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Service and Repair Manual

Serial Number Range

-45/25 DC

from Z452513A

-48153

to Z452516N-57199

This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics

-45/25J DC

from Z452513B-3078

to Z452516M-6699

from Z452513D-101

to Z452516D-939

from Z4525D-940

to Z4525D-3977

from Z4524M-6700

to Z4525M-9726

For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.

from Z4525N-57200

to Z4525N-58604

from Z4525F-58605

to Z4525F-61999

Original Instructions
Part No. 1268530GT
Rev B
May 2022

Содержание Genie Z-45/25 DC

Страница 1: ...chematics Z 45 25J DC from Z452513B 3078 to Z452516M 6699 from Z452513D 101 to Z452516D 939 from Z4525D 940 to Z4525D 3977 from Z4524M 6700 to Z4525M 9726 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine from Z4525N 57200 to Z4525N 58604 from Z4525F 58605 to Z4525F 61999 Original Instructions Part No 1268530GT Rev B May 2022 ...

Страница 2: ...6368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie 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 ...

Страница 3: ... 9 2016 Introduction Serial Number Legend A2 9 2016 Repair 10 1 A3 11 2017 Specifications Machine Specifications B 5 2022 Front cover Add ending serial break Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Страница 4: ...umber Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label located under cover 6 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis ...

Страница 5: ...rator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer 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 regulatio...

Страница 6: ...ushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from flamm...

Страница 7: ...r Legend iv Section 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 1 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Machine Torque Specifications 6 Machine Component Weights 6 Hydraulic Hose and Fitting Torque Specifications 7 Torque Procedure 8 SAE and Metric Fasteners Torque Charts 10 ...

Страница 8: ...1 Jib Boom 21 3 2 Jib Boom Lift Cylinder 22 Primary Boom Components 24 4 1 Cable Track 24 How to Remove the Cable Track Z 45 25 24 How to Remove the Cable Track Z 45 25J 25 How to Repair the Primary Boom Cable Track 27 4 2 Primary Boom 28 How to Disassemble the Primary Boom 29 4 3 Primary Boom Lift Cylinder 30 4 4 Primary Boom Extension Cylinder 31 4 5 Upper Pivot Platform Leveling Cylinder 32 Sec...

Страница 9: ...djust the Secondary Boom Down Relief Valve 44 7 3 Jib Boom Platform Rotate Manifold Components 45 7 4 Turntable Rotation Manifold Components 46 7 5 Valve Coils 47 Turntable Rotation Components 48 8 1 Turntable Rotation Assembly 48 Motor Controllers 49 9 1 Motor Controller 49 Steer Axle Components 50 10 1 Hub and Bearings 50 How to Remove the Hub and Bearings 50 How to Install the Hub and Bearings ...

Страница 10: ...6 Charger Interlock Option 67 Hydraulic Schematics 69 Hydraulic Schematic 70 Electrical Schematics ANSI CSA AS Models 71 Electrical Schematic ANSI CSA AS 72 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS 76 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS 77 Platform Control Box Wiring Diagram ANSI CSA AS 80 Electrical Schematics CE Models 81 Electrical Schematic CE 82 Grou...

Страница 11: ...e classification GL5 Batteries Type 6V DC Group L 16 Quantity 8 Capacity 350 AH Reserve capacity 25A rate 750 minutes Performance Specifications Drive speed maximum Stowed position 3 mph 4 8 km h 40 ft 9 sec 12 2 m 9 sec Raised or extended 0 6 mph 0 98 km h 40 ft 45 sec 12 2 m 45 sec Gradeability See Operator s Manual Braking distance maximum High range on paved surface 5 7 ft 1 5 2 m Joystick fun...

Страница 12: ... HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range If the hydr...

Страница 13: ... 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydraul...

Страница 14: ...Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C cSt 1...

Страница 15: ...ulator 0 6 gpm 2 27 L min Jib boom platform rotate flow regulator 0 4 gpm 1 5 L min Auxiliary Pump Type Fixed displacement gear pump Displacement per revolution 0 5 gpm 1 9 L min Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve Coil Resistance Sp...

Страница 16: ...lbs 244 Nm Drive motor mounting bolts lubricated 55 ft lbs 75 Nm Machine Component Weights Primary boom assembly does not include jib assembly 950 lbs 431 kg Secondary boom assembly 1675 lbs 760 kg Turntable assembly does not include booms jib or counterweight 2500 lbs 1134 kg Counterweight 5921 lbs 2686 kg Drive chassis assembly 6200 lbs 2812 kg Tire and wheel assembly 180 lbs 82 kg Drive hub 100...

Страница 17: ... 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port 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 49 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 Adjustable Fitting Non adjustable fitting 1 jam nut SAE O r...

Страница 18: ...and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut a...

Страница 19: ...umber of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fittin...

Страница 20: ...Service and Repair Manual May 2022 Specifications 10 Z 45 25 DC Part No 1268530GT ...

Страница 21: ...on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm...

Страница 22: ...t personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avo...

Страница 23: ...rmation or assistance consult the Genie Product Support 1 boom function speed controller 2 drive joystick Boom Function Speed Controller Adjustments Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Do not adjust the boom function speed controller unless the static battery supply voltage is a...

Страница 24: ...om 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...

Страница 25: ...primary boom until the leveling 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 leveling cylinder at ...

Страница 26: ...al drift and drive the barrel end pin out 11 Carefully pull the cylinder out of the primary boom How to Blee d th e Platf orm Lev eling Cylin der How to Bleed the Platform Leveling Cylinder Note This procedure will have to be preformed outside 1 Z45 25J Raise the jib to a horizontal position and raise the secondary boom 3 feet Z45 25 Raise the secondary boom 4 feet 2 Move the function enable toggl...

Страница 27: ...lly rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top 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 4 Move the function enable toggle switch to either si...

Страница 28: ...em is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the...

Страница 29: ...m and ground controls and the alarm sounds Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 6 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and ...

Страница 30: ...uitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 14 Test all machine functions from the ground controls Result All ground control functions should operate norma...

Страница 31: ...ot 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 down 9 Use a soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the machine 10 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 11 Remove the hose and cable cover from the side of the jib boom ...

Страница 32: ...ecification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib 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 2 Tag disconnect and plug the jib boom lift cy...

Страница 33: ...The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead lifting device 7 Attach a lifting strap from an suitable lifting device to 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...

Страница 34: ... 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 pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect and plug the hydraulic hoses from the PR1 and PR2 ports on the counterbalance valve manifold located on the platform rotator Cap the f...

Страница 35: ...r pinched How to Re mov e th e Cabl e Track Z 45 25J How to Remove the Cable Track Z 45 25J Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Locate the cables from the primary boom cable t...

Страница 36: ...to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 11 Raise the boom to a horizontal position 12 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 13 ...

Страница 37: ... and fall if not properly attached to the lifting device Component damage hazard Cables and hoses can be damaged if they are kinked or pinched How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A 7 link repair section of cable track is available through the Genie Service Parts ...

Страница 38: ...rom the upper pivot platform leveling cylinder barrel end pivot pin Use a soft metal drift to remove the pin Then lower the cylinder and let it hang down Component damage hazard When lowering the master cylinder down be sure not to damage the master cylinder hoses or fittings 7 Locate the primary boom drive speed limit switch inside of the upper pivot 8 Remove the primary boom drive speed limit sw...

Страница 39: ...oom Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom Refer to Repair Procedure How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom Refer to Repair Procedure How to Remove the Primary Boom 2 Place blocks under the barrel end of the primary boom e...

Страница 40: ... Primary Boom Lift Cylinder Bodily injury hazard This 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 When removing a hose assembly or fitting the O ring if equipped on the fitting and or ho...

Страница 41: ...arrel end pivot pin Carefully remove the primary boom lift cylinder from the machine Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbal...

Страница 42: ...the cylinder after removal The cylinder must be at the same length for installation 4 5 Upper Pivot Platform Leveling Cylinder The upper pivot platform leveling cylinder acts as a pump for the bellcrank platform leveling cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The upper pivot platform levling cylinder is located ...

Страница 43: ... Remove the pin retaining fastener from the rod end pivot pin 7 Place a rod through the rod end pivot pin and twist to remove the pin 8 Remove the leveling cylinder from the machine Crushing hazard The platform leveling cylinder may fall if not properly supported when removed from the machine ...

Страница 44: ... 1268530GT Secondary Boom components 1 upper secondary boom number 1 arm 2 upper tension link number 2 arm 3 lower tension link number 3 arm 4 mid pivot 5 compression link 6 secondary boom lift cylinder 2 7 lower secondary boom number 4 arm 8 turntable pivot 9 boom rest 10upper pivot ...

Страница 45: ... lift cylinder with the crane to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder 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 7 Remove the pin retaining fastener ...

Страница 46: ...uitable lifting device Crushing hazard The upper pivot could fall when the number 1 arm is removed from the machine if not properly supported by the suitable lifting device 21 Using a suitable lifting device attached to the upper pivot raise the secondary boom assembly approximately 30 inches 76 cm 22 Insert a 4 x 4 x 11 inch 10 x 10 x 28 cm block between the number 2 arm and the boom rest Then lo...

Страница 47: ...asteners from both compression link pivot pins Do not remove the pins 37 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm 38 Support the compression link with an suitable lifting device 39 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm Remove the compression link from the machine Crushing hazard The number 2 arm ...

Страница 48: ... 50 Attach a lifting strap from the lifting device to the centerpoint of the number 3 arm for support Do not lift it 51 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser 52 Remove the pin retaining fasteners from the number 3 arm at the turntable riser Do not remove the pin 53 U...

Страница 49: ... 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod end pivot pin 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 pin retain...

Страница 50: ...alves open closed Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 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 Specifications Machine Specifications Bodily injury hazard Beware of hot oil Contact with hot oil m...

Страница 51: ...he valves open closed Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 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 Specifications Machine Specifications Bodily injury hazard Beware of hot oil Contact with hot o...

Страница 52: ...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...

Страница 53: ...May 2022 Service and Repair Manual Manifolds Part No 1268530GT Z 45 25 DC 43 ...

Страница 54: ...t adjust the relief valve higher than specified 6 Repeat steps 2 through 4 and recheck relief valve pressure 7 Remove the pressure gauge How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate the secondary boom down relief va...

Страница 55: ... 25 DC 45 7 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way AA Jib boom platform rotate select 20 ft lbs 27 Nm ...

Страница 56: ...ponents The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index No Description Schematic Item Function Torque 1 Counterbalance valve Y Turntable rotate right 30 35 ft lbs 41 47 Nm 2 Counterbalance valve Z Turntable rotate left 30 35 ft lbs 41 47 Nm ...

Страница 57: ...ult in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to 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 schemati...

Страница 58: ...ircuits could result in death or serious injury Remove all rings watches and other jewelry 7 Place a suitable container under the engine plate 8 Tag and disconnect the fuel hose from the fuel filter and drain the fuel tank into a suitable container Refer to Specifications Machine Specifications 9 Tag disconnect and plug the fuel hoses from the fuel tank 10 Remove the fuel tank strap fasteners and ...

Страница 59: ...on and disconnect the battery packs from the machine 2 Tag and disconnect all power cables from the motor controller Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor ...

Страница 60: ...emoving a bearing always use a new inner bearing seal How to I nstall t he Hu b a nd Bea rings How to Install the Hub and Bearings Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease...

Страница 61: ...e to 35 ft lbs 47 Nm 10 Install a new cotter pin Bend the cotter pin to lock it in place Note Always use a new cotter pin when installing a castle nut 11 Install the dust cap then the tire and wheel assembly 12 Lower the machine and remove the blocks 13 Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications ...

Страница 62: ...ed All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary...

Страница 63: ...t is mounted on the left side of the ground control box Fault codes are two digits The controller status indicator light will blink the first digit of a two digit code pause for 1 second and then blink the second digit There will be a 2 second pause between codes For example the indicator light blinks 4 consecutive times pauses for 1 second and then blinks 1 time That would indicate Fault Code 41 ...

Страница 64: ...on If problem persists replace the motor controller 1 Normal operation 12 HW FAILSAFE 1 2 3 Machine will not drive The motor controller failed self test Replace the motor controller 13 M SHORTED Machine will not drive The motor controller has a internal short between M and B terminals Test the motor controller See Repair Section FIELD OPEN Machine will not drive Motor wiring is loose OR motor is d...

Страница 65: ...joystick is defective Consult Genie Product Support 31 CONT DRVR OC Machine will not drive Main contactor PR1 coil defective OR brake release relay CR5 defective Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller 32 MAIN CONT WELDED Machine will not drive Main contactor PR1 contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open ...

Страница 66: ...2V DC Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller 42 OVERVOLTAGE Machine will not drive Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in Be sure the battery charger is disconnected OR check for loose battery cables or poo...

Страница 67: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 57 This page intentionally left blank ...

Страница 68: ...safety rules and operating instructions in the appropriate operator s manual on your machine 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 watch...

Страница 69: ...nal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally open...

Страница 70: ...on 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid op...

Страница 71: ...May 2022 Service and Repair Manual 61 Platform Options Wiring Diagram ...

Страница 72: ...Service and Repair Manual May 2022 62 Z 45 25 DC Part No 1268530GT Platform Options Wiring Diagram ...

Страница 73: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 63 Power Panel Wiring Diagram ...

Страница 74: ...Service and Repair Manual May 2022 64 Power Panel Wiring Diagram ...

Страница 75: ...May 2022 Service and Repair Manual 65 CTE Option Wiring Diagram CE ...

Страница 76: ...Service and Repair Manual May 2022 66 Z 45 25 DC Part No 1268530GT CTE Option Wiring Diagram CE ...

Страница 77: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 67 Charger Interlock Option ...

Страница 78: ...Service and Repair Manual May 2022 68 Charger Interlock Option ...

Страница 79: ...May 2022 Service and Repair Manual 69 Hydraulic Schematic ...

Страница 80: ...Service and Repair Manual May 2022 70 Z 45 25 DC Part No 1268530GT Hydraulic Schematic ...

Страница 81: ...May 2022 Service and Repair Manual 71 Electrical Schematic ANSI CSA AS ...

Страница 82: ...Service and Repair Manual May 2022 72 Z 45 25 DC Part No 1268530GT Electrical Schematic ANSI CSA AS ...

Страница 83: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 73 Electrical Schematic ANSI CSA AS ...

Страница 84: ...Service and Repair Manual May 2022 74 Electrical Schematic ANSI CSA AS ...

Страница 85: ...May 2022 Service and Repair Manual 75 Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS ...

Страница 86: ...Service and Repair Manual May 2022 76 Z 45 25 DC Part No 1268530GT Ground Control Box Terminal Strip Wiring Diagram ANSI CSA AS ...

Страница 87: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 77 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS ...

Страница 88: ...Service and Repair Manual May 2022 78 Ground Control Box Switch Panel Wiring Diagram ANSI CSA AS ...

Страница 89: ...May 2022 Service and Repair Manual 79 Platform Control Box Wiring Diagram ANSI CSA AS ...

Страница 90: ...Service and Repair Manual May 2022 80 Z 45 25 DC Part No 1268530GT Platform Control Box Wiring Diagram ANSI CSA AS ...

Страница 91: ...May 2022 Service and Repair Manual 81 Electrical Schematic CE ...

Страница 92: ...Service and Repair Manual May 2022 82 Z 45 25 DC Part No 1268530GT Electrical Schematic CE ...

Страница 93: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 83 Electrical Schematic CE ...

Страница 94: ...Service and Repair Manual May 2022 84 Electrical Schematic CE ...

Страница 95: ...May 2022 Service and Repair Manual 85 Ground Control Box Terminal Strip Wiring Diagram CE ...

Страница 96: ...Service and Repair Manual May 2022 86 Z 45 25 DC Part No 1268530GT Ground Control Box Terminal Strip Wiring Diagram CE ...

Страница 97: ...May 2022 Service and Repair Manual Part No 1268530GT Z 45 25 DC 87 Ground Control Box Switch Panel Wiring Diagram CE ...

Страница 98: ...Service and Repair Manual May 2022 88 Ground Control Box Switch Panel Wiring Diagram CE ...

Страница 99: ...May 2022 Service and Repair Manual 89 Platform Control Box Wiring Diagram CE ...

Страница 100: ...Service and Repair Manual May 2022 90 Z 45 25 DC Part No 1268530GT Platform Control Box Wiring Diagram CE Z 4 5 25 DC Z 4 5 25 J DC Part No 126 853 0GT Service a nd Re pair Ma nual May 2 022 ...

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