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