Introduction September 2015

Introduction

Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate operator's these models:
manual on your machine before attempting any
maintenance or repair procedure. Title Part No.

This manual provides detailed scheduled Z-45/25 DC and Z-45/25J DC

maintenance information for the machine owner and Service Manual, Second Edition
user. It also provides troubleshooting fault codes (before serial number 23236) ............................ 106726
and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.

Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper opeation, inspection and
scheduled maintenance.

Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors Copyright © 1999 by Terex Corporation
and send in suggestions for improvement. All 107939 Rev D September 2015
communications will be carefully considered for Third Edition, Fourth Printing
future printings of this and all other manuals. Genie is a registered trademark of Terex South
Dakota, Inc. in the USA and many other
countries. "Z" is a trademark of Terex South
Contact Us: Dakota, Inc.

www.genielift.com Printed on recycled paper

e-mail: awp.techpub@terex.com Printed in U.S.A.

ii Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015

Revision History
Revision Date Section Procedure / Schematic Page / Description
C2 11/2014 3 - Maint. B-16

D 9/1015 Added ending serial break to front cover.

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.

Part No. 107939 Z-45/25 DC • Z-45/25J DC iii

 September 2015

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.

iv Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015

INTRODUCTION

Serial Number Legend

Model: Z-45/25
Serial number: Z452512A-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ESXXXX
Machine unladen weight:

Rated work load (including occupants): XXX lb / XXX kg

Maximum number of platfrm occupants: X
Maximum allowable side force : XXX lb / XXX N
Maximum allowable inclination of the chassis:
0 deg Z4525 05 A - 12345
Maximum wind speed : XX mph/ XX m/s
Maximum platform height : XX ft / XX m
Model Facility
Maximum platform reach : XX ft / XX m code
Gradeability: N/A
Country of manufacture: USA Model year Sequence
number
This machine complies with:

Terex South Dakota, Inc.

500 Oak Wood Road Serial label
Watertown, SD 57201 (located under cover)
USA
Serial number
stamped on chassis

PN - 77055

Part No. 107939 Z-45/25 DC • Z-45/25J DC v

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vi Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015

Safety Rules

Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate operator's
manual on your machine 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. 107939 Z-45/25 DC • Z-45/25J DC vii


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.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
viii Z-45/25 DC • Z-45/25J DC
September 2015
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for use.
Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area is
properly ventilated and well lit.
Part No. 107939
September 2015

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 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
Machine Torque Specifications .............................................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 5
SAE and Metric Fasteners Torque Charts .............................................................. 2 - 6

Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform 30 Day Service ............................................................................... 3 - 9
A-5 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 3 - 9
A-6 Replace the Drive Hub Oil .......................................................................... 3 - 10

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TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures
B-1 Check the Batteries .................................................................................... 3 - 11
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 12
B-3 Test the Key Switch ................................................................................... 3 - 13
B-4 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 14
B-5 Confirm the Proper Brake Configuration ...................................................... 3 - 14
B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque ............... 3 - 15
B-7 Test the Ground Control Override ............................................................... 3 - 16
B-8 Test the Platform Self-leveling ................................................................... 3 - 16
B-9 Test the Drive Brakes ................................................................................ 3 - 17
B-10 Test the Drive Speed - Stowed Position ..................................................... 3 - 17
B-11 Test the Drive Speed - Raised or Extended Position .................................. 3 - 18
B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 18
B-13 Test the Turntable Rotation Stop ................................................................ 3 - 19
B-14 Check the Electrical Contactors ................................................................. 3 - 20
B-15 Perform Hydraulic Oil Analysis ................................................................... 3 - 20
B-16 Test the Emergency Power System ........................................................... 3 - 21
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 22
C-2 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 23
Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 26
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 26
D-3 Check the Free-wheel Configuration ........................................................... 3 - 28
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 29
D-5 Replace the Hydraulic Tank Return Filter Element ..................................... 3 - 30
D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 30
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 32
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 33

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TABLE OF CONTENTS

Section 4 Repair Procedures

Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 Controllers .................................................................................................... 4 - 2
Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2 Platform Rotator ........................................................................................... 4 - 6
2-3 Platform Overload System (if equipped) ....................................................... 4 - 8
Jib Boom Components, Z-45/25J
3-1 Jib Boom .................................................................................................... 4 - 10
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 12
Primary Boom Components
4-1 Cable Track ................................................................................................ 4 - 13
4-2 Primary Boom ............................................................................................ 4 - 17
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 20
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 21
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 22
Secondary Boom Components
5-1 Secondary Boom ........................................................................................ 4 - 23
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 28
Hydraulic Pumps
6-1 Auxiliary and Function Pump ...................................................................... 4 - 29

Part No. 107939 Z-45/25 DC • Z-45/25J DC xi

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TABLE OF CONTENTS

Section 4 Repair Procedures, continued

Manifolds
7-1 Function Manifold Components .................................................................. 4 - 30
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 32
7-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 33
7-4 Turntable Rotation Manifold Components ................................................... 4 - 34
7-5 Valve Coils ................................................................................................. 4 - 35
Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 37
Motor Controller
9-1 Motor Controller .......................................................................................... 4 - 38

Section 5 Fault Codes

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

Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS
(before serial number 31015) ........................................................................ 6 - 6
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (before serial number 31015) .......................................... 6 - 10
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (before serial number 31015) .......................................... 6 - 11
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (before serial number 31015) .......................................... 6 - 13

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TABLE OF CONTENTS

Section 6 Schematics, continued

Electrical Schematic, Z-45/25 and Z-45/25J, CE
(before serial number 31015) ...................................................................... 6 - 16
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE
(before serial number 31015) ...................................................................... 6 - 20
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE
(before serial number 31015) ...................................................................... 6 - 21
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE
(before serial number 31015) ...................................................................... 6 - 23
Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS
(from serial number 31015 to 39313) .......................................................... 6 - 26
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (from serial number 31015 to 39313) .............................. 6 - 30
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI •CSA • AS (from serial number 31015 to 39313) ............................... 6 - 31
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (from serial number 31015 to 39313) .............................. 6 - 33
Electrical Schematic, Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313) .......................................................... 6 - 36
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313) .................................................................... 6 - 40
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313) .................................................................... 6 - 41
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313) .......................................................... 6 - 43
Electrical Schematic, Z-45/25 and Z-45/25J, ANSI • CSA • AS
(after serial number 39313) ......................................................................... 6 - 46
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (after serial number 39313) ............................................ 6 - 50
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI •CSA • AS (after serial number 39313) .............................................. 6 - 51
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (after serial number 39313) ............................................ 6 - 53

Part No. 107939 Z-45/25 DC • Z-45/25J DC xiii

 September 2015

TABLE OF CONTENTS

Section 6 Schematics, continued

Electrical Schematic, Z-45/25 and Z-45/25J, CE
(after serial number 39313) ......................................................................... 6 - 56
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE
(after serial number 39313) ......................................................................... 6 - 60
Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE
(after serial number 39313) ......................................................................... 6 - 61
Platform Control Box Wiring Diagram, Z-45/25 and Z-45/25J, CE
(after serial number 39313) ......................................................................... 6 - 64
Power Cable Wiring Diagram ................................................................................ 6 - 65
CTE Option, CE ................................................................................................... 6 - 68
Charger Interlock Option ...................................................................................... 6 - 69
Platform Control Box LVI / BCI Option Wiring Diagram
(before serial number 31015) ...................................................................... 6 - 72
Platform Control Box LVI / BCI Option Wiring Diagram
(after serial number 31014) ......................................................................... 6 - 73
Hydraulic Schematic ............................................................................................ 6 - 75

xiv Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 2 • Specifications

Specifications
Machine Specifications Fluid capacities

Tires and wheels Hydraulic tank 8 gallons

30.3 liters
Wheel diameter 14.5 inches
Hydraulic system 11 gallons
Wheel width 7 inches (including tank) 41.6 liters
Drive hubs (refer to tag on drive hub to determine type)
Wheel lugs 9 @ 5/8 -18
EW1 type 17 fl oz
Lug nut torque, lubricated 94 ft-lbs 0.51 liter
127.5 Nm W1 type 23 fl oz
0.68 liter
Lug nut torque, dry 125 ft-lbs
Drive hub oil type: EP 80-90W gear oil
169.5 Nm
API service classification GL5
Tire size 9-14.5 LT Batteries

Tire ply rating Tread 8 Type 6V DC

Sidewall 6
Quantity 8
Tire weight, new foam-filled (minimum) 175 lbs
79 kg Capacity 350 AH

Tire contact area 43.5 sq in Reserve capacity @ 25A rate 750 minutes
280 sq cm
Weight, each 106 lbs
Overall tire diameter 28 in 48 kg
71 cm

For operational specifications, refer to the

Operator's Manual.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 2-1

Section 2 • Specifications
SPECIFICATIONS
Performance Specifications
Drive speeds, maximum
Drive speed, stowed
All models
Drive speed, boom
raised or extended,
all models
Braking distance, maximum
High range on paved surface
Gradeability
2-2
September 2015
Boom function speeds, maximum
from platform controls
Jib boom up, Z-45/25J 26 to 40 seconds
3 mph
4.8 km/h Jib boom down, Z-45/25J 22 to 28 seconds
40 ft/9 sec Primary boom up 32 to 40 seconds
12.2 m/9 sec
Primary boom down 26 to 30 seconds
0.6 mph
1 km/h Secondary boom up 38 to 46 seconds
40 ft/45 sec
12.2 m/45 sec Secondary boom down 38 to 46 seconds
Primary boom extend 14 to 18 seconds
5 to 7 ft Primary boom retract 17 to 21 seconds
1.5 to 2 m
Turntable rotate, 355° 95 to 125 seconds
See Operator's Manual primary boom retracted
Platform rotate, 180°, Z-45/25 6 to 10 seconds
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
Z-45/25 DC • Z-45/25J DC Part No. 107939
September 2015 Section 2 • Specifications

SPECIFICATIONS

Hydraulic Specifications Function pump

Hydraulic Oil Specifications Type: Fixed displacement gear pump

Hydraulic oil type Chevron Rykon MV equivalent Displacement 0.183 cu in

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

Water content, maximum 200 ppm Hydraulic tank 10 micron with

return filter 25 psi / 1.7 bar bypass
Chevron Rando HD MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Function manifold
Genie specifications require hydraulic oils which are Function relief valve pressure 3200 psi
designed to give maximum protection to hydraulic 220.6 bar
systems, have the ability to perform over a wide
temperature range, and the viscosity index should Secondary boom down 2100 psi
exceed 140. They should provide excellent antiwear, relief valve pressure 145 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Platform level flow regulator 0.6 gpm
2.27 L/min
Optional fluids
Jib boom/platform rotate flow regulator 0.4 gpm
Biodegradable Petro Canada Environ MV46 1.5 L/min
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S Auxiliary pump

Fire resistant UCON Hydrolube HP-5046 Type: Fixed displacement gear pump
Quintolubric 822
Displacement 0.5 gpm
Mineral based Shell Tellus T32 1.9 L/min
Shell Tellus T46
Chevron Aviation A

Continued use of Chevron Aviation

A hydraulic oil when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures consistently below
0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 2-3

Section 2 • Specifications September 2015

SPECIFICATIONS

Manifold Component Machine Torque Specifications

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

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

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

Valve Coil Resistance Specification 108 Nm

Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω Drive motor and hubs

(schematic items B, C, D, E, F and H)
Drive hub mounting bolts, lubricated 180 ft-lbs
Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω 244 Nm
(schematic items A, K, S and AA)
Drive motor mounting bolts, lubricated 55 ft-lbs
Proportional solenoid valve, 24V DC 17 to 21 Ω 75 Nm
(schematic item I)

2-4 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 2 • Specifications

SPECIFICATIONS

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. 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
SAE O-ring Boss Port number 49612).
(tube fitting - installed into Aluminum)
2 Lubricate the O-ring before installation.
SAE Dash size Torque
3 Be sure that the face seal O-ring is seated and
-4 11 ft-lbs / 14.9 Nm retained properly.
-6 23 ft-lbs / 31.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-8 40 ft-lbs / 54.2 Nm tight.
-10 69 ft-lbs / 93.6 Nm 5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm torque per given size as shown in the table.

-16 139 ft-lbs / 188.5 Nm

6 Operate all machine functions and inspect the
hoses and fittings and related components to
-20 172 ft-lbs / 233.2 Nm confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port Seal-Lok Fittings

®

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

SAE Dash size Torque SAE Dash size Torque

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

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

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

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

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

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

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

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

Part No. 107939 Z-45/25 DC • Z-45/25J DC 2-5

Section 2 • Specifications September 2015

SPECIFICATIONS

SAE FASTENER TORQUE CHART

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

METRIC FASTENER TORQUE CHART

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

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

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

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

2-6 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 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 Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the Indicates an imminently hazardous
Maintenance Inspection Report. The frequency situation which, if not avoided, will
and extent of periodic examinations and tests result in death or serious injury.
may also depend on national regulations. Indicates a potentially hazardous
Failure to properly complete each situation which, if not avoided,
inspection when required may could result in death or serious
cause death, serious injury or injury.
substantial machine damage. Indicates a potentially hazardous
Immediately tag and remove from service a situation which, if not avoided,
damaged or malfunctioning machine. may cause minor or moderate
injury.
Repair any machine damage or malfunction
Indicates a potentially hazardous
before operating the machine.
situation which, if not avoided,
Unless otherwise specified, perform each may result in property damage.
procedure with the machine in the following
Indicates that a specific result is expected after
configuration:
performing a series of steps.
• Machine parked on a firm, level surface
Indicates that an incorrect result has occurred
• Boom in the stowed position after performing a series of steps.
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine

Part No. 107939 Z-45/25 DC • Z-45/25J DC 3-1

Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that a warm motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
3-2 Z-45/25 DC • Z-45/25J DC
September 2015
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
The Scheduled Maintenance Procedures Section
and the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which group(s)
of procedures are required to perform a scheduled
inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A+B
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and govermental regulations
and requirements.
Part No. 107939
Pre-Deliver
Pre-Deliveryy Preparation
September 2015 Section 3 • Scheduled Maintenance Procedures

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

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

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Genie Industries USA Genie UK

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

Part No. 107939 Z-45/25 DC • Z-45/25J DC

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
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September 2015 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model Checklist A
A-1 Manuals and Decals
Serial number
A-2 Pre-operation
Date inspection
A-3 Function tests
Hour meter Perform after 40 hours:
A-4 30 Day Service
Machine owner
Perform every 100 hours:
Inspected by (print) A-5 Grease rotation
bearing
Inspector signature Perform after 150 hours:
A-6 Replace drive hub oil
Inspector title
Y N R Checklist C Y N R
C-1 Grease platform
overload (if equipped)
C-2 Test platform
overload (if equipped)
Checklist D Y N R
D-1 Boom wear pads
D-2 Turntable bearing bolts
D-3 Free-wheel
configuration
D-4 Drive hub oil
D-5 Hydraulic return filter

Inspector company Checklist B Y N R D-6 Turntable bearing wear

B-1 Batteries
Instructions Checklist E Y N R
B-2 Electrical wiring
• Make copies of this page to use for E-1 Hydraulic oil
each inspection. B-3 Key Switch
B-4 Tires and wheels E-2 Wheel bearings
• Select the appropriate checklist(s) for
the type of inspection to be B-5 Brake configuration
performed. B-6 Drive hub oil level
B-7 Ground control
Daily or 8 hour
override
Inspection: A
B-8 Platform leveling
Quarterly or 250 hour
Inspection: A+B B-9 Drive brakes
Semi-annual or 500 hour B-10 Drive speed - stowed
Inspection: A+B+C B-11 Drive speed - raised
Annual or 1000 hours B-12 Alarm package
Inspection: A+B+C+D (if equipped)
2 Year or 2000 hour B-13 Turntable rotation stop
Inspection: A+B+C+D+E B-14 Electrical contactors
B-15 Hydraulic oil analysis
• Place a check in the appropriate box
after each inspection procedure is B-16 Emergency power
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections. Comments
• 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

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September 2015 Section 3 • Scheduled Maintenance Procedures

Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each machine
and should be stored in the container provided in
the platform. An illegible or missing manual will not
provide safety and operational information
necessary for a safe operating condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and in
good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.

1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or are illegible. Remove the machine
from service until the manual is replaced.

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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-2
Perform Pre-operation
Inspection
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong
with a machine before the operator performs the
function tests. The pre-operation inspection also
serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the appropriate operator's manual. Refer
to the Operator's Manual on your machine.
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September 2015
A-3
Perform Function Tests
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
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 appropriate operator's manual. Refer
to the Operator's Manual on your machine.
Part No. 107939
September 2015
A-4
Perform 30 Day Service
The 30 day maintenance procedure is a one-time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage. After this
interval, refer to the maintenance checklists for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
• A-5 Grease the Turntable Rotation
Bearing and Worm Drive Gear
• B-4 Check the Tires, Wheels and Lug Nut
Torque
• D-2 Check the Turnable Rotation
Bearing Bolts
• D-5 Replace the Hydraulic Tank
Return Filter Element
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-5
Grease the Turntable Rotation
Bearing and Rotate Gear
Genie specifications require that this procedure be
performed every 100 hours.
Frequent application of lubrication to the turntable
bearing and rotate drive gear is essential to good
machine performance and service life. Continued
use of an insufficently greased gear will result in
component damage.
1 Before serial number 27001: Locate the grease
fitting on the front turntable cover.
After serial number 27000: Locate the grease
fitting near the ground control box.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3-9
Section 3 • Scheduled Maintenance Procedures September 2015

CHECKLIST A PROCEDURES

A-6
Replace the Drive Hub Oil

Manufacturer drive hub specifications require that

this one-time procedure be performed after the first
150 hours.

Replacing the drive hub oil is essential for good

machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
use may cause the machine to perform poorly and
continued use may cause component damage.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Refer to Section 2, Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.

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September 2015
Checklist B Procedures
B-1
Check the Batteries
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.
Electrocution/burn 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.
1 Disconnect each battery pack from the machine.
2 Release the battery pack latches and rotate
each battery pack out and away from the
chassis.
3 Remove the cover from each battery box.
4 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
5 Be sure that the battery retainers and cable
connections are tight.
6 Fully charge the batteries. Allow the batteries to
rest 24 hours before continuing this procedure to
allow the battery cells to equalize.
7 Put on protective clothing and eye wear.
8 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
9 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 13.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 10.
10 Perform an equalizing charge OR fully charge
the batteries and allow the batteries to rest at
least 6 hours.
11 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
12 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 13.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.217. Replace the battery.
13 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
14 Install the vent caps and neutralize any
electrolyte that may have spilled.
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September 2015
B-2
Inspect the Electrical Wiring
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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/burn 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:
• Power units
• Inside of the ground control box
• Turntable manifold wiring
2 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.
Part No. 107939
September 2015
4 Remove the center turntable cover.
5 Inspect the turntable center area for burnt,
chafed and pinched cables.
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 Inspect for a liberal coating of dielectric grease
at the following location:
• All wire harness connectors to the platform
control box
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-3
Test the Key Switch
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could result in
a hazardous operating situation.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform controls.
3 Check the machine functions from the ground
controls.
Result: The machine functions should not
operate.
4 Turn the key switch to ground controls.
5 Check the machine functions from the platform
controls.
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: No function should operate.
3 - 13
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-4
Check the Tires, Wheels and
Lug Nut Torque
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the tires and wheels, including proper
wheel fastener torque, 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.
1 Check all tire treads 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.
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September 2015
B-5
Confirm the Proper
Brake Configuration
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
brake disengaged position
brake engaged position
Part No. 107939
September 2015
B-6
Check the Oil Level in the Drive
Hubs and Mounting Bolt Torque
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Failure to maintain proper drive hub oil levels,
including proper drive hub fastener torque, 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 is at
90 degrees.
models with pipe plugs
a models with o-ring plugs
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
2 Remove the plug located at 90 degrees and
check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
plug hole. Refer to Section 2, Specifications.
4 Models with pipe plugs: Apply pipe thread
saelant to the plugs and install the plugs into
the drive hub.
5 Models with O-ring plugs: Install the plugs into
the drive hub.
6 Check the torque of the drive hub bolts.
Refer to Section 2, Specifications.
7 Repeat this procedure for each drive hub.
3 - 15
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-7
Test the Ground Control
Override
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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 red 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.
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September 2015
B-8
Test the Platform Self-leveling
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained level by the platform leveling
slave cylinder which is controlled by the platform
leveling master cylinder located at the base of the
primary boom. A platform self-leveling failure
creates an unsafe working condition for platform
and ground personnel.
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.
Part No. 107939
September 2015
B-9
Test the Drive Brakes
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
Refer to B-5, Confirm the Proper
Brake Configuration.
1 Select a test area that is firm, level and free of
obstructions.
2 Mark a test line on the ground for reference.
3 Lower the boom to the stowed position.
4 Turn the key switch to platform controls.
5 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the test line.
6 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
7 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-10
Test the Drive Speed -
Stowed Position
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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.
1 Select a test area that is firm, level and free of
obstructions.
2 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
3 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.
4 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the start and finish lines.
5 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.
6 Continue at full speed and note the time when
your machine reference point passes over the
finish line. Refer to Section 2, Specifications.
3 - 17
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-11
Test the Drive Speed -
Raised or Extended Position
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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.
1 Select a test area that is firm, level and free of
obstructions.
2 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
3 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.
4 Raise the primary boom more than
5 feet / 1.5 m.
5 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the start and finish lines.
6 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.
7 Continue at full speed and note the time when
your machine reference point passes over the
finish line. Refer to Section 2, Specifications.
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September 2015
B-12
Test the Alarm Package
(if equipped)
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The alarm package includes:
• Travel alarm
• Descent alarm
• Flashing beacon
Alarms and a beacon are installed to alert operators
and ground personnel of machine proximity and
motion. The alarm package is installed on the
ground controls side turntable cover.
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.
Part No. 107939
September 2015
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.
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. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-13
Test the Turntable Rotation Stop
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The turntable is capable of rotating the boom 359
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.
3 - 19
Section 3 • Scheduled Maintenance Procedures September 2015

CHECKLIST B PROCEDURES

B-14 B-15
Check the Electrical Contactors Perform Hydraulic Oil Analysis

Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.

Maintaining the electrical contactors in good Replacement or testing of the hydraulic oil is
condition is essential to safe machine operation. essential for good machine performance and
Failure to locate a worn or damaged contactor could service life. Dirty oil and suction strainers may
result in an unsafe working condition and cause the machine to perform poorly and continued
component damage. use may cause component damage. Extremely
dirty conditions may require oil changes to be
Electrocution/burn hazard. Contact performed more often.
with hot or live circuits could result
in death or serious injury. Remove Note: Before replacing the hydraulic oil, the oil may
all rings, watches and other be tested by an oil distributor for specific levels of
jewelry. contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
1 Remove the drive chassis cover from the non-
the two year inspection, test the oil quarterly.
steer end of the machine and locate the
Replace the oil when it fails the test. See E-1,
electrical contactors mounted on the electrical
Test or Replace the Hydraulic Oil.
component mounting panel.
2 Visually inspect the contact points of each
contactor for the following items:
• Excessive burns
• Excessive pitting
Note: Replace the contactors if any damage is
found.

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September 2015 Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-16 5 Turn the key switch to platform controls.

Test the Emergency Power 6 At the platform controls, break the security tie
and lift the emergency power switch cover (if
System equipped).
7 Simultaneously hold the emergency power
switch on and activate each boom function.
Genie specifications require that this procedure be Note: To conserve battery power, test each
performed every 250 hours or quarterly, whichever function through a partial cycle.
comes first.
Result: All boom functions operate.
Testing the emergency power system is essential
to safe operation if the primary power source fails. 8 Close the emergency power switch cover and
secure the cover with a security tie (if
1 Turn the key switch to ground control and pull equipped).
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 At the ground controls, break the security tie
and lift the emergency power switch cover (if
equipped).
3 Simultaneously hold the emergency power
switch on and activate each boom function
toggle switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions operate.
4 Close the emergency power switch cover and
secure the cover with a security tie (if
equipped).

Part No. 107939 Z-45/25 DC • Z-45/25J DC 3 - 21

Section 3 • Scheduled Maintenance Procedures September 2015

Checklist C Procedures
C-1
Grease the Platform Overload
Mechanism (if equipped)

Genie specifications require that this procedure be

performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.

1 Locate the grease fittings on each pivot pin of

the platform overload assembly.
2 Thoroughly pump grease into each grease fitting
using a multi-purpose grease.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent

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September 2015
C-2
Test the Platform Overload
System (if equipped)
Genie specifications require that this procedure be
performed every 500 hours or six months,
whichever comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued use
of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
The platform overload system is designed to detect
an overloaded platform and prevent machine
operation anytime the machine is turned on. When
activated, the system halts all normal boom
operation, giving visual and audible warning to the
operator.
Models equipped with the platform overload option
are provided with additional machine components:
an adjustable spring-loaded platform support
subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
power, and an audio/visual warning indication to
alert the operator of the overload.
The platform support subassembly utilizes two load
support arms that are opposed in a full
parallelogram link. This isolates platform loads into
a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
supports this purely compressive load regardless of
where the load is placed in the platform.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
As weight is added to the platform, the spring will
compress until, when the platform is overloaded,
the lower arm contacts a limit switch and thereby
activating the overload signal. When adjusted
correctly, the platform overload system will
deactivate normal boom operation at platform
capacity.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity
one of the locations shown.
Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Proceedure 2-3, How to Calibrate the Platform
Overload System (if equipped).
3 - 23
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Proceedure 2-3, How to Calibrate the Platform
Overload System (if equipped).
Illustration 1
6 Using a suitable lifting device, place an
additional 10 lbs / 4.5 kg of weight onto the
platform.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload System
(if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
3 - 24 Z-45/25 DC • Z-45/25J DC
September 2015
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload
System (if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash 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.
Result: All ground control functions should not
operate.
11 Using auxiliary power, test all machine functions
from the ground controls.
Result: All ground control functions should
operate.
Part No. 107939
September 2015 Section 3 • Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

12 Using a suitable lifting device, lift the additional

test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.

13 Start the engine and test all machine functions

from the ground controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
How to Calibrate the Platform Overload System
(if equipped).
16 Using a suitable lifting device, remove the
remaining test weights from the platform.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 3 - 25

Section 3 • Scheduled Maintenance Procedures September 2015

Checklist D Procedures
D-1 D-2
Check the Primary Boom Check the Turntable Rotation
Wear Pads Bearing Bolts

Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 1000 hours or annually, whichever performed every 1000 hours or annually, whichever
comes first. comes first.

Maintaining the primary boom wear pads in good Maintaining proper torque on the turntable bearing
condition is essential to safe machine operation. bolts is essential to safe machine operation.
Wear pads are placed on boom tube surfaces to Improper bolt torque could result in an unsafe
provide a low friction, replaceable wear pad operating condition and component damage
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may 1 Raise the primary boom and place a safety
result in component damage and unsafe operating chock on the lift cylinder rod. Carefully lower
conditions. the boom onto the lift cylinder safety chock.
Crushing hazard. Keep hands
1 Measure each wear pad. Replace the wear pad
away from cylinder and all moving
once it reaches the minimum allowable
parts when lowering the boom.
thickness. If the wear pad is still within
specifications, shim as necessary to obtain Note: A lift cylinder safety chock is available
minimum clearance with zero binding. through Genie Service Parts (Genie part no.
36555).
2 Extend and retract the primary boom through the
entire range of motion to check for tight spots
that could cause binding or scraping.
Note: Always maintain squareness between the
primary boom outer and inner tubes.

Primary boom wear

pad specifications Minimum

Top, bottom and side wear pads 5/8 inch

(platform end of boom) 15.9 mm

Side and bottom wear pads 1 /2

inch
(pivot end of boom) 12.7 mm

Top wear pads 5/8 inch

(pivot end of boom) 15.9 mm

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September 2015 Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

2 Check to be sure that each turntable mounting
bolt is torqued in sequence to specification.
Refer to Section 2, Specifications.
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.

Counterweight 5 Check to be sure that each bearing mounting

bolt under the drive chassis is torqued in
18 6 13 sequence to specification. Refer to Section 2,
3 10 Specifications.
11 1
8 15 Counterweight

20 19 10 1
15
7 13 7
16
2 12 6 4
9 4
14 5 17 11 12
Bolt torque sequence
(from serial number 23332 to 26999) 3 5
8 14
16 2 9
Counterweight

18 6 13 Bolt torque sequence

(after serial number 23332)
3 10
11 1
8 15

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

Part No. 107939 Z-45/25 DC • Z-45/25J DC 3 - 27

Section 3 • Scheduled Maintenance Procedures September 2015

CHECKLIST D PROCEDURES

D-3 4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each
Check the Free-wheel non-steer wheel hub.
Configuration brake disengaged
position

Genie specifications require that this procedure be

performed every 1000 hours or annually, whichever brake engaged position
comes first.

Proper use of the free-wheel configuration is 5 Manually rotate each non-steer wheel.
essential to safe machine operation. The
free-wheel configuration is used primarily for towing. Result: Each non-steer wheel should rotate with
A machine configured to free-wheel without operator minimum effort.
knowledge may cause death or serious injury and 6 Engage the drive hubs by turning over
property damage. the drive hub disconnect caps.
Collision hazard. Select a work site 7 Carefully remove the blocks, lower the machine
that is firm and level. and remove the jack.
Component damage hazard. If the Collision hazard. Failure to engage
machine must be towed, do not the drive hubs could result in death
exceed 2 mph / 3.2 km/h. or serious injury and property
1 Chock the steer wheels to prevent the machine damage.
from rolling.
2 Center a lifting jack of ample capacity
(15,000 lbs / 7000 kg) under the drive chassis4
Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
3 Lift the wheels off the ground and place jack
stands under the drive chassis for support.

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September 2015 Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

D-4 4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the plug hole.
Replace the Drive Hub Oil Refer to Section 2, Specifications.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Genie specifications require that this procedure be Models with O-ring plugs: Install the plugs
performed every 1000 hours or annually, whichever into the drive hub.
comes first.
6 Repeat this procedure for each drive hub.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.

models with pipe plugs

models with o-ring plugs

Part No. 107939 Z-45/25 DC • Z-45/25J DC 3 - 29

Section 3 • Scheduled Maintenance Procedures September 2015

CHECKLIST D PROCEDURES

D-5 D-6
Replace the Hydraulic Tank Inspect for Turntable Bearing
Return Filter Element Wear

Genie specifications require that this procedure be Genie requires that this procedure be performed
performed every 1000 hours or annually, whichever every 1000 hours or annually, whichever comes
comes first. Perform this procedure more often if first.
dusty conditions exist.
Periodic inspection of turntable bearing wear is
Replacement of the hydraulic return filter element is essential to safe machine operation, good machine
essential for good machine performance and performance and service life. Continued use of a
service life. A dirty or clogged filter element may worn turntable bearing could create an unsafe
cause the machine to perform poorly and continued operating condition, resulting in death or serious
use may cause component damage. Extremely injury and component damage.
dirty conditions may require that the filter element
be replaced more often. 1 Grease the turntable bearing. See A-5, Grease
the Turntable Bearing and Rotate Gear.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause 2 Torque the turntable bearing bolts to
severe burns. specification. See D-3, Check the Turntable
Rotation Bearing Bolts.
1 Locate the hydraulic return filter next to the
hydraulic tank. 3 Raise the primary and secondary booms to full
height using the ground controls. Do not extend
2 Place a suitable container under the hydraulic the primary boom.
filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of oil to the new oil filter
gasket.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
6 Turn the key switch to ground controls and pull
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.

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September 2015 Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator.
and the turntable at a point that is directly
Result: The measurement is less than
under, or in line with, the boom and no more
0.055 inch / 1.4 mm. The bearing is good.
than 1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
Note: To obtain an accurate measurement, place
0.055 inch / 1.4 mm. The bearing is worn and
the dial indicator no more than 1 inch / 2.5 cm from
needs to be replaced.
the turntable rotation bearing.
8 Fully retract the primary boom. Raise the
primary and secondary booms to full height.
a Visually inspect the the dial indicator to be sure
the needle returns to the "0" position.
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
c
equally spaced areas 90° apart.
11 Lower the primary and secondary booms to the
stowed position and turn the machine off.
d
12 Remove the dial indicator from the machine.
a turntable
b dial indicator
c drive chassis
d turntable rotation bearing

5 Adjust the dial indicator to "0".

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. 107939 Z-45/25 DC • Z-45/25J DC 3 - 31

Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
Genie specifications require that this procedure be
performed every 2000 hours or every two years,
whichever comes first. Perform this procedure more
often if dusty conditions exist.
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 that the oil be changed
more often.
Note: 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.
Note: 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.
3 - 32 Z-45/25 DC • Z-45/25J DC
September 2015
1 Place a suitable container under the hydraulic
tank. See capacity specifications.
2 Remove the drain plug from the hydraulic tank.
3 Completely drain the tank into a container of
suitable capacity. Refer to Section 2,
Specifications.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
4 Tag, disconnect and plug the hydraulic hose
from the hydraulic tank filter at the tank.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
5 Remove the hydraulic tank mounting fasteners.
6 Pull the hydraulic tank out slightly to access the
two suction hoses.
7 Tag, disconnect and plug the two suction hoses
on the back of the hydraulic tank.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Part No. 107939
September 2015
8 Remove the hydraulic tank from the machine.
Component damage hazard. The
hydraulic tank is plastic and may
become damaged if allowed to fall.
9 Remove the suction strainer from the tank and
clean it using a mild solvent.
10 Rinse out the inside of the tank using a mild
solvent.
11 Install the suction strainer and drain plug using
a thread sealer on the threads.
12 Place the hydraulic tank onto the machine.
13 Install the hydraulic hoses.
14 Install the hydraulic tank retaining strap.
Component damage hazard. The
hydraulic tank may become
damaged if the tank strap
fasteners are over tightened.
15 Fill the tank with hydraulic oil until the fluid is
within the FULL and ADD marks on the hydraulic
tank. Do not overfill.
16 Clean up any oil that may have spilled. Properly
discard the used oil.
17 Operate all machine functions through a full
cycle and check for leaks.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-2
Grease the Steer Axle
Wheel Bearings
Genie requires that this procedure be performed
every 2000 hours or every two years, whichever
comes first.
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 and 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 - 33
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 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 to
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.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
10 Remove the castle nut.
11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
12 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the rear
bearing.
13 Pack both bearings with clean, fresh grease.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3 - 34 Z-45/25 DC • Z-45/25J DC
September 2015
14 Place the large inner bearing into the rear of the
hub.
15 Install a new bearing grease seal into the hub by
pressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease seal when
the hub has been removed.
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 Fill the hub cavity with clean, fresh grease.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
Note: Always use a new cotter pin when installing a
castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
Part No. 107939
September 2015
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 appropriate
Operator's Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
4-1
Section 4 • Repair Procedures
Platform Controls
1-1
Controllers
Platform Controls
The drive joystick is connected to the drive motor
controller located under the non-steer end drive
chassis cover. The drive motor controller can also
recognize machine drive malfunctions and display
controller fault codes by flashing an LED at the
ground controls. Refer to Section 5, Fault Codes
for a list of fault codes and additional information.
There are no adjustments needed on the drive
joystick controller. For further information or
assistance, consult the Genie Industries Service
Department.
b a
a boom function speed controller
b drive joystick
4-2 Z-45/25 DC • Z-45/25J DC
September 2015
Boom Function Speed
Controller Adjustments
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: Do not adjust the boom function speed
controller unless the static battery supply voltage is
above 24V DC.
1 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
a threshold adjustable trimpot
b max-out adjustable trimpot
c white/red wire to TP6
d boom function speed controller
Part No. 107939
September 2015 Section 4 • Repair Procedures

PLATFORM CONTROLS

3 Disconnect the blk/red wire of the boom function

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

6 Set the threshold: With the boom in the stowed

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

Boom function speed

controller specifications

Threshold 0.17 to 0.18A

Max-out 0.45 to 0.46A

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4-3

Section 4 • Repair Procedures
Platform Components
2-1
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
How to Remove the Slave
Cylinder
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no
air in the closed loop hydraulic circuit.
Note: 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.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
4-4 Z-45/25 DC • Z-45/25J DC
September 2015
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.
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.
Part No. 107939
September 2015
How to Bleed the Slave Cylinder
Note: This procedure will have to be preformed
outside.
1 Z45/25J: Raise the jib to a horizontal postion
and raise the secondary boom 3 feet.
Z45/25: Raise the secondary boom 4 feet.
2 Move the function enable toggle switch to either
side. Simultaneously activate and hold the
primary boom up and platform level up toggle
switches until the primary boom is fully raised.
The platform should be facing in an upward
position. As shown.
Z-45/25
Z-45/25J
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
PLATFORM COMPONENTS
3 While still holding the function enable toggle
switch, simultaneously activate the primary
boom down and platform level down toggle
switches until the primary boom is fully lowered.
The platform should be facing in a down
position. As shown.
Z-45/25
Z-45/25J
4 Level the platform and return the boom to the
stowed position.
4-5
Section 4 • Repair Procedures September 2015

PLATFORM COMPONENTS

2-2 4 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch
Platform Rotator to the left position until the platform is fully
rotated to the left. Continue holding the toggle
How to Bleed the Platform switch until air stops coming out of the bleed
valve. Close the bleed valve.
Rotator
Crushing hazard. Keep clear of
Note: This procedure will require two people.
the platform during rotation.
1 Move the function enable toggle switch to either 5 Connect the clear hose to the bottom bleed
side. Activate the platform rotate toggle switch valve and open the valve. Do not remove the
to the right, then the left through two platform bleed valve.
rotation cycles, then hold the switch to the right
position until the platform is fully rotated to the 6 Move the function enable toggle switch to either
right. side and hold the platform rotate toggle switch
to the right position until the platform is fully
Before serial number 24304: rotated to the right. Continue holding the toggle
2 Connect a clear hose to the top bleed valve. switch until air stops coming out of the bleed
Place the other end of the hose in a container to valve. Close the bleed valve.
collect any drainage. Secure the container to Crushing hazard. Keep clear of
the boom. the platform during rotation.
3 Open the top bleed valve on the rotator, but do 7 Remove the hose from the bleed valve and
not remove it. clean up any hydraulic oil that may have spilled.
a
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.
After serial number 24303:
2 Place a suitable container underneath the
platform rotator.
3 Open the top bleed screw on the rotator, but do
not remove it.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
d c b connections very slowly to allow
a top bleed valve the oil pressure to dissipate
b bottom bleed valve gradually. Do not allow oil to
c container squirt or spray.
d clear hose

4-6 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

PLATFORM COMPONENTS

4 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch to
the left position until the platform is fully rotated
to the left. Continue holding the toggle switch
until air stops coming out of the bleed screw.
Close the bleed screw.
Crushing hazard. Keep clear of the
platform during rotation.
5 Open the bottom bleed screw on the rotator, but
do not remove it.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and burn
skin. Loosen hydraulic connections
very slowly to allow the oil pressure
to dissipate gradually. Do not allow
oil to
squirt or spray.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch to
the right position until the platform is fully rotated
to the right. Continue holding the toggle switch
until air stops coming out of the bleed screw.
Close the bleed screw.
Crushing hazard. Keep clear of the
platform during rotation.
7 Clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4-7

Section 4 • Repair Procedures
PLATFORM COMPONENTS
2-3
Platform Overload System
(if equipped)
How to Calibrate the Platform
Overload System
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.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Turn the key switch to platform control.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.
4-8 Z-45/25 DC • Z-45/25J DC
September 2015
5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring
adjustment nut in a clockwise direction in 10°
increments until the overload indicator light
turns off, and the alarm does not sound.
Proceed to step 8.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off at
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
Part No. 107939
September 2015 Section 4 • Repair Procedures

PLATFORM COMPONENTS

7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure
beginning with step 6.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
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.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.

9 Test all machine functions from the platform

controls.
Result: All platform control functions should not
operate.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4-9

Section 4 • Repair Procedures
Jib Boom Components, Z-45/25J
3-1
Jib Boom
How to Remove the Jib 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.
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or 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.
4 - 10 Z-45/25 DC • Z-45/25J DC
September 2015
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.
5 Attach a lifting strap from an overhead crane to
the platform rotator for support.
6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
7 Remove the pin retaining fasteners from both
platform rotator pivot pins. Do not remove the
pins.
8 Use a soft metal drift to remove the leveling arm
pivot pin. 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.
Part No. 107939
September 2015 Section 4 • Repair Procedures

JIB BOOM COMPONENTS, Z-45/25J

12 Attach a lifting strap from an overhead crane to 18 Attach a lifting strap from an overhead crane to
the jib boom. the lug on the rod end of the jib boom lift
cylinder.
13 Support the barrel end of the jib boom lift
cylinder with a suitable lifting device. 19 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib
14 Tag, disconnect and plug the jib boom lift
boom lift cylinder from the bellcrank.
cylinder hydraulic hoses. Cap the fittings on the
cylinder. Crushing hazard. The jib boom lift
cylinder could become unbalanced
Bodily injury hazard. Spraying
and fall when removed from the
hydraulic oil can penetrate and
machine if not properly attached to
burn skin. Loosen hydraulic
the overhead crane.
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
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. Let the
cylinder hang down.
Crushing hazard. The jib boom
could fall when when the barrel-
end pivot pin is removed if not
properly supported by the
overhead crane.
17 Remove the pin retaining fastener from the jib
boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
bellcrank.
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 11

Section 4 • Repair Procedures
JIB BOOM COMPONENTS, Z-45/25J
3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Note: 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.
Note: 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.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 - 12 Z-45/25 DC • Z-45/25J DC
September 2015
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin halfway out. 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.
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. 107939
September 2015
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
Note: 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. Tag 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.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
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 at the platform rotator. Cap the
fittings on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Tag, disconnect and plug the hydraulic hoses
from the platform leveling master cylinder. Cap
the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 13
Section 4 • Repair Procedures
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 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.
4 - 14 Z-45/25 DC • Z-45/25J DC
September 2015
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
Note: 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. Tag 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. 107939
September 2015
4 Remove the hose clamp on the primary boom
bellcrank.
5 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
6 Tag, disconnect and plug the hydraulic hoses
from the V1 and V2 ports of the counterbalance
valve manifold at the platform rotator. Cap the
fittings on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Tag and disconnect the hydraulic hoses from
the platform leveling slave cylinder at the union
and connect them together using a connector.
Connect the hoses from the cylinder together
using a connector.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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.
4 - 15
Section 4 • Repair Procedures
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.
14 Remove all hose and cable clamps from the
underside of the primary boom.
15 Support the rod end of the primary boom lift
cylinder with a suitable lifting device.
16 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Do
not remove the pin.
17 Raise the primary boom slightly with the
overhead crane to relieve the pressure on the
primary boom lift cylinder rod-end pivot pin.
18 Use a soft metal drift to remove the primary
boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not properly
supported by the lifting device.
19 Lower the rod end of the primary boom lift
cylinder approximately 12 inches / 30 cm.
4 - 16 Z-45/25 DC • Z-45/25J DC
September 2015
20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
primary boom lift cylinder.
21 Raise the rod end of the primary boom lift
cylinder back into position and install the rod-
end pivot pin. Install the pin retaining fasteners.
22 Attach a strap from an overhead crane to the
cable track.
23 Remove the mounting fasteners from the upper
cable track at the platform end of the extension
boom.
24 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.
25 Remove the cable track from the machine and
place it on a structure capable of supporting it.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
overhead crane.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 107939
September 2015 Section 4 • Repair Procedures

PRIMARY BOOM COMPONENTS

How to Repair the Primary Boom 4-2

Cable Track Primary Boom
Component damage hazard. The
primary boom cable track can be How to Remove the Primary
damaged if it is twisted. Boom
Note: A 7 link repair section of cable track is Bodily injury hazard. This
available through the Genie Industries Service procedure requires specific repair
Parts Department. skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
a component damage. Dealer
service is strongly recommended.
b Note:Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
a link separation point the O-ring on the fitting and/or hose end must be
b lower clip
replaced and then torqued to specification during
1 Use a slotted screwdriver to pry down on the installation.
lower clip. Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to 1 Remove the platform.
the side.
2 Z-45/25: Remove the platform rotator and
3 Repeat steps 1 and 2 for each link to be platform mounting weldment.
removed.
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.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 17

Section 4 • Repair Procedures September 2015

PRIMARY BOOM COMPONENTS

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

4 - 18 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

PRIMARY BOOM COMPONENTS

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

5 Support and slide the extension tube and

extension cylinder assembly out of the boom
tube.
Crushing hazard. The primary
boom extension tube could
become unbalanced and fall when
removed from the primary boom
tube if not properly supported.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 19

Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
4-3
Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers the
primary boom. The primary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove the Primary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: 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.
4 - 20 Z-45/25 DC • Z-45/25J DC
September 2015
5 Support the rod end and the barrel end of the
primary boom lift cylinder with a second
overhead crane or similar lifting device.
6 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
Crushing hazard. The primary
boom will fall if not properly
supported when the primary boom
rod-end pivot pin is removed.
8 Place a support block across both turntable
covers under the primary boom lift cylinder.
9 Lower the rod end of the lift cylinder onto the
block. Protect the cylinder rod from damage.
Crushing hazard. The primary
boom lift cylinder could fall if not
properly supported.
10 Support the barrel end of the primary boom lift
cylinder with an overhead crane or similar lifting
device.
11 Remove the primary boom lift cylinder barrel-
end pivot pin retaining fasteners. Use a slide
hammer to remove the barrel-end pivot pin.
Carefully remove the primary boom lift cylinder
from the machine.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if not properly supported and
secured to the lifting device.
Part No. 107939
September 2015
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.
Note: 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.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
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: Be sure to note the length of the cylinder
after removal. The cylinder must be at the same
length for installation.
4 - 21
Section 4 • Repair Procedures September 2015

PRIMARY BOOM COMPONENTS

4-5 4 Remove the pin retaining fasteners from the

master cylinder barrel-end pivot pin.
Platform Leveling
5 Place a rod through the barrel-end pivot pin and
Master Cylinder twist to remove the pin.
The master cylinder acts as a pump for the slave 6 Remove the pin retaining fastener from the rod-
cylinder. It is part of the closed circuit hydraulic end pivot pin.
loop that keeps the platform level through the
7 Place a rod through the rod-end pivot pin and
entire range of boom motion. The master cylinder
twist to remove the pin.
is located at the base of the primary boom.
8 Remove the master cylinder from the machine.
How to Remove the Platform
Crushing hazard. The master
Leveling Master Cylinder cylinder could become unbalanced
and fall if not properly attached to
Note: When removing a hose assembly or fitting,
the overhead crane.
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 both the rod-end
and barrel-end pivot pins on the master cylinder
are accessible.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Attach an overhead crane or similar lifting
device to the master cylinder.

4 - 22 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

Secondary Boom Components

a b c

h d

Secondary Boom components

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

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 23

Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
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.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the platform.
2 Z-45/25J: Remove the jib boom.
See 3-1, How to Remove the Jib Boom.
3 Remove the primary boom. See 4-2, How to
Remove the Primary Boom.
4 Remove the master cylinder. See 4-5, How to
Remove the Platform Leveling Master Cylinder.
4 - 24 Z-45/25 DC • Z-45/25J DC
September 2015
5 Attach a lifting strap from an overhead crane to
to the lug on the rod end of the primary boom
lift cylinder. 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.
Part No. 107939
September 2015
10 Remove the pin retaining fasteners from both
sides of the secondary boom lift cylinder rod-
end pivot pin and barrel-end pivot pin. Do not
remove the pins.
11 Attach a strap from an overhead crane to the
lug on the rod end of one of the secondary
boom lift cylinders for support. Do not apply any
lifting pressure.
12 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
13 Use a soft metal drift to drive the rod-end pivot
pin half way out.
14 Remove the secondary boom lift cylinder from
the machine.
15 Repeat steps 11 through 14 for the other
secondary boom lift cylinder.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly attached to the overhead
crane.
Component damage hazard. When
removing a secondary boom lift
cylinder from the machine, be
careful not to damage the
counterbalance valve at the barrel
end of the cylinder.
16 Attach a lifting strap from an overhead crane to
the upper pivot for support. Do not lift it.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
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.
Lower the secondary boom assembly onto the
block.
Crushing hazard. The secondary
boom assembly could fall if not
properly supported by the block.
4 - 25
Section 4 • Repair Procedures
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.
24 Remove the hose and cable covers from the top
of the number 2 arm.
25 Pull all of the hoses and cables out of the upper
pivot and out through the mid-pivot. Lay the
hoses and cables on the ground.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use
a soft metal drift to remove the pin.
27 Remove the upper pivot from the machine.
Crushing hazard. The upper pivot
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
28 Attach the lifting strap from an overhead crane
to the number 2 arm at the upper pivot end.
29 Raise the number 2 arm slightly and remove the
4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest
pad.
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.
4 - 26 Z-45/25 DC • Z-45/25J DC
September 2015
33 Remove the pin retaining fasteners from the
number 2, 3 and 4 arm pivot pins at the
mid-pivot. Do not remove the pins.
34 Use a soft metal drift to drive each pin out.
Remove the mid-pivot from the secondary
boom assembly.
Crushing hazard. The mid-pivot
could become unbalanced and fall
when removed from the
secondary boom assembly if not
properly supported by the
overhead crane.
35 Attach the lifting strap from an overhead crane
to the center point of the number 2 arm for
support. Do not lift it.
36 Remove the pin retaining fasteners from both
compression link pivot pins. Do not remove the
pins.
37 Use a soft metal drift to remove the lower
compression link pivot pin at the number 3 arm.
38 Support the compression link with an
appropriate lifting device.
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.
Part No. 107939
September 2015
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.
43 Open the ground controls side turntable cover.
44 Remove the retaining fastener from the ground
control box and function manifold pivot plate.
45 Lower the ground control box and function
manifold pivot plate to access the number 3
arm pivot pin.
46 Attach the lifting strap from the overhead crane
to the centerpoint of the number 3 arm for
support. Do not lift it.
47 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.
48 Remove the pin retaining fasteners from the
number 3 arm at the turntable riser. Do not
remove the pin.
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
49 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.
50 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.
51 Remove the upper and lower hose and cable
covers from the number 3 arm.
52 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.
53 Remove the pin retaining fasteners from the
number 4 arm at the turntable riser. Do not
remove the pin.
54 Attach a lifting strap from the overhead crane to
the center point of the number 4 arm. Do not
lift it.
55 Use a slide hammer to remove the number 4
arm from the turntable riser through the ground
controls side bulkhead.
56 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.
4 - 27
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
5-2
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders
incorporated in the structure of the secondary
boom assembly. These cylinders operate in
parallel and require hydraulic pressure to extend
and retract. Each secondary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove a Secondary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: 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 - 28 Z-45/25 DC • Z-45/25J DC
September 2015
3 Tag, disconnect and plug the hydraulic hoses
on the secondary boom lift cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin
and barrel-end pivot pin. Do not remove the
pins.
5 Attach a strap from an overhead crane to the
lug on the rod end of the secondary boom lift
cylinder for support. Do not apply any lifting
pressure.
6 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
7 Use a soft metal drift to drive the rod-end pivot
pin half way out.
8 Remove the secondary boom lift cylinder from
the machine.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly attached to the overhead
crane.
Component damage hazard. When
removing a secondary boom lift
cylinder from the machine, be
careful not to damage the
counterbalance valve at the barrel
end of the cylinder.
Part No. 107939
September 2015 Section 4 • Repair Procedures

Hydraulic Pumps
6-1
Auxiliary and Function Pump

How to Remove the Auxiliary

Pump or Function Pump
Note: 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.
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.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
4 Tag and disconnect the cables from the auxiliary
pump or function pump.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
5 Tag, disconnect and plug the hydraulic hoses
from the auxiliary pump or function 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.
6 Remove the pump mounting bolts. Carefully
remove the pump.

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 29

Section 4 • Repair Procedures September 2015

Manifolds
7-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
No. Description Item Function Torque

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

4 - 30 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

MANIFOLDS

1 2 3 4 5 6 7 8

A B C D E F G H

I
9
W
22
J
10

V
21

U
20

S, T
19

R
18

Q
17

P
16

K
11

O N M L

15 14 13 12

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 31

Section 4 • Repair Procedures
MANIFOLDS
7-2
Valve Adjustments -
Function Manifold
How to Adjust the System
Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold.
2 With the boom fully retracted, move and hold
the function enable toggle switch to either side
and hold the primary boom extend/retract
toggle switch in the retract direction. Observe
the pressure reading on the pressure gauge.
Refer to Section 2, Specifications.
3 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
(item O).
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
5 Repeat steps 2 through 4 and recheck relief
valve pressure.
4 - 32 Z-45/25 DC • Z-45/25J DC
September 2015
How to Adjust the Secondary
Boom Down Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold.
2 With the secondary boom fully lowered, move
and hold the function enable toggle switch to
either side and hold the secondary boom
up/down toggle switch in the down direction.
Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
3 Turn the machine off. Hold the secondary boom
down relief valve with a wrench and remove
the cap (item W).
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. 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. 107939
September 2015 Section 4 • Repair Procedures

MANIFOLDS

7-3
Jib Boom / Platform Rotate Manifold Components

The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 2 position 3 way ...... AA ........ Jib boom / platform rotate select .................. 20 ft-lbs / 27 Nm

1
AA

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 33

Section 4 • Repair Procedures September 2015

MANIFOLDS

7-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function Torque

1 Counterbalance valve ......................... Y ......... Turntable rotate right ........................ 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve ......................... Z .......... Turntable rotate left ........................... 30-35 ft-lbs / 41-47 Nm

1 2

Y Z

4 - 34 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

MANIFOLDS

7-5 How to Test a Coil Diode

Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
1 Test the coil for resistance. See How to Test a
Coil.

Valve Coil Resistance Specification

Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω

(schematic items B, C, D, E, F and H)

Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω

(schematic items A, K, S and AA)

Proportional solenoid valve, 24V DC 17 to 21 Ω

(schematic item I)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 35

Section 4 • Repair Procedures September 2015

MANIFOLDS

2 Connect a 10Ω resistor to the negative terminal 5 Momentarily connect the positive lead from the
of a known good 9V DC battery. Connect the multimeter to the positive terminal on the 9V DC
other end of the resistor to a terminal on the battery. Note and record the current reading.
coil.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
Ω
Resistor, 10Ω reading.
Genie part number 27287
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
Note: The battery should read 9V DC or more when The coil is good.
measured across the terminals.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
COIL internal diode are faulty and the coil should be
a replaced.
MULTI
d METER

c -
+

b
10 W 9V
RESISTOR BATTERY
+

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

Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6

3 Set a multimeter to read DC current.

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

4 Connect the negative lead to the other terminal

on the coil.

4 - 36 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 4 • Repair Procedures

Turntable Rotation Components

8-1
Turntable Rotation Assembly
How to Remove the Turntable
Rotation Assembly
Note: 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.
Note: Perform this procedure with the machine on a
firm, level surface.
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.
Unlocked position
3 Remove the retaining fasteners from the center
turntable cover. Remove the cover from the
machine.
4 Disconnect the battery backs from the machine.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
5 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor manifold. Cap
the fittings on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
6 Attach a lifting strap from an overhead crane or
other suitable lifting device to the turntable
rotation assembly.
7 Remove the turntable rotation assembly
mounting fasteners.
8 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.

Locked position

Part No. 107939 Z-45/25 DC • Z-45/25J DC 4 - 37

Section 4 • Repair Procedures September 2015

Motor Controller
9-1 5 Connect the leads from an ohmmeter to test
each motor controller terminal combination
Motor Controller listed below and check the forward / reverse
bias (diode test).
The drive motor controller is located under the non-
steer end drive chassis cover. The drive motor Result: All desired results must be within the
controller can recognize machine drive specified range. If any test has a result not
malfunctions and display controller fault codes by within the specified range, replace the motor
flashing a LED at the ground controls and on the controller.
motor controller. See the Fault Code section of this
Forward Bias:
manual for a list of fault codes and additional
information. There are no adjustments needed on
Test Desired result
the drive joystick controller. For further information
or assistance, consult the Genie Industries Service Positive Lead Negative Lead
Department.
M- B+ 0.4 to 0.45
How to Test the Motor Controller B- M- 0.4 to 0.45
Note: Use the following procedure to test the motor F1 B+ 0.45 to 0.5
controller. If the motor controller is found to be
faulty, note which test failed and which fault code F2 B+ 0.45 to 0.5
(if any) was present at the time of failure.
B- F1 0.45 to 0.5
1 Turn the key switch to the off position and
B- F2 0.45 to 0.5
disconnect the battery packs from the machine.
2 Tag and disconnect all power cables from the
motor controller. Reverse Bias:

Electrocution/burn hazard. Contact Test Desired result

with electrically charged circuits
could result in death or serious Positive Lead Negative Lead
injury. Remove all rings, watches
B+ M- Rises to .0L V
and other jewelry.
M- B- Rises to .0L V
3 Press the release tab on the motor controller
harness connector and remove the motor B+ F1 Rises to .0L V
controller harness connector from the motor
controller. B+ F2 Rises to .0L V

4 Set an ohmmeter to diode test mode. F1 B- Rises to .0L V

F2 B- Rises to .0L V

4 - 38 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 107939 Z-45/25 DC • Z-45/25J DC
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Electrocution/burn hazard. Contact
with electrically charged circuits
could 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.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
5-1
Section 5 • Fault Codes September 2015

FAULT CODES

Tip-over hazard. When adjusting

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

Note: When using the hand-held pendant motor

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

5-2 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 5 • Fault Codes

Fault Code Chart

Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display

Push in the ground

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

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

Check for loose or open

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

Defective motor Replace the motor

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

Continued on next page

Part No. 107939 Z-45/25 DC • Z-45/25J DC 5-3

Section 5 • Fault Codes September 2015

FAULT CODE CHART

Code Scanner
Fault Code Condition Possible Causes Solution
Display

Open in wht/red wire

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

Pin 14 (wht/red #32) is

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

Main contactor (PR1) Replace main contactor

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

Main contactor (PR1)

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

Repair short between

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

5-4 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 5 • Fault Codes

FAULT CODE CHART

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

Main contactor PR1 or

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

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

Battery supply voltage

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

Operate machine within

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

Part No. 107939 Z-45/25 DC • Z-45/25J DC 5-5

Section 5 • Fault Codes September 2015

This page intentionally left blank.

5-6 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 6 • Schematics

Schematics
About This Section
There are two groups of schematics in this section.

Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Electrical Schematics
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Hydraulic Schematics

Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Before Troubleshooting: or spray.
Read, understand and obey the safety rules and General Repair Process
operating instructions in the appropriate
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6-1

Section 6 • Schematics September 2015

Electrical Symbols Legend

TB17
15AMP.

TS6
Circuit breaker

GRN/BLK
ORG/BLK-1

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

BLK/RED
WHT
TB20 circuit
BP1

Terminal Boom function

speed controller

Horn NC NO

TP29 LS3

Limit switch
Quick disconnect L1 FB

terminal
Light LS1
NO
BLK #21
TB21

T-circuits connect Limit switch

at terminal normally open
held closed

PLAT
KS1

T-circuits Tilt sensor GRND

connect
Key switch

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

Circuits crossing
no connection
P1 PR4

Red Emergency
Stop button Relay panel
Diode normally closed contactor

TS3
CR4

-
PLAT. DWN
PLAT. UP

Battery Relay contact

normally open Toggle switch SPDT

6-2 Z-45/25 DC • Z-45/25J DC Part No. 107939

September 2015 Section 6 • Schematics

Hydraulic Symbols Legend

0.035”

Orifice with size

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

Variable orifice
or shut-off valve

Filter Solenoid operated Shuttle valve

proportional valve
(before serial number 22566)
Check valve

Check valve, pilot operated

Fixed displacement pump

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

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

Bi-directional motor Pressure switch

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

Solenoid operated 2 pos.,

3 way, directional valve

Cylinder

Counterbalance valve

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6-3

Section 6 • Schematics September 2015

6-4 Z-45/25 DC • Z-45/25J DC Part No. 107939

 Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (before serial number 31015)

6-5 6-6
Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (before serial number 31015)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK

TB134 FS1
P2 RD-(FS) C9P-3
BK C7P-1 P26BAT C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH

P22BAT
RD
WH R42BAT OR/RD

C132PLI BL/WH C1P-12 RD

+

RD
2 LS18 H1
TILT
ALARM

C1B-12
P3
HORN L48
KS1 PLATFORM TB22
10 A P1
P20BAT RD
CB1

C7B-1
GROUND
C1P-4

C1P-5

C1P-6

C1P-3

C2P-5

C1P-2

C2P-4
C3P-9
C2P-1

C7P-2

C3P-3
C2P-2
1 3
4 5

P22LS BK
C32

C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

P23BAT WH

R42BAT OR/RD
C9HRN BK/RD

C134PWR GR

C28TTA RD/BK

C3BAT RD/WH
C133PLA BL/RD
6 7

3 12 8
P20BAT RD

C2B-1

C3B-9

C7B-2
C2B-5

C1B-2

C3B-3

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK
C7B-4

WH
C6B-30

C6B-31

C6B-32

C6B-29

OR OR
CR5
TB40
4 P42BAT OR/RD C6B-3
C12DRE BL/WH
P42BAT OR/RD
C6B-22 RD
TB42
F5
RD/WH
OR/RD

BK/RD
OR/RD

OR/RD

OR/RD
WH

WH/BK

WH/RD

10A F4
AP2 500A
48V 86 30
C6B-40 OR
C6B-12

C6B-24

C6B-20 RD
CR2
PR1 86
+48 V TB23

OR/RD
BK D2 85 87

RD/BK
COIL-PR1

CR5

F2 85 L37
_
+

200A 86 30
BL/WH

CR1
C10-3
C10-4

C10-1
C10-2

BK

5
C6B-39 CR5 RD/BK
OFF-LMT SPD INP
RD 20
_
+

C6B-28
C6B-34
LEFT 85 87
DIODE RETURN

C6B-25 CFIL BK

D79
BOX
BK-4
WH-4

BK-5
WH-5
INTERLOCK
+48V INPUT

BRN
BRN
FORWARD

POT. LOW
REVERSE
_
+

POT. HI

21
LS4 + C12DRE BL/WH
GR

HM
(SEC) _
_
+

22
1 9 10 11 14 16 2 3 17 20 5
AP2 30 86

RD/WH
RD/BK
RD
U6A
CURTIS 1244 CR4
24V SEPEX CONTROLLER
BK-5

RD-5

BK 87 85
6 AP1 F1 F1 M- B+ F2 B-

C8-C
C8-A
+24V 200A
PR3 PR2
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+
_
+

FB
WH-6
BK-7
WH-7

BK-6
BK 2 GA
WH

LEFT A2 A2 F2 F1
MOTOR
_
+

RIGHT
BOX RIGHT
F2 F1 A1 A1 21 13
+ MOTOR LS2 LS1
CHARGER

PUMP (PRI) (EXT) 1

_
+

PUMP

BK
_ 22 14
BRN

+
C8-B
7
BK
_
+

H2
BRN
GROUND

AC POWER

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3
(OPTION)
BEACON
FLASHING

POWER RELAY
CR1 48V DC

POWER RELAY
CR2 48V DC
HORN

HORN RELAY
LIFT PUMP
PRIMARY
LIFT PUMP
AUXILIARY

CONTACTOR COIL
CONTROLLER
PR1 SEPEX

RELEASE COIL
CR5 BRAKE

SENSOR
TILT
METER
HOUR
BOX GROUND
BASE CONTROL
GROUND
CHASSIS

NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED. ES0273G (NON-JIB MODELS)
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. ES0274G (JIB MODELS)
2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6-6 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

Electrical Schematic , Z-45/25 and Z-45/25J,

ANSI • CSA • AS (before serial number 31015)

6-7
2
ENABLE
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

21
22

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN DRIVE ENABLE
LIMIT SWITCH
TB12
D78

LS3

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

13

14
A

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

86

85

BRN
RD/WH
H3

TRAVEL ALARM
+
CR6

D85
CR5

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

87

C2P-3
87
30
ENABLE
DRIVE
B

PS1 BRAKE
Z-45/25 DC • Z-45/25J DC

PS1 PRESSURE
SWITCH
RD/BK-R6

TS15

TB36

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

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

STEER RIGHT
C1P-11
C25-1 C25-2
C6B-38 GR/WH
DP1
C

OR/BK-R6

CR5
C31REV WH/BK

10
C29JSH RD/WH

C32JSL WH/RD

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
LIFT

STEER
FWD

REV

D76

D59

D60
R
20K

L
D

D69

33W
TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

AUXILIARY

PR2
PUMP

PR2
30

87

OR/RD C6B-19
OPTION

PRIMARY PUMP
GR/WH
CONTACTOR COIL
BCI

CR20
September 2015

Part No. 107939

+

D4
OR/RD

CR3
85
86
DISCHARGE

OR/RD RD RD
SET TO “N”
E

AUXILIARY PUMP
1

BK
AUXILIARY

33W
TB27

CONTACTOR COIL
TS51
2

PR3

OR
PUMP
3
5 3

PR3
CR3

OR/RD
BCI

L.V.I.

C6B-27 RD AUXILIARY PUMP

OR/BK CONTACTOR RELAY
4

D73

87
TB19
SET TO “B”
6

30

CR20
RESET

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

WH
86

85

GR/WH PRIMARY PUMP

7

CONTACTOR RELAY
TB6
D74

87a
8
LVI/BCI OPTION

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

BRN
BK

BK/RD

FLOW CONTROL
D71
CR19A

GR/WH
BRN
RD
F

D72
TB18
86

85

D28

PLATFORM ROTATE
BP1

C23-1 C23-2
CONTROL

DOWN C6B-18 GR/BK RIGHT

CR19B

ROTARY

(JIB DOWN - OPT.)

FLOW
OEM

C6B-17 GR
BOOM

TS58

PLATFORM ROTATE
UP
TB17

C22-1 C22-2 LEFT

85
86

JIB

(JIB UP - OPTION)
TB44

C2P-6 C44JDA GR/BK C2B-6 C44DA BK

BOOM

D27

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

JIB
G

C4P-5 C17PRL GR C4B-5 GR

TS8

UP
D82

RIGHT
PLATFORM
JIB MANIFOLD

ROTATE
87a

TS57

C44DA BK

LEFT
CR7
30

D82
85
86
PLATFORM

WH BK
ROTATE

D80

RIGHT
H

GR/WH
TS7

LEFT
C2P-7 C45JSV GR/WH C2B-7
TB14

C20-1 C20-2
D81

UP C6B-14 OR PLATFORM
PLATFORM

LEVEL UP
C6B-15 OR/BK PLATFORM
LEVEL

TS59

DOWN LEVEL DOWN

TB15
C21-1 C21-2
PLATFORM
I

LEVEL

UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TS9

DOWN

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

TS63 C6B-8 BK/WH PRIMARY BOOM

BOOM

RETRACT RETRACT

TB8
C17-1 C18-2
PRIMARY
BOOM
J

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2 PRIMARY

UP C6B-1 RD
BOOM UP

PRIMARY
C6B-2 RD/BK PRIMARY

BOOM

TS61
DOWN BOOM DOWN

TB2
C13-1 C13-2
CR19A
PRIMARY
BOOM

UP C3P-1 C1PBU RD C3B-1

30

87

C3P-2 C2PBD RD/BK C3B-2

K

TB10
TS11

DOWN C18-1 C18-2

UP SECONDARY

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

TS60
BOOM
DOWN BOOM DOWN
SECONDARY

TB11
C19-1 C19-2
CR19B

D29

D30

D50
C44DA BK C6B-33
BOOM

DESCENT ALARM

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87
30

C3P-11 C11SBD BL/BK C3B-11

TS10

TB5
DOWN
C15-1 C15-2
L

RIGHT C6B-5 WH/BK TURNTABLE

TURNTABLE
ROTATE RIGHT

RD

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT

TB4
C14-1 C14-2
TURNTABLE
ROTATE
RIGHT C3P-5 C4TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4
R42BAT OR/RD

TS12
LEFT
P24BAT WH
M

TS55 FUNCTION
ENABLE
C31REV WH/BK

C12DRE BL/WH
C29JSH RD/WH

C32JSL WH/RD

P42BAT OR/RD
C30FWD WH

(GND)
CR5

PR2
PR3
WH

RD

BK
N
September 2015 Section 6 • Schematics

Electrical Schematic , Z-45/25 and Z-45/25J,

ANSI • CSA • AS (before serial number 31015)

6-7 6-8
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(before serial number 31015)

6-9 6 - 10
 8
7
6
5
4
3
2
1

6 - 10
C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)
BRN GND
GR/BK H6
P20BAT RD

BL/WH C1-12
Section 6 • Schematics

D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
B

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
C6B-5 C5TRR WH/BK
C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
C3B-8 C8PBR BK/WH BK/WH-TS63
8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
C

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK D50 BK ALARM
C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59

Z-45/25 DC • Z-45/25J DC
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLAT. ROTATE LEFT-(JIB UP-OPT) 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
D

18 PLAT. ROTATE RIGHT-(JIB DOWN-OPT) 18

C6B-38 C19LPE GR/WH D76 GR/WH
D74
C4B-7 C19LPE GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
ANSI • CSA • AS (before serial number 31015)

GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

BK-ALARM

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
E

33 33

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
D59

Part No. 107939

September 2015

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

37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F

40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
D29 BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 (JIB - OPTION) DESCENT ALARM 44
C6B-34 C134PWR RD RD H6
C2B-5 P134BAT RD RD KS1
134 KEYSWEITCH POWER 134

L37
BK C6B-25
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,

OR/RD-42A OR/RD
G

C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
OR/RD GROUND
GROUND CONTROL
BK
HARNESS

BRN
STUD TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C4B C6B-27 R27AUX

C30FWD WH
C28TTA RD/BK

BROWN C6B-19 R19LPE GR/WH

H

C32JSL WH/RD
C29JSH RD/WH

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

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B
GREEN C3B-3 C3BAT RD/WH

RD/WH OR/RD

BRN BRN
C2B
BLACK
I

CR1 CR2 CR3 CR20

30 30 30 30
BRN

87A 87A 87A 87A

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

86 85 86 85 86 85
C1B 87 87 87 87
GRAY
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

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

BRN 87 87
BRN 85 86 85 86
87A 87A
BK
30
30
ES0274G (JIB MODELS)

D85
K

CR4 CR5
ES0273G (NON-JIB MODELS)
L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (before serial number 31015)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)
BK-7A GR/BK-18A D80
BK 1
BK/WH-8A GR-17A

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V

RD
BK
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
RD-1A D28
CR20 PRIMARY LIFT PUMP RELAY
G6 HOUR METER
KS1 KEY SWITCH GR/BK-44A 3

TS59
TS61
L37 LED, DRIVE CONTROLLER FAULT STATUS

TS58
WH

RD

RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH RD
TS55 FUNCTION ENABLE TOGGLE SWITCH
TS57 PLATFORM ROTATE TOGGLE SWITCH BK
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD C23-6

RD
BK
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH RD 4
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH BK-22A
TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH P20BAT RD (C7B-4)

BL-10A
NOTE: DASHED LINES INDICATE OPTIONS.

KS1
BL/BK-11A

CB1
GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

D2

RD
WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

ES0273G (NON-JIB MODELS)

G6
ES0274G (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 11

September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(before serial number 31015)

6 - 11 6 - 12
 September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (before serial number 31015)
N M L K J I H G F E D C B A

BRN-RELAY

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

RD/BK-R6

RD-J7
CR6 CR7

C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK

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

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

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH

P22BAT BK
P23SWBAT WH
BRN-BATGND

P26BAT BK
P24BAT WH
P25BAT RD

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

BRN-J1
BRN-BATGND 3
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11

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

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

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

C7P-1
C7P-2
C7P-3

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

BK

WH
C1P-2
C28TTA RD/BK

4
C1P(GY)

C3P(GR)

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

12V DC FOOT
D40
BATTERY SWITCH
18/19 CONTROL CABLE
A1

DP1
GR-LFC NOTES:
20k GR 1 C29JSH RD/WH DASHED LINES INDICATE OPTIONS.
GR BP1 OR C32JSL WH/RD
2
RD
BK/RD
WH
3
C30FWD WH
COMPONENT INDEX
TS13
FWD
BK 4
C31REV WH/BK A1 TILT ALARM
6
TS12 TS10
D73 OR/BK-R6
REV

D71
RD RD-DRE BCI BATTERY CHARGE INDICATOR (OPTION)
5 P24BAT WH
WH/GR BP1 ROTARY FLOW CONTROL DIAL
- BCI + YL 6 C12DRE BL/WH
RD-RPM CR6 RELAY - DRIVE ENABLE
LIFT PRPL RD-J7
7 RD-SW CR7 RELAY - JIB (OPTION)
TS11
BL 8
RD/BK-R6
DRIVE
BK/WH-DRE DP1 JOYSTICK - DRIVE / STEER
R42BAT OR/RD

H1 TITL ALARM
BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL 1
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPMP GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT 9
WH/RD C36STCC BL L1 LED - DRIVE ENABLE
LEFT 10
L48 LED - TILT ALARM 7

P26FS BK C9P-1

P22BAT BK C7P-1

P23SWBAT WH C7P-2

C3BAT RD/WH C3-3

P2 EMERGENCY STOP BUTTON
1

1
P3 HORN BUTTON

RD-HRN
RD/BK H1
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C44JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS1 AUXILIARY PUMP TOGGLE SWITCH

TS7 PLATFORM ROTATE TOGGLE SWITCH
TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)

P3
D69 TS9 PLATFORM LEVEL TOGGLE SWITCH
TS9 TS10 SECONDARY BOOM TOGGLE SWITCH
TS15 TS7 8
3

2
4

TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH

NC NC NC

1
NO
D27

1
D81 TS12 TURNTABLE ROTATE TOGGLE SWITCH

2
P3
RD

2
TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
L48
TS1 TS8
D82 P2
TS15 DRIVE ENABLE TOGGLE SWITCH

ES0273G (NON-JIB MODELS)

L1
ES0274G (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 13

September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (before serial number 31015)

6 - 13 6 - 14
 Section 6 • Schematics September 2015

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

(before serial number 31015)

6 - 15 6 - 16
Section 6 • Schematics September 2015

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

(before serial number 31015)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
BK C7P-1 P26BAT C9P-1 BK BK-(FS)
TB134 WH-(FS) C9P-2 P24BAT WH

P22BAT
RD
R42BAT OR/RD

C132 PLI BL/WH C1P-12 RD

3

C1B-12
+

RD
2 LS18
P3 L4 H1
TILT
ALARM L48
HORN
CB1 P1 PLATFORM
P20BAT RD TB22 D39 2 D40

C7B-1
10A KS1
GROUND

C2P-4
C7P-2

C3P-9

C2P-5
C1P-2
C1P-4

C1P-5

C1P-6

C1P-3

C7P-2
C3P-3
C2P-2
1 3
4 C32 5

P22LS

P23BAT WH

P23BAT WH

R42BAT OR/RD
C134PWR GR
C28TTA RD/BK

C3BAT RD/WH
C40LS OR
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

C9HRN BK/RD
6 U33 7
P20BAT RD

BK
3 12 8

L45

C3B-9

C2B-5
C1B-2

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2

C7B-2

C7B-2
C3B-3
H6

GR/BK
C7B-4

WH
C6B-30

C6B-31

C6B-32

C6B-29

OR OR
CR5
TB40
4 P42BAT OR/RD C6B-3
C12DRE BL/WH
P42BAT OR/RD
C6B-22 RD
TB42
F5
RD/WH
OR/RD

OR/RD
OR/RD
OR/RD
WH

WH/BK

WH/RD

F4

BK/RD

RD/BK
AP2 10A
48V DC 500 A
C6B-12

C6B-24

C6B-20 RD
C6B-40 OR

86 30
CR2
PR1 86
+48V DC TB23

OR/RD
D2 85 87
+ - BK
COIL-PR1

CR5

F2 85 L37
200A 86 30
RD 20

BL/WH

+ - CR1
C10-3 BK-4
C10-4 WH-4

C10-1 BK-5
C10-2 WH-5

D79
C6B-39 CR5 RD/BK

5
OFF-LMT SPD INP

C6B-28
C6B-34
LEFT 85 87
C6B-25 CFIL BK
DIODE RETURN
+48V DC INPUT

BRN
BRN
BOX
BK

+ -
INTERLOCK
FORWARD

POT. LOW
REVERSE

POT. HI

21
+ - LS4 + C12DRE BL/WH
GR

(SEC) HM
22 _
1 9 10 11 14 16 2 3 17 20 5
AP2
30 86
U6A

RD/WH
RD/BK
RD
CURTIS 1244 CR4
24V DC
BK-5

RD-5

SEPEX CONTROLLER 87 85
F1 BK
6 AP1
200A F1 M- B+ F2 B-

C8-A

C8-C
+24V DC
PR3 PR2
+ -
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+
FB
BK-7

BK-6
BK 2 GA

BRN
WH-7

WH-6

+
WH

LEFT A2 A2 F2 F1
MOTOR
RIGHT
RIGHT
BOX + - F2 F1 A1 A1 MOTOR 21 13
+ LS2 LS1
CHARGER

PUMP PUMP (PRI) (EXT) 1

22 14

BK
-
+
+
C8-B
7 H2
BK
GROUND

AC POWER BRN

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3
RELEASE COIL
CR5 BRAKE

POWER RELAY
CR2 48VDC
LIFT PUMP
AUXILIARY

POWER RELAY
CR1 48VDC
LIFT PUMP
PRIMARY

CONTACTOR COIL
CONTROLLER
PR1 SEPEX

HORN

HOUR METER

(OPTION)
FLASHING BEACON
HORN RELAY
CHARGER
48V DC

TILT SENSOR
BOX GROUND
BASE CONTROL
GROUND
CHASSIS

8
NOTES: ES0273G (NON-JIB MODELS)
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED. 3 L48 TILT ALARM LED. (OPTION) ES0274G (JIB MODELS)
2. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
2 ADD D40 ONLY IF UNIT HAS L4 AND L48. 4 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6 - 16 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

6 - 17
Electrical Schematic , Z-45/25 and Z-45/25J, CE
(before serial number 31015)

4
ENABLE
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

22

21

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
D78

DRIVE ENABLE
LS3

BL/WH WH-8 RD-8 LIMIT SWITCH

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

TB12

13

14

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

85
86

BRN
86

85

RD/WH
H3

TRAVEL ALARM
+
CR6

D85
CR5
CR8

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

87

87
30
30

87

ENABLE
B

DRIVE

Z-45/25 DC • Z-45/25J DC

PS1 BRAKE
PS1 PRESSURE
SWITCH
RD/BK-R6
TS15

TB36

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

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

STEER RIGHT
C1P-11
C25-1 C25-2
DP1

C6B-38 GR/WH
C

OR/BK-R6

CR5
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

10
1

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH
C40LS OR

DRIVE
LIFT

D59
D76

D60
FWD
REV

STEER
L R
20K
D

33W
TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

AUXILIARY

D69

PR2
PUMP

PR2
30

87

OR/RD C6B-19
PRIMARY PUMP
OPTION

GR/WH
CONTACTOR COIL
BCI
September 2015

BK

Part No. 107939

E
F
+

D4
OR/RD

CR3
86

85
E

OR/RD RD RD
DISCHARGE

SET TO “N”

AUXILIARY PUMP
1

33W
TB27

CONTACTOR COIL
TS51

AUXILIARY

CR20
2

PR3

OR
PUMP
5 3

PR3
BCI

CR3

OR/RD
4

C6B-27 AUXILIARY PUMP

LVI

OR/BK
CONTACTOR RELAY
4

RD
TB19

87
SET TO “B”
6

30

CR20
RESET

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

WH
86

85

GR/WH PRIMARY PUMP

7

CONTACTOR RELAY
D73

D74

TB6

87a
8

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

85 BRN
LVI/BCI OPTION

BK

BK/RD

FLOW CONTROL
D71
CR19A

BRN
F

GR/WH
RD

D72
D28
86

PLATFORM ROTATE
TB18
BP1

C23-1 C23-2 RIGHT

DOWN C6B-18 GR/BK
CONTROL
86 CR19B

(JIB DOWN - OPT.)

ROTARY

FLOW

C6B-17 GR
OEM

PLATFORM ROTATE
BOOM

TS58

UP
TB17

C22-1 C22-2 LEFT

85

JIB

(JIB UP - OPTION)
TB44

C2P-6 C44JDA GR/BK C2B-6 C44DA BK

BOOM

D27

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

JIB
G

C4P-5 C17PRL GR
TS8

UP
D82

RIGHT
PLATFORM
JIB MANIFOLD

ROTATE
87A

C129DA BK
TS57

LEFT
85 CR7
30

D82
86
PLATFORM

WH BK
ROTATE

D80

RIGHT
H

GR/WH
TS7

LEFT
C2P-7 C45JSV GR/WH C2B-7
TB14

C20-1 C20-2
D81

UP C6B-14 OR PLATFORM
PLATFORM

LEVEL UP
C6B-15 OR/BK PLATFORM
LEVEL

TS59

DOWN LEVEL DOWN

TB15
C21-1 C21-2
PLATFORM
I

LEVEL

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

DOWN

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

TS63 C6B-8 BK/WH PRIMARY BOOM

BOOM
RETRACT RETRACT

TB8
C17-1 C18-2
PRIMARY
J

BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY
BOOM UP

PRIMARY
C6B-2 RD/BK PRIMARY

TS61
BOOM
DOWN BOOM DOWN

TB2
C13-1 C13-2
CR19A
PRIMARY
BOOM

UP C3P-1 C1PBU RD C3B-1

30

87
K

C3P-2 C2PBD RD/BK C3B-2

TB10
TS11

DOWN C18-1 C18-2

UP SECONDARY

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

TS60
BOOM
DOWN BOOM DOWN
SECONDARY

TB11
C19-1 C19-2
CR19B

D29

D30

D50
DESCENT ALARM
BOOM

C44DA C6B-33

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87
30

C3P-11 C11SBD BL/BK C3B-11

TS10

TB5
DOWN
L

C15-1 C15-2
RIGHT C6B-5 WH/BK TURNTABLE

TURNTABLE
ROTATE RIGHT

ROTATE
C6B-4 WH TURNTABLE

TS62
LEFT ROTATE LEFT

TB4
C14-1 C14-2
TURNTABLE
ROTATE

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

TS12
LEFT
M

P24BAT WH

TS55 FUNCTION
ENABLE
C31REV WH/BK

C12DRE BL/WH
C29JSH RD/WH

C32JSL WH/RD

P42BAT OR/RD
C30FWD WH

C40LS OR

(GND)
CR5

PR3
PR2
WH

RD

BK
N
September 2015 Section 6 • Schematics

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

(before serial number 31015)

6 - 17 6 - 18
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, CE (before serial number 31015)

6 - 19 6 - 20
 8
7
6
5
4
3
2
1

6 - 20
U33

C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB) BRN GND
P20BAT RD GR/BK H6

BL/WH C1-12
D C B A
Section 6 • Schematics

C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
C3B-4 C4TRL WH WH-TS62
B

4 TURNTABLE ROTATE LEFT 4

RD C32-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C32-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
(before serial number 31015)

C3B-10 C10SBU BL BL-TS60

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK D50 BK ALARM
C

C3B-11 C11SBD BL/BK BL/BK-TS60

11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR

Z-45/25 DC • Z-45/25J DC
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM

18 PLATFORM ROTATE RIGHT/JIB DOWN 18

C6B-38 C19LPE GR/WH D76 GR/WH
D

D74
C4B-7 C19LPE GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
E

33 33

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
D59
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37

Part No. 107939

September 2015

C6B-24 C40LS OR
C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
F

C2B-4 R42BAT OR/RD OR/RD-LED

42 SWITCH 48 VOLTS 42
D29 BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C134PWR RD RD H6
C2B-5 P134BAT RD RD KS1
134 KEYSWEITCH POWER 134

L37
BK C6B-25
OR/RD-42A OR/RD
C2B-7 C45JSV GR/WH GR/WH
G

BRN-HM BRN
GROUND
OR/RD
CONTROL
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE

GROUND BK HARNESS

BRN
STUD TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C6B-27 R27AUX
C30FWD WH

C4B
C28TTA RD/BK

C6B-19 R19LPE GR/WH

C32JSL WH/RD
C29JSH RD/WH

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

BROWN
C6B-35 R48BRK RD/WH
H

C6B-3 P42BAT OR/RD

RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B
C3B-3 C3BAT RD/WH
GREEN
RD/WH OR/RD

BRN BRN
C2B

CR1 CR2 CR3 CR20

BLACK
I

30 30 30 30
BRN

87A 87A 87A 87A

86 85 86 85 86 85 86 85
87 87 87 87
C1B
GRAY
BRN

OR/RD OR/RD GR/WH

C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

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

BRN 87 87
BRN 85 86 85 86
87A 87A
BK
30
30
ES0274G (JIB MODELS)

D85
CR4 CR5
K

ES0273G (NON-JIB MODELS)

L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE
(before serial number 31015)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A D80

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

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK

RD
BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
CR20 PRIMARY LIFT PUMP RELAY RD-1A D28
G6 HOUR METER
H6 PLATFORM OVERLOAD ALARM GR/BK-44A 3

TS59
TS61
KS1 KEY SWITCH

TS58
WH

RD

RD
L37 LED - DRIVE CONTROLLER FAULT STATUS
L45 LED - PLATFORM OVERLOAD
RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH BK
TS55 FUNCTION ENABLE TOGGLE SWITCH
RD C23-6

RD
BK
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD 4
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
BK-22A
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH P20BAT RD (C7B-4)
TS62 TURNTABLE ROTATE TOGGLE SWITCH

RD
BL-10A
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
+

KS1
U33 LOAD SENSE MODULE

L45
BL/BK-11A

CB1
-
NOTE: DASHED LINES INDICATE OPTIONS. GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

RD
D2
GR/BK H6

WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

G6
ES0273G (NON-JIB MODELS)
ES0274G (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 21

September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, CE (before serial number 31015)

6 - 21 6 - 22
 September 2015 Section 6 • Schematics

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

(before serial number 31015)
N M L K J I H G F E D C B A

CR8
BRN-RELAY

BRN-RELAY
2

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

P24BAT WH
RD/BK-R6

RD-J7

RD-J7
CR6 CR7

RD-P2

RD-H1

BK LS CABLE C1P-12
RD LS18

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK
C40LS OR
R41DRE OR/BK
R42BAT OR/RD
C44JDA GR/BK
C45JSV GR/WH

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

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPMP GR/WH

P22BAT BK
P23SWBAT WH
BRN-BATGND

P26BAT BK
P24BAT WH
P25BAT RD

BK-JIBGND
GR/WH-45
GR/WH-45
C16DRE OR/RD
GR/BK L4

BRN-J1
BRN-BATGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11
C2P-3
C2P-3
C2P-4
C2P-6
C2P-7

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

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

C7P-1
C7P-2
C7P-3

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

BK

WH
C2P-6 C133PLA GR/BK

RD
C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

JIB
C7P C9P LS18 OPTION
(OPT.)

12V DC FOOT
D39
BATTERY SWITCH
18/19 CONTROL CABLE
H1 5
NOTES:
DASHED LINES INDICATE OPTIONS.

DP1
GR-LFC
COMPONENT INDEX
20k GR 1 C29JSH RD/WH A1 TILT ALARM
GR BP1 BCI BATTERY CHARGE INDICATOR (OPTION)
RD
OR 2 C32JSL WH/RD
BP1 ROTARY FLOW CONTROL DIAL
6
WH C30FWD WH
BK/RD 3
FWD CR6 RELAY - DRIVE ENABLE
TS10 TS13 BK 4
C31REV WH/BK
TS12 OR/BK-R6 CR7 RELAY - JIB (OPTION)
D73 REV

D71
RD RD-DRE
5 P24BAT WH CR8 RELAY - LIMIT SWITCH
WH/GR
- BCI + YL 6 C12DRE BL/WH
DP1 JOYSTICK - DRIVE / STEER
RD-RPM
LIFT PRPL RD-J7 H1 TITL ALARM
7 RD-SW
TS11
DRIVE
BL 8
RD/BK-R6 L1 LED - DRIVE ENABLE
BK/WH-DRE
L4 LED - PLATFORM OVERLOAD
R42BAT OR/RD
BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPMP GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT

WH/RD
9
C36STCC BL
LS18 PLATFORM OVERLOAD LIMIT SWITCH 7
LEFT 10
P2 EMERGENCY STOP BUTTON

P26FS BK C9P-1

P22BAT BK C7P-1

P23SWBAT WH C7P-2

C3BAT RD/WH C3-3

P3 HORN BUTTON
TS1 AUXILIARY PUMP TOGGLE SWITCH

RD-LS18
GR/BK-H1 (D39)
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C44JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)
TS9 PLATFORM LEVEL TOGGLE SWITCH
D69 TS10 SECONDARY BOOM TOGGLE SWITCH
TS9
TS15 TS7 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH 8
3

2
4

NC NC NC

1
NO
D27

TS12 TURNTABLE ROTATE TOGGLE SWITCH

1
D81

2
P3
RD TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
L4
TS1 TS8
D82 P2 TS15 DRIVE ENABLE TOGGLE SWITCH

ES0273G (NON-JIB MODELS)

L1 ES0274G (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 23

September 2015 Section 6 • Schematics

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

CE (before serial number 31015)

6 - 23 6 - 24
 Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (from serial number 31015 to 39313)

6 - 25 6 - 26
Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (from serial number 31015 to 39313)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK

FS1
P2 RD-(FS) C9P-3
TB134 BK C7P-1 P26BAT C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH

P22BAT
RD
R42BAT OR/RD
C132PLI BL/WH RD
C1P-12
+ WORK DRIVE

RD
2 P3
H1
TILT
ALARM L48
LIGHTS
TS49
LIGHTS
TS48

C1B-12

C7B-1
HORN
P1 PLATFORM
10A
P20BAT RD TB22
CB1 KS1
GROUND 30 86

C3P-9

C2P-5
C1P-2
C1P-4

C1P-5

C1P-6

C1P-3

C7P-2
C3P-3

C2P-4
C2P-1
1 3

C2P-2
CR45

C2P-11

C2P-12
P22LS BK
4 5
87 85
C32

C9HRN BK/RD

P23BAT WH
P134PWR GR

C3BAT RD/WH
C40LS OR

C133PLA BL/RD
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

C28TTA RD/BK

R42BAT OR/RD

BK (16/2)

WH (16/2)

WH (16/2)

WH (16/2)
6 7
P20BAT RD

3 12 8

L30 L30

BK

BK
C2B-11

C2B-12
C7B-2
C3B-3
C2B-1

C3B-9

C2B-5
C1B-2

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK

P134PWR RD
C7B-4

C6B-30

C6B-31

C6B-32

C6B-29

WH
OR OR
CR5
TB40
4 P42BAT OR/RD C6B-3
C12DRE BL/WH
P42BAT OR/RD
C6B-22 R42BAT OR/RD RD
TB42
F5
RD/WH

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

WH

WH/BK

WH/RD

F4

BK/RD
10A
C6B-12

C6B-24

AP2 500A

C6B-20 RD
C6B-40 OR

48V 86 30 48V
CR2
PR1 86 F18
+48 V TB23 (AP2)

OR/RD
85 87 7A
_ BK D2

RD/BK
+
C30FWD

C31REV

C32JSL

C29JSH

C12FTS BL/WH INTERLOCK

C40LS

COIL-PR1

CR5

F2 85 L37
200A 86 30
+ _ CR1
C10-3
C10-4

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

5 30 86
OFF-LMT SPD INP

C6B-28
C6B-34
RD 20

LEFT 85 87
C6B-25 CFIL BK

D79 CR23
DIODE RETURN

BRN
BRN
BOX
C179DPR GR

+ _
BK
BK-4
WH-4

BK-5
WH-5
+48V INPUT

87 85
FORWARD

POT. LOW
REVERSE

POT. HI

21
+ _ LS4 + C12DRE BL/WH
(SEC) HM
22 _
1 9 10 11 14 16 2 3 17 20 5
AP2

WH (16/2)

WH (16/2)
30 86
U6A
CR4

RD/WH
RD/BK
RD
CURTIS 1244
24 V
SEPEX CONTROLLER
BK-5

WH-5

87 85
F1 BK
6 AP1 F1 M- B+ F2 B-

C8-C
C8-A
200A
+24 V PR3 PR2
+ _
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+ L29 L29
FB
_
WH-6
BK-7
WH-7

BK-6

BK

BK
WH

BK 2 GA

LEFT A2 A2 F2 F1
BRN

MOTOR
RIGHT RIGHT
BOX + _ F2 F1 A1 A1 MOTOR 21 13
+
CHARGER

LS2 LS1
PUMP PUMP 1
(PRI) (EXT)
_ 22 14

BK
+ _
+
7 C8-B
BK

H2
GROUND

BRN
AC POWER

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3

(OPTION)
DRIVE LIGHTS
HORN

HORN RELAY

(OPTION)
BEACON
FLASHING
CONTACTOR COIL
CONTROLLER
PR1 SEPEX

HOUR METER
LIFT PUMP
PRIMARY

RELEASE COIL
CR5 BRAKE

POWER RELAY
CR1 48V DC

POWER RELAY
CR2 48V DC

(OPTION)
WORK LIGHTS
LIFT PUMP
AUXILIARY

TILT SENSOR
GROUND
CHASSIS

BOX GROUND
BASE CONTROL

8
ES0273K (NON-JIB MODELS)
ES0274L (JIB MODELS)
NOTES:
JIB TIME DELAY (C1 AND CR14) ADDED AT
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED. 3
SERIAL NUMBER 34515 OR WAS FEILD INSTALLED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC SXCEPT WHERE NOTED. 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6 - 26 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

ANSI • CSA • AS (from serial number 31015 to 39313)

6 - 27
Electrical Schematic, Z-45/25 and Z-45/25J,

ENABLE

2
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

22

21

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
TB12
D78

DRIVE ENABLE
LS3

C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8 LIMIT SWITCH
13

14
A

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

86

85

BRN
CR6

RD/WH
H3

TRAVEL ALARM
+
4

D85
CR5

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

87

30

87
RD/BK-R6

ENABLE

PS1 BRAKE
B

PS1 PRESSURE
Z-45/25 DC • Z-45/25J DC

SWITCH
TS15

TB36

C24-1 C24-2
C36SCC BL C1B-10 C6B-36 BL
RD STEER LEFT
C1P-10
TB37

C37SCW BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT
C1P-11
C25-1 C25-2
C6B-38 GR/WH
DP1
OR/BK-R6
C

CR5
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

10
1

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
LIFT

STEER

D76

D59

D60
REV
FWD

R
20K

L
D69

33W
D

TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

AUXILIARY

PR2
PUMP

30

87

OR/RD C6B-19 PR2

PRIMARY PUMP
OPTION

GR/WH
CONTACTOR COIL
BCI
E
F
September 2015

Part No. 107939

D4

86

85

OR/RD CR3
RD RD
AUXILIARY PUMP
CR20
BRN

33W
AUXILIARY

TB27

CONTACTOR COIL
BRN
E

TS51

BK
LVI/BCI OPTION

PR3
PUMP
WH/RD

PR3
CR3

C6B-27 AUXILIARY PUMP

5 6 7 8
1 2 3 4

RD CONTACTOR RELAY
D73

87
TB19

WH
30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH CR20

85
86

GR/WH PRIMARY PUMP

CONTACTOR RELAY
D74

TB6

87a

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

CR19A

BK/RD

FLOW CONTROL
BK

BP1 D71

GR/WH
GR
RD

D72
D28

TB18

WH
F

PLATFORM ROTATE
C23-1 C23-2
DOWN RIGHT
CR19B

C6B-18 GR/BK
85

CONTROL
86

ROTARY

(JIB DOWN - OPTION)

FLOW

C6B-17 GR
OEM

BOOM

PLATFORM ROTATE
TS58

TB17

UP LEFT
JIB

C22-1 C22-2
85
86

(JIB UP - OPTION)
TB44

C2P-6 C44JDA GR/BK C2B-6

BOOM

D27

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

JIB

C4P-5 C17PRL GR C4B-5 GR

TS8

UP
G

D82

RIGHT
PLATFORM
ROTATE
87a

TS57

LEFT
CR7
30

D82
86

85

BK
85
86
PLATFORM
ROTATE

D80
GR/WH

RIGHT
OR/RD

GR/WH

RD BR
+
_
H

TS7

LEFT
C2B-7
C1

GR/WH
3

BRN
GR/WH

CR14

TB14
D81

C20-1 C20-2 PLATFORM

WH BK UP C6B-14 OR
PLATFORM

LEVEL UP
30

87A

JIB
RD

C6B-15 OR/BK
LEVEL

PLATFORM
TS59

MANIFOLD
3

TB15

DOWN LEVEL DOWN

C21-1 C21-2
PLATFORM

C2P-7 C45JSV GR/WH

LEVEL
I

UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TS9

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

C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63

TB8
RETRACT RETRACT
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

J

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY
BOOM UP

PRIMARY
C6B-2 RD/BK

BOOM
PRIMARY

TS61

TB2
DOWN BOOM DOWN
C13-1 C13-2
CR19A
PRIMARY

BOOM
BOOM

UP C3P-1 C1PBU RD C3B-1

87A
30

C3P-2 C2PBD RD/BK C3B-2

TB10
TS11

DOWN C18-1 C18-2

SECONDARY
K

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

BOOM

TS60

TB11
SECONDARY

DOWN BOOM DOWN

C19-1 C19-2
CR19B

D29

D30

D50
BOOM

C44DA BK C44DA DESCENT ALARM

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87A
30

C3P-11 C11SBD BL/BK C3B-11

TS10

DOWN

TB5
C15-1 C15-2
TURNTABLE

TURNTABLE
RIGHT C6B-5 WH/BK
ROTATE RIGHT
L

ROTATE
C6B-4 WH TURNTABLE

TS62

TB4
LEFT ROTATE LEFT
TURNTABLE

C14-1 C14-2
ROTATE

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

TS12 LEFT
P24BAT WH

FUNCTION
ENABLE
M

C31REV WH/BK
C29JSH RD/WH

C12DRE BL/WH
C32JSL WH/RD

P42BAT OR/RD
P134PWR RD
C30FWD WH

TS55

(GND)
CR5

PR2
PR3
WH

RD

BK
N
September 2015 Section 6 • Schematics

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (from serial number 31015 to 39313)

6 - 27 6 - 28
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(from serial number 31015 to 39313)

6 - 29 6 - 30
 8
7
6
5
4
3
2
1

6 - 30
C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)
BRN GND
GR/BK H6
P20BAT RD

BL/WH C1-12
Section 6 • Schematics

D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
B

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
C6B-5 C5TRR WH/BK
C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
C3B-8 C8PBR BK/WH BK/WH-TS63
8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
C

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK D50 BK ALARM
C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59

Z-45/25 DC • Z-45/25J DC
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLAT. ROTATE LEFT-(JIB UP-OPT) 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
D

18 PLAT. ROTATE RIGHT-(JIB DOWN-OPT) 18

C6B-38 C19LPE GR/WH D76 GR/WH
D74
C4B-7 C19LPE GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

BK-ALARM

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
E
ANSI • CSA • AS (from serial number 31015 to 39313)

33 33

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK

Part No. 107939

September 2015

D59
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F

40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
D29 BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 (JIB - OPTION) DESCENT ALARM 44
C6B-34 C134PWR RD RD H6
C2B-5 P134BAT RD RD KS1
134 KEYSWEITCH POWER 134

L37
BK C6B-25
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,

OR/RD-42A OR/RD
G

C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
OR/RD GROUND
GROUND CONTROL
BK
HARNESS

BRN
STUD TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C4B C6B-27 R27AUX

C30FWD WH
C28TTA RD/BK

BROWN C6B-19 R19LPE GR/WH

H

C32JSL WH/RD
C29JSH RD/WH

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

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B
GREEN C3B-3 C3BAT RD/WH

RD/WH OR/RD

BRN BRN
C2B
I

BLACK CR1 CR3 CR20

CR2
30 30 30 30
BRN

87A 87A 87A 87A

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

86 85 86 85 86 85
C1B 87 87 87 87
GRAY
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

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

BRN 87 87
BRN 85 86 85 86
87A 87A
BK
30
30
ES0274L (JIB MODELS)

D85
K

CR4 CR5
ES0273K (NON-JIB MODELS)
L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (from serial number 31015 to 39313)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)
BK-7A GR/BK-18A D80
BK 1
BK/WH-8A GR-17A

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V

RD
BK
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
RD-1A D28
CR20 PRIMARY LIFT PUMP RELAY
G6 HOUR METER
KS1 KEY SWITCH GR/BK-44A 3

TS59
TS61
L37 LED, DRIVE CONTROLLER FAULT STATUS

TS58
WH

RD

RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH RD
TS55 FUNCTION ENABLE TOGGLE SWITCH
TS57 PLATFORM ROTATE TOGGLE SWITCH BK
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD C23-6

RD
BK
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH RD 4
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH BK-22A
TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH P20BAT RD (C7B-4)

BL-10A
NOTE: DASHED LINES INDICATE OPTIONS.

KS1
BL/BK-11A

CB1
GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

D2

RD
WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

ES0273K (NON-JIB MODELS)
ES0274L (JIB MODELS)

G6
Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 31
September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(from serial number 31015 to 39313)

6 - 31 6 - 32
 September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (from serial number 31015 to 39313)
N M L K J I H G F E D C B A

1
GR/WH +

GR/WH - 45

R45JSV GR/WH
RD OUTPUT

BRN -
C1
CR14 P134PWR RD
GR/WH

BRN-RELAY 2

C45JSV GR/WH

GR/WH - 45

P134PWR RD
GR/WH-R7
OR/RD
OR/BK-R6
OR/BK

RD/BK-R6

RD-J7
CR6 CR7

BR-JIBGND
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK

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

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

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPE GR/WH

P22BAT BK
P23BAT WH
BRN-BATGND

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

BRN-J1
BRN-BATGND
BRN-JIBGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11

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

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

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

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3

BK

WH
C1P-2

4
C28TTA RD/BK

C1P(GY)

C3P(GR)

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

12V DC FOOT
D40
BATTERY SWITCH
18/19 CONTROL CABLE
A1
NOTES: 5
1. DASHED LINES INDICATE OPTIONS.

2. JIB TIME DELAY (C1 AND CR14) ADDED AT

SERIAL NUMBER 34515 OR WAS FEILD INSTALLED.

DP1
GR-LFC COMPONENT INDEX
GR 1 C29JSH RD/WH A1 TILT ALARM
GR BP1 20k OR 2 C32JSL WH/RD BCI BATTERY CHARGE INDICATOR (OPTION) 6
RD
WH C30FWD WH BP1 ROTARY FLOW CONTROL DIAL
BK/RD 3
FWD C1 CAPACITOR, TIME DELAY (JIB OPTION)
TS10 TS13 BK 4
C31REV WH/BK
TS12 OR/BK-R6
D73 REV CR6 RELAY - DRIVE ENABLE

D71
RD RD-DRE
5
WH/GR P24BAT WH CR7 RELAY - JIB (OPTION)
- BCI + YL 6 C12DRE BL/WH
CR14 RELAY - JIB (OPTION)
RD-RPM
PRPL RD-J7
LIFT
7 RD-SW DP1 JOYSTICK - DRIVE / STEER
TS11
BL 8
RD/BK-R6 H1 TITL ALARM
DRIVE
BK/WH-DRE
7
R42BAT OR/RD

L1 LED - DRIVE ENABLE

BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPE GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT 9
WH/RD C36STCC BL L48 LED - TILT ALARM
LEFT 10
P2 EMERGENCY STOP BUTTON

P26FS BK C9P-1

P22BAT BK C7P-1

P23BAT WH C7P-2

C3BAT RD/WH C3-3

P3 HORN BUTTON
TS1 AUXILIARY PUMP TOGGLE SWITCH

RD-HRN
RD/BK H1
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C44JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)
TS9 PLATFORM LEVEL TOGGLE SWITCH

P3
D69
TS9 TS10 SECONDARY BOOM TOGGLE SWITCH 8
TS15 TS7 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
3

2
4

NC NC NC

1
NO
D27

TS12 TURNTABLE ROTATE TOGGLE SWITCH

1
D81

2
P3
RD TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
L48
TS1 TS8
D82 P2 TS15 DRIVE ENABLE TOGGLE SWITCH

L1 ES0273K (NON-JIB MODELS)

ES0274L (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 33

September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (from serial number 31015 to 39313)

6 - 33 6 - 34
 Section 6 • Schematics September 2015

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

(from serial number 31015 to 39313)

6 - 35 6 - 36
Section 6 • Schematics September 2015

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

(from serial number 31015 to 39313)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
TB134 BK C7P-1 P26BAT C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH

P22BAT
RD
R42BAT OR/RD
C132PLI BL/WH C1P-12 RD 3
+ WORK DRIVE

RD
2 LS18
P3 L4 H1
TILT
ALARM L48
LIGHTS
TS49
LIGHTS
TS48

C1B-12

C7B-1
HORN
P1 PLATFORM
10A
P20BAT RD TB22 D39 2 D40
CB1 KS1
GROUND 30 86

C2P-1

C3P-9

C2P-5
C1P-2
C2P-2
C1P-4

C1P-5

C1P-6

C1P-3

C7P-2
C3P-3

C2P-4
1 3 CR45

C2P-11

C2P-12
C32

P22LS BK
4 5
87 85

C9HRN BK/RD

P23BAT WH
P134PWR GR

C3BAT RD/WH
C40LS OR

C133PLA BL/RD
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

C28TTA RD/BK

R42BAT OR/RD

BK (16/2)

WH (16/2)

WH (16/2)

WH (16/2)
6 U33 7
P20BAT RD

3 12 8

L30 L30

BK

BK
L45

C2B-11

C2B-12
C7B-2
C3B-3
C2B-1

C3B-9

C2B-5
C1B-2
H6

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK

P134PWR RD
C7B-4

C6B-30

C6B-31

C6B-32

C6B-29

WH
OR OR
CR5
TB40
4 P42BAT OR/RD C6B-3
C12DRE BL/WH
P42BAT OR/RD
C6B-22 R42BAT OR/RD RD
TB42
F5
RD/WH

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

WH

WH/BK

WH/RD

F4

BK/RD
10A
C6B-12

C6B-24

AP2 500A

C6B-20 RD
C6B-40 OR

48V 86 30 48V
CR2
PR1 86 F18
+48 V TB23 (AP2)

OR/RD
85 87 7A
_ BK D2

RD/BK
+
C30FWD

C31REV

C32JSL

C29JSH

C12FTS BL/WH INTERLOCK

C40LS

COIL-PR1

CR5

F2 85 L37
200A 86 30
+ _ CR1
C10-3
C10-4

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

5 30 86
OFF-LMT SPD INP

C6B-28
C6B-34
RD 20

LEFT 85 87
C6B-25 CFIL BK

D79 CR23
DIODE RETURN

BRN
BRN
BOX
C179DPR GR

+ _
BK
BK-4
WH-4

BK-5
WH-5
+48V INPUT

87 85
FORWARD

POT. LOW
REVERSE

POT. HI

21
+ _ LS4 + C12DRE BL/WH
(SEC) HM
22 _
1 9 10 11 14 16 2 3 17 20 5
AP2

WH (16/2)

WH (16/2)
30 86
U6A
CR4

RD/WH
RD/BK
RD
CURTIS 1244
24 V
SEPEX CONTROLLER
BK-5

WH-5

87 85
BK
6 AP1 F1
F1 M- B+ F2 B-

C8-C
C8-A
200A
+24 V PR3 PR2
+ _
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+ L29 L29
FB
_
WH-6
BK-7
WH-7

BK-6

BK

BK
WH

BK 2 GA

LEFT A2 A2 F2 F1
BRN

MOTOR
RIGHT RIGHT
1
BOX + _ F2 F1 A1 A1 MOTOR 21 13
+
CHARGER

LS2 LS1
PUMP PUMP (PRI) (EXT)
_ 22 14

BK
+ _
+
7
C8-B
BK

H2
GROUND

BRN
AC POWER

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3

(OPTION)
DRIVE LIGHTS
HORN

HORN RELAY

(OPTION)
BEACON
FLASHING
CONTACTOR COIL
CONTROLLER
PR1 SEPEX
LIFT PUMP
PRIMARY

RELEASE COIL
CR5 BRAKE

HOUR METER

POWER RELAY
CR1 48V DC

POWER RELAY
CR2 48V DC

(OPTION)
WORK LIGHTS
LIFT PUMP
AUXILIARY

TILT SENSOR
GROUND
CHASSIS

BOX GROUND
BASE CONTROL

8
NOTES: ES0273K (NON-JIB MODELS)
ES0274L (JIB MODELS)
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED. 3 L48 TILT ALARM LED. (OPTION)
2. ALL SOLENOID AND RELAY COILS ARE 24V DC SXCEPT WHERE NOTED.
2 ADD D40 ONLY IF UNIT HAS L4 AND L48. 4 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6 - 36 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

(from serial number 31015 to 39313)

6 - 37
Electrical Schematic, Z-45/25 and Z-45/25J, CE

ENABLE

4
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

22

21

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
TB12
D78

DRIVE ENABLE
LS3

C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8 LIMIT SWITCH
13

14
A

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

86

85

86

85

BRN
CR8

RD/WH
H3

TRAVEL ALARM
CR6

+
4

D85
CR5

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

87

30

87
RD/BK-R6
30

87

ENABLE

PS1 BRAKE
B

PS1 PRESSURE
Z-45/25 DC • Z-45/25J DC

SWITCH
TS15

TB36

C24-1 C24-2
C36SCC BL C1B-10 C6B-36 BL
RD STEER LEFT
C1P-10
TB37

C37SCW BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT
C1P-11
C25-1 C25-2
C6B-38 GR/WH
DP1
OR/BK-R6
C

CR5
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

10
1

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
LIFT
C40LS OR

STEER

D76

D59

D60
REV
FWD

R
20K

L
D69

33W
D

TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

AUXILIARY

PR2
PUMP

30

87

OR/RD C6B-19 PR2

PRIMARY PUMP
OPTION

GR/WH
CONTACTOR COIL
BCI
E
F
September 2015

Part No. 107939

D4

86

85

OR/RD CR3
RD RD
AUXILIARY PUMP
CR20
BRN

33W
AUXILIARY

TB27

CONTACTOR COIL
BRN
E

TS51

BK
LVI/BCI OPTION

PR3
PUMP
WH/RD

PR3
CR3

C6B-27 AUXILIARY PUMP

5 6 7 8
1 2 3 4

RD CONTACTOR RELAY
D73

87
TB19

WH
30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH CR20

85
86

GR/WH PRIMARY PUMP

CONTACTOR RELAY
D74

TB6

87a

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

CR19A

BK/RD

FLOW CONTROL
BK

BP1 D71

GR/WH
GR
RD

D72

PLATFORM ROTATE
D28

TB18
F

WH
C23-1 C23-2 RIGHT
DOWN
CR19B

C6B-18 GR/BK
CONTROL
85
86

(JIB DOWN - OPT.)

ROTARY

FLOW

C6B-17 GR
OEM

BOOM

PLATFORM ROTATE
TS58

TB17

UP LEFT
JIB

C22-1 C22-2
85
86

(JIB UP - OPTION)
TB44

C2P-6 C44JDA GR/BK C2B-6

BOOM

D27

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

JIB

C4P-5 C17PRL GR C4B-5 GR

TS8
G

UP
D82

RIGHT
PLATFORM
87a

ROTATE

TS57

LEFT
CR7
30

D82
86

85

BK
85
86
PLATFORM
ROTATE

D80
GR/WH

RIGHT
OR/RD

GR/WH

RD BR
+
_
H

TS7

LEFT
C2B-7
C1

GR/WH
BRN
GR/WH

CR14

TB14
D81

C20-1 C20-2 PLATFORM

WH BK UP C6B-14 OR
PLATFORM

LEVEL UP
30

87A

JIB
RD

C6B-15 OR/BK
LEVEL

MANIFOLD PLATFORM
TS59

TB15

DOWN LEVEL DOWN

C21-1 C21-2
PLATFORM

C2P-7 C45JSV GR/WH

LEVEL
I

UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TS9

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

C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63

TB8
RETRACT RETRACT
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

J

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY
BOOM UP

PRIMARY
C6B-2 RD/BK

BOOM
PRIMARY

TS61

TB2
DOWN BOOM DOWN
C13-1 C13-2
CR19A
PRIMARY

BOOM
BOOM

UP C3P-1 C1PBU RD C3B-1

87A
30

C3P-2 C2PBD RD/BK C3B-2

TB10
TS11

DOWN C18-1 C18-2

K

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

BOOM

TS60

TB11
SECONDARY

DOWN BOOM DOWN

C19-1 C19-2
CR19B

D29

D30

D50
BOOM

C44DA BK C44DA DESCENT ALARM

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87A
30

C3P-11 C11SBD BL/BK C3B-11

TS10

DOWN

TB5
C15-1 C15-2
TURNTABLE

TURNTABLE
RIGHT C6B-5 WH/BK
ROTATE RIGHT
L

ROTATE
C6B-4 WH TURNTABLE

TS62

TB4
LEFT ROTATE LEFT
TURNTABLE

C14-1 C14-2
ROTATE

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

TS12
LEFT
P24BAT WH

FUNCTION
ENABLE
M

C31REV WH/BK
C29JSH RD/WH

C12DRE BL/WH
C32JSL WH/RD

P42BAT OR/RD
P134PWR RD
C30FWD WH

C40LS OR

TS55

(GND)
CR5

PR2
PR3
WH

RD

BK
N
September 2015 Section 6 • Schematics

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

(from serial number 31015 to 39313)

6 - 37 6 - 38
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313)

6 - 39 6 - 40
 8
7
6
5
4
3
2
1

6 - 40
U33

C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB) BRN GND
P20BAT RD GR/BK H6

BL/WH C1-12
D C B A
Section 6 • Schematics

C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 BK-ALARM
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
C3B-4 C4TRL WH WH-TS62
B

4 TURNTABLE ROTATE LEFT 4

RD C32-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C32-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60

P20BAT RD C7B-4
10 SECONDARY BOOM UP 10
C6B-11 C11SBD BL/BK D50 BK ALARM
C

C3B-11 C11SBD BL/BK BL/BK-TS60

11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
(from serial number 31015 to 39313)

C6B-15 C15PLD OR/BK

C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR

Z-45/25 DC • Z-45/25J DC
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
BK-ALARM

18 PLATFORM ROTATE RIGHT/JIB DOWN 18

C6B-38 C19LPE GR/WH D76 GR/WH
D

D74
C4B-7 C19LPE GR/WH GR/WH-TS60
19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
E

33 33

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
D59
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37

Part No. 107939

September 2015

C6B-24 C40LS OR
C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
F

C2B-4 R42BAT OR/RD OR/RD-LED

42 SWITCH 48 VOLTS 42
D29 BK-ALARM
C2B-6 C44JDA GR/BK GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C134PWR RD RD H6
C2B-5 P134BAT RD RD KS1
134 KEYSWEITCH POWER 134

L37
BK C6B-25
OR/RD-42A OR/RD
C2B-7 C45JSV GR/WH GR/WH
G

BRN-HM BRN
GROUND
OR/RD
CONTROL
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J, CE

GROUND BK HARNESS

BRN
STUD TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C44DA BK

C6B-27 R27AUX
C30FWD WH

C4B
C28TTA RD/BK

C6B-19 R19LPE GR/WH

C32JSL WH/RD
C29JSH RD/WH

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

BROWN
C6B-35 R48BRK RD/WH
H

C6B-3 P42BAT OR/RD

RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B
C3B-3 C3BAT RD/WH
GREEN
RD/WH OR/RD

BRN BRN
C2B

CR1 CR2 CR3 CR20

BLACK
I

30 30 30 30
BRN

87A 87A 87A 87A

86 85 86 85 86 85 86 85
87 87 87 87
C1B
GRAY
BRN

OR/RD OR/RD GR/WH

C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

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

BRN 87 87
BRN 85 86 85 86
87A 87A
BK
30
30
ES0274L (JIB MODELS)

D85
CR4 CR5
K

ES0273K (NON-JIB MODELS)

L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A D80

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

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK

RD
BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
CR20 PRIMARY LIFT PUMP RELAY RD-1A D28
G6 HOUR METER
H6 PLATFORM OVERLOAD ALARM GR/BK-44A 3

TS59
TS61
KS1 KEY SWITCH

TS58
WH

RD

RD
L37 LED - DRIVE CONTROLLER FAULT STATUS
L45 LED - PLATFORM OVERLOAD
RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH BK
TS55 FUNCTION ENABLE TOGGLE SWITCH
RD C23-6

RD
BK
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD 4
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
BK-22A
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH P20BAT RD (C7B-4)
TS62 TURNTABLE ROTATE TOGGLE SWITCH

RD
BL-10A
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
+

KS1
U33 LOAD SENSE MODULE

L45
BL/BK-11A

CB1
-
NOTE: DASHED LINES INDICATE OPTIONS. GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

RD
D2
GR/BK H6

WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

G6
ES0273K (NON-JIB MODELS)
ES0274L (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 41

September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313)

6 - 41 6 - 42
 September 2015 Section 6 • Schematics

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

(from serial number 31015 to 39313)
N M L K J I H G F E D C B A

1
GR/WH + CR8

GR/WH - 45

R45JSV GR/WH
RD OUTPUT

BRN -
C1
CR14 P134PWR RD
GR/WH

BRN-RELAY 2

GR/WH-R7
OR/RD

C45JSV GR/WH

GR/WH - 45

P134PWR RD
RD
OR/BK-R6
OR/BK

RD/BK-R6

RD-J7

RD-J7

P24BAT WH
CR6 CR7
BRN-RELAY

BR-JIBGND

LS CABLE BK C1P-12
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK
C40LS OR
R41DRE OR/BK
R42BAT OR/RD
C44JDA GR/BK
C45JSV GR/WH

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

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPE GR/WH

P22BAT BK
P23BAT WH
BRN-BATGND

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

BRN-J1
BRN-BATGND
BRN-JIBGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11
C2P-2
C2P-3
C2P-4
C2P-6
C2P-7

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

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

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3

BK

WH

RD
C1P-2

4
C28TTA RD/BK

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

JIB
C7P C9P LS18 OPTION
(OPT.)

12V DC FOOT NOTES:

D40
BATTERY SWITCH 1. DASHED LINES INDICATE OPTIONS.
18/19 CONTROL CABLE
A1 2. JIB TIME DELAY (C1 AND CR14) ADDED AT
5
SERIAL NUMBER 34515 OR WAS FEILD INSTALLED.

COMPONENT INDEX
DP1 A1 TILT ALARM
GR-LFC BCI BATTERY CHARGE INDICATOR (OPTION)
GR 1 C29JSH RD/WH BP1 ROTARY FLOW CONTROL DIAL
GR BP1 20k OR 2 C32JSL WH/RD C1 CAPACITOR, TIME DELAY (JIB OPTION) 6
RD
WH C30FWD WH CR6 RELAY - DRIVE ENABLE
BK/RD 3
FWD CR7 RELAY - JIB (OPTION)
TS10 TS13 BK 4
C31REV WH/BK
TS12
D73 REV OR/BK-R6 CR8 RELAY - LIMIT SWITCH

D71
RD RD-DRE
5 P24BAT WH CR14 RELAY - JIB (OPTION)
WH/GR
- BCI + 6 C12DRE BL/WH
YL RD-RPM DP1 JOYSTICK - DRIVE / STEER
LIFT PRPL RD-J7
H1 TITL ALARM
7 RD-SW
TS11
BL 8
RD/BK-R6 L1 LED - DRIVE ENABLE
DRIVE
BK/WH-DRE
7
R42BAT OR/RD

L4 LED - PLATFORM OVERLOAD

BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPE GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT 9
WH/RD C36STCC BL LS18 PLATFORM OVERLOAD LIMIT SWITCH
LEFT 10
P2 EMERGENCY STOP BUTTON

P26FS BK C9P-1

P22BAT BK C7P-1

P23BAT WH C7P-2

C3BAT RD/WH C3-3

P3 HORN BUTTON
TS1 AUXILIARY PUMP TOGGLE SWITCH

RD-LS18
GR/BK-H1 (D39)
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C44JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)
TS9 PLATFORM LEVEL TOGGLE SWITCH
D69
TS9 TS10 SECONDARY BOOM TOGGLE SWITCH 8
TS15 TS7 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
3

2
4

NC NC NC

1
NO
D27

TS12 TURNTABLE ROTATE TOGGLE SWITCH

1
D81

2
P3
RD TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
L4
TS1 TS8
D82 P2 TS15 DRIVE ENABLE TOGGLE SWITCH

L1 ES0273K (NON-JIB MODELS)

ES0274L (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 43

September 2015 Section 6 • Schematics

Platform Control Box Wiring Diagram,

Z-45/25 and Z-45/25J, CE
(from serial number 31015 to 39313)

6 - 43 6 - 44
 Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (after serial number 39313)

6 - 45 6 - 46
Section 6 • Schematics September 2015

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (after serial number 39313)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK

FS1
P2 RD-(FS) C9P-3
TB134 BK C7P-1 P26BAT C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH

P22BAT
RD
R42BAT OR/RD
C132PLI BL/WH RD
C1P-12
+ WORK DRIVE

RD
2 P3
H1
TILT
ALARM L48
LIGHTS
TS49
LIGHTS
TS48

C1B-12

C7B-1
HORN
P1 PLATFORM
10A
P182BAT RD TB22 D40
CB1 KS1
GROUND 30 86

C3P-9

C2P-5
C1P-2
C1P-4

C1P-5

C1P-6

C1P-3

C7P-2
C3P-3

C2P-4
C2P-1
1 3

C2P-2
CR45

C2P-11

C2P-12
P22LS BK
4 5
87 85
C32
P182BAT RD

C9HRN BK/RD

P23BAT WH
P134PWR GR

C3BAT RD/WH
C40LS OR

C133PLA BL/RD
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

C28TTA RD/BK

R42BAT OR/RD

BK (16/2)

WH (16/2)

WH (16/2)

WH (16/2)
6 7

3 12 8

L30 L30

BK

BK
C2B-11

C2B-12
C7B-2
C3B-3
C2B-1

C3B-9

C2B-5
C1B-2

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
GR/BK

P134PWR RD
C7B-4

C6B-30

C6B-31

C6B-32

C6B-29

WH
OR OR
CR5
TB40
4 C12DRE BL/WH
P42BAT OR/RD C6B-3 P42BAT OR/RD
C6B-22 R42BAT OR/RD RD
TB42
F5
RD/WH

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

WH

WH/BK

WH/RD

F4

BK/RD
10A
C6B-12

C6B-24

AP2 500A

C6B-20 RD
C6B-40 OR

48V 86 30 48V
CR2
PR1 86 F18
+48 V TB23 (AP2)

OR/RD
85 87 7A
_ BK D2

RD/BK
+
C30FWD

C31REV

C32JSL

C29JSH

C12FTS BL/WH INTERLOCK

C40LS

COIL-PR1

CR5

F2 85 L37
200A 86 30
+ _ CR1
C10-3
C10-4

C10-1
C10-2

5
C6B-39 CR5 RD/BK

30 86
OFF-LMT SPD INP

C6B-28
C6B-34
RD 20

LEFT 85 87
C6B-25 CFIL BK

D79 CR23
DIODE RETURN

BRN
BRN
BOX
C179DPR GR

+ _
BK
BK-4
WH-4

BK-5
WH-5
+48V INPUT

87 85
FORWARD

POT. LOW
REVERSE

POT. HI

21
+ _ LS4 + C12DRE BL/WH
(SEC) HM
22 _
1 9 10 11 14 16 2 3 17 20 5
AP2

WH (16/2)

WH (16/2)
30 86
U6A
CR4

RD/WH
RD/BK
RD
CURTIS 1244
24 V
SEPEX CONTROLLER
BK-5

WH-5

87 85
BK
6 AP1 F1
F1 M- B+ F2 B-

C8-C
C8-A
200A
+24 V PR3 PR2
+ _
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+ L29 L29
FB
_
WH-6
BK-7
WH-7

BK-6

BK

BK
WH

BK 2 GA

LEFT A2 A2 F2 F1
BRN

MOTOR
RIGHT RIGHT
BOX + _ F2 F1 A1 A1 MOTOR 21 13
+
CHARGER

LS2 LS1
PUMP PUMP 1
(PRI) (EXT)
_ 22 14

BK
+ _
+
7 C8-B
BK

H2
GROUND

BRN
AC POWER

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3

(OPTION)
DRIVE LIGHTS
HORN

HORN RELAY

(OPTION)
BEACON
FLASHING
CONTACTOR COIL
CONTROLLER
PR1 SEPEX

HOUR METER
LIFT PUMP
PRIMARY

RELEASE COIL
CR5 BRAKE

POWER RELAY
CR1 48V DC

POWER RELAY
CR2 48V DC

(OPTION)
WORK LIGHTS
LIFT PUMP
AUXILIARY

TILT SENSOR
GROUND
CHASSIS

BOX GROUND
BASE CONTROL

8
ES0273 (NON-JIB MODELS)
ES0274M (JIB MODELS)
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED.
2. ALL SOLENOID AND RELAY COILS ARE 24V DC SXCEPT WHERE NOTED. 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6 - 46 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

6 - 47
ANSI • CSA • AS (after serial number 39313)
Electrical Schematic, Z-45/25 and Z-45/25J,

ENABLE

2
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

22

21

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
TB12
D78

DRIVE ENABLE
LS3

C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8 LIMIT SWITCH
13

14
A

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

86

85

BRN
CR6

RD/WH
H3

TRAVEL ALARM
+
2

D85
CR5

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

87

30

87
RD/BK-R6

ENABLE

PS1 BRAKE
B

PS1 PRESSURE
Z-45/25 DC • Z-45/25J DC

SWITCH
TS15

TB36

C24-1 C24-2
C36SCC BL C1B-10 C6B-36 BL
RD STEER LEFT
C1P-10
TB37

C37SCW BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT
C1P-11
C25-1 C25-2
C6B-38 GR/WH
DP1
OR/BK-R6
C

CR5
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

10
1

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
LIFT

STEER

D76

D59

D60
REV
FWD

R
20K

L
D69

33W
TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

D

AUXILIARY

PR2
PUMP

30

87

OR/RD C6B-19 PR2

PRIMARY PUMP
OPTION

GR/WH
CONTACTOR COIL
BCI
E
F
+

D4

86

85

CR3
September 2015

OR/RD RD
Part No. 107939

RD
AUXILIARY PUMP
BRN

33W
AUXILIARY

TB27

CONTACTOR COIL
BRN

TS51

BK
CR20
LVI/BCI OPTION

PR3
PUMP
E

WH/RD

PR3
CR3

C6B-27 AUXILIARY PUMP

5 6 7 8
1 2 3 4

RD CONTACTOR RELAY
D73

87
TB19

WH
30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH CR20

85
86

GR/WH PRIMARY PUMP

CONTACTOR RELAY
D74

TB6

87a

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

CR19A

BK/RD

FLOW CONTROL
BK

BP1 D71

GR/WH
GR
RD

D72
D28

TB18

WH PLATFORM ROTATE
C23-1 C23-2
DOWN RIGHT
CR19B

C6B-18 GR/BK
CONTROL
85
86
F

ROTARY

(JIB DOWN - OPTION)

FLOW

C6B-17 GR
OEM

BOOM

PLATFORM ROTATE
TS58

TB17

UP LEFT
JIB

C22-1 C22-2
85
86

(JIB UP - OPTION)
TB44

C2P-6 C129DA GR/BK C2B-6

BOOM

D27

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

JIB

C4P-5 C17PRL GR C4B-5 GR

TS8

UP
D82

RIGHT
PLATFORM
G

ROTATE
87a

TS57

LEFT
CR7

C129DA BK
30

D82
86

85
85
86
PLATFORM
ROTATE

D80
GR/WH

RIGHT
OR/RD

GR/WH

RD BR
+
_
TS7

LEFT
C2B-7
H

C1

GR/WH
BRN
GR/WH

CR14

TB14
D81

C20-1 C20-2 PLATFORM

WH BK UP C6B-14 OR
PLATFORM

LEVEL UP
30

87A

JIB
RD

C6B-15 OR/BK
LEVEL

PLATFORM
TS59

MANIFOLD
TB15

DOWN LEVEL DOWN

C21-1 C21-2
PLATFORM

C2P-7 C45JSV GR/WH

LEVEL

UP C4P-2 C14PLU OR C4B-2

I

C4P-3 C15PLD OR/BK C4B-3

TS9

DOWN TB7 C16-1 C16-2

EXTEND C6B-7 BK PRIMARY BOOM
EXTEND
PRIMARY

C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63

TB8
RETRACT RETRACT
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2

J

UP C6B-1 RD PRIMARY
BOOM UP
PRIMARY
C6B-2 RD/BK

BOOM
PRIMARY

TS61

TB2
DOWN BOOM DOWN
C13-1 C13-2
CR19A
PRIMARY

BOOM
BOOM

UP C3P-1 C1PBU RD C3B-1

87A
30

C3P-2 C2PBD RD/BK C3B-2

TB10
TS11

DOWN C18-1 C18-2

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

BOOM
K

TS60

TB11
SECONDARY

DOWN BOOM DOWN

C19-1 C19-2
CR19B

D29

D30

D50
C6B-33
BOOM

C129DA BK DESCENT ALARM

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87A
30

C3P-11 C11SBD BL/BK C3B-11

TS10

DOWN

TB5
C15-1 C15-2
TURNTABLE

TURNTABLE
RIGHT C6B-5 WH/BK
ROTATE RIGHT

ROTATE
C6B-4 WH TURNTABLE

TS62

TB4
LEFT ROTATE LEFT
TURNTABLE

C14-1 C14-2
L

ROTATE

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

TS12

LEFT
P24BAT WH

FUNCTION
ENABLE
C31REV WH/BK
C29JSH RD/WH

C12DRE BL/WH
C32JSL WH/RD

P42BAT OR/RD
P134PWR RD
C30FWD WH
M

TS55

(GND)
CR5

PR2
PR3
WH

RD

BK
N
September 2015 Section 6 • Schematics

Electrical Schematic, Z-45/25 and Z-45/25J,

ANSI • CSA • AS (after serial number 39313)

6 - 47 6 - 48
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(after serial number 39313)

6 - 49 6 - 50
 8
7
6
5
4
3
2
1

6 - 50
C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB)
BRN GND
GR/BK H6
P182BAT RD

BL/WH C1-12
Section 6 • Schematics

D C B A
C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 C129DA RD/BK
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
B

C3B-4 C4TRL WH WH-TS62

4 TURNTABLE ROTATE LEFT 4
C6B-5 C5TRR WH/BK
C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
C3B-8 C8PBR BK/WH BK/WH-TS63
8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
C

10 SECONDARY BOOM UP 10

P182BAT RD C7B-4
C6B-11 C11SBD BL/BK D50 C129DA RD/BK
C3B-11 C11SBD BL/BK BL/BK-TS60
11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59

Z-45/25 DC • Z-45/25J DC
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR
C4B-5 C17PRL GR GR-TS57
17 PLAT. ROTATE LEFT-(JIB UP-OPT) 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
D

18 PLAT. ROTATE RIGHT-(JIB DOWN-OPT) 18

C6B-38 C19LPE GR/WH D76 GR/WH
D74
ANSI • CSA • AS (after serial number 39313)

C4B-7 C19LPE GR/WH GR/WH-TS60

19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C129DA RD/BK

C1B-1 C27AUX RD RD-TS51

27 AUXILIARY PUMP SELECT 27
E

33 33

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK

Part No. 107939

September 2015

D59
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37
C6B-24 C40LS OR
C2B-2 C40LS OR
F

40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
C2B-4 R42BAT OR/RD OR/RD-LED
42 SWITCH 48 VOLTS 42
C129DA RD/BK
C2B-6 C129DA GR/BK D29 GR/BK-TS58
44 (JIB - OPTION) DESCENT ALARM 44
C6B-34 C23ALARM RD RD H6
C2B-5 P134BAT RD RD KS1
L37 134 KEYSWEITCH POWER 134
FAULT
STATUS
LED
BK C6B-25
Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 and Z-45/25J,

OR/RD-42A OR/RD
G

C2B-7 C45JSV GR/WH GR/WH

BRN-HM BRN
GROUND
OR/RD GROUND
STUD
CONTROL
BK
HARNESS

BRN
TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C129DA RD/BK

C4B C6B-27 R27AUX

C30FWD WH
C28TTA RD/BK

BROWN C6B-19 R19LPE GR/WH

H

C32JSL WH/RD
C29JSH RD/WH

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

C6B-35 R48BRK RD/WH

C6B-3 P42BAT OR/RD
RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B
GREEN C3B-3 C3BAT RD/WH

RD/WH OR/RD

CR1 CR2 BRN BRN

48V DC 48V DC CR3 CR20
C2B
POWER POWER AUXILIARY CONTROL LIFT PUMP
I

BLACK RELAY RELAY RELAY RELAY

30 30 30 30
BRN

87a 87a 87a 87a

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

86 85 86 85 86 85
C1B 87 87 87 87
GRAY
BRN

OR/RD OR/RD GR/WH

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

J

C3B-9 C9HRN BK/RD

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

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
ES0274M (JIB MODELS)

D85
K

CR4 CR5
HORN BRAKE
ES0273L (NON-JIB MODELS)

RELAY RELEASE
RELAY
L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram, Z-45/25 and Z-45/25J,
ANSI • CSA • AS (after serial number 39313)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)
BK-7A GR/BK-18A D80
BK 1
BK/WH-8A GR-17A

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V

RD
BK
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
RD-1A D28
CR20 PRIMARY LIFT PUMP RELAY
G6 HOUR METER
KS1 KEY SWITCH GR/BK-44A 3

TS59
TS61
L37 LED, DRIVE CONTROLLER FAULT STATUS

TS58
WH

RD

RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH RD
TS55 FUNCTION ENABLE TOGGLE SWITCH
TS57 PLATFORM ROTATE TOGGLE SWITCH BK
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD C23-6

RD
BK
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH RD 4
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH BK-22A
TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH P182BAT RD (C7B-4)

BL-10A
NOTE: DASHED LINES INDICATE OPTIONS.

KS1
BL/BK-11A

CB1
GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

D2

RD
WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

ES0273L (NON-JIB MODELS)
ES0274M (JIB MODELS)

G6
Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 51
September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, ANSI • CSA • AS
(after serial number 39313)

6 - 51 6 - 52
 September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (after serial number 39313)
N M L K J I H G F E D C B A

1
GR/WH +

GR/WH - 45

R45JSV GR/WH
RD OUTPUT

BRN -
C1
CR14 P134PWR RD
GR/WH

BRN-RELAY 2

C45JSV GR/WH

GR/WH - 45

P134PWR RD
GR/WH-R7
OR/RD
OR/BK-R6
OR/BK

RD/BK-R6

RD-J7
CR6 CR7

BR-JIBGND
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK

R41DRE OR/BK
R42BAT OR/RD
C129JDA GR/BK
C45JSV GR/WH
C134PWR GR
C1PBU RD
C2PBD RD/BK
C3BAT RD/WH
C4TRL WH
C5TRR WH/BK
C6LFC WH/RD
C7PBE BK
C8PBR BK/WH
C9HRN BK/RD
C10SBU BL
C11SBD BL/BK
C12DRE BL/WH

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPE GR/WH

P22BAT BK
P23BAT WH
BRN-BATGND

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

BRN-J1
BRN-BATGND
BRN-JIBGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11

C2P-3
C2P-4
C2P-6
C2P-7
C2P-5
C3P-1
C3P-2
C3P-3
C3P-4
C3P-5
C3P-6
C3P-7
C3P-8
C3P-9
C3P-10
C3P-11
C3P-12

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

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3

BK

WH
C1P-2

4
C28TTA RD/BK

C1P(GY)

C3P(GR)

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

12V DC FOOT
D40
BATTERY SWITCH
18/19 CONTROL CABLE
A1
NOTES: 5
1. DASHED LINES INDICATE OPTIONS.

2. JIB TIME DELAY (C1 AND CR14) ADDED AT

SERIAL NUMBER 34515 OR WAS FEILD INSTALLED.

DP1
GR-LFC COMPONENT INDEX
GR 1 C29JSH RD/WH A1 TILT ALARM
GR BP1 20k OR 2 C32JSL WH/RD BCI BATTERY CHARGE INDICATOR (OPTION) 6
RD
WH C30FWD WH BP1 ROTARY FLOW CONTROL DIAL
BK/RD 3
FWD C1 CAPACITOR, TIME DELAY (JIB OPTION)
TS10 TS13 BK 4
C31REV WH/BK
TS12 OR/BK-R6
D73 REV CR6 RELAY - DRIVE ENABLE

D71
RD RD-DRE
5
WH/GR P24BAT WH CR7 RELAY - JIB (OPTION)
- BCI + YL 6 C12DRE BL/WH
CR14 RELAY - JIB (OPTION)
RD-RPM
PRPL RD-J7
LIFT
7 RD-SW DP1 JOYSTICK - DRIVE / STEER
TS11
BL 8
RD/BK-R6 H1 TITL ALARM
DRIVE
BK/WH-DRE
7
R42BAT OR/RD

L1 LED - DRIVE ENABLE

BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPE GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT 9
WH/RD C36STCC BL L48 LED - TILT ALARM
LEFT 10
P2 EMERGENCY STOP BUTTON

P26FS BK C9P-1

P22BAT BK C7P-1

P23BAT WH C7P-2

C3BAT RD/WH C3-3

P3 HORN BUTTON
TS1 AUXILIARY PUMP TOGGLE SWITCH

RD-HRN
RD/BK H1
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C129JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)
TS9 PLATFORM LEVEL TOGGLE SWITCH
8

P3
D69 TS10 SECONDARY BOOM TOGGLE SWITCH
TS9
TS15 TS7 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
3

2
4

NC NC NC

1
NO
D27

TS12 TURNTABLE ROTATE TOGGLE SWITCH

1
D81

2
P3
RD TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH

1
L48
TS1 TS8
D82 P2 TS15 DRIVE ENABLE TOGGLE SWITCH

L1 ES0273L (NON-JIB MODELS)

ES0274M (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 53

September 2015 Section 6 • Schematics

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

ANSI • CSA • AS (after serial number 39313)

6 - 53 6 - 54
 Section 6 • Schematics September 2015

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

(after serial number 39313)

6 - 55 6 - 56
Section 6 • Schematics September 2015

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

(after serial number 39313)
A B C D E F G H I J K L M N
C29JSH RD/WH

C32JSL WH/RD

1 C30FWD WH

C31REV WH/BK
C40LS OR
FS1
P2 RD-(FS) C9P-3
P22BAT BK C7P-1 P26BAT BK-(FS)
OR LS18B BK BK WH-(FS) C9P-2 P24BAT WH
WH RD RD RD

LS18A TILT R42BAT OR/RD

D88
C132PLI GR C1P-12 ALARM

+ WORK DRIVE

RD
2 TB134
L4 H1
R20
4.7KW L48
C9P-1 BK LIGHTS
TS49
LIGHTS
TS48
P3

C1B-12

C7B-1
3
PLATFORM HORN
10A P1
P182BAT RD TB22 D39 D40
CB1 2
KS1
GROUND 30 86

C2P-1

C3P-9

C2P-5
C1P-2
C2P-2
C1P-4

C1P-5

C1P-6

C1P-3

C7P-2
C3P-3

C2P-4
1 3 CR45

C2P-11

C2P-12
C32

P22LS BK
4 5 2 9
+ COM 87 85
2 SEC.

C9HRN BK/RD
5

P23BAT WH
P134PWR GR

C3BAT RD/WH
C40LS OR

C133PLA BL/RD
C30FWD WH

C31REV WH/BK

C32JSL WH/RD

C29JSH RD/WH

C28TTA RD/BK

R42BAT OR/RD

BK (16/2)

WH (16/2)

WH (16/2)

WH (16/2)
6 U33 7
P182BAT RD

NO
8
3 12 8
3
-
U35
L30 L30
30A
+

BK

BK
L45

C2B-11

C2B-12
C7B-2
C3B-3
C2B-1

C3B-9

C2B-5
C1B-2
H6

C2B-4
C1B-4

C1B-5

C1B-6

C1B-3

C2B-2
D90
GR/BK

P134PWR RD
C7B-4

C6B-30

C6B-31

C6B-32

C6B-29

WH
OR OR
CR5
TB40
4 C12DRE BL/WH
P42BAT OR/RD
P42BAT OR/RD C6B-3
C6B-22 R42BAT OR/RD RD
F5
RD/WH

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

WH

WH/BK

WH/RD

TB42
F4

BK/RD
10A
C6B-12

C6B-24

AP2 500A

C6B-20 RD
C6B-40 OR

48V 86 30 48V
CR2
PR1 86 F18
+48 V TB23 (AP2)

OR/RD
85 87 7A
_ BK D2

RD/BK
+
C30FWD

C31REV

C32JSL

C29JSH

C12FTS BL/WH INTERLOCK

C40LS

COIL-PR1

CR5

F2 85 L37
200A 86 30
+ _ CR1
C10-3
C10-4

C10-1
C10-2

5
C6B-39 CR5 RD/BK

30 86
OFF-LMT SPD INP

C6B-28
C6B-34
RD 20

LEFT 85 87
C6B-25 CFIL BK

D79 CR23
DIODE RETURN

BRN
BRN
BOX
C179DPR GR

+ _
BK
BK-4
WH-4

BK-5
WH-5
+48V INPUT

87 85
FORWARD

POT. LOW
REVERSE

POT. HI

21
+ _ LS4 + C12DRE BL/WH
(SEC) HM
22 _
1 9 10 11 14 16 2 3 17 20 5
AP2

WH (16/2)

WH (16/2)
30 86
U6A
CR4

RD/WH
RD/BK
RD
CURTIS 1244
24 V
SEPEX CONTROLLER
BK-5

WH-5

87 85
BK
6 AP1 F1
F1 M- B+ F2 B-

C8-C
C8-A
200A
+24 V PR3 PR2
+ _
C6B-9 BK/RD
C11-3
C11-4

C11-1
C11-2

RD
WH
+ L29 L29
FB
_
WH-6
BK-7
WH-7

BK-6

BK

BK
WH

BK 2 GA

LEFT A2 A2 F2 F1
BRN

MOTOR
RIGHT RIGHT
1
BOX + _ F2 F1 A1 A1 MOTOR 21 13
+
CHARGER

LS2 LS1
PUMP PUMP (PRI) (EXT)
_ 22 14

BK
+ _
+
7 C8-B
BK

H2
GROUND

BRN
AC POWER

(GND)

AP1 BK BK
PR2 PR2
PR3 PR3

(OPTION)
DRIVE LIGHTS
HORN

HORN RELAY

(OPTION)
BEACON
FLASHING
CONTACTOR COIL
CONTROLLER
PR1 SEPEX

HOUR METER
LIFT PUMP
PRIMARY

RELEASE COIL
CR5 BRAKE

POWER RELAY
CR1 48V DC

POWER RELAY
CR2 48V DC

(OPTION)
WORK LIGHTS
LIFT PUMP
AUXILIARY

TILT SENSOR
GROUND
CHASSIS

BOX GROUND
BASE CONTROL

8
NOTES: ES0273L (NON-JIB MODELS)
ES0274M (JIB MODELS)
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 1 SWITCH SHOWN WITH BOOM EXTENDED. 3 L48 TILT ALARM LED. (OPTION)
2. ALL SOLENOID AND RELAY COILS ARE 24V DC SXCEPT WHERE NOTED.
2 ADD D40 ONLY IF UNIT HAS L4 AND L48. 4 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

6 - 56 Z-45/25 DC • Z-45/25J DC Part No. 107939

 1

8
Section 6 • Schematics

6 - 57
Electrical Schematic, Z-45/25 and Z-45/25J, CE
(after serial number 39313)

ENABLE

4
DRIVE

LED

BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

L1

22

21

C4P-1 C13DREL BL/RD C4B-1 BL/RD C6B-13 C13DREL BK-8 BRN-8 C6B-21 DREGND BRN
TB12
D78

DRIVE ENABLE
LS3

C3P-12 C12DRE BL/WH C3B-12 BL/WH C6B-26 C12DRE WH-8 RD-8 LIMIT SWITCH
13

14
A

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

86

85

86

85

BRN
CR8

RD/WH
H3

TRAVEL ALARM
CR6

+
4

D85
CR5

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

87

30

87
RD/BK-R6
30

87

ENABLE

PS1 BRAKE
B

PS1 PRESSURE
Z-45/25 DC • Z-45/25J DC

SWITCH
TS15

TB36

C24-1 C24-2
C36SCC BL C1B-10 C6B-36 BL
RD STEER LEFT
C1P-10
TB37

C37SCW BL/BK C1B-11 C6B-37 BL/BK

STEER RIGHT
C1P-11
C25-1 C25-2
C6B-38 GR/WH
DP1
OR/BK-R6
C

CR5
C31REV WH/BK
C29JSH RD/WH

C32JSL WH/RD

10
1

2
3
4
5

7
8
9
C30FWD WH

P24BAT WH

DRIVE
LIFT
C40LS OR

STEER

D76

D59

D60
REV
FWD

R
20K

L
D69

33W
D

TS1

GR/WH

RD-AUX C1P-1 C27AUX RD C1B-1

AUXILIARY

PR2
PUMP

30

87

OR/RD C6B-19 PR2

PRIMARY PUMP
OPTION

GR/WH
CONTACTOR COIL
BCI
E
F
September 2015

D4

Part No. 107939

86

85

OR/RD CR3
RD RD
AUXILIARY PUMP
CR20
BRN

33W
AUXILIARY

TB27

CONTACTOR COIL
BRN

TS51
E

BK
LVI/BCI OPTION

PR3
PUMP
WH/RD

PR3
CR3

C6B-27 AUXILIARY PUMP

5 6 7 8
1 2 3 4

RD CONTACTOR RELAY
D73

87
TB19

WH
30

C4P-7 C19LPMP GR/WH C4B-7 GR/WH CR20

85
86

GR/WH PRIMARY PUMP

CONTACTOR RELAY
D74

TB6

87a

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

CR19A

BK/RD

FLOW CONTROL
BK

BP1 D71

GR/WH
GR
RD

D72

PLATFORM ROTATE
D28

TB18
F

WH
C23-1 C23-2 RIGHT
DOWN
CR19B

C6B-18 GR/BK
CONTROL
85
86

(JIB DOWN - OPT.)

ROTARY

FLOW

C6B-17 GR
OEM

BOOM

PLATFORM ROTATE
TS58

TB17

UP LEFT
JIB

C22-1 C22-2
85
86

(JIB UP - OPTION)
TB44

C2P-6 C129JDA GR/BK C2B-6

BOOM

D27

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

JIB

C4P-5 C17PRL GR C4B-5 GR

TS8
G

UP
D82

RIGHT
PLATFORM
87a

ROTATE

TS57

LEFT
CR7
30

C129JDA BK
D82
86

85
85
86
PLATFORM
ROTATE

D80
GR/WH

RIGHT
OR/RD

GR/WH

RD BR
+
_
H

TS7

LEFT
C2B-7
C1

GR/WH
BRN
GR/WH

CR14

TB14
D81

C20-1 C20-2 PLATFORM

WH BK UP C6B-14 OR
PLATFORM

LEVEL UP
30

87A

JIB
RD

C6B-15 OR/BK
LEVEL

MANIFOLD PLATFORM
TS59

TB15

DOWN LEVEL DOWN

C21-1 C21-2
PLATFORM

C2P-7 C45JSV GR/WH

LEVEL
I

UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TS9

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

C6B-8 BK/WH PRIMARY BOOM

BOOM

TS63

TB8
RETRACT RETRACT
C17-1 C18-2
PRIMARY
BOOM

EXTEND C3P-7 C7PBE BK C3B-7

J

C3P-8 C8PBR BK/WH C3B-8

TB1
TS13

RETRACT C12-1 C12-2

UP C6B-1 RD PRIMARY
BOOM UP

PRIMARY
C6B-2 RD/BK

BOOM
PRIMARY

TS61

TB2
DOWN BOOM DOWN
C13-1 C13-2
CR19A
PRIMARY

BOOM
BOOM

UP C3P-1 C1PBU RD C3B-1

87A
30

C3P-2 C2PBD RD/BK C3B-2

TB10
TS11

DOWN C18-1 C18-2

K

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

BOOM

TS60

TB11
SECONDARY

DOWN BOOM DOWN

C19-1 C19-2
CR19B

D29

D30

D50
BOOM

C44DA BK C44DA DESCENT ALARM

H4
UP C3P-10 C10SBU BL C3B-10 (OPTION)

+
87A
30

C3P-11 C11SBD BL/BK C3B-11

TS10

DOWN

TB5
C15-1 C15-2
TURNTABLE

TURNTABLE
RIGHT C6B-5 WH/BK
ROTATE RIGHT
L

ROTATE
C6B-4 WH TURNTABLE

TS62

TB4
LEFT ROTATE LEFT
TURNTABLE

C14-1 C14-2
ROTATE

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

TS12
LEFT
P24BAT WH

FUNCTION
ENABLE
M

C31REV WH/BK
C29JSH RD/WH

C12DRE BL/WH
C32JSL WH/RD

P42BAT OR/RD
P134PWR RD
C30FWD WH

C40LS OR

TS55

(GND)
CR5

PR2
PR3
WH

RD

BK
N
September 2015 Section 6 • Schematics

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

(after serial number 39313)

6 - 57 6 - 58
 Section 6 • Schematics September 2015

Ground Control Box Terminal Strip Wiring Diagram,

Z-45/25 and Z-45/25J, CE (after serial number 39313)

6 - 59 6 - 60
 8
7
6
5
4
3
2
1

6 - 60
U33

C32
1 3 4 5 6 7 8 12
A

RD H6
BK 22D
BK C7-1
RD TS51
RD TS55
TERMINAL BASE (TB) BRN GND
P182BAT RD GR/BK H6

BL/WH C1-12
D C B A
Section 6 • Schematics

C6B-1 C1PBU RD
C3B-1 C1PBU RD RD-TS61
1 PRIMARY BOOM UP 1
C6B-2 C2PBD RD/BK D30 C129DA RD/BK
C3B-2 C2PBD RD/BK RD/BK-TS61
2 PRIMARY BOOM DOWN 2
C6B-4 C4TRL WH
C3B-4 C4TRL WH WH-TS62
B

4 TURNTABLE ROTATE LEFT 4

RD C32-1 C6B-5 C5TRR WH/BK
RD 134B C3B-5 C5TRR WH/BK WH/BK-TS62
5 TURNTABLE ROTATE RIGHT 5
C6B-6 C6LFC WH/RD D72
C3B-6 C6LFC WH/RD GR/WH
6 LIFT FLOW CONTROL 6

H6
C6B-7 C7PBE BK
C3B-7 C7PBE BK BK-TS63
GR/BK C32-8 7 PRIMARY BOOM EXTEND 7
C6B-8 C8PBR BK/WH
GR/BK L45
C3B-8 C8PBR BK/WH BK/WH-TS63
GR/BK C2B-6 8 PRIMARY BOOM RETRACT 8
C6B-10 C10SBU BL
C3B-10 C10SBU BL BL-TS60
10 SECONDARY BOOM UP 10

P182BAT RD C7B-4
C6B-11 C11SBD BL/BK D50 C129DA RD/BK
C

C3B-11 C11SBD BL/BK BL/BK-TS60

11 SECONDARY BOOM DOWN 11
C6B-12 C12DRE BL/WH C12DRE BL/WH
C7 C3B-12 C12DRE BL/WH D78 WH-HM
12 FOOTSWITCH POWER #2 12
C6B-14 C14PLU OR
C4B-2 C14PLU OR OR-TS59
14 PLATFORM LEVEL UP 14
C6B-15 C15PLD OR/BK
C4B-3 C15PLD OR/BK OR/BK-TS59
15 PLATFORM LEVEL DOWN 15
C6B-17 C17PRL GR

Z-45/25 DC • Z-45/25J DC
C4B-5 C17PRL GR GR-TS57
17 PLATFORM ROTATE LEFT/JIB UP 17
C6B-18 C18PRR GR/BK
C4B-6 C18PRR GR/BK GR/BK-TS57
18 PLATFORM ROTATE RIGHT/JIB DOWN 18
C6B-38 C19LPE GR/WH D76 GR/WH
D

D74
C129DA RD/BK

C4B-7 C19LPE GR/WH GR/WH-TS60

19 LIFT PUMP 19
GR/WH-CR3
GR/WH-J19
19 LIFT PUMP 19
C6B-20 P22LS BK BK-CR4
C23-4 P22BAT BK BK-KS1
22 +24V DC TO PLATFORM 22

C7B-2 P23BAT WH WH-KS1 (D2)

23 KEYSWITCH POWER 23
RD-CR3
C1B-1 C27AUX RD RD-TS51
27 AUXILIARY PUMP SELECT 27
Ground Control Box Terminal Strip Wiring Diagram,
Z-45/25 and Z-45/25J, CE (after serial number 39313)

33 33
E

C7B-3
C6
34 34

35 35
C6B-36 C36STCC BL
D60
C1B-10 C36STCC BL GR/WH-J19

BATGND BRN
36 STEER LEFT 36
C6B-37 C37STC BL/BK
D59
C1B-11 C37STC BL/BK GR/WH-J19
37 STEER RIGHT 37

Part No. 107939

September 2015

C6B-24 C40LS OR
C2B-2 C40LS OR
40 OFF-LIMIT SPEED 40
C6B-22 R42BAT OR/RD OR/RD-CR1
F

C2B-4 R42BAT OR/RD OR/RD-LED

42 SWITCH 48 VOLTS 42
C129DA RD/BK
C2B-6 C129DA GR/BK D59 GR/BK-TS58
44 JIB DESCENT ALARM 44
C6B-34 C134PWR RD RD H6
C2B-5 P134BAT RD RD KS1
134 KEYSWEITCH POWER 134

L37
BK C6B-25
OR/RD-42A OR/RD
C2B-7 C45JSV GR/WH GR/WH
G

BRN-HM BRN
GROUND
OR/RD
CONTROL
GROUND BK HARNESS

BRN
STUD TO SWITCH

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

C6B-40 C40LS OR PANEL

C6B-26 C12DRE BL/WH
C6B-33 C129DA RD/BK

C6B-27 R27AUX
C30FWD WH

C4B
C28TTA RD/BK

C6B-19 R19LPE GR/WH

C32JSL WH/RD
C29JSH RD/WH

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

BROWN
C6B-35 R48BRK RD/WH
H

C6B-3 P42BAT OR/RD

RD

C6B-39 CR5 RD/BK

RD

C4B-4
C4B-1

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

C3B C3B-3 C3BAT RD/WH

GREEN
RD/WH OR/RD

CR1 CR2 BRN BRN

48V DC 48V DC CR3 CR20
POWER POWER AUXILIARY CONTROL LIFT PUMP
C2B

RELAY RELAY RELAY RELAY

BLACK
I

30 30 30 30
BRN

87a 87a 87a 87a

86 85 86 85 86 85 86 85
87 87 87 87
C1B
GRAY
BRN

OR/RD OR/RD GR/WH

C1B-6
C1B-5
C1B-4
C1B-3
C1B-2

BRN BRN
OR/RD GR/WH

C2B-3 C41DRE OR/BK

C3B-9 C9HRN BK/RD

J

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

BRN 87 87
BRN 85 86 85 86
87a 87a
BK
30
30
ES0274M (JIB MODELS)

D85
CR4 CR5
BRAKE
K

HORN
ES0273L (NON-JIB MODELS)

RELAY RELEASE
RELAY
L
M
N
 September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, CE (after serial number 39313)
N M L K J I H G F E D C B A
C45JSV GR/WH (C2B-7)

BK-7A GR/BK-18A D80

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

TS57
BK WH/BK-5A GR/BK
RD
WH-4A GR
GR

TS62
TS63
BK D82
RD
COMPONENT INDEX BK
CB1 10A CIRCUIT BREAKER RD 2
D4

GR/BK
CR1 POWER RELAY, 48V RD RD-27A

TS51

RD
GR

BK
BK
CR2 POWER RELAY, 48V
CR3 AUXILIARY PUMP RELAY OR/BK-15A OR/BK

RD
BK
CR4 HORN RELAY
RD/BK-2A OR-14A OR
CR5 BRAKE RELEASE RELAY
CR20 PRIMARY LIFT PUMP RELAY RD-1A D28
G6 HOUR METER
H6 PLATFORM OVERLOAD ALARM GR/BK-44A 3

TS59
TS61
KS1 KEY SWITCH

TS58
WH

RD

RD
L37 LED - DRIVE CONTROLLER FAULT STATUS
L45 LED - PLATFORM OVERLOAD
RD
P1 EMERGENCY STOP BUTTON
TS51 AUXILIARY PUMP TOGGLE SWITCH BK
TS55 FUNCTION ENABLE TOGGLE SWITCH
RD C23-6

RD
BK
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS58 JIB UP / DOWN TOGGLE SWITCH (OPTION) RD 4
TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
BK-22A
TS60 SECONDARY BOOM UP / DOWN TOGGLE SWITCH
TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH P182BAT RD (C7B-4)
TS62 TURNTABLE ROTATE TOGGLE SWITCH

RD
BL-10A
TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
+

KS1
U33 LOAD SENSE MODULE

L45
BL/BK-11A

CB1
-
NOTE: DASHED LINES INDICATE OPTIONS. GR/WH-19A BK 5
RD

TS60
RD 134A

RD RD

RD

RD C23-7 RD
6

RD
D2
GR/BK H6

WH 23A

1
WH 7
P1

RD

RD

RD
NC
BRN
2

BRN-HM
WH-HM

TS55
8

BASE BOX HARNESS

G6
ES0273L (NON-JIB MODELS)
ES0274M (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 61

September 2015 Section 6 • Schematics

Ground Control Box Switch Panel Wiring Diagram,

Z-45/25 and Z-45/25J, CE (after serial number 39313)

6 - 61 6 - 62
 Section 6 • Schematics September 2015

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

CE (after serial number 39313)

6 - 63 6 - 64
Section 6 • Schematics September 2015

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

(after serial number 39313)
A B C D E F G H I J K L M N

1 GR/WH + CR8
P26BAT BK

GR/WH - 45

R45JSV GR/WH
RD OUTPUT

BRN -
C1
CR14 P134PWR RD
GR/WH
D90

RD U35
2+

BK

C134PWR RD

BK
BRN-RELAY
BR - GND
2

GR/WH-R7
OR/RD

P134PWR RD
P26BAT BK P2
C3BAT RD/WH C3B-3
RD
3- 5

C45JSV GR/WH

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

RD/BK-R6

RD-J7

RD-J7

P24BAT WH
CR6 CR7

R20
BRN-RELAY

C134PWR RD LS18A

OR - LS18A
BR-JIBGND

C132PLI1 GR C1P-12
C134PWR RD

C27AUX RD

C29JSH RD/WH
C30FWD WH
C31REV WH/BK
C32JSL WH/RD

C36STCC BL
C37STC BL/BK
C132PLI1 BL/WH
C40LS OR
R41DRE OR/BK
R42BAT OR/RD
C129JDA GR/BK
C45JSV GR/WH

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

C13DREL BL/RD
C14PLU OR
C15PLD OR/BK

C17PRL GR
C18PRR GR/BK
C19LPE GR/WH

P22BAT BK
P23BAT WH
BRN-BATGND

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

3
BRN-J1
BRN-BATGND
C134PWR RD
BRN-JIBGND
C2P-5

C1P-1

C1P-3
C1P-4
C1P-5
C1P-6

C1P-10
C1P-11
C1P-12
C2P-2
C2P-3
C2P-4
C2P-6
C2P-7

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

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

C7P-1
C7P-2
C7P-3

C9P-1
C9P-2
C9P-3
LS18 - WH
D88 LS18 - BK

BK

WH
C1P-2

4
C28TTA RD/BK

C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

JIB
C7P C9P LS18 OPTION
(OPT.)

12V DC FOOT
D40
BATTERY SWITCH
18/19 CONTROL CABLE
A1 NOTES:
5 1. DASHED LINES INDICATE OPTIONS.

COMPONENT INDEX
A1 TILT ALARM
DP1 BCI BATTERY CHARGE INDICATOR (OPTION)
GR-LFC BP1 ROTARY FLOW CONTROL DIAL
GR 1 C29JSH RD/WH
C1 CAPACITOR, TIME DELAY (JIB OPTION)
GR BP1 20k OR C32JSL WH/RD
2 CR6 RELAY - DRIVE ENABLE
6 RD
WH C30FWD WH CR7 RELAY - JIB (OPTION)
BK/RD 3
FWD CR8 RELAY - LIMIT SWITCH
TS10 TS13 BK 4
C31REV WH/BK
TS12 OR/BK-R6
D73 REV CR14 RELAY - JIB (OPTION)
D71

RD RD-DRE
5 P24BAT WH
WH/GR DP1 JOYSTICK - DRIVE / STEER
- BCI + YL 6 C12DRE BL/WH
RD-RPM H1 TITL ALARM
LIFT PRPL RD-J7
TS11
7 RD-SW L1 LED - DRIVE ENABLE
BL 8
RD/BK-R6
L4 LED - PLATFORM OVERLOAD
DRIVE
BK/WH-DRE
R42BAT OR/RD

LS18 PLATFORM OVERLOAD LIMIT SWITCH

BRN-BCI

WH/YL C37STC BL/BK

C5TRR WH/BK

C4TRL WH
C10SBU BL
C11SBD BL/BK

C1PBU RD
C2PBD RD/BK

C8PBR BK/WH
C7PBE BK

RD-SW
C19LPE GR/WH
C6LFC WH/RD

BRN-BCI
BRN-J1
RIGHT 9
7 WH/RD C36STCC BL P2 EMERGENCY STOP BUTTON
LEFT 10

P26FS BK C9P-1

P22BAT BK C7P-1

P23BAT WH C7P-2

C3BAT RD/WH C3-3

P3 HORN BUTTON
R20 RESISTOR - 4700W
TS1 AUXILIARY PUMP TOGGLE SWITCH

RD-LS18
GR/BK-H1 (D39)
C9HRN BK/RD

RD-HRN

C27AUX RD

RD-AUX

RD-DRE
BK/WH-DRE

C13DREL BL/RD

C129JDA GR/BK

GR/WH- R7

C18PRR GR/BK

C17PRL GR

GR/WH-45

C15PLD OR/BK
C14PLU OR

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (OPTION)
TS9 PLATFORM LEVEL TOGGLE SWITCH
D69
TS9 TS10 SECONDARY BOOM TOGGLE SWITCH
8 TS15 TS7 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
3

2
4

NC NC NC

1
NO
D27

1
D81 TS12 TURNTABLE ROTATE TOGGLE SWITCH

2
P3
RD

1
L4 TS13 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS1 TS8
D82 P2
TS15 DRIVE ENABLE TOGGLE SWITCH
U35 TIME DELAY RELAY
L1
ES0273L (NON-JIB MODELS)
ES0274M (JIB MODELS)

6 - 64 Z-45/25 DC • Z-45/25J DC Part No. 107939

 September 2015 Section 6 • Schematics

Power Cable Wiring Diagram

N M L K J I H G F E D C B A
FUNCTION HARNESS
TO GROUND CONTROL BOX

LEFT SIDE
CONNECTOR C6B AC POWER CABLE
DC AMMETER CABLE
1
BATTERY PACK
RD-2GA RIGHT SIDE
- BATTERY PACK

-
+
D1

A2 +
AC
_ BATTERY
PRIMARY 2
CHARGER
A1 LIFT PUMP -
+

AUXILIARY LIFT +

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

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

-
+

P42BAT OR/RD +

F5 10A BK-2GA BK-2GA

BK-2GA BK-2GA
4

WH
BK
FOR REFERENCE ONLY - F4 MOUNTS ON PR-1
+ -
LIFT PUMP TOP VIEW OF
+ + CONTACTOR DRIVE CONTACTOR DRIVE CONTACTOR AUXILIARY PUMP 4 5 6 7
3

AP-1

8
1
CONTACTOR

9
BATTERY LED
- - - - AMMETER CHARGER
AC
WH-FROM CHARGER

BK-FROM CHARGER

INDICATOR
AP-2 DIODE DIODE CHARGER
PR-1 + + PLUG

GR/WH-19
33W DIODE
P42BAT OR/RD

33W

PR-2 PR-1 CONTROLLER PR-3 5

RD-2GA

BK-2GA

BK-2GA

R42BAT OR/RD
R42BAT OR/RD R42BAT OR/RD

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

F4 BK BK BK BK RD-2GA
500A RD-P182-12GA

RD-2GA RD-2GA

RD-2GA
24V DC
RD-10GA RD-10GA 6
48V DC F1
200A

F2
200A

C29JSH RD/WH

C32JSL WH/RD
RD-10GA

CR5 RD/BK
RD-2GA

GR
F2 A2 A1 F1
24 23 22 21 20 19 18 17 16 15 14 13 7
12 11 10 9 8 7 6 5 4 3 2 1
F1 A1

RD-2GA
C31REV WH/BK

C12DRE BL/WH
R42BAT OR/RD

R42BAT OR/RD
OR/RD

OR/RD
RD-2GA
C30FWD WH

RD-10GA
C40LS OR A2 F2
CFIL BK

LEFT SIDE RIGHT SIDE

DRIVE MOTOR DRIVE MOTOR
BRN-J8

BK-2GA
BK-FROM CHARGER RD-10GA U6A NOTES:
BK-2GA F1 F2 RD-10GA
1. ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED.
8
BRN-J8
BK-2GA BK-2GA B- M- B+
BK-2GA
RD-2GA ES0273L (NON-JIB MODELS)
CHASSIS ES0274 (JIB MODELS)
GROUND
SEPEX MOTOR CONTROLLER

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 65

September 2015 Section 6 • Schematics

Power Cable Wiring Diagram

6 - 65 6 - 66
 Section 6 • Schematics September 2015

CTE Option, CE

6 - 67 6 - 68
Section 6 • Schematics September 2015

CTE Option, CE

A B C D E F G H I J K L M N
P22LS BK BRN

LIMIT SWITCHES
1

CR18A CR18B
PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15 TB14
2

C14PLU OR
C15PLD OR/BK

BRN

C15PLD OR/BK C21-1

TB40 C14PLU OR C20-1

3

CR18B CR18A

4
C15PLD OR/BK

C14PLU OR

C14PLU OR C4B-2
OR-TS59 C14PLU OR CR18A#86
14 PLATFORM LEVEL UP 14
C15PLD OR/BK C4B-3
OR/BK-TS59 C15PLD OR/BK CR18B#86
15 PLATFORM LEVEL DOWN 15
5

C21-1 C20-1

6
C40LS1 OR C2B-2
C40LS1 OR CR18A#30 C40LS1 OR C10-2
40 BOOM STOWED 40

C21-2 C20-2

FUNCTION HARNESS
P22LS BK
7 GROUND BR
P134BAT RD-LS17 C38-1
P134BAT BK-LS5 C37-3
134 LOAD WEIGHING LIM. SW. +12V (1) 134
P134FB WH-FH
LEVEL DOWN
PLATFORM

LEVEL UP
PLATFORM

RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134

SCHEMATIC - PLATFORM LEVEL CUTOUT

8
GROUND BOLT
ES0276N

WIRING DIAGRAM

6 - 68 Z-45/25 DC • Z-45/25J DC Part No. 107939

 September 2015 Section 6 • Schematics

Charger Interlock Option

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

R42BAT OR/RD C6B-22 R42BAT OR/RD LED

CHARGER
INDICATOR 1
AC
BATTERY

BK
CHARGER C56-1 BK (N.O.)
C56-2 WH
C56-1 BK

2
AC
BATTERY
CHARGER
R42BAT OR/RD

C56-2 WH

WH
48V DC
OUTPUT
PR1
COIL

4
TOP VIEW OF
DRIVE CONTACTOR DRIVE CONTACTOR

BATTERY

DIODE
5
DIODE RETURN

PR-1
+48V INPUT

CONTROLLER
PR-1
GR

C179DPR GR
1 9 10 11 14 16 2 3 17 20 5
WH 6
R42BAT OR/RD BK
U6A
CURTIS 1244 R42BAT OR/RD R42BAT OR/RD
SEPEX MOTOR CONTROLLER

WIRING DIAGRAM
F1 M- B+ F2 B-
7
BATTERY INDICATOR LED
SCHEMATIC 1. THE LED IS RED DURING PHASES I1 AND P (BULK CHARGE). (20% BATTERY CHARGED)
2. THE LED IS YELLOW DURING PHASES U AND I2. (80% BATTERY CHARGED)
3. THE LED IS GREEN AT THE END OF THE CHARGE. (100% BATTERY CHARGED)
4. THE LED IS FLASHING GREEN DURING CYCLE EQUALIZATION.
5. THE LED IS OFF WHEN THE CHARGER IS NOT POWERED ON.
6. THE LED FLASHES RED. INDICATES A DEFECT.
ES0276N
INTERLOCK RELAY (N.O.), 10A CONTACT
1. CHARGER NOT CONNECTED TO BATTERY OR MAIN SUPPLY, CONTACT OPEN. 8
2. CHARGER CONNECTED TO BATTERY, CONTACT CLOSED.
3. CHARGER CONNECTED TO BATTERY AND MAIN SUPPLY, CONTACT OPEN.
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
SEPEX MOTOR CONTROLLER

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 69

September 2015 Section 6 • Schematics

Charger Interlock Option

6 - 69 6 - 70
 Section 6 • Schematics September 2015

Platform Control Box LVI / BCI Option Wiring Diagram

(before serial number 31015)

6 - 71 6 - 72
Section 6 • Schematics September 2015

Platform Control Box LVI / BCI Option Wiring Diagram

(before serial number 31015)
A B C D E F G H I J K L M N

1 OR/RD
1 LVI
2
OR
CR8 3
OR/BK
4
OR/RD
5
WH WH RESET IS SET TO "B",
6
BRN-RELAY DISCHARGE IS SET TO "N"
7
8

CR6 CR7 CR19A CR19B

2

C40LS OR
RD-LR19B

RD-LVI
BL-L10

BL-LR19A
R42BAT OR/RD

OR-LVI
OR/BK-LVI
OR/RD-LVI
P24BAT WH
BRN-LVI
3

C2P-4

C3P-1
C3P-10

4
C1P(GY)

C3P(GR)

C4P(BR)
C2P(BK)

JIB
C7P C9P OPTION OPTION
(OPT.)

12V DC FOOT
H1 18/19 CONTROL CABLE BATTERY SWITCH

5
DP1

GR
1
GR 20k OR
BP1 2
RD
WH
BK/RD 3
FWD
TS12 TS10 TS11 TS13 BK
6 BCI REV
4
RD
5
WH/BK
3 5 4 6
YL
LIFT PRPL
7
BL 8
DRIVE
RIGHT WH/YL 9
OR-LVI

OR/RD-LVI

OR/BK-LVI

BL-LR19A

RD-LR19B

LEFT WH/RD
10

COMPONENT INDEX
BCI BATTERY CHARGE INDICATOR
CR19A PRIMARY BOOM UP CUTOUT RELAY
CR19B SECONDARY BOOM UP CUTOUT RELAY
LVI LOW VOLTAGE INTERRUPT MODULE

NC NC NC
4 NO 3

1
2
8 TS10 SECONDARY BOOM TOGGLE SWITCH

1
2
P3

1
2
TS15 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
P2
TS1 TS8 TS7 TS9
ES0273G (NON-JIB MODELS)
ES0274G (JIB MODELS)
L1

6 - 72 Z-45/25 DC • Z-45/25J DC Part No. 107939

 September 2015 Section 6 • Schematics

Platform Control Box LVI / BCI Option Wiring Diagram

(after serial number 31014)
N M L K J I H G F E D C B A

1
CR8

CR6 CR7 CR19A CR19B

2

RD-TS11
WH-TS1

RD
BL

LVI#3 BK

BL-TS10
LVI#4 BR

LVI#8 R42BAT OR/RD C2P-4

3

C3P-1
C3P-10
4

C3P(GR)
C1P(GY)

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

12V DC FOOT
BATTERY SWITCH
H1 18/19 CONTROL CABLE

5
DP1

GR
1
20k
GR BP1 OR
2
RD
WH
BK/RD 3
FWD
BK
TS12 TS10 TS11 TS13
LVI / BCI
REV
RD
4
6
5
WH/GR
YL 6

PRPL
LIFT
1 4 7
BL
5 8 8
BL-CR19B#87A

RD-CR19B#87A

DRIVE
WH/YL
BR-GND

BK CR19B#85
OR/RD R42BAT
WH P24BAT

RIGHT 9
C2P-4
WH/RD

WH/RD
LEFT 10

7
COMPONENT INDEX
WH CR19A#86

CR19A PRIMARY BOOM UP CUTOUT RELAY

CR19B SECONDARY BOOM UP CUTOUT RELAY

LVI / BCI LOW VOLTAGE INTERRUPT AND

BATTERY CHARGE INDICATOR
TS1 AUXILIARY PUMP TOGGLE SWITCH

NC NC NC
4 NO 3

1
2
TS10 SECONDARY BOOM TOGGLE SWITCH 8

1
2
P3

1
2
TS15 TS11 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS1 TS8 TS7 TS9 P2
ES0273L (NON-JIB MODELS)
ES0274M (JIB MODELS)

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 73

September 2015 Section 6 • Schematics

Platform Control Box LVI / BCI Option Wiring Diagram

(after serial number 31014)

6 - 73 6 - 74
 September 2015 Section 6 • Schematics

Hydraulic Schematic

N M L K J I H G F E D C B A
JIB BOOM
(OPTION) PLATFORM ROTATE 1
L R

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

E R PR2 PR1
2
J1 J2 PR2 PR1

JIB BOOM (OPTION),

PLATFORM ROTATE
AA MANIFOLD

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

3:1
3000 psi
4
Z 207 bar
Y

4.5:1
3500 psi 3:1 3:1
241 bar 1000 psi 1500 psi
3:1 3:1 69 bar 103 bar
3500 psi 3800 psi
241 bar 262 bar
0.030 inch
0.76 mm X
S1
MASTER
V2 V1
5

N.O.
COM
N.C.

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

3200 psi G
221 bar 0.037 inch
AUXILIARY
PUMP
PRIMARY
PUMP
S N
U 0.94 mm 6
M M
0.5 gpm 2.1 gpm
1.9L/min 7.9 L/min 2500 psi V
O 172 bar W
P H
A
2100 psi
Q 145 bar

0.060 inch
E
F
1.5 mm
R K
D C B
0.030 inch
I 0.030 inch T 0.76 mm 0.4 gpm
0.76 mm L
RESERVOIR
1.5 L/min
M
7

T
HZ45DCR
FUNCTION MANIFOLD

Part No. 107939 Z-45/25 DC • Z-45/25J DC 6 - 75

September 2015 Section 6 • Schematics

Hydraulic Schematic

6 - 75 6 - 76

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Phone +46 31 575100
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Phone +33 (0)2 37 26 09 99
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