Service Manual Part No.

110188
Rev B1
Refer to inside cover for additional serial number information May 2008

Bi-Energy Power
(from serial number 23236)
 February 2006

Introduction

Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie Z-45/25 Manuals for these models:
Bi-Energy and Genie Z-45/25J Bi-Energy Operator's
Manual before attempting any maintenance or Title Part No.
repair procedure.
Z-45/25 Bi-Energy and Z-45/25J Bi-Energy
This manual provides detailed scheduled Service Manual, Second Edition
maintenance information for the machine owner and (before serial number 23236) ............................ 106488
user. It also provides troubleshooting fault codes
and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.

Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are subject
to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us: Copyright © 1999 by Genie Industries

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

e-mail: techsup@genieind.com Third Edition, Second Printing

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other
countries.

Printed on recycled paper

Printed in U.S.A.

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

February 2006 Introduction

INTRODUCTION

Serial Number Legend

Model: Z-45/25
Serial number: Z452505-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0274
Machine unladen weight:

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

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg Z4525 05 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 45 ft 6 in/ 13.8 m
Model Sequence
Maximum platform reach : 25 ft 3 in/ 7.7 m
number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4

Genie Industries
18340 NE 76th Street
Serial label
Redmond, WA 98052 (located under cover)
USA
Serial number
stamped on chassis

PN - 77055

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

 February 2006

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

February 2006 Section 1 • Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator’s Manual will
result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.

Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

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

Section 1 • Safety Rules
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Used to indicate operation or
maintenance information.
vi Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
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.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for use.
Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
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 fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area is
properly ventilated and well lit.
Part No. 110188
May 2008

Table of Contents

Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

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

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
B Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 7
A-2 Perform Function Tests ................................................................................ 3 - 7

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 February 2006

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

A-3 Check the Generator Belts and Pulleys ........................................................ 3 - 8
A-4 Perform 30 Day Service ............................................................................... 3 - 9
A-5 Perform Engine Maintenance ..................................................................... 3 - 10
A-6 Perform Engine Maintenance, Z482-E ........................................................ 3 - 10
A-7 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11
A-8 Perform Engine Maintenance ..................................................................... 3 - 11
A-9 Perform Engine Maintenance, Z482-E ........................................................ 3 - 12
A-10 Perform Engine Maintenance ..................................................................... 3 - 12
B Checklist B Procedures
B-1 Check the Radiator ..................................................................................... 3 - 13
B-2 Check the Exhaust System ....................................................................... 3 - 13
B-3 Check the Batteries .................................................................................... 3 - 14
B-4 Inspect the Electrical Wiring ....................................................................... 3 - 15
B-5 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 16
B-6 Confirm the Proper Brake Configuration ...................................................... 3 - 16
B-7 Check the Oil Level in the Drive Hubs ........................................................ 3 - 17
B-8 Check and Adjust the Engine RPM ............................................................ 3 - 18
B-9 Test the Ground Control Override ............................................................... 3 - 19
B-10 Test the Platform Self-leveling ................................................................... 3 - 20
B-11 Test the Engine Idle Select ........................................................................ 3 - 20
B-12 Test the Drive Brakes ................................................................................ 3 - 21
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 21

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

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22
B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 22
B-16 Check the Electrical Contactors ................................................................. 3 - 23
B-17 Perform Hydraulic Oil Analysis ................................................................... 3 - 24
B-18 Perform Engine Maintenance ..................................................................... 3 - 24
B Checklist C Procedures
C-1 Perform Engine Maintenance ..................................................................... 3 - 25
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 25
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 26
C-4 Perform Engine Maintenance ..................................................................... 3 - 28
B Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 29
D-2 Check the Free-wheel Configuration ........................................................... 3 - 29
D-3 Replace the Drive Hub Oil .......................................................................... 3 - 30
D-4 Replace the Hydraulic Tank Return Filter ................................................... 3 - 31
D-5 Calibrate the Platform Overload System (if equipped) ................................ 3 - 32
D-6 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 34
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 35
D-8 Perform Engine Maintenance, Z482-E ........................................................ 3 - 37
D-9 Perform Engine Maintenance, Z482-E2B .................................................... 3 - 37
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 38
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 39
E-3 Perform Engine Maintenance, Z482-E ........................................................ 3 - 41
E-4 Perform Engine Maintenance, Z482-E2B .................................................... 3 - 41

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

 February 2006

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
B Platform Controls
1-1 Controllers .................................................................................................... 4 - 2
B Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2 Platform Rotator ........................................................................................... 4 - 5
A Jib Boom Components, Z-45/25J Models
3-1 Jib Boom ...................................................................................................... 4 - 7
3-2 Jib Boom Lift Cylinder .................................................................................. 4 - 8
B Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 10
4-2 Primary Boom ............................................................................................ 4 - 14
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 17
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 18
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 19
B Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 21
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 26
B Kubota Z482-E and Z482-E2B Engine
6-1 Timing Adjustment ..................................................................................... 4 - 27
6-2 RPM Adjustment ........................................................................................ 4 - 27
6-3 Engine Drive Pulley .................................................................................... 4 - 27

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

February 2006

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

B Generator
7-1 Generator Pulley ........................................................................................ 4 - 29
7-2 Generator Belts .......................................................................................... 4 - 30
7-3 Generator Voltage Regulator ...................................................................... 4 - 30
B Hydraulic Pumps
8-1 Auxiliary Pump ........................................................................................... 4 - 33
8-2 Function Pump ........................................................................................... 4 - 33
A Manifolds
9-1 Function Manifold Components .................................................................. 4 - 34
9-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36
9-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 37
9-4 Turntable Rotation Manifold Components ................................................... 4 - 38
9-5 Valve Coils ................................................................................................. 4 - 39
B Turntable Rotation Components
10-1 Turntable Rotation Assembly ..................................................................... 4 - 41
A Motor Controller
11-1 Motor Controller .......................................................................................... 4 - 43

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
A Fault Code Chart .................................................................................................... 5 - 3

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

 February 2006

TABLE OF CONTENTS

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
A Power Cable Diagram ............................................................................................. 6 - 5
A Engine Panel Diagram ........................................................................................... 6 - 6
A Electrical Schematic, Z-45/25, ANSI and CSA Models .......................................... 6 - 7
A Electrical Schematic, Z-45/25, CE Models ............................................................. 6 - 9
B Electrical Schematic, Z-45/25J, ANSI and CSA Models ...................................... 6 - 11
B Electrical Schematic, Z-45/25J, CE Models ......................................................... 6 - 13
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
ANSI and CSA Models ........................................................................................ 6 - 15
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
ANSI and CSA Models ........................................................................................ 6 - 16
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 17
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25
CE Models ........................................................................................................... 6 - 18
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
ANSI and CSA Models ........................................................................................ 6 - 19
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
ANSI and CSA Models ........................................................................................ 6 - 20
A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 21
A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
CE Models ........................................................................................................... 6 - 22
A Platform Control Box Wiring Diagram, Z-45/25 ..................................................... 6 - 23
A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option) .................... 6 - 24
B Platform Control Box Wiring Diagram, Z-45/25J ................................................... 6 - 25
A Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option) .................. 6 - 26
B Hydraulic Schematic ............................................................................................ 6 - 27

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

May 2008 Section 2 • Specifications

REV C
Specifications
Machine Specifications Fluid capacities

Tires and wheels Fuel tank 9 gallons

34.1 liters
Wheel diameter 14.5 inches
Hydraulic tank 8 gallons
Wheel width 7 inches 30.3 liters
Hydraulic system 11 gallons
Wheel lugs 9 @ 5/8 -18
(including tank) 41.6 liters
Lug nut torque 125 ft-lbs Drive hubs (refer to tag on drive hub to determine type)
169.5 Nm EW1 type 17 fl oz
0.51 liter
Tire size 9-14.5 LT
W1 type 23 fl oz
Tire ply rating Tread 8 0.68 liter
Sidewall 6 Drive hub oil type: EP 80-90W gear oil
API service classification GL5
Tire contact area 43.5 sq in
280 sq cm Batteries

Overall tire diameter 28 in Type 6V DC

71 cm
Quantity 8

Capacity 350 AH
For operational specifications, refer to the
Operator's Manual. Reserve capacity @ 25A rate 750 minutes

Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.

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

Section 2 • Specifications
SPECIFICATIONS
Performance Specifications
Drive speeds, maximum
Drive speed, stowed
Drive speed, boom
raised or extended
Braking distance, maximum
High range on paved surface
Gradeability
2-2
May 2008
REV C
Boom function speeds, maximum
from platform controls
Jib boom up, Z-45/25J 32 to 40 seconds
3 mph
4.8 km/h Jib boom down, Z-45/25J 22 to 28 seconds
40 ft/9 sec Primary boom up 31 to 35 seconds
12.2 m/9 sec
Primary boom down 27 to 31 seconds
0.6 mph
1 km/h Secondary boom up 38 to 42 seconds
40 ft/45 sec
12.2 m/45 sec Secondary boom down 32 to 36 seconds
Primary boom extend 14 to 18 seconds
5 to 7 ft Primary boom retract 17 to 21 seconds
1.5 to 2 m
Turntable rotate, 355° 99 to 105 seconds
See Operator's Manual primary boom retracted
Platform rotate, 180°, Z-45/25 6 to 10 seconds
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188
May 2008 Section 2 • Specifications

REV C SPECIFICATIONS

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type: Fixed displacement gear pump

Hydraulic oil type Chevron Rykon MV equivalent Displacement 0.183 cu in

Approximate SAE grade 5W-20 3 cc
Viscosity index rating 200 Flow rate 2.1 gpm
Cleanliness level, minimum 15/13 7.9 L/min

Water content, maximum 200 ppm Hydraulic tank 10 micron with

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

Optional fluids Jib boom/platform rotate flow regulator 0.4 gpm

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

Use Chevron Aviation A hydraulic

oil when in ambient temperatures
consistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.Function Continuous improvement of our products is a
pump Genie policy. Product specifications are subject
to change without notice.

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

Section 2 • Specifications May 2008

SPECIFICATIONS REV C

Manifold Component Machine Torque Specifications

Specifications
Platform rotator
Plug torque 3 /4 -10 center bolt, GR 8 380 ft-lbs
515 Nm
SAE No. 2 36 in-lbs / 4 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
SAE No. 4 10 ft-lbs / 13 Nm
60 Nm
SAE No. 6 14 ft-lbs / 19 Nm
Turntable rotate assembly
SAE No. 8 38 ft-lbs / 51 Nm
Rotate bearing mounting bolts, lubricated 180 ft-lbs
SAE No. 10 41 ft-lbs / 55 Nm 244 Nm

SAE No. 12 56 ft-lbs / 76 Nm Drive motor/brake mounting bolts, dry 110 ft-lbs
149 Nm

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

Valve Coil Resistance Specification 108 Nm

Description Specification Drive motor and hubs

Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω Drive hub mounting bolts, lubricated 180 ft-lbs
(schematic items B, C, D, E, F and H) 244 Nm

Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω Drive motor mounting bolts, lubricated 55 ft-lbs
(schematic items A, K, S and AA) 75 Nm

Proportional solenoid valve, 24V DC 17 to 21 Ω

(schematic item I)

Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.

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

May 2008 Section 2 • Specifications

REV C SPECIFICATIONS

Kubota Z482-E Engine Injection system

Kubota Z482-E2B Engine Injection pump make Bosch MD

Displacement 29.23 cu in Injection timing 21° BTDC

0.48 liters
Injection pump pressure 1991 psi
Number of cylinders 2 137 bar

Bore and stroke 2.64 x 2.68 inches Fuel requirement

67 x 68 mm
For fuel requirements, refer to the engine Operator's
Horsepower, gross intermittent 12.5 @ 3600 rpm Manual on your machine.
9.3 kW
Starter motor
Firing order 1-2
Brush length, new 0.5188 in
Compression ratio 23:1 13 mm

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

28.4 to 32.3 bar 8.5 mm

Low idle 2000 rpm Battery

High idle 3000 rpm Type 12V DC, Group 70

Governor centrifugal mechanical Quantity 1

Valve clearance, cold 0.0057 to 0.0072 in Cold cranking ampere 450A

0.145 to 0.185 mm
Reserve capacity @ 25A rate 125 minutes
Engine coolant
Alternator
Capacity 2.9 quarts Output 12V DC, 150 watts
2.8 liters 1
Fan belt deflection /4 to 3/8 inch
Lubrication system 7 to 9 mm

Oil pressure 36 to 64 psi

2.48 to 4.41 bar

Oil capacity 2.6 quarts

(including filter) 2.5 liters

Lubrication system

Units ship with 10W-40.

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

Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-5

Section 2 • Specifications May 2008

SPECIFICATIONS REV C

Generator
Generator output
with engine @ 3000 rpm 54V DC, 100A

Generator pulley to engine 1/16inch

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

Generator Torque Specifications

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

Engine pulley retaining bolts 108 in-lbs

12.2 Nm

#10 screw 25 in-lbs

2.8 Nm

#10 nut 25 in-lbs

2.8 Nm

#4 nut 8-10 in-lbs

0.9-1.1 Nm

Voltage regulator 25 in-lbs

mounting fasteners 2.8 Nm

Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.

2-6 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

May 2008 Section 2 • Specifications

REV C SPECIFICATIONS

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
field service kit (Genie part
SAE Dash size Torque
number 49612).
-4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-8 40 ft-lbs / 54.2 Nm
4 Position the tube and nut squarely on the face
-10 69 ft-lbs / 93.6 Nm
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.

-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-20 172 ft-lbs / 233.2 Nm
6 Operate all machine functions and inspect the
-24 208 ft-lbs / 282 Nm hoses and fittings and related components to
confirm that there are no leaks.

SAE O-ring Boss Port Seal-Lok Fittings

®

(tube fitting - installed into Steel) (hose end)

SAE Dash size Torque SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm

-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm

-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm

-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm

-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm

-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm

-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm

-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 2-7

Section 2 • Specifications May 2008

SPECIFICATIONS REV C

SAE FASTENER TORQUE CHART

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

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9

(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

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

2-8 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
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.
Failure to properly complete each
inspection when required may
cause death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
· Machine parked on a firm, level surface
· Boom in the stowed position
· Turntable rotated with the boom between
the non-steer wheels
· Turntable secured with the turntable
rotation lock
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power disconnected from the
machine
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Used to indicate operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
3-1
Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor, pump or
engine will be required to perform this
procedure.
Indicates that a warm motor or pump
will be required to perform this
procedure.
Indicates that dealer service will be
required to perform this procedure.
3-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
Maintenance Schedule
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.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A+B
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
Part No. 110188
Pre-Deliver
Pre-Deliveryy Preparation
February 2006 Section 3 • Scheduled Maintenance Procedures

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

Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333

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

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
3-3
Section 3 • Scheduled Maintenance Procedures February 2006

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3-4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model Checklist A - Rev B Y N R Checklist B - Rev B Y N R
A-1 Pre-operation B-1 Radiator
Serial number inspection B-2 Exhaust system
Date A-2 Function tests B-3 Batteries
A-3 Generator belts and B-4 Electrical wiring
Hour meter pulleys
B-5 Lug nut torque
Perform after 50 hours:
Machine owner B-6 Brake configuration
A-4 30 Day Service
B-7 Drive hub oil level
Inspected by (print) Perform every 50 hours:
B-8 Engine RPM
A-5 Perform engine
B-9 Ground control
Inspector signature maintenance
override
Perform every 75 hours:
Inspector title B-10 Platform leveling
A-6 Perform engine
B-11 Engine idle select
maintenance , Z482-E
Inspector company B-12 Drive brakes
Perform every 100 hours:
B-13 Drive speed - stowed
Instructions A-7 Grease rotation
· Make copies of this page to use for bearing B-14 Drive speed - raised
each inspection. A-8 Perform engine B-15 Alarm package
maintenance (if equipped)
· Select the appropriate checklist(s) for
the type of inspection to be Perform every 150 hours: B-16 Electrical contactors
performed. A-9 Perform engine B-17 Hydraulic oil analysis
maintenance, Z482-E Perform every 400 hours:
Daily or 8 hour
Inspection: A Perform every 200 hours: B-18 Perform engine
A-10 Perform engine maintenance
Quarterly or 250 hour
Inspection: A+B maintenance

Six Month or 500 hour Checklist C - Rev B Y N R

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3-5

Section 3 • Scheduled Maintenance Procedures February 2006

MAINTENANCE INSPECTION REPORT

Model Checklist D - Rev B Y N R

D-1 Boom wear pads
Serial number
D-2 Free-wheel
Date configuration
D-3 Drive hub oil
Hour meter D-4 Hydraulic return filter
D-5 Calibrate platform
Machine owner overload system
(if equipped)
Inspected by (print)
D-6 Turntable bearing bolts
Inspector signature D-7 Turntable bearing wear
Perform every 1000 hours:
Inspector title D-8 Perform engine
maintenance, Z482-E
Inspector company
Perform every 1500 hours:
Instructions D-9 Perform engine
· Make copies of this page to use for maintenance,
each inspection. Z482-E2B
· Select the appropriate checklist(s) for
the type of inspection to be Checklist E - Rev B Y N R
performed. E-1 Hydraulic oil
Daily or 8 hour E-2 Wheel bearings
Inspection: A E-3 Perform engine
Quarterly or 250 hour maintenance, Z482-E
Inspection: A+B E-4 Perform engine
maintenance,
Six Month or 500 hour
Z482-E2B
Inspection: A+B+C
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E

· Place a check in the appropriate box

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

3-6 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 3 • Scheduled Maintenance Procedures

REV B
Checklist A Procedures
A-1
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 operator performs
the function tests. The pre-operation inspection
also serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the Operator's Manual on your
machine.
A-2
Perform Function Tests
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the Operator's Manual on your
machine.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3-7

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST A PROCEDURES REV B

A-3 3 Check to be sure the engine pulley and the

generator pulley are aligned within specification
Check the Generator Belts and using a straightedge. Refer to Section 2,
Pulleys Specifications.

Maintaining the generator belts and the pulleys is

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

Bodily injury hazard. Do not

inspect while the engine d
is running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
c
hot engine components. Contact
with hot engine components may a engine pulley
cause severe burns. b straightedge
c maximum pulley offset
Charging the batteries with the d generator pulley
engine does not fully charge the
batteries. Periodically, use the AC If alignment does not meet
battery charger to fully charge the specification, refer to Repair
batteries. Procedure 6-3, How to Install the
Engine Drive Pulley to adjust the
1 Be sure that all fasteners and cables on the pulley alignment.
generator are tight.
2 Be sure that the pulley mounting fasteners are
tight and that the pulleys show no signs of
damage or unusual wear.

3-8 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST A PROCEDURES

4 Inspect the generator belts for: A-4

· Cracking Perform 30 Day Service
· Glazing
· Separation
· Breaks
The 30 day maintenance procedure is a one time
5 Replace both belts if any damage is found. sequence of procedures to be performed after the
first 30 days or 50 hours of usage. After this
6 Check the generator belts for proper tension.
interval, refer to the maintenance tables for
Refer to Section 2, Specifications.
continued scheduled maintenance.
If the belt deflection is not within
specification, see repair procedure 1 Perform the following maintenance procedures:
7-2, How to Adjust the Generator · B-5 Check the Lug Nut Torque
Belts. (including tires and wheels)
· D-4 Replace the Hydraulic Tank Return
Filter
a · D-6 Check the Turnable Rotation Bearing
Bolts
b

a engine pulley
b generator belts
c generator pulley

7 Check the torque of the pulley retaining nut on

the generator. Refer to Section 2,
Specifications.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3-9

Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-5
Perform Engine Maintenance
Engine specifications require that
this procedure be performed every
50 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
3 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
A-6
Perform Engine Maintenance,
Z482-E Engine
Engine specifications require that
this procedure be performed
every 75 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
Part No. 110188
February 2006
REV B
A-7
Grease the Turntable Rotation
Bearing and Rotate Gear
Genie specifications require that
this procedure be performed every
100 hours of operation. Perform
this procedure more often if dusty
conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Before serial number 27001: Locate the
grease fitting on the front turntable cover.
After serial number 27000: Locate the grease
fitting near the ground control box.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this 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
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8
Perform Engine Maintenance
Engine specifications require that
this procedure be performed
every 100 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-9
Perform Engine Maintenance,
Z482-E Engine
Engine specifications require that
this procedure be performed
every 150 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
3 - 12 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
A-10
Perform Engine Maintenance
Engine specifications require that
this procedure be performed
every 200 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
Part No. 110188
February 2006 Section 3 • Scheduled Maintenance Procedures

REV B
Checklist B Procedures
B-1 B-2
Check the Radiator Check the Exhaust System

Maintaining the radiator in good condition is Maintaining the exhaust system is essential to
essential for good engine performance. Operating good engine performance and service life. Running
a machine with a damaged or leaking radiator may the engine with a damaged or leaking exhaust
result in engine damage. Also, restricting air flow system can cause component damage and unsafe
through the radiator (i.e., dirt or debris) will affect operating conditions.
the performance of the cooling system. A frequent
check allows the inspector to identify changes in Bodily injury hazard. Do not
the condition of the radiator that might indicate inspect while the engine
cooling system problems. is running. Remove the key to
secure from operation.
Bodily injury hazard. Do not
Bodily injury hazard. Beware of
inspect while the engine is
hot engine components. Contact
running. Remove the key to
with hot engine components may
secure from operation.
cause severe burns.
Bodily injury hazard. Beware of
1 Remove the engine pivot plate latch retainer.
hot engine components. Contact
with hot engine components may 2 Open the engine pivot plate latch and swing the
cause severe burns. engine pivot plate out away from the machine to
access the exhaust system.
1 Remove the engine pivot plate latch retainer.
3 Be sure that all nuts and bolts are tight.
2 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine to 4 Inspect all welds for cracks.
access the radiator.
5 Inspect for exhaust leaks; i.e., carbon buildup
3 Inspect the radiator for leaks and physical around seams and joints.
damage.
4 Clean the radiator fins of debris and foreign
materials.
5 Swing the engine back to its original position
and close the engine pivot plate latch.
6 Install the engine pivot plate latch retainer.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 13

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST B PROCEDURES REV B

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

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

3 - 14 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
REV B
B-4
Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
1 Open the engine side turntable cover.
2 Remove the safety pin from the engine pivot
plate latch.
The engine pivot plate latch is
located under the engine turntable
pivot plate at the counterweight
end of the machine.
3 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.
4 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Power units
· Inside of the ground control box
· Generator and power units
· Engine wiring harness
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
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 harness connectors to the ground
control box
8 Raise the secondary boom until the mid-pivot is
approximately 10 feet / 3 m off the ground.
9 Remove the center turntable cover.
10 Inspect the turntable center area for burnt,
chafed and pinched cables.
11 Install the center turntable cover.
12 Lower the boom to the stowed position and turn
the machine off.
13 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Cable track on the primary, jib and
secondary booms
· Jib boom to platform cable harness
· Inside of the platform control box
14 Inspect for a liberal coating of dielectric grease
at the following location:
· All wire harness connectors to the platform
control box
3 - 15
Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST B PROCEDURES REV B

B-5 B-6
Check the Tires, Wheels and Confirm the Proper
Lug Nut Torque Brake Configuration

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

3 - 16 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

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

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 top and the other one is
at 90 degrees.
check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install 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.

models with pipe plugs

a models with o-ring plugs

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 17

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST B PROCEDURES REV B

B-8 4 Loosen the lock nut, then turn the low idle
adjustment screw clockwise to increase the rpm
Check and Adjust the or counterclockwise to decrease the rpm.
Engine RPM Tighten the lock nut and recheck the rpm.

a
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.

1 Remove the engine pivot plate latch retainer.

b
2 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine.
c
3 Connect an rpm gauge to the engine, and then
start the engine from the ground controls. d

Result: Low idle should be 2000 rpm.

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

5 Move the engine idle control switch to high idle

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

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February 2006
REV B
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.
Be sure the solenoid fully retracts
when activating high idle.
7 Swing the engine back to its original position
and close the engine pivot plate latch.
8 Install the engine pivot plate latch retainer.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
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
ground controls whether or not the Emergency
Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
the operator at the platform controls cannot return
the boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
3 Operate each boom function through a
partial cycle at the ground controls.
Result: All boom functions should operate.
3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-10
Test the Platform Self-leveling
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which is controlled by the
master cylinder located at the base of the primary
boom. A platform self-leveling failure creates an
unsafe working condition.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
2 Lower the boom to the stowed position.
3 Hold the function enable toggle switch to either
side and adjust the platform to a level position
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.
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February 2006
REV B
B-11
Test the Engine Idle Select
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are three settings.
Low idle (turtle symbol): Low idle and slow battery
charging.
High idle (rabbit symbol): High idle and quickest
battery charging.
Foot switch activated high idle (rabbit and foot
switch symbols): Activates high idle only when the
foot switch is pressed down.
1 Start the engine from the ground 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 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine should change to low idle.
6 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
7 Press down the foot switch.
Result: The engine should change to high idle.
Part No. 110188
February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

B-12 B-13
Test the Drive Brakes Test the Drive Speed -
Stowed Position

Proper brake action is essential to safe machine

operation. The machine uses drive motor Proper drive function movement is essential to
regenerative braking to stop the machine. safe machine operation. The drive function should
Hydraulically-released individual wheel brakes hold respond quickly and smoothly to operator control.
the machine once it has stopped. The drive motor Drive performance should also be free of
regenerative braking should operate smoothly, free hesitation, jerking and unusual noise over the
of hesitation and jerking. Hydraulically-released entire proportionally controlled speed range.
individual wheel brakes can appear to operate
normally when not fully operational. Select a test area that is firm, level
and free of obstructions.
Collision hazard. Be sure that the
machine is not in free-wheel or 1 Create start and finish lines by marking two
partial free-wheel configuration. lines on the ground 40 feet / 12.2 m apart.
Refer to B-6, Confirm the Proper
2 Lower the boom into the stowed position.
Brake Configuration.
3 Choose a point on the machine; i.e., contact
Select a test area that is firm, level
patch of a tire, as a visual reference for use
and free of obstructions.
when crossing the start and finish lines.
1 Mark a test line on the ground for reference.
4 Bring the machine to maximum drive speed
2 Lower the boom into the stowed position. before reaching the start line. Begin timing
when your reference point on the machine
3 Choose a point on the machine; i.e., contact crosses the start line.
patch of a tire, as a visual reference for use
when crossing the test line. 5 Continue at full speed and note the time when
the machine reference point passes over the
4 Bring the machine to maximum drive speed finish line. Refer to Section 2, Specifications.
before reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
5 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
The brakes must be able to hold
the machine on any slope it is able
to climb.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 21

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST B PROCEDURES REV B

B-14 B-15
Test the Drive Speed - Raised or Test the Alarm Package
Extended Position (if equipped)
The alarm package includes:

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

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February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

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

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 23

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST B PROCEDURES REV B

B-17 B-18
Perform Hydraulic Oil Analysis Perform Engine Maintenance

Replacement or testing of the hydraulic oil is Engine specifications require that

essential for good machine performance and this procedure be performed
service life. Dirty oil and suction strainers may every 400 hours.
cause the machine to perform poorly and
Proper engine maintenance, following the engine
continued use may cause component damage.
manufacturer's maintenance schedule, is essential
Extremely dirty conditions may require oil changes
to good engine performance and service life.
to be performed more often.
Failure to perform the maintenance procedures
Before replacing the hydraulic oil, can lead to poor engine performance and
the oil may be tested by an oil component damage.
distributor for specific levels of
Required maintenance procedures and additional
contamination to verify that
engine information are available in the
changing the oil is necessary. If
Kubota Z482-E Operator's Manual
the hydraulic oil is not replaced
(Kubota part number 16676-89167).
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test. See E-1, Kubota Z482-E Operator's Manual
Test or Replace the Hydraulic Oil. Genie part number 52958

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.

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February 2006
REV B
Checklist C Procedures
C-1
Perform Engine Maintenance
Engine specifications require that
this procedure be performed
every 500 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52957
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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
C-2
Grease the Platform Overload
Mechanism (if equipped)
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
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3 - 25
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3
Test the Platform Overload
System (if equipped)
Genie specifications require that
this procedure be performed every
500 hours or six months,
whichever comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
Perform this procedure with the
machine on a firm, level surface.
1 Turn the key switch to platform control.
2 Level the platform from the platform controls.
3 Determine the maximum platform capacity.
Refer to the machine serial plate.
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February 2006
REV B
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 platform
controls.
6 Add an additional 10 lbs / 4.5 kg of 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.
Result: If the alarm does not sound and the
platform overload indicator light does not come
on with the test weights in any of the platform
locations, the platform overload system needs
to be calibrated. See D-5, Calibrate the
Platform Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
Part No. 110188
February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST C PROCEDURES

7 Carefully move the test weights to each 11 Lift the test weights off the platform floor using a
remaining location in the platform. suitable lifting device.
Result: The alarm should be sounding. Result: The platform overload indicator light and
The platform overload indicator light should be alarm should turn off at both the ground and
flashing at both the ground and platform platform controls.
controls.
There may be an approximate 2
Result: If the alarm does not sound and the second delay before the overload
platform overload indicator light does not come indicator light and alarm turn off.
on with the test weights in any of the platform
12 Test all machine functions from the ground
locations, the platform overload system needs
controls.
to be calibrated. See D-5, Calibrate the
Platform Overload System. Result: All ground control functions should
operate normally.
There may be an approximate 2
second delay before the overload 13 Turn the key switch to platform control.
indicator light turns on and the
alarm sounds. 14 Test all machine functions from the platform
controls.
8 Test all machine functions from the platform
controls. Result: All platform control functions should
operate.
Result: All platform control functions should not
operate. If the platform overload system is
not operating properly, see D-5,
9 Turn the key switch to ground control. Calibrate the Platform Overload
System.
10 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 27

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST C PROCEDURES REV B

C-4
Perform Engine Maintenance

Engine specifications require that

this procedure be performed
every 800 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).

Kubota Z482-E Operator's Manual

Genie part number 52958

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.

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February 2006 Section 3 • Scheduled Maintenance Procedures

REV B
Checklist D Procedures
D-1 D-2
Check the Primary Boom Check the Free-wheel
Wear Pads Configuration

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

3 /4 5/8 brake disengaged position

Top, bottom and side wear pads inch inch
(platform end of boom) 19 mm 15.9 mm

Side and bottom wear pads 5/8 inch 1/2 inch

(pivot end of boom) 15.9 mm 12.7 mm
brake engaged position

Top wear pads 3 /4

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 29

Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate with
minimum effort.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Collision hazard. Failure to
engage the drive hubs could result
in death or serious injury and
property damage.
3 - 30 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
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 hub to be serviced. Then drive
the machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
models with pipe plugs
a models with o-ring plugs
Part No. 110188
February 2006
REV B
3 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Refer to Section 2, Specifications.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub.
6 Repeat steps 1 through 5 for the other drive
hub.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-4
Replace the Hydraulic Tank
Return Filter
Replacement of the hydraulic tank return filter is
essential for good machine performance and
service life. A dirty or clogged filter 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 oil filter wrench.
4 Apply a thin layer of oil to the new oil filter
gasket.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls.
7 Activate any boom function and inspect the filter
and related components to be sure that there
are no leaks.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
3 - 31
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-5
Calibrate the Platform Overload
System (if equipped)
Genie specifications require that
this procedure be performed every
1000 hours or annually, whichever
comes first.
Yearly calibration of the platform overload system
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.
Perform this procedure with the
machine on a firm, level surface.
1 Level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Using a suitable lifting device, place an
appropriate test weight equal to that of the
maximum platform capacity at the center of the
platform floor.
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February 2006
REV B
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 indicator light and alarm turns off.
The platform will need to be
moved up and down and allowed
to settle in between adjustments.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
Result: The overload indicator light and
alarm is off. Slowly loosen the load spring
adjustment nut by turning it counterclockwise
just until the overload indicator light and alarm
turn on.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
The platform will need to be
moved up and down and allowed
to settle in between adjustments.
Part No. 110188
February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST D PROCEDURES

Confirm the setting: 10 Turn the key switch to ground control.

5 Turn the key switch to platform control. 11 Test all machine functions from the ground
controls.
6 Lift the test weight off the platform floor using a
suitable lifting device. Result: All ground control functions should not
operate.
7 Place the test weight back onto the center of
the platform floor using a suitable lifting device. If the platform overload system is
not operating properly, repeat
Result: The alarm should be off. The platform steps 1 through 4.
overload indicator light should be off at both the
ground and platform controls.
There may be an approximate 2
second delay before the overload
indicator light and alarm turn off.
8 Add an additional 10 lb / 4.5 kg test weight to
the original test weight to overload the platform.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at both the ground and platform
controls.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 33

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST D PROCEDURES REV B

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

bolt is torqued in sequence to specification.
Check the Turntable Rotation Refer to Section 2, Specifications.
Bearing Bolts
18 1
9 11
6 7

Maintaining proper torque on the turntable bearing 16 13

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

A lift cylinder safety chock is

available through Genie Service
Parts (Genie part number 33484). Counterweight

18 6 13
3 10
11 1
8 15

16 7
2 12
9 4
14 5 17
Bolt torque sequence
(after serial number 26999)

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February 2006 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST D PROCEDURES

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

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3 - 35

Section 3 • Scheduled Maintenance Procedures February 2006

CHECKLIST D PROCEDURES REV B

4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
To obtain an accurate
measurement, place the dial
indicator no more than 1 inch /
2.5 cm from the turntable rotation
bearing.
a
b bearing has been checked in at least four
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.
Visually inspect the the dial indicator to be sure
the needle returns to the "zero" position.
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
equally spaced areas 90° apart.

c 11 Lower the primary and secondary booms to the

stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
d

a turntable
b dial indicator
c drive chassis
d turntable rotation bearing

5 At the dial indicator, adjust it to "zero" the

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

3 - 36 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
REV B
D-8
Perform Engine Maintenance,
Z482-E Engine
Engine specifications require that
this procedure be performed
every 1000 hours or annually,
whichever comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-9
Perform Engine Maintenance,
Z482-E2B Engine
Engine specifications require that
this procedure be performed
every 1500 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
3 - 37
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
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 may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test.
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Place a suitable container under the hydraulic
tank.
3 - 38 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
2 Remove the drain plug from the hydraulic tank.
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 severe burns.
4 Tag, disconnect and plug the hydraulic hose
from the hydraulic tank filter at the tank.
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.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
5 Remove the hydraulic tank mounting fasteners.
6 Pull the hydraulic tank out slightly to access the
two suction hoses.
7 Tag, disconnect and plug the two suction hoses
on the back of the hydraulic tank.
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.
Part No. 110188
February 2006
REV B
8 Remove the hydraulic tank from the machine.
Component damage hazard. The
hydraulic tank is plastic and may
become damaged if allowed to fall.
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Rinse out the inside of the tank using a mild
solvent.
11 Install the suction strainer and drain plug using
a thread sealer on the threads.
12 Place the hydraulic tank onto the machine.
13 Install the hydraulic hoses.
14 Install the hydraulic tank retaining strap.
Component damage hazard. The
hydraulic tank may become
damaged if the tank strap
fasteners are over tightened.
15 Fill the tank with hydraulic oil until the fluid is
within the FULL and ADD marks on the hydraulic
tank. Do not overfill.
16 Clean up any oil that may have spilled. Properly
discard of oil.
17 Operate all machine functions through a full
cycle and check for leaks.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
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 damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels, then center a lifting
jack under the steer axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.
3 - 39
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
7 Tighten the castle nut to 35 ft-lbs / 47 Nm to
seat the bearings.
8 Loosen the castle nut and re-tighten to
8 ft-lbs / 11 Nm.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue with step 10 and
grease the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 10 and replace the
wheel bearings with new ones.
When replacing a wheel bearing,
both the inner and outer bearings,
including the pressed-in races,
must be replaced.
10 Remove the castle nut.
11 Pull the hub off of the spindle. 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.
3 - 40 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
15 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Always replace the bearing grease
seal when removing the hub.
16 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
17 Place the outer bearing into the hub.
18 Install the washer and castle nut.
19 Tighten the castle nut to 35 ft-lbs / 47 Nm to
seat the bearings.
20 Loosen the castle nut and re-tighten to
8 ft-lbs / 11 Nm.
21 Install a new cotter pin. Bend the cotter pin
to lock it in.
Always use a new cotter pin when
installing a castle nut.
22 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
Part No. 110188
February 2006
REV B
E-3
Perform Engine Maintenance,
Z482-E Engine
Engine specifications require that
this procedure be performed
every 2000 hours or every two
years, whichever comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-4
Perform Engine Maintenance,
Z482-E2B Engine
Engine specifications require that
this procedure be performed
every 3000 hours or every two
years, whichever comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89167).
Kubota Z482-E Operator's Manual
Genie part number 52958
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.
3 - 41
Section 3 • Scheduled Maintenance Procedures February 2006

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3 - 42 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the Operator’s
Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steer wheels
· Turntable secured with the turntable
rotation lock
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Used to indicate operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
4-1
Section 4 • Repair Procedures
Platform Controls
1-1
Controllers
Platform Controls
The drive joystick is connected to the drive motor
controller located under the non-steer end drive
chassis cover. The drive motor controller can also
recognize machine drive malfunctions and display
controller fault codes by flashing an LED at the
ground controls. Refer to Section 5, Fault Codes
for a list of fault codes and additional information.
There are no adjustments needed on the drive
joystick controller. For further information or
assistance, consult the Genie Industries Service
Department.
b a
a boom function speed controller
b drive joystick
4-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
Boom Function Speed
Controller Adjustments
Do not adjust the controllers
unless the static battery supply
voltage is above 24V DC at the
platform red Emergency Stop
button.
Electrocution hazard. 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 platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
a threshold adjustable trimpot
b max-out adjustable trimpot
c white/red wire to TP6
d boom function speed controller
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B PLATFORM CONTROLS

3 Disconnect the blk/red wire of the boom

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

6 Set the threshold: With the boom in the stowed

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

Boom function speed

controller specifications

Threshold 0.17 to 0.18A

Max-out 0.54 to 0.55A

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4-3

Section 4 • Repair Procedures
Platform Components
2-1
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
How to Remove the Platform
Leveling Slave Cylinder
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no
air in the closed loop.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Z-45/25J: Extend 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.
4-4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
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 the unions and
connect them together using a connector.
Connect the hoses from the cylinder together
using a connector.
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 Remove the pin retaining fastener from the
slave cylinder rod-end pivot pin. Do not remove
the pin.
6 Z-45/25J: Remove the external snap rings from
the slave cylinder barrel-end pivot pin. Do not
remove the pin.
Z-45/25: Remove the pin retaining fastener
from the slave cylinder barrel-end pivot pin. Do
not remove the pin.
7 Place a block under the slave cylinder for
support. Protect the cylinder rod from damage.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B PLATFORM COMPONENTS

8 Use a soft metal drift to drive the rod-end pivot 2-2

pin out.
Crushing hazard. The platform
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly supported.
Component damage hazard. The
slave cylinder rod may become
damaged if it is allowed to fall if
not properly supported by the
lifting device.
9 Use a soft metal drift and drive the barrel-end
pin out.
10 Carefully pull the cylinder out of the primary
boom.
Platform Rotator
How to Bleed the Platform
Rotator
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.
Before serial number 24304:

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

d c b

a top bleed valve

b bottom bleed valve
c container
d clear hose

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4-5

Section 4 • Repair Procedures
PLATFORM COMPONENTS
4 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
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
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.
After serial number 24303:
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.
4-6 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
4 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation.
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.
Part No. 110188
February 2006
REV A
Jib Boom Components, Z-45/25J
3-1
Jib Boom
How to Remove the Jib Boom
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Remove the platform.
2 Tag and disconnect the electrical connectors
from the jib boom/platform rotate select
manifold mounted to the platform support.
3 Tag, disconnect and plug all of the hydraulic
hoses from the jib boom/platform rotate select
valve manifold. Cap the fittings on the manifold
and pull the hoses out through the platform
rotator.
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 platform mounting weldment.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
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 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. Remove the hose and cable
separators.
12 Attach a lifting strap from an overhead crane to
the jib boom.
13 Support the barrel end of the jib boom lift
cylinder with a suitable lifting device.
14 Tag, disconnect and plug the jib 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 dissipate
gradually. Do not allow oil to
squirt or spray.
4-7
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, Z-45/25J
15 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
16 Use a soft metal drift to remove the pin and let
the cylinder hang down.
Crushing hazard. The jib boom
could fall when when the barrel-
end pivot pin is removed if not
properly supported by the
overhead crane.
17 Remove the pin retaining fastener from the jib
boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
bellcrank.
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
18 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
19 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib
boom lift cylinder from 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.
4-8 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV A
3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, 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.
Do not rest the entire weight of the
boom on the blocks.
2 Tag, disconnect and plug the jib 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 dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV A JIB BOOM COMPONENTS, Z-45/25J

3 Remove the pin retaining fasteners from the jib

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4-9

Section 4 • Repair Procedures
Primary Boom Components
4-1
Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Remove the Cable Track,
Z-45/25
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
2 Disconnect the cables from the platform control
box.
3 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
4 Raise the primary boom to a horizontal position.
4 - 10 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
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 pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
6 Tag, disconnect and plug the hydraulic hoses
from the "V1" and "V2" ports of the
counterbalance valve manifold at the platform
rotator. Cap the fittings on the manifold.
Bodily injury hazard. Spraying
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 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master 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.
Part No. 110188
February 2006
REV B
8 Tag and disconnect the hydraulic hoses from
the platform leveling slave cylinder and connect
them together using a connector. 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.
9 Pull the four hydraulic hoses toward the
platform to clear the rod end of the primary
boom lift cylinder.
10 Place blocks in 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.
11 Remove all hose and cable clamps from the
underside of the primary 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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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 become unbalanced and fall
if not properly attached to the
overhead crane.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
How to Remove the Cable Track,
Z-45/25J
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
2 Disconnect the cables from the platform control
box.
3 Remove the hose and cable cover from the side
of the jib boom. Remove the hose and cable
separators.
4 - 11
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
4 Remove the hose clamp on the primary boom
bellcrank.
5 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
6 Tag, disconnect and plug the hydraulic hoses
from the "V1" and "V2" ports of the
counterbalance valve manifold at the platform
rotator. Cap the fittings on the manifold.
Bodily injury hazard. Spraying
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 Tag and disconnect the hydraulic hoses from
the platform leveling slave cylinder at the union
and connect them together using a connector.
Connect the hoses from the cylinder together
using a connector.
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 - 12 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
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
gradually. Do not allow oil to
squirt or spray.
9 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located above the
primary boom lift cylinder. Cap the fittings on
the unions.
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 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master 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.
Part No. 110188
February 2006
REV B
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 Attach a lifting strap from an overhead 5 ton /
5,000 kg capacity crane to the platform end of
the primary boom for support. Do not lift it.
14 Remove all hose and cable clamps from the
underside of the primary boom.
15 Support the rod end of the primary boom lift
cylinder with a suitable lifting device.
16 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Do
not remove the pin.
17 Raise the primary boom slightly with the
overhead crane to relieve the pressure on the
primary boom lift cylinder rod-end 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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
primary boom lift cylinder.
21 Raise the rod end of the primary boom lift
cylinder back into position and install the rod-
end pivot pin. Install the pin retaining fasteners.
22 Attach a strap from an overhead crane to the
cable track.
23 Remove the mounting fasteners from the upper
cable track at the platform end of the extension
boom.
24 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.
25 Remove the cable track from the machine and
place it on a structure capable of supporting it.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
overhead crane.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
4 - 13
Section 4 • Repair Procedures February 2006

PRIMARY BOOM COMPONENTS REV B

How to Repair the Primary Boom 4-2

Cable Track
Component damage hazard. The
primary boom cable track can be
damaged if it is twisted.
A 7 link repair section of cable
track is available through the
Genie Industries Service Parts
Department.
a
b boom in the stowed position.
a link separation point
b lower clip
1 Use a slotted screwdriver to pry down on the
lower clip.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to
the side.
3 Repeat steps 1 and 2 for each link to be
removed.
Primary Boom
How to Remove the Primary
Boom
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.
Perform this procedure with the
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Remove the platform.
2 Z-45/25: Remove the platform rotator and
platform mounting weldment.
Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
3 Remove the cable track. See 4-1, How to
Remove the Cable Track.
4 Raise the primary boom to a horizontal position.

4 - 14 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 4 • Repair Procedures

REV B PRIMARY BOOM COMPONENTS

5 Remove the hose and cable cover from the 13 Remove the hose clamp at the pivot end of the
upper pivot. boom.
6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead crane to the
master cylinder barrel-end pivot pin. Use a soft center point of the primary boom.
metal drift to remove the pin. Then lower the
15 Attach a similar lifting device to the primary
cylinder and let it hang down.
boom lift cylinder.
Component damage hazard.
16 Place support blocks under the primary boom
When lowering the master cylinder
lift cylinder.
down, be sure not to damage the
master cylinder hoses or fittings. 17 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
7 Locate the primary boom drive speed limit
a soft metal drift to remove the pin.
switch inside of the upper pivot.
Crushing hazard. The boom lift
8 Remove the primary boom drive speed limit
cylinder and primary boom will fall
switch mounting fasteners. Do not disconnect
if not properly supported.
the wiring.
18 Lower the rod end of the primary boom lift
9 Locate the primary extension boom drive speed
cylinder onto support blocks. Protect the
limit switch inside of the extension boom.
cylinder rod from damage.
10 Remove the primary extension boom drive
19 Remove the pin retaining fasteners from the
speed limit switch mounting fasteners. Do not
primary boom pivot pin.
disconnect the wiring.
20 Remove the primary boom pivot pin with a soft
11 Pull the limit switch and the wiring out of the
metal drift, then carefully remove the primary
extension tube and move it out of the way.
boom from the machine and place it on a
12 Tag, disconnect and plug the primary boom structure capable of supporting it.
extension cylinder hydraulic hoses. Cap the
Crushing hazard. The primary
fittings on the cylinder.
boom could become unbalanced
Bodily injury hazard. Spraying and fall when removed from the
hydraulic oil can penetrate and machine if not properly attached to
burn skin. Loosen hydraulic the overhead crane.
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 15

Section 4 • Repair Procedures February 2006

PRIMARY BOOM COMPONENTS REV B

How to Disassemble the Primary 6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
Boom platform end of the extension tube. Use a soft
Complete disassembly of the metal drift to remove the pin.
boom is only necessary 7 Support and slide the extension cylinder out of
if the outer or inner boom tube the base end of the extension tube. Place the
must be replaced. The extension extension cylinder on blocks for support.
cylinder can be removed without
completely disassembling the Crushing hazard. The extension
boom. See 4-4, How to Remove cylinder could become unbalanced
the Primary Boom Extension and fall when removed from
Cylinder. primary boom extension tube if not
properly supported.
1 Remove the primary boom. See How to
Remove the Primary Boom. During removal, the overhead
crane strap will need to be
2 Place blocks under the barrel end of the primary carefully adjusted for proper
boom extension cylinder for support. balancing.
3 Remove the pin retaining fastener from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom. Use a soft metal
drift to remove the pin.
4 Remove and label the location of the wear pads
from the platform end of the primary boom.
Pay careful attention to the
location and amount of shims
used with each wear pad.
5 Support and slide the extension tube and
extension cylinder assembly out of the boom
tube.
Crushing hazard. The primary
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.

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February 2006
REV B
4-3
Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers
the primary boom. The primary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove the 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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above
the turntable covers.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support.
4 Raise the primary boom with the overhead
crane slightly to take the pressure off the
primary boom lift cylinder pivot pins.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
5 Support the rod end and the barrel end of the
primary boom lift cylinder with a second
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 dissipate
gradually. Do not allow oil to
squirt or spray.
7 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
Crushing hazard. The primary
boom will fall if not properly
supported when the primary boom
rod-end pivot pin is removed.
8 Place a support block across both turntable
covers under the primary boom lift cylinder.
9 Lower the rod end of the lift cylinder onto the
block. Protect the cylinder rod from damage.
Crushing hazard. The primary
boom lift cylinder could fall if not
properly supported.
10 Support the barrel end of the primary boom lift
cylinder with an overhead crane or similar lifting
device.
11 Remove the primary boom lift cylinder barrel-
end pivot pin retaining fasteners. Use a slide
hammer to remove the barrel-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 - 17
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Primary
Boom Extension 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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Extend the primary boom until the primary
boom extension cylinder rod-end pivot pin is
accessible in the primary boom extension tube.
4 - 18 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
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 At the platform end of the boom, remove the
external snap rings from the extension cylinder
rod-end pivot pin. Use a soft metal drift to
remove the pin.
6 Remove the barrel-end pivot pin retaining
fasteners.
7 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
8 Support and slide the extension cylinder out of
the upper pivot.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
Component damage hazard. Be
careful not to damage the
counterbalance valves on the
primary boom extension cylinder
when removing the cylinder from
the primary boom.
Component damage hazard.
Hoses and cables can be
damaged if the primary boom
extension cylinder is dragged
across them.
Note the length of the cylinder
after removal. The cylinder must
be at the same length for
installation.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B PRIMARY BOOM COMPONENTS

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

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 19

Section 4 • Repair Procedures February 2006

Secondary Boom Components REV B

a b c

h d

Secondary Boom components

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

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February 2006
REV B
5-1
Secondary Boom
How to Disassemble the
Secondary Boom
Bodily injury hazard. The
procedures in this section require
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 required.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Remove the platform.
2 Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
3 Remove the primary boom. See 4-2, How to
Remove the Primary Boom.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
4 Remove the master cylinder. See 4-5, How to
Remove the Platform Leveling Master Cylinder.
5 Attach a lifting strap from an overhead crane to
to the lug on the rod end of the primary boom
lift cylinder. Then raise the primary boom 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 from the
primary boom lift cylinder barrel-end pivot pin.
8 Use a slide hammer to remove the pin. Remove
the primary boom lift cylinder from the machine.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the overhead crane.
9 Tag, disconnect 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.
4 - 21
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
10 Remove the pin retaining fasteners from both
sides of the secondary boom lift cylinder rod-
end pivot pin and barrel-end pivot pin. Do not
remove the pins.
11 Attach a strap from an overhead crane to the
lug on the rod end of one of the secondary
boom lift cylinders for support. Do not apply any
lifting pressure.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
13 Use a soft metal drift to drive the rod-end pivot
pin half way out.
14 Remove the secondary boom lift cylinder from
the machine.
15 Repeat steps 11 through 14 for the other
secondary boom lift cylinder.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly attached to the overhead
crane.
Component damage hazard.
When removing a secondary
boom lift cylinder from the
machine, be careful not to damage
the counterbalance valve at the
barrel end of the cylinder.
16 Attach a lifting strap from an overhead crane to
the upper pivot for support. Do not lift it.
4 - 22 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
17 Attach a lifting strap from a second overhead
crane to the number 1 arm at the mid-point
between the upper pivot and mid-pivot.
18 Remove the pin retaining fasteners from the
number 1 arm pivot pins at the mid-pivot and
the upper pivot. Do not remove the pins.
19 Use a soft metal drift to drive both pins out.
20 Remove the number 1 arm from the machine.
Crushing hazard. The number 1
arm could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
Crushing hazard. The upper pivot
could fall when the number 1 arm
is removed from the machine if not
properly supported by the
overhead crane.
21 Using the overhead crane 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 lower the secondary boom assembly onto
the block.
Crushing hazard. The secondary
boom assembly could fall if not
properly supported by the
4 x 4 x 11 inch / 10 x 10 x
28 cm block.
Part No. 110188
February 2006
REV B
23 Pull all of the cables and hoses out through the
upper pivot.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
24 Remove the hose and cable covers from the top
of the number 2 arm.
25 Pull all of the hoses and cables out of the upper
pivot and out through the mid-pivot. Lay the
hoses and cables on the ground.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use
a soft metal drift to remove the pin.
27 Remove the upper pivot from the machine.
Crushing hazard. The upper pivot
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
28 Attach the lifting strap from an overhead crane
to the number 2 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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
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 retaining fasteners from the
number 2, 3 and 4 arm pivot pins at the
mid-pivot. Do not remove the pins.
34 Use a soft metal drift to drive each pin out. Then
remove the mid-pivot from the secondary boom
assembly.
Crushing hazard. The mid-pivot
could become unbalanced and fall
when removed from the
secondary boom assembly if not
properly supported by the
overhead crane.
35 Attach the lifting strap from an overhead crane
to the center point of the number 2 arm for
support. Do not lift it.
36 Remove the pin retaining fasteners 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
appropriate lifting device.
4 - 23
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
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 could fall when the
compression link is disconnected
from the number 2 arm if not
properly supported by the
overhead crane.
Crushing hazard. The
compression link may fall if not
properly supported when removed
from the secondary boom
assembly.
40 Remove the number 2 arm from the machine.
Crushing hazard. The number 2
arm could become unbalanced
and fall when removed from the
secondary boom assembly if not
properly supported by the
overhead crane.
41 Remove the upper and lower hose and cable
covers from the number 3 arm.
42 Pull all of the cables and hoses from the
number 3 arm and lay them over the turntable
counterweight.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
4 - 24 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
43 Open the ground controls side turntable cover.
44 Remove the fuel tank filler cap.
45 Using an approved hand-operated pump, 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-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or contrainer.
Be sure to only use a hand-
operated pump suitable for use
with gasoline and diesel fuel.
46 Tag, disconnect and plug the fuel hoses from
the fuel tank. Clean up any fuel that may have
spilled.
47 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the
machine.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.
Clean the fuel tank and inspect for
cracks and other damage before
installing it onto the machine.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B SECONDARY BOOM COMPONENTS

48 Remove the retaining fastener from the ground 57 Remove the pin retaining fasteners from the
control box and function manifold pivot plate. number 4 arm at the turntable riser. Do not
remove the pin.
49 Lower the ground control box and function
manifold pivot plate to access the number 3 58 Attach a lifting strap from the overhead crane to
arm pivot pin. the center point of the number 4 arm. Do not
lift it.
50 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for 59 Use a slide hammer to remove the number 4
support. Do not lift it. arm from the turntable riser through the ground
controls side bulkhead.
51 Remove the mounting fasteners from the cover
located in the boom storage area to access the 60 Remove the number 4 arm from the machine.
number 3 and number 4 arm pivot pin retaining
Crushing hazard. The number 4
fasteners at the turntable riser.
arm could become unbalanced
52 Remove the pin retaining fasteners from the and fall when removed from the
number 3 arm at the turntable riser. Do not machine if not properly supported
remove the pin. by the overhead crane.
53 Use a slide hammer to remove the number 3
arm pivot pin from the turntable pivot through
the access hole behind the ground control box.
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 at the mid-pivot end. Do not disconnect the
wiring.

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

Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
5-2
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders
incorporated in the structure of the secondary
boom assembly. These cylinders operate in
parallel and require hydraulic pressure to extend
and retract. Each secondary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove a Secondary
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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section 2, Hydraulic Hose
and Fitting Torque Specifications.
1 Lower the secondary boom to the stowed
position.
2 Raise the primary boom so that it is above the
secondary boom lift cylinder rod-end pivot pin.
4 - 26 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
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 retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin
and barrel-end pivot pin. Do not remove the
pins.
5 Attach a strap from an overhead crane to the
lug on the rod end of the secondary boom lift
cylinder for support. Do not apply any lifting
pressure.
6 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
7 Use a soft metal drift to drive the rod-end pivot
pin half way out.
8 Remove the secondary boom lift cylinder from
the machine.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly attached to the overhead
crane.
Component damage hazard.
When removing a secondary
boom lift cylinder from the
machine, be careful not to damage
the counterbalance valve at the
barrel end of the cylinder.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B
Kubota Z482-E and Z482-E2B Engine
6-1 4 Pull the generator away from the machine and
remove the belts from the generator pulley.
Timing Adjustment
5 Remove the 3 bolts that attach the engine drive
Complete information to perform this procedure is pulley to the shaft bushing.
available in the Kubota Z482-E Workshop Manual 6 Install the same 3 bolts that were removed in
(Kubota part number 97897-01165). step 5 into the threaded holes of the engine
drive pulley.
Kubota Z482-E Workshop Manual
7 Carefully tighten each bolt evenly until the
Genie part number 52956
engine drive pulley slides off the shaft.
Component damage hazard. The
engine drive pulley and/or shaft
can be damaged if the bolts are
not tightened evenly.
6-2
RPM Adjustment 8 Loosen the set screw on the pulley bushing,
then slide the pulley bushing off of the engine
See the scheduled maintenance procedure B-8, shaft.
Check and Adjust the Engine RPM.
a b c a

6-3
Engine Drive Pulley

How to Remove the Engine Drive

Pulley
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine out away from the machine to access d e f g f e d
the engine drive pulley.
3 Loosen the tension adjustment bolt on the a gap
generator. b shaft
c set screw
d engine drive pulley
e engine drive pulley bolt
f shaft bushing
g woodruff key

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 27

Section 4 • Repair Procedures
KUBOTA Z482-E ENGINE
How to Install the Engine Drive
Pulley
The generator pulley must already
be installed before performing this
procedure. See 7-1, How to Install
the Generator Pulley.
1 Align the woodruff key on the engine shaft with
the slot in the pulley bushing and slide the
pulley bushing onto the engine shaft. Do not
tighten the set screw.
2 Align the flywheel side of the pulley bushing on
the engine shaft with the outer face of the
generator pulley using a straightedge.
a b c
f e d g
a pulley shaft
b pulley bushing
c engine flywheel
d straightedge
e generator pulley
f generator
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February 2006
REV B
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.
Component damage hazard. Do
not overtighten the pulley
mounting bolts. There must be a
gap visible between the engine
drive pulley and the pulley
bushing.
a b c a
d e f g f e d
a gap
b shaft
c set screw
d engine drive pulley
e pulley mounting bolt
f pulley bushing
woodruff key
6 Check the alignment between the engine drive
pulley and the generator pulley using a
straightedge. Refer to Section 2, Specifications.
If the pulley alignment is not within
specification, remove the engine
pulley and repeat steps 2
through 6. See How to Remove
the Engine Drive Pulley.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B
Generator
7-1 How to Install the Generator
Generator Pulley Pulley
The pulley on the generator must
How to Remove the Generator be installed before installing the
Pulley engine drive pulley.

1 Remove the engine pivot plate latch retainer. 1 Align the woodruff key on the generator shaft
with the slot in the pulley and slide the pulley all
2 Open the engine pivot plate latch and swing the the way onto the generator shaft.
engine out away from the machine to access
the generator pulley. 2 Install the flat washer and pulley retaining nut
onto the generator shaft, then torque the nut to
3 Loosen the tension adjustment bolt on the specification. Refer to Section 2, Specifications.
generator.
3 Adjust the tension of the generator belts.
4 Pull the generator away from the machine and See 7-2, How to Adjust the Generator Belts.
remove the belts from the generator pulley.
5 Disconnect the battery cables from the engine
battery.
Electrocution hazard. Contact with
electrically charged circuits could
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.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 29

Section 4 • Repair Procedures
GENERATOR
7-2
Generator Belts
How to Adjust the Generator
Belts
1 Disconnect the battery packs.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
2 Remove the engine pivot plate latch retainer.
3 Open the engine pivot plate latch and swing the
engine out away from the machine to access
the generator belts.
4 Loosen the tension adjustment bolt on the
generator.
5 Push the generator towards the machine and
tighten the adjustment bolt.
6 Check the generator belts for proper tension.
Refer to Section 2, Specifications. If the belt
deflection is not within specification, perform
steps 4 and 5 and re-check the belt tension.
a other jewelry.
b
a engine pulley
b generator belts
c generator pulley
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February 2006
REV B
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
in component damage.
Be sure the batteries are fully
charged before performing this
procedure.
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine out away from the machine to access
the generator.
3 Connect the positive lead of a voltmeter to the
POS terminal on the generator and the negative
lead of the voltmeter to the NEG terminal on the
generator.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
Part No. 110188
February 2006
REV B
4 Start the engine from the ground controls and
move the rpm select toggle switch to the
maintained high idle position. Check the voltage
on the generator.
Result: The voltage should be 54V DC.
5 If the voltage reading is not 54V DC, insert a
small flat blade screwdriver into the
potentiometer located inside of the generator.
Use the access hole on the back of the
generator labeled VOLT ADJ.
Component damage hazard. Be
sure that the screwdriver is
properly inserted into the
potentiometer or the generator
and/or voltage regulator may
become damaged.
6 Carefully adjust the potentiometer to obtain a
54V DC voltage reading. Turn the
potentiometer clockwise to increase the voltage
or counterclockwise to decrease the voltage.
Do not rotate the potentiometer past the internal
stops.
Component damage hazard. The
voltage regulator inside the
generator will become damaged if
the potentiometer is rotated past
the internal stops.
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.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
GENERATOR
How to Replace the Voltage
Regulator
1 Disconnect the battery packs from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
2 Remove the engine pivot plate latch retainer.
3 Open the engine pivot plate latch and swing the
engine out away from the machine to access
the generator.
4 Tag and disconnect the positive and negative
battery cables from the generator.
5 Loosen the tension adjustment bolt on the
generator.
6 Pull the generator away from the machine and
remove the belts from the generator pulley.
7 Remove the generator mounting fasteners then
remove the generator from the machine.
8 Remove the 3 nuts from the battery cable
terminal posts.
9 Remove the 3 screws that hold the plastic cover
onto the generator. Carefully remove the cover.
4 - 31
Section 4 • Repair Procedures
GENERATOR
10 Locate the 3 white wires that lead from the
voltage regulator to the negative rectifier
assembly.
a g
b h
c guiding the red and black wires from
d 17 Install the new voltage regulator by following the
e
f torque to specification. Refer to Section 2,
a white wires (#10 nuts)
b negative rectifier assembly
c black wire (#10 screw)
d black wire (#4 nut)
e voltage regulator
mounting fastener (#8 screw)
f voltage regulator
g red wire (#10 screw)
h positive rectifier assembly
11 Remove the nuts on those 3 wires from the
negative rectifier assembly, then remove the
wires.
Do not remove the spacers from
the underneath the wires on the
negative rectifier assembly.
4 - 32 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV B
12 Locate the red wire that leads from the voltage
regulator to the positive rectifier assembly.
13 Remove the screw that attaches the red wire to
the positive recitfier assembly.
14 Remove the #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
underneath the bottom support of the positive
and negative rectifier assembly.
previous steps in reverse order.
18 Apply Loctite® removable thread sealant onto
the voltage regulator mounting fasteners and
Specifications.
19 Torque all other fasteners to specification. Refer
to Section 2, Specifications.
20 Install the plastic cover onto the generator then
install the generator onto the machine.
21 Adjust the generator belts. See 7-2, How to
Adjust the Generator Belts.
22 Adjust the voltage regulator. See How to Adjust
the Voltage Regulator.
Component damage hazard. The
voltage regulator and/or generator
may become damaged if the
voltage regulator is not properly
adjusted after replacement.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV B
Hydraulic Pumps
8-1 2 Remove the engine pivot plate latch retainer.
Auxiliary Pump 3 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine.
How to Remove the Auxiliary 4 Tag, disconnect and plug the hydraulic hoses
Pump from the auxiliary pump.
Bodily injury hazard. Spraying
When removing a hose assembly
hydraulic oil can penetrate and
or fitting, the O-ring on the fitting
burn skin. Loosen hydraulic
and/or hose end must be replaced
connections very slowly to allow
and then torqued to specification
the oil pressure to dissipate
during installation. Refer to
gradually. Do not allow oil to squirt
Section 2, Hydraulic Hose and
or spray.
Fitting Torque Specifications.
5 Remove the auxiliary pump mounting bolts.
1 Models with hydraulic tank shut-off valves:
Carefully remove the pump.
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

open closed

Component damage hazard. The

engine must not be started with
the hydraulic tank shut-off valves
in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Models without hydraulic tank shut-off
valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Section 2, Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 33

Section 4 • Repair Procedures February 2006

HYDRAULIC PUMPS REV B

8-2 4 Remove the engine pivot plate latch retainer.

Function Pump 5 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine.
How to Remove the Function 6 Tag, disconnect and plug the hydraulic hoses
Pump from the pump.
Bodily injury hazard. Spraying
When removing a hose assembly
hydraulic oil can penetrate and
or fitting, the O-ring on the fitting
burn skin. Loosen hydraulic
and/or hose end must be replaced
connections very slowly to allow
and then torqued to specification
the oil pressure to dissipate
during installation. Refer to
gradually. Do not allow oil to squirt
Section 2, Hydraulic Hose and
or spray.
Fitting Torque Specifications.
7 Remove the function pump mounting bolts.
1 Models with hydraulic tank shut-off valves:
Carefully remove the pump.
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

open closed

Component damage hazard. The

engine must not be started with
the hydraulic tank shut-off valves
in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Models without hydraulic tank shut-off
valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Section 2, Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.

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February 2006 Section 4 • Repair Procedures

REV B

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Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 35

Section 4 • Repair Procedures February 2006

Manifolds REV A

9-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 2 position 3 way ....... A ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way ....... B ........... Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way ....... C ........... Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way ....... D ........... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way ....... E ........... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ....... F ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7 Shuttle valve ...................................... G ........... Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm
8 Solenoid valve, 3 position 4 way ....... H ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm
9 Proportional solenoid valve ............... I ............ Controls flow to functions ............................. 27 ft-lbs / 37 Nm
10 Pressure switch ................................. J ............ Brake circuit
11 Solenoid valve, 2 position 3 way ....... K ........... Primary boom extend ................................... 20 ft-lbs / 27 Nm
12 Flow regulator valve,
0.4 gpm / 1.5 L/min ............................ L ........... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
13 Needle valve ...................................... M .......... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar ......... N ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar ...... O ........... System relief ................................................ 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar ............... P ........... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17 Orifice, 0.060 inch / 1.5 mm ............... Q ........... Steer circuit
18 Orifice, 0.030 inch / 0.76 mm ............. R ........... Proportional valve circuit
19 Solenoid valve, 2 position 3 way ....... S ........... Brake circuit ................................................. 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm
(from serial number 22566 to 22628
and after serial number 23235)
(located under item S) ....................... T ........... Brake circuit
20 Orifice, 0.037 inch / 0.94 mm ............ U
21 Check valve, pilot operated ............... V ........... Platform level circuit ..................................... 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar ......... W .......... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm

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February 2006 Section 4 • Repair Procedures

REV A MANIFOLDS

1 2 3 4 5 6 7 8

22
10

21

20

19

18

17

16

11

15 14 13 12

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 37

Section 4 • Repair Procedures
MANIFOLDS
9-2
Valve Adjustments -
Function Manifold
How to Adjust the System
Relief Valve
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 function enable toggle switch
to either side and hold the primary boom
extend/retract toggle switch in the retract
direction with the primary boom fully retracted.
Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
3 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
(item O).
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
4 - 38 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
February 2006
REV A
How to Adjust the Secondary
Boom Down Relief Valve
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 function enable toggle switch
to either side and hold the secondary boom
up/down toggle switch in the down direction
with the secondary boom fully lowered.
Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
3 Turn the machine off. Hold the secondary boom
down relief valve with a wrench and remove
the cap (item W).
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
Part No. 110188
February 2006 Section 4 • Repair Procedures

REV A MANIFOLDS

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 39

Section 4 • Repair Procedures February 2006

MANIFOLDS REV A

9-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
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

1 2 3

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February 2006 Section 4 • Repair Procedures

REV A MANIFOLDS

9-5 How to Test a Coil Diode

Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution hazard. Contact with
electrically charged circuits could
result 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.
Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Test the coil for resistance. See How to Test a
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)

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 4 - 41

Section 4 • Repair Procedures February 2006

MANIFOLDS REV A

2 Connect a 10Ω resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the
5 Momentarily connect the positive lead from the
coil.
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
Ω
Resistor, 10Ω
Genie part number 27287 6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
The battery should read 9V DC or
Result: Both current readings are greater than
more when measured across the
0 mA and are different by a minimum of 20%.
terminals.
The coil is good.

COIL
Result: If one or both of the current readings are
a 0 mA, or if the two current readings do not differ
MULTI
d METER by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
- replaced.
c
+

b
10 W 9V
RESISTOR BATTERY
+

c - b

a multimeter
b 9V DC battery
c 10Ω resistor
d coil

Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6

3 Set a multimeter to read DC current.

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

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February 2006
REV B
Turntable Rotation Components
10-1
Turntable Rotation Assembly
How to Remove the Turntable
Rotation Assembly
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the secondary boom until the upper pivot
is above the turntable covers. Turn the machine
off.
2 Secure the turntable from rotating with the
turntable rotation lock.
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.
Unlocked position
Locked position
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 4 • Repair Procedures
3 Remove the engine pivot plate latch retainer.
4 Open the engine pivot plate latch and swing the
engine out and away from the machine to
access the turntable rotation assembly.
5 Remove the retaining fasteners from the center
turntable cover. Remove the cover from the
machine.
6 Disconnect the battery backs from the machine.
Electrocution hazard. Contact with
electrically charged circuits 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 Section 2, Specifications.
9 Tag, disconnect and plug the fuel hoses from
the fuel tank.
10 Remove the fuel tank strap fasteners and
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.
4 - 43
Section 4 • Repair Procedures February 2006

TURNTABLE ROTATION COMPONENTS REV B

13 Attach a lifting strap from and overhead crane

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

4 - 44 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 4 • Repair Procedures

REV A
Motor Controller
11-1 4 Press the release tab on the motor controller
harness connector and remove the motor
Motor Controller controller harness connector from the motor
controller.
The drive motor controller is located under the non-
steer end drive chassis cover. The drive motor 5 Connect the leads from an ohmmeter to test
controller can recognize machine drive each motor controller terminal combination
malfunctions and display controller fault codes by listed below and check for resistance.
flashing a LED at the ground controls and on the Result: All desired results must be 500 kilohms
motor controller. See the Troubleshooting section
or more. If any test has a result less than
of this manual for a list of fault codes and
500 kilohms, replace the motor controller.
additional information. There are no adjustments
needed on the drive joystick controller. For further
information or assistance, consult the Genie Test Desired result
(in kilohms)
Industries Service Department.
F1 to F2 500kΩ or more
How to Test the Motor Controller
Use the following procedure to test F1 to B- 500kΩ or more
the motor controller. If the motor
controller is found to be faulty, F1 to M- 500kΩ or more
note which test failed and which
F1 to B+ 500kΩ or more
fault code (if any) was present at
the time of failure.
F2 to B- 500kΩ or more
1 Turn the key switch to the off position and
disconnect the battery packs from the machine. F2 to M- 500kΩ or more

2 Remove the chassis cover from the non-steer F2 to B+ 500kΩ or more

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

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

Section 4 • Repair Procedures February 2006

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4 - 46 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006
Before Troubleshooting:
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steer wheels
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Section 5 • Fault Codes
Fault Codes
Read, understand and obey the safety rules
and operating instructions printed in the
Operator’s Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Electrocution hazard. Contact
with electrically charged circuits
may result in death or serious
injury. Remove all rings, watches
and other jewelry.
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.
Perform all troubleshooting on a
firm level surface.
5-1
Section 5 • Fault Codes February 2006

FAULT CODES

Tip-over hazard. When adjusting
the raised drive speed settings,
the maximum raised drive speed
must not exceed specification.
Refer to Section 2, Specifications.
If the machine is allowed to drive
faster than specification, the
machine could become unstable
and will tip over.
Additional troubleshooting of the
fault codes may by accomplished
by using the hand-held pendant
motor controller programmer
(Genie part number 56303-S).
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 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.

When using the hand-held

pendant motor controller
programmer, the M1 MAX SPEED
needs to be set to 33. If needed,
adjust the M1 MAX SPEED higher
or lower to achieve the maximum
raised drive speed. Refer to
Section 2, Specifications.

5-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 5 • Fault Codes

REV A
Fault Code Chart
Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display

Push in the ground

control red Emergency
The key switch or red Stop button to the OFF
Controller Emergency Stop position and wait for 5
status indicator button(s) was cycled on seconds. Pull out the
COMMUNICATION
light is OFF or ERROR
Machine will not drive. and off faster than 5 ground control red
is ON but not seconds OR controller Emergency Stop button
sensed an internal error out to the ON position. If
blinking
during start up. problem persists,
replace the motor
controller.

01 Normal operation.
The motor controller Replace the motor
12 HW FAILSAFE 1-2-3 Machine will not drive.
failed self test. controller.
The motor controller
Test the motor
has a internal short
13 M- SHORTED Machine will not drive.
between M- and B-
controller, see the
Repair Section.
terminals.

Check for loose or open

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

Defective motor Replace the motor

ARM SENSOR Machine will not drive.
controller. controller.
Defective motor Replace the motor
FLD SENSOR Machine will not drive.
controller. controller.

Continued on next page

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 5-3

Section 5 • Fault Codes February 2006

FAULT CODE CHART REV A

Code Scanner
Fault Code Condition Possible Causes Solution
Display

Open in wht/red wire

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

Pin 14 (wht/red #32) is

shorted to power or
Consult Genie
ground OR the
THROTTLE FAULT 2 Machine will not drive. Industries Service
potentiometer on the
Department.
drive joystick is
defective.

Main contactor (PR1) Replace main contactor

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

Main contactor (PR1)

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

Repair short between

B+ terminal on motor
controller and ground
External short between
OR replace motor
B+ terminal on motor
controller.
33 PRECHARGE FAULT Machine will not drive. controller and ground
Note: Short can be on
OR motor controller is
any part of circuit
defective.
connected to the B+
terminal on the motor
controller.

5-4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 5 • Fault Codes

REV A FAULT CODE CHART

Code Scanner
Fault Code Condition Possible Causes Solution
Display
Motor controller does
Consult Genie
not detect the main
34 MISSING CONTACTOR Machine will not drive.
contactor PR1 or brake
Industries Service
Department.
release relay CR5.

Main contactor PR1 or

brake release relay CR5
did not close OR open
Consult Genie
in org/red wire to PR1
MAIN CONT DNC Machine will not drive. Industries Service
and/or CR5 OR main
Department.
contactor and/or brake
release relay is
defective.

Completely charge
batteries OR check
Battery supply voltage battery cable condition
LOW BATTERY
41 VOLTAGE
Machine will not drive. to motor controller less OR check for corrosion
than 32V DC. or loose connections at
battery terminals and
motor controller.

Battery supply voltage

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

Operate machine within

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

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 5-5

Section 5 • Fault Codes February 2006

This page intentionally left blank.

5-6 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 6 • Schematics

Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Hydraulic Schematics
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.
General Repair Process
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6-1

Section 6 • Schematics February 2006

Electrical Symbols Legend

REV A

TB17
15AMP.

TS6
Circuit breaker

GRN/BLK
ORG/BLK-1

LEFT
RIGHT
Toggle switch DPDT
Wire color
with cable
number
RED
Solenoid or Ground GRN
relay coil supression

BLK/RED
WHT
TB20 circuit
BP1

Terminal Boom function

speed controller

Horn NC NO

TP29 LS3

Limit switch
Quick disconnect L1 FB

terminal
Light LS1
NO
BLK #21
TB21

T-circuits connect Limit switch

at terminal normally open
held closed

PLAT
KS1

T-circuits Tilt sensor GRND

connect
Key switch

LS2
NC
Connection
no terminal HORN P4
Limit switch
normally closed
held open
Horn button
normally open

Circuits crossing
no connection
P1 PR4

Red Emergency
Stop button Relay panel
Diode normally closed contactor

TS3
CR4

-
PLAT. DWN
PLAT. UP

Battery Relay contact

normally open Toggle switch SPDT

6-2 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

February 2006 Section 6 • Schematics

Hydraulic Symbols Legend

REV A

0.035”

Orifice with size

Pressure gauge
3 position 4 way directional
Differential sensing valve solenoid valve

Variable orifice
or shut-off valve

Filter Solenoid operated Shuttle valve

proportional valve
(before serial number 22566)
Check valve

Check valve, pilot operated

Fixed displacement pump

Relief valve
Solenoid operated
Spring applied, proportional valve
hydraulically released (after serial number 22565)
brake

N.O.
Priority flow regulator
COM
N.C.

Bi-directional motor Pressure switch

2 position 2 way
M solenoid valve
Pump prime mover (motor)

Solenoid operated 2 pos.,

3 way, directional valve

Cylinder

Counterbalance valve

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6-3

Section 6 • Schematics February 2006

6-4 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

Section 6 • Schematics February 2006

Power Cable Diagram

Section 6 • Schematics February 2006

Power Cable Diagram REV A

A B C D E F G H I J K L M N
TO ENGINE PANEL TO GROUND CONTROL BOX
CONNECTOR C6B
1 LEFT SIDE
AC POWER CABLE
DC AMMETER CABLE
BATTERY PACK
RD-2GA RIGHT SIDE
- BATTERY PACK

48V DC -
+ ALTERNATOR

FUNCTION HARNESS
D1 +
AC A2
2 BATTERY
GR/BK-BATT ISM-9

_
CHARGER NEG
PRIMARY
WH-BATT R12

LIFT PUMP
-
+ A1 POS
RD-2GA
AUXILIARY LIFT +

RD-2GA
- PUMP
BK-2GA
D1 -
+ BK-2GA

3 RD-2GA +
RD-20-12GA
-

-
+ WH-FROM CHARGER

P42BAT OR/RD +
WH-BATT
WH-BATT

F5 10A BK-2GA BK-2GA

BK-2GA BK-2GA
4

WH
BK
+ -
TOP VIEW OF AUXILIARY POWER UNIT
+ + DRIVE CONTACTOR DRIVE CONTACTOR CONTACTOR 3
4 5 6
7

2
AP-1

8
1

9
BATTERY - -
- -
AMMETER
AP-2 DIODE DIODE AC
+ + CHARGER
GR/WH-19
33 PR-1 DIODE
33 PLUG

5
P42BAT OR/RD

PR-2 PR-1 CONTROLLER PR-3

BK-FROM CHARGER

LIFT R42BAT OR/RD

CONTACTOR R42BAT OR/RD R42BAT OR/RD

RD-2GA
BK-2GA
BRN-J8 BRN-J8
F4
R27AUX RD RD
RD-2GA

BK-2GA
BK-2GA

BK-2GA

BRN-J8

500A
BK BK BK BK RD-2GA
RD-20-12GA

RD-2GA RD-2GA

RD-2GA
6 RD-10GA RD-10GA 24V DC
48V DC

F2
F1 200A
200A
C29JSH RD/WH

C32JSL WH/RD
RD-10GA
CR5 RD/BK

RD-2GA
F2 F1
7
GR

A2 A1
24 23 22 21 20 19 18 17 16 15 14 13
A1 12 11 10 9 8 7 6 5 4 3 2 1

RD-2GA
C31REV WH/BK

C12DRE BL/WH
R42BAT OR/RD

R42BAT OR/RD
OR/RD

OR/RD
RD-2GA
F1 F2
C30FWD WH

RD-10GA
C40LS OR
CFIL BK

A2

BK-2GA
BRN-J8

BK-2GA RIGHT SIDE

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

6-5 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 February 2006 Section 6 • Schematics

REV A Engine Panel Diagram

N M L K J I H G F E D C B A
NOTE: RD-CB CIRCUT BREAKER
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE. 1
CB3
RD-CB (12V+) 12V, 15A

C21IGN2 WH C21IGN2 WH
C35HRPM BK/RD C35HRPM BK/RD
WH-J5 WH-J5

IGNITION/START
BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4 BRN-J4

1 3 4 7 10 9 2
12/24V DC
MODULE
WH-J4 WH-J4 WH-J6 BK/RD BK/RD
2

RD-CB
87 87 87 87 87 87
85 86 85 86 85 86 85 86 85 86 85 86 GND BRN
87a 87a 87a 87a 87a 87a
RD-CB
30 30 30 30 30 30

CR16 CR11 CR12 CR13 CR14 CR15

FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG
RELAY WH-J4 RELAY C34SA BK/WH

KEYSWITCH PWR.
RELAY
WH-J4 WH-J6 WH-J6 3

24V BATTERY +

ENGINE FAULT
START RELAY

IGN./FUEL ON
START INPUT
RD-J6

TACH. INPUT
RD-J6

(NOT USED)

(NOT USED)
GROUND
RD-CB (12V+)
WH-BATT

OR-GEN NEG
OR-GEN POS

BRN-VOLT

BK-START

10
BK/WH-34

1
BK/RD-35

9
2

8
4
BK-ISM-1

6
WH-R14
WH-R11

RD-J10
4

C23PWR WH
C33STR BK

P20BAT RD

GR/BK-BATT
BRN-ISM5
WH-BATT WH-BATT

WH-ISM10
BK-ISM-1

BL-ISM2

BRN-J5
WH-R14

BK-ISM1 BK-ISM1

BRN-VOLT BL-ISM2 BL-ISM2

C33STR BK
5
BRN-J5
BRN-ISM5 BRN-ISM5

P20BAT RD

WH-BATT
C23PWR WH
BRN-VOLT
BRN-ISM5

6
BL-ISM2

WH-R14
BL-E.H.

BL-E.H.

RD-J10

ENGINE HARNESS (TO DRIVE CHASSIS) GR/BK-BATT

ENGINE HARNESS (TO ENGINE) WH-ISM10

ENGINE HARNESS (TO GROUND CONTROL BOX)

YEL

GR
RD
BK
BL

BL

C5B-18 C35HRPM BK/RD

C5B-22 C34SA BK/WH

C5B-11 C21IGN2 WH
C5B-3 C23PWR WH

C5B-5 C33STR BK
C5B-1 P20BAT RD

C5B-2 GND BRN

12V DC
VOLTAGE REGULATOR 8
C5B
MALE DEUTSCH
CONNECTOR

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6-6

February 2006 Section 6 • Schematics

Engine Panel Diagram

Section 6 • Schematics February 2006

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

A B C D E F G H I J K L M N

1 C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3 P25BAT RD
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH

P22BAT
P26BAT
RD
R42BAT OR/RD

2 C132 PLI BL/WH C1P-12 RD

7 TS6 TS2 HIGH LOW FOOTSWITCH
GLOW

C1B-12
A1 ENGINE RPM RPM HIGH RPM
+

RD
LS18 TILT PLUGS START
L48 TS4
P3 ALARM RPM
CB1 HORN
KS1 PLATFORM
10 A P1

C7P-2
C3P-3

C2P-4

C1P-8

C1P-7

C1P-9
P20BAT RD D40
TB22 6

C7B-1

C2P-5
C1P-2
GROUND

C3P-9
C1P-4

C1P-5

C1P-6

C1P-3

C2P-2
1 3

C33STR BK

C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH

R42BAT OR/RD
4 5
C32

C134PWR GR
C28TTA RD/BK
P23BAT WH

P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH
3 6
5
7

12 8

C1B-8

C1B-7

C1B-9
C3B-3

C2B-4
P20BAT RD

C7B-2

C3B-9

C2B-5
C1B-2

C7B-2
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK
C7B-4

RD
C6B-30

C6B-31

C6B-32

C6B-29

4 OR TB40 OR
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH

WH/BK

WH/RD

RD/WH

OR/RD
OR/RD
OR/RD
OR/RD

F5 TS54

BK/RD
F4

OR/RD
10A TS56 TS52 RPM
C6B-12

C6B-24

500A

C6B-20 RD
C6B-40 OR

AP2 48V DC 30

START
ENGINE
PLUGS
GLOW
CR2 86

C5B-1 P20BAT RD
86 TB23 LOW HIGH
PR1
INDICATOR LED L2
CONTROLLER FAULT

+48V DC
85 87
BK D2

RD/BK
BK
+

COIL-PR1

CR5

F2 85
TB34 TB33
5 200A 86
CR1
30 TB35
IGNITION / START
RD 20

BL/WH

OFF-LMT SPD INP

MODULE
C10-3
C10-4

C10-1
C10-2
C6B-39 CR5 RD/BK

C6B-25 CFIL BK
DIODE RETURN

BK-ISM1

C6B-28
+

C6B-34
85 1 START RELAY
-

LEFT 87
+48V INPUT

BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+

BK-4
WH-4

BK-5
WH-5
POT. LOW
REVERSE
FORWARD

C5B-5 C33STR BK
3
POT. HI

C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR

C5B-11 C21IGN2 WH

C5B-22
LS4 HM C35HRPM
_ 15 A
5 GROUND
+

(SEC)
-

RD-J10 (12GA)
6 BATTERY
2
9

14
10

11

16

17

20

5
1

22
AP2 CB3 C5B-3 C23PWR WH
30 7 KEY SWITCH POWER

RD/WH
RD/BK
86

RD
U6A

C34SA BK/WH
MOTOR CONTROLLER CR4 30 85 8 (NOT USED)
24V DC
6
BK-5

RD-5

87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30

C8-A

C8-C
F1 M- B+ F2 B- 87 86 85 10 ENGINE FAULT
+24V DC 200A CR12

BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+

87 85
C11-3
C11-4

C11-1
C11-2

RD
WH
30 85 CR14
(12V DC) 30 CR16

WH
BRN

BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7

BK-6

86

+12V DC
87
WH

RD

YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK

BK/RD

BRN
BRN
BRN

BRN

BRN
BK/WH
MOTOR
+

RIGHT BATT WH
RIGHT (12V DC) VR1 ALT.
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
+

+ BL
(PRI)

BK
+
LS1 AP2
2 STARTER
PUMP PUMP
ALTERNATOR CHARGER (EXT) AUXILIARY
22 WH-BATT

BK
14
BK 2 GA

7 -
BRN

-
+
C8-B
BK
+

(12V DC)
-

OR-GEN NEG 30 CR16

BRN
GROUND A2

C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)

AP1 BK BK
PR2 PR2
PR3 PR3

RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN

HORN RELAY

RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY

RELAY PR1
CONTACTOR
MOTOR MAIN

RELAY CR5
BRAKE RELEASE

CHASSIS GROUND

BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC

OPTION
BEACON
FLASHING

ALERNATOR
12V DC

RPM SOLENOID

RPM RELAY CR14

TILT SENSOR

SWITCH
PRESSURE
OIL

SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID

RELAY CR13
RPM CUTOUT

FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS

RELAY CR15
GLOW PLUG
LIFT PUMP
AUXILIARY

STARTER RELAY CR11

CHARGER
48V DC

REGULATOR
12V DC VOLTAGE
8

2 SWITCH SHOWN WITH BOOM EXTENDED.

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

6-7 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 1

8
Section 6 • Schematics

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

6-8
ENABLE

SWITCH
3
DRIVE
ENABLE

LIMIT
LED L1
DRIVE
A

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3

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

TB12

14
13

C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86

85

BRN
A2
86

85
B

RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6

+
CR5
CR8

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

C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30

87

87
30
30

87

RD/BK-R6
CE VERSION:

ENABLE
TS15
AND ADD
REMOVE
JUMPER

RELAY

PS1 BRAKE RELEASE

CR5

PRESSURE SWITCH PS1

TB36

C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C

C1P-10
TB37

C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
OR/BK-R6
C31REV WH/BK
C29JSH RD/WH

10
C32JSL WH/RD

2
3
4
5

7
8
9
C30FWD WH
D

P24BAT WH

DRIVE
C40LS OR

LIFT

STEER
FWD

REV
20K

L R
DP1

AUXILIARY
PUMP
33
GR/WH

C1P-1 C27AUX RD C1B-1

TS1

PR2

RD-AUX
BCI OPTION

87
30

OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION

GR/WH RELAY COIL PR2

BCI
E

BK
AUXILIARY
F

POWER

CR3
+

OR/RD

85
86
DISCHARGE

OR/RD RD RD AUXILIARY CONTROL

SET TO "N"
1

Part No. 110188

RELAY COIL CR3

TS51

TB27

CR20
33
February 2006

PR3

OR
3

OR/RD AUXILIARY LIFT

5

L.V.I.
4

C6B-27 PUMP RELAY COIL

OR/BK
4

RD
TB19

PR3
87
BCI

SET TO "B"
6

RESET

30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86

GR/WH CONTACTOR RELAY

7
F

CR20
TB6

87a
8

C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK

85 BRN

BK/RD
CR19A

COIL
BRN

GR/WH
RD
86

TB18

C23-1 C23-2 PLATFORM

CONTROL

RIGHT
CR19B

C6B-18 GR/BK ROTATE RIGHT

ROTARY

PLATFORM
FLOW

ROTATE
OEM

C6B-17 GR PLATFORM
BP1

TS57

LEFT ROTATE LEFT

TB17

C22-1 C22-2
86

85
PLATFORM
G

ROTATE

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

C4P-5 C17PRL GR C4B-5 GR
TS7

LEFT
H

TB14

UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM

UP COIL
C6B-15 OR/BK
LEVEL

PLATFORM LEVEL
TS59
I

DOWN DOWN COIL

TB15
PLATFORM

C21-1 C21-2
LEVEL

PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
C4P-3 C15PLD OR/BK C4B-3
TS9

TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY

C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63

RETRACT RETRACT COIL

TB8
C17-1 C18-2
J

PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13

TB1
RETRACT C12-1 C12-2
UP C6B-1 RD PRIMARY BOOM
UP COIL

PRIMARY
C6B-2 RD/BK PRIMARY BOOM

BOOM

TS61
DOWN DOWN COIL

TB2
C13-1 C13-2
PRIMARY

CR19A
BOOM
K

UP C3P-1 C1PBU RD C3B-1

30

87

C3P-2 C2PBD RD/BK C3B-2

TS11

TB10
DOWN C18-1 C18-2

SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM

TS60
BOOM
SECONDARY

DOWN DOWN COIL

TB11
C19-1 C19-2
CR19B

DESCENT
BOOM

ALARM
UP C3P-10 C10SBU BL C3B-10

A3
OPTION (A3)

+
87
30

C3P-11 C11SBD BL/BK C3B-11

TS10
L

TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT

TURNTABLE
COIL

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT
TURNTABLE

TB4
C14-1 C14-2
COIL
ROTATE

RD
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4
TS12
R42BAT OR/RD

LEFT
P24BAT WH

FUNCTION
M

ENABLE
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

C12DRE BL/WH
P42BAT OR/RD
C30FWD WH

C40LS OR

TS55

(GND)

PR2
PR3
CR5

BK
RD

RD
REV A

N
February 2006 Section 6 • Schematics

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

Section 6 • Schematics February 2006

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

A B C D E F G H I J K L M N

1 C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3 P25BAT RD
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH

P22BAT
P26BAT
RD
R42BAT OR/RD

2 C132PLI BL/WH C1P-12 RD TS6 TS2

HIGH LOW FOOT SWITCH
GLOW ENGINE

C1B-12
RPM RPM HIGH RPM
+

RD
A1 PLUGS START
LS18 TILT TS4
P3 L4 ALARM RPM
CB1 HORN 5
10A KS1 PLATFORM
P1

C7P-2
C3P-3

C2P-4

C1P-8

C1P-7

C1P-9
P20BAT RD D39 D40
TB22 6

C7B-1

C2P-5
C1P-2
GROUND

C7P-2

C3P-9
C1P-4

C1P-5

C1P-6

C1P-3

C2P-2
1 3

C33STR BK

C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH

R42BAT OR/RD
4 5
U33

C134PWR GR
C28TTA RD/BK
P23BAT WH

P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH
3 6
5
7

12 8

C1B-8

C1B-7

C1B-9
C3B-3

C2B-4
P20BAT RD

A6 L45

C7B-2

C3B-9

C2B-5
C1B-2

C7B-2
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK
C7B-4

RD
C6B-30

C6B-31

C6B-32

C6B-29

4 OR TB40 OR
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH

WH/BK

WH/RD

RD/WH

OR/RD
OR/RD
OR/RD
OR/RD

F5

BK/RD
F4

OR/RD
10 A TS56 TS52 TS54
C6B-12

C6B-24

500 A

C6B-20 RD
C6B-40 OR

AP2 48V DC 30 RPM

START
ENGINE
PLUGS
GLOW
CR2 86
TB23 LOW HIGH

C5B-1 P20BAT RD
PR1 86
INDICATOR LED L2
CONTROLLER FAULT

+48V DC
85 87
BK D2

RD/BK
BK
+

COIL-PR1

CR5

F2 85
200 A
5 86
CR1
30 TB34 TB33 TB35
IGNITION / START
RD 20

BL/WH

OFF-LMT SPD INP

MODULE
C10-3
C10-4

C10-1
C10-2
C6B-39 CR5 RD/BK

C6B-25 CFIL BK
DIODE RETURN

BK-ISM1

C6B-28
+

C6B-34
85 1 START RELAY
-

LEFT 87
+48V DC INPUT

BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+

BK-4
WH-4

BK-5
WH-5
POT. LOW
REVERSE
FORWARD

C5B-5 C33STR BK
3
POT. HI

C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR

C5B-11 C21IGN2 WH

C5B-22
LS4 HM C35HRPM
_ 5 GROUND
+

(SEC)
-

RD-J10 (12GA)
6 BATTERY
10

14

16

17

20
11

22
3
9

5
2
1

AP2 CB3 C5B-3 C23PWR WH

30 15 A 7 KEY SWITCH POWER

RD/WH
RD/BK
86

RD

C34SA BK/WH
U6A 30 8 (NOT USED)
CR4 85
6 24V DC MOTOR CONTROLLER
BK-5

RD-5

87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30

C8-A

C8-C
F1 M- B+ F2 B- 87 86 85 10 ENGINE FAULT
+24V DC 200A CR12

BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+

87 85
C11-3
C11-4

C11-1
C11-2

RD
WH
30 85 CR14
30 CR16

WH
BRN
(12V DC)

BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7

BK-6

+12V DC
86
87
WH

RD

YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK

BK/RD

BRN
BRN
BRN

BRN

BRN
BK/WH
MOTOR
+

(12V)
-

RIGHT BATT WH
RIGHT VR1 ALT.
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
+

+ BL
(PRI)

BK
+
LS1 AP2
2 STARTER
PUMP PUMP
ALTERNATOR CHARGER (EXT) AUXILIARY
22 WH-BATT

BK
7 14
BK 2 GA

-
BRN

-
+
C8-B (12V DC)
BK
+

OR-GEN NEG 30 CR16

BRN
GROUND A2

C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)

AP1 BK BK
PR2 PR2
PR3 PR3

48V DC POWER RELAY CR2

48V DC POWER RELAY CR1
HOUR METER
HORN

HORN RELAY

ENGINE POWER RELAY CR12

LIFT PUMP
PRIMARY

RELAY PR1
CONTACTOR
MOTOR MAIN

RELAY CR5
BRAKE RELEASE

CHASSIS GROUND

BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC

FLASHING BEACON OPTION

12V DC ALERNATOR

RPM SOLENOID

RPM RELAY CR14

TILT SENSOR

SWITCH
PRESSURE
OIL

SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID

RELAY CR13
RPM CUTOUT

FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY

STARTER RELAY CR11

RELAY CR15
GLOW PLUG
12V DC VOLTAGE REGULATOR
CHARGER
48V DC

2 SWITCH SHOWN WITH BOOM EXTENDED.

NOTES: 5 CE & PLATFORM LOAD SENSE OPT.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

6-9 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 1

8
Section 6 • Schematics

Electrical Schematic, Z-45/25, CE Models

6 - 10
A

ENABLE

SWITCH
3
DRIVE
ENABLE

LIMIT
LED L1
DRIVE

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3

BL/WH WH-8 RD-8

B

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

TB12

14
13

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

C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86

85

BRN
A2
86

85

RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6

+
CR5
CR8

C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH
BRAKE RELEASE N.C. COIL
C2P-3 RD/WH
DRIVE 30

87

87
30
30

87

RD/BK-R6
CE VERSION:

ENABLE
C

TS15
AND ADD
REMOVE
JUMPER

RELAY

PS1 BRAKE RELEASE

CR5

PRESSURE SWITCH PS1

TB36

C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C1P-10
TB37

C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D

OR/BK-R6
C31REV WH/BK
C29JSH RD/WH

10
C32JSL WH/RD

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
C40LS OR

LIFT

STEER
FWD

REV
20K

L R
DP1

AUXILIARY
E

PUMP
33
GR/WH

C1P-1 C27AUX RD C1B-1

TS1

PR2

RD-AUX
BCI OPTION

Part No. 110188

87
30

OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION
February 2006

GR/WH RELAY COIL PR2

BCI

BK
AUXILIARY
F

POWER

CR3
+

OR/RD

85
86
DISCHARGE

OR/RD RD RD AUXILIARY CONTROL

SET TO "N"
1

RELAY COIL CR3

F

TS51

TB27

CR20
33
2

PR3

OR
3

OR/RD AUXILIARY LIFT

5

L.V.I.
4

C6B-27 PUMP RELAY COIL

OR/BK
4

RD
TB19

PR3
87
BCI

SET TO "B"
6

RESET

30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86

GR/WH CONTACTOR RELAY

7

CR20
TB6

87a
8

C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD

FLOW CONTROL
BK

85 BRN

BK/RD
CR19A

COIL
BRN

GR/WH
RD
86

TB18

PLATFORM
G

C23-1 C23-2
CONTROL

RIGHT
CR19B

C6B-18 GR/BK ROTATE RIGHT

ROTARY

PLATFORM
FLOW

ROTATE
OEM

C6B-17 GR PLATFORM
BP1

TS57

LEFT ROTATE LEFT

TB17

C22-1 C22-2
86

85
PLATFORM
ROTATE

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

C4P-5 C17PRL GR C4B-5 GR
TS7

LEFT
H
I

TB14
UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM

UP COIL
C6B-15 OR/BK
LEVEL

PLATFORM LEVEL
TS59

DOWN DOWN COIL

TB15
PLATFORM

C21-1 C21-2
LEVEL

PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
J

C4P-3 C15PLD OR/BK C4B-3

TS9

TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY
C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63
RETRACT RETRACT COIL

TB8
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13

TB1
C12-1 C12-2
K

RETRACT UP C6B-1 RD PRIMARY BOOM

UP COIL

PRIMARY
C6B-2 RD/BK PRIMARY BOOM

BOOM

TS61
DOWN DOWN COIL

TB2
C13-1 C13-2
PRIMARY

CR19A
BOOM

UP C3P-1 C1PBU RD C3B-1

30

87

C3P-2 C2PBD RD/BK C3B-2

TS11

TB10
DOWN C18-1 C18-2

SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM
L

TS60
BOOM
SECONDARY

DOWN DOWN COIL

TB11
C19-1 C19-2
CR19B

DESCENT
BOOM

ALARM
UP C3P-10 C10SBU BL C3B-10

A3
OPTION (A3)

+
87
30
C3P-11 C11SBD BL/BK C3B-11
TS10

TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT

TURNTABLE
COIL

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT
TURNTABLE

TB4
C14-1 C14-2
COIL
M

ROTATE

RD
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4

TS12
R42BAT OR/RD
LEFT
P24BAT WH

FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

C12DRE BL/WH
P42BAT OR/RD
C30FWD WH

C40LS OR
REV A

TS55

(GND)

PR2
PR3
CR5

BK
RD

RD
February 2006 Section 6 • Schematics

Electrical Schematic, Z-45/25, CE Models

Section 6 • Schematics February 2006

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

A B C D E F G H I J K L M N

1 C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3 P25BAT RD
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH

P22BAT
P26BAT
RD
R42BAT OR/RD

2 C132 PLI BL/WH C1P-12 RD

7 TS6 TS2 HIGH LOW FOOTSWITCH
GLOW

C1B-12
A1 ENGINE RPM RPM HIGH RPM
+

RD
LS18 TILT PLUGS START
L48 TS4
P3 ALARM RPM
CB1 HORN
KS1 PLATFORM
10 A P1

C7P-2
C3P-3

C2P-4

C1P-8

C1P-7

C1P-9
P20BAT RD D40
TB22 6

C7B-1

C2P-5
C1P-2
GROUND

C3P-9
C1P-4

C1P-5

C1P-6

C1P-3

C2P-2
1 3

C33STR BK

C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH

R42BAT OR/RD
4 5
C32

C134PWR GR
C28TTA RD/BK
P23BAT WH

P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH
3 6
5
7

12 8

C1B-8

C1B-7

C1B-9
C3B-3

C2B-4
P20BAT RD

C7B-2

C3B-9

C2B-5
C1B-2

C7B-2
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK
C7B-4

RD
C6B-30

C6B-31

C6B-32

C6B-29

4 OR TB40 OR
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH

WH/BK

WH/RD

RD/WH

OR/RD
OR/RD
OR/RD
OR/RD

F5 TS54

BK/RD
F4

OR/RD
10A TS56 TS52 RPM
C6B-12

C6B-24

500A

C6B-20 RD
C6B-40 OR

AP2 48V DC 30

START
ENGINE
PLUGS
GLOW
CR2 86

C5B-1 P20BAT RD
86 TB23 LOW HIGH
PR1
INDICATOR LED L2
CONTROLLER FAULT

+48V DC
85 87
BK D2

RD/BK
BK
+

COIL-PR1

CR5

F2 85
TB34 TB33
5 200A 86
CR1
30 TB35
IGNITION / START
RD 20

BL/WH

OFF-LMT SPD INP

MODULE
C10-3
C10-4

C10-1
C10-2
C6B-39 CR5 RD/BK

C6B-25 CFIL BK
DIODE RETURN

BK-ISM1

C6B-28
+

C6B-34
85 1 START RELAY
-

LEFT 87
+48V INPUT

BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+

BK-4
WH-4

BK-5
WH-5
POT. LOW
REVERSE
FORWARD

C5B-5 C33STR BK
3
POT. HI

C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR

C5B-11 C21IGN2 WH

C5B-22
LS4 HM C35HRPM
_ 15 A
5 GROUND
+

(SEC)
-

RD-J10 (12GA)
6 BATTERY
2
9

14
10

11

16

17

20

5
1

22
AP2 CB3 C5B-3 C23PWR WH
30 7 KEY SWITCH POWER

RD/WH
RD/BK
86

RD
U6A

C34SA BK/WH
MOTOR CONTROLLER CR4 30 85 8 (NOT USED)
24V DC
6
BK-5

RD-5

87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30

C8-A

C8-C
F1 M- B+ F2 B- 87 86 85 10 ENGINE FAULT
+24V DC 200A CR12

BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+

87 85
C11-3
C11-4

C11-1
C11-2

RD
WH
30 85 CR14
(12V DC) 30 CR16

WH
BRN

BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7

BK-6

86

+12V DC
87
WH

RD

YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK

BK/RD

BRN
BRN
BRN

BRN

BRN
BK/WH
MOTOR
+

RIGHT BATT WH
RIGHT (12V DC) VR1 ALT.
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
+

+ BL
(PRI)

BK
+
LS1 AP2
2 STARTER
PUMP PUMP
ALTERNATOR CHARGER (EXT) AUXILIARY
22 WH-BATT

BK
14
BK 2 GA

7 -
BRN

-
+
C8-B
BK
+

(12V DC)
-

OR-GEN NEG 30 CR16

BRN
GROUND A2

C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)

AP1 BK BK
PR2 PR2
PR3 PR3

RELAY CR2
48V DC POWER
RELAY CR1
48V DC POWER
HOUR METER
HORN

HORN RELAY

RELAY CR12
ENGINE POWER
LIFT PUMP
PRIMARY

RELAY PR1
CONTACTOR
MOTOR MAIN

RELAY CR5
BRAKE RELEASE

CHASSIS GROUND

BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC

OPTION
BEACON
FLASHING

ALERNATOR
12V DC

RPM SOLENOID

RPM RELAY CR14

TILT SENSOR

SWITCH
PRESSURE
OIL

SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID

RELAY CR13
RPM CUTOUT

FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS

RELAY CR15
GLOW PLUG
LIFT PUMP
AUXILIARY

STARTER RELAY CR11

CHARGER
48V DC

REGULATOR
12V DC VOLTAGE
8

2 SWITCH SHOWN WITH BOOM EXTENDED.

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

6 - 11 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 1

8
Section 6 • Schematics

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

6 - 12
A

3
ENABLE

SWITCH
DRIVE
ENABLE

LIMIT
LED L1
DRIVE

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3

BL/WH WH-8 RD-8

B

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

TB12

14
13

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

C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86

85

BRN
A2
86

85

RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6

+
CR5
CR8

C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
C2P-3 RD/WH N.C. COIL
DRIVE 30

87

87
30
30

87

RD/BK-R6
CE VERSION:

ENABLE
C

TS15
AND ADD
REMOVE
JUMPER

RELAY

PS1 BRAKE RELEASE

CR5

PRESSURE SWITCH PS1

TB36

C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C1P-10
TB37

C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D

OR/BK-R6
C31REV WH/BK

10
C29JSH RD/WH

C32JSL WH/RD

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
C40LS OR

LIFT

STEER
FWD

REV
20K

L R
DP1

AUXILIARY
E

PUMP
33
GR/WH

C1P-1 C27AUX RD C1B-1

TS1

PR2

RD-AUX
Part No. 110188
87
30

OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION
February 2006

GR/WH RELAY COIL PR2

BCI

BK
F

CR3
+

OR/RD

AUX

85
ON

86
DISCHARGE

OR/RD RD RD AUXILIARY CONTROL

BCI OPTION
SET TO "N"
1

RELAY COIL CR3

F

TS51

TB27

CR20
33
2

PR3

OR
3

OR/RD AUXILIARY LIFT

5

L.V.I.
4

C6B-27 PUMP RELAY COIL

OR/BK
4

RD
TB19

PR3
87
BCI

SET TO "B"
6

RESET

30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86

GR/WH CONTACTOR RELAY

7

CR20
TB6

87a
8

C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD FLOW

CONTROL
BK

85 BRN

BK/RD
CR19A

BRN

GR/WH

COIL
RD
86

TB18
G

C23-1 C23-2 PLATFORM

CONTROL

DOWN
CR19B

C6B-18 GR/BK ROTATE RIGHT /

ROTARY

JIB DOWN
FLOW
OEM

C6B-17 GR PLATFORM
BOOM
BP1

TS58

UP ROTATE LEFT /
TB17

C22-1 C22-2
86

85

JIB

JIB UP
TB44

C2P-6 C44JDA GR/BK C2B-6

BOOM
JIB

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

C4P-5 C17PRL GR C4B-5 GR
TS8

UP
H

RIGHT
BK C44DA C6B-33
PLATFORM
87a

ROTATE

TS57

LEFT
CR7
30

85
86
PLATFORM
ROTATE

WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
I

LEFT C2P-7 C45JSV GR/WH C2B-7

TB14
UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM

UP COIL
C6B-15 OR/BK
LEVEL

PLATFORM LEVEL
TS59

DOWN DOWN COIL

TB15
PLATFORM

C21-1 C21-2
LEVEL

PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
J

C4P-3 C15PLD OR/BK C4B-3

TS9

TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
PRIMARY EXTEND COIL
C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63
RETRACT RETRACT COIL

TB8
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13

TB1
K

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY BOOM
UP COIL

PRIMARY
C6B-2 RD/BK PRIMARY BOOM

BOOM

TS61
DOWN DOWN COIL

TB2
C13-1 C13-2
PRIMARY

CR19A
BOOM

UP C3P-1 C1PBU RD C3B-1

30

87

C3P-2 C2PBD RD/BK C3B-2

TS11

TB10
DOWN C18-1 C18-2

SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM
L

TS60
BOOM
SECONDARY

DOWN DOWN COIL

TB11
C19-1 C19-2
CR19B

DESCENT
BOOM

ALARM
UP C3P-10 C10SBU BL C3B-10

A3
OPTION (A3)

+
87
30 C3P-11 C11SBD BL/BK C3B-11
TS10

TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT

TURNTABLE
COIL

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT
TURNTABLE

TB4
C14-1 C14-2
COIL
M

ROTATE

RD
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4

TS12
R42BAT OR/RD
LEFT
P24BAT WH

FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
REV B

C40LS OR
N

TS55

(GND)

PR2
PR3
CR5

BK
RD

RD
February 2006 Section 6 • Schematics

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

Section 6 • Schematics February 2006

Electrical Schematic, Z-45/25J, CE Models REV B

A B C D E F G H I J K L M N

1 C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3 P25BAT RD
BK C7P-1 C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH P24BAT WH

P22BAT
P26BAT
RD
R42BAT OR/RD

2 C132PLI BL/WH C1P-12 RD TS6 TS2

HIGH LOW FOOT SWITCH
GLOW ENGINE

C1B-12
RPM RPM HIGH RPM
+

RD
A1 PLUGS START
LS18 TILT TS4
P3 L4 ALARM RPM
CB1 HORN 5
10A KS1 PLATFORM
P1

C7P-2
C3P-3

C2P-4

C1P-8

C1P-7

C1P-9
P20BAT RD D39 D40
TB22 6

C7B-1

C2P-5
C1P-2
GROUND

C7P-2

C3P-9
C1P-4

C1P-5

C1P-6

C1P-3

C2P-2
1 3

C33STR BK

C35HRPM BK/RD
C34SA BK/WH
C3BAT RD/WH

R42BAT OR/RD
4 5
U33

C134PWR GR
C28TTA RD/BK
P23BAT WH

P23BAT WH
C9HRN BK/RD
C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH
3 6
5
7

12 8

C1B-8

C1B-7

C1B-9
C3B-3

C2B-4
P20BAT RD

A6 L45

C7B-2

C3B-9

C2B-5
C1B-2

C7B-2
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK
C7B-4

RD
C6B-30

C6B-31

C6B-32

C6B-29

4 OR TB40 OR
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 TB42 RD
WH

WH/BK

WH/RD

RD/WH

OR/RD
OR/RD
OR/RD
OR/RD

F5

BK/RD
F4

OR/RD
10 A TS56 TS52 TS54
C6B-12

C6B-24

500 A

C6B-20 RD
C6B-40 OR

AP2 48V DC 30 RPM

START
ENGINE
PLUGS
GLOW
CR2 86
TB23 LOW HIGH

C5B-1 P20BAT RD
PR1 86
INDICATOR LED L2
CONTROLLER FAULT

+48V DC
85 87
BK D2

RD/BK
BK
+

COIL-PR1

CR5

F2 85
200 A
5 86
CR1
30 TB34 TB33 TB35
IGNITION / START
RD 20

BL/WH

OFF-LMT SPD INP

MODULE
C10-3
C10-4

C10-1
C10-2
C6B-39 CR5 RD/BK

C6B-25 CFIL BK
DIODE RETURN

BK-ISM1

C6B-28
+

C6B-34
85 1 START RELAY
-

LEFT 87
+48V DC INPUT

BRN
BRN
BOX BL-ISM2 2 TACH. INPUT
INTERLOCK
+

BK-4
WH-4

BK-5
WH-5
POT. LOW
REVERSE
FORWARD

C5B-5 C33STR BK
3
POT. HI

C23PWR WH START INPUT

C5B-18 4 (NOT USED)
21 +
GR

C5B-11 C21IGN2 WH

C5B-22
LS4 HM C35HRPM
_ 5 GROUND
+

(SEC)
-

RD-J10 (12GA)
6 BATTERY
10

14

16

17

20
11

22
3
9

5
2
1

AP2 CB3 C5B-3 C23PWR WH

30 15 A 7 KEY SWITCH POWER

RD/WH
RD/BK
86

RD

C34SA BK/WH
U6A 30 8 (NOT USED)
CR4 85
6 24V DC MOTOR CONTROLLER
BK-5

RD-5

87 85 9 IGNITION ON
F1 BK CR11 85 30 WH
AP1 30

C8-A

C8-C
F1 M- B+ F2 B- 87 86 85 10 ENGINE FAULT
+24V DC 200A CR12

BK
PR3 PR2 CR13
86 87 WH-J4 86
C6B-9 BK/RD
+

87 85
C11-3
C11-4

C11-1
C11-2

RD
WH
30 85 CR14
30 CR16

WH
BRN
(12V DC)

BRN
FB 85 CR15
+
86
WH-6
BK-7
WH-7

BK-6

+12V DC
86
87
WH

RD

YEL
LEFT A2 A2 F2 F1 86
BL 87 GR/BK

BK/RD

BRN
BRN
BRN

BRN

BRN
BK/WH
MOTOR
+

(12V)
-

RIGHT BATT WH
RIGHT VR1 ALT.
BOX F2 F1 A1 A1 MOTOR LS2 21 13 -
+

+ BL
(PRI)

BK
+
LS1 AP2
2 STARTER
PUMP PUMP
ALTERNATOR CHARGER (EXT) AUXILIARY
22 WH-BATT

BK
7 14
BK 2 GA

-
BRN

-
+
C8-B (12V DC)
BK
+

OR-GEN NEG 30 CR16

BRN
GROUND A2

C5B-2
AC POWER ENGINE
OR-GEN POS
GROUND
87 (GND)

AP1 BK BK
PR2 PR2
PR3 PR3

48V DC POWER RELAY CR2

48V DC POWER RELAY CR1
HOUR METER
HORN

HORN RELAY

ENGINE POWER RELAY CR12

LIFT PUMP
PRIMARY

RELAY PR1
CONTACTOR
MOTOR MAIN

RELAY CR5
BRAKE RELEASE

CHASSIS GROUND

BOX GROUND
BASE CONTROL
ALTERNATOR
48V DC

FLASHING BEACON OPTION

12V DC ALERNATOR

RPM SOLENOID

RPM RELAY CR14

TILT SENSOR

SWITCH
PRESSURE
OIL

SWITCH
TEMPERATURE
WATER
ENGINE RUN SOLENOID

RELAY CR13
RPM CUTOUT

FIELD RELAY CR16

ALTERNATOR
GLOW PLUGS
LIFT PUMP
AUXILIARY

STARTER RELAY CR11

RELAY CR15
GLOW PLUG
12V DC VOLTAGE REGULATOR
CHARGER
48V DC

2 SWITCH SHOWN WITH BOOM EXTENDED.

NOTES: 5 CE & PLATFORM LOAD SENSE OPT.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

6 - 13 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 1

8
Section 6 • Schematics

Electrical Schematic, Z-45/25J, CE Models

6 - 14
A

3
ENABLE

SWITCH
DRIVE
ENABLE

LIMIT
LED L1
DRIVE

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

21
22

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
LS3

BL/WH WH-8 RD-8

B

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

TB12

14
13

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

C4P-4 C16DRE OR/RD C4B-4 OR/RD C6B-16 C16DRE

86

85

BRN
A2
86

85

RD/WH BRAKE RELEASE

TRAVEL ALARM (A2)
CR6

+
CR5
CR8

C26-1 C26-2
R41DRE OR/BK C2B-3 C6B-35 RD/WH BRAKE RELEASE
C2P-3 RD/WH N.C. COIL
DRIVE 30

87

87
30
30

87

RD/BK-R6
CE VERSION:

ENABLE
C

TS15
AND ADD
REMOVE
JUMPER

RELAY

PS1 BRAKE RELEASE

CR5

PRESSURE SWITCH PS1

TB36

C24-1 C24-2
C36STCC BL C1B-10 C6B-36 BL
RD STEER LEFT COIL
C1P-10
TB37

C37STC BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT COIL
C1P-11
C25-1 C25-2
C6B-38 GR/WH
D

OR/BK-R6
C31REV WH/BK

10
C29JSH RD/WH

C32JSL WH/RD

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
C40LS OR

LIFT

STEER
FWD

REV
20K

L R
DP1

AUXILIARY
E

PUMP
33
GR/WH

C1P-1 C27AUX RD C1B-1

TS1

PR2

RD-AUX
Part No. 110188
87
30

OR/RD C6B-19 PRIMARY LIFT PUMP

LVI/BCI OPTION
February 2006

GR/WH RELAY COIL PR2

BCI

BK
F

CR3
+

OR/RD

AUX

85
ON

86
DISCHARGE

OR/RD RD RD AUXILIARY CONTROL

BCI OPTION
SET TO "N"
1

RELAY COIL CR3

F

TS51

TB27

CR20
33
2

PR3

OR
3

OR/RD AUXILIARY LIFT

5

L.V.I.
4

C6B-27 PUMP RELAY COIL

OR/BK
4

RD
TB19

PR3
87
BCI

SET TO "B"
6

RESET

30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH LIFT PUMP

WH
85
86

GR/WH CONTACTOR RELAY

7

CR20
TB6

87a
8

C3P-6 C6LFC WH/RD C3B-6 WH/RD C6B-6 WH/RD FLOW

CONTROL
BK

85 BRN

BK/RD
CR19A

BRN

GR/WH

COIL
RD
86

TB18
G

C23-1 C23-2 PLATFORM

CONTROL

DOWN
CR19B

C6B-18 GR/BK ROTATE RIGHT /

ROTARY

JIB DOWN
FLOW
OEM

C6B-17 GR PLATFORM
BOOM
BP1

TS58

UP ROTATE LEFT /
TB17

C22-1 C22-2
86

85

JIB

JIB UP
TB44

C2P-6 C44JDA GR/BK C2B-6

BOOM
JIB

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

C4P-5 C17PRL GR C4B-5 GR
TS8

UP
H

RIGHT
BK C44DA C6B-33
PLATFORM
87a

ROTATE

TS57

LEFT
CR7
30

85
86
PLATFORM
ROTATE

WH BK
RIGHT JIB MANIFOLD
GR/WH
TS7
I

LEFT C2P-7 C45JSV GR/WH C2B-7

TB14
UP C20-1 C20-2
C6B-14 OR PLATFORM LEVEL
PLATFORM

UP COIL
C6B-15 OR/BK
LEVEL

PLATFORM LEVEL
TS59

DOWN DOWN COIL

TB15
PLATFORM

C21-1 C21-2
LEVEL

PLATFORM LEVEL
UP C4P-2 C14PLU OR C4B-2 CUTOUT DOWN
RELAY COIL CR10B
J

C4P-3 C15PLD OR/BK C4B-3

TS9

TB7
DOWN C16-1 C16-2
EXTEND C6B-7 BK PRIMARY BOOM
EXTEND COIL
PRIMARY C6B-8 BK/WH PRIMARY BOOM
BOOM

TS63
RETRACT RETRACT COIL

TB8
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8
TS13

TB1
K

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY BOOM
UP COIL

PRIMARY
C6B-2 RD/BK PRIMARY BOOM

BOOM

TS61
DOWN DOWN COIL

TB2
C13-1 C13-2
PRIMARY

CR19A
BOOM

UP C3P-1 C1PBU RD C3B-1

30

87

C3P-2 C2PBD RD/BK C3B-2

TS11

TB10
DOWN C18-1 C18-2

SECONDARY
UP C6B-10 BL SECONDARY BOOM
UP COIL
C6B-11 BL/BK SECONDARY BOOM
L

TS60
BOOM
SECONDARY

DOWN DOWN COIL

TB11
C19-1 C19-2
CR19B

DESCENT
BOOM

ALARM
UP C3P-10 C10SBU BL C3B-10

A3
OPTION (A3)

+
87
30
C3P-11 C11SBD BL/BK C3B-11
TS10

TB5
DOWN TURNTABLE
C15-1 C15-2
RIGHT C6B-5 WH/BK ROTATE RIGHT

TURNTABLE
COIL

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT
TURNTABLE

TB4
C14-1 C14-2
COIL
M

ROTATE

RD
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4

TS12
R42BAT OR/RD
P24BAT WH LEFT

FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

C12DRE BL/WH
P42BAT OR/RD
C30FWD WH
REV B

C40LS OR
N

TS55

(GND)

PR2
PR3
CR5

BK
RD

RD
February 2006 Section 6 • Schematics

Electrical Schematic, Z-45/25J, CE Models

Section 6 • Schematics February 2006

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

ANSI and CSA Models
 8
7
6
5
4
3
2
1

6 - 15
C23
A
1 3 4 5 6 7 8 12

RD H6
BK 22B
Section 6 • Schematics

BK C7-1
RD TS51
RD TS55

TERMINAL BASE (TB)

BRN GND
GR/BK H6

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

C3B-2 C2PBD RD/BK RD/BK-TS61

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

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45

(CE OPTION ONLY)

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

8 PRIMARY BOOM RETRACT 8

C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60

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

17 PLATFORM ROTATE LEFT 17

C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM

18 PLATFORM ROTATE RIGHT 18

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

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

C7B-2 P23SWBAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
E

C1B-1 C27AUX RD RD-TS51

27 AUXILIARY PUMP SELECT 27
C5B-5 C33STR BK
C1B-7 C33STR BK BK-TS52
33 START ENGINE 33

C7B-3
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD BK/RD-TS54
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,

35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
F
February 2006

C6B-24 C40LS OR

Part No. 110188

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

OR/RD-42A OR/RD HARNESS

C2B-7 C45JSV GR/WH GR/WH
BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)

BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13

C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK
H

C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C6B-19 R19LPMP GR/WH

C32JSL WH/RD
C29JSH RD/WH

C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

C6B-9 R9HRN
RD/WH
GR/WH
GR/WH

C3B-3 C3BAT RD/WH

RD/WH OR/RD

CR1 CR2 BRN BRN

48V DC 48V DC CR3 CR20
I

POWER POWER AUXILIARY CONTROL LIFT PUMP

RELAY RELAY RELAY RELAY

30 30 30 30
BRN

87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

86 85 86 85 86 85
87 87 87 87
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH
J

C2B-3 C41DRE OR/BK

C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH

C5B-2

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
K

30
CR4 CR5
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A

N
 February 2006 Section 6 • Schematics

REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

ANSI and CSA Models
N M L K J I H G F E D C B A
BK/RD BK/RD-35A C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A 1
BK/WH-8A GR-17A

HIGH/LOW
BK WH/BK-5A

TS54

RPM
RD

PLATFORM
ROTATE
WH-4A GR

TS57
ROTATE
TABLE
TURN
TS62
BK

RETRACT
PRIMARY

EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A

AUXILIARY
PUMP

RD

BK
TS51

RD
BK
OR/BK-15A OR/BK

RD/BK-2A OR-14A OR

RD-1A

PLATFORM
3

LEVEL
TS59
PRIMARY
BOOM
TS61
WH

RD

RD

RD
RD

RD C23-6

RD
BK
4
BK-22A

P20BAT RD (C7B-4)

RD
BL-10A RD

OVERLOAD
PLATFORM

(CE ONLY)
+

KS1

BREAKER 1
BL/BK-11A

CIRCUIT
-

CB1
L45
GR/WH-19A BK 5

SECONDARY
P20BAT RD (C5B-1) RD

BOOM
TS60
RD 134A

RD RD

RD

RD
RD C23-7 RD 6

D2
RD

GR/BK H6

RD

ENGINE
START
TS52
WH 23A

BK-33A

EMERGENCY
1
WH 7
STOP
P1

C21IGN2 (C5B-11)

RD

RD

RD
NC
BRN
2

BRN-HM

FUNCTION
ENABLE
GLOW
PLUG
TS56

TS55
RD

BASE BOX HARNESS

BK/WH-34A

HOUR METER
H.M.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 16
February 2006 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

ANSI and CSA Models
Section 6 • Schematics February 2006

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

CE Models
 8
7
6
5
4
3
2
1

6 - 17
U33
1 3 4 5 6 7 8 12
A
CE Models

RD H6
BK 22B
BK C7-1
RD TS51
TERMINAL BASE (TB) RD TS55
BRN GND
GR/BK H6

P20BAT RD

BL/WH C1-12
Section 6 • Schematics

D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
B

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C

C6B-11 C11SBD BL/BK BK ALARM

C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C3B-12 C12DRE BL/WH
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM
D

18 PLATFORM ROTATE RIGHT 18

C6B-38 C19PSW GR/WH GR/WH
C4B-7 C19LPMP GR/WH GR/WH-TS60
19 LIFT PUMP 19

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

GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 C22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23SWBAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
C5B-5 C33STR BK
E

C1B-7 C33STR BK BK-TS52

33 START ENGINE 33

C7B-3
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD BK/RD-TS54
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,

C6B-37 C37STC BL/BK

C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
F
February 2006

C6B-22 R42BAT OR/RD OR/RD-CR1

Part No. 110188

C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C23ALARM RD RD H6
C2B-5 C134PWR RD RD KS1
134 KEYSWEITCH POWER 134
FAULT C5B-3 C23PWR WH
STATUS
C5B-1 P20BAT RD GROUND
LED
BK C6B-25 C5B-11 C21IGN2 WH CONTROL
OR/RD-42A OR/RD HARNESS
C2B-7 C45JSV GR/WH GR/WH
G

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)

BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13

C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C6B-19 R19LPMP GR/WH

C32JSL WH/RD
C29JSH RD/WH

C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
H

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

C6B-9 R9HRN
RD/WH
GR/WH
GR/WH

C3B-3 C3BAT RD/WH

RD/WH OR/RD

CR1 CR2 BRN BRN

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

30 30 30 30
BRN

87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

86 85 86 85 86 85
87 87 87 87
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH

C5B-2

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
HORN BRAKE
K

RELAY RELEASE
RELAY
L
M
REV A

N
 February 2006 Section 6 • Schematics

REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

CE Models
N M L K J I H G F E D C B A
BK/RD BK/RD-35A C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A 1
BK/WH-8A GR-17A

HIGH/LOW
BK WH/BK-5A

TS54

RPM
RD

PLATFORM
ROTATE
WH-4A GR

TS57
ROTATE
TABLE
TURN
TS62
BK

RETRACT
PRIMARY

EXTEND/
BOOM
TS63
RD
BK 2
RD
RD RD-27A

AUXILIARY
PUMP

RD

BK
TS51

RD
BK
OR/BK-15A OR/BK

RD/BK-2A OR-14A OR

RD-1A

PLATFORM
3

LEVEL
TS59
PRIMARY
BOOM
TS61
WH

RD

RD

RD
RD

RD C23-6

RD
BK
4
BK-22A

P20BAT RD (C7B-4)

RD
BL-10A RD

OVERLOAD
PLATFORM

(CE ONLY)
+

KS1

BREAKER 1
BL/BK-11A

CIRCUIT
-

CB1
L45
GR/WH-19A BK 5

SECONDARY
P20BAT RD (C5B-1) RD

BOOM
TS60
RD 134A

RD RD

RD

RD
RD C23-7 RD 6

D2
RD

GR/BK H6

RD

ENGINE
START
TS52
WH 23A

BK-33A

EMERGENCY
1
WH 7
STOP
P1

C21IGN2 (C5B-11)

RD

RD

RD
NC
BRN
2

BRN-HM

FUNCTION
ENABLE
GLOW
PLUG
TS56

TS55
RD

BASE BOX HARNESS

BK/WH-34A

HOUR METER
H.M.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 18
February 2006 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25,

CE Models
Section 6 • Schematics February 2006

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

ANSI and CSA Models
 8
7
6
5
4
3
2
1

6 - 19
C23 A
1 3 4 5 6 7 8 12

RD H6
BK 22B
BK C7-1
RD TS51
RD TS55

TERMINAL BASE (TB)

BRN GND
Section 6 • Schematics

GR/BK H6

P20BAT RD

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

C3B-2 C2PBD RD/BK RD/BK-TS61

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

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45

(CE OPTION ONLY)

C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C

C3B-10 C10SBU BL BL-TS60

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK BK ALARM
C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C3B-12 C12DRE BL/WH
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
D

C4B-6 C18PRR GR/BK GR/BK-TS57

BK-ALARM

18 PLATFORM ROTATE RIGHT/JIB DOWN 18

C6B-38 C19PSW GR/WH GR/WH

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

C4B-7 C19LPMP GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 C22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23SWBAT WH WH-KS1 (D2)

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

27 AUXILIARY PUMP SELECT 27

C5B-5 C33STR BK
C1B-7 C33STR BK BK-TS52
33 START ENGINE 33

C7B-3
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD BK/RD-TS54
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19

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

36 STEER LEFT 36
C6B-37 C37STC BL/BK
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
C6B-24 C40LS OR
F
February 2006

C2B-2 C40LS OR

Part No. 110188

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

C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)

BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13

C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C6B-27 R27AUX
C30FWD WH
H

C28TTA RD/BK

C6B-19 R19LPMP GR/WH

C32JSL WH/RD
C29JSH RD/WH

C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

C6B-9 R9HRN
RD/WH
GR/WH
GR/WH

C3B-3 C3BAT RD/WH

RD/WH OR/RD

CR1 CR2 BRN BRN

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

AUXILIARY CONTROL
RELAY RELAY RELAY RELAY

30 30 30 30
BRN

87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

86 85 86 85 86 85
87 87 87 87
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH

C5B-2

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
K

CR4 CR5
HORN BRAKE
RELAY RELEASE
RELAY
L
M
REV A

N
 February 2006 Section 6 • Schematics

REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

ANSI and CSA Models
N M L K J I H G F E D C B A
BK/RD BK/RD-35A C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A 1
BK
BK/WH-8A GR-17A

HIGH/LOW
BK WH/BK-5A GR/BK

TS54

RPM
RD

PLATFORM
ROTATE
WH-4A GR

TS57
GR

ROTATE
TABLE
TURN
TS62
BK

RETRACT
PRIMARY

EXTEND/
BOOM
TS63
RD
BK 2
RD

GR/BK
RD RD-27A

AUXILIARY
PUMP

RD
GR

BK
TS51

BK
RD
BK
OR/BK-15A OR/BK

RD/BK-2A OR-14A OR

RD-1A

PLATFORM
3

LEVEL
TS59
GR/BK-44A

PRIMARY
BOOM
TS61

JIB BOOM
WH

RD

RD

RD

TS58
RD

BK

RD C23-6

RD
BK
RD
4
BK-22A

P20BAT RD (C7B-4)

RD
BL-10A RD

OVERLOAD
PLATFORM

(CE ONLY)
+

KS1

BREAKER 1
BL/BK-11A

CIRCUIT
-

CB1
L45
GR/WH-19A BK 5

SECONDARY
P20BAT RD (C5B-1) RD

BOOM
TS60
RD 134A

RD RD

RD

RD
RD C23-7 RD 6

D2
RD

GR/BK H6

RD

ENGINE
START
TS52
WH 23A

BK-33A

EMERGENCY
1
WH 7
STOP
P1

C21IGN2 (C5B-11)

RD

RD

RD

RD
NC
BRN
2

BRN-HM

FUNCTION
ENABLE
GLOW
PLUG
TS56

TS55
RD

BASE BOX HARNESS

BK/WH-34A

HOUR METER
H.M.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 20
February 2006 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

ANSI and CSA Models
Section 6 • Schematics February 2006

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

CE Models
 8
7
6
5
4
3
2
1

6 - 21
U33
1 3 4 5 6 7 8 12
A
CE Models

RD H6
BK 22B
BK C7-1
RD TS51
TERMINAL BASE (TB) RD TS55
BRN GND
GR/BK H6

P20BAT RD

BL/WH C1-12
Section 6 • Schematics

D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
B

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
RD C23-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C23-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C

C6B-11 C11SBD BL/BK BK ALARM

C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C3B-12 C12DRE BL/WH
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM
D

18 PLATFORM ROTATE RIGHT/JIB DOWN 18

C6B-38 C19PSW GR/WH GR/WH
C4B-7 C19LPMP GR/WH GR/WH-TS60
19 LIFT PUMP 19

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

GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 C22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23SWBAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
C5B-5 C33STR BK
E

C1B-7 C33STR BK BK-TS52

33 START ENGINE 33

C7B-3
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH BK/WH-TS56
34 GLOW PLUG 34
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD BK/RD-TS54
35 HIGH/LOW RPM 35
C6B-36 C36STCC BL
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J,

C1B-11 C37STC BL/BK GR/WH-J19

37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
F
February 2006

C6B-22 R42BAT OR/RD OR/RD-CR1

Part No. 110188

C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C23ALARM RD RD H6
C2B-5 C134PWR RD RD KS1
134 KEYSWEITCH POWER 134
FAULT C5B-3 C23PWR WH
STATUS
C5B-1 P20BAT RD GROUND
LED
BK C6B-25 C5B-11 C21IGN2 WH CONTROL
OR/RD-42A OR/RD HARNESS
C2B-7 C45JSV GR/WH GR/WH
G

BRN-HM BRN
GROUND (TO
STUD OR/RD
SWITCH
BK PANEL)

BRN
BRN
C6B-21
C6B-32
C6B-31
C6B-30
C6B-29
C6B-28
C6B-16
C6B-13

C6B-40 C40LS OR
C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C6B-27 R27AUX
C30FWD WH
C28TTA RD/BK

C6B-19 R19LPMP GR/WH

C32JSL WH/RD
C29JSH RD/WH

C31REV WH/BK
C16DRE OR/RD
C13DREL BL/RD
H

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

C6B-9 R9HRN
RD/WH
GR/WH
GR/WH

C3B-3 C3BAT RD/WH

RD/WH OR/RD

CR1 CR2 BRN BRN

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

30 30 30 30
BRN

87a 87a 87a 87a

86 85
C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

86 85 86 85 86 85
87 87 87 87
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

BRN
BK/RD
RD/BK
OR/BK
OR/RD
RD/WH

C5B-2

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
CR4 CR5
HORN BRAKE
K

RELAY RELEASE
RELAY
L
M
REV A

N
 February 2006 Section 6 • Schematics

REV A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

CE Models
N M L K J I H G F E D C B A
BK/RD BK/RD-35A C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A 1
BK
BK/WH-8A GR-17A

HIGH/LOW
BK WH/BK-5A GR/BK

TS54

RPM
RD

PLATFORM
ROTATE
WH-4A GR

TS57
GR

ROTATE
TABLE
TURN
TS62
BK

RETRACT
PRIMARY

EXTEND/
BOOM
TS63
RD
BK 2
RD

GR/BK
RD RD-27A

AUXILIARY
PUMP

RD
GR

BK
TS51

BK
RD
BK
OR/BK-15A OR/BK

RD/BK-2A OR-14A OR

RD-1A

PLATFORM
3

LEVEL
TS59
GR/BK-44A

PRIMARY
BOOM
TS61

JIB BOOM
WH

RD

RD

RD

TS58
RD

BK

RD C23-6

RD
BK
RD
4
BK-22A

P20BAT RD (C7B-4)

RD
BL-10A RD

OVERLOAD
PLATFORM

(CE ONLY)
+

KS1

BREAKER 1
BL/BK-11A

CIRCUIT
-

CB1
L45
GR/WH-19A BK 5

SECONDARY
P20BAT RD (C5B-1) RD

BOOM
TS60
RD 134A

RD RD

RD

RD
RD C23-7 RD 6

D2
RD

GR/BK H6

RD

ENGINE
START
TS52
WH 23A

BK-33A

EMERGENCY
1
WH 7
STOP
P1

C21IGN2 (C5B-11)

RD

RD

RD

RD
NC
BRN
2

BRN-HM

FUNCTION
ENABLE
GLOW
PLUG
TS56

TS55
RD

BASE BOX HARNESS

BK/WH-34A

HOUR METER
H.M.
Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 22
February 2006 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,

CE Models
Section 6 • Schematics February 2006

Platform Control Box Wiring Diagram, Z-45/25

Section 6 • Schematics February 2006

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

A B C D E F G H I J K L M N

1
BRN-RELAY

OR/BK-R6
OR/BK

RD/BK-R6
CR6

2
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C33STR BK
C34SA BK/WH
C35HRPM BK/RD
C36STCC BL
C37STC BL/BK

R41DRE OR/BK
R42BAT OR/RD

C1PBU RD
C2PBD RD/BK
C3BAT RD/WH
C4TRL WH
C5TRR WH/BK
C6LFC WH/RD
C7PBE BK
C8PBR BK/WH
C9HRN BK/RD
C10SBU BL
C11SBD BL/BK
C12DRE BL/WH

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH

P22BAT BK
P23SWBAT WH
BRN-BATGND

P26BAT BK
P24BAT WH
P25BAT RD
C16DRE OR/RD
RD/BK L48

BRN-J1

1
BRN-BATGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6
C1P-7
C1P-8
C1P-9
C1P-10
C1P-11

C2P-3
C2P-4

C3P-1
C3P-2
C3P-3
C3P-4
C3P-5
C3P-6
C3P-7
C3P-8
C3P-9
C3P-10
C3P-11
C3P-12

C4P-1
C4P-2
C4P-3
C4P-4
C4P-5
C4P-6
C4P-7

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3
3
C1P-2
C28TTA RD/BK

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

4 C7P C9P JIB LS18 OPT.

D40

A1
FOOT
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY SWITCH

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

BK/WH-DRE
BRN-BCI

BCI C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL 1
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPMP GR/WH P25BAT RD
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT
WH/YL
9 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
OPTION
WH/RD C36STCC BL P2 EMERGENCY STOP BUTTON
LEFT 10
P3 HORN

P26FS BK C9P-1

P22BAT BK C7P-1

P23SWBAT WH C7P-2

C3BAT RD/WH C3-3

7 TS1 AUXILIARY TOGGLE SWITCH
1

1
TS2 ENGINE START TOGGLE SWITCH

RD-HRN
RD/BK H1
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C34SA BK/WH

C33STR BK

RD-AUX
RD-RPM

C35HRPM BK/RD
C18PRR GR/BK

C17PRL GR

C15PLD OR/BK
C14PLU OR

TS4 HIGH / LOW RPM TOGGLE SWITCH

TS6 GLOW PLUG TOGGLE SWITCH
RD TS7 PLATFORM ROTATE TOGGLE SWITCH

P3
TS9 PLATFORM LEVEL TOGGLE SWITCH
TS10 SECONDARY BOOM TOGGLE SWITCH
3

2
4

TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH

NO

NC NC NC

1
8

1
TS12 TURNTABLE ROTATE TOGGLE SWITCH
RD L48

2
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
TS15
P3 DRIVE ENABLE
TS2 TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS6 TS4
ENGINE P2
GLOW PLUG RPM H1 TITL ALARM
TS1 L1 TS7 TS9 START EMERGENCY
AUXILIARY PLATFORM PLATFORM STOP LS18 PLATFORM OVERLOAD LIMIT SWITCH
POWER ROTATE LEVEL L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

6 - 23 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 February 2006 Section 6 • Schematics

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

with LVI/BCI Option
N M L K J I H G F E D C B A
WH
1
1
OR/RD
1
LVI
2
OR
CR8 3
OR/BK
4
OR/RD
5
WH WH RESET IS SET TO "B",
6
BRN-RELAY DISCHARGE IS SET TO "N"
7
8

CR6 CR7 CR19A CR19B 2

C40LS OR
RD-LR19B

RD-LVI
BL-L10

BL-LR19A
R42BAT OR/RD
P24BAT WH
RD-J7

OR-LVI
OR/BK-LVI
OR/RD-LVI
P24BAT WH
BRN-LVI

RD-P2

RD-H1

BK LS CABLE C1P-12
3
GR/BK C133PLA
RD LS18

GR/BK L4

C2P-2
C2P-4

C3P-1
C3P-10

C9P-2

RD
4
C2P-6

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)
C7P C9P JIB LS18 OPT.

D39

1
A1
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH

5
NOTES:

1. LOAD SENSE WIRES SHOWN WITH DASHED LINES

DP1
20k
GR
1 1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN
TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
GR OR
2
TS12 TS11 TS13 RD
TS10
LVI/BCI TURNTABLE SECONDARY PRIMARY EXTEND/ BK/RD
WH
3 COMPONENT INDEX
ROTATE BOOM BOOM RETRACT FWD
BK
4 BCI BATTERY CHARGE INDICATOR
6
REV
RD
5 BP1 ROTARY FLOW CONTROL DIAL
WH/GR
3 5 4 6 P24BAT WH DP1 DRIVE JOYSTICK
YL

PRPL
1 RD-J7 L1 DRIVE ENABLE LED
LIFT
7 L2 LOAD SENSE LED
BP1 BL
DRIVE 8 LVI LOW VOLTAGE INTERRUPT MODULE
WH/YL
RIGHT 9 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
OR-LVI

OR/RD-LVI

OR/BK-LVI

BL-LR19A

RD-LR19B

LEFT
WH/RD
10
P2 EMERGENCY STOP BUTTON
P3 HORN 7
TS1 AUXILIARY TOGGLE SWITCH
TS2 START ENGINE TOGGLE SWITCH

GR/BK-H1 (D39)

RD-LS18
TS4 HIGH / LOW RPM TOGGLE SWITCH
TS6 GLOW PLUG TOGGLE SWITCH
TS7 PLATFORM ROTATE TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
1
TS10 SECONDARY BOOM TOGGLE SWITCH
8
3

2
NO

TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH

NC NC NC

1
4

1
TS12 TURNTABLE ROTATE TOGGLE SWITCH
RD

1
L4
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

2
TS15
P3 DRIVE ENABLE TS6 TS2 P2
TS1 TS7 TS9 GLOW PLUG ENGINE START
TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS4 EMERGENCY STOP
AUXILIARY PLATFORM PLATFORM RPM A1 TILT ALARM
POWER L1 ROTATE LEVEL
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 24

February 2006 Section 6 • Schematics

Platform Control Box Wiring Diagram, Z-45/25

with LVI/BCI Option
Section 6 • Schematics February 2006

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

Section 6 • Schematics February 2006

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

A B C D E F G H I J K L M N

1
BRN-RELAY

GR/WH
GR/WH-45
GR/WH-R7
OR/RD
OR/BK-R6
OR/BK

RD/BK-R6

RD-J7
CR6 CR7

2
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C33STR BK
C34SA BK/WH
C35HRPM BK/RD
C36STCC BL
C37STC BL/BK

R41DRE OR/BK
R42BAT OR/RD
C44JDA GR/BK
C45JSV GR/WH

C1PBU RD
C2PBD RD/BK
C3BAT RD/WH
C4TRL WH
C5TRR WH/BK
C6LFC WH/RD
C7PBE BK
C8PBR BK/WH
C9HRN BK/RD
C10SBU BL
C11SBD BL/BK
C12DRE BL/WH

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH

P22BAT BK
P23SWBAT WH
BRN-BATGND

P26BAT BK
P24BAT WH
P25BAT RD

BK-JIBGND
GR/WH-45
GR/WH-45
C16DRE OR/RD
RD/BK L48

BRN-J1

1
BRN-BATGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6
C1P-7
C1P-8
C1P-9
C1P-10
C1P-11

C2P-3
C2P-4
C2P-6
C2P-7

C3P-1
C3P-2
C3P-3
C3P-4
C3P-5
C3P-6
C3P-7
C3P-8
C3P-9
C3P-10
C3P-11
C3P-12

C4P-1
C4P-2
C4P-3
C4P-4
C4P-5
C4P-6
C4P-7

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3
3 BRN-JIBGND

BK

WH
C1P-2
C28TTA RD/BK

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

4 C7P C9P JIB LS18 OPT.

D40

A1
FOOT
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY SWITCH

GR-LFC DP1 NOTES:

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

BK/WH-DRE
BRN-BCI

BCI C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL 1
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPMP GR/WH P25BAT RD
C6LFC WH/RD

BRN-BCI
BRN-J1
WH/YL
RIGHT 9 P2 EMERGENCY STOP BUTTON
OPTION
WH/RD C36STCC BL P3 HORN
LEFT 10
TS1 AUXILIARY TOGGLE SWITCH

P26FS BK C9P-1

P22BAT BK C7P-1

P23SWBAT WH C7P-2

C3BAT RD/WH C3-3

7 TS2 ENGINE START TOGGLE SWITCH
1

1
TS4 HIGH / LOW RPM TOGGLE SWITCH

RD-HRN
RD/BK H1
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C44JDA GR/BK

GR/WH- R7

C34SA BK/WH

C33STR BK

RD-AUX
RD-RPM

C35HRPM BK/RD
C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS6 GLOW PLUG TOGGLE SWITCH

TS7 PLATFORM ROTATE TOGGLE SWITCH
RD TS8 JIB BOOM UP / DOWN SWITCH

P3
TS9 PLATFORM LEVEL TOGGLE SWITCH
TS10 SECONDARY BOOM TOGGLE SWITCH
TS15
3

2
4

NO

NC NC NC

1
TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
8

1
TS12 TURNTABLE ROTATE TOGGLE SWITCH
RD L48

1
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
P3 DRIVE ENABLE
HORN TS2 TS15 DRIVE ENABLE TOGGLE SWITCH
TS6 TS4
ENGINE P2
GLOW PLUG RPM EMERGENCY
H1 TITL ALARM
TS1 TS8 TS7 TS9 START
AUXILIARY L1 JIB BOOM PLATFORM PLATFORM STOP LS18 PLATFORM OVERLOAD LIMIT SWITCH
POWER ROTATE LEVEL L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

6 - 25 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 110188

 February 2006 Section 6 • Schematics

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

with LVI/BCI Option
N M L K J I H G F E D C B A
WH
1 1
OR/RD
1
LVI
2
OR
CR8 3
OR/BK
4
OR/RD
5
WH WH RESET IS SET TO "B",
6
BRN-RELAY DISCHARGE IS SET TO "N"
7
8

CR6 CR7 CR19A CR19B 2

C40LS OR
RD-LR19B

RD-LVI
BL-L10

BL-LR19A
R42BAT OR/RD
P24BAT WH
RD-J7

OR-LVI
OR/BK-LVI
OR/RD-LVI
P24BAT WH
BRN-LVI

RD-P2

RD-H1

BK LS CABLE C1P-12
3
GR/BK C133PLA
RD LS18

GR/BK L4

C2P-2
C2P-4

C3P-1
C3P-10

C9P-2

RD
4
C2P-6

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)
C7P C9P JIB LS18 OPT.

D39

1
A1
TILT ALARM 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH

5
NOTES:

1. LOAD SENSE WIRES SHOWN WITH DASHED LINES

DP1 1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN

TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
GR
20k 1
GR OR

TS12 TS10 TS11 TS13 RD

2 COMPONENT INDEX
WH
LVI/BCI TURNTABLE SECONDARY PRIMARY EXTEND/ BK/RD 3 BCI BATTERY CHARGE INDICATOR
ROTATE BOOM BOOM RETRACT FWD
BK
4 BP1 ROTARY FLOW CONTROL DIAL
6
REV
RD
5 DP1 DRIVE JOYSTICK
WH/GR
3 5 4 P24BAT WH L1 DRIVE ENABLE LED
YL 6
PRPL
1 RD-J7
L2 LOAD SENSE LED
LIFT
7 LVI LOW VOLTAGE INTERRUPT MODULE
BP1 BL
DRIVE 8 LVI/BCI BATTERY CHARGE INDICATOR FOR LVI OPTION
WH/YL
RIGHT 9 P2 EMERGENCY STOP BUTTON
OR-LVI

OR/RD-LVI

OR/BK-LVI

BL-LR19A

RD-LR19B

WH/RD P3 HORN
LEFT 10
TS1 AUXILIARY TOGGLE SWITCH 7
TS2 START ENGINE TOGGLE SWITCH
TS4 HIGH / LOW RPM TOGGLE SWITCH

GR/BK-H1 (D39)

RD-LS18
TS6 GLOW PLUG TOGGLE SWITCH
TS7 PLATFORM ROTATE TOGGLE SWITCH
TS8 JIB UP / DOWN TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
1
TS10 SECONDARY BOOM TOGGLE SWITCH
8
3

2
TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
NO

NC NC NC

1
4

1
TS12 TURNTABLE ROTATE TOGGLE SWITCH
RD

1
L4
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

2
TS15
P3 DRIVE ENABLE TS6 TS2 P2
TS1 TS8 TS7 GLOW PLUG ENGINE START
TS15 DRIVE ENABLE TOGGLE SWITCH
HORN TS9 TS4 EMERGENCY STOP
AUXILIARY JIB BOOM PLATFORM PLATFORM RPM A1 TILT ALARM
POWER L1 ROTATE LEVEL
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L4 PLATFORM OVERLOAD LED
L48 TILT ALARM LED

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 26

February 2006 Section 6 • Schematics

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

with LVI/BCI Option
 February 2006 Section 6 • Schematics

REV B Hydraulic Schematic

N M L K J I H G F E D C B A

JIB BOOM PLATFORM ROTATE 1

L R

1.5:1 3:1
3800 psi 3000 psi
262 bar 207 bar

PR2
E R PR1
2
J1 J2 PR2 PR1

JIB BOOM / PLATFORM

ROTATE MANIFOLD
AA

3
V2 V1
PLATFORM LEVEL
SLAVE CYLINDER
TURNTABLE ROTATE PRIMARY LIFT CYLINDER EXTENSION CYLINDER
SECONDARY LIFT CYLINDERS
BRAKES STEER CYLINDERS
M M

Z
3:1
3000 psi
Y
4
207 bar

1:1
ATMOS. 3:1
3:1
3500 psi ATMOS.
1000 psi
241 bar 1500 psi
3:1 69 bar
103 bar
3500 psi
241 bar 3:1
0.030 inch 3800 psi
0.76 mm X 262 bar
S1
MASTER
V2 V1 5

N.O.
COM
N.C.
TEST

P PS ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2 SEC1 SEC2 P1 P2 EXT RET
BRAKE

3200 psi G
221 bar 0.037 inch
AUXILIARY S U 0.94 mm
PRIMARY N
PUMP
0.5 gpm
M PUMP
2.1 gpm
M 6
1.9L/min 2500 psi V
7.9 L/min W
O 172 bar
P H
A
Q 2000 psi
138 bar

0.060 inch
E
F
1.5 mm
R K
D C B
0.030 inch
I 0.030 inch T 0.76 mm 0.4 gpm
0.76 mm L
(from serial number 22566 to 22628 1.5 L/min
RESERVOIR and after serial number 23235) M
7

FUNCTION MANIFOLD

Part No. 110188 Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 6 - 27

February 2006 Section 6 • Schematics

Hydraulic Schematic
 California Proposition 65

WARNING
The exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.

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