Download from SN 9996 to 23235, Z-45/25 / Z-45/25J Bi

Service
Manual
Refer to inside cover for additional serial number information
Bi-Energy Power
(from serial number 9996 to 23235)
Part No. 106488
Rev B
June 2005
Introduction
June 2005
Introduction
Important
Serial Number Information
Read, understand and obey the safety rules and
operating instructions in the Genie Z-45/25
Bi-Energy and Genie Z-45/25J Bi-Energy Operator's
Manual before attempting any maintenance or
repair procedure.
Genie Industries offers the following Service
Manuals for these models:
This manual provides detailed scheduled
maintenance information for the machine owner and
user. It also provides troubleshooting fault codes
and repair procedures for qualified service
professionals.
Title
Part No.
Z-45/25 Bi-Energy and Z-45/25J Bi-Energy
Service Manual
(after serial number 23235) ................................ 110188
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
e-mail: [email protected]
106488 Rev B June 2005
Second Edition, Second Printing
"Genie" and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
INTRODUCTION
Serial Number Legend
Model: Z-45/25
Z452505-12345
Serial number:
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
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 45 ft 6 in/ 13.8 m
Maximum platform reach : 25 ft 3 in/ 7.7 m
Gradeability: N/A
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Z4525 05 - 12345
Model
Sequence
number
Model year
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
iii
June 2005
This page intentionally left blank.
iv
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator’s Manual will
result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
v
June 2005
SAFETY RULES
Personal Safety
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
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1
Safety Rules
General Safety Rules .................................................................................................. v
Section 2
Section 3
Rev
Specifications
A
Machine Specifications .......................................................................................... 2 - 1
B
Performance Specifications ................................................................................... 2 - 2
B
Hydraulic Specifications ........................................................................................ 2 - 3
B
Manifold Component Specifications ....................................................................... 2 - 4
B
Machine Torque Specifications .............................................................................. 2 - 4
A
Kubota Z482-E Engine Specifications .................................................................... 2 - 5
A
Generator ............................................................................................................... 2 - 6
A
Generator Torque Specifications ............................................................................ 2 - 6
A
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 7
A
SAE and Metric Fasteners Torque Charts .............................................................. 2 - 8
Rev
Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
B
Part No. 106488
Checklist A Procedures
A-1
Perform Pre-operation Inspection ................................................................. 3 - 7
A-2
Perform Function Tests ................................................................................ 3 - 7
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
vii
June 2005
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 ..................................................................... 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 ..................................................................... 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 Lug Nut Torque (including the tires and wheels) ......................... 3 - 16
B-6
Confirm the Proper Brake Configuration ...................................................... 3 - 16
B-7
Check the Oil Level in the Drive Hubs ........................................................ 3 - 17
B-8
Check and Adjust the Engine RPM ............................................................ 3 - 18
B-9
Test the Ground Control Override ............................................................... 3 - 19
B-10 Test the Platform Self-leveling ................................................................... 3 - 20
B-11 Test the Engine Idle Select ........................................................................ 3 - 20
B-12 Test the Drive Brakes ................................................................................ 3 - 21
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 21
viii
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22
B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 22
B-16 Test the Turntable Rotation Stop ................................................................ 3 - 23
B-17 Check the Electrical Contactors ................................................................. 3 - 24
B-18 Perform Hydraulic Oil Analysis ................................................................... 3 - 24
B-19 Perform Engine Maintenance ..................................................................... 3 - 25
B
B
B
Part No. 106488
Checklist C Procedures
C-1
Perform Engine Maintenance ..................................................................... 3 - 26
C-2
Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 26
C-3
Test the Platform Overload Mechanism (if equipped) ................................. 3 - 27
C-4
Perform Engine Maintenance ..................................................................... 3 - 29
Checklist D Procedures
D-1
Check the Primary Boom Wear Pads ......................................................... 3 - 30
D-2
Check the Turntable Rotation Bearing Bolts ............................................... 3 - 30
D-3
Check the Free-wheel Configuration ........................................................... 3 - 32
D-4
Replace the Drive Hub Oil .......................................................................... 3 - 33
D-5
Replace the Hydraulic Tank Return Filter ................................................... 3 - 34
D-6
Inspect for Turntable Bearing Wear ............................................................ 3 - 34
D-7
Calibrate the Platform Overload System (if equipped) ................................ 3 - 36
D-8
Perform Engine Maintenance ..................................................................... 3 - 37
D-9
Perform Engine Maintenance ..................................................................... 3 - 38
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil ............................................................... 3 - 39
E-2
Grease the Steer Axle Wheel Bearings ...................................................... 3 - 40
E-3
Perform Engine Maintenance ..................................................................... 3 - 42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
ix
June 2005
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction ............................................................................................................ 4 - 1
B
Platform Controls
1-1
B
B
B
B
A
x
Controllers .................................................................................................... 4 - 2
Platform Components
2-1
Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2
Platform Rotator ........................................................................................... 4 - 5
Jib Boom Components, Z-45/25J Models
3-1
Jib Boom ...................................................................................................... 4 - 7
3-2
Jib Boom Lift Cylinder .................................................................................. 4 - 8
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
Secondary Boom Components
5-1
Secondary Boom ........................................................................................ 4 - 21
5-2
Secondary Boom Lift Cylinders .................................................................. 4 - 26
Kubota Z482-E Engine
6-1
Timing Adjustment ..................................................................................... 4 - 27
6-2
RPM Adjustment ........................................................................................ 4 - 27
6-3
Engine Drive Pulley .................................................................................... 4 - 27
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
TABLE OF CONTENTS
Section 4
Rev
A
B
C
B
Repair Procedures, continued
Generator
7-1
Generator Pulley ........................................................................................ 4 - 29
7-2
Generator Belts .......................................................................................... 4 - 30
7-3
Generator Voltage Regulator ...................................................................... 4 - 30
Hydraulic Pumps
8-1
Auxiliary Pump ........................................................................................... 4 - 33
8-2
Function Pump ........................................................................................... 4 - 33
Manifolds
9-1
Function Manifold Components (before serial number 17841) ..................... 4 - 34
9-2
Function Manifold Components (from serial number 17841 to 20379) ......... 4 - 38
9-3
Function Manifold Components (from serial number 20380 to 22565) ......... 4 - 40
9-4
Function Manifold Components (from serial number 22566 to 23235) ......... 4 - 42
9-5
Valve Adjustments - Function Manifold ...................................................... 4 - 44
9-6
Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 46
9-7
Turntable Rotation Manifold Components ................................................... 4 - 47
Turntable Rotation Components
10-1 Rotation Hydraulic Motor (before serial number 18367) ............................... 4 - 48
10-2 Turntable Rotation Assembly (after serial number 18366) ........................... 4 - 50
A
Motor Controller
11-1 Motor Controller .......................................................................................... 4 - 52
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
xi
June 2005
TABLE OF CONTENTS
Section 5
Rev
Fault Codes
Introduction ............................................................................................................ 5 - 1
A
Section 6
Rev
Fault Code Chart .................................................................................................... 5 - 3
Schematics
Introduction ............................................................................................................ 6 - 1
A
Electrical Symbols Legend .................................................................................... 6 - 2
A
Hydraulic Symbols Legend .................................................................................... 6 - 3
Power Cable Diagrams
A
Power Cable Diagram (before serial number 16839) ............................................... 6 - 5
A
Power Cable Diagram (from serial number 16840 to 21179) ................................... 6 - 6
A
Power Cable Diagram (from serial number 21180 to 22050) ................................... 6 - 7
A
Power Cable Diagram (from serial number 22051 to 23235) ................................... 6 - 8
Engine Panel Diagrams
xii
A
Engine Panel Diagram (before serial number 13361) .............................................. 6 - 9
A
Engine Panel Diagram (from serial number 13361 to 14078) ................................ 6 - 10
A
Engine Panel Diagram (from serial number 14079 to 14650) ................................ 6 - 11
A
Engine Panel Diagram (from serial number 14651 to 16839) ................................ 6 - 12
A
Engine Panel Diagram (from serial number 16840 to 17974) ................................ 6 - 13
A
Engine Panel Diagram (from serial number 17975 to 21180) ................................ 6 - 14
A
Engine Panel Diagram (from serial number 21181 to 22050) ................................ 6 - 15
A
Engine Panel Diagram (from serial number 22051 to 23235) ................................ 6 - 16
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Electrical Schematics, Z-45/25
A
Electrical Schematic, Z-45/25 (before serial number 13361) ................................. 6 - 17
A
Electrical Schematic, Z-45/25 (from serial number 13361 to 14078) ..................... 6 - 19
A
Electrical Schematic, Z-45/25 (from serial number 14079 to 14650) ..................... 6 - 21
A
Electrical Schematic, Z-45/25 (from serial number 14651 to 16839) ..................... 6 - 23
A
Electrical Schematic, Z-45/25 (from serial number 16840 to 17974) ..................... 6 - 25
A
Electrical Schematic, Z-45/25 (from serial number 17975 to 21180) ..................... 6 - 27
A
Electrical Schematic, Z-45/25 (from serial number 21181 to 22050) ..................... 6 - 29
A
Electrical Schematic, Z-45/25, ANSI and CSA Models
(from serial number 22051 to 23235) .................................................................... 6 - 31
A
Electrical Schematic, Z-45/25, CE Models
(from serial number 22051 to 23235) .................................................................... 6 - 33
Electrical Schematics, Z-45/25J
A
Electrical Schematic, Z-45/25J (before serial number 13361) ............................... 6 - 35
A
Electrical Schematic, Z-45/25J (from serial number 13361 to 14078) ................... 6 - 37
A
Electrical Schematic, Z-45/25J (from serial number 14079 to 14650) ................... 6 - 39
A
Electrical Schematic, Z-45/25J (from serial number 14651 to 16839) ................... 6 - 41
A
Electrical Schematic, Z-45/25J (from serial number 16840 to 17974) ................... 6 - 43
A
Electrical Schematic, Z-45/25J (from serial number 17975 to 21180) ................... 6 - 45
A
Electrical Schematic, Z-45/25J (from serial number 21181 to 22050) ................... 6 - 47
A
Electrical Schematic, Z-45/25J, ANSI and CSA Models
(from serial number 22051 to 23235) .................................................................... 6 - 49
A
Electrical Schematic, Z-45/25J, CE Models
(from serial number 22051 to 23235) .................................................................... 6 - 51
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
xiii
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Ground Control Box Wiring Diagrams, Z-45/25
xiv
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(before serial number 13361) ................................................................................ 6 - 53
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 13361) ................................................................................ 6 - 54
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 13361 to 14078) .................................................................... 6 - 55
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 13361 to 14078) .................................................................... 6 - 56
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 14079 to 14650) .................................................................... 6 - 57
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14079 to 14650) .................................................................... 6 - 58
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 14651 to 16839) .................................................................... 6 - 59
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14651 to 16839) .................................................................... 6 - 60
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 16840 to 17974) .................................................................... 6 - 61
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 16840 to 17974) .................................................................... 6 - 62
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 17975 to 21180) .................................................................... 6 - 63
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 17975 to 21180) .................................................................... 6 - 64
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
(from serial number 21181 to 22050) .................................................................... 6 - 65
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 21181 to 22050) .................................................................... 6 - 66
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
ANSI and CSA Models (from serial number 22051 to 23235) ............................... 6 - 67
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
ANSI and CSA Models (after serial number 22050) .............................................. 6 - 68
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25
CE Models (from serial number 22051 to 23235) .................................................. 6 - 69
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
CE Models (from serial number 22051 to 23235) .................................................. 6 - 70
Ground Control Box Wiring Diagrams, Z-45/25J
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(before serial number 13361) ................................................................................ 6 - 71
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 13361) ................................................................................ 6 - 72
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078) .................................................................... 6 - 73
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078) .................................................................... 6 - 74
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650) .................................................................... 6 - 75
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650) .................................................................... 6 - 76
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839) .................................................................... 6 - 77
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839) .................................................................... 6 - 78
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974) .................................................................... 6 - 79
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974) .................................................................... 6 - 80
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
xv
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180) .................................................................... 6 - 81
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180) .................................................................... 6 - 82
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050) .................................................................... 6 - 83
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050) .................................................................... 6 - 84
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
ANSI and CSA Models (from serial number 22051 to 23235) ............................... 6 - 85
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
ANSI and CSA Models (from serial number 22051 to 23235) ............................... 6 - 86
A
Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J
CE Models (from serial number 22051 to 23235) .................................................. 6 - 87
A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
CE Models (from serial number 22051 to 23235) .................................................. 6 - 88
Platform Control Box Wiring Diagrams, Z-45/25
xvi
A
Platform Control Box Wiring Diagram, Z-45/25
(before serial number 13361) ................................................................................ 6 - 89
A
Platform Control Box Wiring Diagram, Z-45/25
(with platform load sense and LVI/BCI option)
(before serial number 13361) ................................................................................ 6 - 90
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 13361 to 14078) .................................................................... 6 - 91
A
Platform Control Box Wiring Diagram, Z-45/25
(with platform load sense and LVI/BCI option)
(from serial number 13361 to 14078) .................................................................... 6 - 92
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14079 to 14650) .................................................................... 6 - 93
A
Platform Control Box Wiring Diagram, Z-45/25
(with platform load sense and LVI/BCI option)
(from serial number 14079 to 14650) .................................................................... 6 - 94
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14651 to 16839) .................................................................... 6 - 95
A
Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 14651 to 16839) .................................................................... 6 - 96
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 16840 to 17974) .................................................................... 6 - 97
A
Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 16840 to 17974) .................................................................... 6 - 98
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 17975 to 21180) .................................................................... 6 - 99
A
Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 17975 to 21180) ................................................................... 6 - 100
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 21181 to 22050) ................................................................... 6 - 101
A
Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 21181 to 22050) ................................................................... 6 - 102
A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 22051 to 23235) ................................................................... 6 - 103
A
Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)
(from serial number 22051 to 23235) ................................................................... 6 - 104
Platform Control Box Wiring Diagrams, Z-45/25J
A
Platform Control Box Wiring Diagram, Z-45/25J
(before serial number 13361) ............................................................................... 6 - 105
A
Platform Control Box Wiring Diagram, Z-45/25J
(with platform load sense and LVI/BCI option)
(before serial number 13361) ............................................................................... 6 - 106
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078) ................................................................... 6 - 107
A
Platform Control Box Wiring Diagram, Z-45/25J
(with platform load sense and LVI/BCI option)
(from serial number 13361 to 14078) ................................................................... 6 - 108
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
xvii
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650) ................................................................... 6 - 109
A
Platform Control Box Wiring Diagram, Z-45/25J
(with platform load sense and LVI/BCI option)
(from serial number 14079 to 14650) ................................................................... 6 - 110
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839) ................................................................... 6 - 111
A
Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
(from serial number 14651 to 16839) ................................................................... 6 - 112
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974) ................................................................... 6 - 113
A
Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
(from serial number 16840 to 17974) ................................................................... 6 - 114
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180) ................................................................... 6 - 115
A
Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
(from serial number 17975 to 21180) ................................................................... 6 - 116
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050) ................................................................... 6 - 117
A
Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
(from serial number 21181 to 22050) ................................................................... 6 - 118
A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 22051 to 23235) ................................................................... 6 - 119
A
Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)
(from serial number 22051 to 23235) ................................................................... 6 - 120
Hydraulic Schematics
xviii
B
Hydraulic Schematic (before serial number 16962) .............................................. 6 - 121
B
Hydraulic Schematic (from serial number 16962 to 20379) .................................. 6 - 122
B
Hydraulic Schematic (from serial number 20380 to 22565) .................................. 6 - 123
B
Hydraulic Schematic (from serial number 22566 to 23235) .................................. 6 - 124
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 2 • Specifications
Specifications
REV A
Machine Specifications
Fluid capacities
Tires and wheels
Fuel tank
9 gallons
34.1 liters
Hydraulic tank
8 gallons
30.3 liters
Hydraulic system
(including tank)
11 gallons
41.6 liters
Wheel diameter
14.5 inches
Wheel width
7 inches
Wheel lugs (before serial number 16128)
Front
Rear
8 @ 5/8 -18
9 @ 5/8 -18
Wheel lugs (from serial number 16127 to 23235)
Front
9 @ 5/8 -18
Rear
9 @ 5/8 -18
Drive hubs (refer to tag on drive hub to determine type)
EW1 type
17 fl oz
0.51 liter
W1 type
23 fl oz
0.68 liter
Lug nut torque
125 ft-lbs
169.5 Nm
Drive hub oil type: SAE 90 multipurpose hypoid gear oil
API service classification GL5
Tire size
9-14.5 LT
Batteries
Tire ply rating
Tread 8
Sidewall 6
Type
Quantity
8
Tire contact area
43.5 sq in
280 sq cm
Capacity
350 AH
Overall tire diameter
Tire pressure
28 in
71 cm
100 psi
6.89 bar
Reserve capacity @ 25A rate
6V DC
750 minutes
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
For operational specifications, refer to the
Operator's Manual.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
2-1
Section 2 • Specifications
June 2005
SPECIFICATIONS
REV B
Performance Specifications
Boom function speeds, maximum
from platform controls
Drive speeds, maximum
Drive speed, stowed
All models
Drive speed, boom
raised or extended,
all models
3 mph
4.8 km/h
40 ft/9 sec
12.2 m/9 sec
0.6 mph
1 km/h
40 ft/45 sec
12.2 m/45 sec
Braking distance, maximum
High range on paved surface
5 to 7 ft
1.5 to 2 m
Gradeability (boom stowed)
30%
2-2
Jib boom up, Z-45/25J
30 to 40 seconds
Jib boom down, Z-45/25J
18 to 23 seconds
Primary boom up
30 to 36 seconds
Primary boom down
26 to 32 seconds
Secondary boom up
38 to 42 seconds
Secondary boom down
32 to 36 seconds
Primary boom extend, Z-45/25
25 to 30 seconds
Primary boom extend, Z-45/25J
16 to 24 seconds
Primary boom retract, Z-45/25
21 to 30 seconds
Primary boom retract, Z-45/25J
13 to 23 seconds
Turntable rotate, 359°
primary boom retracted
76 to 82 seconds
Platform rotate, 180°, Z-45/25
6 to 10 seconds
Platform rotate, 160°, Z-45/25J
6 to 10 seconds
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Hydraulic Specifications
Function pump
Before serial number 20926
Hydraulic oil type
Shell Donax TG (Dexron III)
Type:
Displacement
After serial number 20925
Hydraulic oil type
Chevron Rykon MV equivalent
Approximate SAE grade
5W-20
Viscosity index rating
200
Flow rate
Cleanliness level, minimum
Hydraulic tank
return filter
Water content, maximum
15/13
200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Fixed displacement gear pump
0.183 cu in
3 cc
2.1 gpm
7.9 L/min
10 micron with
25 psi / 1.7 bar bypass
Function manifold
Function relief valve pressure
3200 psi
220.6 bar
Primary boom down
relief valve pressure
(before serial number 11819)
2300 psi
158.6 bar
Secondary boom down
relief valve pressure
(before serial number 22566)
1800 psi
124 bar
Secondary boom down
relief valve pressure
(from serial number 22566 to 23235)
2000 psi
138 bar
Optional fluids
Biodegradable
Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant
UCON Hydrolube HP-5046
Quintolubric 822
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.
Platform level flow regulator
(before serial number 20380)
0.1 gpm
0.38 L/min
Platform level flow regulator
(from serial number 20380 to 23235)
0.6 gpm
2.27 L/min
Jib boom/platform rotate flow regulator
(before serial number 22566)
0.6 gpm
2.27 L/min
Jib boom/platform rotate flow regulator
(from serial number 22566 to 23235)
0.4 gpm
1.5 L/min
Auxiliary pump
Type:
Displacement
fixed displacement gear pump
0.5 gpm
1.9 L/min
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.Function
pump
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
2-3
Section 2 • Specifications
June 2005
SPECIFICATIONS
REV B
Manifold Component
Specifications
Machine Torque Specifications
Plug torque
1 -8 center bolt (grade 2)
Platform rotator
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51 Nm
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm
200 ft-lbs
271 Nm
480 ft-lbs
651 Nm
1 -8 center bolt (grade 8)
3 /8
-16 bolts, GR 8
44 ft-lbs
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
180 ft-lbs
244 Nm
Drive motor/brake mounting bolts, dry
110 ft-lbs
149 Nm
Valve Coil Resistance Specification
Drive motor/brake mounting bolts, lubricated
Description
Specification
Solenoid valve, 3 position 4 way, 20V DC
25 to 29 Ω
(schematic items E, H, J, K, L, M, CC, DD,
EE, FF, HH, II, BB, BC, BD, BE, BF, BG, CB,
CD, CE, CF and CH)
Solenoid valve, 2 position 3 way, 20V DC
(schematic items N, P, AA, BB, BA, BJ,
CA, CK and CR)
25 to 29 Ω
Solenoid valve, 2 position 3 way, 20V DC
(schematic item CR)
17 to 21 Ω
Solenoid valve, 2 position 3 way, 20V DC
(schematic item DC)
25 to 28 Ω
Solenoid valve, 2 position 2 way, 20V DC
(schematic items DA and DB)
22 to 26 Ω
Proportional solenoid valve, 24V DC
(schematic items G, JJ, BH and CI)
17 to 21 Ω
Solenoid valve, N.C. poppet, 20V DC
(schematic items F, LL and BI)
25 to 28 Ω
Solenoid valve, N.O. poppet, 20V DC
(schematic items B, VV and BT)
25 to 28 Ω
2-4
80 ft-lbs
108 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated
Drive motor mounting bolts, lubricated
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
180 ft-lbs
244 Nm
55 ft-lbs
75 Nm
Part No. 106488
June 2005
Section 2 • Specifications
REV A
SPECIFICATIONS
Kubota Z482-E Engine
Displacement
Injection system
29.23 cu in
0.48 liters
Number of cylinders
Bore and stroke
Horsepower
Gross intermitent
2
2.64 x 2.68 inches
67 x 68 mm
Bosch MD
Injection timing
21° BTDC
Injection pump pressure
Fuel requirement
1-2
Compression ratio
23:1
412 to 469 psi
28.4 to 32.3 bar
Brush length, new
0.5188 in
13 mm
Brush length, minimum
0.3346 in
8.5 mm
2000 rpm
Battery
High idle
3000 rpm
Type
Governor
centrifugal mechanical
0.0057 to 0.0072 in
0.145 to 0.185 mm
2.9 quarts
2.8 liters
Oil pressure
Oil capacity
(including filter)
Oil viscosity
requirements
1
Cold cranking ampere
Alternator
Output
Fan belt deflection
Lubrication system
12V DC, Group 70
Quantity
Reserve capacity @ 25A rate
Engine coolant
Capacity
diesel number 2-D
Starter motor
Low idle
Valve clearance, cold
1991 psi
137 bar
12.5 @ 3600 rpm
Firing order
Compression pressure
Injection pump make
450A
125 minutes
12V DC, 150 watts
1
/4 to 3/8 inch
7 to 9 mm
36 to 64 psi
2.48 to 4.41 bar
2.6 quarts
2.5 liters
10W-30
Engine oil should have properties of API classification
CC/SE, CD/SE, CC/SF or CD/SF grades.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
2-5
Section 2 • Specifications
June 2005
SPECIFICATIONS
REV A
Generator
Generator output
with engine @ 3000 rpm
54V DC, 100A
1/16
Generator pulley to engine
pulley offset, maximum
inch
1.6 mm
1
/4 inch
6.5 mm
Belt deflection, maximum
Generator Torque Specifications
Generator pulley retaining nut torque
Engine pulley retaining bolts
80-90 ft-lbs
108-122 Nm
108 in-lbs
12.2 Nm
#10 screw
25 in-lbs
2.8 Nm
#10 nut
25 in-lbs
2.8 Nm
#4 nut
Voltage regulator
mounting fasteners
2-6
8-10 in-lbs
0.9-1.1 Nm
25 in-lbs
2.8 Nm
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 2 • Specifications
REV A
SPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
not standard SAE size O-rings.
They are available in the O-ring
field service kit (Genie part
number 49612).
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size
Torque
-4
11 ft-lbs / 14.9 Nm
2 Lubricate the O-ring before installation.
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
3 Be sure that the face seal O-ring is seated and
retained properly.
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
139 ft-lbs / 188.5 Nm
-20
172 ft-lbs / 233.2 Nm
-24
208 ft-lbs / 282 Nm
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok Fittings
(tube fitting - installed into Steel)
(hose end)
®
SAE Dash size
Torque
SAE Dash size
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
27 ft-lbs / 36.6 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 54.2 Nm
-10
105 ft-lbs / 142.4 Nm
-10
63 ft-lbs / 85.4 Nm
-12
140 ft-lbs / 190 Nm
-12
90 ft-lbs / 122 Nm
-16
210 ft-lbs / 284.7 Nm
-16
120 ft-lbs / 162.7 Nm
-20
260 ft-lbs / 352.5 Nm
-20
140 ft-lbs / 190 Nm
-24
315 ft-lbs / 427.1 Nm
-24
165 ft-lbs / 223.7 Nm
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
2-7
Section 2 • Specifications
June 2005
SPECIFICATIONS
REV A
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
100
90
11.3
10.1
80
120
9
13.5
140
120
15.8
13.5
110
160
12.4
18
130
140
14.7
15.8
LUBED
5/16
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(m m )
5
6
7
LUBED
2-8
DRY
LUBED
Class 10.9
8.8
DRY
DRY
LUBED
Class 12.9
10.9
LUBED
12.9
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
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed by
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
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.
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3-1
Section 3 • Scheduled Maintenance Procedures
June 2005
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Schedule
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.
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
Indicates that new parts will be required
to perform this procedure.
Quarterly or every 250 hours
Six months or every 500 hours
Annual or every 1000 hours
Indicates that a cold motor, pump or
engine will be required to perform this
procedure.
Two year or every 2000 hours
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
Maintenance Inspection Report
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
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
Pre-Delivery Preparation
June 2005
Section 3 • Scheduled Maintenance Procedures
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Use the operator’s manual on your machine.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put into
service.
A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed
from service.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
Scheduled maintenance inspections shall be performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed
in the responsibilities manual.
The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.
Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.
If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, place a check
in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Y
N
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
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Part No. 106488
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
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
R
Section 3 • Scheduled Maintenance Procedures
June 2005
This page intentionally left blank.
3-4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A - Rev B
Serial number
A-1 Pre-operation
inspection
B-1 Radiator
Date
A-2 Function tests
B-3 Batteries
B-4 Electrical wiring
Hour meter
A-3 Generator belts and
pulleys
Y N R
Perform after 50 hours:
Machine owner
A-4 30 Day Service
Inspected by (print)
Perform every 50 hours:
Inspector signature
A-5 Perform engine
maintenance
Perform every 75 hours:
Inspector title
A-6 Perform engine
maintenance
Inspector company
Perform every 100 hours:
A-7 Grease rotation
bearing
Instructions
· Make copies of this page to use for
each inspection.
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
Checklist B - Rev B
Y N R
B-2 Exhaust system
B-5 Lug nut torque
B-6 Brake configuration
B-7 Drive hub oil level
B-8 Engine RPM
B-9 Ground control
override
B-10 Platform leveling
B-11 Engine idle select
B-12 Drive brakes
B-13 Drive speed - stowed
B-14 Drive speed - raised
A-8 Perform engine
maintenance
B-15 Alarm package
(if equipped)
Perform every 150 hours:
B-16 Turntable rotation stop
A-9 Perform engine
maintenance
B-17 Electrical contactors
B-18 Hydraulic oil analysis
Perform every 200 hours:
A-10 Perform engine
maintenance
Six Month or 500 hour
Inspection:
A+B+C
Checklist C - Rev B
Y N R
C-1 Perform engine
maintenance
C-2 Grease platform
overload (if equipped)
Annual or 1000 hours
Inspection:
A+B+C+D
C-3 Test platform
overload (if equipped)
2 Year or 2000 hour
Inspection:
A+B+C+D+E
Perform every 800 hours:
C-4 Perform engine
maintenance
· 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
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3-5
Section 3 • Scheduled Maintenance Procedures
June 2005
MAINTENANCE INSPECTION REPORT
Model
Checklist D - Rev B
Y N R
D-1 Boom wear pads
Serial number
D-2 Turntable bearing bolts
Date
D-3 Free-wheel
configuration
Hour meter
D-4 Drive hub oil
D-5 Hydraulic return filter
Machine owner
D-6 Turntable bearing wear
D-7 Calibrate platform
overload system
(if equipped)
Inspected by (print)
Inspector signature
Perform every 1000 hours:
Inspector title
D-8 Perform engine
maintenance
Inspector company
Perform every 1500 hours:
Instructions
· Make copies of this page to use for
each inspection.
D-9 Perform engine
maintenance
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
Checklist E - Rev B
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
Y N R
E-1 Hydraulic oil
E-2 Wheel bearings
A
E-3 Perform engine
maintenance
A+B
Six Month or 500 hour
Inspection:
A+B+C
Annual or 1000 hours
Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E
· Place a check in the appropriate box
after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
3-6
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
REV B
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Perform Pre-operation Inspection
A-2
Perform Function Tests
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.
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 Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator's Manual on
your machine.
Part No. 106488
Complete information to perform this procedure is
available in the Genie Z-45/25 Bi-Energy and
Genie Z-45/25J Bi-Energy Operator's Manual on
your machine.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3-7
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2005
PROCEDURES
A-3
Check the Generator Belts and
Pulleys
REV B
3 Check to be sure the engine pulley and the
generator pulley are aligned within specification
using a straightedge. Refer to Section 2,
Specifications.
a
Maintaining the generator belts and the pulleys is
essential to good engine performance and service
life. The generator will not operate properly with
loose or defective belts and continued use may
cause component damage.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
Charging the batteries with the
engine does not fully charge the
batteries. Periodically, use the AC
battery charger to fully charge the
batteries.
1 Be sure that all fasteners and cables on the
generator are tight.
b
d
c
a
b
c
d
engine pulley
straightedge
maximum pulley offset
generator pulley
If alignment does not meet
specification, refer to Repair
Procedure 6-3, How to Install the
Engine Drive Pulley to adjust the
pulley alignment.
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. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
REV B
4 Inspect the generator belts for:
PROCEDURES
A-4
Perform 30 Day Service
· Cracking
· Glazing
· Separation
· Breaks
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 50 hours of usage. After this
interval, refer to the maintenance tables for
continued scheduled maintenance.
5 Replace both belts if any damage is found.
6 Check the generator belts for proper tension.
Refer to Section 2, Specifications.
If the belt deflection is not within
specification, see repair procedure
7-2, How to Adjust the Generator
Belts.
a
b
1 Perform the following maintenance procedures:
· B-5
Check the Lug Nut Torque
(including tires and wheels)
· D-2 Check the Turnable Rotation Bearing
Bolts
· D-5 Replace the Hydraulic Tank Return
Filter
c
a
b
c
engine pulley
generator belts
generator pulley
7 Check the torque of the pulley retaining nut on
the generator. Refer to Section 2,
Specifications.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3-9
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2005
PROCEDURES
REV B
A-5
Perform Engine Maintenance
A-6
Perform Engine Maintenance
Engine specifications require that
this procedure be performed every
50 hours.
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.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).
Kubota Z482-E Operator's Manual
Genie part number
Kubota Z482-E Operator's Manual
Genie part number
52958
52958
To access the engine:
To access the engine:
1 Remove the engine pivot plate latch retainer.
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine out away from the machine.
2 Open the engine pivot plate latch and swing the
engine out away from the machine.
3 - 10
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST A
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 Locate the grease fitting on the front turntable
cover.
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.
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 16676-89163).
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.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2005
PROCEDURES
REV B
A-9
Perform Engine Maintenance
A-10
Perform Engine Maintenance
Engine specifications require that
this procedure be performed
every 150 hours.
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.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).
Kubota Z482-E Operator's Manual
Genie part number
Kubota Z482-E Operator's Manual
Genie part number
52958
52958
To access the engine:
To access the engine:
1 Remove the engine pivot plate latch retainer.
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine out away from the machine.
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
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
Checklist B Procedures
REV B
B-1
Check the Radiator
B-2
Check the Exhaust System
Maintaining the radiator in good condition is
essential for good engine performance. Operating
a machine with a damaged or leaking radiator may
result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
the performance of the cooling system. A frequent
check allows the inspector to identify changes in
the condition of the radiator that might indicate
cooling system problems.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine to
access the radiator.
3 Inspect the radiator for leaks and physical
damage.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
1 Remove the engine pivot plate latch retainer.
2 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine to
access the exhaust system.
3 Be sure that all nuts and bolts are tight.
4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 13
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
PROCEDURES
REV B
3 Be sure that the cable connections are tight.
B-3
Check the Batteries
4 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
Electrocution hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
Result: If any battery cell displays a specific
gravity of less than 1.026, the battery must be
replaced.
5 Check the battery acid level of the battery. If
needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
6 Install the battery vent caps.
7 Be sure the battery packs are wired correctly.
+
+
+
+
+
-
-
-
-
-
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. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
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 Inspect the following areas for burnt, chafed,
corroded and loose wires:
PROCEDURES
6 Install the center turntable cover.
7 Lower the boom to the stowed position and turn
the machine off.
8 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
9 After serial number 21180: Inspect for a liberal
coating of dielectric grease at the following
location:
· All wire harness connectors to the platform
control box
· Power units
· Inside of the ground control box
· Turntable manifold wiring
· Generator and power units
· Engine wiring harness
2 After serial number 21180: Inspect for a liberal
coating of dielectric grease at the following
location:
· All wire harness connectors to the ground
control box
3 Raise the secondary boom until the mid-pivot is
approximately 10 feet / 3 m off the ground.
4 Remove the center turntable cover.
5 Inspect the turntable center area for burnt,
chafed and pinched cables.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 15
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
PROCEDURES
REV B
B-5
Check the Lug Nut Torque
(including the tires and wheels)
B-6
Confirm the Proper
Brake Configuration
Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
Proper brake configuration is essential to safe
operation and good machine performance.
Hydraulically-released, spring-applied individual
wheel brakes can appear to operate normally when
they are actually not fully operational.
Tip over hazard. An over-inflated
tire can explode which will
compromise machine stability and
and cause the machine to tip over.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
Bodily injury hazard. An overinflated tire can explode and could
result in death or serious injury.
brake disengaged position
brake engaged position
Tip-over hazard. Do not use
temporary flat tire repair products.
The tires on some machines are
foam-filled and do not need air
added to them.
1 Check the tire surface and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
4 Check the pressure in each air-filled tire.
Refer to Section 2, Specifications.
3 - 16
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
PROCEDURES
2 Remove the plug located at 90 degrees and
check the oil level.
B-7
Check the Oil Level
in the Drive Hubs
Result: The oil level should be even with the
bottom of the side plug hole.
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.
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
a
Part No. 106488
models with o-ring plugs
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 17
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
PROCEDURES
REV B
4 Loosen the lock nut, then turn the low idle
adjustment screw clockwise to increase the rpm
or counterclockwise to decrease the rpm.
Tighten the lock nut and recheck the rpm.
B-8
Check and Adjust the
Engine 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
b
c
d
low idle adjustment screw
(not shown)
high idle adjustment nut
rpm solenoid
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.
3 - 18
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST 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.
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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
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.
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.
3 Release the engine idle select toggle switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
5 At the platform controls, move the engine idle
select toggle switch to high idle (rabbit symbol).
Result: The engine should change to high idle.
6 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine should change to low idle.
7 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
8 Press down the foot switch.
Result: The engine should change to high idle.
3 - 20
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV B
B-12
Test the Drive Brakes
PROCEDURES
B-13
Test the Drive Speed Stowed Position
Proper brake action is essential to safe machine
operation. The machine uses drive motor
regenerative braking to stop the machine.
Hydraulically-released individual wheel brakes hold
the machine once it has stopped. The drive motor
regenerative braking should operate smoothly, free
of hesitation and jerking. Hydraulically-released
individual wheel brakes can appear to operate
normally when not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
Refer to B-4, Confirm the Proper
Brake Configuration.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
2 Lower the boom into the stowed position.
3 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
4 Bring the machine to maximum drive speed
before reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
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 Lower the boom into the stowed position.
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.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 21
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
PROCEDURES
B-14
Test the Drive Speed - Raised or
Extended Position
REV B
B-15
Test the Alarm Package
(if equipped)
The alarm package includes:
· Travel alarm
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.
· 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.
3 - 22
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST B
4 Z-45/25J: Move the function enable toggle
switch to either side and activate the jib 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.
5 Turn the key switch to platform control.
Result: The flashing beacon should be on
and flashing.
6 Press down the foot switch. 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 control handle is held down.
7 Press down the foot switch. Activate the
secondary boom toggle switch in the down
position, hold for a moment and then release it.
Result: The descent alarm should sound when
the control handle is held down.
8 Z-45/25J: Press down the foot switch. Activate
the jib 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.
PROCEDURES
B-16
Test the Turntable Rotation Stop
The turntable is capable of rotating the boom 355
degrees and is stopped midpoint between the steer
wheels by the rotation stop. Detecting a rotation
stop malfunction is essential to safe operation and
good machine performance. If the turntable rotates
past the rotation stop, component damage may
result.
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 Rotate the turntable to the left as far as it
will go.
Result: Movement should stop when the
primary boom reaches mid-point between the
steer tires.
3 Rotate the turntable to the right full circle as far
as it will go.
Result: Movement should stop when the
primary boom reaches mid-point between the
steer tires.
9 Press down the foot switch. Move the drive
control handle off center, hold for a moment
and then release it. Move the drive control
handle off center in the opposite direction, hold
for a moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in
either direction.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 23
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2005
PROCEDURES
REV B
B-17
Check the Electrical Contactors
B-18
Perform Hydraulic Oil Analysis
Maintaining the electrical contactors in good
condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor
could result in an unsafe working condition and
component damage.
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.
1 Remove the drive chassis cover from the
non-steer end of the machine and locate the
electrical contactors mounted on the
component mounting panel.
2 Visually inspect the contact points of each
contactor for the following items:
· Excessive burns
· Excessive arcs
· Excessive pitting
Electrocution hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
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. See E-1,
Test or Replace the Hydraulic Oil.
Replace the contactors if any
damage is found.
3 - 24
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV B
PROCEDURES
B-19
Perform Engine Maintenance
Engine specifications require that
this procedure be performed
every 400 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Kubota Z482-E Operator's Manual
(Kubota part number 16676-89163).
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 25
Section 3 • Scheduled Maintenance Procedures
June 2005
Checklist C Procedures
C-1
Perform Engine Maintenance
C-2
Grease the Platform Overload
Mechanism (if equipped)
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 16676-89163).
Kubota Z482-E Operator's Manual
Genie part number
REV B
52958
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.
To access the engine:
Grease Specification
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 - 26
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
REV B
C-3
Test the Platform Overload
System (if equipped)
C PROCEDURES
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.
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.
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-6, Calibrate the
Platform Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 27
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
C
June 2005
PROCEDURES
7 Carefully move the test weights to each
remaining location in 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-6, Calibrate the
Platform Overload System.
There may be an approximate 2
second delay before the overload
indicator light turns on and the
alarm sounds.
8 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
9 Turn the key switch to ground control.
10 Test all machine functions from the ground
controls.
REV B
11 Lift the test weights off the platform floor using a
suitable lifting device.
Result: The platform overload indicator light and
alarm should turn 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.
12 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
13 Turn the key switch to platform control.
14 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
If the platform overload system is
not operating properly, see D-6,
Calibrate the Platform Overload
System.
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.
3 - 28
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
REV B
C PROCEDURES
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 16676-89163).
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 29
Section 3 • Scheduled Maintenance Procedures
June 2005
Checklist D Procedures
REV B
D-1
Check the Primary Boom
Wear Pads
D-2
Check the Turntable Rotation
Bearing Bolts
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.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
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.
1 Raise the primary boom and place a safety
chock on the lift cylinder rod. Carefully lower
the boom onto the lift cylinder safety chock.
Crushing hazard. Keep hands
away from cylinder and all moving
parts when lowering the boom.
A lift cylinder safety chock is
available through Genie
(part number 33484).
Always maintain squareness
between the outer and inner
boom tubes.
Primary boom wear
pad specifications
Top, bottom and side wear pads
(platform end of boom)
Side and bottom wear pads
(pivot end of boom)
Top wear pads
(pivot end of boom)
3 - 30
New
Minimum
inch
19 mm
5/8 inch
15.9 mm
5/8 inch
15.9 mm
1/2 inch
12.7 mm
3 /4
3 /4
inch
19 mm
5/8 inch
15.9 mm
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
2 Check to be sure that each turntable mounting
bolt is torqued in sequence to specification.
Refer to Section 2, Specifications.
9
5
1
3
PROCEDURES
3 Lower the boom to the stowed position.
4 Remove drive chassis covers from both the
steer end and the non-steer end of the
machine.
5 Check to be sure that each bearing mounting
bolt under the drive chassis is torqued in
sequence to specification. Refer to Section 2,
Specifications.
11
1
7
8
D
9
7
4
12
4
5
6
2
10
Bolt torque sequence
(before serial number 23332)
9
18
1
3
6
11
16
Bolt torque sequence
(before serial number 23332)
13
3
20
19
9
15
8
5
12
2
17
10
Bolt torque sequence
(after serial number 23331)
1
11
6
4
14
2
8
7
6
7
16
13
4
3
15
14
8
5
12
2
10
Bolt torque sequence
(after serial number 23331)
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 31
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D
June 2005
PROCEDURES
REV B
5 Manually rotate each non-steer wheel.
D-3
Check the Free-wheel
Configuration
Result: Each non-steer wheel should rotate with
minimum effort.
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.
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.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each non-steer
wheel hub.
brake disengaged position
brake engaged position
3 - 32
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST
D PROCEDURES
D-4
Replace the Drive Hub Oil
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole.
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.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
1 Select the drive hub to be serviced. Then drive
the machine until one of the two plugs is at the
lowest point.
6 Repeat steps 1 through 5 for the other drive
hub.
Models with O-ring plugs: Install the plugs
into the drive hub.
2 Remove both plugs and drain the oil.
3 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
models with pipe plugs
a
a
Part No. 106488
models with o-ring plugs
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 33
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
June 2005
PROCEDURES
REV B
D-5
Replace the Hydraulic Tank
Return Filter
D-6
Inspect for Turntable Bearing
Wear
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.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
Perform this procedure with the
machine on a firm, level surface
and the boom in the stowed
position.
1 Locate the hydraulic return filter next to the
hydraulic tank.
1 Grease the turntable bearing. See A-7, Grease
the Turntable Bearing and Rotate Gear.
2 Place a suitable container under the hydraulic
filter.
2 Torque the turntable bearing bolts to
specification. See D-2, Check the Turntable
Rotation Bearing Bolts.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of oil to the new oil filter
gasket.
3 Start the machine from the ground controls and
raise the primary and secondary booms to full
height. Do not extend the primary boom.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls.
7 Activate any boom function and inspect the filter
and related components to be sure that there
are no leaks.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
3 - 34
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
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.
D PROCEDURES
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.055 inch / 1.4 mm. The bearing is good.
Result: The measurement is more than
0.055 inch / 1.4 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the primary boom. Raise the
primary and secondary booms to full height.
Visually inspect the the dial indicator to be sure
the needle returns to the "zero" position.
a
9 Remove the dial indicator and rotate the
turntable 90°.
b
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
c
11 Lower the primary and secondary booms to the
stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
d
a
b
c
d
turntable
dial indicator
drive chassis
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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 35
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
PROCEDURES
D-7
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.
3 - 36
June 2005
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
REV B
Confirm the setting:
5 Turn the key switch to platform control.
D PROCEDURES
D-8
Perform Engine Maintenance
6 Lift the test weight off the platform floor using a
suitable lifting device.
7 Place the test weight back onto the center of
the platform floor using a suitable lifting device.
Result: The alarm should be off. The platform
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.
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 16676-89163).
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.
10 Turn the key switch to ground control.
11 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
If the platform overload system is
not operating properly, repeat
steps 1 through 4.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 37
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
PROCEDURES
June 2005
REV B
D-9
Perform Engine Maintenance
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 16676-89163).
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 - 38
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
REV B
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. See capacity specifications.
Part No. 106488
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 39
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
June 2005
PROCEDURES
8 Remove the hydraulic tank from the machine.
Component damage hazard. The
hydraulic tank is plastic and may
become damaged if allowed to fall.
REV B
E-2
Grease the Steer Axle
Wheel Bearings
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Rinse out the inside of the tank using a mild
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.
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 - 40
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 3 • Scheduled Maintenance Procedures
REV B
CHECKLIST E
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.
PROCEDURES
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.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of the
hub.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3 - 41
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
PROCEDURES
June 2005
REV B
E-3
Perform Engine Maintenance
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 16676-89163).
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 - 42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
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
Genie Z-45/25 Bi-Energy and Genie Z-45/25J
Bi-Energy Operator’s Manual on your machine.
Be sure that all necessary tools and 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:
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.
· Turntable rotated with the boom between
the non-steer wheels
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
· Turntable secured with the turntable
rotation lock
Used to indicate operation or
maintenance information.
· Machine parked on a firm, level surface
· Boom in stowed position
· Key switch in the off position with the
key removed
Indicates that a specific result is expected after
performing a series of steps.
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 106488
Indicates that an incorrect result has occurred
after performing a series of steps.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4-1
Section 4 • Repair Procedures
June 2005
Platform Controls
1-1
Controllers
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.
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. See the Troubleshooting section
of this manual 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.
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.
b
a
c
d
a
b
c
d
b
a
b
4-2
threshold adjustable trimpot
max-out adjustable trimpot
white/red wire to TP6
boom function speed controller
a
boom function speed controller
drive joystick
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
Before serial number 21180:
3 Remove the wht/red wire from TP6. Temporarily
insert a short piece of stripped wire into TP6.
4 Connect the red (+) lead from an amp meter to
the wht/red wire. Connect the black (-) lead to
the piece of wire at TP6.
From serial number 21180 to 23235:
3 Disconnect the blk/red wire of the boom
function speed controller from the wht/red wire.
4 Connect the red (+) lead from an amp meter to
the blk/red wire. Connect the black (-) lead to
the wht/red wire.
All models:
5 Turn the boom function speed controller to the
CREEP position.
6 Set the threshold: With the boom in the stowed
position, press down the foot switch and move
the primary boom toggle switch in the down
position until the amperage reading appears.
Adjust the amperage to 0.17 to 0.18A. Turn the
threshold trimpot adjustment screw clockwise to
increase the amperage or counterclockwise to
decrease the amperage.
7 Turn the boom function speed controller to
the 9 position.
8 Set the max-out: Press down the foot switch,
then move the primary boom toggle switch in
the down position. Adjust the amperage to 0.54
to 0.55A. Turn the max-out trimpot adjustment
screw clockwise to increase the amperage or
counterclockwise to decrease the amperage.
9 Before serial number 21180: Remove the
temporary wire from TP6 and install the wht/red
wire into TP6.
Boom function speed
controller specifications
Threshold
0.17 to 0.18A
Max-out
0.54 to 0.55A
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4-3
Section 4 • Repair Procedures
June 2005
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
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PLATFORM COMPONENTS
8 Use a soft metal drift to drive the rod-end pivot
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.
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.
2-2
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.
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
a
b
c
d
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
b
top bleed valve
bottom bleed valve
container
clear hose
4-5
Section 4 • Repair Procedures
June 2005
REV B
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.
4-6
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
Jib Boom Components, Z-45/25J
REV B
3-1
Jib Boom
5 Attach a lifting strap from an overhead crane to
the platform rotator for support.
How to Remove the Jib Boom
6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
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. 106488
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4-7
Section 4 • Repair Procedures
June 2005
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 barrelend 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
REV B
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
JIB BOOM COMPONENTS, Z-45/25J
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a suitable
lifting device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not properly
supported by the overhead crane.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4-9
Section 4 • Repair Procedures
June 2005
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
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 on the
counterbalance valve manifold located on 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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PRIMARY BOOM COMPONENTS
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.
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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 11
Section 4 • Repair Procedures
June 2005
REV B
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 on the
counterbalance valve manifold located on 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
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PRIMARY BOOM COMPONENTS
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.
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 rodend 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.
14 Remove all hose and cable clamps from the
underside of the primary boom.
24 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.
15 Support the rod end of the primary boom lift
cylinder with a suitable lifting device.
25 Remove the cable track from the machine and
place it on a structure capable of supporting it.
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 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.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 13
Section 4 • Repair Procedures
June 2005
PRIMARY BOOM COMPONENTS
REV B
How to Repair the Primary Boom
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
a
b
link separation point
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.
4-2
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
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 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. 106488
June 2005
Section 4 • Repair Procedures
REV B
PRIMARY BOOM COMPONENTS
5 Remove the hose and cable cover from the
upper pivot.
13 Remove the hose clamp at the pivot end of the
boom.
6 Remove the pin retaining fastener from the
master cylinder barrel-end pivot pin. Use a soft
metal drift to remove the pin. Then lower the
cylinder and let it hang down.
14 Attach a 5 ton / 5,000 kg overhead crane to the
center point of the primary boom.
Component damage hazard.
When lowering the master cylinder
down, be sure not to damage the
master cylinder hoses or fittings.
7 Locate the primary boom drive speed limit
switch inside of the upper pivot.
8 Remove the primary boom drive speed limit
switch mounting fasteners. Do not disconnect
the wiring.
15 Attach a similar lifting device to the primary
boom lift cylinder.
16 Place support blocks under the primary boom
lift cylinder.
17 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 boom lift
cylinder and primary boom will fall
if not properly supported.
9 Locate the primary extension boom drive speed
limit switch inside of the extension boom.
18 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
cylinder rod from damage.
10 Remove the primary extension boom drive
speed limit switch mounting fasteners. Do not
disconnect the wiring.
19 Remove the pin retaining fasteners from the
primary boom pivot pin.
11 Pull the limit switch and the wiring out of the
extension tube and move it out of the way.
12 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.
Part No. 106488
20 Remove the primary boom pivot pin with a soft
metal drift, then carefully remove the primary
boom from the machine and place it on a
structure capable of supporting it.
Crushing hazard. The primary
boom could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 15
Section 4 • Repair Procedures
June 2005
REV B
PRIMARY BOOM COMPONENTS
How to Disassemble the Primary
Boom
Complete disassembly of the
boom is only necessary
if the outer or inner boom tube
must be replaced. The extension
cylinder can be removed without
completely disassembling the
boom. See 4-4, How to Remove
the Primary Boom Extension
Cylinder.
1 Remove the primary boom. See How to
Remove the Primary Boom.
2 Place blocks under the barrel end of the primary
boom extension cylinder for support.
6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
platform end of the extension tube. Use a soft
metal drift to remove the pin.
7 Support and slide the extension cylinder out of
the base end of the extension tube. Place the
extension cylinder on blocks for support.
Crushing hazard. The extension
cylinder could become unbalanced
and fall when removed from
primary boom extension tube if not
properly supported.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
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.
4 - 16
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PRIMARY BOOM COMPONENTS
4-3
Primary Boom Lift Cylinder
5 Support the rod end and the barrel end of the
primary boom lift cylinder with a second
overhead crane or similar lifting device.
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.
6 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
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.
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 barrelend 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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 17
Section 4 • Repair Procedures
June 2005
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.
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.
4 - 18
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
PRIMARY BOOM COMPONENTS
4-5
Platform Leveling
Master Cylinder
3 Attach overhead crane or similar lifting device to
the master cylinder.
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop
that keeps the platform level through the entire
range of boom motion. The master cylinder is
located at the base of the primary boom.
5 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
4 Remove the pin retaining fasteners from the
master cylinder barrel-end pivot pin.
How to Remove the Platform
Leveling Master Cylinder
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.
6 Remove the pin retaining fastener from the rodend pivot pin.
7 Place a rod through the rod-end pivot pin and
twist to remove the pin.
8 Remove the master cylinder from the machine.
Crushing hazard. The master
cylinder could become unbalanced
and fall if not properly attached to
the overhead crane.
1 Raise the secondary boom until both the rodend 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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 19
Section 4 • Repair Procedures
June 2005
Secondary Boom Components
a
b
REV B
c
j
i
d
h
e
g
f
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
4 - 20
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
SECONDARY BOOM COMPONENTS
4 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder.
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 3-2, How to
Remove the Primary Boom.
Part No. 106488
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 21
Section 4 • Repair Procedures
June 2005
REV B
SECONDARY BOOM COMPONENTS
10 Remove the pin retaining fasteners from both
sides of the secondary boom lift cylinder rodend 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.
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.
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
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
SECONDARY BOOM COMPONENTS
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.
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.
24 Remove the hose and cable covers from the top
of the number 2 arm.
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.
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.
34 Use a soft metal drift to drive each pin out. Then
remove the mid-pivot from the secondary boom
assembly.
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.
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.
30 Lower the number 2 arm onto the boom rest
pad.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 23
Section 4 • Repair Procedures
June 2005
REV B
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
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, wellventilated 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 handoperated 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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
SECONDARY BOOM COMPONENTS
48 Remove the retaining fastener from the ground
control box and function manifold pivot plate.
49 Lower the ground control box and function
manifold pivot plate to access the number 3
arm pivot pin.
50 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for
support. Do not lift it.
51 Remove the mounting fasteners from the cover
located in the boom storage area to access the
number 3 and number 4 arm pivot pin retaining
fasteners at the turntable riser.
52 Remove the pin retaining fasteners from the
number 3 arm at the turntable riser. Do not
remove the pin.
57 Remove the pin retaining fasteners from the
number 4 arm at the turntable riser. Do not
remove the pin.
58 Attach a lifting strap from the overhead crane to
the center point of the number 4 arm. Do not
lift it.
59 Use a slide hammer to remove the number 4
arm from the turntable riser through the ground
controls side bulkhead.
60 Remove the number 4 arm from the machine.
Crushing hazard. The number 4
arm could become unbalanced
and fall when removed from the
machine if not properly supported
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 25
Section 4 • Repair Procedures
June 2005
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
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
Kubota Z482-E Engine
REV A
4 Pull the generator away from the machine and
remove the belts from the generator pulley.
6-1
Timing Adjustment
Complete information to perform this procedure is
available in the Kubota Z482-E Workshop Manual
(Kubota part number 97897-01165).
Kubota Z482-E Workshop Manual
Genie part number
52956
5 Remove the 3 bolts that attach the engine drive
pulley to the shaft bushing.
6 Install the same 3 bolts that were removed in
step 5 into the threaded holes of the engine
drive pulley.
7 Carefully tighten each bolt evenly until the
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
See the scheduled maintenance procedure B-8,
Check and Adjust the Engine RPM.
8 Loosen the set screw on the pulley bushing,
then slide the pulley bushing off of the engine
shaft.
a
c
b
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
the engine drive pulley.
3 Loosen the tension adjustment bolt on the
generator.
Part No. 106488
d
f
e
a
b
c
d
e
f
g
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
g
f
e
d
gap
shaft
set screw
engine drive pulley
engine drive pulley bolt
shaft bushing
woodruff key
4 - 27
Section 4 • Repair Procedures
June 2005
REV A
KUBOTA Z482-E ENGINE
How to Install the Engine Drive
Pulley
3 Tighten the set screw on the pulley bushing
hand tight.
4 Slide the engine pulley onto the pulley bushing.
The generator pulley must already
be installed before performing this
procedure. See 7-1, How to Install
the Generator Pulley.
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.
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
a
a
c
d
4 - 28
c
b
f
e
a
b
c
d
e
f
pulley shaft
pulley bushing
engine flywheel
straightedge
generator pulley
generator
d
f
e
a
b
c
d
e
f
g
g
e
f
d
gap
shaft
set screw
engine drive pulley
pulley mounting bolt
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 6-4, How to
Remove the Engine Drive Pulley.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
Generator
REV A
7-1
Generator Pulley
How to Install the Generator
Pulley
How to Remove the Generator
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
the generator pulley.
3 Loosen the tension adjustment bolt on the
generator.
4 Pull the generator away from the machine and
remove the belts from the generator pulley.
The pulley on the generator must
be installed before installing the
engine drive pulley.
1 Align the woodruff key on the generator shaft
with the slot in the pulley and slide the pulley all
the way onto the generator shaft.
2 Install the flat washer and pulley retaining nut
onto the generator shaft, then torque the nut to
specification. Refer to Section 2, Specifications.
3 Adjust the tension of the generator belts.
See 7-2, How to Adjust the Generator Belts.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 29
Section 4 • Repair Procedures
June 2005
REV A
GENERATOR
7-2
Generator Belts
7-3
Generator Voltage Regulator
How to Adjust the Generator
Belts
How to Adjust the Generator
Voltage Regulator
1 Disconnect the battery packs.
The voltage regulator regulates the output voltage
of the generator. A properly adjusted voltage
regulator is essential to good generator
performance and service life. A defective or
improperly adjusted voltage regulator could result
in component damage.
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.
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.
4 Loosen the tension adjustment bolt on the
generator.
5 Push the generator towards the machine and
tighten the adjustment bolt.
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.
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.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
a
b
c
a
b
c
4 - 30
engine pulley
generator belts
generator pulley
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV A
GENERATOR
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.
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.
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. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 31
Section 4 • Repair Procedures
June 2005
REV A
GENERATOR
12 Locate the red wire that leads from the voltage
regulator to the positive rectifier assembly.
10 Locate the 3 white wires that lead from the
voltage regulator to the negative rectifier
assembly.
13 Remove the screw that attaches the red wire to
the positive recitfier assembly.
a
g
14 Remove the #4 nut that attaches the black wire
to the voltage regulator.
b
h
15 Remove the voltage regulator mounting screws.
16 Remove the voltage regulator while carefully
guiding the red and black wires from
underneath the bottom support of the positive
and negative rectifier assembly.
c
17 Install the new voltage regulator by following the
previous steps in reverse order.
d
e
18 Apply Loctite® removable thread sealant onto
the voltage regulator mounting fasteners and
torque to specification. Refer to Section 2,
Specifications.
f
a
b
c
d
e
f
g
h
white wires (#10 nuts)
negative rectifier assembly
black wire (#10 screw)
black wire (#4 nut)
voltage regulator
mounting fastener (#8 screw)
voltage regulator
red wire (#10 screw)
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.
19 Torque all 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 7-3, 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.
When the voltage regulator is
replaced, the voltage regulator
must be adjusted. See 7-3, How to
Adjust the Voltage Regulator.
4 - 32
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
Hydraulic Pumps
REV B
8-1
Auxiliary Pump
8-2
Function Pump
How to Remove the Auxiliary
Pump
How to Remove the Function
Pump
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.
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.
1 Place a suitable container under the hydraulic
tank.
2 Remove the drain plug from the hydraulic tank.
2 Remove the drain plug from the hydraulic tank.
3 Completely drain the hydraulic tank into a
container of suitable capacity. Refer to
Section 2, Specifications.
3 Completely drain the hydraulic 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.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
4 Remove the engine pivot plate latch retainer.
4 Remove the engine pivot plate latch retainer.
5 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine.
5 Open the engine pivot plate latch and swing the
engine pivot plate out away from the machine.
6 Tag, disconnect and plug the hydraulic hoses
from the auxiliary pump.
6 Tag, disconnect and plug the hydraulic hoses
from the pump.
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 auxiliary pump mounting bolts.
Carefully remove the pump.
Part No. 106488
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 function pump mounting bolts.
Carefully remove the pump.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 33
Section 4 • Repair Procedures
June 2005
Manifolds
REV C
9-1
Function Manifold Components (before serial number 17841)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index
No.
Description
Schematic
Item
1
Differential sensing valve .................. A ........... All functions ....................................... 20-25 ft-lbs / 27-34 Nm
2
Solenoid valve, N.O. poppet .............. B ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
3
Orifice, 0.050 inch / 1.27 mm ............. C ........... Brake circuit
4
Orifice, 0.060 inch / 1.5 mm ............... D ........... Steer circuit
5
Solenoid valve, 3 position 4 way ....... E ........... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
6
Solenoid valve, N.C. poppet .............. F ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
7
Proportional solenoid valve ............... G ........... All functions ....................................... 25-30 ft-lbs / 34-41 Nm
8
Solenoid valve, 3 position 4 way ....... H ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
9
Counterbalance valve ........................ I ............ Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
10
Solenoid valve, 3 position 4 way ....... J ............ Jib boom up/down and
Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm
11
Solenoid valve, 3 position 4 way ....... K ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
12
Solenoid valve, 3 position 4 way ....... L ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
13
Solenoid valve, 3 position 4 way ....... M .......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
14
Solenoid valve, 2 position 3 way ....... N ........... Primary boom extend ........................ 20-25 ft-lbs / 27-34 Nm
15
Orifice, 0.037 inch / 0.94 mm ............. O ........... Secondary boom up
16
Solenoid valve, 2 position 3 way ....... P ........... Primary boom retract ........................ 20-25 ft-lbs / 27-34 Nm
17
Relief valve, 2300 psi / 158.7 bar
(before serial number 11819) ............ Q ........... Primary boom down ........................... 25-30 ft-lbs / 34-41 Nm
18
Relief valve, 1800 psi / 124.1 bar ...... R ........... Secondary boom down ...................... 25-30 ft-lbs / 34-41 Nm
19
Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... S ........... Turntable rotate left/right
(prevents overflowing
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
Function
Torque
This list continues. Please turn the page
4 - 34
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
25
24
15
23
16
22
21
Part No. 106488
20
19
18
17
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 35
Section 4 • Repair Procedures
June 2005
REV C
MANIFOLDS
Function Manifold Components (before serial number 17841), continued
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index
No.
Description
Schematic
Item
Function
Torque
20
Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... T ........... Jib boom up/down,
platform rotate left/right and
platform level up/down
(prevents overflowing
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
21
Counterbalance valve ........................ U ........... Platform level down ........................... 35-40 ft-lbs / 47-54 Nm
22
Relief valve, 3200 psi / 220.6 bar ...... V ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
23
Diagnostic nipple ............................... W .......... Testing
24
Check valve ....................................... X ........... Pressure switch circuit ........................ 10-12 ft-lbs / 14-6 Nm
25
Pressure switch ................................. Y ........... Brake circuit
4 - 36
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
25
24
15
23
16
22
21
Part No. 106488
20
19
18
17
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 37
Section 4 • Repair Procedures
June 2005
REV C
MANIFOLDS
9-2
Function Manifold Components (from serial number 17841 to 20379)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index
No.
Description
1
Solenoid valve, 2 position 3 way ....... AA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2
Solenoid valve, 2 position 3 way ....... AB ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
3
Solenoid valve, 3 position 4 way ....... AC ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
4
Solenoid valve, 3 position 4 way ....... AD ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
5
Solenoid valve, 3 position 4 way ....... AE ......... Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
6
Solenoid valve, 3 position 4 way ....... AF ......... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
7
Counterbalance valve ........................ AG ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
8
Solenoid valve, 3 position 4 way ....... AH ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm
9
Solenoid valve, 3 position 4 way ....... AI .......... Steer left/right ............................................... 25 ft-lbs / 34 Nm
10
Proportional solenoid valve ............... AJ ......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
11
Differential sensing valve .................. AK ......... All functions .................................................. 25 ft-lbs / 34 Nm
12
Solenoid valve, 2 position 2 way,
N.C. poppet ....................................... AL ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
13
Relief valve, 1800 psi / 124 bar ......... AM ........ Secondary boom down ................................ 20 ft-lbs / 27 Nm
14
Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... AN ........ Platform rotate, turntable rotate
and jib boom circuits (Z-45/25J) .................. 20 ft-lbs / 27 Nm
15
Flow control valve,
0.1 gpm / 0.38 L/min .......................... AO ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
16
Counterbalance valve ........................ AP ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
17
Relief valve, 3200 psi / 220.6 bar ...... AQ ........ System relief ................................................ 20 ft-lbs / 27 Nm
18
Diagnostic nipple ............................... AR ........ Testing
19
Check valve ....................................... AS ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
20
Orifice, 0.060 inch / 1.5 mm ............... AT ......... Steer circuit
21
Pressure switch ................................. AU ........ Brake circuit
22
Solenoid valve, 2 position 2 way,
N.O. poppet ....................................... AV ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
—
Orifice, 0.030 inch / 0.76 mm
(located under item VV) ..................... AW ........ Brake circuit
23
Orifice, 0.046 inch / 1.17 mm ............. AX ......... Secondary boom up
4 - 38
Schematic
Item
Function
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Torque
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
1
2
3
4
5
6
7
8
9
10
11
12
23
22
21
20
19
18
17
Part No. 106488
16
15
14
13
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 39
Section 4 • Repair Procedures
June 2005
REV C
MANIFOLDS
9-3
Function Manifold Components (from serial number 20380 to 22565)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index
No.
Description
1
Solenoid valve, 2 position 3 way ....... BA ......... Primary boom retract ................................... 20 ft-lbs / 27 Nm
2
Solenoid valve, 3 position 4 way ....... BB ......... Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3
Solenoid valve, 3 position 4 way ....... BC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4
Solenoid valve, 3 position 4 way ....... BD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5
Solenoid valve, 3 position 4 way ....... BE ......... Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
6
Solenoid valve, 3 position 4 way ....... BF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7
Solenoid valve, 3 position 4 way ....... BG ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
8
Proportional solenoid valve ............... BH ........ Controls flow to functions ............................. 27 ft-lbs / 37 Nm
9
Solenoid valve, 2 position 2 way,
N.C. poppet ....................................... BI .......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
10
Solenoid valve, 2 position 3 way ....... BJ ......... Primary boom extend ................................... 20 ft-lbs / 27 Nm
11
Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... BK ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
12
Counterbalance valve ........................ BL ......... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm
13
Flow control valve .............................. BM ........ Platform level circuit ..................................... 25 ft-lbs / 34 Nm
14
Relief valve, 3200 psi / 220.6 bar ...... BN ........ System relief ................................................ 20 ft-lbs / 27 Nm
15
Diagnostic nipple ............................... BO ........ Testing
16
Check valve ....................................... BP ......... Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17
Orifice, 0.060 inch / 1.5 mm ............... BQ ........ Steer circuit
18
Differential sensing valve .................. BR ........ All functions .................................................. 25 ft-lbs / 34 Nm
19
Pressure switch ................................. BS ......... Brake circuit
20
Solenoid valve, 2 position 2 way,
N.O. poppet ....................................... BT ......... Brake circuit ................................................. 20 ft-lbs / 27 Nm
—
Orifice, 0.030 inch / 0.76 mm
(located under item BT) ..................... BU ........ Brake circuit
21
Orifice, 0.046 inch / 1.17 mm ............. BV ......... Secondary boom up
22
Counterbalance valve ........................ BW ........ Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
23
Relief valve, 1800 psi / 124 bar ......... BX ......... Secondary boom down ................................ 20 ft-lbs / 27 Nm
4 - 40
Schematic
Item
Function
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Torque
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
1
2
3
4
5
6
7
8
23
9
22
21
20
19
18
10
17
16
15
14
Part No. 106488
13
12
11
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 41
Section 4 • Repair Procedures
June 2005
REV C
MANIFOLDS
9-4
Function Manifold Components (from serial number 22566 to 23235)
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 2 position 3 way ....... CA ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm
2
Solenoid valve, 3 position 4 way ....... CB ........ Primary boom up/down ................................ 25 ft-lbs / 34 Nm
3
Solenoid valve, 3 position 4 way ....... CC ........ Secondary boom up/down ........................... 25 ft-lbs / 34 Nm
4
Solenoid valve, 3 position 4 way ....... CD ........ Turntable rotate left/right .............................. 25 ft-lbs / 34 Nm
5
Solenoid valve, 3 position 4 way ....... CE ........ Platform rotate left/right and
jib boom up/down (Z-45/25J) ....................... 25 ft-lbs / 34 Nm
6
Solenoid valve, 3 position 4 way ....... CF ......... Platform level up/down ................................ 25 ft-lbs / 34 Nm
7
Shuttle valve ...................................... CG ........ Platform level circuit ............................ 4-5 ft-lbs / 5.5-6.7 Nm
8
Solenoid valve, 3 position 4 way ....... CH ........ Steer left/right ............................................... 25 ft-lbs / 34 Nm
9
Proportional solenoid valve ............... CI .......... Controls flow to functions ............................. 27 ft-lbs / 37 Nm
Function
Torque
10
Pressure switch ................................. CJ ......... Brake circuit
11
Solenoid valve, 2 position 3 way ....... CK ........ Primary boom extend ................................... 20 ft-lbs / 27 Nm
12
Flow regulator valve,
0.4 gpm / 1.5 L/min ............................ CL ......... Platform rotate and turntable
rotate circuits ................................................ 20 ft-lbs / 27 Nm
13
Needle valve ...................................... CM ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
14
Relief valve, 2500 psi / 172 bar ......... CN ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
15
Relief valve, 3200 psi / 220.6 bar ...... CO ........ System relief ................................................ 20 ft-lbs / 27 Nm
16
Check valve, 5 psi / 0.3 bar ............... CP ........ Brake circuit ...................................... 12-14 ft-lbs / 16-19 Nm
17
Orifice, 0.060 inch / 1.5 mm ............... CQ ........ Steer circuit
18
Orifice, 0.030 inch / 0.76 mm ............. CR ........ Proportional valve circuit
19
Solenoid valve, 2 position 3 way ....... CS ........ Brake circuit ................................................. 20 ft-lbs / 27 Nm
—
Orifice, 0.030 inch / 0.76 mm
(from serial number 22566 to 22628
and after serial number 23235)
(located under item CS) ..................... CT ......... Brake circuit
20
Orifice, 0.037 inch / 0.94 mm ............. CU
21
Check valve, pilot operated ............... CV ........ Platform level circuit ..................................... 20 ft-lbs / 27 Nm
22
Relief valve, 2100 psi / 145 bar ......... CW ....... Secondary boom down circuit ...................... 20 ft-lbs / 27 Nm
4 - 42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
1
2
3
4
5
6
7
8
9
22
10
21
20
19
18
17
16
11
15
Part No. 106488
14
13
12
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 43
Section 4 • Repair Procedures
June 2005
MANIFOLDS
REV C
9-5
Valve Adjustments Function Manifold
How to Adjust the Primary Boom
Down Relief Valve
(before serial number 11819)
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 V, AQ, BN or CO).
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.
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
up/down toggle switch in the down direction
with the primary boom fully lowered. Observe
the pressure reading on the pressure gauge.
Refer to Section 2, Specifications.
3 Turn the machine off. Hold the primary boom
down relief valve with a wrench and remove
the cap (item Q).
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.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
4 - 44
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
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 R, AM, BX or CW).
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 45
Section 4 • Repair Procedures
June 2005
REV C
MANIFOLDS
9-6
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to platform support.
Index
No.
Description
1
Solenoid valve, 2 position 2 way ...... DA ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
2
Solenoid valve, 2 position 2 way ...... DB ........ Jib boom platform rotate select ........... 8-10 ft-lbs / 11-14 Nm
3
Solenoid valve, 2 position 3 way ...... DC ........ Jib boom / platform rotate select .................. 20 ft-lbs / 27 Nm
1
Schematic
Item
Function
2
Torque
1
3
2
From serial number
16963 to 22565
Before serial number 16963
From serial number 22566 to 23235
4 - 46
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV C
MANIFOLDS
9-7
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index
No.
Description
Schematic
Item
Function
1
Shuttle valve 2 position 3 way ........... CX ........ Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2
Counterbalance valve ........................ CY ........ Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm
3
Counterbalance valve ........................ CZ ........ Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm
1
Part No. 106488
2
Torque
3
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 47
Section 4 • Repair Procedures
June 2005
Turntable Rotation Components
REV B
10-1
Rotation Hydraulic Motor
(before serial number 18367)
3 Remove the engine pivot plate latch retainer.
How to Remove the Rotation
Hydraulic Motor
5 Remove the retaining fasteners from the center
turntable cover. Remove the cover from the
machine.
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 pin.
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.
4 Open the engine pivot plate latch and swing the
engine out away from the machine to access
the turntable rotation motor.
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 container of
suitable capacity. See capacity 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.
Unlocked position
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
13 Remove the turntable rotation motor mounting
fasteners. Remove the motor from the brake.
Locked position
4 - 48
14 Remove the turntable rotation motor from the
machine.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable
Rotation Brake
(before serial number 18367)
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 pin.
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.
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. See capacity 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 and
the brake. Cap the fittings on the manifold and
the brake.
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.
Unlocked position
13 Remove the turntable rotation motor mounting
fasteners. Remove the motor from the brake.
14 Remove the brake mounting bolts. Remove the
turntable rotation brake from the machine.
Locked position
3 Remove the engine pivot plate latch retainer.
4 Open the engine pivot plate latch and swing the
engine out away from the machine to access
the turntable rotation motor and brake.
Part No. 106488
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.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 49
Section 4 • Repair Procedures
June 2005
REV B
TURNTABLE ROTATION COMPONENTS
10-2
Turntable Rotation Assembly
(from serial number 18367
to 23235)
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 pin.
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.
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. See capacity 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.
Unlocked position
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.
Locked position
4 - 50
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 4 • Repair Procedures
REV B
TURNTABLE ROTATION COMPONENTS
13 Attach a lifting strap from and overhead crane
or other suitable lifting device to the turntable
rotation assembly.
14 Remove the turntable rotation assembly
mounting fasteners.
15 Carefully remove the turntable rotation
assembly from the machine.
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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
4 - 51
Section 4 • Repair Procedures
June 2005
Motor Controller
11-1
Motor Controller
The drive motor controller is located under the nonsteer end drive chassis cover. The drive motor
controller can recognize machine drive
malfunctions and display controller fault codes by
flashing a LED at the ground controls and on the
motor controller. See the Troubleshooting section
of this manual 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.
How to Test the Motor Controller
Use the following procedure to test
the motor controller. If the motor
controller is found to be faulty,
note which test failed and which
fault code (if any) was present at
the time of failure.
REV A
4 Press the release tab on the motor controller
harness connector and remove the motor
controller harness connector from the motor
controller.
5 Connect the leads from an ohmmeter to test
each motor controller terminal combination
listed below and check for resistance.
Result: All desired results must be 500 kilohms
or more. If any test has a result less than
500 kilohms, replace the motor controller.
Test
Desired result
(in kilohms)
F1 to F2
500kΩ or more
F1 to B-
500kΩ or more
F1 to M-
500kΩ or more
F1 to B+
500kΩ or more
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
end of the machine.
F2 to B+
500kΩ or more
3 Tag and disconnect all power cables from the
motor controller.
B- to M-
500kΩ or more
M- to B+
500kΩ or more
Pin 17 to B-
500kΩ or more
Pin 20 to B-
500kΩ or more
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4 - 52
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie Z-45/25 Bi-Energy and Genie Z-45/25J
Bi-Energy Operator’s Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Repair any machine damage or malfunction
before operating the machine.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
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
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.
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5-1
Section 5 • Fault Codes
June 2005
FAULT CODES
REV A
Tip-over hazard. When adjusting
the raised drive speed settings,
the maximum raised drive speed
must not exceed 0.6 mph / 1Km/h
or 40 feet/45 seconds /
12.2 meters / 45 seconds. 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 of 0.6 mph /
1Km/h or 40 feet / 45 seconds /
12.2 meters / 45 seconds.
5-2
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 5 • Fault Codes
Fault Code Chart
REV A
Fault Code
Controller
status indicator
light is OFF or
is ON but not
blinking
01
12
13
Programmer
Diagnostic Display
COMMUNICATION
ERROR
Condition
Possible Causes
Solution
The key switch or red
Emergency Stop
button(s) was cycled on
and off faster than 5
seconds OR controller
sensed an internal error
during start up.
Push in the ground
control red Emergency
Stop button to the OFF
position and wait for 5
seconds. Pull out the
ground control red
Emergency Stop button
out to the ON position. If
problem persists,
replace the motor
controller.
Machine will not drive.
The motor controller
failed self test.
Replace the motor
controller.
Machine will not drive.
The motor controller
has a internal short
between M- and Bterminals.
Test the motor
controller, see the
Repair Section.
Motor wiring is loose
OR motor is defective
OR motor controller has
an internal short.
Check for loose or open
connections at the drive
motors and motor
controller OR replace
the defective drive
motor OR test the motor
controller. See the
Repair Section.
Defective motor
controller.
Defective motor
controller.
Replace the motor
controller.
Replace the motor
controller.
Machine will not drive.
Normal operation.
HW FAILSAFE 1-2-3
M- SHORTED
FIELD OPEN
Machine will not drive.
ARM SENSOR
Machine will not drive.
FLD SENSOR
Machine will not drive.
Continued on next page
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5-3
Section 5 • Fault Codes
June 2005
FAULT CODE CHART
Fault Code
21
REV A
Code Scanner
Display
THROTTLE FAULT 1
THROTTLE FAULT 2
31
32
33
5-4
CONT DRVR OC
MAIN CONT WELDED
PRECHARGE FAULT
Condition
Possible Causes
Solution
Machine will not drive.
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
to pins 14 and 16 at the
motor controller OR pin
14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick
defective.
Consult Genie
Industries Service
Department.
Machine will not drive.
Pin 14 (wht/red #32) is
shorted to power or
ground OR the
potentiometer on the
drive joystick is
defective.
Consult Genie
Industries Service
Department.
Machine will not drive.
Main contactor (PR1)
coil defective OR brake
release relay CR5
defective.
Replace main contactor
PR1 or brake release
relay CR5 OR replace
the motor controller.
Machine will not drive.
Main contactor (PR1)
contacts stuck closed
OR grn wire at pin 17 on
motor controller shorted
to ground OR open in
motor armature wiring
OR motor controller has
a internal short to
ground.
Consult Genie
Industries Service
Department.
External short between
B+ terminal on motor
controller and ground
OR motor controller is
defective.
Repair short between
B+ terminal on motor
controller and ground
OR replace motor
controller.
Note: Short can be on
any part of circuit
connected to the B+
terminal on the motor
controller.
Machine will not drive.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 5 • Fault Codes
REV A
FAULT CODE CHART
Fault Code
34
Code Scanner
Display
MISSING CONTACTOR
MAIN CONT DNC
41
42
43
Part No. 106488
LOW BATTERY
VOLTAGE
OVERVOLTAGE
THERMAL CUTBACK
Condition
Possible Causes
Machine will not drive.
Motor controller does
not detect the main
contactor PR1 or brake
release relay CR5.
Consult Genie
Industries Service
Department.
Machine will not drive.
Main contactor PR1 or
brake release relay CR5
did not close OR open
in org/red wire to PR1
and/or CR5 OR main
contactor and/or brake
release relay is
defective.
Consult Genie
Industries Service
Department.
Machine will not drive.
Battery supply voltage
to motor controller less
than 32V DC.
Completely charge
batteries OR check
battery cable condition
OR check for corrosion
or loose connections at
battery terminals and
motor controller.
Machine will not drive.
Battery supply voltage
to motor controller more
than 55V DC OR
machine is being
operated with the
battery charger plugged
in.
Be sure the battery
charger is disconnected
OR check for loose
battery cables or poor
connections
Machine will not drive.
Machine being operated
outside of temperature
range of -13°F to
185°F / -25°C to 85°C
OR machine being
driven under excessive
load OR motor
controller is not being
cooled sufficently.
Operate machine within
specified temperature
limits OR check for
debris around motor
controller preventing
proper cooling of the
controller OR check for
mechanical restrictions
causing excessive load
on the machine.
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Solution
5-5
Section 5 • Fault Codes
June 2005
This page intentionally left blank.
5-6
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey:
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
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.
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.
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
Genie Z-45/25 Bi-Energy and Genie Z-45/25J
Bi-Energy Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 106488
problem
solved
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
June 2005
Electrical Symbols Legend
REV A
TB17
15AMP.
TS6
RIGHT
LEFT
GRN/BLK
ORG/BLK-1
Circuit breaker
Toggle switch DPDT
Wire color
with cable
number
GRN
WHT
TB20
RED
Ground
supression
circuit
BP1
Terminal
Boom function
speed controller
Horn
NC
NO
LS3
TP29
Quick disconnect
terminal
Limit switch
L1 FB
Light
BLK #21
BLK/RED
Solenoid or
relay coil
LS1
NO
TB21
Limit switch
normally open
held closed
T-circuits connect
at terminal
PLAT
KS1
T-circuits
connect
Connection
no terminal
Tilt sensor
GRND
Key switch
LS2
NC
Limit switch
normally closed
held open
HORN
P4
Horn button
normally open
Circuits crossing
no connection
P1
Diode
PR4
Red Emergency
Stop button
normally closed
Relay panel
contactor
+
TS3
Relay contact
normally open
PLAT. UP
PLAT. DWN
-
6-2
CR4
Battery
Toggle switch SPDT
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
June 2005
Section 6 • Schematics
Hydraulic Symbols Legend
REV A
0.035”
Orifice with size
Pressure gauge
Differential sensing valve
3 position 4 way directional
solenoid valve
Variable orifice
or shut-off valve
Solenoid operated
proportional valve
(before serial number 22566)
Filter
Shuttle valve
Check valve
Check valve, pilot operated
Fixed displacement pump
Relief valve
Solenoid operated
proportional valve
(after serial number 22565)
Spring applied,
hydraulically released
brake
Priority flow regulator
N.O.
COM
N.C.
Bi-directional motor
M
Pressure switch
2 position 2 way
solenoid valve
Pump prime mover (motor)
Solenoid operated 2 pos.,
3 way, directional valve
Cylinder
Counterbalance valve
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6-3
Section 6 • Schematics
6-4
June 2005
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
Section 6 • Schematics
June 2005
Power Cable Diagram
(before serial number 16839)
Section 6 • Schematics
June 2005
REV A
Power Cable Diagram
(before serial number 16839)
A
B
C
D
1
E
F
G
H
I
TO BASE CONTROL BOX
AND ENGINE PANEL
LEFT SIDE
BATTERY PACK
J
K
L
M
N
AC POWER CABLE
DC AMMETER CABLE
RIGHT SIDE
BATTERY PACK
RED-2GA
+
48V DC
ALTERNATOR
-
+
+
3
NEG
-
A1
PRIMARY
LIFT PUMP
AUXILIARY LIFT
PUMP
BLACK-2GA
BLACK-2GA
-
POS
RED-2GA
D1
+
+
+
BI-ENERGY
ONLY
RED-2GA
RED#20-12GA
-
-
-
WHITE-FROM CHARGER
FUSE-F3, 500A
+
ORG/RED-R2
WHITE-BATT
WHITE-BATT
4
D1
A2
RED-2GA
_
AC
BATTERY
CHARGER
CHASSIS HARNESS
GRN/BLK-BATT ISM-9
WHT-BATT R12
2
+
FUSE-F5, 10A
BLACK-2GA
BLACK-2GA
BLACK-2GA
BLACK-2GA
FUSE-F4, 500A
RED-2GA
LIFT CONTACTOR
RED-2GA
RED-2GA
BI-ENERGY
MODELS ONLY
DRIVE CONTACTOR
AUXILIARY POWER
UNIT CONTACTOR
PR-1
ORG/RED-42
ORG/RED-42
BRN-J9
RED-27
RED-2GA
5
BLACK-2GA
BLACK-2GA
BLACK-FROM CHARGER
BLACK-2GA
PR-2
1
-
-
+
+
PR-3
ORG/RED-42
BRN-J9
RED-27
RED-2GA
RED#20-12GA
BRN-J8
6
AP-1
5
6
7
AMMETER
GRN/WHT-19
AP-2
2
DIODE
4
RED-2GA
RED-10GA
RED-2GA
RED-10GA
48V
AC
CHARGER
PLUG
BLACK-2GA
RED-2GA
-
3
RED-2GA
-
+
DIODE
9
+
8
+
24V DC
F2-200A
BLK-2GA
BLK-2GA
BLACK-FROM CHARGER
BLK-2GA
BRN-J8
BLK-2GA
LEFT SIDE DRIVE MOTOR
E1
BLU/WHT-12
ORG/RED-42
ORANGE-40
A1
ORG/RED-42
RED-2GA
RED-10GA
GREEN
BLACK-LED
BLU/RED-39
ORG/RED-42
WHT/BLK-31
BI-ENERGY MODELS ONLY
RED-10GA
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
WHT-30
A1
8
ORG/RED-42
RED-2GA
RED-10GA
E1
RED/WHT-29
J1
A2
BRN-J8
7
RED/BLK-R5
RED-10GA
RED-2GA
E2
WHT/RED-32
F1-200A
E2
A2
RIGHT SIDE DRIVE MOTOR
RED-10GA
F2
F1
BLK-2GA
BLACK-2GA
RED-2GA
B-
CHASSIS GROUND
6-5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
M-
B+
MOTOR CONTROLLER
NOTES:
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED
June 2005
Section 6 • Schematics
REV A
Power Cable Diagram
(from serial number 16840 to 21179)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
TO BASE CONTROL BOX
AND ENGINE PANEL
LEFT SIDE
BATTERY PACK
AC POWER CABLE
DC AMMETER CABLE
RIGHT SIDE
BATTERY PACK
RED-2GA
+
48V DC
ALTERNATOR
CHASSIS HARNESS
+
+
A2
NEG
-
A1
PRIMARY
LIFT PUMP
AUXILIARY LIFT
PUMP
BLACK-2GA
BLACK-2GA
-
POS
RED-2GA
D1
+
+
3
+
BI-ENERGY
ONLY
RED-2GA
RED#20-12GA
-
-
-
WHITE-FROM CHARGER
+
ORG/RED-R2
WHITE-BATT
WHITE-BATT
FUSE-F3, 500A
2
+
D1
RED-2GA
GRN/BLK-BATT ISM-9
WHT-BATT R12
_
AC
BATTERY
CHARGER
FUSE-F5, 10A
BLACK-2GA
BLACK-2GA
FUSE-F4, 500A
RED-2GA
-
-
+
+
5
6
7
AMMETER
DRIVE CONTACTOR
AUXILIARY POWER
UNIT CONTACTOR
PR-1
ORG/RED-42
ORG/RED-42
BRN-J9
RED-27
RED-2GA
RED-2GA
RED-2GA
BI-ENERGY
MODELS ONLY
BLACK-2GA
BLACK-2GA
BLACK-FROM CHARGER
BLACK-2GA
PR-2
AP-1
PR-3
ORG/RED-42
BRN-J9
RED-27
RED-2GA
RED#20-12GA
BRN-J8
RED-2GA
RED-10GA
RED-2GA
RED-10GA
48V
AC
CHARGER
PLUG
5
6
RED-2GA
LIFT CONTACTOR
GRN/WHT-19
AP-2
2
DIODE
4
1
-
3
BLACK-2GA
RED-2GA
-
+
DIODE
9
+
8
+
4
BLACK-2GA
BLACK-2GA
24V DC
F2-200A
LEFT SIDE DRIVE MOTOR
BLK-2GA
BLK-2GA
BLACK-FROM CHARGER
BLK-2GA
BRN-J8
BLK-2GA
A1
ORG/RED-42
RED-2GA
RED-10GA
BLU/WHT-12
7
E1
ORG/RED-42
ORANGE-40
BLACK-LED
ORG/RED-42
BI-ENERGY MODELS ONLY
BRN-J8
A1
WHT/BLK-31
RED-2GA
RED-10GA
E1
RED-10GA
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
WHT-30
ORG/RED-42
A2
WHT/RED-32
J1
RED/WHT-29
RED/BLK-R5
RED-10GA
RED-2GA
E2
GREEN
F1-200A
E2
A2
8
RIGHT SIDE DRIVE MOTOR
RED-10GA
F2
F1
BLK-2GA
BLACK-2GA
RED-2GA
CHASSIS GROUND
B-
M-
B+
MOTOR CONTROLLER
Part No. 106488
NOTES:
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6-6
June 2005
Section 6 • Schematics
Power Cable Diagram
(from serial number 16840 to 21179)
Section 6 • Schematics
June 2005
Power Cable Diagram
(from serial number 21180 to 22050)
Section 6 • Schematics
June 2005
REV A
Power Cable Diagram
(from serial number 21180 to 22050)
A
B
C
D
TO ENGINE PANEL
1
E
F
G
H
I
TO GROUND CONTROL BOX
CONNECTOR C6B
J
K
L
M
N
AC POWER CABLE
DC AMMETER CABLE
LEFT SIDE
BATTERY PACK
RIGHT SIDE
BATTERY PACK
RD-2GA
+
48V DC
ALTERNATOR
+
+
D1
A2
AC
BATTERY
CHARGER
-
PRIMARY
LIFT PUMP
NEG
-
A1
POS
RD-2GA
+
AUXILIARY LIFT
PUMP
BK-2GA
BK-2GA
-
3
D1
+
RD-2GA
RD-20-12GA
-
+
-
-
WH-FROM CHARGER
+
WH-BATT
WH-BATT
P42BAT OR/RD
F3 500A
4
F5 10A
BK-2GA
BK-2GA
BK-2GA
BK-2GA
F4 500A
RD-2GA
+
BATTERY
-
BRN-J8
PR-1
R42BAT OR/RD
R42BAT OR/RD
BRN-J8
R27AUX RD
BK
BK
DIODE
CONTROLLER
PR-1
LIFT
CONTACTOR
BRN-J8
RD
BK
2
+
7
RD-2GA
RD-10GA
F1
A1
OR/RD
RD-2GA
RD-10GA
C12DRE BL/WH
R42BAT OR/RD
C40LS OR
J1
CFIL BK
C30FWD WH
R42BAT OR/RD
OR/RD
C31REV WH/BK
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
BRN-J8
BK-2GA
BRN-J8
A1
24V DC
RD-10GA
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
RD-2GA
RD-10GA
RD-2GA
RD-20-12GA
F2
200A
C32JSL WH/RD
A2
C29JSH RD/WH
CR5 RD/BK
F2
GR
F1-200A
RD-10GA
RD-2GA
33
AC
CHARGER
PLUG
PR-3
BK
48V DC
8
+
6
R42BAT OR/RD
RD-2GA
RD-10GA
6
LEFT SIDE
DRIVE MOTOR
-
5
BK-2GA
RD-2GA
PR-2
RD-2GA
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
RD-2GA
RD-2GA
5
DIODE
GR/WH-19
DIODE
33
F1
-
4
AMMETER
AP-2
7
3
AP-1
9
AUXILIARY POWER UNIT
CONTACTOR
1
TOP VIEW OF
DRIVE CONTACTOR
DRIVE CONTACTOR
8
-
+
RD-2GA
+
BK
WH
_
+
RD-2GA
GR/BK-BATT ISM-9
WH-BATT R12
2
FUNCTION HARNESS
-
F2
A2
RIGHT SIDE
DRIVE MOTOR
RD-10GA
F2
F1
BK-2GA
BK-2GA
RD-2GA
B-
CHASSIS
GROUND
6-7
M-
B+
MOTOR CONTROLLER
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
NOTES:
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
June 2005
Section 6 • Schematics
REV A
Power Cable Diagram
(from serial number 22051 to 23235)
N
M
L
K
J
TO ENGINE PANEL
I
H
G
F
TO GROUND CONTROL BOX
CONNECTOR C6B
E
D
C
B
1
AC POWER CABLE
DC AMMETER CABLE
LEFT SIDE
BATTERY PACK
RIGHT SIDE
BATTERY PACK
RD-2GA
-
48V DC
ALTERNATOR
POS
RD-2GA
+
AUXILIARY LIFT
PUMP
-
BK-2GA
BK-2GA
RD-2GA
GR/BK-BATT ISM-9
WH-BATT R12
-
A1
D1
3
+
RD-2GA
RD-20-12GA
+
+
-
-
WH-FROM CHARGER
+
WH-BATT
WH-BATT
P42BAT OR/RD
F5 10A
BK-2GA
BK-2GA
BK-2GA
BK-2GA
BK
WH
2
-
+
+
5
6
7
9
PR-1
CONTROLLER
PR-1
R42BAT OR/RD
R42BAT OR/RD
BRN-J8
R27AUX RD
BK
LIFT
CONTACTOR
BK
DIODE
5
PR-3
R42BAT OR/RD
BRN-J8
RD
BK
RD-2GA
RD-10GA
BK
RD-2GA
RD-10GA
48V DC
RD-2GA
RD-20-12GA
6
24V DC
C32JSL WH/RD
C12DRE BL/WH
R42BAT OR/RD
C40LS OR
CFIL BK
C30FWD WH
R42BAT OR/RD
OR/RD
BRN-J8
RD-2GA
RD-10GA
C31REV WH/BK
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
A1
7
F1
A1
OR/RD
RD-2GA
A2
GR
CR5 RD/BK
RD-10GA
RD-2GA
F2
C29JSH RD/WH
F2
200A
F1
200A
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
BRN-J8
BK-2GA
33
AC
CHARGER
PLUG
BK-2GA
RD-2GA
PR-2
BRN-J8
P42BAT OR/RD
BK-2GA
BK-2GA
BK-FROM CHARGER
BK-2GA
RD-2GA
F4
500A
DIODE
GR/WH-19
DIODE
33
LEFT SIDE
DRIVE MOTOR
-
4
AMMETER
AP-2
F1
3
AP-1
BATTERY
-
-
+
AUXILIARY POWER UNIT
CONTACTOR
8
TOP VIEW OF
DRIVE CONTACTOR
DRIVE CONTACTOR
1
+
-
4
RD-2GA
+
2
NEG
PRIMARY
LIFT PUMP
-
FUNCTION HARNESS
+
D1
A2
+
+
AC
BATTERY
CHARGER
-
_
A
F2
A2
RIGHT SIDE
DRIVE MOTOR
RD-10GA
F2
F1
8
RD-10GA
BK-2GA
BK-2GA
NOTES:
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
RD-2GA
CHASSIS
GROUND
B-
M-
B+
MOTOR CONTROLLER
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6-8
June 2005
Section 6 • Schematics
Power Cable Diagram
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Engine Panel Diagram
(before serial number 13361)
Section 6 • Schematics
June 2005
REV A
Engine Panel Diagram
(before serial number 13361)
A
B
C
D
E
F
G
H
I
J
K
L
WHT-BATT.
WHT-21
1
BLK/RED-35
BLK/WHT-34
RED-J1
BRN-VOLT
GLOW PLUG
CR15
RED-CB
CIRCUT BREAKER
CB3
12V, 15A
BROWN-CHH
BLK-ISM-1
BLK/RD
ENGINE FAULT
10
WHT-ISM10
(NOT USED)
IGNITION/FUEL ON
8
9
GRN/BLK-BATT.
24V BATTERY +
KEY SWITCH POWER
7
WHITE-23
6
5
BRN-ISM5
START RELAY
TACH. INPUT
2
1
BLK-ISM-1
WHT-R14
GRN
YEL
RED
BLU
BLK
BLU
5
BLU-ISM2
4
GROUND
IGNITION/START
MODULE
12/24V DC
RED-CB (12V+)
BLK/WHT-34
BLK/RED#35
BLU-E.H.
RED-J2
WHT-R11
BLU-E.H.
BRN-J4
WHT-J3
WHT-J2
BLK-START
BRN-J3
RED-ISM6
BRN-J2
WHT-J1
24V
24V
START INPUT
24V
3
24V
BLK#33B
24V
BRN-J1
3
RPM
CR14
(NOT USED)
CR13
WHT-R14
2
CR12
4
CR11
RPM
CUTOUT
BRN-J5
ENGINE
POWER
START
6
WHITE-23
BLK/RED-35
GRN/BLK-BATT
BLK/WHT-34
WHITE-21
WHITE-BATT.
7
8
9 10 11 12
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
WHITE-23
6
GRN/BLK-BATT
5
BLK/RED-35
4
BLK/WHT-34
3
WHITE-BATT.
2
WHITE-21
1
BROWN
8
MALE DEUTSCH
CONNECTOR
RED-PISM7
ENGINE HARNESS
(TO ENGINE)
BLACK-33
12V VOLTAGE
REGULATOR
BLACK-33
7
RED-PISM7
BROWN
ENGINE HARNESS (TO CHASSIS HARNESS)
CHASSIS HARNESS
6-9
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
M
N
June 2005
Section 6 • Schematics
REV A
Engine Panel Diagram
(from serial number 13361 to 14078)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RED-CB
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
CIRCUT BREAKER
CB3
15A
1
RED-CB (12V+)
WHT-BATT
WHT-21
BLK/RED-35
87
87
85
BRN-J4
WHT-J6
WHT-J4
87a
85
86
BRN-J4
BLK/RD
BRN-J4
87
87a
86
85
BRN-J4
BLK/RD
87
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87a
86
85
87
87a
86
85
87a
1 3 4 7 10 9 2
BRN-J4
BROWN-CH H
86
RED-CB
BLU-ISM2
24V BATTERY +
KEYSWITCH PWR.
(NOT USED)
6
7
8
ENGINE FAULT
GROUND
5
IGN./FUEL ON
(NOT USED)
4
9
START INPUT
3
10
TACH. INPUT
2
WHITE-23
GRN/BLK-BATT.
BLK-ISM-1
BLU-ISM2
BRN-VOLT
RED-ISM6
BLK-ISM-1
BRN-J5
BRN-ISM5
WHT-R14
BLK-33
BLK-ISM-1
BLK/RED-35
WHT-R14
START RELAY
RED-J6
RED-J10
BLK-START
BLK-ISM-1
WHT-R11
ORG-GEN NEG
BRN-VOLT
BLK/WHT-34
WHT-J6
RED-J6
3
4
BLK-33
BRN-J5
5
BRN-ISM5
BRN-ISM5
RED-ISM6
WHT-R14
BRN-VOLT
BRN-ISM5
BLU-E.H.
BLU-ISM2
RED-J10
BLU-E.H.
WHITE-23
GRN/BLK-BATT.
6
WHT-ISM10
GRN/BLK-BATT
WHITE-23
BLK/RED-35
BLK/WHT-34
WHITE-21
WHITE-BATT
BLACK-33
RED-PISM6
BROWN-CH H
7
6
7
8
9
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
10
11 12
8
WHITE-23
GRN/BLK-BATT
5
BLK/RED-35
4
WHITE-21
3
BLK/WHT-34
2
WHITE-BATT
1
BLACK-33
MALE DEUTSCH
CONNECTOR
RED-PISM6
GRN
YEL
BLU
ENGINE HARNESS
(TO ENGINE)
BROWN-J3
12V DC
VOLTAGE REGULATOR
RED
BLU
ENGINE HARNESS (TO CHASSIS HARNESS)
BLK
ORG-GEN POS
2
30
CR15
GLOW PLUG
RELAY
1
WHT-J4
WHT-J6
30
CR14
RPM RELAY
BLU-ISM2
WHT-J4
30
CR13
RPM CUTOUT
RELAY
RED-CB (12V+)
30
CR12
ENGINE POWER
RELAY
CR11
START RELAY
BLK/WHT-34
30
30
CR16
FIELD RELAY
WHT-ISM10
BRN-J4
IGNITION/START
MODULE
12/24V DC
WHT-J5
BRN-J4
WHT-J4
WHT-J5
WHT-BATT
WHT-21
BLK/RED-35
RED-CB
WHT-BATT
CHASSIS HARNESS
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 10
June 2005
Section 6 • Schematics
Engine Panel Diagram
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
Engine Panel Diagram
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
REV A
Engine Panel Diagram
(from serial number 14079 to 14650)
A
B
C
D
E
F
G
H
I
J
K
M
RED-CB
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
1
L
CIRCUT BREAKER
CB3
15A
RED-CB (12V+)
WHT-BATT
WHT-21
BLK/RED-35
85
86
87
87a
86
85
BRN-J4
BLK/RD
87
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87a
86
85
87
87a
86
85
87a
1 3 4 7 10 9 2
87a
BRN-J4
BLK/RD
BRN-J4
BROWN-CH H
86
RED-CB
BLU-ISM2
BLK-33
BRN-J5
5
BRN-ISM5
BRN-ISM5
RED-ISM6
WHT-R14
BRN-VOLT
BRN-ISM5
BLU-E.H.
BLU-ISM2
RED-J10
BLU-E.H.
WHITE-23
GRN/BLK-BATT.
6
WHT-ISM10
GRN/BLK-BATT
WHITE-23
BLK/RED-35
BLK/WHT-34
WHITE-21
WHITE-BATT
6
7
8
9
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
10
11 12
WHITE-23
BROWN-J3
8
GRN/BLK-BATT
5
BLK/RED-35
4
WHITE-21
3
BLK/WHT-34
2
WHITE-BATT
1
BLACK-33
MALE DEUTSCH
CONNECTOR
RED-PISM6
12V DC
VOLTAGE REGULATOR
BLACK-33
7
RED-PISM6
ENGINE HARNESS
(TO ENGINE)
BROWN-CH H
GRN
YEL
BLU
RED
BLK
BLU
ENGINE HARNESS (TO CHASSIS HARNESS)
CHASSIS HARNESS
6 - 11
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
IGN./FUEL ON
9
(NOT USED)
8
GROUND
5
24V BATTERY +
(NOT USED)
4
6
START INPUT
TACH. INPUT
3
2
KEYSWITCH PWR.
WHITE-23
GRN/BLK-BATT.
BLK-ISM-1
BLU-ISM2
RED-ISM6
BLK-ISM-1
BRN-VOLT
BRN-J5
BRN-ISM5
WHT-R14
BLK-33
BLK-ISM-1
BLK/RED-35
WHT-R14
RED-J10
BLK-START
BLK-ISM-1
WHT-R11
ORG-GEN NEG
BRN-VOLT
ORG-GEN POS
4
START RELAY
RED-J6
RED-J6
3
BLK/WHT-34
WHT-J6
7
30
CR15
GLOW PLUG
RELAY
1
WHT-J4
WHT-J6
30
CR14
RPM RELAY
BLU-ISM2
WHT-J4
30
CR13
RPM CUTOUT
RELAY
RED-CB (12V+)
30
CR12
ENGINE POWER
RELAY
CR11
START RELAY
BLK/WHT-34
30
30
CR16
FIELD RELAY
ENGINE FAULT
87
87
85
BRN-J4
WHT-J6
WHT-J4
10
2
BRN-J4
WHT-ISM10
BRN-J4
IGNITION/START
MODULE
12/24V DC
WHT-J5
BRN-J4
WHT-J4
WHT-J5
WHT-BATT
WHT-21
BLK/RED-35
RED-CB
WHT-BATT
N
June 2005
Section 6 • Schematics
REV A
Engine Panel Diagram
(from serial number 14651 to 16839)
N
M
L
K
J
I
H
G
F
E
D
C
B
RED-CB
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
A
CIRCUT BREAKER
CB3
15A
1
RED-CB (12V+)
WHT-BATT
WHT-21
BLK/RED-35
87
87
85
BRN-J4
WHT-J6
WHT-J4
87a
85
86
BRN-J4
BLK/RD
BRN-J4
87
87a
86
85
BRN-J4
BLK/RD
87
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87a
86
85
87
87a
86
85
87a
1 3 4 7 10 9 2
BRN-J4
BROWN-CH H
86
RED-CB
BLU-ISM2
(NOT USED)
IGN./FUEL ON
ENGINE FAULT
8
9
10
24V BATTERY +
KEYSWITCH PWR.
7
GROUND
5
6
WHITE-23
START INPUT
(NOT USED)
3
BRN-J5
BRN-ISM5
GRN/BLK-BATT.
BLK-ISM-1
BLU-ISM2
BRN-VOLT
RED-ISM6
BLK-ISM-1
4
TACH. INPUT
2
BLK-ISM-1
WHT-R14
BLK-33
WHT-R14
BLK/RED-35
START RELAY
RED-J6
RED-J10
BLK-START
BLK-ISM-1
WHT-R11
ORG-GEN NEG
BRN-VOLT
BLK/WHT-34
WHT-J6
RED-J6
3
4
BLK-33
BRN-J5
5
BRN-ISM5
BRN-ISM5
RED-ISM6
WHT-R14
BRN-VOLT
BRN-ISM5
BLU-E.H.
BLU-ISM2
RED-J10
BLU-E.H.
WHT-23
GRN/BLK-BATT.
6
WHT-ISM10
WHT-23
GRN/BLK-BATT
BLK/WHT-34
BLK/RED-35
WHT-BATT
WHT-21
RED-PISM6
BRN-CH H
BLK-33
7
MALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
10
11 12
WHT-23
GRN/BLK-BATT
BLK/RED-35
BLK/WHT-34
WHT-21
WHT-BATT
RED-PISM6
8
BLK-33
GRN
YEL
RED
BLU
ENGINE HARNESS
(TO ENGINE)
BRN-J3
12V DC
VOLTAGE REGULATOR
BLK
ENGINE HARNESS (TO CHASSIS HARNESS)
BLU
ORG-GEN POS
2
30
CR15
GLOW PLUG
RELAY
1
WHT-J4
WHT-J6
30
CR14
RPM RELAY
BLU-ISM2
WHT-J4
30
CR13
RPM CUTOUT
RELAY
RED-CB (12V+)
30
CR12
ENGINE POWER
RELAY
CR11
START RELAY
BLK/WHT-34
30
30
CR16
FIELD RELAY
WHT-ISM10
BRN-J4
IGNITION/START
MODULE
12/24V DC
WHT-J5
BRN-J4
WHT-J4
WHT-J5
WHT-BATT
WHT-21
BLK/RED-35
RED-CB
WHT-BATT
CHASSIS HARNESS
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 12
June 2005
Section 6 • Schematics
Engine Panel Diagram
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
Engine Panel Diagram
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
REV A
Engine Panel Diagram
(from serial number 16840 to 17974)
A
B
C
D
E
F
G
H
I
J
K
M
RED-CB
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
1
L
CIRCUT BREAKER
CB3
15A
RED-CB (12V+)
WHT-BATT
WHT-21
BLK/RED-35
85
86
87
87a
86
85
BRN-J4
BLK/RD
87
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87a
86
85
87
87a
86
85
87a
1 3 4 7 10 9 2
87a
BRN-J4
BLK/RD
BRN-J4
BROWN-CH H
86
RED-CB
BLU-ISM2
BLK-33
BRN-J5
BRN-ISM5
BRN-ISM5
RED-ISM6
WHT-R14
BRN-VOLT
BRN-ISM5
BLU-E.H.
BLU-ISM2
RED-J10
BLU-E.H.
WHT-23
GRN/BLK-BATT.
6
WHT-ISM10
WHT-23
GRN/BLK-BATT
BLK/RED-35
BLK/WHT-34
WHT-BATT
WHT-21
RED-PISM6
5
6
7
8
9
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
10
11 12
WHT-23
BRN-J3
8
BLK/RED-35
4
GRN/BLK-BATT
3
BLK/WHT-34
2
WHT-21
1
WHT-BATT
MALE DEUTSCH
CONNECTOR
RED-PISM6
12V DC
VOLTAGE REGULATOR
BRN-CH H
7
BLK-33
ENGINE HARNESS
(TO ENGINE)
BLK-33
GRN
YEL
RED
BLK
BLU
BLU
ENGINE HARNESS (TO CHASSIS HARNESS)
CHASSIS HARNESS
6 - 13
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
(NOT USED)
IGN./FUEL ON
9
8
24V BATTERY +
GROUND
5
6
(NOT USED)
4
KEYSWITCH PWR.
WHITE-23
START INPUT
TACH. INPUT
3
BRN-J5
BRN-ISM5
GRN/BLK-BATT.
BLK-ISM-1
BLU-ISM2
RED-ISM6
BLK-ISM-1
BRN-VOLT
BLK-33
WHT-R14
5
START RELAY
BLK-ISM-1
BLK/RED-35
WHT-R14
RED-J10
BLK-START
BLK-ISM-1
WHT-R11
ORG-GEN NEG
BRN-VOLT
ORG-GEN POS
4
1
RED-J6
RED-J6
3
BLK/WHT-34
WHT-J6
7
30
CR15
GLOW PLUG
RELAY
2
WHT-J4
WHT-J6
30
CR14
RPM RELAY
BLU-ISM2
WHT-J4
30
CR13
RPM CUTOUT
RELAY
RED-CB (12V+)
30
CR12
ENGINE POWER
RELAY
CR11
START RELAY
BLK/WHT-34
30
30
CR16
FIELD RELAY
ENGINE FAULT
87
87
85
BRN-J4
WHT-J6
WHT-J4
10
2
BRN-J4
WHT-ISM10
BRN-J4
IGNITION/START
MODULE
12/24V DC
WHT-J5
BRN-J4
WHT-J4
WHT-J5
WHT-BATT
WHT-21
BLK/RED-35
RED-CB
WHT-BATT
N
June 2005
Section 6 • Schematics
REV A
Engine Panel Diagram
(from serial number 17975 to 21180)
N
M
L
K
J
I
H
G
F
E
D
C
B
RED-CB
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
A
CIRCUT BREAKER
CB3
15A
1
RED-CB (12V+)
WHT-BATT
WHT-21
BLK/RED-35
87
87
85
BRN-J4
WHT-J6
WHT-J4
87a
85
86
BRN-J4
BLK/RD
BRN-J4
87
87a
86
85
BRN-J4
BLK/RD
87
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87a
86
85
87
87a
86
85
87a
1 3 4 7 10 9 2
BRN-J4
BROWN-CH H
86
RED-CB
BLU-ISM2
(NOT USED)
IGN./FUEL ON
ENGINE FAULT
8
9
10
24V BATTERY +
KEYSWITCH PWR.
7
GROUND
5
6
WHITE-23
START INPUT
(NOT USED)
3
4
TACH. INPUT
BRN-VOLT
GRN/BLK-BATT.
BLK-ISM-1
BLU-ISM2
RED-ISM6
BLK-ISM-1
BRN-J5
BRN-ISM5
WHT-R14
BLK-33
BLK-ISM-1
START RELAY
WHT-R14
BLK/RED-35
1
RED-J6
RED-J10
BLK-START
BLK-ISM-1
WHT-R11
ORG-GEN NEG
BRN-VOLT
BLK/WHT-34
WHT-J6
RED-J6
3
4
BLK-33
BRN-J5
5
BRN-ISM5
BRN-ISM5
RED-ISM6
WHT-R14
BRN-VOLT
BRN-ISM5
BLU-E.H.
BLU-ISM2
RED-J10
BLU-E.H.
WHT-23
GRN/BLK-BATT.
6
WHT-ISM10
WHT-23
GRN/BLK-BATT
BLK/WHT-34
BLK/RED-35
WHT-BATT
WHT-21
RED-PISM6
BRN-CH H
BLK-33
7
MALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9
FEMALE DEUTSCH
CONNECTOR
1
2
3
4
5
6
7
8
9 10 11 12
10
11 12
WHT-23
GRN/BLK-BATT
BLK/RED-35
BLK/WHT-34
WHT-21
WHT-BATT
RED-PISM6
8
BLK-33
GRN
YEL
RED
BLK
ENGINE HARNESS
(TO ENGINE)
BRN-J3
12V DC
VOLTAGE REGULATOR
BLU
ENGINE HARNESS (TO CHASSIS HARNESS)
BLU
ORG-GEN POS
2
30
CR15
GLOW PLUG
RELAY
2
WHT-J4
WHT-J6
30
CR14
RPM RELAY
BLU-ISM2
WHT-J4
30
CR13
RPM CUTOUT
RELAY
RED-CB (12V+)
30
CR12
ENGINE POWER
RELAY
CR11
START RELAY
BLK/WHT-34
30
30
CR16
FIELD RELAY
WHT-ISM10
BRN-J4
IGNITION/START
MODULE
12/24V DC
WHT-J5
BRN-J4
WHT-J4
WHT-J5
WHT-BATT
WHT-21
BLK/RED-35
RED-CB
WHT-BATT
CHASSIS HARNESS
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 14
June 2005
Section 6 • Schematics
Engine Panel Diagram
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
Engine Panel Diagram
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
REV A
Engine Panel Diagram
(from serial number 21181 to 22050)
A
B
C
D
E
F
G
H
I
J
K
L
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
M
RD-CB
1
N
CIRCUT BREAKER
CB3
RD-CB (12V+)
86
85
BRN-J4
BK/RD
86
85
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87
87a
BRN-J4
BK/RD
87
87a
86
85
87
87a
86
85
87a
GND BRN
86
1 3 4 7 10 9 2
87
87a
BRN-J4
RD-CB
BRN-VOLT
BL-ISM2
C33STR BK
5
BRN-J5
BRN-ISM5
WH-R14
6
BRN-VOLT
BRN-ISM5
BL-E.H.
BL-ISM2
RD-J10
BL-E.H.
WH-BATT
BRN-ISM5
C5B
MALE DEUTSCH
CONNECTOR
6 - 15
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C5B-22 C34SA BK/WH
C5B-11 C21IGN2 WH
C5B-5 C33STR BK
C5B-3 C23PWR WH
C5B-2 GND BRN
C5B-1 P20BAT RD
12V DC
VOLTAGE REGULATOR
C5B-18 C35HRPM BK/RD
GR
YEL
RD
BK
BL
BL
8
C23PWR WH
ENGINE HARNESS (TO DRIVE CHASSIS)
GR/BK-BATT
ENGINE HARNESS (TO ENGINE)
WH-ISM10
ENGINE HARNESS (TO GROUND CONTROL BOX)
7
P20BAT RD
IGN./FUEL ON
(NOT USED)
8
24V BATTERY +
GROUND
5
KEYSWITCH PWR.
(NOT USED)
4
6
START INPUT
9
GR/BK-BATT
BK-ISM1
BL-ISM2
P20BAT RD
BK-ISM1
3
START RELAY
BK-ISM-1
WH-BATT
WH-R14
BRN-J5
BRN-ISM5
WH-BATT
BL-ISM2
4
C33STR BK
WH-R14
1
RD-J6
TACH. INPUT
C34SA BK/WH
WH-J6
C23PWR WH
CR15
GLOW PLUG
RELAY
CR14
RPM RELAY
CR13
RPM CUTOUT
RELAY
7
30
RD-J10
BK-START
BK-ISM-1
WH-R11
OR-GEN NEG
BRN-VOLT
WH-BATT
OR-GEN POS
3
WH-J4
WH-J6
RD-J6
30
2
CR12
ENGINE POWER
RELAY
WH-J4
CR11
START RELAY
30
RD-CB (12V+)
CR16
FIELD RELAY
30
BK/WH-34
30
BK/RD-35
30
ENGINE FAULT
87
85
BRN-J4
WH-J6
WH-J4
10
2
WH-J5
BRN-J4
WH-J4
BRN-J4
WH-ISM10
BRN-J4
RD-CB
WH-J5
C21IGN2 WH
C35HRPM BK/RD
IGNITION/START
MODULE
12/24V DC
C21IGN2 WH
C35HRPM BK/RD
12V, 15A
June 2005
Section 6 • Schematics
REV A
Engine Panel Diagram
(from serial number 22051 to 23235)
N
M
L
K
J
I
H
G
F
E
D
C
NOTE:
RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.
B
RD-CB
A
CIRCUT BREAKER
CB3
RD-CB (12V+)
BRN-J4
WH-J6
WH-J4
87
87a
86
85
BRN-J4
BRN-J4
BK/RD
86
85
87a
85
86
BRN-J4
BRN-J4
BRN-J4
87
87
87a
BRN-J4
BK/RD
87
87a
86
85
87
87a
86
85
87a
GND BRN
86
1 3 4 7 10 9 2
87
85
WH-J5
BRN-J4
WH-J4
BRN-J4
RD-CB
BRN-VOLT
KEYSWITCH PWR.
7
ENGINE FAULT
24V BATTERY +
6
10
GROUND
5
(NOT USED)
(NOT USED)
4
IGN./FUEL ON
START INPUT
3
9
TACH. INPUT
2
C33STR BK
3
4
GR/BK-BATT
BL-ISM2
P20BAT RD
BK-ISM1
BL-ISM2
BRN-J5
BRN-ISM5
BK-ISM1
START RELAY
BK-ISM-1
WH-BATT
WH-R14
C33STR BK
WH-BATT
BL-ISM2
RD-J6
1
C34SA BK/WH
WH-J6
C23PWR WH
CR15
GLOW PLUG
RELAY
CR14
RPM RELAY
CR13
RPM CUTOUT
RELAY
8
30
RD-CB (12V+)
WH-J4
WH-J6
RD-J6
30
RD-J10
BK-START
BK-ISM-1
WH-R11
30
BK/WH-34
CR12
ENGINE POWER
RELAY
WH-J4
CR11
START RELAY
OR-GEN NEG
BRN-VOLT
5
BRN-J5
BRN-ISM5
WH-R14
BRN-VOLT
BRN-ISM5
BL-E.H.
BL-ISM2
RD-J10
BL-E.H.
WH-BATT
BRN-ISM5
P20BAT RD
C23PWR WH
6
ENGINE HARNESS (TO DRIVE CHASSIS)
GR/BK-BATT
ENGINE HARNESS (TO ENGINE)
WH-ISM10
C5B-22 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C5B-5 C33STR BK
C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
12V DC
VOLTAGE REGULATOR
C5B-2 GND BRN
7
C5B-1 P20BAT RD
YEL
GR
RD
BL
BK
ENGINE HARNESS (TO GROUND CONTROL BOX)
BL
WH-BATT
OR-GEN POS
CR16
FIELD RELAY
30
BK/RD-35
30
WH-R14
30
2
WH-ISM10
BRN-J4
C21IGN2 WH
C35HRPM BK/RD
RD-CB
WH-J5
12V, 15A
IGNITION/START
MODULE
12/24V DC
C21IGN2 WH
C35HRPM BK/RD
1
8
C5B
MALE DEUTSCH
CONNECTOR
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 16
June 2005
Section 6 • Schematics
Engine Panel Diagram
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(before serial number 13361)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
LOAD SENSE OPTION
RED/WHT #29
ORG/RED
1
1 2 3 4
P2
LOAD SENSE PCB
WHT/RED #32
L4
BLK LSTOP
1 2 3 4 5 6 7 8 9 10 11 12
BRN
3A
86
WHT #30
BLK-26
30
RED L7
WHT/BLK #31
FS1
87a
87
RED-FS
BLK-FS
WHT-FS
TP26
LOAD SENSE OPTION (SEE DETAIL ABOVE)
CR17
CR17
85
RED L1
2
P2
BLK-2
BLK-FS
BLK#26
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
RED
ORG/RED-42
TB22
GROUND
LOW
RPM
HIGH
RPM
TS2
ENGINE
START
GLOW
PLUGS
FOOTSWITCH
HIGH RPM
TS4
RPM
TP3
TP34
TP33
TP35
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
RED/WHT-3
RED/WHT-1
WHT-2
WHT/RED-1
RED/BLK-1
TP29
TP42
TP28
BLK/RED-3
TP32
WHT/BLK-1
TP23
TILT
ALARM
A1
TS6
TB39
TP31
WHT-1
RED
TB32
TB29
TB31
TB30
TB20
TP9
BLU/RED-1
TP30
3
TP39
+
CONTROLLER
FAULT LED
L3
ORG/RED-42
KS1
P1
RED 20
CB1
RED
BLK/RED-9
10 A
PLATFORM
RED/WHT-3
P3
HORN
ORG #40
TB40
RED-8
TB3
4
RED/
WHTCR2
TB42
BLU/WHT #12
ORG/RED R2
+
-
+
-
2
BLU ISM2
WHT #21
15 A
RED (12GA)
86
30
87
85
(12V)
+12V
+
CR4
STARTER
+
-
AC POWER
10 A
AP1
VR1
ALT.
BLU
87
85
86
87
85
87
START INPUT
4
(NOT USED)
5
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
GRN/BLK
85
WHT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
BRN
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
RPM CUTOUT RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG RELAY CR15
GLOW PLUGS
12V ALTERNATOR
12V
VOLTAGE REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V POWER RELAY CR2
48V POWER RELAY CR1
FLASHING BEACON
(OPTION)
TILT SENSOR
Part No. 106488
HOUR METER
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
3
(GND)
HORN RELAY
CHASSIS
GROUND
TACH. INPUT
CR14
HORN
GROUND CONTROL
BOX GROUND
48V CHARGER
48V ALTERNATOR
PRIMARY LIFT
PUMP
AUXILIARY LIFT
PUMP
BLACK
2 GA.
START RELAY
2
10 ENGINE FAULT
CB2
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT AS NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.
6 - 17
85
BLU
30
CR15
BRN
GROUND
8
87
BLK
+
RIGHT
MOTOR
(12V)
BLK
-
A1
86
-
-
+
A1
30
86
1
BLK/RED
E1
*SWITCH
SHOWN
WITH BOOM
EXTENDED.
30
BLK/WHT
E2
CHARGER
These items
removed after
serial number
10667.
WHT
87
85
CR13
FB
WHT
86
CR12
YEL
-
+
E1
30
BLK
ALTERNATOR
E2
WHT
30
86
CR11
RED
PUMP
A2
WHT
WHT
WHT
PUMP
A2
BLK/RED
CB3
+
RED
-
WHT
+
+
7
LEFT
MOTOR
BLK-33
BRN
*
TB21
IGNITION / START
MODULE
TB35
BLK ISM1
WHT #23
ENABLE
3
LS1
(EXT.)
BLK-7
-
+
RIGHT
BOX
TB33
TB34
87
BLK
14
30
RED/WHT #23
B-
F1
CR1
85
RED/WHT #23
RED-7
B+
HM
BLK/RED #CR4
TB49
PR2
HIGH
87
1
BLK-6
5
20
17
M-
F2
PR3
TB9
LS2
(PRI.)
13
LOW
BLK/WHT
22
RED/BLK #28
BLK #22
RED-6
C1
0.1
mF
RPM
RED PISM6
85
21
30
TS54
TS52
TB28
86
SEPEX CONTROLLER
F1
200 A
86
TS56
ENGINE
START
BLK-8
BLK
RED/BLK-R5
GRN
3
6
16
2
11
AP1
14
10
1
9
500 A
+24 V
CR2
TB23
TB50
CURTIS 1244
24 V
F3
RED
LS4
(SEC.)
GLOW
PLUGS
22
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
85
21
ORG/RED
ORG/RED #42
ORG/RED
ORG/RED #42
FAULT LED
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
POT. LOW
REVERSE
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
AP2
6
86
-
+
F2
200 A
5
LEFT
BOX
BLU/RED #39
BLU/WHT #12
RED/WHT#29
WHT/RED#32
PR1
WHT/BLK#31
48V
AP2
WHT#30
F4
500 A
+48 V
ORG/RED #42
F5
10 A
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25
(before serial number 13361)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
RED/WHT #29
WHT/RED #32
WHT #30
1
WHT/BLK #31
WHT-24
WHT-24
ORG/RED-42
WHT-24
2
RED
TURNTABLE
ROTATE
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
JP1 (REMOVE FOR CE VERSION)
TS7
TS9
DP1
RED
TS10
TS12
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
RIGHT
LEFT
UP
AUXILIARY
PUMP
TP5
TP11
TP10
TP2
TP1
TP7
TP8
TP14
TP15
LIFT
RED
BRN
+
4
REV
5
RED/BLK-R6
C
R
L R
STEER
85
87
TP41
3
BRN
TP13
ORG/BLK-1
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
BLU/RED - 3
BLU/WHT - 3
RED
BLU/WHT #12
DRIVE
ENABLE
LED L1
TP12
TP36
TP16
TP37
TP6
CR6 86
DRIVE 30
ENABLE
TS15
L
ORG/BLK-R6
TP27
BCI
DRIVE
BLU-1
F
E
TP19
FWD
BLU/BLK-1
BLK/RED
A
B
3
RED - 1
GRN-3
GRN/BLK-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
TP18
TP17
20K
2
ORG/RED-16
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
1
TS1
BP1
TP4
BLU/WHT#12
ORG/RED-42
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
TS59
TS57
RIGHT
TB37
TB6
TB36
WHT/RED #6
RED/WHT #48
BLU #36
BLU/BLK #37
LS3*
14
85
21
*
WHT-40
+
A2
TB16
SWITCH SHOWN WITH
BOOM ROTATED PAST
EITHER NON-STEER WHEEL
BRN-7
CR10A 85
22
RED-7
87
6
13
CR3
87a
ORG #14
FUNCTION
MANIFOLD
GROUND
ORG/BLK #15
A3
RED #27
87
86
RED
87
+
30
86
GRN/WHT
CR10B
30
GRN/WHT
85
30
WHT/RED #6
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
GRN/BLK #18
TB14
TB15
86
(GND)
GRN #17
BLK #7
BLK/WHT # 8
RED #1
RED/BLK #2
BLU #10
BLU/BLK #11
WHT/BLK #5
WHT #4
ORG
BRN-2
TB17
TB13
BLK-7
TB18
TB7
TB8
TB48
GRN/WHT#19
TB19
WHT-7
TB1
TB2
87
ORG/RED - 3
TB10
TB11
CR5
PS1
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB5
5
TB41
30
J1
TB27
GRN/WHT #19
TB4
BRAKE
RELEASE
JACK
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
7
13
LS2
14
BRAKE/STEER
MANIFOLD
GROUND
(GND)
DRIVE ENABLE
LIMIT SWITCH
BRAKE RELEASE
TRAVEL ALARM
BRAKE RELEASE N.C.
BRAKE RELEASE N.O.
BRAKE RELEASE
PRESSURE SWITCH (PS1)
STEER RIGHT
Part No. 106488
STEER LEFT
AUXILIARY CONTROL
RELAY COIL (CR3)
PROPORTIONAL
VALVE
LIFT PUMP
RELAY COIL (PR2)
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
UP CUTOUT RELAY
(CR10A)
PLATFORM LEVEL
UP
PLATFORM LEVEL
DOWN
PLATFORM LEVEL
DOWN CUTOUT
RELAY (CR10B)
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
SECONDARY
BOOM DOWN
SECONDARY
BOOM UP
DESCENT ALARM
(OPTION)
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
AUXILIARY LIFT
PUMP RELAY COIL (PR3)
BRN
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 18
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(before serial number 13361)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 13361 to 14078)
A
B
C
D
E
F
G
H
I
K
L
M
2
3
RED/WHT-29
ORG/RED
1
4
P2
LOAD SENSE PCB
1
2
3
4
5
BRN
3A
6
7
8
L4
WHT-30
9 10 11 12
30
WHT/BLK-31
FS1
BLK-26
RED-FS
BLK-FS
87
WHT-FS
TP26
CR17
RED L7
86
WHT/RED-32
87a
BLK LSTOP
LOAD SENSE OPTION (SEE DETAIL)
CR17
85
P2
BLK-2
RED L1
BLK-FS
BLK-26
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
ORG/RED-42
RED
2
TB22
CB1
GROUND
+
TP23
A1
TILT
ALARM
TP28
L3
CONTROLLER
FAULT LED
TB3
15 A
CB3
30
2
87
+
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
GRN/BLK
BATT
BRN
+
+
-
+
BATTERY
CR16
BRN
+
6
7
86
WHT-BATT
ENGINE
GROUND
WHT
AP2
AUXILIARY
(GND)
(GND)
AP1
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR1
48V DC POWER
RELAY CR2
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
CHASSIS
GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 19
GROUND
86
87
HORN
87
(NOT USED)
5
(12V DC)
30
ORG GEN POS
4
85
BRN
ORG GEN NEG
CR16
86
86
BRN
+
AC POWER
ALT.
BLU
WHT
CR14
BRN
BLK
GROUND
STARTER
85
87
BLU
VR1
BLK
87
(12V DC)
85
CR15
BLK/RED
CR4
CHARGER
-
86
START INPUT
85
87
30
85
BRN
30
WHT-J4
BLK/WHT
E1
RIGHT
MOTOR
3
CR13
30
YEL
E2
30
87
86
RED
A1
TACH. INPUT
BLK/RED-35
CR12
BRN
A2
A1
BRN
-
A2
2
BLK
ALTERNATOR
E1
START RELAY
BLU-ISM2
BLK-33
30
85
FB
(12V DC)
1
WHT-23
WHT
-
+
PUMP
+
LEFT
MOTOR
E2
86
CR11
BRN
WHT
RED
BLK-7
WHT
-
85
+12V DC
14
LS1
(EXT.)
BLK-ISM1
WHT-21
B-
F1
PR2
+
PUMP
-
RED-J10 (12GA)
BLK
B+
-
+
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
2
WHT-21
RED/WHT-23
TB49
RED-7
M-
F2
HIGH
87
WHT-23
ENABLE
3
RED/WHT-23
5
20
17
BLK/RED-9
HM
TB33
TB34
85
13
PR3
LOW
30
1
BLK-6
+
87
CR1
BRN
TB9
LS2
(PRI.)
86
RED/BLK-28
BLK-22
-
85
TB28
RED-6
-
30
RED PISM6
86
TB23
TS54
RPM
TS52
ENGINE
START
CR2
TS56
GLOW
PLUGS
BLK-8
22
BLK
RED/BLK-R5
GRN
3
6
16
2
11
14
10
1
9
AP1
+24V DC
F1
200A
RED
LS4
(SEC.)
TB50
21
BLU/WHT-12
ORG/RED
22
CONTROLLER FAULT
INDICATOR LED L2
85
CR5
COIL-PR1
FAULT LED
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
500A
TB42
RED/
WHT-3
ORG/RED-42
ORG/RED
ORG/RED-42
86
21
MOTOR CONTROLLER
24V DC
F3
BLK/RED-1
RED-8
AP2
6
BLK-1
TB40
-
+
F2
200 A
5
LEFT
BOX
BLU/RED-39
BLU/WHT-12
RED/WHT-29
WHT/RED-32
WHT/BLK-31
WHT-30
PR1
ORG/RED-42
48V DC
AP2
+48V DC
FOOTSWITCH
HIGH RPM
TP35
TP33
BLK/WHT-1
ORG/RED-1
RED/WHT-3
WHT-2
TB29
TB32
TB31
TB30
ORG-40
ORG/RED-R2
F5
10A
TP34
HIGH LOW
RPM RPM
RED
4
F4
500 A
TS2
ENGINE
START
TS6
GLOW
PLUGS
TP42
TP3
RED/BLK-1
BLK/RED-3
RED/WHT-1
TB39
WHT/RED-1
BLU/RED-1
TP29
WHT/BLK-1
TP9
TP39
TP31
WHT-1
TB20
TP32
TP30
3
RED
RED/WHT-3
P1
RED-20
PLATFORM
BLK/RED-9
10 A
KS1
TS4
RPM
ORG/RED-42
P3
HORN
8
N
LOAD SENSE OPTION
1
7
J
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25
(from serial number 13361 to 14078)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
RED/WHT-29
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24
WHT-24
ORG/RED-42
WHT-24
2
RED
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
JP1 (REMOVE FOR CE VERSION)
TS7
TS9
DP1
RED
TS10
TS12
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
TP11
TP10
TP2
TP8
TP1
TP15
TP7
TP14
TP17
LIFT
RED
BRN
+
5
RED/BLK-R6
C
R
L R
STEER
DRIVE 30
ENABLE
TS15
L
85
87
ORG/BLK-R6
TP41
TP13
ORG/BLK-1
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
BLU/RED-3
BLU/WHT-3
RED
BLU/WHT-12
DRIVE
ENABLE
LED L1
TP12
TP36
3
TP16
TP37
TP6
CR6 86
BRN
BCI
DRIVE
BLU-1
TP19
REV
TP27
F
E
FWD
4
BLU/BLK-1
BLK/RED
B
3
RED - 1
GRN-3
GRN/BLK-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
TP18
A
ORG/RED-16
TS1
AUXILIARY
PUMP
TP5
20K
2
RED
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
1
BP1
TP4
BLU/WHT-12
TURNTABLE
ROTATE
ORG/RED-42
4
TB12
RED
TS55
FUNCTION
ENABLE
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
TS59
TS57
TS51
AUXILIARY
POWER
TB17
TB37
TB6
TB36
WHT/RED-6
LS3
14
6
22
21
RED-7
85
A2
TB16
BRN-7
+
3
DRIVE
ENABLE
LIMIT
SWITCH
7
13
LS2
14
BRAKE/STEER
MANIFOLD
GROUND
(GND)
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
AUXILIARY CONTROL
RELAY COIL CR3
LIFT PUMP
RELAY COIL PR2
FLOW CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
DOWN COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
Part No. 106488
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
3 SWITCH SHOWN WITH BOOM ROTATED
PAST EITHER NON-STEER WHEEL.
RED/WHT-48
BLU-36
BLU/BLK-37
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
13
CR3
CR10A 85
ORG #14
A3
ORG/BLK #15
+
RED-27
87a
86
RED
87a
30
86
GRN/WHT
CR10B
30
GRN/WHT
85
30
WHT/RED-6
PLATFORM LEVEL CUTOUT
(CE MODELS ONLY)
GRN/BLK-18
TB14
TB15
86
(GND)
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB18
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
GRN/WHT-19
TB19
WHT-7
TB10
TB11
CR5
87
ORG/RED-3
TB5
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB27
GRN/WHT-19
TB4
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
8
6 - 20
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 14079 to 14650)
A
B
1
C
D
E
F
G
H
I
J
K
L
3
RED/WHT-29
ORG/RED
2
4
P2
LOAD SENSE PCB
2
3
4
5
BRN
3A
6
7
8
9 10 11 12
L4
WHT-30
30
WHT/BLK-31
FS1
BLK-26
RED-FS
BLK-FS
87
WHT-FS
TP26
CR17
RED L7
86
WHT/RED-32
87a
BLK LSTOP
1
LOAD SENSE OPTION (SEE DETAIL)
CR17
85
P2
BLK-2
2
RED L1
BLK-FS
BLK-26
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
RED
ORG/RED-42
RED-20
TB22
CB1
GROUND
+
A1
TILT
ALARM
CB3
30
2
87
+
ALT.
BLU
86
CR15
+
-
+
-
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
86
87
GRN/BLK
BATT
+
-
WHT-BATT
ENGINE
GROUND
WHT
AP2
AUXILIARY
(GND)
(GND)
AP1
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR1
48V DC POWER
RELAY CR2
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 21
7
86
HORN
87
BATTERY
(12V DC)
30
ORG GEN POS
(NOT USED)
GROUND
6
85
BRN
+
86
CR14
BRN
+
87
BRN
ORG GEN NEG
CR16
87
BLU
VR1
85
85
BRN
+
AC POWER
85
BRN
BLK
GROUND
STARTER
85
30
BLK
87
(12V DC)
30
BLK/RED
CR4
CHARGER
-
86
30
WHT
4
5
CR13
WHT-J4
BRN
30
87
86
BLK/WHT
E1
RIGHT
MOTOR
85
YEL
E2
START INPUT
BLK/RED-35
CR12
RED
A1
CR11
BRN
A2
A1
BRN
-
A2
TACH. INPUT
3
BLK
ALTERNATOR
E1
START RELAY
2
BLK-33
30
FB
(12V DC)
1
BLU-ISM2
WHT-23
WHT
PUMP
+
LEFT
MOTOR
E2
86
BRN
WHT
RED
-
85
+12V DC
LS1
(EXT.)
BLK-7
WHT
-
+
+
PUMP
-
RED-J10 (12GA)
BLK-ISM1
WHT-21
14
RED PISM6
15 A
BLK
PR2
-
+
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
2
WHT-21
RED/WHT-23
B-
F1
HIGH
87
WHT-23
ENABLE
3
TB33
TB34
85
RED/WHT-23
PR3
B+
LOW
30
CR1
BRN
HM
BLK/RED-9
M-
BLK/RED-1
RED/BLK-28
86
13
F2
ENGINE
START
87
TS54
RPM
TS52
GLOW
PLUGS
85
ORG/RED
30
1
RED-7
F1
200A
TB9
LS2
(PRI.)
TB49
MOTOR CONTROLLER
86
TS56
TB28
BLK-6
AP1
CR2
TB23
BLK-22
22
5
20
17
500A
+24V DC
RED
RED-6
21
BLU/WHT-12
LS4
(SEC.)
TB50
BLK
RED/BLK-R5
GRN
3
6
16
2
F3
TB42
RED/
WHT-3
22
CONTROLLER FAULT
INDICATOR LED L2
85
21
AP2
24V DC
BLK-1
TB3
BLK-8
86
CR5
COIL-PR1
FAULT LED
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
11
14
10
1
9
6
FOOTSWITCH
HIGH RPM
TP35
TP33
BLK/WHT-1
RED-8
ORG/RED-42
ORG/RED
ORG/RED-42
BLU/RED-39
BLU/WHT-12
RED/WHT-29
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
LEFT
BOX
ORG/RED-1
ORG-40
F2
200 A
TP34
HIGH LOW
RPM RPM
RED
TB40
-
+
5
WHT/RED-32
+48V DC
WHT/BLK-31
PR1
WHT-30
48V DC
AP2
ORG/RED-42
F5
10A
TS2
ENGINE
START
TS6
GLOW
PLUGS
TP42
TP3
ORG/RED-R2
F4
500 A
L3
CONTROLLER
FAULT LED
RED/WHT-3
WHT-2
TB29
TP28
RED/BLK-1
TB32
TP23
BLK/RED-3
RED/WHT-1
TB31
TB39
WHT/RED-1
BLU/RED-1
TP29
WHT/BLK-1
TP9
TP39
TP31
TB30
TP32
WHT-1
TB20
4
TP30
3
RED
RED/WHT-3
KS1
P1
BLK/RED-9
10 A
PLATFORM
TS4
RPM
ORG/RED-42
P3
HORN
8
N
LOAD SENSE OPTION
1
7
M
Electrical Schematic, Z-45/25
REV A
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
DP1
BLU/WHT-12
RED
ORG/RED-16
RED
AUXILIARY
PUMP
TP12
TP16
BRN
TP13
ORG/BLK-1
BLU-1
BLU/BLK-1
RED - 1
GRN-3
GRN/BLK-3
PLATFORM
CONTROL BOX
GROUND
BLU/WHT-3
BLU/RED-3
4
GRN/
WHT-3
RED
CR5
RED
WHT/RED-3
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
BRN-2
BLK-7
WHT-7
ORG/RED-3
RED/WHT-48
BLU-36
RED-7
RED-27
BLU/BLK-37
GRN/WHT
WHT/RED-6
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
BRN-7
RED
GRN/WHT
WHT-40
ORG #14
ORG/BLK #15
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL PR3
LIFT PUMP
RELAY COIL PR2
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 22
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
3
WHT-4
BRAKE/STEER
MANIFOLD
GROUND
(GND)
TB16
A2
21
86
87
LEFT
A3
CR3
22
30
14
7
CR10A 85
CR10B
TB36
WHT/RED-6
8
BRN
+
+
TB37
TB19
TB18
85
87
87a
30
87a
86
RIGHT
RED
DRIVE
ENABLE
LIMIT
SWITCH
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
TB27
TB13
TB48
GRN/WHT-19
GRN/WHT-19
5
TB41
TS57
LS3
TB15
86
30
87a
85
LEFT
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
TS51
RED
13
TB14
ORG
13
LS2
14
FUNCTION
MANIFOLD
GROUND
(GND)
UP
DOWN
EXTEND
RETRACT
UP
DOWN
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
BLU/WHT-12
3
86
6
TB6
TB17
TB7
TB8
TB1
TB2
TP19
30
TS59
TS61
TS60
TS62
TP6
TP41
TP36
TP37
F
BLK/RED
BCI
E
TP27
+
TP18
TP17
2
DRIVE
ENABLE
LED L1
BRN
BRAKE
RELEASE
JACK
J1
PLATFORM
ROTATE
TS63
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
TB10
TB11
TB5
TB4
UP
DOWN
RIGHT
LEFT
RED
FUNCTION
ENABLE
AUX
ON
TS55
9
85
BP1
RED/BLK-R6
7
CR6
TS15
DRIVE 30
ENABLE
10
L R
STEER
6
LIFT
8
DRIVE
TS1
87
RED
ROTARY
OEM
FLOW
CONTROL
TP14
TP15
TP7
TP8
TS7
TS9
TS13
TS11
TS10
TP1
TP2
TP10
TP11
TP5
TP4
5
JP1 (REMOVE FOR CE VERSION)
4
ORG/BLK-R6
3
REV
TS12
2
20K
1
WHT-24
WHT-24
WHT-24
WHT-24
FWD
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
ORG/RED-42
WHT/BLK-31
WHT/BLK-31
1
RED/WHT-29
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 14079 to 14650)
ORG/RED-42
RED
TB12
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 14651 to 16839)
A
1
TP22
B
P2
FS1
BLK-(FS)
BLK-26
BLK-26 LOAD
LOAD
SENSOR
BOX
C
E
F
G
H
I
J
K
L
B+
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
GROUND
TILT
ALARM
A1
CB3
30
87
+
+
-
+
86
CR15
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
87
GRN/BLK
BATT
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 23
GROUND
6
86
AP1
8
(NOT USED)
5
86
HORN
87
4
85
CR14
BRN
+
87
BRN
-
85
BRN
-
30
BRN
BLU
86
85
BLK/RED
ALT.
85
BRN
30 CR16
ORG GEN POS
START INPUT
WHT
BRN
ORG GEN NEG
30
BLK/WHT
BLK
GROUND
+
AC POWER
87
BLU
VR1
BLK
-
(12V DC)
STARTER
85
TACH. INPUT
3
CR13
WHT-J4
30
YEL
CHARGER
87
86
RED
CR4
87
85
FB
86
2
BLK/RED-35
30
BRN
30
START RELAY
BLU-ISM2
BLK-33
CR12
WHT
E1
RIGHT
MOTOR
CR11
86
BRN
E2
BRN
-
A1
85
(12V DC)
1
WHT-23
BLK
ALTERNATOR
A2
A1
RED-J10 (12GA)
+12V DC
+
-
15 A
+
WHT
PUMP
A2
TB21
BLK-ISM1
WHT-21
2
RED
PUMP
+
E1
RED PISM6
WHT-21
BLK
LS1
(EXT.)
BLK-7
WHT
-
+
+
LEFT
MOTOR
E2
BLK/RED-1
2
ENABLE
3
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
WHT-23
RED/WHT-23
14
HIGH
87
BRN
HM
TB33
TB34
85
RED/WHT-23
PR2
LOW
30
CR1
1
TB49
B-
F1
TS54
RPM
ENGINE
START
87
13
-
+
7
RIGHT
BOX
BLK-1
85
TS52
GLOW
PLUGS
30
ORG/RED
86
RED/BLK-28
TB9
LS2
(PRI.)
BLK/RED-9
PR3
B+
BLK-22
M-
86
TS56
TB28
RED-7
SEPEX CONTROLLER
F2
CR2
TB23
BLK-6
5
20
17
6
2
3
16
F1
200A
RED
RED-6
22
BLK
RED/BLK-R5
GRN
FAULT LED
21
BLU/WHT-12
LS4
(SEC.)
TB50
CURTIS 1244
24V DC
500 A AP1
+24V DC
TB42
RED/
WHT-3
22
CONTROLLER FAULT
INDICATOR LED L2
85
21
AP2
F3
TP35
TB3
BLK-8
86
CR5
COIL-PR1
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
14
11
10
9
1
6
FOOT SWITCH
HIGH RPM
TS4
RPM
TP33
BLK/WHT-1
RED-8
ORG/RED-42
ORG/RED
BLU/RED-39
ORG/RED-42
RED/WHT-29
BLU/WHT-12
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
LEFT
BOX
ORG/RED-1
ORG-40
F2
200A
HIGH
RPM
TS2
ENGINE
START
TP34
LOW
RPM
RED
TB40
-
+
5
WHT/RED-32
+48V DC
WHT/BLK-31
PR1
WHT-30
48V DC
ORG/RED-42
AP2
TS6
GLOW
PLUGS
TP42
TP3
ORG/RED-R2
F5
10A
L3
CONTROLLER
FAULT LED
RED/WHT-3
WHT-2
TB29
TP28
RED/BLK-1
TB32
TP23
BLK/RED-3
RED/WHT-1
TB31
BLU/RED-1
WHT/RED-1
TB39
TP29
WHT/BLK-1
TP9
TP39
TP31
TB30
TP32
WHT-1
TB20
TP30
3
+
RED/WHT-3
TB22
CB1
10A
RED
BLK/RED-9
KS1
P1
RED-20
PLATFORM
ORG/RED-42
P3
HORN
F4
500 A
N
TP24
LOAD SENSOR OPTION
4
M
WHT/RED-32
ORG-LOAD
2
D
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
Electrical Schematic, Z-45/25
REV A
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
DP1
BLU/WHT-12
RED
ORG/RED-16
RED
AUXILIARY
PUMP
TP12
TP16
BRN
TP13
ORG/BLK-1
BLU-1
BLU/BLK-1
RED - 1
GRN-3
GRN/BLK-3
PLATFORM
CONTROL BOX
GROUND
BLU/WHT-3
BLU/RED-3
4
GRN/
WHT-3
RED
CR5
RED
WHT/RED-3
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
BRN-2
BLK-7
WHT-7
ORG/RED-3
RED/WHT-48
BLU-36
RED-7
RED-27
BLU/BLK-37
GRN/WHT
WHT/RED-6
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
BRN-7
RED
GRN/WHT
WHT-40
ORG #14
ORG/BLK #15
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL PR3
LIFT PUMP
RELAY COIL PR2
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 24
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
3
WHT-4
BRAKE/STEER
MANIFOLD
GROUND
(GND)
TB16
A2
21
86
87
LEFT
A3
CR3
22
30
14
7
CR10A 85
CR10B
TB36
WHT/RED-6
8
BRN
+
+
TB37
TB19
TB18
85
87
87a
30
87a
86
RIGHT
RED
DRIVE
ENABLE
LIMIT
SWITCH
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
TB27
TB13
TB48
GRN/WHT-19
GRN/WHT-19
5
TB41
TS57
LS3
TB15
86
30
87a
85
LEFT
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
TS51
RED
13
TB14
ORG
13
LS2
14
FUNCTION
MANIFOLD
GROUND
(GND)
UP
DOWN
EXTEND
RETRACT
UP
DOWN
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
BLU/WHT-12
3
86
6
TB6
TB17
TB7
TB8
TB1
TB2
TP19
30
TS59
TS61
TS60
TS62
TP6
TP41
TP36
TP37
F
BLK/RED
BCI
E
TP27
+
TP18
TP17
2
DRIVE
ENABLE
LED L1
BRN
BRAKE
RELEASE
JACK
J1
PLATFORM
ROTATE
TS63
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
TB10
TB11
TB5
TB4
UP
DOWN
RIGHT
LEFT
RED
FUNCTION
ENABLE
AUX
ON
TS55
9
85
BP1
RED/BLK-R6
7
CR6
TS15
DRIVE 30
ENABLE
10
L R
STEER
6
LIFT
8
DRIVE
TS1
87
RED
ROTARY
OEM
FLOW
CONTROL
TP14
TP15
TP7
TP8
TS7
TS9
TS13
TS11
TS10
TP1
TP2
TP10
TP11
TP5
TP4
5
JP1 (REMOVE FOR CE VERSION)
4
ORG/BLK-R6
3
REV
TS12
2
20K
1
WHT-24
WHT-24
WHT-24
WHT-24
FWD
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
ORG/RED-42
WHT/BLK-31
WHT/BLK-31
1
RED/WHT-29
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 14651 to 16839)
ORG/RED-42
RED
TB12
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 16840 to 17974)
A
1
TP22
B
P2
FS1
BLK-(FS)
BLK-26
BLK-26 LOAD
LOAD
SENSOR
BOX
C
E
F
G
H
I
J
K
L
M
N
B+
WHT/RED-32
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
TP24
ORG-LOAD
2
D
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
LOAD SENSOR OPTION
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
TB22
GROUND
TS6
GLOW
PLUGS
HIGH
RPM
TS2
ENGINE
START
TP34
FOOT SWITCH
HIGH RPM
TS4
RPM
TP35
TP33
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
TB29
TP42
TP3
RED/WHT-3
TB32
TP28
WHT-2
RED/WHT-1
TB31
TP23
TILT
ALARM
A1
RED/BLK-1
WHT/RED-1
TP9
BLK/RED-3
TP29
WHT/BLK-1
TB30
TP31
WHT-1
TP32
TP30
3
+
RED/WHT-3
BLK/RED-9
KS1
P1
RED-20
CB1
10A
RED
ORG/RED-42
P3
HORN
PLATFORM
LOW
RPM
RED
4
ORG-40
TB40
RED-8
TB3
+
-
+
15 A
CB3
30
LS1
(EXT.)
2
87
+
+
-
+
86
ALT.
BLU
86
CR15
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
87
GRN/BLK
BATT
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 25
GROUND
6
86
AP1
8
(NOT USED)
5
86
HORN
87
4
85
CR14
BRN
+
87
BRN
-
85
BRN
-
30
BRN
30 CR16
ORG GEN POS
START INPUT
WHT
BRN
ORG GEN NEG
87
BLU
VR1
85
85
BLK/RED
+
AC POWER
30
BLK
BLK
GROUND
STARTER
85
87
(12V DC)
30
BRN
CR4
CHARGER
-
86
TACH. INPUT
3
CR13
WHT-J4
BLK/WHT
30
87
86
FB
YEL
E1
RIGHT
MOTOR
85
RED
E2
BRN
-
A1
2
BLK/RED-35
CR12
BLK
ALTERNATOR
A2
A1
START RELAY
BLU-ISM2
BLK-33
30
BRN
PUMP
A2
1
WHT-23
WHT
PUMP
+
E1
CR11
86
BRN
WHT
RED
BLK-7
WHT
-
+
+
LEFT
MOTOR
85
(12V DC)
BLK-ISM1
WHT-21
14
E2
RED-J10 (12GA)
BLK
PR2
-
+
7
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
BRN
2
WHT-21
RED/WHT-23
B-
HIGH
87
WHT-23
ENABLE
3
TB33
TB34
13
F1
LOW
30
CR1
85
RED/WHT-23
-
87
TS54
RPM
RED PISM6
86
RED/BLK-28
PR3
B+
HM
BLK/RED-9
M-
F2
BLK-22
RED-7
F1
200A
SEPEX CONTROLLER
85
1
BLK-6
5
20
17
500 A AP1
+24V DC
TB9
LS2
(PRI.)
TB49
CURTIS 1244
24V DC
30
TS52
TB28
RED-6
22
86
TS56
ENGINE
START
BLK-8
21
AP2
F3
CR2
TB23
TB50
BLK
RED/BLK-R5
GRN
2
3
16
14
11
10
9
1
6
RED
LS4
(SEC.)
GLOW
PLUGS
22
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
85
21
BLU/WHT-12
ORG/RED
ORG/RED-42
ORG/RED
ORG/RED-42
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
F2
200A
-
+
LEFT
BOX
86
-
+
5
RED/WHT-29
+48V DC
BLU/WHT-12
PR1
WHT/RED-32
48V DC
WHT/BLK-31
AP2
WHT-30
F5
10A
ORG/RED-42
F4
500 A
TB42
RED/
WHT-3
ORG/RED-R2
+12V DC
TB20
Electrical Schematic, Z-45/25
REV A
RED/WHT-29
WHT/RED-32
WHT-30
WHT-30
DP1
BLU/WHT-12
RED
ORG/RED-16
RED
RIGHT
AUXILIARY
PUMP
TP12
TP16
BRN
TP13
ORG/BLK-1
BLU-1
BLU/BLK-1
RED - 1
GRN-3
GRN/BLK-3
PLATFORM
CONTROL BOX
GROUND
BLU/WHT-3
BLU/RED-3
4
GRN/
WHT-3
RED
RED
WHT/RED-3
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
BRN-2
BLK-7
WHT-7
ORG/RED-3
RED/WHT-48
BLU-36
RED-7
RED-27
BLU/BLK-37
GRN/WHT
WHT/RED-6
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
BRN-7
RED
GRN/WHT
WHT-40
ORG #14
ORG/BLK #15
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL PR3
LIFT PUMP
RELAY COIL PR2
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 26
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
CR5
RIGHT
WHT-4
BRAKE/STEER
MANIFOLD
GROUND
(GND)
TB16
A2
3
86
87
LEFT
A3
7
87a
CR10A 85
87a
CR10B
21
30
14
22
6
TB36
WHT/RED-6
8
BRN
+
+
CR3
86
TB37
TB19
TB18
85
87
87a
30
86
30
85
LEFT
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
RED
DRIVE
ENABLE
LIMIT
SWITCH
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
TB27
TB13
TB48
GRN/WHT-19
GRN/WHT-19
5
TB41
TS57
LS3
TB15
13
LS2
14
FUNCTION
MANIFOLD
GROUND
(GND)
UP
DOWN
EXTEND
RETRACT
UP
DOWN
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
BLU/WHT-12
13
TB14
ORG
TB6
TB17
TB7
TB8
TB1
TB2
TP19
30
TS59
TS61
TS60
TS62
TP6
TP41
TP36
TP37
F
BRAKE
RELEASE
JACK
J1
PLATFORM
ROTATE
TS63
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
TB10
TB11
TB5
TB4
UP
DOWN
RIGHT
LEFT
RED
FUNCTION
ENABLE
AUX
ON
TS55
TS51
RED
BCI
E
TP27
+
BLK/RED
3
86
CR6
9
DRIVE
ENABLE
LED L1
BRN
TP18
TP17
TP14
TP15
TP7
TP8
TP1
TP2
TP10
TP11
TP5
TP4
RED/BLK-R6
7
85
87
RED
ROTARY
OEM
FLOW
CONTROL
5
JP1 (REMOVE FOR CE VERSION)
4
ORG/BLK-R6
3
REV
TS15
DRIVE 30
ENABLE
10
L R
STEER
BP1
DRIVE
6
LIFT
8
TS1
2
20K
1
WHT-24
WHT-24
WHT-24
WHT-24
FWD
TS7
TS9
TS13
TS11
TS10
TS12
2
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
ORG/RED-42
WHT/BLK-31
WHT/BLK-31
1
RED/WHT-29
WHT/RED-32
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 16840 to 17974)
ORG/RED-42
RED
TB12
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 17975 to 21180)
A
1
TP22
P2
B
FS1
BLK-(FS)
BLK-26
D
E
F
BLK-26 LOAD
LOAD
SENSOR
BOX
C
H
I
J
K
L
M
N
B+
WHT/RED-32
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
ORG-LOAD
TP24
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
LOAD SENSOR OPTION
2
G
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
TB22
GROUND
TS6
GLOW
PLUGS
HIGH
RPM
TS2
ENGINE
START
TP34
FOOT SWITCH
HIGH RPM
TS4
RPM
TP35
TP33
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
RED/WHT-1
TP42
TP3
RED/WHT-3
TP29
WHT/RED-1
TP28
WHT-2
TP32
WHT/BLK-1
TP23
TILT
ALARM
A1
RED/BLK-1
TP31
WHT-1
TP9
BLK/RED-3
TP30
3
+
RED/WHT-3
PLATFORM
BLK/RED-9
KS1
P1
RED-20
CB1
10A
RED
ORG/RED-42
P3
HORN
LOW
RPM
RED
TB29
ORG-40
TB40
RED-8
TB3
RED/
WHT-3
ORG/RED-R2
+
-
+
ENABLE
+
WHT-21
15 A
CB3
30
2
87
+
+
-
+
+
-
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
GRN/BLK
BATT
BRN
86
BRN
-
KEY SWITCH POWER
8
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR1
48V DC POWER
RELAY CR2
FLASHING
BEACON
OPTION
Part No. 106488
TILT SENSOR
HOUR METER
HORN RELAY
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BASE CONTROL
BOX GROUND
BRAKE RELEASE
RELAY CR5
BLK
2 GA
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 27
BATTERY
CR16
AP1
8
6
7
86
HORN
87
GROUND
86
87
BRN
ORG GEN POS
(NOT USED)
5
85
CR14
BRN
30 CR16
WHT
BRN
ORG GEN NEG
ALT.
BLU
85
CR15
BLK/RED
BLK
GROUND
+
AC POWER
87
BLU
VR1
85
86
87
30
30
BLK
-
(12V DC)
STARTER
85
87
WHT-J4
BRN
CR4
CHARGER
87
86
FB
86
START INPUT
4
CR13
BLK/WHT
30
RIGHT
MOTOR
TACH. INPUT
3
85
CR12
YEL
F1
F2
86
RED
A1
2
BLK/RED-35
30
BRN
A2
A1
BRN
-
A2
START RELAY
BLU-ISM2
BLK-33
30
85
BLK
ALTERNATOR
F1
1
WHT-23
WHT
PUMP
LEFT
MOTOR
F2
CR11
BRN
WHT
RED
PUMP
+
85
(12V DC)
BLK-ISM1
WHT-21
LS1
(EXT.)
BLK-7
-
WHT
+
+
RED-J10 (12GA)
BLK
14
-
+
7
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
BRN
-
TB33
TB34
RED/WHT-23
TB49
B-
F1
HIGH
87
13
PR2
LOW
30
CR1
85
RED/WHT-23
-
87
TS54
RPM
RED PISM6
86
RED/BLK-28
HM
BLK/RED-9
B+
BLK-22
M-
F2
85
WHT-23
RED-7
SEPEX CONTROLLER
PR3
TB9
LS2
(PRI.)
BLK-6
F1
200A
30
TS52
TB28
RED-6
5
20
17
2
3
16
14
11
10
9
1
500 A AP1
+24V DC
86
TS56
ENGINE
START
BLK-8
22
BLK
GRN
RED/BLK-R5
21
CURTIS 1244
24V DC
F3
CR2
TB23
TB50
AP2
6
RED
LS4
(SEC.)
GLOW
PLUGS
22
CONTROLLER FAULT
INDICATOR LED L2
85
CR5
COIL-PR1
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
POT. LOW
REVERSE
FORWARD
+48V INPUT
-
+
DIODE RETURN
RED 20
F2
200A
21
BLU/WHT-12
ORG/RED
ORG/RED-42
ORG/RED
ORG/RED-42
RED/WHT-29
86
-
+
5
LEFT
BOX
BLU/WHT-12
PR1
WHT/RED-32
48V DC
WHT/BLK-31
AP2
+48V DC
WHT-30
F5
10A
ORG/RED-42
F4
500 A
TB42
+12V DC
TB32
TB31
TB30
TB20
4
Electrical Schematic, Z-45/25
REV A
RED/WHT-29
WHT/RED-32
WHT-30
WHT-30
1
BLU/WHT-12
RED
ORG/RED-16
RED
AUXILIARY
PUMP
TP12
TP16
BRN
TP13
ORG/BLK-1
BLU-1
BLU/BLK-1
RED - 1
GRN-3
GRN/BLK-3
PLATFORM
CONTROL BOX
GROUND
BLU/WHT-3
BLU/RED-3
4
GRN/
WHT-3
5
RED
RED
WHT/RED-3
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
BRN-2
BLK-7
WHT-7
6
ORG/RED-3
3
RED/WHT-48
BLU-36
RED-7
RED-27
BLU/BLK-37
GRN/WHT
WHT/RED-6
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
BRN-7
RED
GRN/WHT
WHT-40
ORG #14
ORG/BLK #15
BRAKE/STEER
MANIFOLD
GROUND
(GND)
TB16
A2
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL PR3
LIFT PUMP
RELAY COIL PR2
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 28
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
14
86
8
BRN
85
21
DRIVE
ENABLE
LIMIT
SWITCH
22
30
87
RIGHT
TB36
WHT/RED-6
TB13
TB48
GRN/WHT-19
GRN/WHT-19
CR5
LEFT
A3
CR10A 85
CR10B
RIGHT
RED
7
+
+
CR3
86
TB27
LS3
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
87
87a
30
87a
86
30
87a
85
LEFT
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU/WHT-12
13
TB14
TB15
13
LS2
14
FUNCTION
MANIFOLD
GROUND
(GND)
UP
DOWN
EXTEND
RETRACT
UP
DOWN
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
TB7
TB8
TB1
TB2
TB10
TB11
ORG
TB6
TB17
TB37
TB5
TP6
TB41
TS57
TB19
TB18
TB4
UP
DOWN
RIGHT
TS51
RED
BCI
E
TP19
TP41
F
30
TS59
TS61
TS60
TS62
9
DRIVE
ENABLE
LED L1
BRN
BRAKE
RELEASE
JACK
J1
PLATFORM
ROTATE
TS63
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
2
3
BP1
TP36
TP37
TP27
+
BLK/RED
86
CR6
TS15
DRIVE 30
ENABLE
8
DRIVE
10
L R
STEER
RED/BLK-R6
7
LEFT
RED
FUNCTION
ENABLE
AUX
ON
TS55
LIFT
85
87
RED
ROTARY
OEM
FLOW
CONTROL
TP18
TP17
TP14
TP15
TP7
TP8
TP1
TP2
TP10
TP11
TP5
TP4
5
TS7
TS9
TS13
TS11
TS10
TS1
4
ORG/BLK-R6
REV
JP1 (REMOVE FOR CE VERSION)
3
TS12
6
2
20K
WHT-24
WHT-24
WHT-24
WHT-24
FWD
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
ORG/RED-42
WHT/BLK-31
WHT/BLK-31
1
RED/WHT-29
WHT/RED-32
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 17975 to 21180)
ORG/RED-42
RED
DP1
TB12
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25
(from serial number 21180 to 22050)
A
1
B
C
P2
C7P-1
FS1
P22BAT BK
RD-(FS)
C9P-3
WH-(FS)
P25BAT
C9P-2
P24BAT
BK-(FS)
C9P-1 BK
P26BAT
D
F
G
H
I
J
K
L
M
N
LOAD
SENSOR
MODULE
BK
C
C29JSH RD/WH
WH
C32JSL WH/RD
WH-LOAD
B+
GND
BRN
LOAD SENSOR OPTION
8
C30FWD WH
OR-LOAD
BK-26 LOAD
2
E
C31REV WH/BK
LOAD
C40LS OR
CELL
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
P22BAT
BK
P26BAT
C9P-3
P25BAT RD
WH-(FS)
C9P-2
P24BAT WH
P24BAT WH
RD
C7B-1
+
TS6
GLOW
PLUGS
TS2
ENGINE
START
LOW
RPM
HIGH
RPM
FOOT SWITCH
HIGH RPM
C1P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C7B-2
C1B-2
C3B-3
C2B-4
C1B-8
C1B-7
C1B-9
C6B-29
P23SWBAT WH
C6B-32
C7P-2
C1B-3
C6B-31
C3B-9
C1B-6
C9HRN BK/RD
C29JSH RD/WH
C1B-5
TS4
RPM
C3P-9
C32JSL WH/RD
C2B-2
C1P-3
C31REV WH/BK
C40LS OR
C1P-6
C6B-30
TILT
ALARM
A1
GROUND
4
R42BAT OR/RD
RD
P3
HORN
TB22
C7B-4
OR
RD-(FS)
RD
PLATFORM
C2P-2
C1P-5
C1B-4
P20BAT RD
C30FWD WH
3
C1P-4
CB1
10 A
KS1
P1
P20BAT RD
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BK-(FS)
C9P-1 BK
C7P-1
P20BAT RD
CR5
OR
TB40
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
+
+
-
+
-
START RELAY
2
TACH. INPUT
3
START INPUT
4
(NOT USED)
5
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
85
CR16
86
86
87
GR/BK
BATT
BRN
BRN
BRN
+12V DC
86
CR14
BRN
-
+
85
87
85
CR15
BK/RD
BK
STARTER
86
WH
IGNITION / START
MODULE
1
CR13
BRN
ALT.
BL
85
BK/WH
YEL
87
BL
VR1
(12V DC)
30
30
30
RD
+
WH-J4
BRN
WH
BRN
-
WH
-
87
86
(12V DC)
WH-BATT
WH
AP2
AUXILIARY
(12V DC)
C5B-2
BRN
87
ENGINE
GROUND
(GND)
BK
BK
8
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY
CR16
RPM CUTOUT
RELAY CR13
RPM RELAY
CR14
RPM
SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC
ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
6 - 29
C5B-1 P20BAT RD
CR12
+
2
C34SA BK/WH
86
30
85
C8-B
+
C5B-22
87
CR11
BK
C8-C
14
85
BK
LS1
(EXT)
C5B-18
C35HRPM
C5B-3 C23PWR WH
30
13
OR-GEN POS
AP1
ENGINE
START
BRN
BRN
RD/WH
RD/BK
RD
30 CR16
C6B-28
C8-A
OR-GEN NEG
GROUND
22
C5B-5 C33STR BK
RD-J10 (12GA)
FB
BRN
BK
AC POWER
WH-6
-
C11-2
CHARGER
C6B-9 BK/RD
LS2 21
(PRI)
BK-6
RIGHT
MOTOR
WH-7
A1
C11-1
A2
A1
BK-7
A2
BK 2 GA
-
F1
C11-4
ALTERNATOR
F2
F1
F2
C11-3
-
WH
+
PUMP
+
LEFT
MOTOR
BL-ISM2
85
87
PR2
+
PUMP
BK
TB35
87
15 A
86
HIGH
BK-ISM1
C5B-11 C21IGN2 WH
RD
B-
F1
85
LOW
TB33
TB34
30
CR1
+
CR4
RD-5
B+
RD/BK
WH-5
C6B-34
C10-2
BK-5
M-
F2
PR3
86
TS54
RPM
CB3
CURTIS 1244
SEPEX CONTROLLER
87
_
BK-5
F1
200A
WH
BK/RD
BK
C10-1
WH-4
BK-4
HM
LS4
(SEC)
22
-
+
RIGHT
BOX
AP1
85
TS52
C23PWR WH
21
5
20
17
3
2
16
14
11
10
9
1
500 A
+24 V
30
TB23
30
24 V DC
86
TS56
GLOW
PLUGS
CR2
OR/RD
C6B-20 RD
BK
C10-4
C6B-25 CFIL BK
GR
C6B-39 CR5 RD/BK
C10-3
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
INTERLOCK
POT. HI
REVERSE
POT. LOW
FORWARD
+48V INPUT
OFF-LIMIT SPEED INPUT
BL/WH
85
C6B-40 OR
OR/RD
OR/RD
OR/RD
86
AP2
F3
7
DIODE RETURN
RD 20
-
+
6
RD
TB42
-
+
F2
200 A
LEFT
BOX
C6B-24
C6B-12
RD/WH
WH/RD
PR1
+48V DC
5
WH/BK
48V DC
AP2
WH
F4
500 A
OR/RD
F5
10A
Electrical Schematic, Z-45/25
REV A
C40LS OR
C40LS OR
P24BAT WH
P24BAT WH
RD-AUX
C3P-12
C4P-1
C16DRE OR/RD
C12DRE BL/WH
C13DREL BL/RD
R41DRE OR/BK
C2P-3
C4B-1
C3B-12
BRN
C4B-4
C2B-3
C1B-10
C1B-11
BL/WH
BL/RD
BRN
C6B-26 C12DRE
C6B-13 C13DREL
C7P-3 BATGND BRN
WH-8
BK-8
RD/WH
RD/WH
C6B-16 C16DRE
RD/WH
C6B-35
RD/WH
OR/RD
RD
PS1
C6B-36 BL
C6B-37 BL/BK
GR/WH
C6B-27
RD
C6B-6 WH/RD
C6B-18 GR/BK
C6B-17 GR
C6B-14 OR
C6B-15 OR/BK
C6B-7 BK
C6B-8 BK/WH
C6B-1 RD
C6B-2 RD/BK
C6B-10 BL
C6B-11 BL/BK
BRN-8
7
RD-8
C7B-3 BATGND BRN
C25-2
C24-2
C26-2
C27-2
C6B-21 DREGND BRN
C27-1
C26-1
C24-1
C25-1
C6B-19
GR/WH
C23-1
C22-1
C20-1
C21-1
C16-1
C17-1
C12-1
C13-1
C18-1
C19-1
C15-1
C14-1
C23-2
C22-2
C20-2
C21-2
C16-2
C18-2
C12-2
C13-2
C18-2
C19-2
C15-2
C14-2
(GND)
21
14
C6B-5 WH/BK
+
3
DRIVE
ENABLE
LIMIT
SWITCH
33
C36STCC BL
C1P-10
C37STC BL/BK
C1P-11
RD
OR/RD
TB37
BRAKE RELEASE
TRAVEL ALARM
(A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
PRIMARY LIFT PUMP
RELAY COIL PR2
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL PR3
FLOW CONTROL
COIL
LIFT PUMP
CONTACTOR RELAY
CR20
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 30
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C1B-1
RD
C4B-7 GR/WH
C3B-6 WH/RD
RIGHT
LEFT
C4B-6 GR/BK
C4B-5 GR
UP
DOWN
DOWN
UP
RETRACT
EXTEND
TB27
8
BK
BK
PR2
C27AUX RD
CR5
22
5
87
C4P-4
C1P-1
C19LPMP GR/WH
C6LFC WH/RD
C18PRR GR/BK
C17PRL GR
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
UP
DOWN
RIGHT
CR3
LS3
6
TB36
86
13
C6B-4 WH
PR2
C6B-38 GR/WH
GR/WH
GR/WH
RD
AUXILIARY
PUMP
C4P-7
C3P-6
C4P-5
C4P-6
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C3B-2
J1
LEFT
87
CR20
85
OR/RD
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C2PBD RD/BK
C3B-10
C3B-11
C3B-5
CR5
CR5
C12DRE BL/WH
4
C3B-4
TB19
30
PR3
86
OR
OR/RD
OR/BK
WH
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
C3P-2
C10SBU BL
C11SBD BL/BK
C3P-10
C3P-11
C4TRL WH
C4TRR WH/BK
PR3
F
A2
33
A3
DOWN
UP
DOWN
C3P-5
C3P-4
TS51
RD
TB12
OR/RD
P42BAT OR/RD
BCI
E
85
RIGHT
LEFT
+
85
87
87a
+
BK/RD
30
TB6
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
TS63
TB18
TB4
TS57
TS59
TS61
TS60
TS62
BRN
86
CR6
9
85
RD
BP1
BCI OPTION
3
10
L R
STEER
8
DRIVE
85 BRN
87
L.V.I.
87
ROTARY
OEM
FLOW
CONTROL
DRIVE
ENABLE
LED L1
RD/BK-R6
TS15
DRIVE 30
ENABLE
7
SET TO "N"
SET TO "B"
6
LIFT
DISCHARGE
RESET
CR19A
BRAKE
RELEASE
JACK
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
C6B-23 P20BAT RD
P20BAT RD
CR19B
86
86
85
CR19A
30
CR19B
87
5
OR/BK-R6
TS1
30
CR8
86
3
FWD
4
REV
1
2
3
2
BK
4
5
6
7
8
1
TS7
30
RD
FUNCTION
ENABLE
C31REV WH/BK
C31REV WH/BK
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
20K
3
5
4
C30FWD WH
LVI/BCI OPTION
C30FWD WH
2
DP1
BCI
PLATFORM
ROTATE
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
AUX
ON
TS55
C32JSL WH/RD
C32JSL WH/RD
1
C29JSH RD/WH
C29JSH RD/WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 21180 to 22050)
R42BAT OR/RD
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25, ANSI and CSA Models
(from serial number 22051 to 23235)
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
BK
2
C132 PLI BL/WH
C1B-12
TS2
ENGINE
START
LOW
RPM
HIGH
RPM
FOOTSWITCH
HIGH RPM
TS4
RPM
L48
C1P-8
C1P-7
C1P-9
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C2B-4
C1B-8
C1B-7
C1B-9
D40
C7B-2
GR/BK
TS6
GLOW
PLUGS
C2P-4
8
P24BAT WH
C3B-3
12
7
P24BAT WH
P23BAT WH
5
C9P-2
C3BAT RD/WH
C1B-2
6
WH-(FS)
C7P-2
C2B-5
5
C32
P25BAT RD
C3P-3
C28TTA RD/BK
C6B-29
C134PWR GR
C2B-2
C6B-32
C2P-5
C1B-3
C6B-31
C1P-2
C40LS OR
C1B-6
C6B-30
C3B-9
C29JSH RD/WH
C1B-5
C9HRN BK/RD
C3P-9
4
6
C7B-2
C32JSL WH/RD
C1B-4
OR
3
P23BAT WH
C2P-2
C1P-3
C1P-6
C31REV WH/BK
C7B-4
C30FWD WH
P20BAT RD
4
C1P-5
C1P-4
3
1
C7B-1
TB22
GROUND
C9P-3
7
A1
TILT
ALARM
+
P3
HORN
PLATFORM
KS1
P1
P20BAT RD
LS18
RD-(FS)
R42BAT OR/RD
RD
C1P-12
RD
CB1
10 A
BK-(FS)
C9P-1 BK
P26BAT
RD
P22BAT
TB134
FS1
P2
C7P-1
RD
OR
TB40
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
+
-
+
+
3
START INPUT
4
(NOT USED)
5
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
86
IGNITION ON
10
ENGINE FAULT
CR16
86
86
87
BRN
BRN
BRN
GR/BK
BATT
BK
-
WH-BATT
WH
AP2
AUXILIARY
(12V DC)
C5B-2
BRN
A2
9
85
CR14
BRN
86
85
87
85
CR15
BK/RD
ALT.
BL
WH
CR13
BRN
87
BL
VR1
85
BK/WH
YEL
(12V DC)
30
30
30
RD
+12V DC
WH-J4
BRN
-
87
86
WH
-
CR12
BRN
+
TACH. INPUT
BK
+
C5B-1 P20BAT RD
C34SA BK/WH
30
85
STARTER
OR-GEN POS
ENGINE
GROUND
(GND)
BK
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC
ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
Part No. 106488
ENGINE RUN SOLENOID
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
STARTER RELAY CR11
ANSI/CSA
48V DC POWER
RELAY CR2
ADD D40 ONLY IF UNIT HAS L4 AND L48.
7
48V DC POWER
RELAY CR1
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
FLASHING
BEACON
OPTION
6
TILT SENSOR
SWITCH SHOWN WITH BOOM EXTENDED.
NOTES:
HOUR METER
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
2
6 - 31
2
BK
AUXILIARY
LIFT PUMP
8
START RELAY
BL-ISM2
C5B-18
C35HRPM
C5B-22
CR11
BK
C8-C
WH
RD
+
87
86
87
AP1
ENGINE
START
GLOW
PLUGS
BRN
RD/WH
RD
RD/BK
30 CR16
14
85
C8-B
AC POWER
22
30
(12V DC)
2
1
C5B-3 C23PWR WH
+
13
LS1
(EXT)
RD-J10 (12GA)
FB
BRN
BK
OR-GEN NEG
GROUND
C5B-11 C21IGN2 WH
IGNITION / START
MODULE
BK-ISM1
C5B-5 C33STR BK
85
87
HIGH
TB35
87
BRN
C6B-34
86
C6B-9 BK/RD
-
-
WH-6
CHARGER
C11-2
LS2 21
(PRI)
BK-6
F1
RIGHT
MOTOR
C11-1
F2
BK-7
A1
WH-7
A2
A1
BK 2 GA
7
ALTERNATOR
A2
C11-4
PUMP
+
F1
C11-3
-
WH
+
PUMP
LEFT
MOTOR
F2
85
LOW
TB33
TB34
30
CR1
15 A
PR2
+
87
+
C8-A
B-
F2
RD-5
B+
HM
CR4
-
+
RIGHT
BOX
M-
F1
86
C6B-28
WH-5
BK-5
30
BK
85
CB3
MOTOR CONTROLLER
PR3
RD/BK
BK
C10-2
C10-1
WH-4
BK-4
+24V DC
F1
200A
30
TS54
RPM
TS52
C23PWR WH
_
BK-5
AP1
D2
21
LS4
(SEC)
22
5
20
17
6
86
TS56
TB23
U6A
24V DC
CR2
OR/RD
BK/RD
C6B-20 RD
BK
C10-4
C6B-25 CFIL BK
C6B-39 CR5 RD/BK
GR
3
16
2
11
14
10
1
9
AP2
C10-3
CONTROLLER FAULT
INDICATOR LED L2
85
CR5
COIL-PR1
POT. HI
INTERLOCK
OFF-LMT SPD INP
BL/WH
POT. LOW
FORWARD
REVERSE
+48V INPUT
-
+
DIODE RETURN
RD 20
F2
200A
C6B-40 OR
OR/RD
OR/RD
86
-
+
5
RD
TB42
OR/RD
C6B-24
C6B-12
RD/WH
WH/RD
PR1
+48V DC
LEFT
BOX
WH/BK
F4
500A
48V DC
WH
AP2
OR/RD
F5
10A
Electrical Schematic, Z-45/25, ANSI and CSA Models
REV A
C29JSH RD/WH
C32JSL WH/RD
P24BAT WH
P24BAT WH
C13DREL BL/RD
C4B-4
C3B-12
C4B-1
BL/WH
BL/RD
R41DRE OR/BK
C2P-3
C1B-10
C2B-3
C7P-3 BATGND BRN
C6B-13 C13DREL
C6B-26 C12DRE
C6B-16 C16DRE
C6B-35
RD/WH
PS1
OR/RD
RD
BK-8
RD/WH
RD/WH
WH-8
3
C6B-4 WH
C6B-5 WH/BK
C6B-11 BL/BK
C6B-10 BL
C6B-2 RD/BK
C6B-1 RD
C6B-8 BK/WH
C6B-7 BK
C6B-15 OR/BK
C6B-14 OR
C6B-17 GR
C6B-18 GR/BK
C6B-6 WH/RD
GR/WH
C6B-27
RD
C6B-37 BL/BK
C6B-36 BL
21
14
BRN
C4P-1
C12DRE BL/WH
C36STCC BL
C1P-10
C1B-11
OR/RD
C16DRE OR/RD
C37STC BL/BK
C1P-11
C1B-1
BRN
C27AUX RD
C4B-6 GR/BK
LEFT
RIGHT
C3B-6 WH/RD
C4B-7 GR/WH
RD
5
C4B-5 GR
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
33
BRN-8
RD-8
C7B-3 BATGND BRN
C6B-21 DREGND BRN
C26-2
C24-2
C25-2
C19-1
C18-1
C13-1
C12-1
C17-1
C16-1
C21-1
C20-1
C22-1
C23-1
C19-2
C18-2
C13-2
C12-2
C18-2
C16-2
C21-2
C20-2
C22-2
C23-2
C6B-19
GR/WH
C25-1
C24-1
C26-1
+
DRIVE
ENABLE
LIMIT
SWITCH
LS3
22
13
6
TB36
CR3
C4P-4
C1P-1
C19LPMP GR/WH
C6LFC WH/RD
C18PRR GR/BK
C17PRL GR
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
TB27
C3P-12
CR5
CR5
C12DRE BL/WH
C15-1
C14-1
C15-2
C14-2
TURNTABLE
ROTATE LEFT
COIL
TURNTABLE
ROTATE RIGHT
COIL
DESCENT
ALARM
OPTION (A3)
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
UP COIL
PLATFORM
ROTATE LEFT
PLATFORM
ROTATE RIGHT
FLOW CONTROL
COIL
LIFT PUMP
CONTACTOR RELAY
CR20
AUXILIARY LIFT
PUMP RELAY COIL
PR3
AUXILIARY CONTROL
RELAY COIL CR3
PRIMARY LIFT PUMP
RELAY COIL PR2
STEER RIGHT COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
BRAKE RELEASE N.C. COIL
BRAKE RELEASE
TRAVEL ALARM (A2)
8
BK
BK
PR2
RD
AUXILIARY
PUMP
C4P-7
C3P-6
C4P-5
C4P-6
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C3B-2
DOWN
RIGHT
LEFT
PR2
6 - 32
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
RD-AUX
OR/RD
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C2PBD RD/BK
C3B-10
C3B-11
C3B-5
C3B-4
CR5
RD
7
87
CR20
85
30
PR3
86
OR
OR/RD
OR/BK
WH
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
C3P-2
C10SBU BL
C4TRL WH
C4TRR WH/BK
C11SBD BL/BK
C3P-10
C3P-11
C3P-5
PR3
BCI OPTION
A2
33
A3
F
C6B-38 GR/WH
GR/WH
GR/WH
3
87
C3P-4
+
DOWN
UP
DOWN
TS51
RD
85
87
87a
86
30
TB6
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
+
9
85
RIGHT
LEFT
TB19
TB12
OR/RD
P42BAT OR/RD
BCI
E
TB37
TB18
TB4
TS57
TS59
TS63
TS61
TS60
TS62
87
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
SET TO "N"
85
RD
8
DRIVE
10
L R
STEER
BP1
BK/RD
86
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
7
SET TO "B"
85 BRN
87
BRN
ROTARY
OEM
FLOW
CONTROL
DRIVE
ENABLE
LED L1
LIFT
6
L.V.I.
86
85
CR19A
30
CR19B
87
3
FWD
OR/BK-R6
5
TS1
1
2
3
4
5
6
7
DISCHARGE
86
CR8
2
BK
4
8
CR19B
20K
3
5
4
REV
86
RESET
CR19A
30
2
DP1
BCI
PLATFORM
ROTATE
30
AUXILIARY
POWER
FUNCTION
ENABLE
TS55
C40LS OR
C40LS OR
4
RD
C31REV WH/BK
C31REV WH/BK
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
1
TS7
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
C30FWD WH
LVI/BCI OPTION
C30FWD WH
1
C29JSH RD/WH
C32JSL WH/RD
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 22051 to 23235)
R42BAT OR/RD
(GND)
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25, ANSI and CSA Models
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25, CE Models
(from serial number 22051 to 23235)
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
C7P-1
BK
2
C132PLI BL/WH
C1B-12
A1
TILT
ALARM
LOW
RPM
HIGH
RPM
FOOT SWITCH
HIGH RPM
C2P-4
C1P-8
C1P-7
C1P-9
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C3B-3
C2B-4
C1B-8
C1B-7
C1B-9
C7B-2
C3BAT RD/WH
P23BAT WH
C3P-3
C7P-2
C1B-2
C6B-29
C2B-5
C6B-32
C28TTA RD/BK
C1B-3
C6B-31
C134PWR GR
C1B-6
C6B-30
C2B-2
C1B-5
C7B-4
C1B-4
GR/BK
C2P-5
P20BAT RD
L45
D40
C1P-2
8
6
TS2
ENGINE
START
TS4
RPM
C3B-9
7
P24BAT WH
TS6
GLOW
PLUGS
C9HRN BK/RD
5
P24BAT WH
C3P-9
C40LS OR
C29JSH RD/WH
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
6
12
C9P-2
C7B-2
5
U33
WH-(FS)
P23BAT WH
3
P25BAT RD
C7P-2
C7B-1
C2P-2
C1P-3
C1P-6
C1P-5
C1P-4
1
4
A6
OR
+
D39
GROUND
C9P-3
R42BAT OR/RD
L4
5
P3
HORN
TB22
3
4
LS18
PLATFORM
KS1
P1
P20BAT RD
RD-(FS)
RD
C1P-12
RD
CB1
10A
BK-(FS)
C9P-1 BK
P26BAT
RD
P22BAT
TB134
FS1
P2
RD
OR
TB40
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
GR/BK
BATT
BRN
+12V DC
-
(NOT USED)
5
86
BRN
-
+
START INPUT
4
86
87
BRN
-
+
+
3
WH-BATT
WH
AP2
AUXILIARY
C5B-2
ENGINE
GROUND
(GND)
BK
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE REGULATOR
ENGINE POWER RELAY CR12
ENGINE RUN SOLENOID
Part No. 106488
STARTER RELAY CR11
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
48V DC POWER RELAY CR2
ADD D40 ONLY IF UNIT HAS L4 AND L48.
48V DC POWER RELAY CR1
6
FLASHING BEACON OPTION
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
CE & PLATFORM LOAD SENSE OPT.
TILT SENSOR
SWITCH SHOWN WITH BOOM EXTENDED.
5
HOUR METER
2
NOTES:
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
6 - 33
TACH. INPUT
(12V DC)
BRN
A2
OR-GEN POS
START RELAY
2
85
BK
AUXILIARY
LIFT PUMP
8
86
CR14
BRN
BK
STARTER
85
87
85
CR15
BK/RD
ALT.
BL
86
WH
IGNITION / START
MODULE
1
CR13
BRN
87
BL
VR1
85
BK/WH
YEL
(12V)
30
30
30
RD
-
WH-J4
BRN
+
87
86
(12V DC)
WH
+
CR12
BRN
+
86
30
85
BK
14
CR11
+
2
C34SA BK/WH
WH
RD
LS1
(EXT)
85
BK
C8-C
87
13
C5B-1 P20BAT RD
C5B-22
30
87
AP1
ENGINE
START
GLOW
PLUGS
BRN
RD/WH
RD
RD/BK
30 CR16
C5B-18
C35HRPM
C5B-3 C23PWR WH
15 A
C8-B
AC POWER
C5B-5 C33STR BK
FB
BRN
BK
OR-GEN NEG
GROUND
22
BL-ISM2
85
87
C6B-9 BK/RD
-
-
WH-6
CHARGER
C11-2
LS2 21
(PRI)
BK-6
RIGHT
MOTOR
C11-1
A1
BK-7
A1
F1
BK 2 GA
7
ALTERNATOR
F1
F2
WH-7
PUMP
F2
+
A2
BK-ISM1
C5B-11 C21IGN2 WH
C8-A
BK
C11-4
-
WH
+
PUMP
86
HIGH
TB35
CB3
C11-3
-
+
+
A2
LOW
87
RD-J10 (12GA)
PR2
LEFT
MOTOR
85
TS54
RPM
TB33
TB34
30
_
RD-5
B-
87
+
CR4
F2
85
TS52
C23PWR WH
HM
BK-5
B+
30
CR1
BRN
C6B-34
WH-5
BK-5
WH-4
BK-4
5
20
17
M-
F1
PR3
86
C6B-28
C10-2
C10-1
C10-4
C10-3
C6B-25 CFIL BK
C6B-39 CR5 RD/BK
GR
2
3
16
F1
200A
RD/BK
BK
D2
21
LS4
(SEC)
22
U6A
MOTOR CONTROLLER
86
OR/RD
BK/RD
C6B-20 RD
C6B-40 OR
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
POT. HI
INTERLOCK
OFF-LMT SPD INP
BL/WH
11
14
10
AP1
85
BK
CR2
TS56
TB23
30
24V DC
+24V DC
POT. LOW
FORWARD
1
9
6
REVERSE
+48V DC INPUT
DIODE RETURN
RD 20
-
+
AP2
RIGHT
BOX
OR/RD
-
+
LEFT
BOX
OR/RD
86
F2
200 A
5
RD
TB42
OR/RD
PR1
+48V DC
C6B-24
C6B-12
RD/WH
WH/RD
WH/BK
WH
F4
500 A
48V DC
AP2
OR/RD
F5
10 A
C29JSH RD/WH
C32JSL WH/RD
C40LS OR
C40LS OR
P24BAT WH
P24BAT WH
RD-AUX
OR/RD
RD
6
C6B-13 C13DREL
C7P-3 BATGND BRN
BL/RD
OR/RD
RD
BK-8
RD/WH
RD/WH
WH-8
3
C6B-4 WH
C6B-5 WH/BK
C6B-11 BL/BK
C6B-10 BL
C6B-2 RD/BK
C6B-1 RD
C6B-8 BK/WH
C6B-7 BK
C6B-15 OR/BK
C6B-14 OR
C6B-17 GR
C6B-18 GR/BK
C6B-6 WH/RD
GR/WH
C6B-27
RD
C6B-37 BL/BK
C6B-36 BL
21
14
BRN
C4B-1
C13DREL BL/RD
C6B-26 C12DRE
C4P-1
BL/WH
C12DRE BL/WH
C4B-4
PS1
C6B-35
RD/WH
C3B-12
C3P-12
C16DRE OR/RD
C2B-3
C6B-16 C16DRE
R41DRE OR/BK
C2P-3
C1B-10
OR/RD
C36STCC BL
C1P-10
C1B-11
RD
C4B-7 GR/WH
C3B-6 WH/RD
RIGHT
LEFT
C4B-6 GR/BK
33
BRN-8
RD-8
C7B-3 BATGND BRN
C15-1
C14-1
C25-2
C24-2
C26-2
C6B-21 DREGND BRN
C19-1
C18-1
C13-1
C12-1
C17-1
C16-1
C21-1
C20-1
C22-1
C23-1
C6B-19
GR/WH
C25-1
C24-1
C26-1
+
DRIVE
ENABLE
LIMIT
SWITCH
LS3
22
13
5
C4B-5 GR
UP
DOWN
UP
DOWN
UP
RETRACT
EXTEND
TB27
BRN
C4P-4
C37STC BL/BK
C1P-11
C19LPMP GR/WH
C6LFC WH/RD
C18PRR GR/BK
C17PRL GR
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
CR5
C23-2
C22-2
C20-2
C21-2
C16-2
C18-2
C12-2
C13-2
C18-2
C19-2
C15-2
C14-2
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE N.C. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
PRIMARY LIFT PUMP
RELAY COIL PR2
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL
PR3
LIFT PUMP
CONTACTOR RELAY
CR20
FLOW CONTROL
COIL
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 34
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C1B-1
C1P-1
C4P-7
C3P-6
C4P-5
C4P-6
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C3B-2
DOWN
RIGHT
LEFT
PR2
C6B-38 GR/WH
GR/WH
GR/WH
C27AUX RD
AUXILIARY
PUMP
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C2PBD RD/BK
C3B-10
C3B-11
C3B-5
C3B-4
TB19
TB36
CR3
4
BCI OPTION
9
A
B
8
BK
BK
PR2
30
RD
7
87
CR20
85
OR
OR/RD
OR/BK
WH
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
C3P-2
C10SBU BL
C11SBD BL/BK
C3P-10
C3P-11
C4TRL WH
C4TRR WH/BK
CR5
CR5
C12DRE BL/WH
3
C3P-5
PR3
F
87
C3P-4
TS51
RD
30
PR3
86
TB12
OR/RD
P42BAT OR/RD
BCI
E
A2
33
A3
DOWN
UP
DOWN
RIGHT
+
85
87
87a
86
30
TB6
+
BK/RD
TB37
TB18
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
TB4
TS57
TS59
TS63
TS61
TS60
TS62
87
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
85 BRN
85
RD
8
DRIVE
10
L R
STEER
BP1
SET TO "N"
87
BRN
86
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
7
CR19A
30
CR19B
87
ROTARY
OEM
FLOW
CONTROL
DRIVE
ENABLE
LED L1
LIFT
L.V.I.
86
85
SET TO "B"
6
85
OR/BK-R6
5
TS1
1
2
3
4
5
6
7
3
FWD
4
8
CR19B
DISCHARGE
86
CR8
2
BK
REV
86
RESET
CR19A
30
20K
3
5
4
1
C29JSH RD/WH
C32JSL WH/RD
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
LEFT
RD
C31REV WH/BK
C31REV WH/BK
2
DP1
BCI
PLATFORM
ROTATE
C30FWD WH
LVI/BCI OPTION
C30FWD WH
1
TS7
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
AUXILIARY
POWER
FUNCTION
ENABLE
TS55
Electrical Schematic, Z-45/25, CE Models
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 22051 to 23235)
R42BAT OR/RD
(GND)
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25, CE Models
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(before serial number 13361)
A
C
1 2 3 4
P2
LOAD SENSE PCB
BRN
3A
E
F
I
J
K
L
M
N
WHT #30
WHT/BLK #31
FS1
87
RED-FS
BLK-FS
WHT-FS
TP26
CR17
LOAD SENSE OPTION (SEE DETAIL BELOW)
CR17
P2
BLK-2
RED L1
2
H
L4
BLK-26
30
RED L7
85
G
WHT/RED #32
87a
BLK LSTOP
1 2 3 4 5 6 7 8 9 10 1112
86
D
RED/WHT #29
LOAD SENSE OPTION
ORG/RED
1
B
BLK#26
BLK-FS
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
RED
ORG/RED-42
PLATFORM
TB22
GROUND
TILT
ALARM
A1
LOW
RPM
HIGH
RPM
TS2
TS6
ENGINE
START
GLOW
PLUGS
FOOT SWITCH
HIGH RPM
TS4
RPM
RED
TP42
TP34
TP33
TP35
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
RED/WHT-3
RED/WHT-1
WHT-2
WHT/RED-1
TP3
TP28
RED/BLK-1
TP29
TP23
BLK/RED-3
TP32
WHT/BLK-1
BLU/RED-1
TP31
WHT-1
RED
TB32
TB29
TB31
TB30
TB20
TP9
TP39
TB39
TP30
3
+
CONTROLLER
FAULT LED
L3
ORG/RED-42
KS1
P1
RED 20
RED
BLK/RED-9
10 A
CB1
RED/WHT-3
P3
HORN
ORG #40
4
TB40
RED-8
TB3
RED/
WHTCR2
TB42
BLU/WHT #12
ORG/RED #CR2
86
86
(12V)
CR4
87
BLU
ALT.
VR1
-
+
-
-
+
+
+
CHARGER
30
STARTER
85
+
-
86
BLU
86
87
85
30
86
87
85
87
85
CR15
10 A
AP1
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
BRN
OIL PRESSURE SWITCH
WATER TEMPERATURE
SWITCH
RPM CUTOUT RELAY
CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG RELAY
CR15
GLOW PLUGS
12V ALTERNATOR
12V VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V POWER RELAY CR2
48V POWER RELAY CR1
FLASHING BEACON
(OPTION)
Part No. 106488
TILT SENSOR
HOUR METER
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
GROUND
6
(GND)
HORN RELAY
NOTES:
1. ALL LIMIT SWITCHES ARE SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT WHERE NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.
5
WHT
HORN
GROUND CONTROL
BOX GROUND
48V
CHARGER
48V
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
CHASSIS
GROUND
(NOT USED)
GRN/BLK
CB2
BLACK
2GA.
START INPUT
4
CR14
BRN
AC POWER
WHT
3
BLK/RED
*SWITCH
SHOWN
WITH BOOM
EXTENDED
30
BLK/WHT
A1
These items
removed after
serial number
10667.
TACH. INPUT
BRN
(12V)
+12V
30
CR13
WHT
87
85
FB
BLK
A1
E1
RIGHT
MOTOR
2
WHT
CR12
YEL
+
CR11
RED
E1
E2
START RELAY
BLU-ISM2
BLK/RED
30
86
WHT
E2
A2
BLK
GROUND
85
BLK
+
A2
1
BLK-33
WHT
BLK
ALTERNATOR
WHT
+
PUMP
LEFT
MOTOR
BLK-ISM 1
RED (12GA)
30
+
RED
-
TB21
15 A
IGNITION / START
MODULE
TB35
CB3
87
BLK-7
WHT
-
+
-
RED/WHT #23
RED/WHT #23
14
HIGH
87
WHT #21
LS1
(EXT.)*
TB33
TB34
85
WHT #23
ENABLE
HM
3
2
BLK/RED #CR4
RED-7
PR2
LOW
30
CR1
1
TB49
B-
F1
RPM
RED PISM6
TB9
LS2
(PRI.)
BLK-6
5
20
17
PR3
B+
ENGINE
START
87
TS54
BLK/WHT
RED/BLK #28
BLK #22
RED-6
BLK
RED/BLK-R5
GRN
3
6
16
2
11
M-
F2
-
6 - 35
85
GLOW
PLUGS
BLK-8
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
FAULT LED
INTERLOCK
OFF-LIMIT SPEED INPUT
POT. HI
C1
0.1
mF
22
30
TS52
TB28
86
21
86
TS56
13
PUMP
8
CR2
TB23
TB50
SEPEX CONTROLLER
F1
200 A
RED
LS4
(SEC.)
ORG/RED
ORG/RED #42
ORG/RED
ORG/RED #42
BLU/RED #39
BLU/WHT #12
RED/WHT#29
22
-
+
RIGHT
BOX
AP1
14
500 A
+24 V
85
21
CURTIS 1244
24 V
F3
REVERSE
10
1
9
AP2
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
6
7
WHT/RED#32
F2
200 A
LEFT
BOX
86
-
+
5
PR1
WHT/BLK#31
48V
AP2
WHT#30
F4
500 A
+48 V
ORG/RED #42
F5
10 A
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(before serial number 13361)
N
M
L
K
J
I
H
G
F
E
D
RED/WHT #29
C
B
A
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
WHT/RED #32
WHT #30
1
WHT/BLK #31
WHT-24
WHT-24
ORG/RED-42
WHT-24
2
RED
TURNTABLE
ROTATE
PRIMARY
BOOM
SECONDARY
BOOM
TS10
TS11
TS13
PLATFORM
LEVEL
PLATFORM
ROTATE
TS9
TS7
JIB BOOM
CR7A
JP1 (REMOVE FOR CE VERSION)
30
87
TS8
DOWN
UP
RIGHT
LEFT
UP
DOWN
TP11
TP10
TP2
TP8
TP1
TP15
TP7
TP14
30
TP17
+
5
85
87
TP36
TP41
3
TP13
BLU/WHT #12
BLU/RED - 3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT - 3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
TP6
CR6 86
DRIVE 30
ENABLE
TS15
L
ORG/BLK-R6
TP27
BCI
RED/BLK-R6
C
R
L R
STEER
TP16
F
E
TP19
REV
DRIVE
BRN
BLK/RED
FWD
4
ORG/BLK-1
85
CR7B
BRN
B
3
BLU-1
BRN
85
RED
A
BLU/BLK-1
86
LIFT
RED - 1
CR7A
86
GRN/BLK-3
RED
TP18
GRN-3
T1
JIB
MANIFOLD
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
87
AUXILIARY
PUMP
BP1
TP45
TP5
20K
2
ORG/RED-16
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
1
TS1
RED
TP4
DP1
RED
TS12
PRIMARY
BOOM
BLU/WHT#12
ORG/RED-42
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB41
CR5
J1
TB27
87
TB48
GRN/WHT#19
GRN/WHT #19
TB17
CR9
TB37
TB6
TB36
WHT/RED #6
RED/WHT #48
BLU #36
LS3*
14
22
21
*SWITCH SHOWN
WITH BOOM ROTATED
PAST EITHER
NON-STEER WHEEL.
RED-7
87
6
13
CR3
85
+
A2
TB16
BRN-7
RED
GRN/WHT
CR10A 85
BLU/BLK #37
RED #27
86
87a
ORG #14
FUNCTION
MANIFOLD
GROUND
87
ORG/BLK #15
A3
87
GRN/WHT
CR10B
30
30
86
WHT #40
85
+
30
WHT/RED #6
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
GRN/BLK #18
TB14
TB15
86
(GND)
GRN #17
BLK #7
BLK/WHT # 8
RED #1
RED/BLK #2
BLU #10
BLU/BLK #11
WHT/BLK #5
WHT #4
ORG
BRN-2
TB18
TB7
TB8
BLK-7
TB1
TB2
TB13
WHT-7
TB10
TB11
TB19
ORG/RED - 3
TB5
TB4
5
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
7
13
LS2
14
BRAKE/STEER
MANIFOLD
GROUND
(GND)
DRIVE ENABLE
LIMIT SWITCH
BRAKE RELEASE
TRAVEL ALARM
BRAKE RELEASE N.C.
BRAKE RELEASE N.O.
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER LEFT
Part No. 106488
STEER RIGHT
AUXILIARY CONTROL
RELAY COIL CR3
LIFT PUMP RELAY
COIL PR2
PROPORTIONAL
VALVE
PLATFORM
ROTATE RIGHT/
JIB BOOM DOWN
PLATFORM
ROTATE LEFT/
JIB BOOM UP
PLATFORM LEVEL
UP RELAY CR10A
PLATFORM LEVEL
UP
PLATFORM LEVEL
DOWN
PLATFORM LEVEL
DOWN CUTOUT
RELAY CR10B
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
SECONDARY BOOM
DOWN
SECONDARY BOOM
UP
DESCENT ALARM
(OPTION)
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 36
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(before serial number 13361)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 13361 to 14078)
A
B
1
C
D
E
F
G
H
I
J
K
L
3
RED/WHT-29
ORG/RED
2
4
P2
LOAD SENSE PCB
2
3
4
5
BRN
3A
6
7
8
9 10 11 12
L4
WHT-30
30
WHT/BLK-31
FS1
BLK-26
RED-FS
BLK-FS
87
WHT-FS
TP26
CR17
RED L7
86
WHT/RED-32
87a
BLK LSTOP
1
LOAD SENSE OPTION (SEE DETAIL)
CR17
85
P2
BLK-2
2
RED L1
BLK-FS
BLK-26
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
RED
ORG/RED-42
RED-20
TB22
CB1
GROUND
+
A1
TILT
ALARM
CB3
30
2
87
+
ALT.
BLU
86
CR15
+
-
+
-
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
86
87
GRN/BLK
BATT
+
-
WHT-BATT
ENGINE
GROUND
WHT
AP2
AUXILIARY
(GND)
(GND)
AP1
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR1
48V DC POWER
RELAY CR2
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 37
7
86
HORN
87
BATTERY
(12V DC)
30
ORG GEN POS
(NOT USED)
GROUND
6
85
BRN
+
86
CR14
BRN
+
87
BRN
ORG GEN NEG
CR16
87
BLU
VR1
85
85
BRN
+
AC POWER
85
BRN
BLK
GROUND
STARTER
85
30
BLK
87
(12V DC)
30
BLK/RED
CR4
CHARGER
-
86
30
WHT
4
5
CR13
WHT-J4
BRN
30
87
86
BLK/WHT
E1
RIGHT
MOTOR
85
YEL
E2
START INPUT
BLK/RED-35
CR12
RED
A1
CR11
BRN
A2
A1
BRN
-
A2
TACH. INPUT
3
BLK
ALTERNATOR
E1
START RELAY
2
BLK-33
30
FB
(12V DC)
1
BLU-ISM2
WHT-23
WHT
PUMP
+
LEFT
MOTOR
E2
86
BRN
WHT
RED
-
85
+12V DC
LS1
(EXT.)
BLK-7
WHT
-
+
+
PUMP
-
RED-J10 (12GA)
BLK-ISM1
WHT-21
14
RED PISM6
15 A
BLK
PR2
-
+
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
2
WHT-21
RED/WHT-23
B-
F1
HIGH
87
WHT-23
ENABLE
3
TB33
TB34
85
RED/WHT-23
PR3
B+
LOW
30
CR1
BRN
HM
BLK/RED-9
M-
BLK/RED-1
RED/BLK-28
86
13
F2
ENGINE
START
87
TS54
RPM
TS52
GLOW
PLUGS
85
ORG/RED
30
1
RED-7
F1
200A
TB9
LS2
(PRI.)
TB49
MOTOR CONTROLLER
86
TS56
TB28
BLK-6
AP1
CR2
TB23
BLK-22
22
5
20
17
500A
+24V DC
RED
RED-6
21
BLU/WHT-12
LS4
(SEC.)
TB50
BLK
RED/BLK-R5
GRN
3
6
16
2
F3
TB42
RED/
WHT-3
22
CONTROLLER FAULT
INDICATOR LED L2
85
21
AP2
24V DC
BLK-1
TB3
BLK-8
86
CR5
COIL-PR1
FAULT LED
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
11
14
10
1
9
6
FOOTSWITCH
HIGH RPM
TP35
TP33
BLK/WHT-1
RED-8
ORG/RED-42
ORG/RED
ORG/RED-42
BLU/RED-39
BLU/WHT-12
RED/WHT-29
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
LEFT
BOX
TP34
ORG/RED-1
RED/WHT-3
WHT-2
TB29
ORG-40
F2
200 A
HIGH LOW
RPM RPM
RED
TB40
-
+
5
WHT/RED-32
+48V DC
WHT/BLK-31
PR1
WHT-30
48V DC
AP2
ORG/RED-42
F5
10A
TS2
ENGINE
START
TS6
GLOW
PLUGS
TP42
TP3
ORG/RED-R2
F4
500 A
L3
CONTROLLER
FAULT LED
RED
TP28
RED/BLK-1
TB32
TP23
BLK/RED-3
RED/WHT-1
TB31
TB39
WHT/RED-1
BLU/RED-1
TP29
WHT/BLK-1
TP9
TP39
TP31
TB30
TP32
WHT-1
TB20
4
TP30
3
RED
RED/WHT-3
KS1
P1
BLK/RED-9
10 A
PLATFORM
TS4
RPM
ORG/RED-42
P3
HORN
8
N
LOAD SENSE OPTION
1
7
M
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(from serial number 13361 to 14078)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
RED/WHT-29
WHT/RED-32
WHT-30
WHT/BLK-31
WHT-24
WHT-24
ORG/RED-42
WHT-24
2
RED
ORG/RED-42
PRIMARY
BOOM
SECONDARY
BOOM
TS10
TS11
TS13
JP1 (REMOVE FOR CE VERSION)
30
87a
TS7
TS9
JIB BOOM
CR7A
TS8
BP1
TP2
TP8
TP1
TP15
TP7
TP14
30
DRIVE 30
ENABLE
TS15
L
85
TP36
TP41
3
TP13
BLU/WHT-12
BLU/RED-3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT-3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
TP6
CR6 86
87
TP16
TP19
L R
STEER
ORG/BLK-R6
TP27
BCI
RED/BLK-R6
R
ORG/BLK-1
85
CR7B
5
DRIVE
BRN
85
F
E
REV
BLU-1
86
+
BLK/RED
4
C
BLU/BLK-1
86
BRN
FWD
RED - 1
CR7A
GRN/BLK-3
BRN
JIB
MANIFOLD
RED
TP18
GRN-3
T1
87
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
TP17
RED
A
B
3
ORG/RED-16
TP10
AUXILIARY
PUMP
TP11
LIFT
2
TP45
TP5
20K
RED
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
1
TS1
RED
TP4
DP1
RED
TS12
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
BLU/WHT-12
TURNTABLE
ROTATE
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB27
TB17
CR9
TB6
TB36
WHT/RED-6
RED/WHT-48
BLU-36
BLU/BLK-37
22
21
RED-7
RED-27
85
+
A2
TB16
DRIVE
ENABLE
LIMIT
SWITCH
6
3
7
BRN-7
RED
CR10A 85
13
LS2
14
BRAKE/STEER
MANIFOLD
GROUND
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
Part No. 106488
AUXILIARY CONTROL
RELAY COIL CR3
FLOW
CONTROL COIL
LIFT PUMP
RELAY COIL PR2
PLATFORM
ROTATE RIGHT/
JIB DOWN
PLATFORM
ROTATE LEFT/
JIB UP
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
LS3
14
(GND)
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
13
CR3
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
86
86
ORG #14
A3
ORG/BLK #15
+
30
GRN/WHT
CR10B
30
87a
GRN/WHT
85
30
87a
WHT/RED-6
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
GRN/BLK-18
TB14
TB15
86
(GND)
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
TB37
WHT-7
TB10
TB11
TB19
ORG/RED-3
TB5
TB4
CR5
87
GRN/WHT-19
GRN/WHT-19
TB18
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 38
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 14079 to 14650)
A
B
1
C
D
E
F
G
H
I
J
K
L
3
RED/WHT-29
ORG/RED
2
4
P2
LOAD SENSE PCB
2
3
4
5
BRN
3A
6
7
8
9 10 11 12
L4
WHT-30
30
WHT/BLK-31
FS1
BLK-26
RED-FS
BLK-FS
87
WHT-FS
TP26
CR17
RED L7
86
WHT/RED-32
87a
BLK LSTOP
1
LOAD SENSE OPTION (SEE DETAIL)
CR17
85
P2
BLK-2
2
RED L1
BLK-FS
BLK-26
FS1 RED-FS
TP25
WHT-FS
TP24
TP26
TP22
WHT-24
RED
RED
ORG/RED-42
RED-20
TB22
CB1
GROUND
+
A1
TILT
ALARM
CB3
30
2
87
+
ALT.
BLU
86
CR15
+
-
+
-
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
86
87
GRN/BLK
BATT
+
-
WHT-BATT
ENGINE
GROUND
WHT
AP2
AUXILIARY
(GND)
(GND)
AP1
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR1
48V DC POWER
RELAY CR2
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 39
7
86
HORN
87
BATTERY
(12V DC)
30
ORG GEN POS
(NOT USED)
GROUND
6
85
BRN
+
86
CR14
BRN
+
87
BRN
ORG GEN NEG
CR16
87
BLU
VR1
85
85
BRN
+
AC POWER
85
BRN
BLK
GROUND
STARTER
85
30
BLK
87
(12V DC)
30
BLK/RED
CR4
CHARGER
-
86
30
WHT
4
5
CR13
WHT-J4
BRN
30
87
86
BLK/WHT
E1
RIGHT
MOTOR
85
YEL
E2
START INPUT
BLK/RED-35
CR12
RED
A1
CR11
BRN
A2
A1
BRN
-
A2
TACH. INPUT
3
BLK
ALTERNATOR
E1
START RELAY
2
BLK-33
30
FB
(12V DC)
1
BLU-ISM2
WHT-23
WHT
PUMP
+
LEFT
MOTOR
E2
86
BRN
WHT
RED
-
85
+12V DC
LS1
(EXT.)
BLK-7
WHT
-
+
+
PUMP
-
RED-J10 (12GA)
BLK-ISM1
WHT-21
14
RED PISM6
15 A
BLK
PR2
-
+
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
2
WHT-21
RED/WHT-23
B-
F1
HIGH
87
WHT-23
ENABLE
3
TB33
TB34
85
RED/WHT-23
PR3
B+
LOW
30
CR1
BRN
HM
BLK/RED-9
M-
BLK/RED-1
RED/BLK-28
86
13
F2
ENGINE
START
87
TS54
RPM
TS52
GLOW
PLUGS
85
ORG/RED
30
1
RED-7
F1
200A
TB9
LS2
(PRI.)
TB49
MOTOR CONTROLLER
86
TS56
TB28
BLK-6
AP1
CR2
TB23
BLK-22
22
5
20
17
500A
+24V DC
RED
RED-6
21
BLU/WHT-12
LS4
(SEC.)
TB50
BLK
RED/BLK-R5
GRN
3
6
16
2
F3
TB42
RED/
WHT-3
22
CONTROLLER FAULT
INDICATOR LED L2
85
21
AP2
24V DC
BLK-1
TB3
BLK-8
86
CR5
COIL-PR1
FAULT LED
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
11
14
10
1
9
6
FOOTSWITCH
HIGH RPM
TP35
TP33
BLK/WHT-1
RED-8
ORG/RED-42
ORG/RED
ORG/RED-42
BLU/RED-39
BLU/WHT-12
RED/WHT-29
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
LEFT
BOX
TP34
ORG/RED-1
RED/WHT-3
WHT-2
TB29
ORG-40
F2
200 A
HIGH LOW
RPM RPM
RED
TB40
-
+
5
WHT/RED-32
+48V DC
WHT/BLK-31
PR1
WHT-30
48V DC
AP2
ORG/RED-42
F5
10A
TS2
ENGINE
START
TS6
GLOW
PLUGS
TP42
TP3
ORG/RED-R2
F4
500 A
L3
CONTROLLER
FAULT LED
RED
TP28
RED/BLK-1
TB32
TP23
BLK/RED-3
RED/WHT-1
TB31
TB39
WHT/RED-1
BLU/RED-1
TP29
WHT/BLK-1
TP9
TP39
TP31
TB30
TP32
WHT-1
TB20
4
TP30
3
RED
RED/WHT-3
KS1
P1
BLK/RED-9
10 A
PLATFORM
TS4
RPM
ORG/RED-42
P3
HORN
8
N
LOAD SENSE OPTION
1
7
M
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(from serial number 14079 to 14650)
N
M
L
K
J
I
H
G
F
E
D
RED/WHT-29
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
WHT/BLK-31
C
B
A
1
WHT/BLK-31
WHT-24
WHT-24
WHT-24
ORG/RED-42
RED
DP1
2
20K
WHT-24
1
ORG/RED-42
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
PLATFORM
LEVEL
PLATFORM
ROTATE
TS9
TS7
JIB BOOM
CR7A
2
30
87a
RED
TS10
TS12
PRIMARY
BOOM
TS8
TP2
TP1
6
RED/BLK-R6
8
TS15
DRIVE 30
ENABLE
9
BP1
TP7
TP8
TP14
TP15
30
TP36
TP13
TP6
TP41
BLU/WHT-12
BLU/RED-3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT-3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
3
TP16
TP19
85
ORG/BLK-1
85
CR7B
TP27
BCI
CR6 86
BRN
85
F
E
BLU-1
86
+
BLK/RED
BLU/BLK-1
86
BRN
10
87
RED - 1
CR7A
GRN/BLK-3
BRN
JIB
MANIFOLD
RED
TP18
GRN-3
T1
87
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
TP17
RED
L R
STEER
ORG/RED-16
TP10
JP1 (REMOVE FOR CE VERSION)
ORG/BLK-R6
7
DRIVE
AUXILIARY
PUMP
TP11
4
RED
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TP5
3
REV
LIFT
TP45
TP4
FWD
5
TS1
RED
BLU/WHT-12
TURNTABLE
ROTATE
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB27
TB17
CR9
TB6
TB36
WHT/RED-6
85
+
A2
BRAKE/STEER
MANIFOLD
GROUND
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
Part No. 106488
AUXILIARY CONTROL
RELAY COIL CR3
FLOW
CONTROL COIL
LIFT PUMP
RELAY COIL PR2
PLATFORM
ROTATE RIGHT/
JIB DOWN
PLATFORM
ROTATE LEFT/
JIB UP
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
TB16
3
7
13
LS2
14
(GND)
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
21
DRIVE
ENABLE
LIMIT
SWITCH
6
BRN-7
CR10A 85
22
RED-7
(GND)
CR3
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
LS3
86
86
ORG #14
A3
ORG/BLK #15
+
13
14
RED
CR10B
30
87a
GRN/WHT
85
30
87a
RED/WHT-48
86
BLU-36
30
BLU/BLK-37
RED-27
GRN/WHT
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
WHT/RED-6
TB14
TB15
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
TB37
WHT-7
TB10
TB11
TB19
ORG/RED-3
TB5
TB4
CR5
87
GRN/WHT-19
GRN/WHT-19
TB18
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 40
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 14651 to 16839)
A
1
TP22
B
P2
FS1
BLK-(FS)
BLK-26
BLK-26 LOAD
LOAD
SENSOR
BOX
C
E
F
G
H
I
J
K
L
B+
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
GROUND
TILT
ALARM
A1
CB3
30
87
+
+
-
+
86
CR15
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
87
GRN/BLK
BATT
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 41
GROUND
6
86
AP1
8
(NOT USED)
5
86
HORN
87
4
85
CR14
BRN
+
87
BRN
-
85
BRN
-
30
BRN
BLU
86
85
BLK/RED
ALT.
85
BRN
30 CR16
ORG GEN POS
START INPUT
WHT
BRN
ORG GEN NEG
30
BLK/WHT
BLK
GROUND
+
AC POWER
87
BLU
VR1
BLK
-
(12V DC)
STARTER
85
TACH. INPUT
3
CR13
WHT-J4
30
YEL
CHARGER
87
86
RED
CR4
87
85
FB
86
2
BLK/RED-35
30
BRN
30
START RELAY
BLU-ISM2
BLK-33
CR12
WHT
E1
RIGHT
MOTOR
CR11
86
BRN
E2
BRN
-
A1
85
(12V DC)
1
WHT-23
BLK
ALTERNATOR
A2
A1
RED-J10 (12GA)
+12V DC
+
-
15 A
+
WHT
PUMP
A2
TB21
BLK-ISM1
WHT-21
2
RED
PUMP
+
E1
RED PISM6
WHT-21
BLK
LS1
(EXT.)
BLK-7
WHT
-
+
+
LEFT
MOTOR
E2
BLK/RED-1
2
ENABLE
3
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
WHT-23
RED/WHT-23
14
HIGH
87
BRN
HM
TB33
TB34
85
RED/WHT-23
PR2
LOW
30
CR1
1
TB49
B-
F1
TS54
RPM
ENGINE
START
87
13
-
+
7
RIGHT
BOX
BLK-1
85
TS52
GLOW
PLUGS
30
ORG/RED
86
RED/BLK-28
TB9
LS2
(PRI.)
BLK/RED-9
PR3
B+
BLK-22
M-
86
TS56
TB28
RED-7
SEPEX CONTROLLER
F2
CR2
TB23
BLK-6
5
20
17
6
2
3
16
F1
200A
RED
RED-6
22
BLK
RED/BLK-R5
GRN
FAULT LED
21
BLU/WHT-12
LS4
(SEC.)
TB50
CURTIS 1244
24V DC
500 A AP1
+24V DC
TB42
RED/
WHT-3
22
CONTROLLER FAULT
INDICATOR LED L2
85
21
AP2
F3
TP35
TB3
BLK-8
86
CR5
COIL-PR1
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
14
11
10
9
1
6
FOOT SWITCH
HIGH RPM
TS4
RPM
TP33
BLK/WHT-1
RED-8
ORG/RED-42
ORG/RED
BLU/RED-39
ORG/RED-42
RED/WHT-29
BLU/WHT-12
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
-
+
LEFT
BOX
TP34
ORG/RED-1
RED/WHT-3
WHT-2
TB29
ORG-40
F2
200A
HIGH
RPM
TS2
ENGINE
START
RED
TB40
-
+
5
WHT/RED-32
+48V DC
WHT/BLK-31
PR1
WHT-30
48V DC
ORG/RED-42
AP2
TS6
GLOW
PLUGS
TP42
TP3
ORG/RED-R2
F5
10A
L3
CONTROLLER
FAULT LED
LOW
RPM
RED
TP28
RED/BLK-1
TB32
TP23
BLK/RED-3
RED/WHT-1
TB31
BLU/RED-1
WHT/RED-1
TB39
TP29
WHT/BLK-1
TP9
TP39
TP31
TB30
TP32
WHT-1
TB20
TP30
3
+
RED/WHT-3
TB22
CB1
10A
RED
BLK/RED-9
KS1
P1
RED-20
PLATFORM
ORG/RED-42
P3
HORN
F4
500 A
N
TP24
LOAD SENSOR OPTION
4
M
WHT/RED-32
ORG-LOAD
2
D
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(from serial number 14651 to 16839)
N
M
L
K
J
I
H
G
F
E
D
RED/WHT-29
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
WHT/BLK-31
C
B
A
1
WHT/BLK-31
WHT-24
WHT-24
WHT-24
ORG/RED-42
RED
DP1
2
20K
WHT-24
1
ORG/RED-42
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
PLATFORM
LEVEL
PLATFORM
ROTATE
TS9
TS7
JIB BOOM
CR7A
2
30
87a
RED
TS10
TS12
PRIMARY
BOOM
TS8
TP2
TP1
6
RED/BLK-R6
8
TS15
DRIVE 30
ENABLE
9
BP1
TP7
TP8
TP14
TP15
30
TP36
TP13
TP6
TP41
BLU/WHT-12
BLU/RED-3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT-3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
3
TP16
TP19
85
ORG/BLK-1
85
CR7B
TP27
BCI
CR6 86
BRN
85
F
E
BLU-1
86
+
BLK/RED
BLU/BLK-1
86
BRN
10
87
RED - 1
CR7A
GRN/BLK-3
BRN
JIB
MANIFOLD
RED
TP18
GRN-3
T1
87
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
TP17
RED
L R
STEER
ORG/RED-16
TP10
JP1 (REMOVE FOR CE VERSION)
ORG/BLK-R6
7
DRIVE
AUXILIARY
PUMP
TP11
4
RED
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TP5
3
REV
LIFT
TP45
TP4
FWD
5
TS1
RED
BLU/WHT-12
TURNTABLE
ROTATE
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB27
TB17
CR9
TB6
TB36
WHT/RED-6
85
+
A2
BRAKE/STEER
MANIFOLD
GROUND
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
Part No. 106488
AUXILIARY CONTROL
RELAY COIL CR3
FLOW
CONTROL COIL
LIFT PUMP
RELAY COIL PR2
PLATFORM
ROTATE RIGHT/
JIB DOWN
PLATFORM
ROTATE LEFT/
JIB UP
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
TB16
3
7
13
LS2
14
(GND)
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
21
DRIVE
ENABLE
LIMIT
SWITCH
6
BRN-7
CR10A 85
22
RED-7
(GND)
CR3
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
LS3
86
86
ORG #14
A3
ORG/BLK #15
+
13
14
RED
CR10B
30
87a
GRN/WHT
85
30
87a
RED/WHT-48
86
BLU-36
30
BLU/BLK-37
RED-27
GRN/WHT
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
WHT/RED-6
TB14
TB15
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
TB37
WHT-7
TB10
TB11
TB19
ORG/RED-3
TB5
TB4
CR5
87
GRN/WHT-19
GRN/WHT-19
TB18
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 42
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 16840 to 17974)
A
1
TP22
B
P2
FS1
BLK-(FS)
BLK-26
BLK-26 LOAD
LOAD
SENSOR
BOX
C
E
F
G
H
I
J
K
L
M
N
B+
WHT/RED-32
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
TP24
ORG-LOAD
2
D
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
LOAD SENSOR OPTION
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
TB22
GROUND
TS6
GLOW
PLUGS
HIGH
RPM
TS2
ENGINE
START
FOOT SWITCH
HIGH RPM
TS4
RPM
RED
TP34
TP35
TP33
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
TB29
TP42
TP3
RED/WHT-3
TB32
TP28
WHT-2
RED/WHT-1
TB31
TP23
TILT
ALARM
A1
RED/BLK-1
WHT/RED-1
TP9
BLK/RED-3
TP29
WHT/BLK-1
TB30
TP31
WHT-1
TP32
TP30
3
+
RED/WHT-3
BLK/RED-9
KS1
P1
RED-20
CB1
10A
RED
ORG/RED-42
P3
HORN
PLATFORM
LOW
RPM
RED
4
ORG-40
TB40
RED-8
TB3
+
-
+
15 A
CB3
30
LS1
(EXT.)
2
87
+
+
-
+
86
ALT.
BLU
86
CR15
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
87
GRN/BLK
BATT
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 43
GROUND
6
86
AP1
8
(NOT USED)
5
86
HORN
87
4
85
CR14
BRN
+
87
BRN
-
85
BRN
-
30
BRN
30 CR16
ORG GEN POS
START INPUT
WHT
BRN
ORG GEN NEG
87
BLU
VR1
85
85
BLK/RED
+
AC POWER
30
BLK
BLK
GROUND
STARTER
85
87
(12V DC)
30
BRN
CR4
CHARGER
-
86
TACH. INPUT
3
CR13
WHT-J4
BLK/WHT
30
87
86
FB
YEL
E1
RIGHT
MOTOR
85
RED
E2
BRN
-
A1
2
BLK/RED-35
CR12
BLK
ALTERNATOR
A2
A1
START RELAY
BLU-ISM2
BLK-33
30
BRN
PUMP
A2
1
WHT-23
WHT
PUMP
+
E1
CR11
86
BRN
WHT
RED
BLK-7
WHT
-
+
+
LEFT
MOTOR
85
(12V DC)
BLK-ISM1
WHT-21
14
E2
RED-J10 (12GA)
BLK
PR2
-
+
7
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
BRN
2
WHT-21
RED/WHT-23
B-
HIGH
87
WHT-23
ENABLE
3
TB33
TB34
13
F1
LOW
30
CR1
85
RED/WHT-23
-
87
TS54
RPM
RED PISM6
86
RED/BLK-28
PR3
B+
HM
BLK/RED-9
M-
F2
BLK-22
RED-7
F1
200A
SEPEX CONTROLLER
85
1
BLK-6
5
20
17
500 A AP1
+24V DC
TB9
LS2
(PRI.)
TB49
CURTIS 1244
24V DC
30
TS52
TB28
RED-6
22
86
TS56
ENGINE
START
BLK-8
21
AP2
F3
CR2
TB23
TB50
BLK
RED/BLK-R5
GRN
2
3
16
14
11
10
9
1
6
RED
LS4
(SEC.)
GLOW
PLUGS
22
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
85
21
BLU/WHT-12
ORG/RED
ORG/RED-42
ORG/RED
ORG/RED-42
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
F2
200A
-
+
LEFT
BOX
86
-
+
5
RED/WHT-29
+48V DC
BLU/WHT-12
PR1
WHT/RED-32
48V DC
WHT/BLK-31
AP2
WHT-30
F5
10A
ORG/RED-42
F4
500 A
TB42
RED/
WHT-3
ORG/RED-R2
+12V DC
TB20
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(from serial number 16840 to 17974)
N
M
L
K
J
I
H
G
F
E
D
RED/WHT-29
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
WHT/BLK-31
C
B
A
1
WHT/BLK-31
WHT-24
WHT-24
WHT-24
ORG/RED-42
RED
DP1
2
20K
WHT-24
1
ORG/RED-42
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
PLATFORM
LEVEL
PLATFORM
ROTATE
TS9
TS7
JIB BOOM
CR7A
2
30
87a
RED
TS10
TS12
PRIMARY
BOOM
TS8
TP2
TP1
6
RED/BLK-R6
8
TS15
DRIVE 30
ENABLE
9
BP1
TP7
TP8
TP14
TP15
30
TP36
TP13
TP6
TP41
BLU/WHT-12
BLU/RED-3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT-3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
3
TP16
TP19
85
ORG/BLK-1
85
CR7B
TP27
BCI
CR6 86
BRN
85
F
E
BLU-1
86
+
BLK/RED
BLU/BLK-1
86
BRN
10
87
RED - 1
CR7A
GRN/BLK-3
BRN
JIB
MANIFOLD
RED
TP18
GRN-3
T1
87
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
TP17
RED
L R
STEER
ORG/RED-16
TP10
JP1 (REMOVE FOR CE VERSION)
ORG/BLK-R6
7
DRIVE
AUXILIARY
PUMP
TP11
4
RED
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TP5
3
REV
LIFT
TP45
TP4
FWD
5
TS1
RED
BLU/WHT-12
TURNTABLE
ROTATE
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB27
TB17
CR9
TB6
TB36
WHT/RED-6
85
+
A2
BRAKE/STEER
MANIFOLD
GROUND
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
Part No. 106488
AUXILIARY CONTROL
RELAY COIL CR3
FLOW
CONTROL COIL
LIFT PUMP
RELAY COIL PR2
PLATFORM
ROTATE RIGHT/
JIB DOWN
PLATFORM
ROTATE LEFT/
JIB UP
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
TB16
3
7
13
LS2
14
(GND)
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
21
DRIVE
ENABLE
LIMIT
SWITCH
6
BRN-7
CR10A 85
22
RED-7
(GND)
CR3
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
LS3
86
86
ORG #14
A3
ORG/BLK #15
+
13
14
RED
CR10B
30
87a
GRN/WHT
85
30
87a
RED/WHT-48
86
BLU-36
30
BLU/BLK-37
RED-27
GRN/WHT
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
WHT/RED-6
TB14
TB15
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
TB37
WHT-7
TB10
TB11
TB19
ORG/RED-3
TB5
TB4
CR5
87
GRN/WHT-19
GRN/WHT-19
TB18
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 44
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 17975 to 21180)
A
1
TP22
B
P2
FS1
BLK-(FS)
BLK-26
BLK-26 LOAD
LOAD
SENSOR
BOX
C
E
F
G
H
I
J
K
L
M
N
B+
WHT/RED-32
WHT-LOAD
8
GND
WHT-30
WHT-24
WHT/BLK-31
TP24
ORG-LOAD
2
D
RED/WHT-29
RED-(FS)
WHT-(FS)
TP26
C
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BLK-(FS)
BLK
BLK-2
LOAD SENSOR OPTION
TP22
TP26
RED-(FS)
TP25
WHT-(FS)
TP24
WHT-24
RED
ORG/RED-42
RED
TB22
GROUND
TS6
GLOW
PLUGS
HIGH
RPM
TS2
ENGINE
START
FOOT SWITCH
HIGH RPM
TS4
RPM
RED
TP34
TP35
TP33
BLK/RED-1
BLK-1
BLK/WHT-1
ORG/RED-1
TB29
TP42
TP3
RED/WHT-3
TB32
TP28
WHT-2
RED/WHT-1
TB31
TP23
TILT
ALARM
A1
RED/BLK-1
WHT/RED-1
TP9
BLK/RED-3
TP29
WHT/BLK-1
TB30
TP31
WHT-1
TP32
TP30
3
+
RED/WHT-3
BLK/RED-9
KS1
P1
RED-20
CB1
10A
RED
ORG/RED-42
P3
HORN
PLATFORM
LOW
RPM
RED
4
ORG-40
TB40
RED-8
TB3
+
-
+
15 A
CB3
30
LS1
(EXT.)
2
87
+
+
-
+
86
BLU
86
CR15
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
87
GRN/BLK
BATT
WHT-BATT
WHT
AP2
AUXILIARY
(12V)
ENGINE
GROUND
(GND)
(GND)
BRN
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN SOLENOID
STARTER RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
BASE CONTROL
BOX GROUND
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BRAKE RELEASE
RELAY CR5
CHASSIS
GROUND
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
2 GA
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 45
GROUND
6
86
AP1
8
(NOT USED)
5
86
HORN
87
4
85
CR14
BRN
+
87
BRN
-
85
BRN
-
30
BRN
ALT.
85
BLK/RED
87
BLU
VR1
85
BRN
30 CR16
ORG GEN POS
START INPUT
WHT
BRN
ORG GEN NEG
30
30
BLK
BLK
GROUND
+
AC POWER
(12V DC)
STARTER
85
TACH. INPUT
3
CR13
WHT-J4
BLK/WHT
CR4
CHARGER
-
86
87
87
86
FB
YEL
30
RIGHT
MOTOR
85
RED
F1
F2
BRN
-
A1
2
BLK/RED-35
CR12
BLK
ALTERNATOR
A2
A1
START RELAY
BLU-ISM2
BLK-33
30
BRN
PUMP
A2
1
WHT-23
WHT
PUMP
+
F1
CR11
86
BRN
WHT
RED
BLK-7
WHT
-
+
+
LEFT
MOTOR
85
(12V DC)
BLK-ISM1
WHT-21
14
F2
RED-J10 (12GA)
BLK
PR2
-
+
7
RIGHT
BOX
TB21
IGNITION / START
MODULE
TB35
BLK/WHT-34
BRN
BRN
-
WHT-21
RED/WHT-23
B-
HIGH
87
ENABLE
+
TB33
TB34
13
F1
LOW
30
CR1
85
RED/WHT-23
-
87
TS54
RPM
RED PISM6
86
RED/BLK-28
PR3
B+
HM
BLK/RED-9
M-
F2
BLK-22
RED-7
F1
200A
SEPEX CONTROLLER
85
WHT-23
BLK-6
5
20
17
500 A AP1
+24V DC
TB9
LS2
(PRI.)
TB49
CURTIS 1244
24V DC
30
TS52
TB28
RED-6
22
86
TS56
ENGINE
START
BLK-8
21
AP2
F3
CR2
TB23
TB50
BLK
RED/BLK-R5
GRN
2
3
16
14
11
10
9
1
6
RED
LS4
(SEC.)
GLOW
PLUGS
22
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
85
21
BLU/WHT-12
ORG/RED
ORG/RED-42
ORG/RED
ORG/RED-42
OFF-LIMIT SPEED INPUT
POT. HI
INTERLOCK
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RED 20
F2
200A
-
+
LEFT
BOX
86
-
+
5
RED/WHT-29
+48V DC
BLU/WHT-12
PR1
WHT/RED-32
48V DC
WHT/BLK-31
AP2
WHT-30
F5
10A
ORG/RED-42
F4
500 A
TB42
RED/
WHT-3
ORG/RED-R2
+12V DC
TB20
June 2005
Section 6 • Schematics
REV A
Electrical Schematic, Z-45/25J
(from serial number 17975 to 21180)
N
M
L
K
J
I
H
G
F
E
D
RED/WHT-29
RED/WHT-29
WHT/RED-32
WHT/RED-32
WHT-30
WHT-30
WHT/BLK-31
C
B
A
1
WHT/BLK-31
WHT-24
WHT-24
WHT-24
ORG/RED-42
RED
DP1
2
20K
WHT-24
1
ORG/RED-42
PRIMARY
BOOM
SECONDARY
BOOM
TS11
TS13
PLATFORM
LEVEL
PLATFORM
ROTATE
TS9
TS7
JIB BOOM
CR7A
2
30
87a
RED
TS10
TS12
PRIMARY
BOOM
TS8
TP2
TP1
6
RED/BLK-R6
8
TS15
DRIVE 30
ENABLE
9
BP1
TP7
TP8
TP14
TP15
30
TP36
TP13
TP6
TP41
BLU/WHT-12
BLU/RED-3
PLATFORM
CONTROL BOX
GROUND
GRN/
WHT-3
GRN/
WHT-1
BLU/WHT-3
GROUND
RED
DRIVE
ENABLE
LED L1
TP12
TP37
3
TP16
TP19
85
ORG/BLK-1
85
CR7B
TP27
BCI
CR6 86
BRN
85
F
E
BLU-1
86
+
BLK/RED
BLU/BLK-1
86
BRN
10
87
RED - 1
CR7A
GRN/BLK-3
BRN
JIB
MANIFOLD
RED
TP18
GRN-3
T1
87
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT-3
WHT/BLK-3
ROTARY
OEM
FLOW
CONTROL
CR7B
TP17
RED
L R
STEER
ORG/RED-16
TP10
JP1 (REMOVE FOR CE VERSION)
ORG/BLK-R6
7
DRIVE
AUXILIARY
PUMP
TP11
4
RED
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TP5
3
REV
LIFT
TP45
TP4
FWD
5
TS1
RED
BLU/WHT-12
TURNTABLE
ROTATE
4
TB12
TS51
RED
TS55
FUNCTION
ENABLE
AUX
ON
RED
PRIMARY
BOOM
TS61
TS63
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
TS59
TS57
TS58
DOWN
UP
TB27
TB17
CR9
TB6
TB36
WHT/RED-6
85
+
A2
BRAKE/STEER
MANIFOLD
GROUND
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
Part No. 106488
AUXILIARY CONTROL
RELAY COIL CR3
FLOW
CONTROL COIL
LIFT PUMP
RELAY COIL PR2
PLATFORM
ROTATE RIGHT/
JIB DOWN
PLATFORM
ROTATE LEFT/
JIB UP
PLATFORM LEVEL
CUTOUT UP
RELAY COIL CR10A
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
AUXILIARY LIFT
PUMP RELAY COIL PR3
BRN
NOTES:
TB16
3
7
13
LS2
14
(GND)
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
21
DRIVE
ENABLE
LIMIT
SWITCH
6
BRN-7
CR10A 85
22
RED-7
(GND)
CR3
87
87a
WHT-40
FUNCTION
MANIFOLD
GROUND
LS3
86
86
ORG #14
A3
ORG/BLK #15
+
13
14
RED
CR10B
30
87a
GRN/WHT
85
30
87a
RED/WHT-48
86
BLU-36
30
BLU/BLK-37
RED-27
GRN/WHT
PLATFORM LEVEL CUTOUT
(CE VERSION ONLY)
WHT/RED-6
TB14
TB15
GRN/BLK-18
GRN-17
BLK-7
BLK/WHT-8
RED-1
RED/BLK-2
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
ORG
BRN-2
TB7
TB8
TB13
BLK-7
TB1
TB2
TB48
TB37
WHT-7
TB10
TB11
TB19
ORG/RED-3
TB5
TB4
CR5
87
GRN/WHT-19
GRN/WHT-19
TB18
5
TB41
30
PS1
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
TB45
BRAKE
RELEASE
JACK
J1
RED
TS60
TS62
PRIMARY
BOOM
RED
SECONDARY
BOOM
WHT/RED-3
TURNTABLE
ROTATE
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
8
6 - 46
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J
(from serial number 21180 to 22050)
A
1
B
C
P2
C7P-1
FS1
P22BAT BK
RD-(FS)
C9P-3
WH-(FS)
P25BAT
C9P-2
P24BAT
BK-(FS)
C9P-1 BK
P26BAT
D
F
G
C
I
J
K
L
M
N
C29JSH RD/WH
WH
C32JSL WH/RD
WH-LOAD
GND
BRN
8
C30FWD WH
OR-LOAD
B+
LOAD SENSOR OPTION
C31REV WH/BK
LOAD
C40LS OR
CELL
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
P22BAT
BK
LOAD SENSOR OPTION (SEE DETAIL)
FS1
P2
BK-(FS)
C9P-1 BK
C7P-1
P26BAT
C9P-3
P25BAT RD
WH-(FS)
C9P-2
P24BAT WH
P24BAT WH
RD
C7B-1
R42BAT OR/RD
TS6
GLOW
PLUGS
RD
P3
HORN
TB22
+
TS2
ENGINE
START
LOW
RPM
HIGH
RPM
FOOT SWITCH
HIGH RPM
C1P-2
C3P-3
C2P-4
C1P-8
C1P-7
C1P-9
C28TTA RD/BK
C3BAT RD/WH
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C7B-2
C1B-2
C3B-3
C2B-4
C1B-8
C1B-7
C1B-9
C6B-29
P23SWBAT WH
C6B-32
C7P-2
C1B-3
C6B-31
C3B-9
C1B-6
C9HRN BK/RD
C29JSH RD/WH
C1B-5
TS4
RPM
C3P-9
C32JSL WH/RD
C2B-2
C1P-3
C31REV WH/BK
TILT
ALARM
A1
GROUND
C40LS OR
C1P-6
OR
RD-(FS)
RD
PLATFORM
C2P-2
C1P-5
C6B-30
C7B-4
C1B-4
P20BAT RD
C30FWD WH
3
C1P-4
CB1
10 A
KS1
P1
P20BAT RD
4
H
LOAD
SENSOR
MODULE
BK
BK-26 LOAD
2
E
P20BAT RD
CR5
OR
TB40
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
(12V DC)
+
+
-
+
-
TACH. INPUT
3
START INPUT
4
(NOT USED)
5
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
85
CR14
CR16
86
BRN
BRN
BRN
GR/BK
BATT
-
WH-BATT
C5B-2
BRN
ENGINE
GROUND
WH
AP2
AUXILIARY
(GND)
BK
BK
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY
CR16
RPM CUTOUT
RELAY CR13
RPM RELAY
CR14
RPM
SOLENOID
GLOW PLUG
RELAY CR15
GLOW
PLUGS
12V DC
ALERNATOR
12V DC
VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
ENGINE RUN
SOLENOID
STARTER
RELAY CR11
48V DC POWER
RELAY CR2
48V DC POWER
RELAY CR1
FLASHING
BEACON
OPTION
TILT SENSOR
Part No. 106488
HOUR METER
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
6 - 47
86
START RELAY
2
(12V DC)
87
AP1
87
BRN
BK
STARTER
86
85
1
86
87
BK/RD
ALT.
BL
85
CR15
BRN
87
BL
VR1
(12V DC)
85
30
WH
IGNITION / START
MODULE
CR13
30
BK/WH
YEL
+12V DC
WH-J4
30
RD
+
87
86
BRN
+
85
WH
-
30
CR12
BRN
-
86
+
2
C34SA BK/WH
87
CR11
C8-B
+
85
BK
WH
14
C5B-22
RD/WH
C8-C
LS1
(EXT)
C5B-18
C35HRPM
C5B-3 C23PWR WH
30
13
C5B-1 P20BAT RD
C5B-5 C33STR BK
RD-J10 (12GA)
FB
OR-GEN POS
8
ENGINE
START
BRN
BRN
BL-ISM2
BK
30 CR16
RD
OR-GEN NEG
GROUND
22
RD/BK
C8-A
BK
AC POWER
87
85
87
BRN
-
WH-6
CHARGER
C11-2
LS2 21
(PRI)
C6B-28
86
HIGH
TB35
CB3
C6B-9 BK/RD
RIGHT
MOTOR
BK-6
F1
F2
WH-7
A1
C11-1
A2
A1
BK-7
A2
BK 2 GA
-
F1
C11-4
ALTERNATOR
LEFT
MOTOR
F2
LOW
BK-ISM1
C5B-11 C21IGN2 WH
RD
BK
C11-3
-
PUMP
+
85
TS54
RPM
TB33
TB34
30
CR1
15 A
PR2
+
PUMP
RD-5
B-
F1
RD/BK
C6B-34
WH-5
B+
86
_
BK-5
M-
F2
PR3
87
+
CR4
SEPEX CONTROLLER
WH
+
RIGHT
BOX
F1
200A
WH
C10-2
BK-5
HM
CURTIS 1244
-
+
7
AP1
BK/RD
BK
C10-1
WH-4
BK-4
5
20
17
3
2
16
14
11
10
9
1
500 A
+24 V
85
TS52
C23PWR WH
21
LS4
(SEC)
22
30
24 V DC
30
TB23
AP2
F3
86
TS56
GLOW
PLUGS
CR2
OR/RD
C6B-20 RD
BK
C10-4
C6B-25 CFIL BK
GR
C6B-39 CR5 RD/BK
C10-3
CONTROLLER FAULT
INDICATOR LED L2
CR5
85
C6B-40 OR
OR/RD
OR/RD
COIL-PR1
INTERLOCK
OFF-LIMIT SPEED INPUT
BL/WH
POT. HI
REVERSE
POT. LOW
FORWARD
+48V INPUT
DIODE RETURN
RD 20
-
6
+
LEFT
BOX
86
-
+
F2
200 A
RD
TB42
OR/RD
PR1
+48V DC
C6B-24
C6B-12
RD/WH
WH/RD
48V DC
AP2
WH/BK
5
WH
F4
500 A
OR/RD
F5
10A
C31REV WH/BK
C31REV WH/BK
C40LS OR
C40LS OR
P24BAT WH
P24BAT WH
C4P-4
C4P-1
C16DRE OR/RD
C12DRE BL/WH
C13DREL BL/RD
R41DRE OR/BK
C2P-3
C4B-1
BL/RD
BRN
C6B-16 C16DRE
C6B-26 C12DRE
C6B-13 C13DREL
C7P-3 BATGND BRN
WH-8
BK-8
C6B-36 BL
RD/WH
RD/WH
BL/WH
PS1
RD/WH
C6B-35
RD/WH
OR/RD
C4B-4
RD
C3B-12
BRN
C2B-3
C1B-10
C6B-37 BL/BK
C6B-27
RD
GR/WH
C6B-6 WH/RD
C6B-18 GR/BK
C6B-17 GR
C6B-14 OR
C6B-15 OR/BK
C6B-7 BK
C6B-8 BK/WH
C6B-1 RD
C6B-2 RD/BK
C6B-10 BL
C6B-11 BL/BK
C6B-5 WH/BK
C6B-4 WH
C7B-3 BATGND BRN
C25-2
C24-2
C26-2
C27-2
C6B-21 DREGND BRN
C15-1
C14-1
C23-2
C22-2
C20-2
C21-2
C16-2
C18-2
C12-2
C13-2
C18-2
C19-2
C15-2
C14-2
(GND)
BRN-8
RD-8
C19-1
C18-1
C13-1
C12-1
C17-1
C16-1
C21-1
C20-1
C22-1
C23-1
C6B-19
GR/WH
C25-1
C24-1
C26-1
C27-1
+
21
14
7
30
3
DRIVE
ENABLE
LIMIT
SWITCH
33
C36STCC BL
C1P-10
C1B-11
RD
OR/RD
TB37
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
N.O. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
PRIMARY LIFT PUMP
RELAY COIL PR2
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL
PR3
LIFT PUMP
CONTACTOR RELAY
CR20
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT /
JIB DOWN
PLATFORM
ROTATE LEFT /
JIB UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 48
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C37STC BL/BK
C1P-11
C1B-1
RD
C4B-7 GR/WH
C3B-6 WH/RD
DOWN
UP
C4B-6 GR/BK
LEFT
RIGHT
C4B-5 GR
C2B-7
UP
DOWN
UP
RETRACT
EXTEND
TB27
8
BK
BK
PR2
C27AUX RD
CR5
22
LS3
5
87
C3P-12
C1P-1
C19LPMP GR/WH
C6LFC WH/RD
C2B-6
C45JSV GR/WH
JIB MANIFOLD
C4B-2
C4B-3
C3B-7
C3B-8
DOWN
UP
DOWN
RIGHT
LEFT
PR2
C6B-38 GR/WH
GR/WH
GR/WH
RD
AUXILIARY
PUMP
CR5
CR5
C12DRE BL/WH
13
6
TB36
CR3
BK C44DA C6B-33
RD-AUX
C4P-7
C3P-6
C17PRL GR
C18PRR GR/BK
C44JDA GR/BK
C4P-6
C4P-5
C2P-7
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C3B-1
C3B-2
C3B-10
C3B-11
C3B-5
C3B-4
TB19
87
CR20
85
OR/RD
C2P-6
C4P-2
C4P-3
C3P-7
C3P-8
C1PBU RD
C2PBD RD/BK
C3P-1
C3P-2
C4TRL WH
C4TRR WH/BK
C11SBD BL/BK
C10SBU BL
C3P-11
C3P-10
C3P-5
C3P-4
TS51
RD
OR
OR/RD
OR/BK
WH
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
F
4
BCI OPTION
3
9
85
RIGHT
LEFT
PR3
85
87
87a
86
30
TB6
PR3
86
TB12
OR/RD
P42BAT OR/RD
BCI
E
A2
33
A3
J1
GR/WH
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
TS58
TS57
TS59
TS63
TS61
TS60
+
BK/RD
BRAKE
RELEASE
JACK
TS62
CR7
85
JIB
BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
86
TB18
TB4
+
C6B-23 P20BAT RD
P20BAT RD
85 BRN
85
RD
8
DRIVE
10
L R
STEER
BP1
BRN
86
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
87
L.V.I.
87
ROTARY
OEM
FLOW
CONTROL
DRIVE
ENABLE
LED L1
TS1
6
LIFT
DISCHARGE
7
SET TO "N"
SET TO "B"
5
OR/BK-R6
CR19B
3
FWD
4
REV
1
2
3
2
BK
4
5
6
7
8
86
86
85
CR19A
30
CR19B
87
TS8
RESET
CR19A
30
86
CR8
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
1
TS7
30
TB44
RD
FUNCTION
ENABLE
C32JSL WH/RD
C32JSL WH/RD
1
C29JSH RD/WH
C29JSH RD/WH
2
DP1
BCI
87a
C30FWD WH
LVI/BCI OPTION
C30FWD WH
20K
3
5
4
JIB
BOOM
30
PLATFORM
ROTATE
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
AUX
ON
TS55
Electrical Schematic, Z-45/25J
REV A
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 21180 to 22050)
R42BAT OR/RD
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J, ANSI and CSA Models
(from serial number 22051 to 23235)
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
BK
2
C132 PLI BL/WH
C1B-12
TS2
ENGINE
START
LOW
RPM
HIGH
RPM
FOOTSWITCH
HIGH RPM
TS4
RPM
L48
C1P-8
C1P-7
C1P-9
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C2B-4
C1B-8
C1B-7
C1B-9
D40
C7B-2
GR/BK
TS6
GLOW
PLUGS
C2P-4
8
P24BAT WH
C3B-3
12
7
P24BAT WH
P23BAT WH
5
C9P-2
C3BAT RD/WH
C1B-2
6
WH-(FS)
C7P-2
C2B-5
5
C32
P25BAT RD
C3P-3
C28TTA RD/BK
C6B-29
C134PWR GR
C2B-2
C6B-32
C2P-5
C1B-3
C6B-31
C1P-2
C40LS OR
C1B-6
C6B-30
C3B-9
C29JSH RD/WH
C1B-5
C9HRN BK/RD
C3P-9
4
6
C7B-2
C32JSL WH/RD
C1B-4
OR
3
P23BAT WH
C2P-2
C1P-3
C1P-6
C31REV WH/BK
C7B-4
C30FWD WH
P20BAT RD
4
C1P-5
C1P-4
3
1
C7B-1
TB22
GROUND
C9P-3
7
A1
TILT
ALARM
+
P3
HORN
PLATFORM
KS1
P1
P20BAT RD
LS18
RD-(FS)
R42BAT OR/RD
RD
C1P-12
RD
CB1
10 A
BK-(FS)
C9P-1 BK
P26BAT
RD
P22BAT
TB134
FS1
P2
C7P-1
RD
OR
TB40
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
+
-
+
+
3
START INPUT
4
(NOT USED)
5
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
86
IGNITION ON
10
ENGINE FAULT
CR16
86
86
87
BRN
BRN
BRN
GR/BK
BATT
BK
-
WH-BATT
WH
AP2
AUXILIARY
(12V DC)
C5B-2
BRN
A2
9
85
CR14
BRN
86
85
87
85
CR15
BK/RD
ALT.
BL
WH
CR13
BRN
87
BL
VR1
85
BK/WH
YEL
(12V DC)
30
30
30
RD
+12V DC
WH-J4
BRN
-
87
86
WH
-
CR12
BRN
+
TACH. INPUT
BK
+
C5B-1 P20BAT RD
C34SA BK/WH
30
85
STARTER
OR-GEN POS
ENGINE
GROUND
(GND)
BK
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC
ALERNATOR
12V DC VOLTAGE
REGULATOR
ENGINE POWER
RELAY CR12
Part No. 106488
ENGINE RUN SOLENOID
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
STARTER RELAY CR11
ANSI/CSA
48V DC POWER
RELAY CR2
ADD D40 ONLY IF UNIT HAS L4 AND L48.
7
48V DC POWER
RELAY CR1
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
FLASHING
BEACON
OPTION
6
TILT SENSOR
SWITCH SHOWN WITH BOOM EXTENDED.
NOTES:
HOUR METER
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
2
6 - 49
2
BK
AUXILIARY
LIFT PUMP
8
START RELAY
BL-ISM2
C5B-18
C35HRPM
C5B-22
CR11
BK
C8-C
WH
RD
+
87
86
87
AP1
ENGINE
START
GLOW
PLUGS
BRN
RD/WH
RD
RD/BK
30 CR16
14
85
C8-B
AC POWER
22
30
(12V DC)
2
1
C5B-3 C23PWR WH
+
13
LS1
(EXT)
RD-J10 (12GA)
FB
BRN
BK
OR-GEN NEG
GROUND
C5B-11 C21IGN2 WH
IGNITION / START
MODULE
BK-ISM1
C5B-5 C33STR BK
85
87
HIGH
TB35
87
BRN
C6B-34
86
C6B-9 BK/RD
-
-
WH-6
CHARGER
C11-2
LS2 21
(PRI)
BK-6
F1
RIGHT
MOTOR
C11-1
F2
BK-7
A1
WH-7
A2
A1
BK 2 GA
7
ALTERNATOR
A2
C11-4
PUMP
+
F1
C11-3
-
WH
+
PUMP
LEFT
MOTOR
F2
85
LOW
TB33
TB34
30
CR1
15 A
PR2
+
87
+
C8-A
B-
F2
RD-5
B+
HM
CR4
-
+
RIGHT
BOX
M-
F1
86
C6B-28
WH-5
BK-5
30
BK
85
CB3
MOTOR CONTROLLER
PR3
RD/BK
BK
C10-2
C10-1
WH-4
BK-4
+24V DC
F1
200A
30
TS54
RPM
TS52
C23PWR WH
_
BK-5
AP1
D2
21
LS4
(SEC)
22
5
20
17
6
86
TS56
TB23
U6A
24V DC
CR2
OR/RD
BK/RD
C6B-20 RD
BK
C10-4
C6B-25 CFIL BK
C6B-39 CR5 RD/BK
GR
3
16
2
11
14
10
1
9
AP2
C10-3
CONTROLLER FAULT
INDICATOR LED L2
85
CR5
COIL-PR1
POT. HI
INTERLOCK
OFF-LMT SPD INP
BL/WH
POT. LOW
FORWARD
REVERSE
+48V INPUT
-
+
DIODE RETURN
RD 20
F2
200A
C6B-40 OR
OR/RD
OR/RD
86
-
+
5
RD
TB42
OR/RD
C6B-24
C6B-12
RD/WH
WH/RD
PR1
+48V DC
LEFT
BOX
WH/BK
F4
500A
48V DC
WH
AP2
OR/RD
F5
10A
C29JSH RD/WH
C32JSL WH/RD
C40LS OR
C40LS OR
P24BAT WH
P24BAT WH
RD-AUX
RD
C3P-12
C4P-1
C36STCC BL
C1P-10
R41DRE OR/BK
C2P-3
C16DRE OR/RD
C12DRE BL/WH
C13DREL BL/RD
C1B-11
C1B-10
C2B-3
C4B-4
C3B-12
C4B-1
BL/RD
C7P-3 BATGND BRN
C6B-13 C13DREL
C6B-26 C12DRE
C6B-16 C16DRE
BK-8
WH-8
RD/WH
RD/WH
21
C6B-11 BL/BK
C6B-10 BL
C6B-2 RD/BK
C6B-1 RD
C6B-8 BK/WH
C6B-7 BK
C6B-15 OR/BK
C6B-14 OR
C6B-17 GR
C6B-18 GR/BK
C6B-6 WH/RD
GR/WH
C6B-27
RD
C6B-37 BL/BK
14
C6B-5 WH/BK
BRN-8
RD-8
C7B-3 BATGND BRN
C6B-21 DREGND BRN
C26-2
C24-2
C25-2
C19-1
C18-1
C13-1
C12-1
C17-1
C16-1
C21-1
C20-1
C22-1
C23-1
C19-2
C18-2
C13-2
C12-2
C18-2
C16-2
C21-2
C20-2
C22-2
C23-2
C6B-19
GR/WH
C25-1
C24-1
C26-1
+
3
C6B-36 BL
LS3
BRN
BL/WH
OR/RD
C6B-35
RD/WH
PS1
RD
OR/RD
TB37
DRIVE
ENABLE
LIMIT
SWITCH
33
BRN
C4P-4
C37STC BL/BK
C1P-11
LEFT
RIGHT
C4B-5 GR
C4B-6 GR/BK
UP
DOWN
C3B-6 WH/RD
C4B-7 GR/WH
RD
5
C2B-7
UP
DOWN
UP
DOWN
UP
RETRACT
EXTEND
TB27
C15-1
C14-1
C15-2
C14-2
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
PRIMARY LIFT PUMP
RELAY COIL PR2
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL
PR3
LIFT PUMP
CONTACTOR RELAY
CR20
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT /
JIB DOWN
PLATFORM
ROTATE LEFT /
JIB UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 50
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C1B-1
C1P-1
C19LPMP GR/WH
C2B-6
C6LFC WH/RD
BK
JIB MANIFOLD
C45JSV GR/WH
C4B-2
C4B-3
C3B-7
C3B-8
CR5
22
13
C6B-4 WH
PR2
C27AUX RD
AUXILIARY
PUMP
C4P-7
C3P-6
C17PRL GR
C18PRR GR/BK
C44JDA GR/BK
C4P-6
C4P-5
WH
C2P-7
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C3B-1
C3B-2
DOWN
RIGHT
LEFT
85
OR/RD
C2P-6
C4P-2
C4P-3
C3P-7
C3P-8
C1PBU RD
C2PBD RD/BK
C3P-1
C3P-2
C3B-10
C3B-11
87
8
BK
BK
PR2
7
87
CR20
C6B-38 GR/WH
GR/WH
GR/WH
86
6
TB36
CR3
BK C44DA C6B-33
30
PR3
86
OR
OR/RD
OR/BK
WH
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
C10SBU BL
C11SBD BL/BK
C3P-10
C3P-11
C3B-5
C3B-4
PR3
BCI OPTION
A2
33
A3
F
C4TRR WH/BK
TB19
BCI
E
C4TRL WH
+
85
87
87a
86
30
TB6
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
GR/WH
TB18
TB4
UP
DOWN
C3P-5
C3P-4
CR5
CR5
C12DRE BL/WH
3
87
BRN
9
85
RIGHT
LEFT
TS51
RD
TB12
OR/RD
P42BAT OR/RD
30
AUX
ON
RD
TS58
TS57
TS59
TS63
TS61
TS60
TS62
86
JIB
BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
CR7
85
+
BK/RD
SET TO "N"
SET TO "B"
85 BRN
87
85
RD
8
DRIVE
10
L R
STEER
BP1
7
L.V.I.
86
85
CR19A
30
CR19B
87
ROTARY
OEM
FLOW
CONTROL
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
DRIVE
ENABLE
LED L1
LIFT
6
DISCHARGE
OR/BK-R6
5
TS1
1
2
3
4
5
6
7
3
FWD
4
8
CR19B
2
BK
REV
86
RESET
CR19A
30
86
CR8
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
1
A
B
C
4
RD
C31REV WH/BK
C31REV WH/BK
1
C29JSH RD/WH
C32JSL WH/RD
2
DP1
BCI
87a
C30FWD WH
LVI/BCI OPTION
C30FWD WH
20K
3
5
4
JIB
BOOM
TS8
30
PLATFORM
ROTATE
TS7
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
TB44
FUNCTION
ENABLE
TS55
Electrical Schematic, Z-45/25J, ANSI and CSA Models
REV A
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 22051 to 23235)
R42BAT OR/RD
(GND)
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J, ANSI and CSA Models
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Electrical Schematic, Z-45/25J, CE Models
(from serial number 22051 to 23235)
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
C7P-1
BK
2
C132PLI BL/WH
C1B-12
A1
TILT
ALARM
LOW
RPM
HIGH
RPM
FOOT SWITCH
HIGH RPM
C2P-4
C1P-8
C1P-7
C1P-9
R42BAT OR/RD
C34SA BK/WH
C33STR BK
C35HRPM BK/RD
C3B-3
C2B-4
C1B-8
C1B-7
C1B-9
C7B-2
C3BAT RD/WH
P23BAT WH
C3P-3
C7P-2
C1B-2
C6B-29
C2B-5
C6B-32
C28TTA RD/BK
C1B-3
C6B-31
C134PWR GR
C1B-6
C6B-30
C2B-2
C1B-5
C7B-4
C1B-4
GR/BK
C2P-5
P20BAT RD
L45
D40
C1P-2
8
6
TS2
ENGINE
START
TS4
RPM
C3B-9
7
P24BAT WH
TS6
GLOW
PLUGS
C9HRN BK/RD
5
P24BAT WH
C3P-9
C40LS OR
C29JSH RD/WH
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
6
12
C9P-2
C7B-2
5
U33
WH-(FS)
P23BAT WH
3
P25BAT RD
C7P-2
C7B-1
C2P-2
C1P-3
C1P-6
C1P-5
C1P-4
1
4
A6
OR
+
D39
GROUND
C9P-3
R42BAT OR/RD
L4
5
P3
HORN
TB22
3
4
LS18
PLATFORM
KS1
P1
P20BAT RD
RD-(FS)
RD
C1P-12
RD
CB1
10A
BK-(FS)
C9P-1 BK
P26BAT
RD
P22BAT
TB134
FS1
P2
RD
OR
TB40
CR5
C12DRE BL/WH
P42BAT OR/RD C6B-3
P42BAT OR/RD
C6B-22
GROUND
6
BATTERY
7
KEY SWITCH POWER
8
(NOT USED)
9
IGNITION ON
10
ENGINE FAULT
CR16
GR/BK
BATT
BRN
+12V DC
-
(NOT USED)
5
86
BRN
-
+
START INPUT
4
86
87
BRN
-
+
+
3
WH-BATT
WH
AP2
AUXILIARY
C5B-2
ENGINE
GROUND
(GND)
BK
PR2
PR2
PR3
PR3
WATER
TEMPERATURE
SWITCH
OIL
PRESSURE
SWITCH
ALTERNATOR
FIELD RELAY CR16
RPM CUTOUT
RELAY CR13
RPM RELAY CR14
RPM SOLENOID
GLOW PLUG
RELAY CR15
GLOW PLUGS
12V DC ALERNATOR
12V DC VOLTAGE REGULATOR
ENGINE POWER RELAY CR12
ENGINE RUN SOLENOID
Part No. 106488
STARTER RELAY CR11
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
48V DC POWER RELAY CR2
ADD D40 ONLY IF UNIT HAS L4 AND L48.
48V DC POWER RELAY CR1
6
FLASHING BEACON OPTION
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
CE & PLATFORM LOAD SENSE OPT.
TILT SENSOR
SWITCH SHOWN WITH BOOM EXTENDED.
5
HOUR METER
2
NOTES:
HORN RELAY
HORN
BASE CONTROL
BOX GROUND
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
MOTOR MAIN
CONTACTOR
RELAY PR1
48V DC
CHARGER
48V DC
ALTERNATOR
PRIMARY
LIFT PUMP
6 - 51
TACH. INPUT
(12V DC)
BRN
A2
OR-GEN POS
START RELAY
2
85
BK
AUXILIARY
LIFT PUMP
8
86
CR14
BRN
BK
STARTER
85
87
85
CR15
BK/RD
ALT.
BL
86
WH
IGNITION / START
MODULE
1
CR13
BRN
87
BL
VR1
85
BK/WH
YEL
(12V)
30
30
30
RD
-
WH-J4
BRN
+
87
86
(12V DC)
WH
+
CR12
BRN
+
86
30
85
BK
14
CR11
+
2
C34SA BK/WH
WH
RD
LS1
(EXT)
85
BK
C8-C
87
13
C5B-1 P20BAT RD
C5B-22
30
87
AP1
ENGINE
START
GLOW
PLUGS
BRN
RD/WH
RD
RD/BK
30 CR16
C5B-18
C35HRPM
C5B-3 C23PWR WH
15 A
C8-B
AC POWER
C5B-5 C33STR BK
FB
BRN
BK
OR-GEN NEG
GROUND
22
BL-ISM2
85
87
C6B-9 BK/RD
-
-
WH-6
CHARGER
C11-2
LS2 21
(PRI)
BK-6
RIGHT
MOTOR
C11-1
A1
BK-7
A1
F1
BK 2 GA
7
ALTERNATOR
F1
F2
WH-7
PUMP
F2
+
A2
BK-ISM1
C5B-11 C21IGN2 WH
C8-A
BK
C11-4
-
WH
+
PUMP
86
HIGH
TB35
CB3
C11-3
-
+
+
A2
LOW
87
RD-J10 (12GA)
PR2
LEFT
MOTOR
85
TS54
RPM
TB33
TB34
30
_
RD-5
B-
87
+
CR4
F2
85
TS52
C23PWR WH
HM
BK-5
B+
30
CR1
BRN
C6B-34
WH-5
BK-5
WH-4
BK-4
5
20
17
M-
F1
PR3
86
C6B-28
C10-2
C10-1
C10-4
C10-3
C6B-25 CFIL BK
C6B-39 CR5 RD/BK
GR
2
3
16
F1
200A
RD/BK
BK
D2
21
LS4
(SEC)
22
U6A
MOTOR CONTROLLER
86
OR/RD
BK/RD
C6B-20 RD
C6B-40 OR
CONTROLLER FAULT
INDICATOR LED L2
CR5
COIL-PR1
POT. HI
INTERLOCK
OFF-LMT SPD INP
BL/WH
11
14
10
AP1
85
BK
CR2
TS56
TB23
30
24V DC
+24V DC
POT. LOW
FORWARD
1
9
6
REVERSE
+48V DC INPUT
DIODE RETURN
RD 20
-
+
AP2
RIGHT
BOX
OR/RD
-
+
LEFT
BOX
OR/RD
86
F2
200 A
5
RD
TB42
OR/RD
PR1
+48V DC
C6B-24
C6B-12
RD/WH
WH/RD
WH/BK
WH
F4
500 A
48V DC
AP2
OR/RD
F5
10 A
C40LS OR
C40LS OR
C29JSH RD/WH
C29JSH RD/WH
P24BAT WH
P24BAT WH
RD-AUX
OR/RD
RD
C3P-12
C4P-1
R41DRE OR/BK
C2P-3
C16DRE OR/RD
C12DRE BL/WH
C13DREL BL/RD
C1B-10
C2B-3
C4B-4
C3B-12
C4B-1
BL/RD
BRN
BL/WH
OR/RD
C7P-3 BATGND BRN
C6B-13 C13DREL
C6B-26 C12DRE
C6B-16 C16DRE
C6B-35
RD/WH
PS1
BK-8
WH-8
RD/WH
RD/WH
21
14
C6B-11 BL/BK
C6B-10 BL
C6B-2 RD/BK
C6B-1 RD
C6B-8 BK/WH
C6B-7 BK
C6B-15 OR/BK
C6B-14 OR
C6B-17 GR
C6B-18 GR/BK
C6B-6 WH/RD
GR/WH
C6B-27
RD
C6B-37 BL/BK
C6B-36 BL
LS3
C6B-5 WH/BK
BRN-8
RD-8
C7B-3 BATGND BRN
C6B-21 DREGND BRN
C26-2
C24-2
C25-2
C19-1
C18-1
C13-1
C12-1
C17-1
C16-1
C21-1
C20-1
C22-1
C23-1
C19-2
C18-2
C13-2
C12-2
C18-2
C16-2
C21-2
C20-2
C22-2
C23-2
C6B-19
GR/WH
C25-1
C24-1
C26-1
+
3
DRIVE
ENABLE
LIMIT
SWITCH
33
BRN
C4P-4
C36STCC BL
C1P-10
C1B-11
RD
OR/RD
TB37
C15-1
C14-1
C15-2
C14-2
BRAKE RELEASE
TRAVEL ALARM (A2)
BRAKE RELEASE
N.C. COIL
STEER LEFT COIL
BRAKE RELEASE
PRESSURE SWITCH PS1
STEER RIGHT COIL
PRIMARY LIFT PUMP
RELAY COIL PR2
AUXILIARY CONTROL
RELAY COIL CR3
AUXILIARY LIFT
PUMP RELAY COIL
PR3
LIFT PUMP
CONTACTOR RELAY
CR20
FLOW
CONTROL
COIL
PLATFORM
ROTATE RIGHT /
JIB DOWN
PLATFORM
ROTATE LEFT /
JIB UP
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
PLATFORM LEVEL
CUTOUT DOWN
RELAY COIL CR10B
PRIMARY BOOM
RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
DOWN COIL
PRIMARY BOOM
UP COIL
SECONDARY BOOM
DOWN COIL
SECONDARY BOOM
UP COIL
DESCENT
ALARM
OPTION (A3)
TURNTABLE
ROTATE RIGHT
COIL
TURNTABLE
ROTATE LEFT
COIL
6 - 52
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
C37STC BL/BK
C1P-11
RD
C4B-7 GR/WH
C3B-6 WH/RD
DOWN
UP
C4B-6 GR/BK
LEFT
RIGHT
C4B-5 GR
C2B-7
UP
DOWN
DOWN
UP
RETRACT
EXTEND
TB27
22
13
C6B-4 WH
BK
BK
PR2
C1B-1
C1P-1
C19LPMP GR/WH
C2B-6
C6LFC WH/RD
BK
JIB MANIFOLD
C45JSV GR/WH
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
UP
DOWN
RIGHT
LEFT
PR2
C27AUX RD
AUXILIARY
PUMP
C4P-7
C3P-6
C17PRL GR
C18PRR GR/BK
C44JDA GR/BK
C4P-6
C4P-5
WH
C2P-7
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C3B-2
CR5
7
87
CR20
85
OR
C2P-6
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C2PBD RD/BK
C3B-10
C3B-11
C3B-5
C3B-4
87
A
B
8
PR3
OR/RD
OR/BK
WH
DOWN
UP
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
C3P-2
C10SBU BL
C11SBD BL/BK
C4TRR WH/BK
CR3
BK C44DA C6B-33
30
PR3
86
TB36
86
30
C6B-38 GR/WH
GR/WH
GR/WH
A2
33
A3
BCI OPTION
86
9
6
85
87
87a
F
C4TRL WH
TB19
BCI
E
C3P-10
C3P-11
C3P-5
CR5
CR5
C12DRE BL/WH
3
87
BRN
C3P-4
+
DOWN
UP
DOWN
RIGHT
LEFT
TS51
RD
TB12
OR/RD
P42BAT OR/RD
5
TS58
+
BK/RD
ROTARY
OEM
FLOW
CONTROL
30
AUX
ON
RD
TB6
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB11
TB5
CR7
85
TB18
TB4
GR/WH
TS57
TS59
TS63
TS61
TS60
TS62
86
JIB
BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
SECONDARY
BOOM
TURNTABLE
ROTATE
85 BRN
87
3
85
RD
BP1
DRIVE
10
L R
STEER
8
SET TO "N"
2
CR6
RD/BK-R6
TS15
DRIVE 30
ENABLE
7
CR19A
30
CR19B
87
1
DRIVE
ENABLE
LED L1
LIFT
L.V.I.
86
85
SET TO "B"
6
85
OR/BK-R6
5
TS1
CR8
86
FWD
4
REV
1
2
3
4
5
6
7
8
CR19B
DISCHARGE
RESET
CR19A
30
2
20K
4
RD
C31REV WH/BK
C31REV WH/BK
1
C32JSL WH/RD
C32JSL WH/RD
CE VERSION:
REMOVE
JUMPER
30
AND ADD
RELAY
87
86
C30FWD WH
LVI/BCI OPTION
C30FWD WH
DP1
BCI
87a
BK
3
5
4
JIB
BOOM
TS8
30
PLATFORM
ROTATE
TS7
PLATFORM
LEVEL
TS9
PRIMARY
BOOM
TS13
PRIMARY
BOOM
TS11
SECONDARY
BOOM
TS10
TURNTABLE
ROTATE
TS12
TB44
FUNCTION
ENABLE
TS55
Electrical Schematic, Z-45/25J, CE Models
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
June 2005
(from serial number 22051 to 23235)
R42BAT OR/RD
(GND)
June 2005
Section 6 • Schematics
Electrical Schematic, Z-45/25J, CE Models
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(before serial number 13361)
6 - 53
BLK-LED
M.H.
SECONDARY BOOM
LIMIT SWITCH (LS4)
CABLE #4
#3
M.H.
EXT.
PRIMARY
SECONDARY
7
ENABLE
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
PRIMARY BOOM
LIMIT SWITCH (LS2)
CABLE #5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
DRIVE ENABLE LIMIT
SWITCH (LS3)
CABLE #7
BOOM
CABLE #3
Part No. 106488
BOOM
CABLE #2
FAULT
STATUS
LED
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
BOOM
CABLE #1
FUNCTION
MANIFOLD
HARNESS
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
LIFT PUMP
14
15
16
17
18
19
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
49
50
50
49
48
GRN/WHT-19
ORG/RED-42 LED
8
+
SPARE
PLUGGED
CHASSIS
HARNESS
GRN/WHT-R3
BLK/RED-R4
(TO
SWITCH
PANEL)
GROUND
CONTROL
BOX
HARNESS
K
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
BRAKE RELEASE
48
47
46
45
44
43
42
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BL-15
ORG-14
BLU/WHT-12
J
ORG/RED-42 LED
ORG/BLK
ORG
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
(UNUSED)
(UNUSED)
47
45
46
(SPARE)
JIB VALVE
44
(SPARE)
SWITCH 48 VOLTS
42
43
DRIVE ENABLE OUTPUT
41
41
40
OFF LIMIT SPEED
38
37
40
37
36
39
STEER RIGHT
36
35
(SPARE)
STEER LEFT
35
34
CONTROLLER FAULT LED
HIGH/LOW RPM
34
32
33
39
GLOW PLUG
33
31
30
29
28
27
26
25
24
23
22
21
20
19
19
18
17
16
15
14
38
JOYSTICK POTENTIOMETER LOW
START ENGINE
32
FORWARD
REVERSE
JOYSTICK POT. HIGH
29
30
TILT ALARM
28
31
AUXILIARY PUMP SELECT
(UNUSED)
26
27
(UNUSED)
(UNUSED)
KEYSWITCH POWER
23
25
+24 VOLT TO PATFORM
22
24
HOUR METER ENABLE
+24 VOLT POWER
21
20
LIFT PUMP
DRIVE ENABLE LIGHT
13
19
FOOTSWITCH POWER #2
13
11
12
11 SECONDARY BOOM DOWN
12
BLU-10
BLK
BLU/BLK-11
I
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
6
H
GRN/BLK
9
BLK/WHT-8
BLK/RED-R4
G
ORG/RED
ORG/RED-42
GRN
HORN
9
8
BLK-7
F
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
PRIMARY BOOM RETRACT
8
7
GRN/WHT
E
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
RED
PRIMARY BOOM EXTEND
7
6
WHT/BLK-5
D
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
LIFT FLOW CONTROL
6
5
WHT-4
2
RED-20
TURNTABLE ROTATE LEFT
5
4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
GRN/WHT-19
ORG/RED
RED
GRN
GRN
GRN/BLK
GRN/BLK
GRN/WHT
GRN/WHT
TURNTABLE ROTATE RIGHT
4
3
A
B
ORG/BLK
48 V RELAY COIL POWER
3
2
10
PRIMARY BOOM DOWN
2
1
10 SECONDARY BOOM UP
PRIMARY BOOM UP
B
A
BLU
BLU
BLU/BLK
BLU/BLLK
BLU/WHT
WHT
BLU/RED
BLK
ORG
5
1
TERMINAL BASE (TB)
4
C
3
WHT
WHT
WHT/BLK
WHT/BLK
WHT/RED
WHT/RED
BLK
BLK
BLK/WHT
BLK/WHT
BLK/RED
RED
RED
RED/BLK
RED/BLK
RED/WHT
D
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(before serial number 13361)
L
M
BASE BOX HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
N
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
RED-ALARM (USED ONLY FOR FLASHING BEACON OPTION)
GROUND CONTROL BOX HARNESS
RED
WHT-23
RED
HOUR METER
H.M.
RED
BLK-22
BRN
RED
RED
Part No. 106488
85
ORG/BLK-41
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
30
85
WHT-40
ORG/BLK
ORG
BRN
PLATFORM LEVEL
CUTOUT UP RELAY
CR10B
WHT
86
WIRE GOES
TO T.B. 27A
30
RED-27
GRN/WHT-19
30
85
PLATFORM LEVEL
CUTOUT DOWN
RELAY CR10A
86
87
87a
GRN/BLK-18
BRAKE RELEASE
RELAY CR5
86
87
UNUSED
B
HORN RELAY
CR4
85
GRN/WHT-R3
87a
86
ORG
30
BRN
86
87
RED-27P
87
30
87a
ORG/BLK
ORG
87a
85
ORG/BLK
BLK-22
87
86
BLK
87
ORG/RED
30
87a
C
87a
RED
ORG/RED
BRN
85
BRN
BRN
86
GRN/BLK
87
87a
30
BRN
AUXILIARY CONTROL
RELAY CR3
BLK
D
BRN
ORG/RED-42
RED
85
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
RED
PLATFORM
ROTATE TS57
E
48 V
POWER
RELAY CR2
RED
PLATFORM
LEVEL TS59
RED
BLK
GRN/WHT-45
GRN/BLK-18
ORG/BLK-15
F
ORG/RED-R2
RED/WHT-3
RED/WHT-3
48 V POWER
RELAY CR1
RED
GRN-17
GRN
RED
ORG
BLK
RED
ORG/BLK
GRN-17
TURNTABLE
ROTATE
TS62
G
CIRCUIT
BREAKER 10A
CB1
RED
RED
ORG-14
BLK
RED
RED
BLK
RED
BLK
RED
RED-20
SECONDARY
BOOM TS60
BLU-10
BLU/BLK-11
WHT/BLK-5
WHT-4
REV A
FUNCTION
ENABLE TS55
BRN
RED
GRN/WHT-19
BLK
RED
PRIMARY
BOOM
EXTEND/
RETRACT
TS63
HIGH/LOW
RPM
TS54
H
RED
BLK-22
RED
RED
GLOW
PLUG TS56
BLK/WHT-34
BLK-33
PRIMARY
BOOM
TS61
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
RED-27
RED
BLK/RED-35
RED
RED
RED
START
ENGINE
TS51
BLK-33
WHT-21
BRN
WHT-23
RED
AUXILIARY
PUMP TS51
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
BLK-22
RED-POWER
J
3
2
WHT-23
KEY SWITCH
KS1
K
GROUND CONTROL BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
L
ON
M
NO
N
EMERGENCY
STOP
P1
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 13361)
A
BLK
1
WHT
2
WHT
BRN
BLK/RED-9
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 54
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(before serial number 13361)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 13361 to 14078)
BLK-LED
M.H.
8
SECONDARY BOOM
LIMIT SWITCH (LS4)
CABLE #4
6 - 55
#3
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
PRIMARY BOOM
LIMIT SWITCH (LS2)
CABLE #5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
M.H.
EXT.
SECONDARY
PRIMARY
ENABLE
BOOM
CABLE #3
Part No. 106488
BOOM
CABLE #2
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
7
GRN/WHT-19
FAULT
STATUS
LED
BOOM
CABLE #1
FOOTSWITCH POWER #2
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
12
13
14
15
19
19
26
29
30
31
32
39
40
FORWARD
REVERSE
JOYSTICK POTENTIOMETER LOW
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
(SPARE)
CONTROLLER FAULT LED
OFF LIMIT SPEED
DRIVE ENABLE OUTPUT
SWITCH 48 VOLTS
31
32
33
34
35
36
37
38
39
40
41
42
FUNCTION
MANIFOLD
HARNESS
LS2-LS4 JUNCTION
50
50
49
GRN/WHT-19
ORG/RED-42 LED
DRIVE ENABLE LIMIT
SWITCH (LS3)
CABLE #7
SPARE
PLUGGED
CHASSIS
HARNESS
GRN/WHT-R3
BLK/RED-R4
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
(TO
SWITCH
PANEL)
GROUND
CONTROL
BOX
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
LS1-LS2 JUNCTION
49
RED/WHT-48
1
48
GRN/WHT-45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BL-15
ORG-14
BLU/WHT-12
K
ORG/RED-42 LED
ORG/BLK
ORG
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
BRAKE RELEASE
48
47
46
(UNUSED)
(UNUSED)
45
47
45
JIB VALVE
44
46
44
(SPARE)
(SPARE)
43
43
42
41
38
37
36
35
34
33
28
JOYSTICK POT. HIGH
27
30
(UNUSED)
26
25
29
(UNUSED)
25
23
24
TILT ALARM
(UNUSED)
24
28
KEYSWITCH POWER
23
22
AUXILIARY PUMP SELECT
+24 VOLT TO PATFORM
22
21
20
27
HOUR METER ENABLE
+24 VOLT POWER
21
20
19
LIFT PUMP
18
LIFT PUMP
18
PLATFORM ROTATE LEFT/JIB UP
17
19
16
17
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE RIGHT/JIB DOWN
16
14
13
12
11
BLU-10
BLK
BLU/BLK-11
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
SECONDARY BOOM DOWN
11
10
I
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
SECONDARY BOOM UP
10
9
H
GRN/BLK
HORN
9
BLK/WHT-8
BLK/RED-R4
G
ORG/RED
ORG/RED-42
GRN
15
PRIMARY BOOM RETRACT
8
BLK-7
F
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
7
PRIMARY BOOM EXTEND
7
GRN/WHT
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
E
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
RED
6
LIFT FLOW CONTROL
6
A
D
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
5
TURNTABLE ROTATE LEFT
5
8
4
TURNTABLE ROTATE RIGHT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
3
1
PRIMARY BOOM UP
1
B
C
GRN/WHT-19
ORG/RED
RED
GRN
GRN
GRN/BLK
GRN/BLK
GRN/WHT
GRN/WHT
5
B
ORG/BLK
4
TERMINAL BASE (TB)
A
BLU
BLU
BLU/BLK
BLU/BLLK
BLU/WHT
WHT
BLU/RED
BLK
ORG
C
3
D
2
WHT
WHT
WHT/BLK
WHT/BLK
WHT/RED
WHT/RED
BLK
BLK
BLK/WHT
BLK/WHT
BLK/RED
RED
RED
RED/BLK
RED/BLK
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 13361 to 14078)
L
M
BASE BOX HARNESS
#3
#1
#2
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENSION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
N
RED-ALARM (USED ONLY FOR FLASHING BEACON OPTION)
GROUND CONTROL BOX HARNESS
RED
WHT-23
RED
HOUR METER
H.M.
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
87
30
87a
86
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
RED-27
GRN/WHT-19
30
85
WIRE GOES
TO T.B. 27A
30
86
87
B
CR4
HORN RELAY
ORG/BLK-41
87
86
GRN/WHT-R3
87a
BRN
85
85
RED-27P
BLK-22
86
ORG/RED
87
ORG/BLK
ORG
87
RED
ORG/RED
BRN
86
C
87a
85
30
87a
BLK
85
87
30
87a
BRN
BRN
86
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
D
BRN
RED
30
CR2
48V DC
POWER
RELAY
E
ORG/RED-R2
RED/WHT-3
RED/WHT-3
BLK
BLK
RED
RED
GRN/WHT-45
GRN/BLK-18
BLK
GRN-17
TS57
PLATFORM
ROTATE
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
RED
ORG/BLK
F
CR1
48V DC POWER RELAY
RED
BLK
RED
ORG/BLK-15
ORG
GRN-17
TS62
TURNTABLE
ROTATE
G
CB1
CIRCUIT
BREAKER 1
RED
RED
ORG-14
BLK
RED
RED
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
BLU-10
BLU/BLK-11
GRN/WHT-19
REV A
TS55
FUNCTION
ENABLE
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
RED
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
RED-27
RED
BLK/RED-35
RED
RED
TS51
ENGINE
START
BLK-33
WHT-21
BRN
WHT-23
RED
I
TS56
GLOW
PLUG
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
J
3
2
WHT-23
BLK-22
RED-POWER
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 13361 to 14078)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 56
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 14079 to 14650)
8
6 - 57
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
33
34
35
37
38
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
32
33
34
35
36
37
42
SWITCH 48 VOLTS
41
42
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
41
DRIVE ENABLE OUTPUT
40
(SPARE)
40
OFF-LIMIT SPEED
39
43
39
(SPARE)
CONTROLLER FAULT LED
38
36
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
A ORG-14
ORG/BLK
A ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 14079 to 14650)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
A NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
87
30
87a
86
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
85
87
B
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
BRN
WIRE GOES
TO T.B. 27A
87a
GRN/WHT-R3
85
86
RED-27P
BLK-22
86
85
ORG/BLK
ORG
87
ORG/RED
87
BLK
87a
RED
ORG/RED
BRN
86
30
87a
C
85
85
BRN
87
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
D
BRN
86
87a
30
CR2
48V DC
POWER
RELAY
E
BRN
RED
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
TS57
PLATFORM
ROTATE
RED
GRN-17
BLK
TS59
PLATFORM
LEVEL
RED
ORG/BLK
BLK
RED
GRN/WHT-45
GRN/BLK-18
ORG/BLK-15
ORG
GRN-17
TS62
TURNTABLE
ROTATE
F
CR1
48V DC POWER RELAY
RED
BLK
CB1
CIRCUIT
BREAKER 1
RED
RED
ORG-14
BLK
RED
RED
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
BLU-10
BLU/BLK-11
G
RED
RED
GRN/WHT-19
REV A
TS55
FUNCTION
ENABLE
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14079 to 14650)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 58
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 14651 to 16839)
8
6 - 59
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
33
34
35
37
38
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
32
33
34
35
36
37
42
SWITCH 48 VOLTS
41
42
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
41
DRIVE ENABLE OUTPUT
40
(SPARE)
40
OFF-LIMIT SPEED
39
43
39
(SPARE)
CONTROLLER FAULT LED
38
36
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
1 ORG-14
ORG/BLK
1 ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 14651 to 16839)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
1 NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
87
30
87a
86
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
85
87
B
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
BRN
WIRE GOES
TO T.B. 27A
87a
GRN/WHT-R3
85
86
RED-27P
BLK-22
86
85
ORG/BLK
ORG
87
ORG/RED
87
BLK
87a
RED
ORG/RED
BRN
86
30
87a
C
85
85
BRN
87
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
D
BRN
86
87a
30
CR2
48V DC
POWER
RELAY
E
BRN
RED
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
TS57
PLATFORM
ROTATE
RED
GRN-17
BLK
TS59
PLATFORM
LEVEL
RED
ORG/BLK
BLK
RED
GRN/WHT-45
GRN/BLK-18
ORG/BLK-15
ORG
GRN-17
TS62
TURNTABLE
ROTATE
F
CR1
48V DC POWER RELAY
RED
BLK
CB1
CIRCUIT
BREAKER 1
RED
RED
ORG-14
BLK
RED
RED
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
BLU-10
BLU/BLK-11
G
RED
RED
GRN/WHT-19
REV A
TS55
FUNCTION
ENABLE
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14651 to 16839)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 60
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 16840 to 17974)
8
6 - 61
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
42
SWITCH 48 VOLTS
42
(SPARE)
41
DRIVE ENABLE OUTPUT
41
43
40
OFF-LIMIT SPEED
40
37
38
37
STEER RIGHT
36
39
36
STEER LEFT
35
(SPARE)
35
HIGH/LOW RPM
34
(SPARE)
34
GLOW PLUG
33
39
33
START ENGINE
32
38
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
ORG
ORG-40
ORG/BLK
BLU/RED
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
1 ORG-14
ORG/BLK
1 ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 16840 to 17974)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
1 NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BLK/RED-R4
87
86
ORG/BLK
ORG
WHT
87
87
30
87a
86
85
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
86
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
85
87
30
87a
B
CR4
HORN RELAY
ORG/BLK-41
30
WIRE GOES
TO T.B. 27A
30
86
BRN
87
RED-27
GRN/WHT-19
87a
86
GRN/WHT-R3
85
85
RED-27P
BLK-22
86
ORG/RED
87
ORG/BLK
ORG
87
86
ORG/RED
BRN
RED
GRN/WHT-R3
87a
85
30
87a
C
85
87
BRN
BRN
86
30
87a
CR20 LIFT PUMP
RELAY
BRN
BLK
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
D
BRN
RED
ORG/RED
E
30
CR2
48V DC
POWER
RELAY
BLK
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
RED
GRN/WHT-45
GRN/BLK-18
BLK
TS57
PLATFORM
ROTATE
RED
GRN-17
BLK
TS59
PLATFORM
LEVEL
RED
ORG/BLK
BLK
RED
GRN/WHT-45
GRN/BLK-18
ORG/BLK-15
ORG
GRN-17
TS62
TURNTABLE
ROTATE
F
CR1
48V DC POWER RELAY
RED
BLK
CB1
CIRCUIT
BREAKER 1
RED
RED
ORG-14
BLK
RED
RED
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
BLU-10
BLU/BLK-11
G
RED
RED
GRN/WHT-19
REV A
TS55
FUNCTION
ENABLE
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 16840 to 17974)
A
GRN/WHT
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 62
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 17975 to 21180)
8
6 - 63
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
ENABLE
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
26
(SPARE)
(SPARE)
OFF-LIMIT SPEED
DRIVE ENABLE OUTPUT
SWITCH 48 VOLTS
38
39
40
41
42
THESE WIRES
TERMINATE AT THE
SWITCH PANEL
BLK-ALARM (USED ONLY FOR ALARM OPTION)
RED-ALARM (USED ONLY FOR ALARM OPTION)
(TO SWITCH PANEL)
GROUNDCONTROL
HARNESS
1
GRN/WHT-R3
BLK/RED-R4
RED/WHT-48
GRN/WHT-45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
K
GRN/WHT-19
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
50
LS2-LS4 JUNCTION
50
ORG/RED-42 LED
RED
BLU/WHT-12
RED-ALARM
BLK-ALARM
49
LS1-LS2 JUNCTION
49
48
(UNUSED)
BRAKE RELEASE
48
47
46
45
44
43
42
41
38
37
36
35
34
33
32
31
47
(UNUSED)
STEER RIGHT
37
46
STEER LEFT
36
JIB VALVE
HIGH/LOW RPM
35
45
GLOW PLUG
34
(SPARE)
START ENGINE
33
JIB DESCENT ALARM
40
JOYSTICK POTENTIOMETER LOW
32
44
39
REVERSE
31
43
29
30
FORWARD
28
JOYSTICK POTENTIOMETER HIGH
27
30
(UNUSED)
26
25
29
(UNUSED)
25
24
TILT ALARM
(UNUSED)
24
23
28
KEYSWITCH POWER
23
22
AUXILIARY PUMP SELECT
+24V DC TO PLATFORM
22
21
20
19
27
HOUR METER ENABLE
+24V DC POWER
LIFT PUMP
21
20
19
19
18
17
16
15
ORG-14
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
ORG
ORG-40
ORG/BLK
BLU/RED
PLATFORM LEVEL DOWN
15
13
14
BLU/WHT-12
I
CHASSIS
HARNESS
SECONDARY
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
M.H.
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
PLATFORM LEVEL UP
14
12
11
BLU-10
BLK
BLU/BLK-11
BLK/RED-R4
BLK/WHT-8
BLK-7
GRN/WHT
F
FAULT
STATUS
LED
6
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
DRIVE ENABLE LIGHT
13
LIFT PUMP
FOOTSWITCH POWER #2
12
19
SECONDARY BOOM DOWN
11
10
9
8
7
6
WHT/BLK-5
E
BOOM CABLE #2
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
SECONDARY BOOM UP
10
PLATFORM ROTATE RIGHT/JIB DOWN
HORN
9
18
PRIMARY BOOM RETRACT
8
DRIVE ENABLE RELAY COIL
PRIMARY BOOM EXTEND
7
PLATFORM ROTATE LEFT/JIB UP
LIFT FLOW CONTROL
6
5
WHT-4
D
BOOM CABLE #3
7
17
TURNTABLE ROTATE RIGHT
5
4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
16
TURNTABLE ROTATE LEFT
4
3
2
1
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
3
PRIMARY BOOM UP
1
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
ORG-14
ORG/BLK
ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 17975 to 21180)
L
M
GROUND CONTROL HARNESS
N
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
NOTE:
DASHED LINES INDICATE OPTION WIRES
1
2
HOUR METER
H.M.
NC
RED
BLK-22
BRN
RED
RED
Part No. 106488
RED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BLK/RED-R4
CR4
HORN RELAY
86
CR5
BRAKE RELEASE
RELAY
30
87a
87
ORG/BLK-41
30
85
86
87
85
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
B
BLK-22
86
BRN
87
85
RED-27
GRN/WHT-19
87a
ORG/RED
87
30
87a
CR3
AUXILIARY CONTROL
RELAY
BRN
C
85
86
ORG/RED
BRN
RED
BRN
85
BRN
87
87a
30
CR2
48V DC POWER
RELAY
D
BRN
ORG/RED-42
86
87a
RED
ORG/RED
BLK
E
30
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
RED
BLK
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
GRN-17
TS57
PLATFORM
ROTATE
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
ORG/BLK-15
TS59
PLATFORM
LEVEL
GRN-17
RED
RED
F
CR1
48V DC POWER RELAY
RED
RED
ORG-14
BLK
RED
CB1
CIRCUIT
BREAKER 1
BLK
RED
RED-20
TS60
SECONDARY
BOOM
G
RED
BRN
BLU-10
TS62
TURNTABLE
ROTATE
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
REV A
TS55
FUNCTION
ENABLE
BLK-22
WHT-4
WHT/BLK-5
BLK
RED
BLK
RED
RED
RED
RED
BLU/BLK-11
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
RED-27
RED
BLK/RED-35
RED
RED
RED
GRN/WHT-19
WHT-23
RED
RED
H
TS51
START
ENGINE
BLK/WHT-34
BLK-33
4
BLK-22
RED-POWER
I
TS56
GLOW
PLUG
BLK/WHT-34
BLK-33
BRN
WHT-21
4
3
NO
J
BRN
BRN
WHT-21
BLK-22
RED
3
NO
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
RED
RED
L
TS51
AUXILIARY
PUMP
M
KS1
KEY SWITCH
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 17975 to 21180)
A
BLK
GRN/BLK-18
1
BLK
GRN/WHT-R3
GRN/WHT
2
BRN
RED-27P
WIRE GOES
TO T.B. 27A
3
RED/WHT-48
ORG/RED
BRN
BLK/RED-9
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 64
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
(from serial number 21181 to 22050)
GROUND
STUD
8
6 - 65
FAULT
STATUS
LED
P20BAT RD C7B-4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
BATGND BRN
Part No. 106488
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
87
BRN
C5B-2
BK
87
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
I
CR4
HORN
RELAY
30
86
OR/BK
87a
85
BRN
85
87
GR/WH
RD/WH
BRN
OR/RD
OR/RD
BRN
86
87a
30
CR2
48V DC
POWER
RELAY
GR/BK-TS58
OR/RD-CR1
OR/RD-LED
BK-ALARM
BRN
C9HRN BK/RD
85
RD/WH
44
42
GR/WH-J19
GR/WH-J19
BK/RD-TS54
BK/WH-TS56
BK-TS52
WH-KS1
RD-CR3
RD-TS51
GR/WH-J19
BK-CR4
BK-KS1
GR/BK-TS57
GR/WH
GR/WH-TS60
GR-TS57
OR/BK-TS59
OR-TS59
C12DRE BL/WH
BK ALARM
BL/BK-TS60
H
C41DRE OR/BK
OR/RD
BRN
86
87a
30
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
C6B-33 C44DA BK
C6B-23 P20BAT RD
JIB DESCENT ALARM
SWITCH 48 VOLTS
37
40
BK/WH-TS63
BL-TS60
G
BRN
C6B-21
BRN
BRN
C6B-26 C12DRE BL/WH
BK
OR/RD
BRN
GR/WH
OR/RD
STEER RIGHT
OFF-LIMIT SPEED
36
GR/WH
BK-TS63
F
C3B-9
C2B-3
5
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
44
42
40
37
STEER LEFT
35
34
33
27
23
22
19
19
18
WH-TS62
WH/BK-TS62
1
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
C2B-6 C44JDA GR/BK
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
36
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
KEYSWITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
LIFT PUMP
PLATFORM ROTATE RIGHT
17
15
14
12
11
10
8
7
6
5
4
RD-TS61
BK-ALARM
RD/BK-TS61
E
BRN-HM
C6B-25
OR/RD-42A
C6B-22 R42BAT OR/RD
C1B-10 C36STCC BL
C1B-11 C37STC BL/BK
35
34
33
27
23
22
19
19
18
PLATFORM ROTATE LEFT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
2
1
D
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
17
15
14
12
11
10
8
7
6
5
4
PRIMARY BOOM DOWN
PRIMARY BOOM UP
P20BAT RD
C
C6B-36 C36STCC BL
C6B-20 C22LS BK
C7B-1 P22BAT BK
C6B-34 C23ALARM WH
C7B-2 P23SWBAT WH
C6B-38 C19PSW GR/WH
C6B-18 C18PRR GR/BK
C4B-5 C17PRL GR
C4B-3 C15PLD OR/BK
C4B-2 C14PLU OR
C3B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
2
1
A
B
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C6B-12 C12DRE BL/WH
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C6B-7 C7PBE BK
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C3B-4 C4TRL WH
C3B-2 C2PBD RD/BK
B
A
BK
7
C6B-4 C4TRL WH
6
C3B-1 C1PBU RD
4
C6B-1 C1PBU RD
C
3
C6B-2 C2PBD RD/BK
D
2
TERMINAL BASE (TB)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
REV A
(from serial number 21181 to 22050)
J
K
BK-ALARM
GR/WH
RD
RD
RD/WH
OR/RD
RD/BK
BK/RD
L
M
N
June 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 21181 to 22050)
H
G
F
E
D
BK/RD
C
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
B
A
1
GR
BK
TS62
TURN
TABLE
ROTATE
WH-4A
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
BK
RD
2
RD
RD-27A
BK
RD
RD
RD
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
TS59
PLATFORM
LEVEL
TS61
PRIMARY
BOOM
RD
RD
RD
RD-1A
BK
RD
TS57
PLATFORM
ROTATE
TS54
HIGH/LOW
RPM
BK
3
BK
RD
RD
4
P20BAT RD (C6B-23)
P20BAT RD (C7B-4)
BK-22A
BL/BK-11A
WH-23A
GR/WH-19A
CB1
CIRCUIT
BREAKER 1
RD
BK
SECONDARY
BOOM TS60
4
NO
4
NO
BL-10A
3
P20BAT RD (C5B-1)
RD
5
RD
RD
RD
6
RD
RD
TS52
ENGINE
START
WH
BRN
BRN-HM
7
BK-33A
BASE BOX HARNESS
Part No. 106488
RD
TS55
FUNCTION
ENABLE
2
TS56
GLOW
PLUG
HOUR METER
H.M.
1
NC
RD
RD
C21IGN2 (C5B-11)
I
3
J
RD
K
TS51
AUXILIARY
PUMP
L
KS1
KEY SWITCH
M
P1
EMERGENCY
STOP
N
8
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 66
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25
ANSI and CSA Models (from serial number 22051 to 23235)
GROUND
STUD
8
6 - 67
P20BAT RD C7B-4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
Part No. 106488
BK
BATGND BRN
H6
(CE OPTION ONLY)
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
BRN
C5B-2
CR4
HORN
RELAY
30
86
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
GR/WH-J19
RD KS1
GR/BK-TS58
RD H6
OR/RD-CR1
OR/RD-LED
BK-ALARM
GR/WH-J19
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
J
BK
87
OR/BK
87a
87
85
30
87a
BRN
85
OR/RD
OR/RD
BRN
86
GR/WH
RD/WH
BRN
85
CR2
48V DC
POWER
RELAY
134
44
42
40
37
36
BK/RD-TS54
BRN
C9HRN BK/RD
87
87a
30
RD/WH
KEYSWEITCH POWER
JIB DESCENT ALARM
SWITCH 48 VOLTS
34
35
BK-TS52
BK/WH-TS56
I
C41DRE OR/BK
OR/RD
BRN
86
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
STEER RIGHT
OFF-LIMIT SPEED
27
33
WH-KS1 (D2)
RD-CR3
RD-TS51
GR/WH-J19
BK-CR4
BK-KS1
GR/BK-TS57
GR/WH
GR/WH-TS60
GR-TS57
OR/BK-TS59
OR-TS59
C12DRE BL/WH
H
BRN
C6B-21
BRN
BRN
C6B-33 C44DA BK
BK
OR/RD
BRN
GR/WH
OR/RD
134
44
42
40
37
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
23
22
19
19
18
BL-TS60
BK ALARM
BL/BK-TS60
G
C3B-9
C2B-3
5
C6B-26 C12DRE BL/WH
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
C2B-5 C134PWR RD
C2B-6 C44JDA GR/BK
C6B-34 C23ALARM RD
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
36
35
34
33
27
KEYSWITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
LIFT PUMP
PLATFORM ROTATE RIGHT
15
17
BK-TS63
BK/WH-TS63
F
BRN-HM
C6B-25
OR/RD-42A
C6B-22 R42BAT OR/RD
C1B-10 C36STCC BL
C1B-11 C37STC BL/BK
22
23
PLATFORM LEVEL DOWN
PLATFORM ROTATE LEFT
14
12
11
10
8
7
GR/WH
E
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
C23-4 P22BAT BK
19
19
18
17
15
PLATFORM LEVEL UP
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
5
6
WH-TS62
WH/BK-TS62
D
C6B-36 C36STCC BL
C7B-2 P23SWBAT WH
C6B-20 C22LS BK
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
C4B-5 C17PRL GR
14
12
11
10
8
7
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
2
4
BRN GND
GR/BK H6
RD TS55
RD TS51
BK C7-1
BK 22B
BL/WH C1-12
RD H6
C6B-38 C19PSW GR/WH
C4B-2 C14PLU OR
C4B-3 C15PLD OR/BK
5
6
PRIMARY BOOM DOWN
TURNTABLE ROTATE LEFT
RD-TS61
BK-ALARM
RD/BK-TS61
C
C6B-18 C18PRR GR/BK
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C3B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
2
4
1
P20BAT RD
2
C6B-12 C12DRE BL/WH
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
C3B-4 C4TRL WH
PRIMARY BOOM UP
A
B
FAULT
STATUS
LED
GR/BK C23-8
GR/BK L45
GR/BK C2B-6
C6B-7 C7PBE BK
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C6B-4 C4TRL WH
1
B
A
C3B-2 C2PBD RD/BK
C3B-1 C1PBU RD
6
RD C23-1
RD 134B
7
C6B-1 C1PBU RD
C
3
C6B-2 C2PBD RD/BK
D
4
TERMINAL BASE (TB)
C23
1
1 3 4 5 6 7 8 12
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,
ANSI and CSA Models (from serial number 22051 to 23235)
REV A
K
L
BK-ALARM
GR/WH
RD
RD
RD/WH
OR/RD
RD/BK
BK/RD
M
N
June 2005
REV A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,
ANSI and CSA Models (from serial number 22051 to 23235)
F
E
D
TS54
HIGH/LOW
RPM
BK/RD
C
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
B
1
GR
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
WH-4A
BK
A
BK
RD
2
RD
RD
BK
RD
RD
RD-27A
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
BK
G
TS57
PLATFORM
ROTATE
H
TS62
TURN
TABLE
ROTATE
I
TS59
PLATFORM
LEVEL
TS61
PRIMARY
BOOM
RD
RD
RD
WH
RD-1A
3
BK
RD C23-6
RD
RD
4
BK-22A
RD
P20BAT RD (C7B-4)
RD
CB1
CIRCUIT
BREAKER 1
L45
PLATFORM
OVERLOAD
(CE ONLY)
BL-10A
+
KS1
BL/BK-11A
-
GR/WH-19A
BK
TS60
SECONDARY
BOOM
P20BAT RD (C5B-1)
RD 134A
5
RD
RD
RD
RD
RD
6
RD
RD C23-7
RD
TS52
ENGINE
START
GR/BK H6
WH 23A
BK-33A
1
Part No. 106488
RD
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
RD
TS55
FUNCTION
ENABLE
TS56
GLOW
PLUG
BASE BOX HARNESS
RD
RD
BRN
HOUR METER
H.M.
2
7
BRN-HM
NC
WH
C21IGN2 (C5B-11)
J
RD
K
TS51
AUXILIARY
PUMP
L
D2
M
P1
EMERGENCY
STOP
N
Section 6 • Schematics
8
6 - 68
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,
ANSI and CSA Models (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,
CE Models (from serial number 22051 to 23235)
GROUND
STUD
8
6 - 69
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
Part No. 106488
BK
BATGND BRN
H6
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
BRN
87
C5B-2
30
86
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
OR/BK
87a
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
134
44
42
40
RD KS1
GR/BK-TS58
RD H6
OR/RD-CR1
OR/RD-LED
BK-ALARM
GR/WH-J19
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
J
CR4
HORN
RELAY
85
87
BRN
BK
OR/RD
OR/RD
BRN
86
GR/WH
RD/WH
BRN
85
87a
30
CR2
48V DC
POWER
RELAY
36
37
BK/RD-TS54
GR/WH-J19
I
C9HRN BK/RD
87
RD/WH
34
35
BK-TS52
BK/WH-TS56
BRN
C41DRE OR/BK
OR/RD
BRN
86
87a
30
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
27
33
WH-KS1 (D2)
RD-CR3
RD-TS51
GR/WH-J19
BK-CR4
BK-KS1
H
BRN
C6B-21
BRN
BRN
C6B-33 C44DA BK
BK
OR/RD
BRN
GR/WH
OR/RD
KEYSWEITCH POWER
JIB DESCENT ALARM
SWITCH 48 VOLTS
OFF-LIMIT SPEED
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
23
22
19
19
18
GR-TS57
GR/BK-TS57
GR/WH
GR/WH-TS60
G
C3B-9
C2B-3
5
C6B-26 C12DRE BL/WH
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
134
44
42
40
37
36
35
34
33
27
KEYSWITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
LIFT PUMP
PLATFORM ROTATE RIGHT
15
17
OR-TS59
OR/BK-TS59
F
BRN-HM
C6B-25
OR/RD-42A
C5B-3 C23PWR WH
C2B-5 C134PWR RD
C2B-6 C44JDA GR/BK
C6B-34 C23ALARM RD
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
C1B-11 C37STC BL/BK
C1B-10 C36STCC BL
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
23
22
19
PLATFORM LEVEL DOWN
PLATFORM ROTATE LEFT
14
C12DRE BL/WH
BK ALARM
BL/BK-TS60
BL-TS60
BK/WH-TS63
BK-TS63
GR/WH
E
C6B-22 R42BAT OR/RD
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C6B-36 C36STCC BL
C7B-2 P23SWBAT WH
C23-4 P22BAT BK
19
18
17
15
PLATFORM LEVEL UP
12
11
10
8
7
WH-TS62
WH/BK-TS62
D
FAULT
STATUS
LED
P20BAT RD C7B-4
C6B-20 C22LS BK
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
C4B-5 C17PRL GR
14
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
5
6
RD-TS61
BK-ALARM
RD/BK-TS61
C
C6B-38 C19PSW GR/WH
C4B-2 C14PLU OR
C4B-3 C15PLD OR/BK
12
11
10
8
7
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
4
2
1
BRN GND
GR/BK H6
RD TS55
RD TS51
BK C7-1
BK 22B
BL/WH C1-12
RD H6
C6B-18 C18PRR GR/BK
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C3B-12 C12DRE BL/WH
5
6
TURNTABLE ROTATE LEFT
PRIMARY BOOM DOWN
PRIMARY BOOM UP
P20BAT RD
2
C6B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
4
2
1
A
B
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C6B-7 C7PBE BK
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C3B-4 C4TRL WH
C3B-2 C2PBD RD/BK
B
A
GR/BK C23-8
GR/BK L45
GR/BK C2B-6
RD C23-1
RD 134B
7
C6B-4 C4TRL WH
6
C3B-1 C1PBU RD
4
C6B-1 C1PBU RD
C
3
C6B-2 C2PBD RD/BK
D
U33
TERMINAL BASE (TB)
1
1 3 4 5 6 7 8 12
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25,
CE Models (from serial number 22051 to 23235)
REV A
K
BK-ALARM
GR/WH
RD
RD
RD/WH
OR/RD
RD/BK
BK/RD
L
M
N
June 2005
REV A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,
CE Models (from serial number 22051 to 23235)
F
E
D
TS54
HIGH/LOW
RPM
BK/RD
C
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
B
1
GR
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
WH-4A
BK
A
TS57
PLATFORM
ROTATE
BK
RD
2
RD
RD
BK
RD
RD
RD-27A
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
BK
G
TS62
TURN
TABLE
ROTATE
H
TS59
PLATFORM
LEVEL
TS61
PRIMARY
BOOM
RD
RD
RD
RD-1A
WH
3
BK
RD C23-6
RD
RD
4
BK-22A
RD
P20BAT RD (C7B-4)
+
RD
CB1
CIRCUIT
BREAKER 1
BL-10A
L45
PLATFORM
OVERLOAD
(CE ONLY)
BL/BK-11A
-
GR/WH-19A
BK
TS60
SECONDARY
BOOM
P20BAT RD (C5B-1)
RD 134A
5
RD
RD
RD
RD
RD
6
RD
RD C23-7
RD
TS52
ENGINE
START
GR/BK H6
WH 23A
BK-33A
1
Part No. 106488
RD
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
RD
TS55
FUNCTION
ENABLE
TS56
GLOW
PLUG
BASE BOX HARNESS
RD
RD
BRN
HOUR METER
H.M.
2
7
BRN-HM
NC
WH
C21IGN2 (C5B-11)
I
KS1
J
RD
K
TS51
AUXILIARY
PUMP
L
D2
M
P1
EMERGENCY
STOP
N
Section 6 • Schematics
8
6 - 70
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25,
CE Models (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(before serial number 13361)
8
6 - 71
SECONDARY BOOM
LIMIT SWITCH (LS4)
CABLE #4
BLK-LED
M.H.
#3
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
PRIMARY BOOM
LIMIT SWITCH (LS2)
CABLE #5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
M.H.
EXT.
SECONDARY
PRIMARY
ENABLE
7
BOOM
CABLE #3
Part No. 106488
BOOM
CABLE #2
FAULT
STATUS
LED
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
BOOM
CABLE #1
35
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
34
35
36
37
40
41
42
OFF LIMIT SPEED
DRIVE ENABLE OUTPUT
SWITCH 48 VOLTS
40
41
42
38
39
FUNCTION
MANIFOLD
HARNESS
46
47
48
JIB VALVE
(UNUSED)
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
45
46
47
48
49
50
GRN/WHT-19
ORG/RED-42 LED
DRIVE ENABLE LIMIT
SWITCH (LS3)
CABLE #7
SPARE
PLUGGED
CHASSIS
HARNESS
GRN/WHT-R3
BLK/RED-R4
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
(TO
SWITCH
PANEL)
GROUND
CONTROL
BOX
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
50
RED/WHT-48
GRN/WHT-45
K
ORG/RED-42 LED
ORG/BLK
ORG
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
45
(SPARE)
44
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
1
49
44
(SPARE)
43
43
39
(SPARE)
CONTROLLER FAULT LED
38
37
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
34
GLOW PLUG
33
I
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
33
START ENGINE
32
36
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
H
GRN/BLK
FORWARD
30
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
G
ORG/RED
ORG/RED-42
GRN
30
JOYSTICK POT. HIGH
29
29
28
26
TILT ALARM
25
26
(UNUSED)
(UNUSED)
25
28
24
(UNUSED)
24
27
23
KEYSWITCH POWER
23
AUXILIARY PUMP SELECT
22
+24 VOLT TO PATFORM
22
27
21
20
HOUR METER ENABLE
+24 VOLT POWER
21
20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
F
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
19
19
LIFT PUMP
19
LIFT PUMP
18
19
18
PLATFORM ROTATE LEFT/JIB UP
17
16
17
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE RIGHT/JIB DOWN
16
ORG/BL-15
E
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
RED
PLATFORM LEVEL DOWN
15
ORG-14
BLU/WHT-12
BLU-10
BLK
BLU/BLK-11
BLK/RED-R4
BLK/WHT-8
BLK-7
GRN/WHT
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
D
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
15
PLATFORM LEVEL UP
14
A
C
GRN/WHT-19
ORG/RED
RED
GRN
GRN
GRN/BLK
GRN/BLK
GRN/WHT
GRN/WHT
14
DRIVE ENABLE LIGHT
13
13
12
9
HORN
9
FOOTSWITCH POWER #2
8
PRIMARY BOOM RETRACT
8
12
7
PRIMARY BOOM EXTEND
7
11
6
LIFT FLOW CONTROL
6
11 SECONDARY BOOM DOWN
5
TURNTABLE ROTATE LEFT
5
10
4
TURNTABLE ROTATE RIGHT
4
10 SECONDARY BOOM UP
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
3
1
B
B
ORG/BLK
5
PRIMARY BOOM UP
3
1
TERMINAL BASE (TB)
A
BLU
BLU
BLU/BLK
BLU/BLLK
BLU/WHT
WHT
BLU/RED
BLK
ORG
C
4
D
2
WHT
WHT
WHT/BLK
WHT/BLK
WHT/RED
WHT/RED
BLK
BLK
BLK/WHT
BLK/WHT
BLK/RED
RED
RED
RED/BLK
RED/BLK
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(before serial number 13361)
L
M
BASE BOX HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENSION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
N
RED-ALARM (USED ONLY FOR FLASHING BEACON OPTION)
GROUND CONTROL BOX HARNESS
RED
RED
RED
BLK-22
BRN
RED
RED
RED
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
85
BLK/RED-R4
RED-27
GRN/WHT-19
30
85
WHT-40
ORG/BLK
ORG
BRN
PLATFORM LEVEL
CUTOUT UP RELAY
CR10B
WHT
86
WIRE GOES
TO T.B. 27A
30
87
30
85
PLATFORM LEVEL
CUTOUT DOWN
RELAY CR10A
86
87
87a
GRN/BLK-18
BRAKE RELEASE
RELAY CR5
86
ORG/BLK-41
87a
UNUSED
B
HORN RELAY
CR4
85
87
86
ORG
30
BRN
86
GRN/WHT-R3
87
30
87a
RED-27P
87a
85
ORG/BLK
BLK-22
87
86
ORG/BLK
ORG
87
ORG/RED
30
87a
C
87a
RED
ORG/RED
BRN
85
BRN
BRN
86
GRN/BLK
87
87a
BRN
AUXILIARY CONTROL
RELAY CR3
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
D
BRN
ORG/RED-42
RED
30
BLK
85
BLK
PLATFORM
ROTATE TS57
E
48 V
POWER
RELAY CR2
RED
BLK
RED
RED
GRN-17
GRN
GRN/WHT-45
GRN/BLK-18
PLATFORM
LEVEL TS59
F
ORG/RED-R2
RED/WHT-3
RED/WHT-3
48 V POWER
RELAY CR1
RED
ORG
ORG/BLK
RED
RED
BLK
RED
ORG-14
BLK
BLK
ORG/BLK-15
RED
GRN/BLK
GRN
BLK
GRN-17
BLK
RED
CIRCUIT
BREAKER 1
CB1
BLK
RED
RED-20
SECONDARY
BOOM TS60
TURNTABLE
ROTATE
TS62
REV A
FUNCTION
ENABLE TS55
RED
BLU-10
RED
JIB BOOM UP/DOWN
TS58
WHT/BLK-5
PRIMARY
BOOM
EXTEND/
RETRACT
TS63
G
RED
BRN
WHT-4
BLK
RED
RED
BLK-22
RED
RED
BLU/BLK-11
GRN/WHT-19
RED
RED
BLK/WHT-34
BLK-33
BLK
RED
RED
START
ENGINE
TS51
BLK-33
PRIMARY
BOOM
TS61
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
HIGH/LOW
RPM TS54
H
GLOW
PLUG TS56
BLK/WHT-34
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BASE BOX HARNESS
(TO TERMINAL STRIP)
WHT-23
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
AUXILIARY
PUMP TS51
K
HOUR METER
H.M.
1
NC
RED
KEY SWITCH
KS1
L
ON
M
NO
N
EMERGENCY STOP
P1
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 13361)
A
BLK
1
WHT
2
WHT
BRN
BLK/RED-9
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 72
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(before serial number 13361)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078)
8
6 - 73
BLK-LED
M.H.
SECONDARY BOOM
LIMIT SWITCH (LS4)
CABLE #4
#3
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
PRIMARY BOOM
LIMIT SWITCH (LS2)
CABLE #5
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
M.H.
EXT.
SECONDARY
PRIMARY
ENABLE
7
BOOM
CABLE #3
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
BOOM
CABLE #2
FAULT
STATUS
LED
BOOM
CABLE #1
14
15
FOOTSWITCH POWER #2
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
12
13
14
15
19
LIFT PUMP
19
40
41
42
DRIVE ENABLE OUTPUT
SWITCH 48 VOLTS
41
42
38
FUNCTION
MANIFOLD
HARNESS
45
46
47
48
JIB VALVE
(UNUSED)
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
45
46
47
48
49
50
GRN/WHT-19
ORG/RED-42 LED
DRIVE ENABLE LIMIT
SWITCH (LS3)
CABLE #7
SPARE
PLUGGED
CHASSIS
HARNESS
GRN/WHT-R3
BLK/RED-R4
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
(TO
SWITCH
PANEL)
GROUND
CONTROL
BOX
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
50
RED/WHT-48
GRN/WHT-45
K
ORG/RED-42 LED
ORG/BLK
ORG
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
(SPARE)
44
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
1
49
43
(SPARE)
43
39
OFF LIMIT SPEED
37
STEER RIGHT
37
40
36
STEER LEFT
36
(SPARE)
35
HIGH/LOW RPM
35
CONTROLLER FAULT LED
34
GLOW PLUG
34
39
33
START ENGINE
33
38
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
30
FORWARD
30
32
29
JOYSTICK POT. HIGH
29
31
28
26
26
TILT ALARM
25
(UNUSED)
(UNUSED)
25
28
24
(UNUSED)
24
27
23
KEYSWITCH POWER
23
AUXILIARY PUMP SELECT
22
+24 VOLT TO PATFORM
22
27
21
20
HOUR METER ENABLE
+24 VOLT POWER
21
20
19
18
PLATFORM ROTATE LEFT/JIB UP
18
LIFT PUMP
17
17
19
16
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE RIGHT/JIB DOWN
16
ORG/BL-15
ORG-14
BLU/WHT-12
BLU-10
BLK
BLU/BLK-11
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
13
SECONDARY BOOM DOWN
11
10
I
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
12
SECONDARY BOOM UP
10
BLK/RED-R4
H
GRN/BLK
11
HORN
9
BLK/WHT-8
G
ORG/RED
ORG/RED-42
GRN
8
PRIMARY BOOM RETRACT
8
BLK-7
F
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
7
PRIMARY BOOM EXTEND
7
GRN/WHT
E
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
RED
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
D
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
5
TURNTABLE ROTATE LEFT
5
A
C
GRN/WHT-19
ORG/RED
RED
GRN
GRN
GRN/BLK
GRN/BLK
GRN/WHT
GRN/WHT
4
TURNTABLE ROTATE RIGHT
4
9
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
3
1
B
B
ORG/BLK
5
PRIMARY BOOM UP
3
1
TERMINAL BASE (TB)
A
BLU
BLU
BLU/BLK
BLU/BLLK
BLU/WHT
WHT
BLU/RED
BLK
ORG
C
4
D
2
WHT
WHT
WHT/BLK
WHT/BLK
WHT/RED
WHT/RED
BLK
BLK
BLK/WHT
BLK/WHT
BLK/RED
RED
RED
RED/BLK
RED/BLK
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 13361 to 14078)
L
M
BASE BOX HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENSION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
N
RED-ALARM (USED ONLY FOR FLASHING BEACON OPTION)
GROUND CONTROL BOX HARNESS
RED
WHT-23
RED
HOUR METER
H.M.
RED
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
WHT-40
ORG
87
30
87a
86
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
ORG/BLK
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
GRN/BLK-18
CR5
BRAKE RELEASE
RELAY
85
87
BLK
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
BRN
WIRE GOES
TO T.B. 27A
87a
86
GRN/WHT-R3
85
85
B
BLK-22
86
ORG/RED
87
RED-27P
87
RED
ORG/RED
BRN
86
ORG/BLK
ORG
87a
85
30
87a
C
85
87
BRN
BRN
86
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
GRN/BLK
87a
CR2
48V DC
POWER
RELAY
D
BRN
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
E
30
BLK
TS57
PLATFORM
ROTATE
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
RED
GRN-17
GRN
ORG/RED-R2
RED/WHT-3
RED/WHT-3
BLK
ORG/BLK-15
F
CR1
48V DC POWER RELAY
RED
ORG/BLK
ORG
RED
RED
TS62
TURNTABLE
ROTATE
BLK
RED
RED
BLK
ORG-14
BLK
GRN/BLK
GRN
BLK
GRN-17
BLK
RED
CB1
CIRCUIT
BREAKER 1
BLK
RED
RED-20
TS60
SECONDARY
BOOM
RED
REV A
TS55
FUNCTION
ENABLE
RED
BLU-10
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
G
RED
BRN
BLU/BLK-11
TS58
JIB BOOM
BLK
RED
RED
BLK-22
RED
RED
RED
GRN/WHT-19
RED
WHT-4
WHT/BLK-5
BLK
RED
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
TS54
HIGH/LOW
RPM
H
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 74
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650)
8
6 - 75
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
33
34
35
37
38
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
32
33
34
35
36
37
42
SWITCH 48 VOLTS
41
42
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
41
DRIVE ENABLE OUTPUT
40
(SPARE)
40
OFF-LIMIT SPEED
39
43
39
(SPARE)
CONTROLLER FAULT LED
38
36
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
A ORG-14
ORG/BLK
A ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 14079 to 14650)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
A NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
WHT-40
ORG
87
30
87a
86
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
ORG/BLK
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
GRN/BLK-18
CR5
BRAKE RELEASE
RELAY
85
87
BLK
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
BRN
WIRE GOES
TO T.B. 27A
87a
86
GRN/WHT-R3
85
85
B
BLK-22
86
ORG/RED
87
RED-27P
87
RED
ORG/RED
BRN
86
ORG/BLK
ORG
87a
85
30
87a
C
85
87
BRN
BRN
86
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
GRN/BLK
87a
CR2
48V DC
POWER
RELAY
D
BRN
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
E
30
BLK
TS57
PLATFORM
ROTATE
RED
BLK
RED
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
RED
GRN-17
GRN
ORG/RED-R2
RED/WHT-3
RED/WHT-3
BLK
ORG/BLK-15
F
CR1
48V DC POWER RELAY
RED
ORG/BLK
ORG
RED
RED
TS62
TURNTABLE
ROTATE
BLK
RED
RED
BLK
ORG-14
BLK
GRN/BLK
GRN
BLK
GRN-17
BLK
RED
CB1
CIRCUIT
BREAKER 1
BLK
RED
RED-20
TS60
SECONDARY
BOOM
RED
REV A
TS55
FUNCTION
ENABLE
RED
BLU-10
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
G
RED
BRN
BLU/BLK-11
TS58
JIB BOOM
BLK
RED
RED
BLK-22
RED
RED
RED
GRN/WHT-19
RED
WHT-4
WHT/BLK-5
BLK
RED
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
TS54
HIGH/LOW
RPM
H
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 76
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839)
8
6 - 77
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
33
34
35
37
38
START ENGINE
GLOW PLUG
HIGH/LOW RPM
STEER LEFT
STEER RIGHT
32
33
34
35
36
37
42
SWITCH 48 VOLTS
41
42
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
41
DRIVE ENABLE OUTPUT
40
(SPARE)
40
OFF-LIMIT SPEED
39
43
39
(SPARE)
CONTROLLER FAULT LED
38
36
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
BLU/RED
BLU/RED-39
ORG
ORG-40
ORG/BLK
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
1 ORG-14
ORG/BLK
1 ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 14651 to 16839)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
1 NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BLK/RED-R4
87
86
ORG/BLK
ORG
WHT
87
30
87a
86
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
UNUSED
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
85
87
B
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
86
WIRE GOES
TO T.B. 27A
87a
BRN
85
85
GRN/WHT-R3
BLK-22
86
ORG/RED
87
RED-27P
87
RED
ORG/RED
BRN
86
ORG/BLK
ORG
87a
85
30
87a
C
85
87
BRN
BRN
86
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
GRN/BLK
87a
CR2
48V DC
POWER
RELAY
D
BRN
RED
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
GRN/WHT-45
GRN/BLK-18
BLK
TS57
PLATFORM
ROTATE
E
30
BLK
BLK
BLK
RED
RED
GRN-17
GRN
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
RED
ORG/BLK
F
CR1
48V DC POWER RELAY
RED
BLK
ORG/BLK-15
ORG
TS62
TURNTABLE
ROTATE
BLK
RED
BLK
ORG-14
BLK
RED
RED
BLK
RED
CB1
CIRCUIT
BREAKER 1
RED
GRN/BLK
GRN
BLK
GRN-17
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
RED
REV A
TS55
FUNCTION
ENABLE
RED
BLU-10
BLU/BLK-11
TS58
JIB BOOM
G
RED
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
RED
GRN/WHT-19
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839)
A
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 78
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974)
8
6 - 79
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
13
15
16
17
18
19
DRIVE ENABLE LIGHT
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
DRIVE ENABLE RELAY COIL
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
LIFT PUMP
13
14
15
16
17
18
19
26
(UNUSED)
26
29
30
TILT ALARM
JOYSTICK POTENTIOMETER HIGH
FORWARD
28
29
30
47
48
49
50
(UNUSED)
BRAKE RELEASE
LS1-LS2 JUNCTION
LS2-LS4 JUNCTION
46
47
48
49
50
GRN/WHT-R3
BLK/RED-R4
(TO SWITCH
PANEL)
GROUND
CONTROL
HARNESS
BLK-ALARM (USED ONLY FOR TRAVEL ALARM OPTION)
ORG/BLK
ORG
WHT-40
BLU/WHT-12
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
RED/WHT-48
GRN/WHT-45
1
USED ONLY FOR PLATFORM LEVEL CUTOUT OPTION
46
(UNUSED)
45
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
K
ORG/RED-42 LED
ORG/BLK-15
ORG-14
WHT
BLU/WHT-12
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-ALARM
BLK-ALARM
GRN/WHT-19
44
45
(SPARE)
JIB VALVE
44
43
42
SWITCH 48 VOLTS
42
(SPARE)
41
DRIVE ENABLE OUTPUT
41
43
40
OFF-LIMIT SPEED
40
37
38
37
STEER RIGHT
36
39
36
STEER LEFT
35
(SPARE)
35
HIGH/LOW RPM
34
(SPARE)
34
GLOW PLUG
33
39
33
START ENGINE
32
38
31
32
REVERSE
JOYSTICK POTENTIOMETER LOW
31
28
AUXILIARY PUMP SELECT
27
27
24
25
(UNUSED)
(UNUSED)
23
KEYSWITCH POWER
23
25
22
+24 V TO PLATFORM
22
24
21
20
HOUR METER ENABLE
+24 V POWER
21
20
19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
ORG-14
BLU/WHT-12
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
ORG
ORG-40
ORG/BLK
BLU/RED
12
FOOTSWITCH POWER #2
12
I
CHASSIS
HARNESS
ENABLE
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
11
SECONDARY BOOM DOWN
11
BLU-10
BLK
BLU/BLK-11
F
FAULT
STATUS
LED
SECONDARY
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
10
SECONDARY BOOM UP
10
BLK/RED-R4
BLK/WHT-8
BLK-7
E
BOOM CABLE #2
M.H.
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
9
HORN
9
LIFT PUMP
8
PRIMARY BOOM RETRACT
8
19
7
PRIMARY BOOM EXTEND
7
GRN/WHT
D
BOOM CABLE #3
7
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
6
LIFT FLOW CONTROL
6
WHT/BLK-5
WHT-4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
14
5
TURNTABLE ROTATE RIGHT
5
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
4
TURNTABLE ROTATE LEFT
4
2
3
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
1
3
PRIMARY BOOM UP
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
1 ORG-14
ORG/BLK
1 ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
1
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 16840 to 17974)
L
M
RED-ALARM (USED ONLY FOR STROBE LIGHT OPTION)
GROUND CONTROL HARNESS
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
1 NOT USED FOR PLATFORM LEVEL
CUTOUT OPTION
N
RED
WHT-23
RED
HOUR METER
H.M.
RED
RED
Part No. 106488
BLK-22
BRN
RED
RED
ORG/RED-42
BLK/RED-R4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
87
86
ORG/BLK
ORG
WHT
87
87
30
87a
86
85
ORG/BLK
WHT-40
ORG
CR10A
PLATFORM LEVEL
CUTOUT DOWN RELAY
85
86
GRN/BLK-18
CR10B
PLATFORM LEVEL
CUTOUT UP RELAY
30
87a
85
BLK
CR5
BRAKE RELEASE
RELAY
85
87
30
87a
B
CR4
HORN RELAY
30
86
RED-27
GRN/WHT-19
30
ORG/BLK-41
87
BRN
WIRE GOES
TO T.B. 27A
87a
86
GRN/WHT-R3
85
85
RED-27P
BLK-22
86
ORG/RED
87
ORG/BLK
ORG
87
86
ORG/RED
BRN
RED
GRN/WHT-R3
87a
85
30
87a
BRN
LIFT PUMP
RELAY CR20
C
85
87
BRN
BRN
86
30
87a
BRN
CR3
AUXILIARY CONTROL
RELAY
ORG/RED
GRN/BLK
87a
CR2
48V DC
POWER
RELAY
D
BRN
RED
ORG/RED-R2
RED/WHT-3
RED/WHT-3
RED
GRN/WHT-45
GRN/BLK-18
BLK
TS57
PLATFORM
ROTATE
E
30
BLK
BLK
BLK
RED
RED
GRN-17
GRN
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
RED
ORG/BLK
F
CR1
48V DC POWER RELAY
RED
BLK
ORG/BLK-15
ORG
TS62
TURNTABLE
ROTATE
BLK
RED
BLK
ORG-14
BLK
RED
RED
BLK
RED
CB1
CIRCUIT
BREAKER 1
RED
GRN/BLK
GRN
BLK
GRN-17
BLK
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
RED
REV A
TS55
FUNCTION
ENABLE
RED
BLU-10
BLU/BLK-11
TS58
JIB BOOM
G
RED
BRN
WHT-4
WHT/BLK-5
BLK
RED
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
H
RED
BLK-22
RED
RED
RED
GRN/WHT-19
RED
TS51
ENGINE
START
BLK/WHT-34
BLK-33
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
TS56
GLOW
PLUG
BLK-33
WHT-21
BRN
WHT-23
RED
RED-27
RED
BLK/RED-35
RED
I
BLK/WHT-34
WHT-21
BRN
BRN
WHT-23
BLK-22
RED
RED
RED
J
3
2
WHT-23
RED-POWER
BLK-22
TS51
AUXILIARY
PUMP
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
1
NC
RED
KS1
KEY SWITCH
L
ON
M
NO
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974)
A
GRN/WHT
BRN
BLK/RED-9
1
WHT
2
BRN
WHT
3
RED/WHT-48
ORG/RED
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 80
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180)
8
6 - 81
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
ENABLE
Part No. 106488
#2
#1
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
PRIMARY
SECONDARY
ENABLE
GRN/WHT-19
26
(SPARE)
(SPARE)
OFF-LIMIT SPEED
DRIVE ENABLE OUTPUT
SWITCH 48 VOLTS
38
39
40
41
42
THESE WIRES
TERMINATE AT THE
SWITCH PANEL
BLK-ALARM (USED ONLY FOR ALARM OPTION)
RED-ALARM (USED ONLY FOR ALARM OPTION)
(TO SWITCH PANEL)
GROUNDCONTROL
HARNESS
1
GRN/WHT-R3
BLK/RED-R4
RED/WHT-48
GRN/WHT-45
GRN/BLK-44
BLK-ALARM
ORG/BLK-41
ORG/RED-42 LED
ORG/RED-42
RED
GRN/WHT-J19
GRN/WHT-J19
BLK/RED-35
BLK/WHT-34
BLK-33
WIRE GOES TO
RELAY #3 ON THE
SWITCH PANEL.
RED-27
RED-27
BLK-22
RED-ALARM
WHT-23
WHT-21
RED-20
GRN/WHT-J19
GRN/BLK-18
GRN/WHT
GRN/WHT-19
GRN-17
ORG/BLK-15
K
GRN/WHT-19
RED-27
ORG/RED-R2
RED/BLK-R5
RED-PBRK
RED-PISM6
GRN/WHT-19
BLK/RED-9
RED-27P
ORG/RED-R2
RED/BLK-R5
RED-POWER
50
LS2-LS4 JUNCTION
50
ORG/RED-42 LED
RED
BLU/WHT-12
RED-ALARM
BLK-ALARM
49
LS1-LS2 JUNCTION
49
48
(UNUSED)
BRAKE RELEASE
48
47
46
45
44
43
42
41
38
37
36
35
34
33
32
31
47
(UNUSED)
STEER RIGHT
37
46
STEER LEFT
36
JIB VALVE
HIGH/LOW RPM
35
45
GLOW PLUG
34
(SPARE)
START ENGINE
33
JIB DESCENT ALARM
40
JOYSTICK POTENTIOMETER LOW
32
44
39
REVERSE
31
43
29
30
FORWARD
28
JOYSTICK POTENTIOMETER HIGH
27
30
(UNUSED)
26
25
29
(UNUSED)
25
24
TILT ALARM
(UNUSED)
24
23
28
KEYSWITCH POWER
23
22
AUXILIARY PUMP SELECT
+24V DC TO PLATFORM
22
21
20
19
27
HOUR METER ENABLE
+24V DC POWER
LIFT PUMP
21
20
19
19
18
17
16
15
ORG-14
J
BRN
BRN-J3
BRN-J1
BRN-J7
BRN
BRN
BRN
BRN
BRN
RED/WHT-48
RED/WHT-48
BLK
RED
BLK
RED
GRN/WHT
GRN/BLK
ORG/RED
ORG/RED-42
GRN
ORG
ORG-40
ORG/BLK
BLU/RED
PLATFORM LEVEL DOWN
15
13
14
BLU/WHT-12
I
CHASSIS
HARNESS
SECONDARY
H
FUNCTION
MANIFOLD
HARNESS
PRIMARY
G
BOOM CABLE #1
EXT.
BLK-LED
M.H.
RED/BLK
RED/BLK-28
RED/WHT
RED/WHT-29
WHT
WHT-30
WHT/BLK
WHT/BLK-31
WHT/RED
WHT/RED-32
BLK
BLK-33
BLK/WHT
BLK/WHT-34
BLK/RED
BLK/RED-35
BLU
BLU-36
BLU/BLK
BLU/BLK-37
BLU/WHT
PLATFORM LEVEL UP
14
12
11
BLU-10
BLK
BLU/BLK-11
BLK/RED-R4
BLK/WHT-8
BLK-7
GRN/WHT
F
FAULT
STATUS
LED
6
RED
WHT-21
BLK
BLK
WHT
RED/WHT-23
WHT-23
RED-20
DRIVE ENABLE LIGHT
13
LIFT PUMP
FOOTSWITCH POWER #2
12
19
SECONDARY BOOM DOWN
11
10
9
8
7
6
WHT/BLK-5
E
BOOM CABLE #2
DRIVE
ENABLE LIMIT
SWITCH (LS3)
CABLE #7
#3
GRN/WHT-19
SECONDARY BOOM UP
10
PLATFORM ROTATE RIGHT/JIB DOWN
HORN
9
18
PRIMARY BOOM RETRACT
8
DRIVE ENABLE RELAY COIL
PRIMARY BOOM EXTEND
7
PLATFORM ROTATE LEFT/JIB UP
LIFT FLOW CONTROL
6
5
WHT-4
D
BOOM CABLE #3
7
17
TURNTABLE ROTATE RIGHT
5
4
RED/WHT-3
RED-1
BLK
RED/BLK-2
C
PRIMARY
LIMIT SWITCH (LS2)
CABLE #5
M.H.
16
TURNTABLE ROTATE LEFT
4
3
2
1
A
B
BOOM EXTEND
LIMIT SWITCH (LS1)
CABLE #6
SECONDARY
LIMIT SWITCH (LS4)
CABLE #4
PRIMARY BOOM DOWN
48 V RELAY COIL POWER
2
3
PRIMARY BOOM UP
1
B
A
BLU
BLU-10
BLU/BLK
BLU/BLK-11
BLU/WHT
WHT
BLU/RED
BLK
ORG
ORG-14
ORG/BLK
ORG/BLK-15
ORG/RED
RED
GRN
GRN-17
GRN/BLK
GRN/BLK-18
GRN/WHT
GRN/WHT-19
5
TERMINAL BASE (TB)
3
WHT
WHT-4
WHT/BLK
WHT/BLK-5
WHT/RED
WHT/RED-6
BLK
BLK-7
BLK/WHT
BLK/WHT-8
BLK/RED
C
4
D
2
SPARE PLUGGED
RED
RED-1
RED/BLK
RED/BLK-2
RED/WHT
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 17975 to 21180)
L
M
GROUND CONTROL HARNESS
N
GROUND
CONTROL HARNESS
#1
#2
#3
CHASSIS HARNESS
MANIFOLD HARNESS
EXTENTION
C.H.
M.H.
EXT.
PRIMARY
SECONDARY
ENABLE
PRI.
SEC.
ENA.
GRN/WHT-19
ORG/RED-42 LED
NOTE:
DASHED LINES INDICATE OPTION WIRES
1
2
HOUR METER
H.M.
NC
RED
BLK-22
BRN
RED
RED
RED
Part No. 106488
RED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
BLK/RED-R4
30
86
CR5
BRAKE RELEASE
RELAY
30
87a
87
ORG/BLK-41
CR4
HORN RELAY
85
86
87
85
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
B
BLK-22
86
BRN
87
85
RED-27
GRN/WHT-19
87a
ORG/RED
87
30
87a
CR3
AUXILIARY CONTROL
RELAY
BRN
C
85
86
ORG/RED
BRN
RED
BRN
85
BRN
87
87a
30
CR2
48V DC POWER
RELAY
BLK
D
BRN
ORG/RED-42
86
RED
87a
BLK
RED
GRN/WHT-45
GRN/BLK-18
BLK
GRN/BLK
30
BLK
TS57
PLATFORM
ROTATE
RED
ORG/RED
RED
BLK
RED
GRN-17
GRN
GRN/WHT-45
GRN/BLK-18
TS59
PLATFORM
LEVEL
BLK
ORG/RED-R2
RED/WHT-3
RED/WHT-3
BLK
ORG/BLK-15
RED
ORG-14
BLK
RED
RED
BLK
RED
CB1
CIRCUIT
BREAKER 1
RED
GRN/BLK
GRN
BLK
GRN-17
E
CR1
48V DC POWER RELAY
RED
BLK
RED
RED-20
TS60
SECONDARY
BOOM
F
RED
RED
TS62
TURNTABLE
ROTATE
G
TS55
FUNCTION
ENABLE
BRN
BLU-10
RED
TS58
JIB BOOM
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
REV A
RED
BLK-22
WHT-4
WHT/BLK-5
BLK
RED
BLK
RED
RED
RED
RED
RED
TS61
PRIMARY
BOOM
RED-1
RED/BLK-2
BLK/WHT-8
BLK/RED-7
RED
RED-27
RED
BLK/RED-35
RED
RED
BLU/BLK-11
GRN/WHT-19
WHT-23
RED
RED
H
TS51
START
ENGINE
BLK/WHT-34
BLK-33
4
RED-POWER
BLK-22
I
TS56
GLOW
PLUG
BLK/WHT-34
BLK-33
BRN
WHT-21
4
3
NO
J
BRN
BRN
WHT-21
BLK-22
RED
3
NO
K
BASE BOX HARNESS
(TO TERMINAL STRIP)
RED
RED
L
TS51
AUXILIARY
PUMP
M
KS1
KEY SWITCH
N
P1
EMERGENCY
STOP
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180)
A
BLK
GRN/BLK-18
1
GRN/WHT-R3
GRN/WHT
2
BRN
RED-27P
WIRE GOES
TO T.B. 27A
3
RED/WHT-48
ORG/RED
BRN
BLK/RED-9
4
RED/BLK-R5
5
BRN
6
BLK-22
BRN
7
8
RED
6 - 82
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050)
GROUND
STUD
8
6 - 83
FAULT
STATUS
LED
P20BAT RD C7B-4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
BATGND BRN
Part No. 106488
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
87
BRN
C5B-2
BK
87
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
I
CR4
HORN
RELAY
30
86
OR/BK
87a
85
BRN
85
87
GR/WH
RD/WH
BRN
OR/RD
OR/RD
BRN
86
87a
30
CR2
48V DC
POWER
RELAY
GR/BK-TS58
OR/RD-CR1
OR/RD-LED
BK-ALARM
BRN
C9HRN BK/RD
85
RD/WH
44
42
GR/WH-J19
GR/WH-J19
BK/RD-TS54
BK/WH-TS56
BK-TS52
WH-KS1
RD-CR3
RD-TS51
GR/WH-J19
BK-CR4
BK-KS1
GR/BK-TS57
GR/WH
GR/WH-TS60
GR-TS57
OR/BK-TS59
OR-TS59
C12DRE BL/WH
BK ALARM
BL/BK-TS60
H
C41DRE OR/BK
OR/RD
BRN
86
87a
30
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
C6B-33 C44DA BK
C6B-23 P20BAT RD
JIB DESCENT ALARM
SWITCH 48 VOLTS
37
40
BK/WH-TS63
BL-TS60
G
BRN
C6B-21
BRN
BRN
C6B-26 C12DRE BL/WH
BK
OR/RD
BRN
GR/WH
OR/RD
STEER RIGHT
OFF-LIMIT SPEED
36
GR/WH
BK-TS63
F
C3B-9
C2B-3
5
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
44
42
40
37
STEER LEFT
35
34
33
27
23
22
19
WH-TS62
WH/BK-TS62
1
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
C5B-3 C23PWR WH
C2B-6 C44JDA GR/BK
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
36
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
KEYSWITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
19
18
LIFT PUMP
PLATFORM ROTATE RIGHT/JIB DOWN
RD-TS61
BK-ALARM
RD/BK-TS61
E
BRN-HM
C6B-25
OR/RD-42A
C6B-22 R42BAT OR/RD
C1B-10 C36STCC BL
C1B-11 C37STC BL/BK
35
34
33
27
23
22
19
19
18
15
14
12
11
10
8
7
6
5
4
17
RD
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
2
1
D
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
17
15
14
12
11
10
8
7
6
5
4
PRIMARY BOOM DOWN
PRIMARY BOOM UP
P20BAT RD
C
C6B-36 C36STCC BL
C6B-20 C22LS BK
C7B-1 P22BAT BK
C6B-34 C23ALARM WH
C7B-2 P23SWBAT WH
C6B-38 C19PSW GR/WH
C6B-18 C18PRR GR/BK
C4B-5 C17PRL GR
C4B-3 C15PLD OR/BK
C4B-2 C14PLU OR
C3B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
2
1
A
B
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C6B-12 C12DRE BL/WH
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C6B-7 C7PBE BK
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C3B-4 C4TRL WH
C3B-2 C2PBD RD/BK
B
A
BK
7
C6B-4 C4TRL WH
6
C3B-1 C1PBU RD
4
C6B-1 C1PBU RD
C
3
C6B-2 C2PBD RD/BK
D
2
TERMINAL BASE (TB)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
REV A
(from serial number 21181 to 22050)
J
K
BK-ALARM
GR/WH
RD
RD/WH
OR/RD
RD/BK
BK/RD
L
M
N
June 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050)
H
G
F
E
D
BK/RD
C
B
A
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
GR/BK
WH-4A
GR
GR
1
BK
BK
RD
2
RD
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
TS59
PLATFORM
LEVEL
GR/BK-44A
TS58
JIB BOOM
TS61
PRIMARY
BOOM
RD
RD
RD
RD-1A
RD
BK
RD
GR
RD-27A
BK
GR/BK
RD
RD
BK
TS57
PLATFORM
ROTATE
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
RD
TS62
TURN
TABLE
ROTATE
TS54
HIGH/LOW
RPM
BK
3
BK
P20BAT RD (C6B-23)
RD
BK
4
RD
P20BAT RD (C7B-4)
BL/BK-11A
WH-23A
GR/WH-19A
4
BK-22A
CB1
CIRCUIT
BREAKER 1
RD
BK
SECONDARY
BOOM TS60
4
3
NO
BL-10A
3
P20BAT RD (C5B-1)
RD
5
RD
RD
RD
6
RD
RD
TS52
ENGINE
START
WH
BRN
BRN-HM
7
BASE BOX HARNESS
Part No. 106488
RD
RD
TS55
FUNCTION
ENABLE
2
TS56
GLOW
PLUG
HOUR METER
H.M.
1
NC
RD
BK-33A
RD
C21IGN2 (C5B-11)
I
NO
J
RD
K
TS51
AUXILIARY
PUMP
L
KS1
KEY SWITCH
M
P1
EMERGENCY
STOP
N
8
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 84
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J
ANSI and CSA Models (from serial number 22051 to 23235)
GROUND
STUD
8
6 - 85
P20BAT RD C7B-4
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
Part No. 106488
BK
BATGND BRN
H6
(CE OPTION ONLY)
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
BRN
C5B-2
BK
87
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
RD KS1
GR/BK-TS58
RD H6
OR/RD-CR1
OR/RD-LED
BK-ALARM
GR/WH-J19
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
J
CR4
HORN
RELAY
30
86
OR/BK
87a
87
85
30
87a
BRN
85
OR/RD
OR/RD
BRN
86
GR/WH
RD/WH
BRN
85
CR2
48V DC
POWER
RELAY
BK/RD-TS54
GR/WH-J19
BRN
C9HRN BK/RD
87
87a
30
RD/WH
BK-TS52
BK/WH-TS56
I
C41DRE OR/BK
OR/RD
BRN
86
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
134
44
42
40
37
36
35
34
33
27
WH-KS1 (D2)
RD-CR3
RD-TS51
H
BRN
C6B-21
BRN
BRN
C6B-33 C44DA BK
BK
OR/RD
BRN
GR/WH
OR/RD
KEYSWEITCH POWER
JIB DESCENT ALARM
SWITCH 48 VOLTS
OFF-LIMIT SPEED
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
22
23
GR/WH-J19
BK-CR4
BK-KS1
G
C3B-9
C2B-3
5
C6B-26 C12DRE BL/WH
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
134
44
42
40
37
36
35
34
33
27
KEYSWITCH POWER
+24V DC TO PLATFORM
19
19
GR/BK-TS57
GR/WH
GR/WH-TS60
GR-TS57
OR/BK-TS59
OR-TS59
C12DRE BL/WH
BK ALARM
BL/BK-TS60
BL-TS60
F
BRN-HM
C6B-25
OR/RD-42A
C5B-3 C23PWR WH
C2B-5 C134PWR RD
C2B-6 C44JDA GR/BK
C6B-34 C23ALARM RD
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
C1B-11 C37STC BL/BK
22
23
LIFT PUMP
LIFT PUMP
18
PLATFORM ROTATE RIGHT/JIB DOWN
15
14
12
11
17
RD
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
8
10
BK-TS63
BK/WH-TS63
E
C6B-22 R42BAT OR/RD
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C1B-10 C36STCC BL
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
C23-4 P22BAT BK
19
19
18
17
15
14
12
11
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
6
7
WH/BK-TS62
GR/WH
D
C6B-36 C36STCC BL
C7B-2 P23SWBAT WH
C6B-20 C22LS BK
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
C4B-5 C17PRL GR
C4B-3 C15PLD OR/BK
8
10
LIFT FLOW CONTROL
PRIMARY BOOM EXTEND
5
WH-TS62
BRN GND
GR/BK H6
RD TS55
RD TS51
BK C7-1
BK 22B
BL/WH C1-12
RD H6
C6B-38 C19PSW GR/WH
C3B-12 C12DRE BL/WH
C4B-2 C14PLU OR
6
7
TURNTABLE ROTATE RIGHT
2
4
RD-TS61
BK-ALARM
RD/BK-TS61
C
C6B-18 C18PRR GR/BK
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
5
PRIMARY BOOM DOWN
TURNTABLE ROTATE LEFT
1
P20BAT RD
2
C6B-12 C12DRE BL/WH
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C6B-7 C7PBE BK
C3B-5 C5TRR WH/BK
C3B-6 C6LFC WH/RD
2
4
PRIMARY BOOM UP
A
B
FAULT
STATUS
LED
GR/BK C23-8
GR/BK L45
GR/BK C2B-6
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C3B-4 C4TRL WH
1
B
A
C6B-4 C4TRL WH
C3B-2 C2PBD RD/BK
C3B-1 C1PBU RD
6
C6B-2 C2PBD RD/BK
C
3
RD C23-1
RD 134B
7
C6B-1 C1PBU RD
D
4
TERMINAL BASE (TB)
C23
1
1 3 4 5 6 7 8 12
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J,
ANSI and CSA Models (from serial number 22051 to 23235)
REV A
K
BK-ALARM
GR/WH
RD
RD/WH
OR/RD
RD/BK
BK/RD
L
M
N
June 2005
REV A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,
ANSI and CSA Models (from serial number 22051 to 23235)
I
H
G
F
E
D
BK/RD
C
B
A
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
GR/BK
WH-4A
GR
GR
1
BK
TS57
PLATFORM
ROTATE
TS62
TURN
TABLE
ROTATE
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
BK
BK
RD
2
BK
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
BK
RD
BK
GR/BK
RD
RD-27A
GR
RD
RD
TS59
PLATFORM
LEVEL
GR/BK-44A
TS58
JIB BOOM
TS61
PRIMARY
BOOM
RD
RD
RD
WH
RD-1A
RD
3
BK
RD
BK
RD C23-6
4
RD
BK-22A
RD
P20BAT RD (C7B-4)
RD
CB1
CIRCUIT
BREAKER 1
L45
PLATFORM
OVERLOAD
(CE ONLY)
BL-10A
+
KS1
BL/BK-11A
-
GR/WH-19A
BK
TS60
SECONDARY
BOOM
P20BAT RD (C5B-1)
RD 134A
5
RD
RD
RD
RD
RD
6
RD
RD C23-7
RD
TS52
ENGINE
START
GR/BK H6
WH 23A
BK-33A
1
Part No. 106488
RD
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
RD
RD
TS55
FUNCTION
ENABLE
TS56
GLOW
PLUG
BASE BOX HARNESS
RD
RD
BRN
HOUR METER
H.M.
2
7
BRN-HM
NC
WH
C21IGN2 (C5B-11)
J
RD
K
TS51
AUXILIARY
PUMP
L
D2
M
P1
EMERGENCY
STOP
N
Section 6 • Schematics
8
6 - 86
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,
ANSI and CSA Models (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J,
CE Models (from serial number 22051 to 23235)
GROUND
STUD
8
6 - 87
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
C7B-3
Part No. 106488
BK
BATGND BRN
H6
C6B-13
C13DREL BL/RD
C4B-1
C6B-16
C16DRE OR/RD
C4B-4
C6B-28
C28TTA RD/BK
C1B-2
C6B-29
C29JSH RD/WH
C1B-3
C6B-30
C30FWD WH
C1B-4
C6B-31
C31REV WH/BK
C1B-5
C6B-32
C32JSL WH/RD
C1B-6
BRN
87
C5B-2
30
86
87
30
87a
86
CR5
BRAKE
RELEASE
RELAY
85
OR/BK
87a
85
86
87
87a
85
30
BRN
CR3
AUXILIARY CONTROL
RELAY
OR/RD
134
44
42
40
RD KS1
GR/BK-TS58
RD H6
OR/RD-CR1
OR/RD-LED
BK-ALARM
GR/WH-J19
GR/WH
GR/WH
86
87
87a
85
30
CR20
LIFT PUMP
RELAY
BRN
(TO
SWITCH
PANEL)
GROUND
CONTROL
HARNESS
J
CR4
HORN
RELAY
85
87
BRN
BK
OR/RD
OR/RD
BRN
86
GR/WH
RD/WH
BRN
85
87a
30
CR2
48V DC
POWER
RELAY
36
37
BK/RD-TS54
GR/WH-J19
I
C9HRN BK/RD
87
RD/WH
34
35
BK-TS52
BK/WH-TS56
BRN
C41DRE OR/BK
OR/RD
BRN
86
87a
30
CR1
48V DC
POWER
RELAY
C3B-3 C3BAT RD/WH
C6B-9 R9HRN
C6B-3 P42BAT OR/RD
C6B-39 CR5 RD/BK
C6B-35 R48BRK RD/WH
C6B-27 R27AUX
C6B-19 R19LPMP GR/WH
27
33
WH-KS1 (D2)
RD-CR3
RD-TS51
GR/WH-J19
BK-CR4
BK-KS1
H
BRN
C6B-21
BRN
BRN
C6B-33 C44DA BK
BK
OR/RD
BRN
GR/WH
OR/RD
KEYSWEITCH POWER
JIB DESCENT ALARM
SWITCH 48 VOLTS
OFF-LIMIT SPEED
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
AUXILIARY PUMP SELECT
23
22
19
GR-TS57
GR/BK-TS57
GR/WH
GR/WH-TS60
G
C3B-9
C2B-3
5
C6B-26 C12DRE BL/WH
C6B-40 C40LS OR
C2B-7 C45JSV GR/WH
C5B-1 P20BAT RD
C5B-11 C21IGN2 WH
134
44
42
40
37
36
35
34
33
27
KEYSWITCH POWER
+24V DC TO PLATFORM
LIFT PUMP
OR-TS59
OR/BK-TS59
F
BRN-HM
C6B-25
OR/RD-42A
C5B-3 C23PWR WH
C2B-5 C134PWR RD
C2B-6 C44JDA GR/BK
C6B-34 C23ALARM RD
C2B-4 R42BAT OR/RD
C2B-2 C40LS OR
C1B-11 C37STC BL/BK
C1B-10 C36STCC BL
C1B-1 C27AUX RD
C5B-5 C33STR BK
C1B-7 C33STR BK
C5B-22 C34SA BK/WH
C1B-8 C34SA BK/WH
C5B-18 C35HRPM BK/RD
C1B-9 C35HRPM BK/RD
23
22
19
19
18
LIFT PUMP
PLATFORM ROTATE RIGHT/JIB DOWN
15
17
RD
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
14
C12DRE BL/WH
BK ALARM
BL/BK-TS60
BL-TS60
BK/WH-TS63
BK-TS63
GR/WH
E
C6B-22 R42BAT OR/RD
C6B-24 C40LS OR
C6B-37 C37STC BL/BK
C6B-36 C36STCC BL
C7B-2 P23SWBAT WH
C23-4 P22BAT BK
19
18
17
15
PLATFORM LEVEL UP
12
11
10
8
7
WH-TS62
WH/BK-TS62
D
FAULT
STATUS
LED
P20BAT RD C7B-4
C6B-20 C22LS BK
C4B-7 C19LPMP GR/WH
GR/WH-CR3
C4B-6 C18PRR GR/BK
C4B-5 C17PRL GR
14
FOOTSWITCH POWER #2
SECONDARY BOOM DOWN
SECONDARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
5
6
RD-TS61
BK-ALARM
RD/BK-TS61
C
C6B-38 C19PSW GR/WH
C4B-2 C14PLU OR
C4B-3 C15PLD OR/BK
12
11
10
8
7
LIFT FLOW CONTROL
TURNTABLE ROTATE RIGHT
4
2
1
BRN GND
GR/BK H6
RD TS55
RD TS51
BK C7-1
BK 22B
BL/WH C1-12
RD H6
C6B-18 C18PRR GR/BK
C6B-17 C17PRL GR
C6B-15 C15PLD OR/BK
C6B-14 C14PLU OR
C3B-12 C12DRE BL/WH
5
6
TURNTABLE ROTATE LEFT
PRIMARY BOOM DOWN
PRIMARY BOOM UP
P20BAT RD
2
C6B-12 C12DRE BL/WH
C3B-11 C11SBD BL/BK
C3B-10 C10SBU BL
C3B-8 C8PBR BK/WH
C3B-7 C7PBE BK
C3B-6 C6LFC WH/RD
C3B-5 C5TRR WH/BK
4
2
1
A
B
C6B-11 C11SBD BL/BK
C6B-10 C10SBU BL
C6B-8 C8PBR BK/WH
C6B-7 C7PBE BK
C6B-6 C6LFC WH/RD
C6B-5 C5TRR WH/BK
C3B-4 C4TRL WH
C3B-2 C2PBD RD/BK
B
A
GR/BK C23-8
GR/BK L45
GR/BK C2B-6
RD C23-1
RD 134B
7
C6B-4 C4TRL WH
6
C3B-1 C1PBU RD
4
C6B-1 C1PBU RD
C
3
C6B-2 C2PBD RD/BK
D
U33
TERMINAL BASE (TB)
1
1 3 4 5 6 7 8 12
Section 6 • Schematics
June 2005
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J,
CE Models (from serial number 22051 to 23235)
REV A
K
BK-ALARM
GR/WH
RD
RD/WH
OR/RD
RD/BK
BK/RD
L
M
N
June 2005
REV A
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,
CE Models (from serial number 22051 to 23235)
I
H
G
F
E
D
BK/RD
C
B
A
BK/RD-35A
C45JSV GR/WH (C2B-7)
BK-7A
GR/BK-18A
BK/WH-8A
GR-17A
BK
RD
WH/BK-5A
GR/BK
WH-4A
GR
GR
1
BK
TS57
PLATFORM
ROTATE
TS62
TURN
TABLE
ROTATE
TS63
PRIMARY
BOOM
EXTEND/
RETRACT
TS54
HIGH/LOW
RPM
BK
BK
RD
2
BK
RD
RD/BK-2A
OR/BK-15A
OR/BK
OR-14A
OR
BK
RD
GR
RD-27A
BK
GR/BK
RD
RD
TS59
PLATFORM
LEVEL
GR/BK-44A
TS58
JIB BOOM
TS61
PRIMARY
BOOM
RD
RD
RD
WH
RD-1A
RD
3
BK
RD
BK
RD C23-6
4
RD
BK-22A
RD
P20BAT RD (C7B-4)
RD
CB1
CIRCUIT
BREAKER 1
L45
PLATFORM
OVERLOAD
(CE ONLY)
BL-10A
+
KS1
BL/BK-11A
-
GR/WH-19A
BK
TS60
SECONDARY
BOOM
P20BAT RD (C5B-1)
RD 134A
5
RD
RD
RD
RD
RD
6
RD
RD C23-7
RD
TS52
ENGINE
START
GR/BK H6
WH 23A
BK-33A
1
Part No. 106488
RD
BK/WH-34A
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
RD
RD
TS55
FUNCTION
ENABLE
TS56
GLOW
PLUG
BASE BOX HARNESS
RD
RD
BRN
HOUR METER
H.M.
2
7
BRN-HM
NC
WH
C21IGN2 (C5B-11)
J
RD
K
TS51
AUXILIARY
PUMP
L
D2
M
P1
EMERGENCY
STOP
N
Section 6 • Schematics
8
6 - 88
June 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, Z-45/25J,
CE Models (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(before serial number 13361)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(before serial number 13361)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BROWN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
-
7
+
TURNTABLE
ROTATE TS12
BCI
SECONDARY
BOOM TS10
EXTEND/
RETRACT TS13
PRIMARY
BOOM TS11
20k
B
LIFT
C
DRIVE
R
RIGHT
L
LEFT
1
2
FWD
REV
3
4
5
BP1
BLK/WHT
NC
L3
TS15
+
8
HORN
AUXILIARY
TS1
FAULT LED
DRIVE ENABLE
+
L1
NC
NO
P3
PLATFORM ROTATE
TS7
PLATFORM LEVEL
TS9
GLOW PLUG
TS6
ORG/RED-42
6 - 89
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
START
TS2
RPM
TS4
EMERG/STOP
P2
RED-TILT
A
GREEN
RED
BLK/RED
WHT #23
BLK #22
DP1
COMPONENT INDEX
BRN-J1
RED/WHT #3
BLK/RED # 35
BLK #26
ORG/BLK#R6
WHT/BLK #31
WHT #30
RED/WHT #29
WHT/RED #32
BLU/WHT #12
WHT #24
RED/BLK #R6
BLU#36
BLU/BLK#37
ORG/RED#42
BLK/WHT # 34
BLK # 33
RED-# 25
WHT/RED #6
GRN/WHT #19
BLACK #7
BLK/WHT #8
BLU/RED #39
RED/BLK #2
RED #1
BLUE #10
BLU/BLK #11
WHT #4
WHT/BLK #5
ORG/BLK #15
ORG #14
GRN #17
GRN/BLK #18
BLU/RED #13
RED #27
BLK/RED #9
6
ORG-1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
FOOT
SWITCH
(FS)
JIB
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
AC
POWER
CABLE
#1
LIFT PUMP
5
CABLE
#2
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
CABLE
#3
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK#28
A1
TILT
ALARM
SEC. BOOM UP
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-TILT
GRND.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
4
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
CR17
CR19A
CR19B
DP1
L1
L3
L4
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
LOAD SENSOR RELAY (LOAD SENSOR OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY A (LVI OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY B (LVI OPTION ONLY)
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
OVERLOAD LED (LOAD SENSOR OPTION)
LDS
LVI
LVI/BCI
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
LOAD SENSOR MODULE
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP #2
HORN
TIME DELAY #1
AUXILIARY SWITCH
START ENGINE SWITCH (BI-ENERGY ONLY)
HIGH / LOW RPM SWITCH (BI-ENERGY ONLY)
GLOW PLUG SWITCH (BI-ENERGY ONLY)
PLATFORM ROTATE SWITCH
JIB BOOM UP / DOWN SWITCH (JIB ONLY)
PLATFORM LEVEL SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM UP / DOWN SWITCH
TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND / RETRACT SWITCH
DRIVE RANGE HIGH / LOW SWITCH
DRIVE ENABLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
(with Platform Load Sense and LVI/BCI Option) (before serial number 13361)
M
L
K
J
I
G
F
E
A
WHT-LV24
AC POWER
AC1
ORG/RED-LV42
BLUE-L10
WHT-L6
B
1
RED-L7
FUSE 3 AMP
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
BLUE-L10
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
WHT-L6
BROWN-LJ
RED-L1
BLK-26
ORG/RED-16
RED-L7
ORG/RED-LV42
BROWN
BLK-26
ORG/RED-16
BLUE-LR15
ORG/BLK-LVJ
ORG/RED-LED
1
2
ORG-LVJ
CR17
CR6
ORG/RED-LVJ
WHT-L6
BROWN-LVJ
RED-L1
3
4
5
6
WHT-LV24
7
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
LVI
BROWN-LVJ
WHT-LV24
BROWN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
8
N
3
RED-LVI
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
BRN-LJ
+
+
HORN
AUXILIARY
TS1
FAULT LED
DRIVE ENABLE
+
L1
NC
NO
PLATFORM ROTATE PLATFORM LEVEL
TS9
TS7
GLOW PLUG
TS6
START
TS2
RPM
TS4
LOAD LED
L4
EMERGENCY STOP
P2
ORG/RED-42
Part No. 106488
ORG/RED-LED
5
RED-TILT
4
WHT #23
LEFT
BLK #22
RIGHT
L
3
REV
NC
L3
TS15
R
2
FWD
BP1
BLK/WHT
P3
4
COMPONENT INDEX
BRN-J1
LVI/BCI OPTION
SECONDARY
BOOM TS10
EXTEND/
RETRACT
TS13
RED/WHT #3
TURNTABLE
ROTATE TS12
PRIMARY BOOM
TS11
DRIVE
BLK/RED # 35
4
C
ORG/BLK#R6
5
LIFT
BLK-LSTOP (LOAD OPTIOIN)
3
1
20k
B
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
A
GREEN
RED
BLK/RED
WHT/BLK #31
WHT #30
RED/WHT #29
WHT/RED #32
BLU/WHT #12
WHT-LV24
RED/BLK #R6
BLU#36
BLU/BLK#37
BLK/WHT # 34
ORG/RED#42
BLK # 33
RED-# 25
WHT/RED #6
GRN/WHT #19
BLACK #7
BLK/WHT #8
BLU/RED #39
RED/BLK #2
RED-LR15
BLU/BLK #11
BLUE-LR15
WHT #4
WHT/BLK #5
ORG/BLK #15
ORG #14
GRN #17
GRN/BLK #18
BLU/RED #13
RED #27
ORG/BLK-LVJ
ORG-LVJ
ORG/RED-LVJ
BLK/RED #9
DP1
ORG-1
FOOT
SWITCH
(FS)
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
AC
POWER
CABLE
#1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
CABLE
#3
A1
TILT
ALARM
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
RED/BLK#28
LIFT PUMP
BROWN-J1
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
RED-TILT
SEC. BOOM UP
BROWN-J7
BROWN-LJ
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
CR19B
BRN-J6
RED-LR15
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
CR17
CR19A
CR19B
DP1
L1
L3
L4
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
LOAD SENSOR RELAY (LOAD SENSOR OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY A (LVI OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY B (LVI OPTION ONLY)
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
OVERLOAD LED (LOAD SENSOR OPTION)
LDS
LVI
LVI/BCI
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
LOAD SENSOR MODULE
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP #2
HORN
TIME DELAY #1
AUXILIARY SWITCH
START ENGINE SWITCH (BI-ENERGY ONLY)
HIGH / LOW RPM SWITCH (BI-ENERGY ONLY)
GLOW PLUG SWITCH (BI-ENERGY ONLY)
PLATFORM ROTATE SWITCH
JIB BOOM UP / DOWN SWITCH (JIB ONLY)
PLATFORM LEVEL SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM UP / DOWN SWITCH
TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND / RETRACT SWITCH
DRIVE RANGE HIGH / LOW SWITCH
DRIVE ENABLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5
6
7
8
6 - 90
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
(with Platform Load Sense and LVI/BCI Option) (before serial number 13361)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 13361 to 14078)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BROWN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
CABLE
#2
ORG-1
CABLE
#3
A1
TILT
ALARM
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
5
SEC. BOOM UP
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
RED-TILT
4
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
+
-
7
TS12
T.T. ROTATE
BCI
TS10
SECONDARY BOOM
TS11
PRIMARYBOOM
TS13
EXT/RETR
LIFT
C
DRIVE
R
RIGHT
L
LEFT
+
3
4
5
+
TS7 PLATFORM
ROTATE
TS9
PLATFORM LEVEL
ORG/RED-42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
NC
L3
FAULT LED
DRIVE ENABLE
L1
6 - 91
REV
BP1
NO
TS1
AUXILIARY
POWER
2
FWD
NC
TS15
P3
HORN
1
BLK/WHT
RED
8
20k
B
TS6
GLOW PLUG
TS2
ENGINE
START
RED-TILT
A
A
BRN-J1
COMPONENT INDEX
DP1
GREEN
RED
BLK/RED
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK #26
ORG/BLK-R6
WHT/BLK-31
WHT-30
RED/WHT-29
WHT/RED-32
BLU/WHT-12
WHT #24
RED/BLK-R6
BLU-36
BLU/BLK-37
BLK/WHT-34
ORG/RED-42
BLK-33
RED-25
WHT/RED-6
GRN/WHT-19
BLACK-7
BLK/WHT-8
BLU/RED-39
RED #1
RED/BLK-2
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN/BLK-18
GRN-17
BLU/RED-13
RED-27
BLK/RED-9
6
TS4
RPM
P2
EMERGENCY
STOP
A1
AC1
BCI
BP1
CR6
DP1
L1
L3
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
TS9
TS10
TS11
TS12
TS13
TS14
TS15
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with Platform Load Sense and LVI/BCI Option (from serial number 13361 to 14078)
M
L
K
J
I
F
E
ORG/RED-LV42
WHT-LV24
A
AC POWER
AC1
RED-L7
BLUE-L10
WHT-L6
B
1
FUSE 3A
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
BLUE-L10
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
WHT-L6
BROWN-LJ
RED-L1
BLK-26
RED-TIME
ORG/RED-16
RED-L7
ORG/RED-LV42
BRN
BLK-26
ORG/RED-16
BLUE-LR15
ORG/BLK-LVJ
ORG/RED-LED
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
1
2
ORG-LVJ
CR17
CR6
ORG/RED-LVJ
BROWN-LVJ
RED-L1
3
4
5
6
WHT-L6
7
WHT-LV24
BRN-J4
G
LVI
BROWN-LVJ
WHT-LV24
BROWN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
8
N
3
RED-LVI
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
ORG-1
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
CABLE
#1
FOOT
SWITCH
(FS)
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#2
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#3
A1
TILT
ALARM
LIFT PUMP
RED/BLK-28
AC
POWER
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BROWN-J1
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-TILT
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
BROWN-J7
BROWN-LJ
GRND.
SEC. BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
CR19B
BRN-J6
RED-LR15
RED-TILT
A
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN A & B
5
COMPONENT INDEX
A1
TS12
T.T. ROTATE
LVI/BCI OPTION
P3
HORN
TS10
SECONDARY
BOOM
TS11
PRIMARY
BOOM
TS13
EXTEND/
RETRACT
L3
TS15
R
RIGHT
L
LEFT
FWD
LDS
REV
LOAD SENSOR MODULE
4
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
5
BP1
BRN-LJ
BLK/WHT
RED
DRIVE
+
+
NO
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
L4
LOAD
LED
P2
EMERGENCY
STOP
ORG/RED-42
Part No. 106488
ORG/RED-LED
OVERLOAD LED
3
NC
4
C
2
RED-TILT
CONTROLLER FAULT LED
L4
NC
5
LIFT
RED/WHT-3
3
B
WHT-23
DRIVE ENABLE LED
L3
BLK-22
DRIVE JOYSTICK
L1
1
20k
BRN-J1
DP1
A
A
BLK/RED-35
LOW VOLTAGE INTERRUPT/BCI RELAY B
ORG/BLK-R6
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
BLK-LSTOP (LOAD OPTIOIN)
LOAD SENSOR RELAY
CR19A
WHT/BLK-31
DRIVE ENABLE RELAY
CR17
WHT-30
ROTARY FLOW CONTROL DIAL
CR6
RED/WHT-29
BP1
WHT/RED-32
BATTERY CHARGE INDICATOR
BLU/WHT-12
GRN/WHT-JOYS
WHT-LV24
RED/BLK-R6
BLU-36
BLU/BLK-37
BLK/WHT-34
ORG/RED-42
BLK-33
RED-25
WHT/RED-6
GRN/WHT-19
BLACK-7
BLK/WHT-8
BLU/RED-39
RED/BLK-2
RED-LR15
BLU/BLK-11
BLUE-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
AC OUTLET BOX
BCI
DP1
GREEN
RED
BLK/RED
TILT ALARM
AC1
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 92
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with Platform Load Sense and LVI/BCI Option
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14079 to 14650)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BRN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
STEER RIGHT
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
TILT
ALARM
CABLE
#2
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
ORG-1
CABLE
#3
A1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
BRN-GRND.
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
5
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
SEC. BOOM UP
4
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
RED-TILT
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
A FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS 6 & 7
ON THE DRIVE JOYSTICK.
1
2
WHT
6
FWD
-
DRIVE
RIGHT
TS12
T.T. ROTATE
BCI
TS10
SECONDARY BOOM
LEFT
TS13
EXT/RETR
BP1
4
WHT/RED-32
WHT-30
WHT/BLK-31
5
WHT #24
6
A
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
7
TS11
PRIMARY BOOM
BLK
RED
WHT/GRN
YEL
PRPL
LIFT
+
3
RED/WHT-29
BLU-36
BLU/BLK-37
RED/BLK-R6
REV
GREEN
RED
BLK/RED
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK #26
GRN
ORG
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
BLU/RED-39
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLU #10
WHT-4
WHT/BLK-5
ORG/BLK-15
GRN-17
ORG-14
GRN/BLK-18
BLU/RED-13
RED-27
BLK/RED-9
DP1
20k
BLK/WHT
RED
BLK/WHT
RED
NC
L3
+
8
P3
HORN
TS1
AUXILIARY
POWER
TS15
DRIVE ENABLE
+
L1
NC
NO
FAULT LED
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY STOP
RED
ORG/RED-42
6 - 93
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
L3
P2
P3
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
EMERGENCY STOP BUTTON
HORN
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS14
TS15
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with Platform Load Sense and LVI/BCI Option(from serial number 14079 to 14650)
N
M
L
K
J
I
G
F
E
B
1
AC POWER
AC1
8
WHT-LV24
A
ORG/RED-LV42
BLU-L10
WHT-L6
RED-L7
FUSE 3A
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
BLU-L10
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
WHT-L6
BRN-LJ
RED-L1
ORG/RED-LV42
BLK-26
ORG/RED-16
RED-L7
ORG/BLK-LVJ
BRN
BLK-26
ORG/RED-16
BLU-LR15
1
2
ORG-LVJ
CR17
CR6
ORG/RED-LED
3
4
ORG/RED-LVJ
WHT-L6
WHT-LV24
BRN-LVJ
RED-L1
5
6
7
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
LVI
BRN-LVJ
WHT-LV24
BRN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
3
RED-LVI
(SPARE)
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
ORG-1
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
FOOT
SWITCH
(FS)
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#1
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#2
LIFT PUMP
CABLE
#3
A1
TILT
ALARM
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
RED/BLK-28
AC
POWER
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BRN-J1
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-TILT
SEC. BOOM UP
BRN-J7
BRN-LJ
GRND.
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-LR15
A
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
5
COMPONENT INDEX
A1
RED
WHT/GRN
YEL
PRPL
LIFT
DRIVE
4
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT-30
WHT/BLK-31
5
WHT-LV24
6
A
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR17
LOAD SENSOR RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
L3
CONTROLLER FAULT LED
L4
OVERLOAD LED
LDS
LOAD SENSOR MODULE
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
WHT/RED-32
NC
GREEN
RED
BLK/RED
3
BLK
RED/WHT-29
BATTERY CHARGE INDICATOR
NC
REV
5
2
WHT
FWD
3
1
ORG
AC OUTLET BOX
BCI
ORG/RED-LED
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-LSTOP (LOAD OPTIOIN)
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN
20k
BLU/WHT-12
WHT-LV24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
GRN/WHT-19
BLK-7
BLU/RED-39
RED/BLK-2
RED-LR15
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
BLK/WHT
RED
BRN-LJ
P3
HORN
BLK/WHT
RED
L3
TS15
+
+
NO
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
+
L1
TS7
PLATFORM
ROTATE
TS9
PLATFORM
LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
L4
LOAD
LED
TS4
RPM
P2
EMERGENCY
STOP
RED
Part No. 106488
TILT ALARM
AC1
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 94
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with Platform Load Sense and LVI/BCI Option
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 14651 to 16839)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BRN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
STEER RIGHT
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
TILT
ALARM
CABLE
#2
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
ORG-1
CABLE
#3
A1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
BRN-GRND.
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
5
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
SEC. BOOM UP
4
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
RED-TILT
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1 FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS 6 & 7
ON THE DRIVE JOYSTICK.
1
2
WHT
6
FWD
-
DRIVE
RIGHT
TS12
T.T. ROTATE
BCI
TS10
SECONDARY BOOM
LEFT
TS13
EXT/RETR
BP1
4
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
7
TS11
PRIMARY BOOM
BLK
RED
WHT/GRN
YEL
PRPL
LIFT
+
3
RED/WHT-29
WHT/RED-32
BLU-36
BLU/BLK-37
RED/BLK-R6
REV
GREEN
RED
BLK/RED
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK #26
GRN
ORG
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK/WHT-8
BLU/RED-39
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLU #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
RED-27
BLK/RED-9
DP1
20k
BLK/WHT
RED
BLK/WHT
RED
NC
L3
+
8
P3
HORN
TS1
AUXILIARY
POWER
TS15
DRIVE ENABLE
+
L1
NC
NO
FAULT LED
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY STOP
RED
ORG/RED-42
6 - 95
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
L3
P2
P3
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
EMERGENCY STOP BUTTON
HORN
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS14
TS15
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 14651 to 16839)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
E
D
C
B
A
1
LVI
BRN-LVJ
3
4
1
2
AC POWER
AC1
ORG/RED-LV42
ORG-LVJ
ORG/BLK-LVJ
8
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
WHT-LV24
BRN-LVJ
BRN-LVJ
5
6
7
BRN
ORG/RED-16
BLU-LR15
2
ORG/RED-16
CR19A
BRN-J5
BLU-L10
BLU-L10
WHT-L6
WHT-L6
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
ORG/BLK-41
WHT-LV24
3
RED-LVI
(SPARE)
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
FOOT
SWITCH
(FS)
JIB
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
AC
POWER
CABLE
#1
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#2
LIFT PUMP
CABLE
#3
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
RED/BLK-28
A1
TILT
ALARM
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BRN-J1
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-TILT
SEC. BOOM UP
BRN-J7
BRN-LJ
GRND.
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-LR15
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
A
ORG
FWD
LIFT
4
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
4
WHT/RED-32
WHT-30
WHT/BLK-31
5
WHT-LV24
6
A
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
BLK
RED
WHT/GRN
YEL
PRPL
DRIVE
5
2
3
RED/WHT-29
BLU-36
BLU/BLK-37
RED/BLK-R6
REV
3
1
WHT
GREEN
RED
BLK/RED
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
GRN
BLU/WHT-12
WHT-LV24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK/WHT-8
BLU/RED-39
BLK-7
RED/BLK-2
RED-LR15
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
RED-27
ORG/BLK-LVJ
ORG-LVJ
ORG/RED-LVJ
BLK/RED-9
DP1
20k
BLK/WHT
RED
P3
HORN
BLK/WHT
RED
NC
L3
TS15
+
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
+
L1
NC
NO
TS7
PLATFORM
ROTATE
TS9
PLATFORM
LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY
STOP
RED
Part No. 106488
5
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
COMPONENT INDEX
A1
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
L3
CONTROLLER FAULT LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 96
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 16840 to 17974)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BRN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
STEER RIGHT
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
FOOT
SWITCH
(FS)
JIB
1
ORG
2
6
GREEN
RED
BLK/RED
DRIVE
RIGHT
TS11
TS10
SECONDARY BOOM PRIMARY BOOM
LEFT
TS13
EXT/RETR
BP1
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
4
RED
WHT/GRN
YEL
PRPL
LIFT
+
BLK
WHT/RED-32
BLU-36
BLU/BLK-37
RED/BLK-R6
REV
3
RED/WHT-29
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
20k
WHT
BCI
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK/WHT-34
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN/BLK-18
GRN-17
BLU/RED-13
RED-27
ORG/RED-42
BLK/RED-9
DP1
FWD
-
ORG-1
AC
POWER
CABLE
#1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
CABLE
#2
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#3
A1
TILT
ALARM
7
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
SEC. BOOM UP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
5
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
RED-TILT
4
BLK/WHT
RED
BLK/WHT
RED
NC
TS15
P3
HORN
NC
NO
8
TS1
AUXILIARY
POWER
DRIVE ENABLE
+
L1
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
RED
6 - 97
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
P2
EMERGENCY
STOP
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1
FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
DP1
L1
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS14
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 16840 to 17974)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
1
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
LVI
BRN-LVJ
3
4
2
D
C
B
AC POWER
AC1
8
BRN
ORG/RED-16
BLU-LR19A
2
ORG/RED-16
CR19A
BLU-L10
WHT-L6
WHT-L6
ORG/BLK-41
WHT-LV24
BRN-LVI
3
RED-LVI
(SPARE)
(SPARE)
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BRN-LVI
SEC. BOOM UP
RED-TILT
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-LR19B
GRND.
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
BLU-L10
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
ORG-1
CABLE
#2
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
CABLE
#3
A1
TILT
ALARM
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
A
1
2
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT-30
WHT/BLK-31
5
6
A
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
BLK
BLU-36
BLU/BLK-37
RED/BLK-R6
GREEN
RED
BLK/RED
3
WHT/RED-32
BLU/WHT-12
WHT
RED/WHT-29
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
ORG
REV
5
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK/WHT-8
BLK-7
RED/BLK-2
RED-LR19B
BLU-LR19A
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
WHT-LV24
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
20k
FWD
3
A
1
ORG/RED-LV42
ORG/BLK-LVJ
ORG-LVJ
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
WHT-LV24
BRN-LVJ
BRN-LVJ
5
6
7
E
BLK/WHT
RED
P3
HORN
BLK/WHT
RED
NC
TS15
NC
NO
TS1
AUXILIARY
POWER
DRIVE ENABLE
+
L1
TS7
PLATFORM
ROTATE
TS9
PLATFORM
LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY
STOP
RED
Part No. 106488
5
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
COMPONENT INDEX
A1
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 98
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 17975 to 21180)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
AC POWER
AC1
CR6
BRN
2
ORG/RED-16
ORG/RED-16
ORG/BLK-41
ORG/BLK-41
3
(SPARE)
(SPARE)
STEER RIGHT
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
SEC. BOOM UP
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
1
ORG
2
6
GREEN
RED
BLK/RED
DRIVE
RIGHT
TS11
TS10
SECONDARY BOOM PRIMARY BOOM
LEFT
TS13
EXT/RETR
BP1
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
BCI
4
RED
WHT/GRN
YEL
PRPL
LIFT
+
BLK
WHT/RED-32
BLU-36
BLU/BLK-37
RED/BLK-R6
REV
3
RED/WHT-29
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
20k
WHT
7
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK-33
BRN-J1
WHT/RED-6
BLK/WHT-34
RED-25
BLK/WHT-8
GRN/WHT-19
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN/BLK-18
GRN-17
BLU/RED-13
RED-27
ORG/RED-42
BLK/RED-9
DP1
FWD
-
ORG-1
CABLE
#2
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
CABLE
#3
A1
TILT
ALARM
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
5
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GRND.
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
RED-TILT
4
BLK/WHT
RED
BLK/WHT
1
2
NC
1
TS15
TS1
AUXILIARY
POWER
DRIVE ENABLE
+
L1
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
RED
6 - 99
NC
NO
P3
HORN
3
4
8
2
RED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
P2
EMERGENCY
STOP
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1
FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
DP1
L1
DRIVE JOYSTICK
DRIVE ENABLE LED
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS14
TS15
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 17975 to 21180)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
LVI
BRN-LVJ
3
4
D
C
B
A
1
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
1
2
AC POWER
AC1
ORG/RED-LV42
ORG/BLK-LVJ
ORG-LVJ
8
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
WHT-LV24
BRN-LVJ
BRN-LVJ
5
6
7
E
BRN
ORG/RED-16
BLU-LR19A
2
ORG/RED-16
CR19A
BLU-L10
BLU-L10
WHT-L6
WHT-L6
ORG/BLK-41
WHT-LV24
BRN-LVI
3
RED-LVI
(SPARE)
(SPARE)
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
LIFT PUMP
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BRN-LVI
SEC. BOOM UP
RED-TILT
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-LR19B
GRND.
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
AC
POWER
CABLE
#1
FOOT
SWITCH
(FS)
JIB
ORG-1
CABLE
#2
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
CABLE
#3
A1
TILT
ALARM
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
A
2
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT-30
WHT/BLK-31
5
6
A
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
BLK
WHT/RED-32
BLU-36
BLU/BLK-37
RED/BLK-R6
GREEN
RED
BLK/RED
3
RED/WHT-29
BLU/WHT-12
WHT
REV
5
1
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
ORG
FWD
3
RED-TILT
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK/WHT-8
BLK-7
RED/BLK-2
RED-LR19B
BLU-LR19A
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
WHT-LV24
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
20k
BLK/WHT
RED
BLK/WHT
+
L1
TS7
PLATFORM
ROTATE
TS9
PLATFORM
LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
1
DRIVE ENABLE
NC
2
P3
HORN
TS1
AUXILIARY
POWER
1
TS15
NC
NO
3
4
2
RED
TS4
RPM
P2
EMERGENCY
STOP
RED
Part No. 106488
5
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
COMPONENT INDEX
A1
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 100
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 21181 to 22050)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
BRN-RELAY
OR-LOAD
BK-LOAD
OR/RD
C9P-3
C9P-2
C9P-1
1
P25BAT RD
P24BAT WH
P26BAT BK
C7P-3
C7P-2
C7P-1
1
1
C4P-7
C4P-6
C4P-5
C4P-4
C4P-3
C4P-2
C4P-1
C3P-12
C3P-11
C3P-10
C3P-9
C3P-8
C3P-7
C3P-6
C3P-5
C3P-4
C3P-3
C3P-2
C3P-1
C2P-4
C2P-3
BRN-BATGND
P23SWBAT WH
P22BAT BK
C19LPMP GR/WH
C18PRR GR/BK
C17PRL GR
C16DRE OR/RD
C15PLD OR/BK
C14PLU OR
C13DREL BL/RD
C12DRE BL/WH
C11SBD BL/BK
C10SBU BL
C9HRN BK/RD
C8PBR BK/WH
C7PBE BK
C6LFC WH/RD
C5TRR WH/BK
C4TRL WH
C3BAT RD/WH
C2PBD RD/BK
C1PBU RD
C1P-11
C1P-10
C1P-9
C1P-8
C1P-7
C1P-6
C1P-5
C1P-4
C1P-3
1
C1P-1
R42BAT OR/RD
R41DRE OR/BK
C37STC BL/BK
C36STCC BL
C35HRPM BK/RD
C34SA BK/WH
C33STR BK
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
C29JSH RD/WH
BRN-J1
BRN-BATGND
C27AUX RD
RD-STOP
3
RD/BK-R6
OR/BK
OR/BK-R6
2
CR6
C1P-2
C4P(BR)
C3P(GR)
TILT ALARM
C2P(BK)
C1P(GY)
C28TTA RD/BK
4
C7P
12V DC
BATTERY
19/18 CONTROL CABLE
C9P
JIB
OPT.
FOOT SWITCH
5
GR-LFC
DP1
GR
20k
TS13
EXTEND/RETRACT
WH
FWD
REV
-
DRIVE
RIGHT
LEFT
5
6
PRPL
8
WH/YL
9
WH/RD
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
TS9
PLATFORM
LEVEL
Part No. 106488
C31REV WH/BK
OR/BK-R6
RD-DRE
P24BAT WH
C12DRE BL/WH
RD-RPM
RD-J7
RD-SW
RD/BK-R6
BK/WH-DRE
C37STC BL/BK
NOTES:
1. LOAD SENSE WIRES SHOWN WITH DASHED LINES.
1
1
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
COMPONENT INDEX
C36STCC BL
RD-HRN
OR-LOAD
C35HRPM BK/RD
RD-RPM
RD-AUX
C33STR BK
TS7
PLATFORM
ROTATE
10
C30FWD WH
1
NO
L1
7
BL
RD
2
2
L2
TS15
DRIVE ENABLE
TS1
AUXILIARY
POWER
6 - 101
4
RD
3
4
RD
P3
HORN
C32JSL WH/RD
P22BAT BK
RD-STOP
P23SWBAT WH
C3BAT RD/WH
P26BAT BK
BK-LOAD
BRN-LOAD
BRN-J1
BRN-BCI
C34SA BK/WH
C14PLU OR
C15PLD OR/BK
C17PRL GR
C18PRR GR/BK
C13DREL BL/RD
BK/WH-DRE
RD-DRE
RD-AUX
C27AUX RD
RD-HRN
C9HRN BK/RD
C6LFC WH/RD
C19LPMP GR/WH P25BAT RD
RD-SW
C7PBE BK
C8PBR BK/WH
C2PBD RD/BK
1
C1PBU RD
C11SBD BL/BK
C10SBU BL 1
C4TRL WH
1
1
C5TRR WH/BK
7
8
BP1
R42BAT OR/RD
BRN-BCI
BCI
BK
YL
LIFT
C29JSH RD/WH
2
3
WH/GR
+
1
NC
6
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
OR
NC
TS12
TURNTABLE
ROTATE
GR
RD
BK/RD
1
1
P2
EMERGENCY
STOP
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
EMERGENCY STOP BUTTON
HORN
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 21181 to 22050)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
WH
1
1
OR/RD
OR
OR/BK
OR/RD
WH
CR8
WH
BRN-RELAY
CR6
CR7
CR19A
LVI
1
2
3
4
5
6
7
8
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
2
CR19B
BRN-LVI
P24BAT WH
OR/RD-LVI
OR/BK-LVI
OR-LVI
RD-J7
P24BAT WH
R42BAT OR/RD
BL-LR19A
BL-L10
RD-LVI
RD-LR19B
C40LS OR
3
C9P-2
C3P-10
C3P-1
C2P-4
C2P-2
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
4
19/18 CONTROL CABLE
TILT ALARM
C7P
C9P
12V DC BATTERY
FOOT
SWITCH
JIB
OPT.
5
DP1
20k
TS12
TURNTABLE
ROTATE
LVI/BCI
TS10
SECONDARY
BOOM
TS11
PRIMARY
BOOM
TS13
EXTEND/
RETRACT
GR
RD
BK/RD
OR
WH
FWD
REV
3
5
BK
RD
WH/GR
4
YL
LIFT
BP1
DRIVE
RIGHT
RD-LR19B
BL-LR19A
OR/BK-LVI
OR/RD-LVI
OR-LVI
LEFT
PRPL
BL
WH/YL
WH/RD
1
2
NOTES:
3
1
4
P24BAT WH
6
1
7
COMPONENT INDEX
RD-J7
8
9
10
2
TS15
DRIVE ENABLE
TS1
AUXILIARY
POWER
L1
TS7
PLATFORM
ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
6
FOR CE OPTION, TAKE OFF JUMPER ON JOYSTICK
BETWEEN TERMINALS 6 & 7 AND ADD CR8.
5
3
4
NO
P3
HORN
GR
2
NC
NC
1
1
P2
EMERGENCY
STOP
TS4
RPM
Part No. 106488
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
7
8
6 - 102
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25
(after serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25
(from serial number 22051 to 23235)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
BRN-RELAY
RD/BK-R6
OR/BK
OR/BK-R6
CR6
2
P25BAT RD
P24BAT WH
P26BAT BK
BRN-BATGND
P23SWBAT WH
P22BAT BK
C19LPMP GR/WH
C18PRR GR/BK
C17PRL GR
C16DRE OR/RD
1
1
1
C9P-3
C9P-2
C9P-1
C7P-3
C7P-2
C7P-1
C4P-7
C4P-6
C4P-5
C4P-4
C4P-3
C4P-2
C4P-1
C3P-12
C3P-11
C3P-10
C3P-9
C3P-8
C3P-7
C3P-6
C3P-5
C3P-4
C3P-3
C3P-2
C3P-1
C2P-4
C2P-3
C1P-11
C1P-10
C1P-9
C1P-8
C1P-7
C1P-6
C1P-5
C1P-4
C1P-3
3
C15PLD OR/BK
C14PLU OR
C13DREL BL/RD
C12DRE BL/WH
C11SBD BL/BK
C10SBU BL
C9HRN BK/RD
C8PBR BK/WH
C7PBE BK
C6LFC WH/RD
C5TRR WH/BK
C4TRL WH
C3BAT RD/WH
C2PBD RD/BK
C1PBU RD
1
C1P-1
R42BAT OR/RD
R41DRE OR/BK
C27AUX RD
RD/BK L48
C2P-5
C37STC BL/BK
C36STCC BL
C35HRPM BK/RD
C34SA BK/WH
C33STR BK
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
C29JSH RD/WH
C134PWR RD
BRN-J1
BRN-BATGND
C1P-2
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
C28TTA RD/BK
4
C7P
C9P
JIB
LS18
OPT.
D40
A1
TILT ALARM
19/18 CONTROL CABLE
FOOT
SWITCH
12V DC BATTERY
5
GR-LFC
DP1
GR
20k
TS12
TURNTABLE
ROTATE
6
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
GR
RD
BK/RD
TS13
EXTEND/
RETRACT
OR
WH
FWD
REV
-
YL
LIFT
DRIVE
RIGHT
LEFT
BL
WH/YL
WH/RD
2
C32JSL WH/RD
3
4
5
6
7
8
9
COMPONENT INDEX
C31REV WH/BK
OR/BK-R6
RD-DRE
P24BAT WH
C12DRE BL/WH
RD-RPM
RD-J7
RD-SW
RD/BK-R6
BK/WH-DRE
C37STC BL/BK
1
C36STCC BL
P3
TS4
RPM
1
Part No. 106488
TS6
GLOW PLUG
1
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
TS9
PLATFORM
LEVEL
2
TS7
PLATFORM
ROTATE
1
2
L1
NC NC NC
2
TS1
AUXILIARY
POWER
TS2
ENGINE
START
P2
EMERGENCY
STOP
C3BAT RD/WH C3-3
RD-HRN
RD/BK H1
C35HRPM BK/RD
RD-RPM
RD-AUX
C33STR BK
NO
L48
TS15
DRIVE ENABLE
P23SWBAT WH C7P-2
1
RD
P22BAT BK C7P-1
10
NOTES:
1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
C30FWD WH
3
4
RD
P3
HORN
6 - 103
PRPL
C29JSH RD/WH
P26FS BK C9P-1
BRN-J1
BRN-BCI
C34SA BK/WH
C14PLU OR
C15PLD OR/BK
C17PRL GR
C18PRR GR/BK
C13DREL BL/RD
BK/WH-DRE
RD-DRE
RD-AUX
C27AUX RD
RD-HRN
C9HRN BK/RD
C6LFC WH/RD
C19LPMP GR/WH P25BAT RD
RD-SW
C7PBE BK
C8PBR BK/WH
C2PBD RD/BK
1
C1PBU RD
C11SBD BL/BK
C10SBU BL 1
C4TRL WH
C5TRR WH/BK
1
1
8
BP1
R42BAT OR/RD
BRN-BCI
7
RD
WH/GR
+
BCI
OPTION
BK
1
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS15
H1
LS18
L4
L48
DRIVE JOYSTICK
DRIVE ENABLE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TITL ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 22051 to 23235)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
WH
1
1
OR/RD
OR
OR/BK
OR/RD
WH
CR8
WH
BRN-RELAY
CR6
CR7
CR19A
LVI
1
2
3
4
5
6
7
8
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
2
CR19B
BRN-LVI
P24BAT WH
OR/RD-LVI
OR/BK-LVI
OR-LVI
RD-J7
P24BAT WH
R42BAT OR/RD
BL-LR19A
BL-L10
RD-LVI
RD-LR19B
C40LS OR
C9P-2
C3P-10
C3P-1
C2P-4
C2P-2
GR/BK C133PLA
GR/BK L4
RD LS18
BK LS CABLE C1P-12
RD-H1
RD-P2
3
RD
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
C2P-6
D39
C7P
C9P
JIB
4
LS18
OPT.
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
TS12
TURNTABLE
ROTATE
LVI/BCI
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
TS13
EXTEND/
RETRACT
GR
RD
BK/RD
5
2
WH
FWD
4
RD
5
LIFT
DRIVE
RD-LR19B
BL-LR19A
OR/BK-LVI
OR/RD-LVI
OR-LVI
RIGHT
LEFT
P24BAT WH
6
YL
BP1
COMPONENT INDEX
3
BK
WH/GR
4
1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN
TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
1
OR
REV
3
GR
1
PRPL
7
BL
RD-J7
8
WH/YL
WH/RD
9
10
RD-LS18
GR/BK-H1 (D39)
1
TS6
GLOW PLUG
TS2
ENGINE START
1
TS9
PLATFORM
LEVEL
1
L1
TS7
PLATFORM
ROTATE
2
TS15
DRIVE ENABLE
1
2
TS1
AUXILIARY
POWER
RD
NC NC NC
2
3
4
NO
P3
HORN
L4
P2
EMERGENCY STOP
TS4
RPM
Part No. 106488
6
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS10
TS11
TS12
TS13
TS15
A1
LS18
L4
L48
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TILT ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
7
8
6 - 104
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25
with LVI/BCI Option (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(before serial number 13361)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(before serial number 13361)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
K
AC POWER
AC1
RED
GRN/WHT
BROWN
CR6
BRN
GRN/WHT-45
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
-
7
+
TURNTABLE
ROTATE TS12
BCI
SECONDARY
BOOM TS10
PRIMARY BOOM
TS11
EXTEND/
RETRACT
TS13
20k
B
LIFT
C
DRIVE
R
RIGHT
L
LEFT
1
2
FWD
REV
3
4
5
BP1
BLK/WHT
+
8
HORN
AUXILIARY
TS1
FAULT LED
DRIVE ENABLE
+
L1
NC
NO
P3
JIB BOOM
TS8
PLATFORM ROTATE
TS7
PLATFORM LEVEL
TS9
ORG/RED-42
6 - 105
NC
L3
TS15
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
GLOW PLUG
TS6
START
TS2
RPM
TS4
EMERGENCY STOP
P2
RED-STOP
A
GREEN
RED
BLK/RED
WHT #23
BLK #22
DP1
COMPONENT INDEX
BRN-J1
RED/WHT #3
BLK/RED # 35
BLK #26
ORG/BLK#R6
WHT/BLK #31
WHT #30
RED/WHT #29
WHT/RED #32
BLU/WHT #12
GRN/WHT-JOYS
WHT #24
RED/BLK #R6
BLU#36
BLU/BLK#37
ORG/RED#42
BLK/WHT # 34
BLK # 33
RED-# 25
WHT/RED #6
GRN/WHT #19
BLACK #7
BLK/WHT #8
BLU/RED #39
RED/BLK #2
RED #1
BLUE #10
BLU/BLK #11
WHT #4
WHT/BLK #5
ORG/BLK #15
ORG #14
GRN #17
GRN/BLK #18
BLU/RED #13
GRN/WHT #45
GRN/WHT-R12
RED #27
BLK/RED #9
6
ORG-1
FOOT
SWITCH
(FS)
JIB
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
CABLE
#1
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
5
CABLE
#2
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#3
AC
POWER
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
BLK
BROWN-GRND.
A1
TILT
ALARM
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK#28
WHT
RED-JIB
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
GROUND
LIFT PUMP
GRN/WHT-R12
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
GRN/WHT-JOYS
SEC. BOOM UP
RED-TIME
4
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
BROWN-J1
GRN/WHT-R12
CR7B
RED
RED-TILT
ORG/BLK-41
BRN-J7
BRN
CR7A
ORG/BLK-41
BRN-J3
N
RED-TIME
ORG/RED-16
RED-TIME
ORG/RED-16
3
M
TIME DELAY
T1
BRN-J4
2
L
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
CR17
CR19A
CR19B
DP1
L1
L3
L4
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
LOAD SENSOR RELAY (LOAD SENSOR OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY A (LVI OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY B (LVI OPTION ONLY)
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
OVERLOAD LED (LOAD SENSOR OPTION)
LDS
LVI
LVI/BCI
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
LOAD SENSOR MODULE
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP #2
HORN
TIME DELAY #1
AUXILIARY SWITCH
START ENGINE SWITCH (BI-ENERGY ONLY)
HIGH / LOW RPM SWITCH (BI-ENERGY ONLY)
GLOW PLUG SWITCH (BI-ENERGY ONLY)
PLATFORM ROTATE SWITCH
JIB BOOM UP / DOWN SWITCH (JIB ONLY)
PLATFORM LEVEL SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM UP / DOWN SWITCH
TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND / RETRACT SWITCH
DRIVE RANGE HIGH / LOW SWITCH
DRIVE ENABLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(with Platform Load Sense and LVI/BCI Option) (before serial number 13361)
M
L
K
J
I
F
B
A
1
AC POWER
AC1
RED-L7
FUSE 3 AMP
BROWN-LJ
RED-L1
GRN/WHT-45
ORG/RED-LV42
WHT-LV24
BRN-J7
BLUE-L10
WHT-L6
RED
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
CR7A
BRN
BLUE-L10
WHT-L6
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
GRN/WHT
BROWN
BLK-26
RED-TIME
ORG/RED-16
RED-L7
ORG/RED-LV42
BRN
BLK-26
RED-TIME
ORG/RED-16
BLUE-LR15
E
TIME DELAY
T1
1
2
ORG-LVJ
ORG/RED-LED
ORG/BLK-LVJ
CR17
CR6
ORG/RED-LVJ
BROWN-LVJ
RED-L1
3
4
5
6
WHT-L6
7
WHT-LV24
BRN-J4
G
LVI
BROWN-LVJ
WHT-LV24
BROWN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
8
N
3
RED-LVI
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
LEFT
4
5
BRN-LJ
+
+
HORN
AUXILIARY
TS1
FAULT LED
DRIVE ENABLE
GLOW PLUG
TS6
+
L1
NC
NO
P3
JIB BOOM
TS8
PLATFORM ROTATE
TS7
NC
L3
RIGHT
L
BP1
BLK/WHT
TS15
R
START
TS2
RPM
TS4
LOAD LED
L4
PLATFORM LEVEL
TS9
EMERGENCY STOP
P2
ORG/RED-42
Part No. 106488
ORG/RED-LED
EXTEND/
RETRACT
TS13
3
REV
RED-STOP
PRIMARY BOOM
TS11
2
FWD
WHT #23
SECONDARY
BOOM TS10
BLK #22
LVI/BCI OPTION
4
COMPONENT INDEX
BRN-J1
TURNTABLE
ROTATE TS12
DRIVE
RED/WHT #3
4
C
BLK/RED # 35
5
LIFT
ORG/BLK#R6
3
1
20k
B
BLK-LSTOP (LOAD OPTIOIN)
A
GREEN
RED
BLK/RED
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
WHT/BLK #31
WHT #30
RED/WHT #29
WHT/RED #32
BLU/WHT #12
GRN/WHT-JOYS
WHT-LV24
RED/BLK #R6
BLU#36
BLU/BLK#37
BLK/WHT # 34
ORG/RED#42
BLK # 33
RED-# 25
WHT/RED #6
GRN/WHT #19
BLACK #7
BLK/WHT #8
BLU/RED #39
RED/BLK #2
RED-LR15
BLU/BLK #11
BLUE-LR15
WHT #4
WHT/BLK #5
ORG/BLK #15
ORG #14
GRN #17
GRN/BLK #18
BLU/RED #13
GRN/WHT #45
GRN/WHT-R12
RED #27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED #9
DP1
ORG-1
FOOT
SWITCH
(FS)
JIB
JOYSTICK POT. LOW
AC
POWER
CABLE
#1
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
CABLE
#2
DRIVE REVERSE
DRIVE FORWARD
JOYSTICK POT. HIGH
TILT ALARM
CABLE
#3
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
BLK
BROWN-GRND.
A1
TILT
ALARM
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK#28
WHT
RED-JIB
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
BROWN-J1
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A &
ON THE DRIVE JOYSTICK
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
BROWN-J7
BROWN-LJ
GROUND
LIFT PUMP
GRN/WHT-R12
PLAT. ROTATE LEFT
PLAT. ROTATE RIGHT
DRIVE ENABLE RLY.
GRN/WHT-JOYS
SEC. BOOM UP
RED-LR15
RED-TIME
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROTATE LEFT
TURN. ROTATE RIGHT
48V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-JIB
BROWN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
CR17
CR19A
CR19B
DP1
L1
L3
L4
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB VALVE RELAY
LOAD SENSOR RELAY (LOAD SENSOR OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY A (LVI OPTION ONLY)
LOW VOLTAGE INTERRUPT/BCI RELAY B (LVI OPTION ONLY)
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
OVERLOAD LED (LOAD SENSOR OPTION)
LDS
LVI
LVI/BCI
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
LOAD SENSOR MODULE
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP #2
HORN
TIME DELAY #1
AUXILIARY SWITCH
START ENGINE SWITCH (BI-ENERGY ONLY)
HIGH / LOW RPM SWITCH (BI-ENERGY ONLY)
GLOW PLUG SWITCH (BI-ENERGY ONLY)
PLATFORM ROTATE SWITCH
JIB BOOM UP / DOWN SWITCH (JIB ONLY)
PLATFORM LEVEL SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM UP / DOWN SWITCH
TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND / RETRACT SWITCH
DRIVE RANGE HIGH / LOW SWITCH
DRIVE ENABLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5
6
7
8
6 - 106
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
(with Platform Load Sense and LVI/BCI Option) (before serial number 13361)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 13361 to 14078)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
K
AC POWER
AC1
RED
GRN/WHT
BROWN
CR6
BRN
GRN/WHT-45
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
STEER RIGHT
JOYSTICK POT. LOW
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
+
-
7
TS12
T.T. ROTATE
BCI
TS10
SECONDARY BOOM
TS11
PRIMARYBOOM
TS13
EXT/RETR
LIFT
C
DRIVE
R
RIGHT
L
LEFT
+
3
4
5
+
TS8
JIB BOOM
TS7 PLATFORM
ROTATE
TS9
PLATFORM LEVEL
ORG/RED-42
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
NC
L3
FAULT LED
DRIVE ENABLE
L1
6 - 107
REV
BP1
NO
TS1
AUXILIARY
POWER
2
FWD
NC
TS15
P3
HORN
1
BLK/WHT
RED
8
20k
B
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY
STOP
RED-STOP
A
GREEN
RED
BLK/RED
WHT-23
BLK-22
DP1
A
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
2. FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
BRN-J1
RED/WHT-3
BLK/RED-35
BLK #26
ORG/BLK-R6
WHT/BLK-31
WHT-30
RED/WHT-29
WHT/RED-32
BLU/WHT-12
GRN/WHT-JOYS
WHT #24
RED/BLK-R6
BLU-36
BLU/BLK-37
ORG/RED-42
BLK/WHT-34
BLK-33
RED-25
WHT/RED-6
GRN/WHT-19
BLK/WHT-8
BLACK-7
BLU/RED-39
RED #1
RED/BLK-2
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
GRN-17
ORG-14
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
BLK/RED-9
6
ORG-1
JIB
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
CABLE
#1
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
CABLE
#2
FOOT
SWITCH
(FS)
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#3
A1
TILT
ALARM
AC
POWER
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BLK
BROWN-GRND.
LIFT PUMP
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED/BLK-28
WHT
RED-JIB
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
GRN/WHT-R12
RED-STOP
GRND.
SEC. BOOM UP
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
GRN/WHT-R12
CR7B
BROWN-J1
RED-TIME
4
5
ORG/BLK-41
BRN-J7
CR7A
BRN
RED
RED-TILT
RED-TIME
ORG/RED-16
ORG/BLK-41
BRN-J3
N
T1
RED-TIME
ORG/RED-16
3
M
TIME DELAY
BRN-J4
2
L
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
DP1
L1
L3
LVI/BCI
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
TIME DELAY #1
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
REV A
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with Platform Load Sense and LVI/BCI Option (from serial number 13361 to 14078)
M
L
K
J
I
F
B
A
1
FUSE 3A
AC POWER
AC1
RED-L7
BROWN-LJ
RED-L1
GRN/WHT-45
ORG/RED-LV42
WHT-LV24
BRN-J7
BLUE-L10
WHT-L6
RED
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
CR7A
BRN
BLUE-L10
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
WHT-L6
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
GRN/WHT
BROWN
BLK-26
RED-TIME
ORG/RED-16
RED-L7
ORG/RED-LV42
BRN
BLK-26
RED-TIME
ORG/RED-16
BLUE-LR15
ORG/BLK-LVJ
ORG/RED-LED
1
2
ORG-LVJ
CR17
CR6
ORG/RED-LVJ
WHT-L6
BROWN-LVJ
RED-L1
3
4
5
6
E
T1
TIME DELAY
LVI
7
WHT-LV24
BRN-J4
G
BROWN-LVJ
WHT-LV24
BROWN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
8
N
3
RED-LVI
DRIVE ENABLE LED
L3
CONTROLLER FAULT LED
L4
OVERLOAD LED
LDS
TS12
T.T. ROTATE
LVI/BCI OPTION
P3
HORN
TS10
SECONDARY
BOOM
TS11
PRIMARY
BOOM
TS13
EXTEND/
RETRACT
RIGHT
L
LEFT
REV
LOAD SENSOR MODULE
3
LVI
LOW VOLTAGE INTERRUPT MODULE
4
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
5
BRN-LJ
+
+
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
+
L1
NC
NO
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
NC
L3
TS15
R
FWD
BP1
BLK/WHT
RED
DRIVE
RED/WHT-3
4
C
2
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
L4
LOAD
LED
P2
EMERGENCY
STOP
ORG/RED-42
Part No. 106488
ORG/RED-LED
L1
RED-STOP
DRIVE JOYSTICK
WHT-23
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
BLK-22
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
BRN-J1
LOAD SENSOR RELAY
CR19A
BLK/RED-35
JIB VALVE RELAY
CR17
ORG/BLK-R6
JIB CUTOUT RELAY
CR7B
BLK-LSTOP (LOAD OPTIOIN)
5
LIFT
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
DRIVE ENABLE RELAY
CR7A
WHT/BLK-31
ROTARY FLOW CONTROL DIAL
CR6
WHT-30
BATTERY CHARGE INDICATOR
BP1
RED/WHT-29
BCI
WHT/RED-32
AC OUTLET BOX
BLU/WHT-12
GRN/WHT-JOYS
WHT-LV24
RED/BLK-R6
BLU-36
BLU/BLK-37
ORG/RED-42
BLK/WHT-34
BLK-33
RED-25
WHT/RED-6
GRN/WHT-19
BLACK-7
BLK/WHT-8
BLU/RED-39
RED/BLK-2
RED-LR15
BLU/BLK-11
BLUE-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
3
B
COMPONENT INDEX
AC1
1
20k
4
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN A & B
TILT ALARM
A
A
A
A1
DP1
GREEN
RED
BLK/RED
ORG-1
FOOT
SWITCH
(FS)
JIB
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48V
DRIVE ENABLE OUT.
(UNUSED)
CONT. FAULT LED
(SPARE)
AC
POWER
STEER RIGHT
BLK
CABLE
#1
JOYSTICK POT. LOW
TILT
ALARM
CABLE
#2
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
CABLE
#3
A1
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
RED-JIB
BROWN-GRND.
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
RED/BLK-28
WHT
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BROWN-J1
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
F.S. POWER #1
KEY SWITCH POWER
+24V TO PLAT.
(UNUSED)
(UNUSED)
BROWN-J7
BROWN-LJ
GRND.
LIFT PUMP
GRN/WHT-R12
PLAT. ROT. LEFT
PLAT. ROT. RIGHT
DRIVE ENABLE RLY.
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
RED-LR15
RED-TIME
SEC. BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48V RELAY PWR
PRIMARY DN.
PRIMARY UP
CR19B
BRN-J6
RED-JIB
BROWN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5
6
7
8
6 - 108
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with Platform Load Sense and LVI/BCI Option
(from serial number 13361 to 14078)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14079 to 14650)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
AC POWER
AC1
GRN/WHT
RED
BRN
CR6
BRN
GRN/WHT-45
STEER RIGHT
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
2
LIFT
+
RIGHT
LEFT
TS13
EXT/RETR
BP1
BLK
4
WHT-30
WHT/BLK-31
5
WHT #24
6
A
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS11
PRIMARY BOOM
3
RED/WHT-29
WHT/RED-32
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK #26
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
1
RED
WHT/GRN
YEL
PRPL
DRIVE
TS10
SECONDARY BOOM
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
GREEN
RED
BLK/RED
TS12
T.T. ROTATE
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
GRN
ORG
REV
BCI
JOYSTICK POT. LOW
ORG/RED-42
BLK/WHT-34
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
BLK-7
BLU/RED-39
RED/BLK-2
RED #1
BLU/BLK-11
BLU #10
WHT-4
WHT/BLK-5
ORG/BLK-15
GRN-17
ORG-14
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
BLK/RED-9
DP1
20k
WHT
6
7
BLK/WHT
RED
BLK/WHT
RED
NC
L3
+
P3
HORN
TS1
AUXILIARY
POWER
TS15
DRIVE ENABLE
+
L1
NC
NO
8
FAULT LED
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY STOP
RED
ORG/RED-42
6 - 109
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
A FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS 6 & 7
ON THE DRIVE JOYSTICK.
FWD
-
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
FOOT
SWITCH
(FS)
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
TILT
ALARM
AC
POWER
CABLE
#1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
5
CABLE
#2
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#3
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BLK
BRN-GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED/BLK-28
WHT
RED-JIB
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-R12
RED-STOP
GRND.
SEC. BOOM UP
GRN/WHT-JOYS
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
GRN/WHT-R12
CR7B
BRN-J1
RED-TIME
4
A1
ORG/BLK-41
BRN-J7
CR7A
BRN
RED
RED-TILT
RED-TIME
ORG/RED-16
ORG/BLK-41
BRN-J3
M
T1
RED-TIME
ORG/RED-16
3
L
TIME DELAY
BRN-J4
2
K
Part No. 106488
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
L3
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
EMERGENCY STOP BUTTON
HORN
TIME DELAY #1
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
N
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with Platform Load Sense and LVI/BCI Option(from serial number 14079 to 14650)
M
L
K
J
I
F
B
A
1
FUSE 3A
AC POWER
AC1
RED-L7
BRN-LJ
RED-L1
GRN/WHT
GRN/WHT-45
ORG/RED-LV42
WHT-LV24
BRN-J7
BLU-L10
WHT-L6
RED
BRN
RED-L1
ORG/BLK-41
BLK-26
CR19A
BRN-J5
CR7A
BRN
BLU-L10
C
2
RED-L7
ORG/RED-LV42
RED-L1
ORG/BLK-41
WHT-L6
D
LOAD SENSOR
LDS
1 2 3 4 5 6 7 8 9 10 11 12
T1
ORG/RED-LV42
BLK-26
RED-TIME
ORG/RED-16
RED-L7
ORG/BLK-LVJ
BRN
BLK-26
RED-TIME
ORG/RED-16
BLU-LR15
1
2
ORG-LVJ
CR17
CR6
ORG/RED-LED
3
4
ORG/RED-LVJ
WHT-L6
BRN-LVJ
RED-L1
E
TIME DELAY
LVI
5
6
7
WHT-LV24
BRN-J4
G
BRN-LVJ
WHT-LV24
BRN-LVJ
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
RED-L7
BLK-LSTOP
H
8
N
3
RED-LVI
2
WHT
GREEN
RED
BLK/RED
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT/RED-32
WHT-30
WHT/BLK-31
5
WHT-LV24
6
A
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
3
BLK
RED/WHT-29
ORG-1
ORG
REV
5
1
BLK/WHT
RED
BRN-LJ
P3
HORN
BLK/WHT
RED
+
+
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
TS6
GLOW PLUG
+
L1
NC
NO
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
NC
L3
TS15
TS2
ENGINE
START
L4
LOAD
LED
TS4
RPM
RED
Part No. 106488
A
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
GRN
20k
ORG/RED-LED
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-LSTOP (LOAD OPTIOIN)
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT-LV24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK-7
BLK/WHT-8
BLU/RED-39
RED/BLK-2
RED-LR15
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
GRN/WHT-45
GRN/WHT-R12
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
FWD
3
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
FOOT
SWITCH
(FS)
JIB
STEER RIGHT
AC
POWER
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
BLK
CABLE
#1
JOYSTICK POT. LOW
CABLE
#2
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
CABLE
#3
A1
TILT
ALARM
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
RED-JIB
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
RED/BLK-28
WHT
BRN-GRND.
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BRN-J1
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
BRN-J7
BRN-LJ
GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
GRN/WHT-R12
SEC. BOOM UP
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
RED-LR15
RED-TIME
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-JIB
BRN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
P2
EMERGENCY
STOP
4
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
COMPONENT INDEX
A1
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR7A
JIB CUTOUT RELAY
CR7B
JIB VALVE RELAY
CR17
LOAD SENSOR RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
L3
CONTROLLER FAULT LED
L4
OVERLOAD LED
LDS
LOAD SENSOR MODULE
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
5
6
7
8
6 - 110
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with Platform Load Sense and LVI/BCI Option
(from serial number 14079 to 14650)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 14651 to 16839)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
AC POWER
AC1
GRN/WHT
RED
BRN
CR6
BRN
GRN/WHT-45
STEER RIGHT
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
2
LIFT
+
RIGHT
LEFT
TS13
EXT/RETR
BP1
BLK
4
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
RED/BLK-R6
8
WHT/YEL
BLU/BLK-37
9
WHT/RED
BLU-36
10
RED
RED
RED
TS11
PRIMARY BOOM
3
RED/WHT-29
WHT/RED-32
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK #26
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
1
RED
WHT/GRN
YEL
PRPL
DRIVE
TS10
SECONDARY BOOM
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
GREEN
RED
BLK/RED
TS12
T.T. ROTATE
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
GRN
ORG
REV
BCI
JOYSTICK POT. LOW
ORG/RED-42
BLK/WHT-34
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
BLU/RED-39
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLU #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
BLK/RED-9
DP1
20k
WHT
6
7
BLK/WHT
RED
BLK/WHT
RED
NC
L3
+
P3
HORN
TS1
AUXILIARY
POWER
TS15
DRIVE ENABLE
+
L1
NC
NO
8
FAULT LED
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS6
GLOW PLUG
TS9
PLATFORM LEVEL
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY STOP
RED
ORG/RED-42
6 - 111
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1 FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS 6 & 7
ON THE DRIVE JOYSTICK.
FWD
-
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
FOOT
SWITCH
(FS)
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
TILT
ALARM
AC
POWER
CABLE
#1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
5
CABLE
#2
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#3
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BLK
BRN-GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED/BLK-28
WHT
RED-JIB
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-R12
RED-STOP
GRND.
SEC. BOOM UP
GRN/WHT-JOYS
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
GRN/WHT-R12
CR7B
BRN-J1
RED-TIME
4
A1
ORG/BLK-41
BRN-J7
CR7A
BRN
RED
RED-TILT
RED-TIME
ORG/RED-16
ORG/BLK-41
BRN-J3
M
T1
RED-TIME
ORG/RED-16
3
L
TIME DELAY
BRN-J4
2
K
Part No. 106488
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
L3
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
CONTROLLER FAULT LED
EMERGENCY STOP BUTTON
HORN
TIME DELAY #1
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
N
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 14651 to 16839)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
3
4
1
2
C
B
A
1
T1
AC POWER
AC1
RED
GRN/WHT
BRN
ORG/RED-LV42
ORG/BLK-LVJ
ORG-LVJ
8
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
BRN-LVJ
WHT-LV24
BRN-LVJ
BRN-J4
5
6
7
D
TIME DELAY
LVI
BRN-LVJ
E
BRN
2
RED-TIME
ORG/RED-16
RED-TIME
ORG/RED-16
BLU-LR15
WHT-L6
WHT-L6
ORG/BLK-41
BRN-J7
BLU-L10
WHT-LV24
GRN/WHT-45
CR19A
BRN-J5
CR7A
BRN
BLU-L10
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
3
RED-LVI
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
CONT. FAULT LED
(SPARE)
STEER RIGHT
ORG-1
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
FOOT
SWITCH
(FS)
JIB
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
CABLE
#1
JOYSTICK POT. LOW
CABLE
#2
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
CABLE
#3
A1
TILT
ALARM
AC
POWER
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
BLK
BRN-GRND.
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
RED/BLK-28
WHT
RED-JIB
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BRN-J1
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
LIFT PUMP
BRN-J7
BRN-LJ
GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
GRN/WHT-R12
SEC. BOOM UP
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
RED-LR15
RED-TIME
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
RED-JIB
BRN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
1
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
5
COMPONENT INDEX
A1
GREEN
RED
BLK/RED
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT-30
WHT/BLK-31
5
1
7
BLU
DRIVE ENABLE RELAY
CR7A
JIB CUTOUT RELAY
CR7B
JIB VALVE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
L3
CONTROLLER FAULT LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
RED/BLK-R6
8
BLU/BLK-37
9
WHT/RED
ROTARY FLOW CONTROL DIAL
CR6
WHT-LV24
6
WHT/YEL
BP1
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
3
BLK
RED/WHT-29
WHT/RED-32
NC
REV
5
2
WHT
FWD
3
1
ORG
BATTERY CHARGE INDICATOR
NC
GRN
20k
AC OUTLET BOX
BCI
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT-LV24
ORG/BLK-R6
WHT/BLK-31
WHT-30
ORG/RED-42
BLK/WHT-34
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK-33
RED-25
BLK-7
BLK/WHT-8
BLU/RED-39
RED/BLK-2
RED-LR15
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
BLK/WHT
RED
BRN-LJ
P3
HORN
BLK/WHT
RED
L3
TS15
+
NO
TS1
AUXILIARY
POWER
FAULT LED
DRIVE ENABLE
TS6
GLOW PLUG
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS2
ENGINE
START
TS4
RPM
RED
Part No. 106488
TILT ALARM
AC1
P2
EMERGENCY
STOP
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 112
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 14651 to 16839)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 16840 to 17974)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
K
AC POWER
AC1
GRN/WHT
RED
BRN
BRN
GRN/WHT-45
STEER RIGHT
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1
GRN
2
WHT
FWD
REV
GREEN
RED
BLK/RED
DRIVE
RIGHT
TS11
TS10
SECONDARY BOOM PRIMARY BOOM
TS13
EXT/RETR
LEFT
BP1
4
RED/WHT-29
WHT/RED-32
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
BCI
3
BLK
RED
WHT/GRN
YEL
PRPL
LIFT
+
-
1
ORG
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
BLK/WHT-8
GRN/WHT-19
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
ORG/RED-42
BLK/RED-9
DP1
20k
6
7
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
FOOT
SWITCH
(FS)
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
AC
POWER
CABLE
#1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
5
CABLE
#2
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#3
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BLK
BRN-GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED/BLK-28
WHT
RED-JIB
SEC. BOOM UP
GRN/WHT-R12
RED-STOP
GRND.
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-JOYS
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
GRN/WHT-R12
CR7B
BRN-J1
RED-TIME
4
A1
TILT
ALARM
ORG/BLK-41
BRN-J7
CR7A
BRN
RED
RED-TILT
RED-TIME
ORG/RED-16
ORG/BLK-41
BRN-J3
BLK/WHT
RED
BLK/WHT
RED
NC
TS15
P3
HORN
NC
NO
8
TS1
AUXILIARY
POWER
DRIVE ENABLE
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
RED
6 - 113
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
N
T1
RED-TIME
ORG/RED-16
3
M
TIME DELAY
CR6
2
L
Part No. 106488
P2
EMERGENCY
STOP
FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN
TIME DELAY #1
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 16840 to 17974)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
E
3
4
1
2
B
1
AC POWER
AC1
GRN/WHT
RED
BRN
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
8
BRN
2
RED-TIME
ORG/RED-16
RED-TIME
ORG/RED-16
BLU-LR19A
WHT-L6
BRN-J7
WHT-L6
ORG/BLK-41
WHT-LV24
GRN/WHT-45
CR19A
BRN-J5
CR7A
BRN
BLU-L10
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
BLU-L10
A
T1
ORG/RED-LV42
ORG/BLK-LVJ
ORG-LVJ
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
WHT-LV24
BRN-LVJ
BRN-LVJ
5
6
7
C
TIME DELAY
LVI
BRN-LVJ
D
3
RED-LVI
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
FOOT
SWITCH
(FS)
JIB
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AC
POWER
CABLE
#1
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
CABLE
#2
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#3
A1
TILT
ALARM
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
BLK
BRN-GRND.
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
WHT
RED-JIB
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
GRN/WHT-R12
SEC. BOOM UP
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
RED-LR19B
RED-TIME
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
BRN-LVI
RED-JIB
BRN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
1
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
5
COMPONENT INDEX
A1
ORG
2
GREEN
RED
BLK/RED
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT/RED-32
WHT-30
WHT/BLK-31
5
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
3
BLK
RED/WHT-29
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT
REV
5
1
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
FWD
3
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK-7
BLK/WHT-8
RED/BLK-2
RED-LR19B
BLU-LR19A
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
WHT-LV24
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
20k
BLK/WHT
RED
P3
HORN
BLK/WHT
RED
NC
TS15
NC
NO
TS1
AUXILIARY
POWER
DRIVE ENABLE
TS6
GLOW PLUG
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS2
ENGINE
START
TS4
RPM
P2
EMERGENCY
STOP
RED
Part No. 106488
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR7A
JIB CUTOUT RELAY
CR7B
JIB VALVE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 114
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 16840 to 17974)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 17975 to 21180)
A
B
C
D
E
F
G
H
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
1
I
J
K
AC POWER
AC1
RED
GRN/WHT
BRN
BRN
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
NOTES:
1. ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES.
1
GRN
REV
GREEN
RED
BLK/RED
DRIVE
RIGHT
TS11
TS10
SECONDARY BOOM PRIMARY BOOM
TS13
EXT/RETR
LEFT
BP1
4
RED/WHT-29
WHT/RED-32
WHT-30
WHT/BLK-31
5
WHT #24
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
BCI
3
BLK
RED
WHT/GRN
YEL
PRPL
LIFT
+
7
2
WHT
FWD
-
1
ORG
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT #24
ORG/BLK-R6
WHT/BLK-31
WHT-30
BLK-33
BRN-J1
GRN/WHT-19
WHT/RED-6
BLK/WHT-34
RED-25
BLK/WHT-8
GRN/BLK-44
BLK-7
RED/BLK-2
RED #1
BLU/BLK-11
BLUE #10
WHT-4
WHT/BLK-5
ORG/BLK-15
GRN-17
ORG-14
GRN/WHT-45
GRN/BLK-18
GRN/WHT-R12
BLU/RED-13
RED-27
ORG/RED-42
BLK/RED-9
DP1
20k
6
BLK/WHT
RED
BLK/WHT
NC
1
2
NC
1
P3
HORN
3
NO
4
8
2
RED
TS15
TS1
AUXILIARY
POWER
DRIVE ENABLE
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
RED
6 - 115
GRN/WHT-45
GRN/WHT-45
JIB VALVE
JIB DESCENT ALARM
STEER RIGHT
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
FOOT
SWITCH
(FS)
JIB
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
AC
POWER
CABLE
#1
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#2
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
CABLE
#3
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
BLK
BRN-GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED/BLK-28
WHT
RED-JIB
SEC. BOOM UP
GRN/WHT-R12
RED-STOP
GRND.
5
ORG/BLK-41
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
GRN/WHT-JOYS
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
GRN/WHT-JOYS
RED-JIB
GRN/WHT-R12
CR7B
BRN-J1
RED-TIME
4
A1
TILT
ALARM
GRN/WHT-45
BRN-J7
CR7A
BRN
RED
RED-TILT
GRN/WHT-45
RED-TIME
ORG/RED-16
ORG/BLK-41
BRN-J3
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
N
T1
RED-TIME
ORG/RED-16
3
M
TIME DELAY
CR6
2
L
Part No. 106488
P2
EMERGENCY
STOP
FOR LIFT/DRIVE SELECT OPTION, REMOVE JUMPER BETWEEN TERMINALS A & B
ON THE DRIVE JOYSTICK.
COMPONENT INDEX
A1
AC1
BCI
BP1
CR6
CR7A
CR7B
TILT ALARM
AC OUTLET BOX
BATTERY CHARGE INDICATOR
BOOM PROPORTIONAL ROTARY CONTROLLER
DRIVE ENABLE RELAY
JIB BOOM CUTOUT RELAY
JIB BOOM VALVE RELAY
DP1
L1
DRIVE JOYSTICK
DRIVE ENABLE LED
P2
P3
T1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS14
TS15
EMERGENCY STOP BUTTON
HORN
TIME DELAY #1
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 17975 to 21180)
N
M
L
K
J
I
RED/BLK-R6
ORG/BLK-R6
ORG/BLK-41
H
G
F
E
3
4
1
2
B
A
1
T1
AC POWER
AC1
RED
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
GRN/WHT
BRN
ORG/RED-LV42
ORG/BLK-LVJ
ORG-LVJ
8
CR6
ORG/RED-LVJ
WHT-L6
WHT-LV24
WHT-LV24
BRN-LVJ
BRN-LVJ
5
6
7
C
TIME DELAY
LVI
BRN-LVJ
D
BRN
2
RED-TIME
ORG/RED-16
RED-TIME
ORG/RED-16
BLU-LR19A
WHT-L6
WHT-L6
ORG/BLK-41
BRN-J7
BLU-L10
WHT-LV24
GRN/WHT-45
CR19A
BRN-J5
CR7A
BRN
BLU-L10
ORG/RED-LV42
ORG/RED-LV42
ORG/BLK-41
3
RED-LVI
JIB VALVE
(SPARE)
(SPARE)
SWITCHED 48 V
DRIVE ENABLE OUT.
(SPARE)
(SPARE)
(SPARE)
STEER RIGHT
STEER LEFT
HIGH/LOW RPM
GLOW PLUG
START ENGINE
JOYSTICK POT. LOW
ORG-1
GRN/WHT-1
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
FOOT
SWITCH
(FS)
JIB
REVERSE
FORWARD
JOYSTICK POT. HIGH
TILT ALARM
AC
POWER
CABLE
#1
AUX. PUMP SEL.
POWER TO F.S.
F.S. UP POWER
CABLE
#2
BLU/RED-1
BLU/WHT-1
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
BLK (F.S.)
RED (F.S.)
WHT (F.S.)
WHT-2
BLK-2
CABLE
#3
A1
TILT
ALARM
F.S. POWER #1
KEY SWITCH POWER
+24 V TO PLAT.
(UNUSED)
(UNUSED)
BLK
BRN-GRND.
LIFT PUMP
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-3
RED/BLK-28
WHT
RED-JIB
4
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RED-STOP
GRND.
PLAT. ROT. RIGHT
PLAT. ROT. LEFT
DRIVE ENABLE RLY.
GRN/WHT-R12
SEC. BOOM UP
GRN/WHT-JOYS
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LT.
F.S. POWER #2
SEC. BOOM DOWN
RED-LR19B
RED-TIME
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURN. ROT. LEFT
TURN. ROT. RIGHT
48 V RELAY POWER
PRIMARY DOWN
PRIMARY UP
CR19B
BRN-J6
BRN-LVI
RED-JIB
BRN-J1
GRN/WHT-JOYS
CR7B
RED
RED-TILT
GRN/WHT-R12
BRN-J3
NOTES:
ALL WIRES WITHOUT LABELS ARE
EITHER RED OR BLACK JUMPER WIRES.
1
FOR LIFT DRIVE SELECTOR OPTION
TAKE OFF JUMP BETWEEN 6 & 7
5
COMPONENT INDEX
A1
ORG
2
GREEN
RED
BLK/RED
DRIVE
RIGHT
LVI/BCI OPTION
TS11
PRIMARY
BOOM
LEFT
TS13
EXTEND/
RETRACT
BP1
WHT/RED-32
WHT-30
WHT/BLK-31
5
6
1
7
BLU
8
WHT/YEL
9
WHT/RED
RED/BLK-R6
BLU/BLK-37
BLU-36
10
RED
RED
RED
TS12
T.T. ROTATE
TS10
SECONDARY
BOOM
4
RED
WHT/GRN
YEL
PRPL
LIFT
4
3
BLK
RED/WHT-29
BLU-36
BLU/BLK-37
RED/BLK-R6
GRN/WHT-JOYS
BLU/WHT-12
WHT
REV
5
1
ORG/BLK-R6
WHT/BLK-31
WHT-30
GRN
FWD
3
RED-STOP
WHT-23
BLK-22
RED/WHT-3
BLK/RED-35
BLK-26
BLK/WHT-34
BRN-J1
WHT/RED-6
BLK-33
RED-25
GRN/WHT-19
BLK-7
BLK/WHT-8
RED/BLK-2
RED-LR19B
BLU-LR19A
BLU/BLK-11
BLU-LR15
WHT-4
WHT/BLK-5
ORG/BLK-15
ORG-14
GRN-17
GRN/BLK-18
BLU/RED-13
GRN/WHT-45
GRN/WHT-R12
WHT-LV24
RED-27
ORG/BLK-LVJ
ORG/RED-LVJ
ORG-LVJ
BLK/RED-9
DP1
20k
BLK/WHT
RED
BLK/WHT
TS6
GLOW PLUG
+
L1
TS8
JIB BOOM
TS7
PLATFORM ROTATE
TS9
PLATFORM LEVEL
TS2
ENGINE
START
NC
DRIVE ENABLE
1
2
P3
HORN
TS1
AUXILIARY
POWER
1
TS15
NC
NO
3
4
2
RED
TS4
RPM
RED
Part No. 106488
P2
EMERGENCY
STOP
TILT ALARM
AC1
AC OUTLET BOX
BCI
BATTERY CHARGE INDICATOR
BP1
ROTARY FLOW CONTROL DIAL
CR6
DRIVE ENABLE RELAY
CR7A
JIB CUTOUT RELAY
CR7B
JIB VALVE RELAY
CR19A
LOW VOLTAGE INTERRUPT/BCI RELAY A
CR19B
LOW VOLTAGE INTERRUPT/BCI RELAY B
DP1
DRIVE JOYSTICK
L1
DRIVE ENABLE LED
LVI
LOW VOLTAGE INTERRUPT MODULE
LVI/BCI
BATTERY CHARGE INDICATOR FOR LVI OPTION
P2
EMERGENCY STOP BUTTON
P3
HORN
T1
TIME DELAY #1
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
HIGH / LOW RPM TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE HIGH / LOW TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 116
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 17975 to 21180)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 21181 to 22050)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
BRN-RELAY
OR-LOAD
BK-LOAD
OR/RD
GR/WH-R7
GR/WH-45
GR/WH
RD-J7
GR/WH-45
GR/WH-45
BRN-JIBGND
C9P-3
C9P-2
C9P-1
1
P25BAT RD
P24BAT WH
P26BAT BK
C7P-3
C7P-2
C7P-1
1
1
C4P-7
C4P-6
C4P-5
C4P-4
C4P-3
C4P-2
C4P-1
C3P-12
C3P-11
C3P-10
C3P-9
C3P-8
C3P-7
C3P-6
C3P-5
C3P-4
C3P-3
C3P-2
C3P-1
C2P-7
C2P-6
C2P-4
C2P-3
BRN-BATGND
P23SWBAT WH
P22BAT BK
C19LPMP GR/WH
C18PRR GR/BK
C17PRL GR
C16DRE OR/RD
C15PLD OR/BK
C14PLU OR
C13DREL BL/RD
C12DRE BL/WH
C11SBD BL/BK
C10SBU BL
C9HRN BK/RD
C8PBR BK/WH
C7PBE BK
C6LFC WH/RD
C5TRR WH/BK
C4TRL WH
C3BAT RD/WH
C2PBD RD/BK
C1PBU RD
C1P-11
C1P-10
C1P-9
C1P-8
C1P-7
C1P-6
C1P-5
C1P-4
C1P-3
1
C1P-1
C45JSV GR/WH
C44JDA GR/BK
R42BAT OR/RD
R41DRE OR/BK
C37STC BL/BK
C36STCC BL
C35HRPM BK/RD
C34SA BK/WH
C33STR BK
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
C29JSH RD/WH
BRN-J1
BRN-BATGND
BRN-JIBGND
CR7
C27AUX RD
RD-STOP
3
RD/BK-R6
OR/BK
OR/BK-R6
2
CR6
BK
WH
C1P-2
C4P(BR)
C3P(GR)
TILT ALARM
C2P(BK)
C1P(GY)
C28TTA RD/BK
4
C7P
12V DC
BATTERY
19/18 CONTROL CABLE
C9P
JIB
OPT.
FOOT SWITCH
5
GR-LFC
DP1
GR
20k
WH
FWD
6
REV
-
LIFT
DRIVE
RIGHT
LEFT
5
6
PRPL
WH/YL
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
TS9
PLATFORM
LEVEL
Part No. 106488
NOTES:
C31REV WH/BK
OR/BK-R6
RD-DRE
P24BAT WH
C12DRE BL/WH
RD-RPM
RD-J7
RD-SW
RD/BK-R6
BK/WH-DRE
C37STC BL/BK
1. LOAD SENSE WIRES SHOWN WITH DASHED LINES.
1
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
RPM
1
FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
EMERGENCY STOP BUTTON
HORN
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
COMPONENT INDEX
C36STCC BL
RD-HRN
TS7
PLATFORM
ROTATE
10
OR-LOAD
TS8
JIB BOOM
9
WH/RD
C35HRPM BK/RD
RD-RPM
RD-AUX
C33STR BK
L1
8
C30FWD WH
1
NO
TS1
AUXILIARY
POWER
7
BL
RD
2
2
L2
TS15
DRIVE ENABLE
C32JSL WH/RD
4
RD
3
4
RD
P3
HORN
2
P22BAT BK
RD-STOP
P23SWBAT WH
C3BAT RD/WH
P26BAT BK
BK-LOAD
BRN-LOAD
BRN-J1
BRN-BCI
C34SA BK/WH
GR/WH-45
C14PLU OR
C15PLD OR/BK
C6LFC WH/RD
C19LPMP GR/WH P25BAT RD
RD-SW
C7PBE BK
C8PBR BK/WH
C2PBD RD/BK
1
C1PBU RD
C17PRL GR
GR/WH- R7
C18PRR GR/BK
C11SBD BL/BK
C10SBU BL 1
C4TRL WH
C13DREL BL/RD
BK/WH-DRE
RD-DRE
RD-AUX
C27AUX RD
RD-HRN
C9HRN BK/RD
C44JDA GR/BK
1
1
8
6 - 117
C5TRR WH/BK
R42BAT OR/RD
BRN-BCI
7
BCI
BK
YL
BP1
C29JSH RD/WH
3
WH/GR
+
1
NC
TS13
EXTEND/RETRACT
OR
NC
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
TS12
TURNTABLE
ROTATE
GR
RD
BK/RD
1
1
P2
EMERGENCY
STOP
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 21181 to 22050)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
WH
1
1
OR/RD
OR
OR/BK
OR/RD
WH
CR8
WH
BRN-RELAY
CR6
CR7
CR19A
LVI
1
2
3
4
5
6
7
8
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
2
CR19B
BRN-LVI
P24BAT WH
OR/RD-LVI
OR/BK-LVI
OR-LVI
RD-J7
P24BAT WH
R42BAT OR/RD
BL-LR19A
BL-L10
RD-LVI
RD-LR19B
C40LS OR
3
C9P-2
C3P-10
C3P-1
C2P-4
C2P-2
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
4
19/18 CONTROL CABLE
TILT ALARM
C7P
C9P
12V DC BATTERY
FOOT
SWITCH
JIB
OPT.
5
DP1
20k
TS12
TURNTABLE
ROTATE
LVI/BCI
TS10
SECONDARY
BOOM
TS11
PRIMARY
BOOM
TS13
EXTEND/
RETRACT
GR
RD
BK/RD
OR
WH
FWD
REV
3
5
BK
RD
WH/GR
4
YL
LIFT
BP1
DRIVE
RIGHT
RD-LR19B
BL-LR19A
OR/BK-LVI
OR/RD-LVI
OR-LVI
LEFT
PRPL
1
1
5
TS15
DRIVE ENABLE
L1
TS8
JIB BOOM
TS7
PLATFORM
ROTATE
TS9
PLATFORM LEVEL
TS6
GLOW PLUG
TS2
ENGINE
START
6
1
7
8
WH/YL
9
COMPONENT INDEX
P24BAT WH
6
RD-J7
10
2
TS1
AUXILIARY
POWER
FOR CE OPTION, TAKE OFF JUMPER ON JOYSTICK
BETWEEN TERMINALS 6 & 7 AND ADD CR8.
4
BL
WH/RD
NOTES:
2
3
3
4
NO
P3
HORN
GR
2
NC
NC
1
1
P2
EMERGENCY
STOP
TS4
RPM
Part No. 106488
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
7
8
6 - 118
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 21181 to 22050)
Section 6 • Schematics
June 2005
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
REV A
Platform Control Box Wiring Diagram, Z-45/25J
(from serial number 22051 to 23235)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
BRN-RELAY
OR/RD
GR/WH-R7
GR/WH-45
GR/WH
CR7
RD-J7
RD/BK-R6
OR/BK
OR/BK-R6
CR6
2
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
C28TTA RD/BK
C7P
C9P
WH
BK
C1P-2
4
GR/WH-45
GR/WH-45
BK-JIBGND
C9P-3
C9P-2
C9P-1
1
P25BAT RD
P24BAT WH
P26BAT BK
C7P-3
C7P-2
C7P-1
C4P-7
C4P-6
C4P-5
C4P-4
C4P-3
C4P-2
C4P-1
C3P-12
C3P-11
C3P-10
C3P-9
C3P-8
C3P-7
C3P-6
C3P-5
C3P-4
C3P-3
C3P-2
C3P-1
C2P-7
C2P-6
C2P-4
C2P-3
BRN-BATGND
P23SWBAT WH
P22BAT BK
C19LPMP GR/WH
C18PRR GR/BK
C17PRL GR
C16DRE OR/RD
C15PLD OR/BK
C14PLU OR
C13DREL BL/RD
1
C1P-11
C1P-10
C1P-9
C1P-8
C1P-7
C1P-6
C1P-5
C1P-4
C1P-3
1
C1P-1
C12DRE BL/WH
C11SBD BL/BK
C10SBU BL
C9HRN BK/RD
C8PBR BK/WH
C7PBE BK
C6LFC WH/RD
C5TRR WH/BK
C4TRL WH
C3BAT RD/WH
C2PBD RD/BK
C1PBU RD
C37STC BL/BK
C36STCC BL
C35HRPM BK/RD
C34SA BK/WH
C33STR BK
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
C29JSH RD/WH
1
C27AUX RD
RD/BK L48
C2P-5
C45JSV GR/WH
C44JDA GR/BK
R42BAT OR/RD
R41DRE OR/BK
C134PWR RD
3
BRN-J1
BRN-BATGND
BRN-JIBGND
JIB
LS18
OPT.
D40
A1
TILT ALARM
19/18 CONTROL CABLE
FOOT
SWITCH
12V DC BATTERY
5
GR-LFC
DP1
NOTES:
GR
20k
6
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
TS12
TURNTABLE
ROTATE
GR
RD
BK/RD
TS13
EXTEND/
RETRACT
OR
WH
FWD
REV
-
YL
LIFT
DRIVE
RIGHT
LEFT
BL
WH/YL
WH/RD
2
C32JSL WH/RD
3
4
5
6
7
8
9
COMPONENT INDEX
C31REV WH/BK
OR/BK-R6
RD-DRE
P24BAT WH
C12DRE BL/WH
RD-RPM
RD-J7
RD-SW
RD/BK-R6
BK/WH-DRE
C37STC BL/BK
1
C36STCC BL
P3
Part No. 106488
TS6
GLOW PLUG
TS4
RPM
1
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
TS9
PLATFORM
LEVEL
1
TS7
PLATFORM
ROTATE
2
TS8
JIB BOOM
1
2
L1
NC NC NC
2
TS1
AUXILIARY
POWER
TS2
ENGINE
START
P2
EMERGENCY
STOP
C3BAT RD/WH C3-3
RD-HRN
RD/BK H1
C35HRPM BK/RD
RD-RPM
RD-AUX
C33STR BK
NO
L48
TS15
DRIVE ENABLE
P23SWBAT WH C7P-2
1
RD
P22BAT BK C7P-1
10
1 FOR LVI/BCI OPTION REMOVE INDICATED WIRES.
C30FWD WH
3
4
RD
P3
HORN
6 - 119
PRPL
C29JSH RD/WH
P26FS BK C9P-1
BRN-J1
BRN-BCI
C34SA BK/WH
GR/WH-45
C14PLU OR
C15PLD OR/BK
C6LFC WH/RD
C19LPMP GR/WH P25BAT RD
RD-SW
C7PBE BK
C8PBR BK/WH
C2PBD RD/BK
1
C1PBU RD
C17PRL GR
GR/WH- R7
C18PRR GR/BK
C11SBD BL/BK
C10SBU BL 1
C4TRL WH
C44JDA GR/BK
C13DREL BL/RD
BK/WH-DRE
RD-DRE
RD-AUX
C27AUX RD
RD-HRN
C9HRN BK/RD
C5TRR WH/BK
1
1
8
BP1
R42BAT OR/RD
BRN-BCI
7
RD
WH/GR
+
BCI
OPTION
BK
1
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
H1
LS18
L4
L48
DRIVE JOYSTICK
DRIVE ENABLE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TITL ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
June 2005
Section 6 • Schematics
REV A
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 22051 to 23235)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
WH
1
1
OR/RD
OR
OR/BK
OR/RD
WH
CR8
WH
BRN-RELAY
CR6
CR7
CR19A
LVI
1
2
3
4
5
6
7
8
RESET IS SET TO "B",
DISCHARGE IS SET TO "N"
2
CR19B
BRN-LVI
P24BAT WH
OR/RD-LVI
OR/BK-LVI
OR-LVI
RD-J7
P24BAT WH
R42BAT OR/RD
BL-LR19A
BL-L10
RD-LVI
RD-LR19B
C40LS OR
C9P-2
C3P-10
C3P-1
C2P-4
C2P-2
GR/BK C133PLA
GR/BK L4
RD LS18
BK LS CABLE C1P-12
RD-H1
RD-P2
3
RD
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
C2P-6
D39
C7P
C9P
JIB
4
LS18
OPT.
1
A1
TILT ALARM
19/18 CONTROL CABLE
12V DC BATTERY
FOOT SWITCH
5
NOTES:
1. LOAD SENSE WIRES SHOWN WITH DASHED LINES
1 FOR CE OPTION, REMOVE JUMPER ON JOYSTICK BETWEEN
TERMINALS 6 & 7 AND ADD CR8, LS18 AND L4.
DP1
20k
TS12
TURNTABLE
ROTATE
LVI/BCI
TS11
PRIMARY
BOOM
TS10
SECONDARY
BOOM
TS13
EXTEND/
RETRACT
GR
RD
BK/RD
5
1
OR
FWD
3
BK
4
RD
5
WH/GR
4
BP1
DRIVE
RD-LR19B
BL-LR19A
OR/BK-LVI
OR/RD-LVI
OR-LVI
RIGHT
LEFT
P24BAT WH
6
YL
LIFT
COMPONENT INDEX
2
WH
REV
3
GR
1
PRPL
7
BL
RD-J7
8
WH/YL
WH/RD
9
10
RD-LS18
GR/BK-H1 (D39)
1
TS9
PLATFORM
LEVEL
TS6
GLOW PLUG
TS2
ENGINE START
1
TS7
PLATFORM
ROTATE
1
L1
TS8
JIB BOOM
2
TS15
DRIVE ENABLE
1
2
TS1
AUXILIARY
POWER
RD
NC NC NC
2
3
4
NO
P3
HORN
L4
P2
EMERGENCY STOP
TS4
RPM
Part No. 106488
BCI
BP1
BATTERY CHARGE INDICATOR
ROTARY FLOW CONTROL DIAL
DP1
L1
L2
LVI
LVI/BCI
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
A1
LS18
L4
L48
DRIVE JOYSTICK
DRIVE ENABLE LED
LOAD SENSE LED
LOW VOLTAGE INTERRUPT MODULE
BATTERY CHARGE INDICATOR FOR LVI OPTION
EMERGENCY STOP BUTTON
HORN
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH / LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP / DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM TOGGLE SWITCH
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TILT ALARM
PLATFORM OVERLOAD LIMIT SWITCH
PLATFORM OVERLOAD LED
TILT ALARM LED
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6
7
8
6 - 120
June 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, Z-45/25J
with LVI/BCI Option (from serial number 22051 to 23235)
Section 6 • Schematics
June 2005
Hydraulic Schematic
(before serial number 16962)
Section 6 • Schematics
June 2005
REV B
Hydraulic Schematic
(before serial number 16962)
A
B
C
D
E
F
G
1
H
JIB BOOM
CYLINDER
I
K
L
M
N
PLATFORM ROTATE
3500 psi
241 bar
SEMI RESTRICTIVE
1.5:1
2
J
2000 psi
138 bar
3:1
V2
J2
V1
J1
R2
0.030 inch
0.762 mm
3
DA
R1
0.030 inch
0.762 mm
JIB BOOM/
PLATFORM ROTATE
MANIFOLD
DB
V2
V1
SLAVE
CYLINDER
TURNTABLE
ROTATE
STEER CYLINDERS
4
SECONDARY BOOM
CYLINDERS
M
BRAKES
M
1500 psi
103 bar
3:1
CZ
PRIMARY BOOM
EXTENSION CYLINDER
PRIMARY BOOM
CYLINDER
CY
3500 psi
241 bar
3:1
5
MASTER
CX
S1
0.030 inch
0.762 mm
V2
3500 psi
241 bar
ATMOS.
1:1
COM
W
6
P1
AUXILIARY
PUMP
0.5 gpm
1.9 L/min
M
PRIMARY
PUMP
2.1 gpm
7.9 L/min
G1
C
3200 psi
220.6 bar
M
BRAKE
0.050 inch
1.27 mm
N.O.
N.C.
PS
S2
S1
PL1
L1
TR1
L2
TR2
F
E
X
O
I
D
3500 psi
241 bar
4.5:1
3800 psi
262 bar
1.5:1
PC1
PC2
Q
R
V
A
SC2
SC1
0.037 inch
0.94 mm
B
1800 psi
124 bar
2300 psi
159 bar
P
U
0.060 inch
1.52 mm
0.6 gpm
2.3 L/min
G
RESERVOIR
T1
8
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
K
H
T
0.6 gpm
2.3 L/min
S
L
M
RET
EXT
This valve was
removed after
serial number
11818
J
7
6 - 121
PL2
1500 psi
103 bar
ATMOS.
5:1
1000 psi
69 bar
ATMOS.
3:1
V1
Y
N
June 2005
Section 6 • Schematics
REV B
Hydraulic Schematic
(from serial number 16962 to 20379)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM ROTATE
JIB BOOM
0.025 inch
0.64 mm
0.025 inch
0.64 mm
3:1
3000 psi
207 bar
1.5:1
3800 psi
262 bar
2
J2
J1
R2
DA
R1
DB
3
V2
BRAKES
JIB BOOM
MANIFOLD
V1
SLAVE CYLINDER
STEER CYLINDERS
TURNTABLE ROTATE
M
M
CZ
3:1
3000 psi
207 bar
A
SECONDARY
CYLINDERS
PRIMARY CYLINDER
4
CY
B
1:1
3500 psi
241 bar
ATMOS.
3:1
3500 psi
241 bar
3:1
3800 psi
262 bar
(after serial
number 17735)
CX
V2
V1
COM
5
1.5:1
(before serial
number 17736)
AU
AR
3:1
1500 psi
103 bar
ATMOS.
3:1
1000 psi
69 bar
0.030 inch
0.76 mm
S1
MASTER
EXTENSION CYLINDER
N.O.
N.C.
TEST
BRAKE
P
AUXILIARY
PUMP
M
0.5 gpm
1.9 L/min
PRIMARY
PUMP
2.1 gpm
7.9 L/min
PS
ST2
ST1
PR1
PR2
PL2
PL1
SW2
SW1
3200 psi
221 bar
AX
M
AI
AS
AG
AT
AV
AJ
0.060 inch
1.5 mm
4.5:1
3500 psi
241 bar
ATMOS
P2
EXT
RET
0.046 inch
1.17 mm
6
AF
1800 psi
124 bar
AP
AW
0.030 inch
0.76 mm
0.6 gpm
2.27 L/min
AA
AM
AH
AB
AE
RESERVOIR
P1
AL
AQ
AK
SEC2
SEC1
AD
AC
AN
0.1 gpm
0.38 L/min
7
AO
T
FUNCTION MANIFOLD
8
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 122
June 2005
Section 6 • Schematics
Hydraulic Schematic
(from serial number 16962 to 20379)
Section 6 • Schematics
June 2005
Hydraulic Schematic
(from serial number 20380 to 22565)
Section 6 • Schematics
June 2005
REV B
Hydraulic Schematic
(from serial number 20380 to 22565)
A
B
C
D
E
F
1
G
H
I
J
K
L
M
N
PLATFORM ROTATE
JIB BOOM
0.025 inch
0.64 mm
0.025 inch
0.64 mm
3:1
3000 psi
207 bar
1.5:1
3800 psi
262 bar
2
J2
J1
R2
DA
3
BRAKES
M
DB
JIB BOOM
MANIFOLD
V2
R1
V1
SLAVE CYLINDER
STEER CYLINDERS
TURNTABLE ROTATE
M
4
CZ
PRIMARY CYLINDER
S1
3:1
3800 psi
262 bar
(after serial
number 17735)
CX
V2
V1
1.5:1
(before serial
number 17736)
BS
BO
COM
3:1
1500 psi
103 bar
ATMOS.
3:1
1000 psi
69 bar
0.030 inch
0.76 mm
MASTER
EXTENSION CYLINDER
CY
1:1
3500 psi
241 bar
ATMOS.
3:1
3500 psi
241 bar
5
3:1
3000 psi
207 bar
SECONDARY
CYLINDERS
N.O.
N.C.
TEST
BRAKE
P
6
AUXILIARY
PUMP
M
0.5 gpm
1.9 L/min
PRIMARY
PUMP
2.1 gpm
7.9 L/min
PS
ST2
ST1
PR1
PR2
PL2
PL1
SW2
SW1
3200 psi
221 bar
BV
M
BG
BP
4.5:1
3500 psi
241 bar
ATMOS
BW
BQ
BT
BH
BU
RESERVOIR
EXT
BE
0.060 inch
1.5 mm
1800 psi
124 bar
RET
0.030 inch
0.76 mm
0.6 gpm
2.27 L/min
BF
BK
BM
FUNCTION MANIFOLD
8
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Part No. 106488
BA
BX
T
6 - 123
P2
0.046 inch
1.17 mm
BL
BJ
BD
7
P1
BI
BN
BR
SEC2
SEC1
BC
BB
June 2005
Section 6 • Schematics
REV B
Hydraulic Schematic
(from serial number 22566 to 23235)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM ROTATE
JIB BOOM
L
R
3:1
3000 psi
207 bar
1.5:1
3800 psi
262 bar
E
R
PR2
PR1
J1
J2
PR2
PR1
2
JIB BOOM / PLATFORM
ROTATE MANIFOLD
DC
3
V1
V2
SLAVE CYLINDER
BRAKES
TURNTABLE ROTATE
SECONDARY CYLINDERS
PRIMARY CYLINDER
EXTENSION CYLINDER
STEER CYLINDERS
M
M
CZ
3:1
3000 psi
207 bar
4
CY
1:1
ATMOS.
3500 psi
241 bar
3:1
3500 psi
241 bar
S1
0.030 inch
0.76 mm
3:1
ATMOS.
1500 psi
103 bar
3:1
1000 psi
69 bar
3:1
3800 psi
262 bar
CX
MASTER
V2
5
V1
CJ
COM
TEST
P
AUXILIARY
PUMP
M
0.5 gpm
1.9L/min
BRAKE
N.O.
N.C.
ST1
PS
ST2
PR1
PR2
PL2
PL1
3200 psi
221 bar
PRIMARY
PUMP
2.1 gpm
7.9 L/min
SW2
SW1
SEC2
SEC1
P1
P2
EXT
RET
CG
CU
CS
CN
0.037 inch
0.94 mm
6
M
2500 psi
172 bar
CO
CV
CW
CP
0.060 inch
1.5 mm
CE
CF
CR
CI
0.030 inch
0.76 mm
RESERVOIR
CT
0.030 inch
0.76 mm
(from serial number 22566 to 22628
and after serial number 23235)
CA
2000 psi
138 bar
CQ
CD
0.4 gpm
1.5 L/min
CC
CB
CK
CL
7
CM
T
FUNCTION MANIFOLD
8
Part No. 106488
Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
6 - 124
June 2005
Section 6 • Schematics
Hydraulic Schematic
(from serial number 22566 to 23235)
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.
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone
Phone
Fax
0800 180 9017
+49 422 149 1818
+49 422 149 1820
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Genie North America
Service Manual
Z-45/25 • Z-45/25J Bi-Energy Power
(from serial number 9996 to 23235)
Part No.
106488
Rev B