating of dielectric grease at the following location All wire harn...

Page 44: ... when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position CHECKLIST B PROCEDURES B 7 Check the Oil Level in the Drive Hubs Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until one of the plugs is located on to...

Page 45: ... the plugs into the drive hub 5 Repeat steps 1 through 4 for the other drive hub 6 Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications B 8 Check and Adjust the Engine RPM 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...

Page 46: ...stment 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 the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and recheck the rpm...

Page 47: ...on using the platform level toggle switch 4 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 9 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the...

Page 48: ... controls Move the engine idle select toggle switch to high idle rabbit symbol Result The engine should change to high idle 2 Release the engine idle select toggle switch Result The engine should return to low idle 3 Turn the key switch to platform controls 4 At the platform controls move the engine idle select toggle switch to high idle rabbit symbol Result The engine should change to high idle 5...

Page 49: ...ne Release the drive joystick when your reference point on the machine crosses the test line 5 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 13 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation T...

Page 50: ...aching the start line Begin timing when your reference point on the machine crosses the start line 5 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications B 15 Test the Alarm Package if equipped The alarm package includes Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators ...

Page 51: ...imary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 7 Press down the foot switch Activate the secondary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 8 Z 45 25J Press down the foot switc...

Page 52: ... Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactors if any damage is found B 17 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use ma...

Page 53: ... the emergency power switch cover if equipped 3 Simultaneously hold the emergency power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions operate 4 Close the emergency power switch cover and secure the cover with a security tie if equipped CHECKLIST B PROCEDURES 5 Turn the key switch to platfo...

Page 54: ...enanceproceduresandadditional engine information are available in the KubotaZ482 E2BOperator sManual Kubotapartnumber16676 89167 KubotaZ482 E3BOperator sManual Kubotapartnumber1G689 89160 Kubota Z482 E2B Operator s Manual Genie part number 52958 Kubota Z482 E3B Operator s Manual Genie part number 139420 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot pla...

Page 55: ...vot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine C 2 Grease the Platform Overload Mechanism if equipped Note Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanis...

Page 56: ...e serial plate 4 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown Result The platform overload indicator light should be off at both the ground and platform controls 5 Carefully move the test weight to each remaining location Result The platform overload indicator light should be off at both the ground and...

Page 57: ...rol functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate Note Machine functions should still operate with auxiliary power at the ground controls CHECKLIST C PROCEDURES 11 Lift the test weights off the platform floor using a suitable lifting device Result The platform overlo...

Page 58: ...eduresandadditional engine information are available in the KubotaZ482 E2BOperator sManual Kubotapartnumber16676 89167 KubotaZ482 E3BOperator sManual Kubotapartnumber1G689 89160 Kubota Z482 E2B Operator s Manual Genie part number 52958 Kubota Z482 E3B Operator s Manual Genie part number 139420 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch a...

Page 59: ...fications New Minimum Top bottom and side wear pads 3 4 inch 5 8 inch platform end of boom 19 mm 15 9 mm Side and bottom wear pads 5 8 inch 1 2 inch pivot end of boom 15 9 mm 12 7 mm Top wear pads 3 4 inch 5 8 inch pivot end of boom 19 mm 15 9 mm D 2 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is ...

Page 60: ...ack stands Collision hazard Failure to engage the drive hubs could result in death or serious injury and property damage D 3 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive h...

Page 61: ...lter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Locate the hydraulic return filter next to the hydraulic tank 2 Place a suitable container under the hydraulic filter 3 Remove the filter with an o...

Page 62: ...to that of the maximum platform capacity at the center of the platform floor Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload in...

Page 63: ...cator 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 Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarmsounds 9 Test all machine funct...

Page 64: ...boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands away from cylinder and all moving parts when lowering the boom Note A lift cylinder safety chock is available through Genie Service Parts Genie part number 33484 2 Check to be sure that each turntable mounting bolt is torqued in sequence to specification Re...

Page 65: ... bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 8 Grease the Turntab...

Page 66: ...wer the primary boom to a horizontal position Fully extend the primary boom CHECKLIST D PROCEDURES 7 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height V...

Page 67: ...Requiredmaintenanceproceduresandadditional engine information are available in the KubotaZ482 E2BOperator sManual Kubotapartnumber16676 89167 KubotaZ482 E3BOperator sManual Kubotapartnumber1G689 89160 Kubota Z482 E2B Operator s Manual Genie part number 52958 Kubota Z482 E3B Operator s Manual Genie part number 139420 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the eng...

Page 68: ...installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Place a suitable container under the hydraulic tank 2 Remove the drain plug from the hydraulic tank Checklist E Procedures 3 Completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of hot oil Contact with hot oil may cause severeburns 4 Tag discon...

Page 69: ...at may have spilled Properly discard of oil 17 Operate all machine functions through a full cycle and check for leaks E 2 Grease the Steer Axle Wheel Bearings Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component dama...

Page 70: ...pindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace ...

Page 71: ...2 E3B Operator s Manual Genie part number 139420 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 3000 hours Injector pump Requiredmaintenanceproceduresandadditional engi...

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Page 73: ... lock Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine 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 Perform disassembly procedures to the point w...

Page 74: ...ction speed controller b drive joystick Boom Function Speed Controller Adjustments Note Do not adjust the controllers unless the static battery supply voltage is above 24V DC at the platform red Emergency Stop button Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Turn the key switch to platfor...

Page 75: ...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 m...

Page 76: ...nd the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at...

Page 77: ...o Bleed the Platform Rotator Note This procedure will require two people 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open ...

Page 78: ...o dissipate gradually Do not allow oil to squirt or spray 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platformduringrotation 7 Clean up a...

Page 79: ...mounting weldment 5 Attach a lifting strap from an overhead crane to the platform rotator for support 6 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 7 Remove the pin retaining fasteners from both platform rotator pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang...

Page 80: ...rom the bellcrank Crushing hazard The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane JIB BOOM COMPONENTS Z 45 25J 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fit...

Page 81: ...a suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The jib boom could fall when the barrel end pivot pin is removed if not properly supported by the overhead crane 7 Attach a lifting strap from an overhead crane to the lug on the rod end...

Page 82: ...ack Do not pull out the hydraulic hoses 4 Raise the primary boom to a horizontal position Primary Boom Components 5 Tag disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder Cap the fittings on the unions Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pres...

Page 83: ... boom 12 Attach a strap from an overhead crane to the cable track 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 14 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom 15 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track could...

Page 84: ... Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate...

Page 85: ...d pivot pin 18 Use a soft metal drift to remove the primary 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 20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of...

Page 86: ...his procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or...

Page 87: ...cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the hose clamp at the pivot end of the boom 14 Attach a 5 ton 5 000 kg overhead crane to the center point of the primary boom 15 Attach a similar lifting device to the primary boom li...

Page 88: ... the primary boom Note Pay careful attention to the location and amount of shims used with each wear pad 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube Crushing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported Note During removal the overhead crane strap will need t...

Page 89: ...er pivot pins 5 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 6 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipat...

Page 90: ...in the primary boom extension tube 3 Remove the hose and cable guard from the upper pivot 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5...

Page 91: ...d barrel end pivot pins on the master cylinder are accessible 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach overhead crane or similar lifting de...

Page 92: ...Boom Components 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 j a b c d e i g f h ...

Page 93: ...ect and plug the hydraulic hoses on both of the secondary boom lift cylinders Cap the fittings on the cylinders Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray SECONDARY BOOM COMPONENTS 5 1 Secondary Boom How to Disassemble the Secondary Boom Bodily ...

Page 94: ...m the machine be careful not to damage the counterbalance valve at the barrel end of the cylinder 16 Attach a lifting strap from an overhead crane to the upper pivot for support Do not lift it 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the midpoint between the upper pivot and mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the ...

Page 95: ...arm at the upper pivot end 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch 10 x 10 x 28 cm block 30 Lower the number 2 arm onto the boom rest pad 31 Insert a 4 x 4 x 81 2 inch 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid pivot end 32 Attach a lifting strap from the overhead crane to the mid pivot for support Do not lift it 33 Remove the pin retai...

Page 96: ...eight Componentdamagehazard Cables and hoses can be damaged if they are kinked or pinched 43 Open the ground controls side turntable cover 44 Remove the fuel tank filler cap 45 Usinganapprovedhand operatedpump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well vent...

Page 97: ... access hole behind the ground control box 54 Remove the number 3 arm from the machine Crushing hazard The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 55 Remove the upper and lower hose and cable covers from the number 3 arm 56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm ...

Page 98: ...ary boom so that it is above the secondary boom lift cylinder rod end pivot pin SECONDARY BOOM COMPONENTS 3 Tag disconnect and plug the hydraulic hoses on the secondary boom lift cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the p...

Page 99: ...en the engine pivot plate latch and swing the engine out away from the machine to access the engine drive pulley 3 Loosen the tension adjustment bolt on the generator 4 Pull the generator away from the machine and remove the belts from the generator pulley 5 Remove the 3 bolts that attach the engine drive pulley to the shaft bushing 6 Install the same 3 bolts that were removed in step 5 into the t...

Page 100: ...ulley f generator 3 Tighten the set screw on the pulley bushing hand tight 4 Slide the engine pulley onto the pulley bushing 5 Install the pulley mounting bolts and tighten them to specification Refer to Section 2 Specifications Componentdamagehazard Do not overtighten the pulley mounting bolts There must be a gap visible between the engine drive pulley and the pulley bushing a gap b shaft c set s...

Page 101: ... could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the engine battery hold down then remove the battery from the machine 7 Remove the generator pulley retaining nut from the generator shaft 8 Slide the pulley off of the generator shaft How to Install the Generator Pulley Note The pulley on the generator must be installed before installing the engine drive ...

Page 102: ... and 5 and re check the belt tension a engine pulley b generator belts c generator pulley 7 3 Generator Voltage Regulator How to Adjust the Generator Voltage Regulator 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 ...

Page 103: ...gulator inside the generator will become damaged if the potentiometer is rotated past the internal stops Note 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 How to Replace the Voltage Regulator 1 Disconnect the battery packs from the machine Electrocution burnhazard Contact with electrically charged circuits could...

Page 104: ... 4 nut that attaches the black wire to the voltage regulator 15 Remove the voltage regulator mounting screws 16 Remove the voltage regulator while carefully guiding the red and black wires from underneath the bottom support of the positive and negative rectifier assembly 17 Install the new voltage regulator by following the previous steps in reverse order 18 Apply Loctite removable thread sealant ...

Page 105: ...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 shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of hot oil Contact with hot oil may cause seve...

Page 106: ...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 shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of hot oil Contact with hot oil may cause severeburns 2 R...

Page 107: ...PartNo 237062 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 35 September2015 Section 4 Repair Procedures This page intentionally left blank ...

Page 108: ...oid 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 lb...

Page 109: ... Z 45 25 Bi Energy Z 45 25J Bi Energy 4 37 September2015 Section 4 Repair Procedures MANIFOLDS 1 2 3 4 5 6 7 8 12 13 14 15 22 21 19 20 17 16 18 10 9 11 Y25 Y22 Y52 Y24 Y16 Y19 Y3 Y9 Y2 Y4 Y20 Y17 Y23 Y53 Y21 Y26 PS1 ...

Page 110: ...ll the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 5 Repeat steps 2 through 4 and recheck relief valve pressure MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Move and hold the func...

Page 111: ...air Procedures 9 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to platform support Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way AA Jib boom platform rotate select 20 ft lbs 27 Nm MANIFOLDS 1 Y18 ...

Page 112: ... mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function Torque 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 MANIFOLDS 1 2 3 ...

Page 113: ...ification 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 How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by supp...

Page 114: ...The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both curr...

Page 115: ...remove the tank strap 11 Remove the fuel tank from the machine 12 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 1 Turntable R...

Page 116: ...tation assembly mounting fasteners 15 Carefully remove the turntable rotation assembly from the machine Crushing hazard The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position Crushing hazard The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the ...

Page 117: ...ure 1 Turn the key switch to the off position and disconnect the battery packs from the machine 2 Remove the chassis cover from the non steer end of the machine 3 Tag and disconnect all power cables from the motor controller Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 Press the release tab ...

Page 118: ...4 46 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 237062 September2015 Section 4 Repair Procedures This page intentionally left blank ...

Page 119: ...tructure and secure it from movement Electrocution burnhazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Note Perform all troubleshooting on a firm level surface Fault Codes Observe and Obey Troubleshootingandrepairproceduresshallbe completed by a person trained and qualified on the repair of this machine Immediately ...

Page 120: ...en using the hand held pendant motor controller programmer the M1 MAX SPEED needs to be set to 33 If needed adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed Refer to Section 2 Specifications The controller status indicator light will flash a fault code to aid in troubleshooting This indicator light is mounted on the left side of the ground control box Fault codes a...

Page 121: ...eplace the motor controller 01 Normal operation 12 HW Failsafe Machine will The motor controller failed Replace the motor controller 1 2 3 not drive self test 13 M shorted Machine will The motor controller has an Test the motor controller not drive internalshortbetween refertoRepairProcedure M and B terminals 11 1 Fieldopen Machine will Drive motor wiring is loose Check for loose or open not drive...

Page 122: ...n the drive joystick is defective 31 CONTDRVR Machine will Main contactor PR1 coil is Replace PR1 contactor OR OC not drive defective OR brake release CR5 relay OR motor relay CR5 is defective OR controller motor controller is defective 32 Main cont Machine will Main contactor PR1 contacts Consult the Genie service welded not drive stuck closed OR green wire department at pin 17 on the motor contr...

Page 123: ...nections at the battery terminals and the motor controller 42 Overvoltage Machine will Battery supply voltage to Be sure the battery charger not drive motor controller is more than is disconnected OR check 55V DC OR machine is being for loose and or poor battery operated with the battery cable connections OR adjust charger plugged in OR the 48V DC voltage regulator 48V DC alternator voltage OR rep...

Page 124: ...5 6 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 237062 September2015 Section 5 Fault Codes This page intentionally left blank ...

Page 125: ...ng any maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injur...

Page 126: ... button normally closed Toggle switch SPDT Horn button normally open Key switch Solenoid with ground suppresion Boom function speed controller OR BK C2P 1 TB20 TB20 LS2 NC HO P1 TB20 GR BK LS2 NO HC KS1 PLATFORM GROUND P3 PR1 TS1 TS1 RD GR WH BK RD BP1 CR1 86 85 30 87 CR1 86 85 30 87 PR3 33W L1 F1 200A R1 4 7K W BR RD GR WH C1 PS1 NO U35 30A 2 SEC 5 2 COM 9 3 8 LED Limit switch normally open held ...

Page 127: ...mp prime mover motor Cylinder Orifice with size Variable orfice or shut off valve Check valve Relief valve Priority flow regulator 2 position 2 way solenoid valve Counterbalance valve Differrential sensing valve Solenoid operated proportional valve M 0 035 COM N O N C Pressure switch 2 position 3 way solenoid operated directional valve 3 position 4 way solenoid operate directional valve Shuttle va...

Page 128: ...September2015 Section 6 Schematics 6 4 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 237062 This page intentionally left blank ...

Page 129: ...6 5 Section 6 Schematics September2015 Electrical Schematic ANSI CSA from serial number Z452510A 39314 to Z452513A 45734 6 6 ...

Page 130: ...M CUTOUT CR14 CR13 WH J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 30 85 BRN BRN G6 PR1 OFF LMT ...

Page 131: ... C14PLU OR C7PBE BK C8PBR BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3...

Page 132: ...6 8 September2015 Section 6 Schematics 6 7 Electrical Schematic ANSI CSA from serial number Z452510A 39314 to Z452513A 45734 ...

Page 133: ...6 9 Section 6 Schematics September2015 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial number Z452510A 39314 to Z452513A 45734 6 10 ...

Page 134: ...3B 4 C4TRL WH C3B 5 C5TRR WH BK C3B 6 C6LFC WH RD C3B 7 C7PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD...

Page 135: ... ROTATE CW CCW TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH OPTION TS59 PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE CW CCW TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH COMPONENT INDEX GROUND CONTROLS NOTE DASHED LINES INDICATE OPTIONS RD RD RD RD BK BK GR D2 BASE BOX HARNESS P182BA...

Page 136: ...6 12 September2015 Section 6 Schematics 6 11 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial number Z452510A 39314 to Z452513A 45734 ...

Page 137: ...R6 BK WH DE C37STC BL BK C36STCC BL P23SWBAT WH C7P 2 C3BAT RD WH C3 3 P22BAT BK C7P 1 P26FS BK C9P 1 C5TRR WH BK C4TRL WH C10SBU BL C2PBD RD BK C8PBR BK WH C7PBE BK RD SW C19LPE GR WH C6LFC WH RD TS12 TS10 TS11 TS13 TS8 TS7 TS9 TS1 P3 TS6 TS2 TS4 TS15 RD BRN BCI GR LFC RD RPM RD BK H1 GR WH 45 L1 BCI OPTION GR 1 2 3 4 5 6 7 8 9 10 FWD REV 20k LIFT DRIVE RIGHT LEFT OR WH BK RD YL PRPL BL WH YL WH ...

Page 138: ...6 14 September2015 Section 6 Schematics 6 13 Platform Control Box Wiring Diagram ANSI CSA from serial number Z452510A 39314 to Z452513A 45734 ...

Page 139: ...6 15 Section 6 Schematics September2015 6 16 Electrical Schematic ANSI CSA from serial number Z452513A 45735 ...

Page 140: ... CR14 CR13 WH J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 30 85 BRN BRN G6 PR1 OFF LMT SPD INP ...

Page 141: ...K C8PBR BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6 WH RD C4P 5 C4...

Page 142: ...6 18 September2015 Section 6 Schematics 6 17 Electrical Schematic ANSI CSA from serial number Z452513A 45735 ...

Page 143: ...6 19 Section 6 Schematics September2015 6 20 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA from serial number Z452513A 45735 ...

Page 144: ...L WH C3B 5 C5TRR WH BK C3B 6 C6LFC WH RD C3B 7 C7PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD BK C6...

Page 145: ...E TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH OPTION TS59 PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH COMPONENT INDEX GROUND CONTROLS NOTE DASHED LINES INDICATE OPTIONS RD RD RD RD BK BK GR D2 BASE BOX HARNESS P182BAT RD C5B 1 1 2 NC C2...

Page 146: ...6 22 September2015 Section 6 Schematics 6 21 Ground Control Box Switch Panel Wiring Diagram ANSI CSA from serial number Z452513A 45735 ...

Page 147: ...RD P24BAT WH BR J1 BR BATGND BR JIBGND C133PLA GR BK C1P 1 C1P 3 C1P 4 C1P 5 C2P 6 C1P 6 C1P 7 C1P 9 C1P 8 C1P 10 C1P 11 C2P 3 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 C9P 1 C9P 2 C9P 3 R42BAT OR RD C2P 4 C1P GY C2P BK C4P BR C3P GR 18 19 CONTROL CABLES C9P C7P 12V DC BATTERY FOOT SWITCH JIB OPTION P134BAT RD B...

Page 148: ...6 24 September2015 Section 6 Schematics 6 23 Platform Control Box Wiring Diagram ANSI CSA from serial number Z452513A 45735 ...

Page 149: ...6 25 Section 6 Schematics September2015 6 26 Electrical Schematic CE from serial number Z452510A 39314 to Z4525Z452513A 45734 ...

Page 150: ...YEL BK WH BK RD ALT CR15 CR13 RELAY RPM CUTOUT CR14 CR13 WH J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 ...

Page 151: ...C7PBE BK C8PBR BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6 WH RD C...

Page 152: ...6 28 September2015 Section 6 Schematics 6 27 Electrical Schematic CE from serial number Z452510A 39314 to Z452513A 45734 ...

Page 153: ...6 29 Section 6 Schematics September2015 6 30 Ground Control Box Terminal Strip Wiring Diagram CE from serial number Z452510A 39314 to Z452513A 45734 ...

Page 154: ... C3B 7 C7PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD BK C6B 4 C4TRL WH C6B 5 C5TRR WH BK C6B 6 C6L...

Page 155: ...TFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH OPTION TS59 PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH COMPONENT INDEX GROUND CONTROLS NOTE DASHED LINES INDICATE OPTIONS RD RD RD RD BK BK GR D2 BASE BOX HARNESS P182BAT RD C5B ...

Page 156: ...6 32 September2015 Section 6 Schematics 6 31 Ground Control Box Switch Panel Wiring Diagram CE from serial number Z452510A 39314 to Z452513A 45734 ...

Page 157: ... GR WH C6LFC WH RD TS12 TS10 TS11 TS13 TS8 TS7 TS9 TS1 P3 TS6 TS2 TS4 TS15 RD BRN BCI GR LFC RD RPM GR BK H6 D39 GR WH 45 L1 BCI OPTION GR 1 2 3 4 5 6 7 8 9 10 FWD REV 20k LIFT DRIVE RIGHT LEFT OR WH BK RD YL PRPL BL WH YL WH RD WH GR DP1 3 4 NO BRN J1 C1PBU RD C11SBD BL BK P2 RD HRN P24BAT WH GR WH R7 R42BAT OR RD BR BCI RD CR7 CR6 GR BK L4 D39 H1 C2P 5 OPTION L4 1 2 NC 1 2 NC 1 2 NC P3 RD C134PW...

Page 158: ...6 34 September2015 Section 6 Schematics 6 33 Platform Control Box Wiring Diagram CE from serial number Z452510A 39314 to Z452513A 45734 ...

Page 159: ...6 35 Section 6 Schematics September2015 6 36 Electrical Schematic CE from serial number Z452513A 45735 ...

Page 160: ... BK RD ALT CR15 CR13 RELAY RPM CUTOUT CR14 CR13 WH J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 ...

Page 161: ...WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6 WH RD C4P 5 C4P 6 C2P 6 D...

Page 162: ...6 38 September2015 Section 6 Schematics 6 37 Electrical Schematic CE from serial number Z452513A 45735 ...

Page 163: ...6 39 Section 6 Schematics September2015 6 40 Ground Control Box Terminal Strip Wiring Diagram CE from serial number Z452513A 45735 ...

Page 164: ...PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD BK C6B 4 C4TRL WH C6B 5 C5TRR WH BK C6B 6 C6LFC WH RD ...

Page 165: ...ATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH OPTION TS59 PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH COMPONENT INDEX GROUND CONTROLS NOTE DASHED LINES INDICATE OPTIONS RD RD RD RD BK BK GR D2 BASE BOX HARNESS P182BAT RD C5B 1 1 2 NC ...

Page 166: ...6 42 September2015 Section 6 Schematics 6 41 Ground Control Box Switch Panel Wiring Diagram CE from serial number Z452513A 45735 ...

Page 167: ...P 1 C1P 3 C1P 4 C1P 5 C2P 6 C1P 6 C1P 7 C1P 9 C1P 8 C1P 10 C1P 11 C2P 3 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 C9P 1 C9P 2 C9P 3 R42BAT OR RD C2P 4 C1P GY C2P BK C4P BR C3P GR 18 19 CONTROL CABLES C9P C7P 12V DC BATTERY FOOT SWITCH JIB OPTION P134BAT RD BRN BATGND P22BAT BK P23SWBAT WH C7P 1 C7P 2 C7P 3 OR RD...

Page 168: ...6 44 September2015 Section 6 Schematics 6 43 Platform Control Box Wiring Diagram CE from serial number Z452513A 45735 ...

Page 169: ...6 45 Section 6 Schematics September2015 Electrical Schematic AS from serial number Z452510A 39314 to Z452511A 40559 6 46 ...

Page 170: ...CUTOUT CR14 CR13 WH J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 30 85 BRN BRN G6 PR1 OFF LMT SP...

Page 171: ...4PLU OR C7PBE BK C8PBR BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6...

Page 172: ...6 48 September2015 Section 6 Schematics Electrical Schematic AS from serial number Z452510A 39314 to Z452511A 40559 6 47 ...

Page 173: ...6 49 Section 6 Schematics September2015 Ground Control Box Terminal Strip Wiring Diagram AS from serial number Z452510A 39314 to Z452511A 40559 6 50 ...

Page 174: ...4 C4TRL WH C3B 5 C5TRR WH BK C3B 6 C6LFC WH RD C3B 7 C7PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD...

Page 175: ...BK TS59 BK RD RD OR OR BK BK BK RD GR GR TS57 BK D4 D13 D80 D82 D28 P1 ES0275M ES0276N LABEL DESCRIPTION CB1 CONTROLS CIRCUIT BREAKER 15A CR1 48V DC POWER RELAY CR2 48V DC POWER RELAY CR3 AUXILIARY PUMP RELAY CR4 HORN RELAY CR5 BRAKE RELEASE RELAY CR20 PRIMARY PUMP RELAY G6 HOURMETER KS1 KEY SWITCH L2 LED FAULT INDICATOR L45 LED PLATFORM OVERLOAD P1 EMERGANCY STOP BUTTON TS51 AUXILIARY PUMP TOGGLE...

Page 176: ...6 52 September2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram AS from serial number Z452510A 39314 to Z452511A 40559 6 51 ...

Page 177: ...SBU BL C12DE BL WH C13DEL BL RD C14PLU OR C15PLD OR BK C16DE OR RD C17PRL GR C18PRR GR BK C19LPE GR WH P26BAT BK P25BAT RD P24BAT WH BR J1 BR BATGND BR JIBGND C133PLA GR BK C1P 1 C1P 3 C1P 4 C1P 5 C2P 6 C1P 6 C1P 7 C1P 9 C1P 8 C1P 10 C1P 11 C2P 3 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 C9P 1 C9P 2 C9P 3 R42BAT...

Page 178: ...6 54 September2015 Section 6 Schematics Platform Control Box Wiring Diagram AS from serial number Z452510A 39314 to Z452511A 40559 6 53 ...

Page 179: ...6 55 Section 6 Schematics September2015 Electrical Schematic AS from serial number Z452511A 40560 to Z452513A 45734 6 56 ...

Page 180: ...H J4 12V 12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 30 85 BRN BRN G6 PR1 OFF LMT SPD INP INTERLOCK L2...

Page 181: ...C14PLU OR C7PBE BK C8PBR BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6 WH...

Page 182: ...6 58 September2015 Section 6 Schematics Electrical Schematic AS from serial number Z452511A 40560 to Z452513A 45734 6 57 ...

Page 183: ...6 59 Section 6 Schematics September2015 Ground Control Box Terminal Strip Wiring Diagram AS from serial number Z452511A 40560 to Z452513A 45734 6 60 ...

Page 184: ... C3B 7 C7PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD BK C6B 4 C4TRL WH C6B 5 C5TRR WH BK C6B 6 C6L...

Page 185: ...BK RD RD OR OR BK BK BK RD GR GR TS57 BK D4 D13 D80 D82 D28 P1 ES0275M ES0276N L45 GR BK H6 RD LABEL DESCRIPTION CB1 CONTROLS CIRCUIT BREAKER 15A CR1 48V DC POWER RELAY CR2 48V DC POWER RELAY CR3 AUXILIARY PUMP RELAY CR4 HORN RELAY CR5 BRAKE RELEASE RELAY CR20 PRIMARY PUMP RELAY G6 HOURMETER KS1 KEY SWITCH L2 LED FAULT INDICATOR L45 LED PLATFORM OVERLOAD P1 EMERGANCY STOP BUTTON TS51 AUXILIARY PUM...

Page 186: ...6 62 September2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram AS from serial number Z452511A 40560 to Z452513A 45734 6 61 ...

Page 187: ...LFC RD RPM GR BK H6 D39 GR WH 45 L1 BCI OPTION GR 1 2 3 4 5 6 7 8 9 10 FWD REV 20k LIFT DRIVE RIGHT LEFT OR WH BK RD YL PRPL BL WH YL WH RD WH GR DP1 3 4 NO BRN J1 C1PBU RD C11SBD BL BK P2 RD HRN P24BAT WH GR WH R7 R42BAT OR RD BR BCI RD CR7 CR6 GR BK L4 D39 H1 C2P 5 OPTION L4 1 2 NC 1 2 NC 1 2 NC P3 RD C134PWR RD GR WH R45JSV GR WH GR WH 45 C45JSV GR WH GR WH 45 C1 BRN RD OUTPUT GR WH CR14 CR6 CR...

Page 188: ...6 64 September2015 Section 6 Schematics Platform Control Box Wiring Diagram AS from serial number Z452511A 40560 to Z452513A 45734 6 63 ...

Page 189: ...6 65 Section 6 Schematics September2015 Electrical Schematic AS from serial number Z452513A 45735 6 66 ...

Page 190: ...12V VOLTAGE REGULATOR CR14 RELAY HIGH RPM 86 87 30 87 85 86 86 85 30 87 86 87 BRN BRN BRN BRN 85 86 CR16 CR16 RELAY ALTERNATOR FIELD BRN BRN 10 ENGINE FAULT 85 85 30 WH FS FS1 H1 P25BAT RD RD FS PLATFORM GROUND P1 KS1 TB22 P3 HORN P2 RD RD P182BAT RD BK FS OR RD CR1 CB3 15A C5B 11 C21IGN2 WH CR2 TB42 RD WH C23PWR WH 30 87 85 86 30 87 86 85 30 85 BRN BRN G6 PR1 OFF LMT SPD INP INTERLOCK L2 5 3 17 G...

Page 191: ... BK WH DOWN TS61 UP PRIMARY BOOM TS63 EXTEND PRIMARY BOOM C3B 7 C3B 8 PLATFORM LEVEL DOWN TS59 C2B 7 UP GR WH C4B 3 C4B 2 C3P 7 C3P 8 EXTEND PRIMARY BOOM RETRACT TS13 DOWN TS9 C4P 3 C4P 2 PLATFORM LEVEL UP C17PRL GR C18PRR GR BK C129DA GR BK C6LFC WH RD C19LPMP GR WH TB44 PLATFORM ROTATE LEFT TS57 C4B 6 GR BK C4B 5 GR RIGHT C2B 6 UP TS58 DOWN JIB BOOM OPTION C4B 7 GR WH C3B 6 WH RD C4P 5 C4P 6 C2P...

Page 192: ...6 68 September2015 Section 6 Schematics Electrical Schematic AS from serial number Z452513A 45735 6 67 ...

Page 193: ...6 69 Section 6 Schematics September2015 Ground Control Box Terminal Strip Wiring Diagram AS from serial number Z452513A 45735 6 70 ...

Page 194: ...PBE BK C3B 8 C8PBR BK WH C3B 10 C10SBU BL C3B 11 C11SBD BL BK C3B 12 C12DE BL WH C4B 2 C14PLU OR C4B 3 C15PLD OR BK C4B 5 C17PRL GR C4B 6 C18PRR GR BK C4B 7 C19LPE GR WH C1B 1 C27AUX RD C1B 7 C33STR BK C1B 8 C34SA BK WH C1B 9 C35HRPM BK RD C1B 11 C37STC BL BK C1B 10 C36STCC BL C2B 4 R42BAT OR RD C2B 6 C129DA GR BK C6B 1 C1PBU RD C6B 2 C2PBD RD BK C6B 4 C4TRL WH C6B 5 C5TRR WH BK C6B 6 C6LFC WH RD ...

Page 195: ...OR OR BK BK BK RD GR GR TS57 BK D4 D13 D80 D82 D28 P1 ES0275R ES0276T L45 GR BK H6 RD LABEL DESCRIPTION CB1 CONTROLS CIRCUIT BREAKER 15A CR1 48V DC POWER RELAY CR2 48V DC POWER RELAY CR3 AUXILIARY PUMP RELAY CR4 HORN RELAY CR5 BRAKE RELEASE RELAY CR20 PRIMARY PUMP RELAY G6 HOURMETER KS1 KEY SWITCH L2 LED FAULT INDICATOR L45 LED PLATFORM OVERLOAD P1 EMERGANCY STOP BUTTON TS51 AUXILIARY PUMP TOGGLE ...

Page 196: ...6 72 September2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram AS from serial number Z452513A 45735 6 71 ...

Page 197: ...H R45JSV GR WH GR WH 45 C45JSV GR WH GR WH 45 C1 BRN RD OUTPUT GR WH CR14 GR WH R7 WH BK BR JIBGND D69 D83 D27 D81 D73 D71 LS18 ES0275R ES0276T CR8 C40LS OR C2P 2 BR DP1 7 RD RD RD LS18 C3BAT RD WH C3 3 C134PWR RD P26BAT BK P2 RD COM U35 BR GND BR GND D88 GR C132PLI1 GR C1P 12 WH LS18 C134PWR RD LS18A BK LS18 OR LS18A P26BAT BK C9P 1 C54 C54 3 P41DE RD BK C54 C54 2 P24BAT RD C54 5 C10SBU BL C54 6 ...

Page 198: ...6 74 September2015 Section 6 Schematics Platform Control Box Wiring Diagram AS from serial number Z452513A 45735 6 73 ...

Page 199: ...6 75 Section 6 Schematics September2015 Platform Options Wiring Diagram from serial number Z452510A 39314 to Z452513A 45734 6 76 ...

Page 200: ...DRIVE LIGHTS TOGGLE SWITCH TS49 WORK LIGHTS TOGGLE SWITCH COMPONENT INDEX PLATFORM CONTROLS C1P GY C2P BK C4P BR C3P GR 18 19 CONTROL CABLES C9P C7P 12V DC BATTERY FOOT SWITCH OPTION JIB OPTION BP1 BK RD RD GR TS12 TS10 TS11 TS13 TS8 TS7 TS9 TS1 P3 TS6 TS2 TS4 TS15 L1 GR 1 2 3 4 5 6 7 8 9 1 FWD REV 20k LIFT DRIVE RIGHT LEFT 0 OR WH BK RD YL PRPL BL WH YL WH RD WH GR DP1 3 4 NO PLATFORM CONTROL BOX...

Page 201: ...LIGHTS TOGGLE SWITCH COMPONENT INDEX PLATFORM CONTROLS C1P GY C2P BK C4P BR C3P GR 18 19 CONTROL CABLES C9P C7P 12V DC BATTERY FOOT SWITCH OPTION JIB OPTION BP1 BK RD RD GR TS12 TS10 TS11 TS13 TS8 TS7 TS9 TS1 P3 TS6 TS2 TS4 TS15 L1 3 4 NO PLATFORM CONTROL BOX P2 1 2 NC 1 2 NC LVI BCI LVI 8 R42BAT OR RD CR19B CR19A CR7 CR6 RD LR19A BL LR19B H1 1 2 NC LVI 4 BR OR RD R42BAT C2P 4 BR GND BK CR19B 85 W...

Page 202: ...6 78 September2015 Section 6 Schematics 6 77 Platform Options Wiring Diagram from serial number Z452513A 45735 ...

Page 203: ...6 79 Section 6 Schematics September2015 Engine Panel Wiring Diagram 6 80 ...

Page 204: ...C CB3 RD BR GND C34SA BK WH 85 87 87a BR J4 30 CR15 86 BK RD 35 BK WH 34 C35HRPM BK RD ENGINE HARNESS TO ENGINE ENGINE HARNESS TO GROUND CONTROL BOX RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE 86 87 85 87a BR J4 BK RD CR14 30 86 85 87 87a CR13 30 WH R14 86 85 87a 87 30 BR J4 WH J4 86 87 87a 30 WH R14 BL ISM2 BK ISM 1 RD J10 BR VOLT WH J4 WH J6 RD J6 BR J4 WH BATT BR J4 WH J5 87 87a 85 30 86...

Page 205: ...1 19 18 C29JSH RD WH C32JSL WH RD 16 17 15 13 14 BRN J8 RD GR BK BATT ISM 9 AP 2 WH BATT WH BATT _ WH BATT R12 LEFT SIDE BATTERY PACK R42BAT OR RD R42BAT OR RD P42BAT OR RD RD P182 12GA PR 2 LIFT CONTACTOR DIODE GR WH 19 BK 2GA BK 2GA FUNCTION HARNESS BK 2GA BK 2GA RD 2GA R42BAT OR RD PR 1 DRIVE CONTACTOR F5 10A PR 1 TOP VIEW OF DRIVE CONTACTOR AUXILIARY LIFT PUMP A2 D1 D1 PRIMARY LIFT PUMP A1 RD ...

Page 206: ...6 82 September2015 Section 6 Schematics Power Panel Wiring Diagram 6 81 ...

Page 207: ...6 83 Section 6 Schematics September2015 6 84 CTE Option Wiring Diagram CE ...

Page 208: ...LU OR CR20 C14PLU OR TB40 OVERLOAD LIM SW 12V 2 OVERLOAD LIM SW 12V 1 BOOM STOWED PLATFORM LEVEL DOWN PLATFORM LEVEL UP WIRING DIAGRAM CR20 PLATFORM LEVEL UP RELAY OR TS59 OR BK TS59 14 15 P22LS BK P134FB WH FH RD KS C40LS1 OR CR20 30 40 134 134 GROUND BOLT C15PLD OR BK C21 1 C14PLU OR C20 1 BR CR21 PLATFORM LEVEL DOWN RELAY C15PLD OR BK CR21 86 C14PLU OR CR20 86 C15PLD OR BK C4B 3 C14PLU OR C4B 2...

Page 209: ...11 10 9 8 C179DPR GR CR5 RD BK 20 22 21 19 18 C29JSH RD WH C32JSL WH RD 16 17 15 13 14 PR 1 DIODE AC BATTERY CHARGER C56 1 BK NO C56 2 WH COM 48V DC OUTPUT SCHEMATIC C49 10 WIRING DIAGRAM CHARGER ECU SUPPLY BATTERY CONTACT OPEN NC NC CLOSED CONNECT NC OPEN CONNECT CONNECT OPEN NC CONNECT 87 30 86 85 ES0276N BATTERYINDICATORLED 1 LED IS RED DURING PHASES I1 AND P BULK CHARGE 20 BATTERY CHARGED 2 LE...

Page 210: ...6 86 September2015 Section 6 Schematics 6 85 Charger Interlock Option ...

Page 211: ... 241 bar S1 SW1 SW2 V2 0 030 inch 0 76 mm V1 2100 psi 145 bar SEC1 SEC2 P1 3 1 3800 psi 262 bar 4 5 1 ATMOS 3500 psi 241 bar P2 EXT 3 1 1000 psi 69 bar RET PRIMARY LIFT CYLINDER PLATFORM LEVEL SLAVE CYLINDER 3 1 3000 psi 207 bar TURNTABLE ROTATE 3 1 3000 psi 207 bar SECONDARY LIFT CYLINDERS PLATFORM ROTATE EXTENSION CYLINDER V2 V1 0 037 inch 0 94 mm 0 030 inch 0 76 mm P 3 1 ATMOS 1500 psi 103 bar ...

Page 212: ...6 88 September2015 Section 6 Schematics Hydraulic Schematic 6 87 ...

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