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

1. RED BLK R6 TIME DELAY 1 ORG BLK R6 ORG BLK 41 BRN J4 m 9 2 gt 5 5 gt 8 5 RED TIME RED TIME y 2 2 ORG RED 16 ORG RED 16 S ORG BLK 41 ORG BLK 41 3 2 3 3 gt 2 amp 3 D D 5 5 Fem o o gt 8 o 5 2 Du rug Amm NIG dio I 9 deg BIB 8 5 5 55 55224 SE 5335 lt lt 5 52244628 Sse SBS
2. Avay NHOH eee oe 28 2 8 58 18 18 Nua E 8 a 8 5 86 z 6 860 6 HWH9 am 48 48 48 48 e 58 S8 98 58 Mio 18 28 28 v 8 LJ oe oe oe 1 Nua Nua 149
3. REV A Power Cable Diagram from serial number 16840 to 21179 N M L K J H G F E D 1 TO BASE CONTROL BOX AND ENGINE PANEL LEFT SIDE 7 DC CABLE BATTERY PACK 1 RED 2GA BATTERY PACK 0 ee 48V DC ALTERNATOR 2 3 e 2 8 BATTERY CHARGER lt 5 lt 8 PRIMARY 20 5 PUMP 7777 5 AUXILIARY LIFT lt GE PUMP _________ ___________________________ __________________ 8 3 A BLACK 2GA RED 2GA ONLY 5 2 RED 20 12GA WHITE FROM CHARGER Fd Q bd ORG RED R2 1 EET 4 4 BLACK 2GA FUSET
4. Platform Control Box Wiring Diagram Z 45 25J REV A before serial number 13361 A B D E F G H J L M N RED BLK R6 TIME DELAY 1 ORG BLK R6 Ti ORG BLK 41 BRN J4 5 9 _ 5 5 3 E Q 5 3 5 RED TIME RED TIME 1 2 2 ORG RED 16 ORG RED 16 2 2 ORG BLK 41 ORG BLK 41 3 3 E 2 5 N 3 BRN J3 9 9 IEEE 3 5 2 gt 19 oD b Ammo 5 I Qoo o 5 S Se b 2 gt RED TILT 25 2 3 2 3 gt 9 S 4555 5 9 anig Omm mmo lo 9122 allg egla almal 10 2 lt 8 5
5. Nua 2 Nua lt Nua 1 Zr NH8 2g i 9 5 50 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau eo 1 vru aau na 6 aau na V d U IHWNHO 61 IHWNHO bd 1 Suorig aau SS3NHVH d SISSVHO ___ SMT Mm N iw LLILIAES DLL _ 22 _______ ___________ fw 91 19 0 G3 100102 13 31 HOS AINO id 1 HOLIMS OL 57 257 Eja o
6. Ground Control Box Terminal Strip Wiring Diagram Z 45 25J CE Models from serial number 22051 to 23235 Section 6 Schematics D anis asy3734 AY HH ayvua NHOH 05 lt 4 ss 9 8 m 58 18 18 t 9 gt 6 860 g uo Nua Nua quio E e 48 48 48 48 58 98 58 58 98 228 2 8 228 98 75 2 oe hd oe oe ee AVIS 231 1041400 Nua
7. RED BLK R6 BRN LVJ TIME DELAY FOAD SENSOR 1 iaai 8 7 6 5 4 3 2 1 128456 78 9101112 41 RED L7 9 OD OY 9 0 O QD OOQOOQOOOOO 2 2 3 w o 2 BRN J4 BEPSTOP 8 258 8 2 mij 2 BRN LVJ dos 5 o 2 t E 5 B S 5 RED L1 155 B FEES z 3 58 a 9 ORG RED LED 5 8 5 N 2 BLK 26 BLK 26 m E 5 RED TIME RED TIME 2 2 ORG RED 16 ORG RED 16 BLU LR15 RED L7 RED L7 ORG RED LV42 5 RED L1 RED L1 2 E S 9 ORG BLK 41 ORG BLK 41 3 5 8 8 9 gt 2 BLU L10 BLU L10 WHT LV24 amp WHT L6 WHT L6 8 lt S e 3 lolo RED LVI 22 oo 2 p lo x o 1 0 8
8. Platform Control Box Wiring Diagram Z 45 25J REV A from serial number 16840 to 17974 RED BLK R6 TIME DELAY 1 ORG BLK R6 Ti ORG BLK 41 Q Qo 9 5 5 5 gt 7 5 2g 5 RED TIME RED TIME 2 ORG RED 16 ORG RED 16 2 a ORG BLK 41 ORG BLK 41 3 z 2 gt 2 amp 3 3 D D Bg ME SESE ERE SR RES ECS SSS RSG a EA 2 v vd eles ee aS IE EREE S m E E 22 5 5 5 m 9 52 m RSIS AS SSB olf 21519 1516151513 18 56 5042 82 5 9 2 95 RED TIME 5 o mtuommeg Am 5 xm T
9. RED BLK R6 BRN LVJ TIME DELAY 1 ORG BLK RG 8 7 6 5 4 8 2 1 Ti ORG BLK 41 Q 9 5 o o 9 lo 3 BRN J4 BB 5 2 BRN LVJ 9 S 5 5 5 5155 B m i 23 T E lt 9 lt 5 5 S g RED TIME RED TIME 2 3 ORG RED 16 ORG RED 16 BLU LR15 ORG RED LV42 5 o 2 2 o 9 ORG BLK 41 ORG BLK 41 3 3 ES JTN Hizi 2 BLU L10 BLU L10 WHT LV24 2 amp J WHT L6 WHT L6 S S 3 22 c 2 0 5 5 1 16 06 lt 65 5 0 1999 5 9 lt 5 5 5 gt gt gt 2 3 T e m 2 01 lt lt RED TIL
10. Platform Control Box Wiring Diagram Z 45 25 REV A before serial number 13361 A B D E F G H J L M N RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt 2 5 les D o ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 3 c amp 5 iGIEmg LImriimmo i ms gomsrteeizammzss iaHsmnimm t amp ooroomg9mpoomn mg 51000602 15 5 19 9 FREE ASE coins RAAE m o r DID Dia rm SSS SSSSSSESSssis 28257 44 9 3292 42 9 5112 50 505 ml NOTES D 4 gt n 79 m 3 gt 5 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 2 E gt lt m 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp B 4 2 ON TH
11. 1 TO BASE CONTROL BOX AND ENGINE PANEL LEFT SIDE 2 POWER CABLE DC AMMETER CABLE BATTERY PACK RIGHT SIDE RED 2A BATTERY PACK 48V DC ALTERNATOR 2 o AG 5 BATTERY o 5 2 CHARGER Fs 5 E ala PRIMARY 26 SE E LIFT PUMP 5 AUXILIARY LIFT 5 ols PUMP 722 8 BLACK 2GA 3 BI ENERGY ONLY RED 2GA RED 20 12GA t U EN n WHITE FROM CHARGER a ORG RED R2 1 i 4 BLACK 2GA RUBE LOA BLACK 2GA A II BLACK 2GA BLACK 2GA L __FUSE F4 500A 1 bd bd RED 2GA rj m Ex DIODE 1 4 NC H i la gt AMMETER LIFT CONTAC
12. Ground Control Box Terminal Strip Wiring Diagram 2 45 25 ANSI and CSA Models from serial number 22051 to 23235 Section 6 Schematics 3 vug NHOH SHO 72 05 05 ud 2m 18 18 Nua I m 6 8 8 A c a Co cum z 6 860 Nua m 48 48 48 48 5 s8 98 se 2 8 vI8 218 lJ og J 131 H3MOd A8 Nua H HWQHlVSEO 1 E NHH6H 6 890 SHO 68 892 33 LL Gu HO 6 890 H 56 892
13. A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G T e 0 v0LHO AVIA 110119 1 01 9 SHO 159 TAAFIWHOSLVId THA31WHOdlv1d Av 13H NHOH mE 4 08 I 08 og 5444 58 98 58 98 8 8 828 2 8 lz was 48 48 48 48 lt N 3 9 x x x x EIE a 5 Eo a a 5 E E Nua n as az 6 6 Nua 48 48 48 2 8 2 8 2 8 98 98 98 58 98 98 5 gt 05 05 05 5 5 I Av 13H Av 13H 189 AV 13H 1 H3MOd NH8 A 8t IHWG3H d a 8 Sr IHWNHO St LHWNHO 2
14. RED BLK R6 BROWN LVJ LVI PAD tari 1 CRESCIT 8 7 6 5 4 3 2 1 123456 78 9 10 11 12 41 REDIT 9 m 2 Dm m BLK LSTOP BRN J4 8 5 8 5 o 0 3 5 2 RED L1 cicle D m 5 2 E N 5 m n gt 2 5 P E 99 gt E ORG RED LED e m BLK 26 BLK 26 RED TIME 2 2 ORG RED 16 ORG RED 16 BLUE LR15 RED L7 RED L7 ORG RED LV42 RED L1 RED L1 9 ORG BLK 41 ORG BLK 41 5 z 8 2 BLUE L10 BLUE L10 WHT LV24 5 1 4 J WHT L6 WHT L6 8 S RED LVI a c 2 2 21 515 955 RIES 995 3 IBIS IS Jo 292 198 5 28 25 5 5 5
15. Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25 REVA from serial number 13361 to 14078 A B C D E F G H J L M RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt 58 H 7 E e 2 ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 3 c 0 0 EO 55 ISIS S 5 8 6 5 1 25 1 4 S288 18S 51255 mL mn momi rimmimc 22 m 2 DD ee 2 2 2 2 82921 9171256 mom Am mi 5 285 9 x RED TILT 2 9 E 4 2 2 5 5 ud v S s e RED BLK 28 DD DIS S 50 5 S PRSASARS
16. o E a gt lt 9 6 8 uz 5 202 5 lt pL Su 00 2 2 lt gt Wein Az z Eg 855 22 a gt zie a lt 205 RmIZIZ 5g 5 ge 2225480 CES ts 55552 2558 9499 555 T zz 5 lt O gt 9 t 0 gt 2 amp m Uoc a 2 2 oF gt gt 9 2 2 gt 30328 21 Og 0 22 2919 9 858 0 D Fa lt lt 1 1 1 i P22BAT BK RD STOP P23SWBAT WH
17. JIB BOOM v1 ie MANIFOLD SLAVE CYLINDER BRAKES STEER CYLINDERS TURNTABLE ROTATE S NBER PRIMARY CYLINDER EXTENSION CYLINDER M k L L e eee pepe 4 3000 psi 1 c 60 1 pee A X iae did ud 7 gt 1 1 1 i p 4 ESM 1 1 1 1 1 fae OI m di tm M P MET dog Seer 17 ATMOS Vy E 1000 pei P 1500 psi E We ee TT a 10 76 3800 pal Grepp RRA ERES 262 b MASTER c rue M after serial 5 vs a number 17735 1 5 1 before serial number 17736 8 COM viue BRAKE PS STi 572 PR2 PL2 swi sw2 SEC1 SEC2 P1 P2 EXT RET o 4 i AUXILIARY PRIMARY 221 bar ken 6 of 1 17 1 Li id me A MI HD 1 9 L min 7 9 Limin a T T X ee Ha 1800 psi gh cn 1 124 bar 3500 fo Te 241 bor PNE Y ATMOS Ll ie ay 4 i a
18. Part No 106488 iagram ing D A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Ground Control Box Terminal Strip Wir before serialnumber 13361 Section 6 Schematics 8 E x Nua 8 5 Nua Zr NH8 IJZ T 934 58 ___ PS e ere A MNT e oec ee m bd ENIE 6 a3unna H LHWNHO 6I IHWNHO bd bd Suorig adu Surig aau 9 9 E 12 3 22 44 pup ae Picea a Ot LHM pa cer Oe 8 580 100109 13 31 WHO4LV1d AINO Gasn HOLIMS
19. from serial number 22051 to 23235 RD CB CIRCUT BREAKER RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE 1 CB3 RD CB 12V 12V 15 C21IGN2 WH C21IGN2 WH 5 BK RD BK RD WH J5 WH J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 S WH J4 WH J4 WH J6 BK RD pug m 22 gt 2 aS oe Soa 87 87 87 87 87 87 ON GND BRN 87 86 87 85 87a 87a s Hes 87a B6 les 87a oo RD CB 30 30 CR16 CR11 CR12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WH J4 RELAY RELAY C34SA BK WH x WH J4 WH J6 WH J6 3 gt gt 8 2 RD J6 RD J6 4 5 5 5 8 9 2 a at 2 E 5 3 q 3 B z 3 28 2 51921 5 5 5 2168 g 5 5 m 8 8 o B x amp y 9 912 5 Q Oo 9 Qoo T m
20. RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt gt R 5 9 2 ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 9 99 gt 5 22 519 20952 09 5 522188 685 ea Bsa 8 22 255852385232 2 wlw ooo 2572 5 5 lt 5 z 9588353588252 5 8 m m Ei 55 RED TILT 5 95 56 BOIS M S 18 1139 m 215914714 51 795 5 z m 5s 2 2 Q 4 ES I one 5 RED BLK 28 lx v w l l lolo lo lo lo lo m mm pp E nr rp Ip r im ug pr p np PSsusaazssssssbpeerss Rnaussavssas288 555s 55 58 rz SPSS BRE ae ES Re es es eel
21. 1 JIB BOOM PLATFORM ROTATE CYLINDER FT 3500 psi 241b L z uf i SEMI RESTRICTIVE ES 2 1 5 1 31 v2 vi 1 H gt Tre iem Dm 0 762 mm JIB BOOM fw w PLATFORM ROTATE 3 63 MANIFOLD puse 2 vi SLAVE CYLINDER TURNTABLE ROTATE STEER CYLINDERS m 4 LJ SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM 4 CYLINDERS CYLINDER EXTENSION CYLINDER ETAT 1500 psi BRAKES 3 1 pee p LU MEE ION t 5 3500 psi pod be 241 rr 3 1 Lf gt s ae MASTER T gt d 1000 psi 1500 psi Weenie va 69 bb s 108 Bar 3500 psi ATMOS ATMOS 4 241 3800 3 1 51 ATMOS 262 bar E ME 13 151 6 Sp a a BRAKE Ps s1 s2 PL2 L1 L2 TRI TR2 5 1 sc2 per ______ 2 _____ T 3200 psi 1 This valve was 220 6 0 050 inch 00
22. bo 110179 an TBATIWSOdIY Td WHO41V 1d NHOH vOLHO 40 42 SHO vHO DU IM CNN ELS joe lt 4 08 og sna 8 228 228 ele 58 98 58 58 48 48 48 48 lt 85 3 o 9 7 x x a E a a a 3 m zc z m c c g gg g 8 z a a m E 93 a gt az 6 go z 2 E 5 A 18 S8 lt 98 98 98 98 98 aasnnn 8 EN 0 5 oe H3MOd H3MOd a 81 418 1 Si LHWNHO St LHWNHO T 31viOH 998 4 WHOSLW1d WHOALW1d 1951 6951 1 91 NOILONNA 5 m 189 SSSL 5 x
23. RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt xu 5 9 Se 2 ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 zalm 1315 125 59 92 19 1916 2 lt 25 8 55 2 lt lt lola 266 5 1918 9195 213 2 19 95 2592 2 2 5 5 1229 19191512 51 65 506 510 021 922 9 29575 Bs RED TILT 59571256 5 Ayes n 275 9 x jo MS 5 3 7 5 9 4 g 2 x E iiu e S UJ RED BEK 28 2 2 9955 22 2 2 2 22 99955 5 PISS amp lt lt 555 55555 5555 Rs ese SB Eee ea 2s BRN GRND SR RIS 39 52 0 jas a a FOOT e 9 6
24. 16 1 16 2 C6B 7 C6B 8 BK WH d 8 RETRACT RETRACT COIL T9689 C17 1 C182 PRIMARY BOOM TB8 C3P 7 C7PBE BK C3B 7 C3P 8 C8PBR BK WH C3B 8 TB1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL C12 1 C12 2 C6B 1 RD l C6B 2 RD BK Bl PRIMARY BOOM TB2 CR19A 5 PRIMARY BOOM 1 C1PBU C3B 1 30 87 2 C2PBD RD BK C3B 2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL 6 10 BL C6B 11 BL BK SECONDARY BOOM 11 pont DESCENT ALARM OPTION A3 SECONDARY C3P 10 C10SBU BL C3B 10
25. NH8 NH8 Nua lt TANWd IHL 9 ASSHL 8 5 2 OL 1 H LHWNHO 61 LHWNHO bg PA 9INSId Q3H 1 i SS3NuvH id Sura aag 5 N 2 i Y 61 LHWNHO SS3NHVH ee eee ERE EAE 2 SISSVHO DD MATCHED mos qm os NOILONNP 51 2571 09 a 257 157 a sunmwau e 8t Q 8r O ur 5 aasnnn 2 df 8 SANA St Q g 2 IHWNHS l Oliv 1 305301 air vy Q IG UNUM X 8 NHS es Fel es NOILONN Gyvas sls lt gt 9 JP SEIONSEHOUMS id 9
26. REV A Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option before serial number 13361 N M K J F E D B A RED BLK R6 BROWN LVJ LVI EDAD Nee eee 8 7 6 5 4 8 2 1 123456 78 9 101112 PED 9 00 m 3 E m E BLK LSTOP 2 8 5 BROWN Lvu 5 jS 9 o 3 5 RED L1 8 2 519 58 Y E lt 5 2 2 ORG RED LED e 5 m m BLK 26 BLK 26 gt 8 5 ORG RED 16 ORG RED 16 BLUE LR15 RED L7 RED L7 ORG RED LV42 RED L1 RED L1 2 9 ORG BLK 41 ORG BLK 41 E 5 8 gt BLUE L10 BLUE L10 WHT LV24 A WHT L6 WHT L6 8 8 RED LVI alha 33 22582128 056255 245122509928 528 125005322282 2 2 EH gt 2 lt SIME JE 296 52985 25 1215 3 2 PL JD BBO ele 159 Sp 9 52 9535 54 9 5512 5 91 12 6
27. Nua 2 Nua lt Nua 1 Zr NH8 2g i 9 5 50 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau 1 vru aau na 6 aau na d U IHWNHO 61 IHWNHO bd 1 Suorig aau d SISSVHO ___ SMT Mm N iw LLILIAES DLL _ 22 _______ ___________ fw 91 19 0 G3 100102 13 31 HOS AINO id 1 HOLIMS OL 57 257 Eja o bog NOILONAP 257 157 6b Q SS3NHVH 7OHINOO 8v 8v erimwasu O S IN 9 1 8v p bog rt 9 E LO INVA Sy O
28. REV A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 22051 to 23235 N L K J H G F E D B A He Se tg ese se es ee ps gt sys wa ee cuve WN ee ee ee ag eg ee GSE pk eth ns oy ae tet 1 I ORRD LVI WH RESET IS SET BRN RELAY DISCHARGE IS SET N N CR6 CR19A CR19B 2 tot 2 1 PE FRERE it 2 lt lt i 98 2 1 a 8 8 A 3 9 5 8 oA 1 9 1 jo if iP 1 12 alo olo x 5 i ss 5 NN RIES al il Poo P 1 1 EB a g fg 19 2 2 2 2 JIB 1818 OPT y o 9 ls 4 039 2 3 2 2 1 lt 1 TILT ALARM 19 18 CONTROL CABLE 12VDCBATTERY FOOT SWITCH 5 NOTES Ne ee re rere ee eg
29. Nua 2 Nua lt Nua 1 Zr NH8 2g i 9 5 50 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau 1 vru aau na 6 aau na d U IHWNHO 61 IHWNHO bd 1 Suorig aau d SISSVHO ___ SMT Mm N iw LLILIAES DLL _ 22 _______ ___________ fw 91 19 0 G3 100102 13 31 HOS AINO id 1 HOLIMS OL 57 257 Eja o bog NOILONAP 257 157 6b Q SS3NHVH 7OHINOO 8v 8v erimwasu O S IN 9 1 8v p bog rt 9 E LO INVA Sy O gt Guvas 51915 NE
30. Avay NHOH eee oe 28 2 8 58 18 18 Nua E 8 a 8 5 86 z 6 860 6 HWH9 am 48 48 48 48 e 58 S8 98 58 Mio 18 28 28 v 8 LJ oe oe oe 1 Nua Nua 149 quio H 19880 8EO NHH6H 6 899 55 174 2 52152 SHO 65 899 55 899 H HIWQH 55 899 ala 61 899 1818 72 890 1 62 892 Varro 55 899 ANJ M M 92 892 55906686 S100 07 890 ee ek E YY Houme Nua WH NHS ASPSPO 2820 B SS3NHVH H OHINOO HM 1 850 sz a90 1 1 490 aW HM HMdEZO 869 snivis 1 325300 alf rnv
31. N Ke NMOG 100109 IHM an 1n01n9 AV aH TENTIWUOdIY Md WMHOJ1V1d NHOH volo 5 80 40 suo 7 4 0 08 ze 48 48 8 Nog 48 48 48 48 EE e 9 5 i a 5 x So a ZA I Eu n 26 a a 5 2 n NH8 S8 Ve 2 5 85 5 5 48 48 48 58 98 58 98 98 98 5 2 8 ezg 2 8 oe 0 P 145 LHIWG3H zu qau ouo x X m 81 St LHWNHO St LHWNHO ggg 434 WHOSLW1d WHOALW1d lg 1851 cee m 15 189 SSSL SA e QOO gx eo a a 71 90 8 a c x a w
32. N NHOH vHO io Zen 2 8 2 8 n se 58 Nua 48 48 fa eo 95 i E x gE EE 2 g 8 x x t a g 3 az g us 2 1 18 5 28 18 18 98 98 98 98 98 98 928 2 8 278 Sz a os 0 0 oe XE L 9 H3MOd E Nua 1HIWI3H 8 gt St LHWNHO St LIHWNHO z 31v10H 5 WHOSLW1d 218 1961 L 5 1 al noo NOILONNA 195 9951 G A 6981 L Jul 2 a 5 x 8 a X8 NHO wooa a 0951 a orma Q4 d send CM
33. RED BLK R6 BRN LVJ ORG BLK R6 E d let a is Tek ORG BLK 41 Q Go puo Qo 2g 8 BRN LVJ zou 9 g 3 5 5 51 B KS gt T a m lt m 3 gt 5 2 ORG RED 16 ORG RED 16 BLU LR15 ORG RED LV42 3 9 ORG BLK 41 ORG BLK 41 3 w iz 2 BLU L10 BLU L10 WHT LV24 j WHT L6 WHT L6 S gt 215 155 2 2292 2 455 2 gt gt 5 v 151 221 252 lt lt lt lt 29 95 5 95 5 131 2 E 365540 RED LR15 gt 29065 9 m 21 911 2 8 lt zm i 2 5 Q e S D T GRND ERNY BEDANE 5 3
34. BK RD BK RD 35A e C45JSV GR WH C2B 7 BK 7A GR BK 18A x 1 gt BK BK WH 8A GR 17A gt BK WH BK 5A 5 e RD gt AJ RD PO ENS WH 4A GR O 59 a FEO gt xL BK 5 050r 84545 FFEQ RD BK 2 c aoi RD gt RD RD 27A _ gt RSs 2 5 0 5 5 OMe x e OR BK RD BK 2A OR 14A OR RD 1A 3 gt ono a 8 c c DO DO a J RD 4 P20BAT RD C6B 23 P20BAT RD 7 4 e C78 4 BL 10A RD BA lt 5 BK 22A BL BK 11A 2 OQ 1 58 5 2 WH 23A GR WH 19A BK org z WII OS3 e n om P20BAT RD C5B 1 8 RD 85 ug RD RD RD 6 a a WH 5 BRN N 5 7 2 N o a a 5 1 2 gt m 2 TH 4 a 3 21888 RD S 52 8 8 9 lt a 7 lt a A TEREX COMPANY PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 66 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 21181 to 22050 Section 6 Schematics June 2005 __________ Ground
35. June 2005 RED WHT 29 WHT RED 32 WHT 30 REVA eS kou ze 59 Isur TOEN u us E 255 BRN 2 E 2 BLU RED 3 BLK7 BRN 7 m ES DRIVE ENABLE 8 LIMIT SWITCH BLUWHT 12 BLUMHT WHT 7 m ORG RED 16 _ TP16 ORG RED 3 3 ter 8 8 BRN PLATFORM 1 7 BRAKE RELEASE g d CONTROL BOX g 11 TRAVEL ALARM i GROUND B ORG BLK 1 5 m TUM REDET 448 N BRAKE RELEASE z ews E ai 9 x BRAKE RELEASE 22 5 5 8 5a 5 a 8 5 BRAKE RELEASE PS1 5 PRESSURE SWITCH 51 b 203 8 522 5 P 6 4 STEER LEFT 1 e BLU BLK 1 BLU BLK 37 e i STEER RIGHT BPIPIPIPIE H M 57545
36. REVA 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS amp B ON THE DRIVE JOYSTICK COMPONENT INDEX 1 TILT ALARM AC1 AC OUTLET BOX BCl BATTERY CHARGE INDICATOR BP1 BOOM PROPORTIONAL ROTARY CONTROLLER CR6 DRIVE ENABLE RELAY CR7A JIB BOOM CUTOUT RELAY CR7B JIB BOOM VALVE RELAY DP1 DRIVE JOYSTICK LA DRIVE ENABLE LED P2 EMERGENCY STOP BUTTON P3 HORN T1 TIME DELAY 1 TS1 AUXILIARY TOGGLE SWITCH TS2 START ENGINE TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH RED BLK R6 TIME DELAY 1 ORG BLK R6 ORG BLK 41 3 a S 2 6 2 8 gt 0 I 9 5 RED TIME RED TIME GRN WHT 45 2 2 ORG RED 16 ORG RED 16 GRN WHT 45 D 2 2 o ORG BLK 41 ORG BLK 41 D i d 2 gt 3 am
37. E GR LFC 1 S 20k t GR ei C29JSH RD WH GR S C32JSL WH RD 22 TS11 RD e 1 TS12 TS10 PRIMARY TS13 WH C30FWD WH 1 BK RD 3 wer T MEE ONP 6 8 24 RD RD DRE 5 A 5 5 256 _ WH lt He vi 726 C12DRE BL WH RD RPM PRPL RD J7 4 o4 LIFT D7 i ee x losa 2 5 2 OPTION 9 9 gt RIGHT WH YL 290 C37STC E gt 7010 22 ee 1 2 Qmd b c WH RD C36STCC BL 1 Sy rg mm 5209 Bis LEFT 2710 2 1 7 3 88 5 E Sg EB N 0 2 gt ___ gt A AR A 28 A 28 gt o 2 2 zo 9 o o oo 3 E g 9 9 IE X 12 az 8 Qo 8 3 N 2 3 3 2 25 5 3 RE 5 E 9 RB 5 gt E x a gt 3 2 Xx zl 9 A D 1 2 2 9 2 a m RD 1 E m 5 gt 2 35 o x 3 5 OEIC vai 8 OPO S
38. Nua 2 Nua lt Nua Z 2g i 9 59 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau eo 1 vru aau na 6 aau na V d U IHWNHO 6L IHWNHO bd 1 Suorig aau SS3NHVH bd diz dau SISSVHO ___ SMT Mm N iw LLILIAES DLL _ 22 _______ ___________ fw 91 19 0 G3 100102 13A31 HOS AINO id 1 HOLIMS OL 57 257 Eja o wig NOLLONA 257 157 SS3NHVH 7OHINOO P IN 9 8v p bog rt 9 ale bi INVA Sy 8 bog x z z oW B Guvas THWNES amp 3l 5 E X 18 NHO 4 Gyvas
39. Section B Schematics A RED BLK R6 BROWN LVJ LVI Ti in 1 TIME DELAY ORGIBUCAT E ub 6 9 d 1284596 78 9 101112 DT Q Q QOOQOOQOOOOO 2 2 BLK LSTOP x o 8 BRN Jd 4 28 8 B2 5 85 2 BROWN LW 9 g 3 5 5 5 5 Q RED L1 B m 3 29 9 9 5 89 e L 9 ORG RED LED amp 5 5 BLK 26 BLK 26 g L 5 RED TIME RED TIME 2 2 ORG RED 16 ORG RED 16 BLUE LR15 RED L7 RED L7 ORG RED LV42 RED L1 RED L1 2 2 9 ORG BLK 41 ORG BLK 41 5 2 gt 3 e v 3 gt 2 BLUE L10 BLUE L10 WHT LV24 8 E 5 J WHT L6 WHT L6 8 4 gt
40. RED BLK R6 BRN LVJ LVI TIME DELAY 1 ORG BLKRE 8 7 6 5 4 3 2 1 ORG BLK 41 9 0 00 E oo 3 o 9 2 2 RESET IS SET B 2 gt BRN LVJ 8 9 5 DISCHARGE IS SET TO N 5 5 p Ss m gt EROR g e g 5 E 8 z RED TIME RED TIME 2 2 ORG RED 16 ORG RED 16 BLU LR19A ORG RED LV42 o 2 8 2 5 9 ORG BLK 41 ORG BLK 41 3 2 3 gt 2 BLU L10 BLU L10 WHT LV24 WHT L6 WHT L6 5 S bad 3 D Dd pms 5 5 pes c z m 9 45 lm Ola ealas 9 9 93 2 9 22 lt 55 38 29 0 49225 5 25 gt 122 218 15 2115 RED TILT 811 55 lt 26 8 gt 1 3 4 2 1 1555 42555 S lt 2 m x 5 2 gt 1 3 8 Pee ZEB SSR SSS E SSS SSS ss 2 5 5 2932 4 5 2 59 2 5 lt 3 6 7 E 59 554 RED LR19B Valpo 2 e m 5 gt 5 RED TIME 5951956 852 lt m Alm mie GRN WHT JOYS 9 3 Q x
41. RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt m 8 3 2 3 ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 2 356 5 5 DIS S 55 55522426288 2 5 1 5 25 12 2 5 2 215 5 5319 9 2819 28 57 2 21855 19 2824955 586 B 3 m T elie RED TILT 4579 iin 5 9 z 9 4 2 5 2 lt m I GRND 5 2 5 5 5 2 85 5 55 8 8 8 2 28 3 2 85 gt 58 2 8 RED BLK 28 W ID lololo m oie im Ep Er EI rr PERS ASSESSES SSSA SIS 5 5 5 5 8 810 2 2 2 B S Bld la lao 5 2 5 E 2 22 92 IS 59 AAS n RA RO Ale 554 e EODD d do Aja ala ERRA 3 2 1 JIB SWITCH 5 TILT J Q FS ALARM NOTES SER 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 907
42. Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 117 June 2005 Section 6 Schematics REV A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 21181 to 22050 N M K J F E D cc 1 LVI CT Es Gre OR BK ae ORRD oc Lf WH WH RESET IS SET TO B BRN RELAY 7 DISCHARGE IS SET N 0 CR6 CRI9A CR19B 2 il o n coi ooo l oh som 2585 ERSE 98 EE i I E m i 1 i 1 1 ik 1 1 H 1 1 1 if 4 gt 5 i FOOT TILT ALARM 19 18 CONTROL CABLE 12V DC BATTERY SWITCH I ce ee E O EA INPS I URS ONDE pe ga a eee
43. 6 80 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 NMOG 100109 dn LNOLNO AAS WHOsLV Id NHOH VOLO 90190 Hh s 4 og og 06 18 ce 2 s 8 18 18 18 18 EUM gt e lt lt 9 2 amp a 33 3 3 d gt gt 2 I n 26 a a 5 9 g Nua I Ve 96 o cL 2 E 18 5 18 18 18 98 58 98 1 S8 98 98 8 8 8 8 N 0 0 J AVTSY FOULNOD Lan H3MOd Nua Nua IHWG3H LHIWG3H X m 81 1 I aLVLOY ggg 933 4 WHOdlV 1d 18 2581 6951 1 25 4 9951 5
44. 1 Suorig aau SS3NHVH bd diz dau SISSVHO ___ SMT Mm N iw LLILIAES DLL _ 22 _______ ___________ fw 91 19 0 G3 100102 13A31 HOS AINO id 1 HOLIMS OL 57 257 Eja o wig NOLLONA 257 157 SS3NHVH 7OHINOO P IN 9 8v p bog rt 9 ale bi INVA Sy 8 bog x z z oW B Guvas THWNES amp 3l 5 E X 18 NHO 4 Gyvas y m LO 87 HOLIMS bg Je IN bg Ga dau ou E LO ok 1ndlno INYA Wy G voyo Havoda E m 0 daadS LINIT 440 Ov Q X rt if bog 6 3uvds 6 d N A rt Gyvas 8 Q bd 1 FO 8 APO
45. 12 039 NG dau 2 L 1951 LSA 14 HOLIMS 6 54 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 before serial number 13361 Section 6 Schematics June 2005 _____________ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 13361 to 14078 REVA June 2005 Diagram 2 45 25 Part No 106488 ing enie A G Ground Control Box Terminal Strip Wir from serial number 13361 to 14078 Section 6 Schematics E x 8 Nua Nua 5 NH8 o 2 5 2 r Nua Pay Bed Ed N
46. 3 12 A 10 Perform Engine 3 12 Checklist B Procedures Bel Chek the Radiator nire terere SENSE 3 13 B 2 Check the Exhaust System 24 00 00 00 3 13 B 3 Check the Batteries siiin hanane iaaa 3 14 B 4 Inspect the Electrical 4 3 15 B 5 Check the Lug Nut Torque including the tires and 3 16 6 gt Proper Brake Configuration 2 3 16 B 7 Check the Oil Level in the Drive Hubs 3 17 B 8 Check and Adjust the Engine 3 18 B 9 Testthe Ground Control Override 2 3 19 B 10 Test the Platform Self leveling 3 20 B 11 Test the Engine Idle 3 20 B 12 Test the Drive Brakes 2 3 21 B 13 Test the Drive Speed Stowed Position 3 21 Genie viii Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 p TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 14
47. RED CB CIRCUT BREAKER RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE Wo 1 RED CB 12V 27 WHT BATT WHT BATT WHT BATT WHT 21 WHT 21 BLK RED 35 BLK RED 35 WHT J5 WHT J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 Ewe ae WHT J4 WHTJ4 _ WHT J6 BLK RD BLK RD 555 tn o amp 5 1 m 1 1 1 of 2 9 529 87 87 87 87 87 87 t 85 86 85 86 BROWN CH H ov 87a 86 les 87a 86 87a 35 87a 87a les 87a n RED CB ae 30 30 30 CR16 CR12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAX WHT J4 RELAY RELAY BLK WHT 34 WHT J4 WHT J6 WHT J6 2 gt gt 14 gt a RED J6 RED J6 lt 3 2 s 5 5 lt gt e t t E a 5 galg gle g ol 91215 2 9 2 8 3 8 a 6 a 9 wo o 9 IE 5 oz gt I 9 55 T 8 28 4 WHT R14 o 9 x gl a a I BLK ISM 1 BLK ISM 1 2 BRN VOLT 5 BLU ISM2 BLU ISM2 BLK 33 BRN J5 5 BRN ISMS BRN ISMS RED ISM6 23 t xz arze S855 3 22559 Saat GRN BLK BATT 6 WHT ISM10 INAN ENGINE HARNESS TO CHASSIS HARNESS
48. 2 90 Wdvivoid 2 499 JO ANVOR o 1 80 1840 1 990 V 5 1 8585 2 81 asva WWNINYSL ae 9 5 T ezo N 10 N Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 85 REVA June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25J ANSI and CSA Models from serial number 22051 to 23235 BK RD 35 _ 4 C45JSV GR WH 28 7 BK 7A GR BK 18A e a 1 BK WH 8A GR 17A gt BK WH BK 5A GR BK 4522 BIE gt For WH 4A GR ow 6 eva 5 g p SB GR FEO Sse lt 4 lt HEKO 85600 rae RD 2 rakl RD gt RD RD 27A x 5 lt E gt x 055 o m a 5 ONC 5 8 e OR BK 15A OR BK RD BK 2A OR 14A OR RD 1A gt gt GR BKA4A gow
49. eee eee 1 LOAD SENSE WIRES SHOWN WITH DASHED LINES S FOR OPTION REMOVE JUMPER ON JOYSTICK BETWEEN D TERMINALS 6 amp 7 AND ADD CP8 LS18 AND L4 010 O GR GS OR Fu COMPONENT INDEX LVI BCI TURNTABLE SECONDARY PRIMARY EXTEND O BK RD e a 23 BATTERY CHARGE INDICATOR ROTATE BOOM BOOM RETRACT FWD 6 ev 242 ROTARY FLOW CONTROL DIAL fo 952 1 DRIVE JOYSTICK 5 4 O DS P2ABAT WH L1 DRIVE ENABLE LED S en lt 4 12 LOAD SENSE LED pis 27 LVI LOW VOLTAGE INTERRUPT MODULE 1 pave e 780 LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION 5 meu P2 EMERGENCY STOP BUTTON 2 8 ne 200 P3 HORN 7 p E 5 TS1 AUXILIARY TOGGLE SWITCH BOE gt 8 9 START ENGINE TOGGLE SWITCH 754 HIGH LOW RPM TOGGLE SWITCH E 8 TS6 GLOW PLUG TOGGLE SWITCH m 57 PLATFORM ROTATE TOGGLE SWITCH 2 TS8 JIB UP DOWN TOGGLE SWITCH 759 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH O O 9 O 511 PRIMARY BOOM UP DOWN TOGGLE SWITCH 8 512 TURNTABLE ROTATE TOGGLE SWITCH
50. 10 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED NOTES 1 Part No 106488 gt ADD 040 ONLY IF UNIT HAS L4 AND 148 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 33 Section 6 Schematics from serial number 22051 to 23235 6 34 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN 1 C13DREL BURD C4B 1 BL RD C6B 13 C13DREL BRN 8 C6B 21 DREGND BRN 12 C12DRE BL WH C3B 12 BL WH C6B 26 C12DRE WH 8 52 12 13 7 14 4 C16DRE OR RD C4B 4 OR RD C6B 16 C16DRE 2 8 BRN A2 4 BRAKE RELEASE TRAVEL ALARM 2 C262 SRAIDRE _ C2B 3 5 C6B 35 RD WH Pt 187 BRAKE RELEASE N C COIL RD BK R6 a BRAKE RELEASE PRESSURE SWITCH PS1 C24 1 C242 18 C6B 36 BL IA STEER LEFT COIL PS1 A TEREX COMPANY C36STCC BL C1B 10 E 10 G 7 C37STC C1B 11 1 11 C6B 37 BL BK STEER RIGHT COIL 25 1 25 2 Electrical Schematic Z 45 25 Models C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK C40LS OR LVI BCI OPTION June 2005 C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK
51. Wwongeuo 1 L4 znavo Wooa 03395 330 Or e UO 6 3uvas 6 a 88 88799 8 Lo 1 1 3 4 6 1 9 a 9 1engima gna 6LI IHWNHO 01 SAS s a 9 UH ma O 01 SN 9 swa 9 6 Dil MOT EN o 1 8 1 15 a Wooa 8 MOILSAOP 26 18 lt saan X18 1HM ee 05 0 1HM 8 6 HOSIHH3ISWOLN3IOdMOHSAOh a Q TANVd HOLIMS ENE 3 4 SUM O Ojs 82 SN o LO 22 1909135 dWnd Auvriixnv 22 Q cix 22 34 gt aasnnn o gasnnn E 2 8 E 2 O 5 EZ LHM 44 318vo H3MOd HOLIMSA3M 257 HOLIMS 2 Wavv aau 1HM 2 WHO4LV1d OL 22 a iz iz LZ LHM
52. i Em BRN RELAY n CR6 8 3289 i i 2 i 226 53 i 2 2 BS ERRE 8522520 288 9 2 50 2 2 85 2285335 52 555 555 2 Tu 1 89 gt lt 2 js 1399 JI 5 oo zz 1 A A a 48 EsEi sses5 9822 a3 ss 6329820 28 8 2 Fre B3 38 Re B RO 22 5 1 n BRN BATGND A A A A 3 BRN JIBGND 8 9 99929099299 39389 888888888888 SSS 888 P Pppp P PP a A 1 7 m T 1 i zl 1 gt 4 2 IE 2 1518 i 1 i i D40 i i a FOOT SIUE 19 18 CONTROL CABLE 12V DC BATTERY SWITCH eat Oe DEO TERN RERO NE CUM AE ek
53. RED PISM6 BLK RED 35 BLK WHT 34 GRN BLK BATT CHASSIS HARNESS Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy enie A TEREX COMPANY 6 12 June 2005 Section 6 Schematics Engine Panel Diagram from serial number 14651 to 16839 Section 6 Schematics June 2005 ETC Engine Panel Diagram from serial number 16840 to 17974 Section 6 Schematics June 2005 Engine Panel Diagram from serial number 16840 to 17974 A B M 2 RED CB CIRCUT BREAKER 1 RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE Perd RED CB 12V4 WHT BATT WHT BATT WHT BATT WHT 21 WHT 21 BLK RED 35 BLK RED 35 WHT J5 WHT J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 o 4 WHT J4 WHTJ4 WHT J6 BLK RD B
54. 7 NOTE RED CB CIRCUT BREAKER 1 RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE 263 RED CB 12V WHT BATT WHT BATT WHT BATT WHT 21 WHT 21 BLK RED 35 BLK RED 35 WHT J5 WHT J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 5 WHT J4 WHTJA _ WHT J6 BLK RD BLK RD 555 Q Qs oo 9 S p ESa 2 529 87 87 5 87 87 87 87 85 86 85 86 BROWN CH H ov 85 87a 86 87 86 99 87 87 87 87a 86 RED CB ae 30 30 30 30 30 CR16 CH12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WHT J4 RELAY RELAY BLK WHT 34 WHT J4 WHT J6 WHT J6 gt gt 8 zz RED J6 RED J6 4151516 trigo 2 5 5 3 2 gt 5 t m E E gt 2 9 a 2 D 3 m amp E a x 9 9 95 ou 5 g g 9 giz 5 I 6 a bind N e e E 3 8 8 4 WHT R14 2 2 5 55 2 E 9 d a mc m c BLK ISM 1 BLK ISM 1 2 BRN VOLT 5 BLU ISM2 BLU ISM2 BLK 33 BRN J5 5 BRN ISM5 BRN ISMS RED ISM6 WHITE 23 arzo 5885 3 2556 GRN BLK BATT
55. LOAD SENSE PCB 1 2 3 4 112131415 6 7 8 9 10 11 12 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V ALTERNATOR 12V VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY CR11 48V POWER RELAY CR2 48V POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY GROUND CONTROL BOX GROUND 5 x a a a az gt 2 25 3 5 5253 5 g ak S 28 5 52525 2215 2 52 5295 s 5 5 2 55 m 5 gt 2 E 5 RED PISM6 25 65 iE 57 GG n o T TT Es g BRN 05 5 5 X33 9 4 8 2 8 GE Pa 3x 5 th 5 9 8 8 i 5 Sg gt eo e M 8 zt 8 BLK RED 8 ENGINE BLK 1 START E 1 8 A BLK WHT p gt 5 TOT t 58 8
56. WH LOAD 8 gt 5 SAV LOAD SENSOR MODULE BRN C2P 2 C2B 2 C6B 20 RD C10 2 WH 5 5 8 5 C6B 9 BK RD Ri 0 5 11 2 WH 6 151 EXT C10 1 BK 5 11 1 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY CR11 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY HORN BK 6 s x 10 4 WH 4 11 4 WH 7 C6B 40 OR C10 3 BK 4 11 3 BK 7 OR V CONTROLLER FAULT INDICATOR LED L2 C6B 25 CFIL BK 22 BK 5 21 154 SEC 1 BASE CONTROL BOX GROUND Part No 106488 CHASSIS GROUND P20BAT RD C29JSH RD WH C1B 3 TB40 OR 5 CR5 68 39 CRS RD BK 20 COIL PR1 GR 17 C6B 22 1 OFF LIMIT SPEED INPUT C6B 29 BL WH INTERLOCK F1 POT 30 cR16 6 C32JSL WH RD C1B 6 C6B 32 CURTIS 1244 POT LOW 1 5 C31REV WH BK C1B 5
57. PRIMARY BOOM UP DOWN TOGGLE SWITCH 8 TS12 TURNTABLE ROTATE TOGGLE SWITCH 515 4 1513 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 1 DRIVE ENABLE TS6 TS2 P2 abis IN 187 E even ENGINE START TM 17615 DRIVE ENABLE TOGGLE SWITCH AUXILIARY C PLATFORM RPM TILT ALARM LEVEE LS18 PLATFORM OVERLOAD LIMIT SWITCH PLATFORM OVERLOAD LED oS Re jes i SE DS ee SE RE PM EM MED ee ee M KR 148 TILT ALARM LED PartNo 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 104 June 2005 Section 6 Schematics 2 __ _ Platform Control Box Wiring Diagram 7 45 25 with LVI BCI Option from serial number 22051 to 23235 Section 6 Schematics June 2005 p 7 Platform Control Box Wiring Diagram Z 45 25J before serial number 13361 Section 6 Schematics June 2005
58. 16 1 16 2 C6B 7 9 C6B 8 BK WH nl d 8 RETRACT RETRACT COIL 7963 C17 1 C182 PRIMARY BOOM TB8 PRIMARY BOOM C3P 7 C7PBE BK C3B 7 C3P 8 C8PBR BK WH C3B 8 TB1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL C6B 1 RD C6B 2 RD BK Bl C132 PRIMARY BOOM TB2 C3P 1 C1PBU RD C3B 1 C3P 2 C2PBD RD BK C3B 2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL C6B 10 BL C6B 11 BL BK SECONDARY BOOM TB11 pud DESCENT ALARM OPTION A3 SECONDARY C3P 10 C10SBU BL C3B 10 11 1 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL TBS C6B 5 WH BK m o I EI 4 9 m si C6B 4 WH C14 1 C14 2 TURNTABLE ROTATE RI RIGHT C3P
59. I 28 5 2 9 2 S 5 55 5 m E 5 56 028 gt 9 RED TIME 5921255 9 m 4 918 GRN WHT JOYS gt 51 41 5 4 GRN WHT R12 m lt x GRND 2 5 9 255 1916 49 x mm mmm lo o lo lolo m v o gp ES S 2995 aana Ea 2 2 22 59955 5 RED JIB 55 5 ISIS EIS 5 5 2 2552 gt gt lt SRO RE els eal BRN GANE 0 Aa jae 589 53 NOTES i g a Ax P foie caste caste DOWER N MUN x e 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 5 2 1 C FS FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS 6 amp 7 ALARM ON THE DRIVE JOYSTICK 4 e 9 9 9 9 I 2 olo z z mm mo RESO 2 212 12 T 5 5 DP1
60. bg 1 1 1 4 4 1 a eg 4 TV DC VOLTAGE REGULATOR 1 1 lt 1 E 2E 8 4 BRN 4 ENGINE POWER RELAY CR12 S 2 e bg 3 amp bg pod T WH 4 ray ENGINE RUN SOLENOID 5 bg BAN 4 STARTER RELAY CR11 1 3 878 8 NN gt Pel 1 bah 2 bg 5 E i EN ma 2 2 4 RA2BAT OR RD C2B 4 1 OR RD bg E 1 E 8 8 1 pod 5 g 5 bd aw 8 5 8 5 pg 55 1 88 E Ud RD WH 558 48V DC POWER RELAY CR2 219 C7P 2 P23BAT WH C7B 2 TI o 5 BRN 71 48V POWER RELAY CRI 8 8 1 bg ee 1 1 E g FLASHING BEACON OPTION 2 i 14 5 cx A NE EN M 2 to C1P 2 C28TTA RD BK C1B 2 C6B 28 RD BK WH oe B caps ci34PwRGR C2B 5 C6B 34 RD RD 1BK BRN TILT SENSOR 2 lt BR L 3 Fd S SSS 1 HOUR METER M ned C3P 9_ COHRN BK RD C3B 9 BK RD bg bg bg bg 2 P23BAT WH C7B 2 red AB EN a 1 5 T 1 5 a m 22 gi C7B 1 1 e
61. hos C12DRE BL WH P42BAT OR RD TS55 FUNCTION ENABLE RD 5 4 C14 1 C14 2 GND BK PR2 IB a E a 6 48 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PRIMARY LIFT PUMP RELAY COIL PR2 AUXILIARY CONTROL RELAY COIL CR3 AUXILIARY LIFT PUMP RELAY COIL PR3 Part No 106488 71771 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT ALARM OPTION A3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL June 2005 Section 6 Schematics aie ey Electrical Schematic Z 45 25J from serial number 21181 to 22050 June 2005 Section 6 Schematics REVA Electrical Schematic Z 45 25J ANSI and CSA Models from serial number 22051 to 23235 C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK C40LS OR P24BAT WH R42BAT OR RD FOOTSWITCH HIGH RPM 1 9 5 BK RD 1 9 C12DRE BL WH P42BAT OR RD RD RD IGNITION START MODULE START RELAY
62. 59 a PES ee pol po OA co Of po gt OF OT po eo 8 583 2 8 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part N
63. beo i ATMOS i Ba bd tee sae om Tt S 3500 psi M 1000 psi atmos i 1 er it 1 L DL 1500 psi 3500 psi 4 p 103 241 ber mere a 0 030 e po MASTER v2 5 COM BRAKE PS sn ST2 PRI PR2 PL2 SWi c2 1 P2 EXT RET to 4 0 037 inch AUXILIARY PRIMARY e 1 0987 ine ipi diss 6 1 9 min ith umi 4 2500 psi Sue T uS gt 79Umin J gt j 6 H BL H Hym cq og pu pesce LI STKE e ari x HDI Hx ANE eg Ec t PE y 0 030 9 030 inch 0 4 gpm 0 76 mm from serial number 22566 to 22628 15 Umin RESERVOIR T 1 and after serial number 23235 7 ciel gee FUNCTION MANIFOLD o o A TEREX COMPANY PartNo 106488
64. bg i HN 8 2 5 HORN RELAY gt 85 8 BRN T T 1 BK 8 25 C6B 9 BK RD 4 HORN 8 3 E 2 C6B 20 RD 10 2 WH 5 RD 5 2 i Oe 5 7 5 iR 10 1 5 11 1 BK6 BASE CONTROL x GROUND a 5 10 4 WH 4 11 4 WH7 5 5 C6B 40 OR 10 3 4 BK7 98 BK 5 2 bag al 5 5 amp SR a 9 bg 6 CONTROLLER FAULT 5 i bog NDIGATOREEDI2 JE 2 S 4 C6B 25 CFILBK 5 BK2GA a pe E 4OR RD 885 C6B 39 CRS 59 1 BRAKE RELEASE C2P 2 C40LS OR C2B 2 4 z 3 RELAY CRS lt 1 bg p qnem 5 MOTOR MAIN Se T OR RD Pe CONTACTOR RELAY PRI 8 _ 5 OFF LMT SPD _ g 8 Fd A E bg E ul 6 12 1 BLWH INTERLOCK E a bog 2 9 9 E 3 C29JSH RD WH C1B 3 C6B 29 RD WH 1 Jig lt 5 Dd 5 1 59 1 6 4 C32JSL WH RD 6 C6B 32 WH RD POT LOW 14 i o 5 C31REV WH BK C1B 5 C6B 31 WH BK REVERSE 5 1 1 4 C30FWD WH C1B 4 C6B 30 WH FORWARD DIODE RETURN 9 8 OR RD 48V DC INPUT bg
65. 6 12 A Engine Panel Diagram from serial number 16840 to 17974 6 13 A Engine Panel Diagram from serial number 1797510 21180 6 14 A Engine Panel Diagram from serial number 21181 to 22050 6 15 A EnginePanelDiagram from serial number 22051 to 23235 6 16 Genio Xii Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 TABLE OF CONTENTS Section 6 Rev Schematics continued Electrical Schematics Z 45 25 A Electrical Schematic Z 45 25 before serial number 13361 6 17 A Electrical Schematic Z 45 25 from serial number 13361 to 14078 6 19 A Electrical Schematic Z 45 25 from serial number 14079 to 14650 6 21 A Electrical Schematic Z 45 25 from serial number 14651 to 16839 6 23 A Electrical Schematic Z 45 25 from serial number 16840 to 17974 6 25 A Electrical Schematic Z 45 25 from serial number 17975 to 21180 6 27 A Electrical Schematic Z 45 25 from serial number 21181 to 22050 6 29 A Electrical Schematic Z 45 25 ANSI and CSA Models from serial number 22051 23235 6 31 A Electrical Schematic Z 45 25 CE Models from serial number 22051 to 23235 6 33 El
66. 9 9 0 5 5 RED BLK 28 vlv o lo lo m 33 NOTES RED JIB 58894442255 5 59882221 5 9 55 5 5 5 6100 lt lt ALL WIRES WITHOUT LABELS ARE gt gt lt 3m 2 2 EITHER RED OR BLACK JUMPER WIRES BRN GRND AIS 6 ISIS 56 AI xS FS SAS 0 5 ES olal SJE 22 jaja FOR LIFT DRIVE SELECTOR OPTION CABLE POWER switcu TAKE OFF JUMP BETWEEN 6 amp 7 5 2 TILT J W es ALARM 2 1 TILT ALARM 9 89 9 288 BRI 8B 22 OS g Dei S OUTLET BOX S IE 3 g S8 5 3 21812818 5 148 5 GRN REDIWHT 29 55529 BCI BATTERY CHARGE INDICATOR lt lt 2 2 o 5 3 i M BP1 ROTARY FLOW CONTROL DIAL amp gt B 5 ORG 2 _WHT RED 32 2
67. 918 815 o jo lo lolo w d w j BIRR SSS ERE 3283265 ele 5 le le Si 253393 SS SSS SPS 2225 SSeS AT SS SS 2 Sls E I T en le I r 23 Sale 53 lee 214 9 415 Foo Q5 d ca ds ou LA AM m uh CABLE CABLE CABLE JIB switcH TILT 72 M ALARM 9 bd eoo 9 9 9 9 9 9 9 9 9 m o o o m olo 2 o RA m mimis amp 6 o 223 8 5 16 1 9 RR 5 5 5 5 547 25 85 2 E 5 1 585 518 GRN RED WHT 29 lt m E EIN 8 m T 20k 1 Om SIN 9 9 x x x 43 3 zug 5 5 5 T 7 5 5 DAE a g ORG WHT RED 32 3 E gt a 92 51 lt a RIS t 7 5 9 5 WHT gt WHT 30 5 two 222r BLK 1 WHT BLK 31 zu e e 94 RED 58 25 Sin m WHT GAN WHT LV24 s B S rE PRPL J C O BLK RED ag O A oe 4 LA BLU RED BLK R6 bs 8 3 5 4 e MHTYEL Tog BLU BLK 37 e e WHTIRED
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70. 14 7080 TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 1 DRIVE ENABLE TS6 TS2 P2 1 jx m tow PLUG ENGINE START ON TS15 DRIVE ENABLE TOGGLE SWITCH AUXILIARY JIB BOOM PLATFORM PLATFORM RPM Al TILT ALARM POWER UNE mE 1618 PLATFORM OVERLOAD LIMIT SWITCH 14 PLATFORM OVERLOAD LED M M P a M 148 TILT ALARM LED Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 120 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 22051 to 23235 Section 6 Schematics June 2005 Hydraulic Schematic before serial number 16962 Section 6 Schematics June 2005 I I Hydraulic Schematic before serial number 16962 A B C D E F G H J K L M N REV
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74. 225231883852 EIE 831522222 52434245561 1516 42955 3 5 m m m 22 8 25 9 287905828552 59 70225825 912191914 RED TILT 5251255 9 Sm 2 EIL g 2 I r 3 qm lt 5 4 5 GRND 7 3 u s 3 5 58 5 5 5 5 5 5 55 RED BLK 28 0 101 W W O O O 0 0 0 DIS 5 DDD FSS SAASSSESS SSR RZEE SESS parse 22 laa aE 919 Z39 jas nam s AC FOOT 6 a gt ima Es CABLE CABLE CABLE POWER 2 SWITCH 5 TILT P FS ALARM NOTES 5 9 9 9 E 5 m m 9 E m 5 m 5 5 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 5 5 5 5 8 sm Sis 575 22 GRN RED WHT 29 5942 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp B m E N m BIA 5 E x 20k SRSR ON THE DRIVE JOYSTICK 9 9 5 a biz Y ORG WHT RED 5 5 2 5 19 s jz 2 t e 2 298
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76. C32JSL WH RD C32JSL WH RD C30FWD WH LVI BCI OPTION C30FWD WH C31REV WH BK C31REV WH BK C40LS OR C40LS OR P24BAT WH P24BAT WH OR BK R6 DRIVE C2P 3 30 87 ENABLE C36STCC BL C1B 10 C6B RD WH RD WH PS1 JACK G Ji BRAKE RELEASE C6B 36 BL 26 1 6 26 2 C24 1 C24 2 I C1P 10 C37STC BL BK 1 11 TB37 C6B 37 1 11 5 7 RD AUX L AUXILIARY PUMP C27AUX RD C1B 1 C6B 23 P20BAT RD 2 1 1 7 1 R42BAT OR RD SECONDARY a a 2 5 81765432 BCI OPTION 864 CR19B C4P 7 C19LPMP GR WH C6B 38 GR WH 4 GR WH OR RD C25 1 C252 BRAKE RELEASE TRAVEL ALARM A2 BRAKE RELEASE N C COIL BRAKE RELEASE N O COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL 5 OR RD C4B 7 GR WH 27 uu c Ne us i TB19 0 6 WH RD RD BRN ROTARY OEM FLOW CONTROL BP1 C2P 6 C44JDA GR BK C2B 6 lt C3B 6 WH RD 2
77. RED BLK R6 BROWN LVJ TIME DELAY Bur ad 1 E BUG 8 7 6 5 4 3 2 1 123 45 6 7 8 9101112 RED L7 OD OY QO QO oo QOOQOOQOOOOO o 2 2 8 BRN J4 BEKLSTOP 9 909 RS 8 jp 3 g 9 E 8 2 RED L1 B IE 5 2 N gt gt i Y Y a P E 9 9 z 9 8 gt 3 ORG RED LED 5 Vv ii 5 gt BLK 26 BLK 26 Y gt wo RED TIME RED TIME 2 2 ORG RED 16 ORG RED 16 BLUE LR15 RED L7 RED L7 ORG RED LV42 RED L1 RED L1 8 2 9 41 ORG BLK 41 E gt 2 BLUE L10 BLUE L10 WHT LV24 LE 5 WHT L6 WHT L6 825 S lolo RED LVI 22 2 visi lt m amp x lt 83 9 5 188 5 59 2 5 9 RED TILT 3 25 5 mE S iS 2 a 2 c m 5 amp 5s 22585814 EEEE lt Selaka ma Ea eaaa 592 lt 9 Raela 5 RED LR15 9 2 gt 92 mm nu RED TIME 1911 B o s NOTES 2 GRN WHT JOYS 5 918 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 4 GRN
78. TEREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 106 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option before serial number 13361 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 13361 to 14078 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 13361 to 14078 REVA RED BLK R6
79. 5 Q 2 WOOG Q ee ee wg noo 99 3uvds WOO8 9 V 81 3Sva IWNINYAL 10 Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 61 Section 6 Schematics June 2005 Ground Control Box Switch Panel Wiring Diagram Z 45 25 REVA from serial number 16840 to 17974 N Ke 100109 1HM Lnoino TENTMWUOdIYMd 1 T3A31 WHOSLV 1d NHOH VOLHO 90199 SHO THO p joe 4 0 08 ze 48 48 8 Nog 48 48 48 48 e lt ON X E amp x x ao 3 8 Be
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82. jaja jaja 1 CABLE CABLE CABLE POWER ie NOTES 3 2 re ALL WIRES WITHOUT LABELS ARE 5 TILT EITHER RED OR BLACK JUMPER WIRES ALARM FOR LIFT DRIVE SELECTOR OPTION TAKE OFF JUMP BETWEEN 6 amp 7 e e m 5 m olo d d o mm m x 1 5 cT mm mir DP1 amp 212 2 om amp amp o 5 t B ES 55 558 5 GAN PEDINHT 29 dz COMPONENT INDEX 5 PEE a Y oRG WHT RED 32 E TILT ALARM a 8 t t 289 ACI AC OUTLET BOX 6 WHT 5 RS 2 5 E BCI BATTERY CHARGE INDICATOR m ty 4 GL WELK E BP1 ROTARY FLOW CONTROL DIAL RED 5 2 CR6 DRIVE ENABLE RELAY WHT GRN s B GI GREEN EL 5 CRI9A LOW VOLTAGE INTERRUPT BCI RELAY RED PARE CRI9B LOW VOLTAGE INTERRUPT BCI RELAY LIFT 2 M 9 BLK RED 27 ale DP1 DRIVE JOYSTICK Ore Ord 4 BLU RED BLK R6 5 oo DRIVE L1 DRIVE ENABLE LED 3 5 4 po e BLUBLK37 LOW VOLTAGE INTERRUPT MODULE o e eoo BLU 36 BATTERY CHARGE INDICATOR FOR LVI OPTION 7
83. 6 119 A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI option from serial number 22051 1 023235 22 0024200 4 0 6 120 Hydraulic Schematics B Hydraulic Schematic before serial number 16962 6 121 B Hydraulic Schematic from serial number 16962 to 20379 6 122 B Hydraulic Schematic from serial number 20380 to 22565 6 123 B Hydraulic Schematic from serial number 22566 to 23235 6 124 xviii Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 2 Specifications REVA Machine Specifications Tires and wheels Wheel diameter 14 5 inches Wheel width 7 inches Wheel lugs before serial number 16128 Front 58 18 Rear 9 58 18 Specifications Fluid capacities Fuel tank 9 gallons 34 1 liters Hydraulic tank 8 gallons 30 3 liters Hydraulic system 11 gallons including tank 41 6 liters Drive hubs refer to tag on drive hub to determine type EW1 type 17 fl oz Wheel lugs from serial number 16127 to 23235 0 51 liter Front 9 58 18 wy 23 fl oz Rear 9 5 8 18 0 68 liter Lug nut torque 125 ft lbs Drive hub oil type SAE 90 multipurpose hypoid gear oil 169 5 Nm API service classification GL5 Tire size 9 14 5LT Batteri
84. 8 8 1 WOOG Q Bm OL n JOULNOD 141 9 inmwwuo P 9 G3H IHM GSH IHM LO QOIS 31VLOH 5 Sor 1HM v 1457 SLVLOW 9 IN 9 IHM 8 100 5 Q 2 WOOG Q ee ee wg noo 99 3uvds WOO8 9 V 81 3Sva IWNINYAL 10 Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 79 Section 6 Schematics from serial number 16840 to 17974 Ground Control Box Switch Panel Wiring Diagram Z 45 25J June 2005 REVA
85. A TEREX COMPANY 6 123 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics ee See Hydraulic Schematic from serial number 22566 to 23235 N M L K J H G F E D B A REV B JIB BOOM PLATFORM ROTATE 1 b bog Sal zur nif fe bd 1 1 1 1 tot i 1 1 1 1 o OM TE 262bar fee 207 bar U4 eI R PR2 PRI 2 J2 PR2 PRI s JIB BOOM PLATFORM ROTATE MANIFOLD L 1 v2 v1 SLAVE CYLINDER TURNTABLE ROTATE SECONDARY CYLINDERS PRIMARY CYLINDER EXTENSION CYLINDER BRAKES STEER CYLINDERS 4 1 34 4 3000 psi 1 LJ L t4 mt C eile ul eet EP M do ENS 13 i
86. Priority flow regulator sel 2 position 2 way solenoid valve I amp s 21 Counterbalance valve PartNo 106488 TEREX COMPANY Hydraulic Symbols Legend Differential sensing valve KH Solenoid operated proportional valve before serial number 22566 T Solenoid operated proportional valve after serial number 22565 N C Pressure switch Solenoid operated 2 pos 3 way directional valve 3 position 4 way directional solenoid valve lt gt Shuttle valve Check valve pilot operated Z 45 25 Bi Energy Z 45 25J Bi Energy Section 6 Schematics June 2005 A TEREX COMPANY 6 4 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 Section 6 Schematics June 2005 Dn Power Cable Diagram before serial number 16839 Section 6 Schematics June 2005 E aU a I I Power Cable Diagram before serialnumber 16839 REV A
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89. 2 Machine Specifications 2 4004024 0 1 00 Performance Specifications Hydraulic Specifications Manifold Component Specifications Machine Torque Specifications Kubota 2482 Engine Specifications erar M Generator Torque Specifications Hydraulic Hose and Fitting Torque Specifications SAE and Metric Fasteners Torque Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy vil June 2005 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued A 3 Check the Generator Belts and Pulleys 3 8 4 Perform 30 Day rete tede pedet adn 3 9 5 Perform Engine Maintenance 3 10 6 Perform Engine Maintenance 2 3 10 A 7 Grease the Turntable Rotation Bearing and Rotate Gear 3 11 8 Engine Maintenance 3 11 A 9 Perform Engine Maintenance
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91. LHIWG3H zu qau ouo m 1 9 ggg 434 WHOL 1d WHOSLW1d 1951 6951 9 NOILONNA 189 9951 5 TROL Dx z B 9 a c ES woog dau AHVGNOO3S dau 0951 dau orna lt 2951 POY a mma x bs A 1 N mr o z 6L LHWNHO VE LHWY d xa diH LS TVNIIWH3 L OL mE SS3NuVH 3SV8 wa WH ONAL woog Oe Qoo AHVIAIHd 5951 1951 2 WS 1 qd3d 4 m L Nua Nua O uus OOO E 79951 HB amp R 8 f 42 T aay zaa 5 9 NG wamoa aau 248 HOLIMS 9018 LSJ 1551 td 6 60 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy
92. 1290 1 DRIVE JOYSTICK 2 m z a o DRIVE ENABLE LED 5 LOAD SENSE LED 7 S gt 5 LOW VOLTAGE INTERRUPT MODULE LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON HORN 151 AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH LOW RPM TOGGLE SWITCH O O OOO O O 186 GLOW PLUG TOGGLE SWITCH 8 Ne PLATFORM ROTATE TOGGLE SWITCH Q 9 TS15 9 9 789 PLATFORM LEVEL TOGGLE SWITCH DRIVE ENABLE TS6 TS2 B3 Em nm m ai ENGINE m T810 SECONDARY BOOM TOGGLE SWITCH HORN AUXILIARY PLATFORM START APNI EMERGENCY PRIMARY BOOM UP DOWN TOGGLE SWITCH EN ROTATE STOP TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 515 DRIVE ENABLE TOGGLE SWITCH Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 102 June 2005 Section 6 Schematics 2 4 Platform Control Box Wiring Diagram 7 45 25 wi
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97. 11 C3B 11 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL TBS RIGHT C6B 5 WH BK B C6B 4 WH C14 1 C14 2 TURNTABLE ROTATE RD RIGHT C3P 5 C4TRR WH BK C3B 5 2 5 4 C4TRL WH C3B 4 P24BAT WH R42BAT OR RD FUNCTION ENABLE C40LS OR RD C12DRE BL WH P42BAT OR RD RD TS55 GND BK PR2 prc p ED June 2005 Section 6 Schematics as Se Electrical Schematic Z 45 25J ANSI and CSA Models from serial number 22051 to 23235 REVA C29JSH RD WH June 2005 Electrical Schematic Z 45 25J CE Models from serial number 22051 to 23235 Section 6 Schematics pg 1 1 1 z r o 2995
98. 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 BRN WHT 21 WHT 1 RED J10 12GA 85 CR12 12V ENGINE RUN SOLENOID gj 21 TP25 TP24 STARTER RELAY CR11 WHT 23 WHT 21 STARTER ORG RED 42 ORG RED 1 ORG RED Bl gl TB42 CONTROLLER E 5 2 NA 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 RED WHT 3 RED WHT 3 RED WHT 3 B i FLASHING BEACON OPTION RED WHT 23 FS1 RED FS A1 TILT ALARM RED BLK 28 WHT RED WHT 23 RED RED BLK 1 TP26 WHT 2 m e TILT SENSOR ENABLE HOUR METER z d RED 1 BLK RED 9 BLK RED 3 li HORN RELAY BLK RED 9 g p BRN T 1 BLK 2 BLK 22 ans V7 BASE CONTROL BOX GROUND TB22 Ls4 SEC Ls2 TP23 5 TB23 BLK 8 RED 6 BLK 6 4 TB50 9 TB49 21 21 PRI 13 S 14 PLATFORM GROUND RED 8 INDICATOR LED L2 KS1 ORG RED 42 YN BLK 4 CONTROLLER FAULT 1 40 BRAKE RELEASE RELAY CR5 i ORG RED 9 RED BLK R5 g 8 8 ORG RED 42
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101. E e 48 48 48 48 s8 8 58 s8 98 228 2 8 228 98 75 2 oe hd oe oe ee AVIS 1041400 Nua 1 2 NHH6H 6 499 26252 66890 88 1 6 899 92 890 HN H9 61 899 a 7 XNVZ2 72 890 9055 ES J 8V avro 55 899 9855 55 92 890 71070 0 899 c 6 ae A YAS PN 22 88888 8 rl Nua WHNHG ANE ASPSPO 1 820 SS3NuvH OH1NOO HM ZN IIZO 11 850 sz aoo E 1 8024 1 860 snus HM 85 inva vel vel dI UWGVEID 9H 5 89 8561 C4 9 820 Wavavoia zv SIOA HOLIMS zi arao 9 1Vgerd 7 820 22 89 77 03395 330 9 HO 5100 2 820 81092 72 990 6LI HINHO E 9 915 59 913 60 26 890
102. RED LR15 amp 2 5 581854 REPPE ei Fly ial ier Nos m z mi 3 re 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES m 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS amp BROWN J7 ON THE DRIVE JOYSTICK GRND 9 6 X BROWN LJ N o O A OO X ISO BROWN J1 RED BLK 28 2 2 m lala IE I REE EE PETE IE BS Ie Le Lee 33 2 o s 25 2 2 2 5 RB 51 x a me gt g Q d a An aja EN INDEX 1 SWITCH 1 Rc FS AC AC OUTLET BOX ALARM BCI BATTERY CHARGE INDICATOR BP1 BOOM PROPORTIONAL ROTARY CONTROLLER CR6 DRIVE ENABLE RELAY 9 8 a 2 8 2 989 8m 9 SE JIB BOOM CUTOUT RELAY 9 2 4 5 5 5 2 lt 56 6 35 2 3 5 m B 5
103. 1 IER 225 PUN il 57 5 0 amp amp LIT E 2 RED BLK4 RED BLK28 WHT E LI WHT 2 ul RED WHT 23 RED IBLK BRN pO s ii iQ g 8 15 vie 1B x 1 ig ig ml 1 1 1 Uu i g 5 t BLK RED 9 BLK RED 3 BLK RED 9 3 E y a but Megane BLK 22 5 m i 58 ae 2 g s a a 29 Bik F 6 RED 5 2 2 4 E 9 pr e BE 1 CONTROLLER FAULT 5 INDICATOR LED 12 imi ORG RED 42 BLK i 5 el ORG RED ose RED BLK RS 50 9 ORG RED 42 COIL PR1 GRN 17 1 A t OFF LIMIT SPEED INPUT BLUWHT 12 INTERLOCK 3 5 29 REDWHT 1 TB29 _ REDMWHT 29 244 8 E 5 1 2 wHT RED i 2 _ WHT RED 32 POT LOW 44 88 ES E T ui WHT BLK 1 WHT BLK 1 88 TPS a REVERSE y g 21 2 2 TP30___WHT 1 7830 WHT 30 FORWARD S gg DIODE RETURN 9 B cope 5 9 we ORG RED 42 48V INPUT amp
104. 210 ig 2 o 2 8 I 5 1 z 1 1 AUXILIARY PUMP AEBS gt 8 p x RED 35 RED 1 RED 27 898 AUXILIARY CONTROL 1 5 gt RELAY COIL B 8 u w Flt T NI 4 AUXILIARY LIFT PUMP RELAY COIL PR3 o 1 2 GRN EC WHT3 GRNWHT 8 eee m gt GRNWHT LIFT PUMP RELAY 2 g th COIL PR2 B nna RB o x 8 gt WHT RED 3 WHT RED 6 5 PROPORTIONAL u VALVE p PLATFORM a EI dg DOWN E GRN BLK 18 ROTATE RIGHT TT JIB BOOM DOWN 5598 8 n GRN 17 z 2808 9 PLATFORM 5 m UP ROTATE LEFT JIB BOOM UP 1 2 E DOWN GRNBLK 3 2i GRN 3 5 2 amp RIGHT ot 8 50 EL 2 pere 2 55 LEFT 5 ac oe JE Eu 39 32 WHT 40 Qe E 16 1 mw ae s 4 rz 91 BRN 3 Bt zu PLATFORM LEVEL th 92 UP RELAY CR10A g Fl ES a 2 P JN m 5 s ORG 14 PLATFORM LEVEL 1 UP mi
105. 5 SL 18 680 IN Siongiouo gt y 318vo 187 HOLIMS i vL Q aoe e 5 anaba nodi Bas zi pr THOM EL 2 a lt M H3MOd HOLIMSLOOS THA ala a 4 LO NMOG m 25 Q monga vi mama gt rS HOLIMS LO 8 orma orma 5 ma 8 mamma O 016 NHOH 6 Q 5 saw 18 WOO 8 Q ee ie Bm OL n JOULNOD 141 9 inmwwuo P 9 G3H IHM GSH IHM LO QOIS 31VLOH 5 Sor 1HM v 1457 SLVLOW 7 1HM 9 IN 9 T LHM IHM 8 H3MOd 100 AV HH A 8 Q O 2 WOOG Q ee ee wg noo 99 3uvds WOO8 raga 9 81 3Sva IWNINYAL 10 Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 59 Section 6
106. 9 zx S 208 COMPONENT INDEX At CABLE CABLE POWER SWITCH P 5 3 2 in JIB FS TILT ACI AC OUTLET BOX ALARM BCI BATTERY CHARGE INDICATOR 1 ROTARY FLOW CONTROL DIAL CR6 DRIVE ENABLE RELAY 2 v 2 o 0 2 D t 1183388 855 5 8 E E 85955 8 8 8 8 8 2 88 8 8 Bgs s RELAY 2 T CIC 5 8 5 5 RO S 515 3 5 2 1 8 5 915 CR17 LOAD SENSOR RELAY 5 9 8 x Sis 598 23 Die 55 z 5 5 5 m CR19A LOW VOLTAGE INTERRUPT BCI RELAY A 6 CR19B LOW VOLTAGE INTERRUPT BCI RELAY 2 2 9 1 DRIVE JOYSTICK lt 5 L1 DRIVE ENABLE LED L3 CONTROLLER FAULT LED GREEN 1 TO id RED 14 OVERLOAD LED LIFT OOO BLK RED LDS LOAD SENSOR MODULE FWD ove a LOW VOLTAGE INTERRUPT MODULE 3 5 4 REV LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON 7 1512 TS10 7511 TS13 L tert 5 34 AORN LVI BCI OPTION T T ROTATE SECONDARY PRIMARY EXTEND BP1 BOOM BOOM RETRACT J TIME DELAY 1 5 TS1 AUXILIARY TOGGLE SWITCH E
107. PartNo 106488 4 eu 7 C19LPMP GR WH C4B 7 GR WH 3 e 6 814132111 gi sh GR WH 8 n C3P 6 C6LFC WH RD z a C3B 6 WH RD C6B 6 WH RD s BK RD BRN 85 BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP m 023 1 5932 C6B 17 GR 22 1 22 2 Bl 3 5 9 28 55 CR19B TB17 C2P 6 C44JDA GR BK C2B 6 1844 6 C18PRR GR BK C4B 6 C4P 5 C17PRL GR C4B 5 GR BK C44DA C6B 33 JIB MANIFOLD GR WH C2P 7 C45J8V GR WH C2B 7 PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL 20 1 20 2 C6B 14 OR 5l Nd C6B 15 OR BK C21 1 C21 2 PLATFORM LEVEL 15 PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B 2 C14PLU OR C4B 2 4 3 C15PLD OR BK C4B 3 TB7 EXTEND 4 PRIMARY BOOM EXTEND COIL PRIMARY BOOM
108. REVERSE C30FWD WH C1B 4 C6B 30 FORWARD P20BAT RD CB1 10A e re P20BAT RD C7B 4 P42BAT OR RD C6B 3 DIODE RETURN ev INPUT OR RD PR1 U6A MOTOR CONTROLLER 5 BASE CONTROL BOX GROUND CHASSIS GROUND 2 F1 30 cR16 OR GEN NEG OR GEN POS F4 500A AC POWER WH BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 SWITCH SHOWN WITH BOOM EXTENDED 48V DC CHARGER PRIMARY F5 10A F2 200A 24V DC BK AP2 AP1 GROUND LIFT PUMP AUXILIARY PUMP NOTES gt ADD 040 ONLY IF UNIT HAS 14 AND 148 gt ANSI CSA 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 4 ALLSOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 6 49 Section 6 Schematics from serial number 22051 to 23235 6 50 3 DRIVE ENABLE LED L1 DRIVE ENABLE LIMIT SWITCH BRN C7P 3 BATGND BRN C7B 3 BATGND BRN 22 21 y 6 1 C13DREL BL RD C4B 1 BURD C6B 13 C13DREL BK 8 BRN 8 C6B 21 DREGND BRN 12 C12DRE BL WH C3B 12 BL WH C6B 26 C12DRE RD 8 12 4 4 C16DRE OR RD C4B 4 OR RD C6B 16 C16DRE BRN
109. WE 1 ORRD LVI 02 1 OR ene OR BK ae ORRD oc WH WH 56 RESET IS SET BRN RELAY 7 DISCHARGE IS SET N 0 s CR6 CRI9A CR19B 2 il o n 2m coi ooo E AE E se ZIRE ERE 9 EE I E m i 1 i 1 1 ik 1 1 H 1 1 1 if 4 gt 5 i i 1 FOOT TILT ALARM 19 18 CONTROL CABLE 12V DC BATTERY SWITCH ee INPS I URS ONDE dore PC concor cro Prr cM eee eee 1 5 Mert QE E S PE ee ee aive e Vig ee Poe NOTI ST UM Xi I MI eG EGO ee gE cV 1 1 5 o S ite 5 512 TS10 TS13 RD 920 NOTES TURNTABLE SECONDARY PRIMARY EXTEND O BK RD 23 ROTATE BOOM BOOM RETRACT FOR CE OPTION TAKE OFF JUMPER ON JOYSTICK 6 i BETWEEN TERMINALS 6 amp 7 AND ADD 8 O O O O P24BAT WH i x COMPONENT INDEX BCI BATTERY CHARGE INDICATOR BPI ROTARY FLOW CONTROL DIAL
110. lui o iu E gu E 2 See 9 9 E t 0 0 E 4 8 5 62 a ixi 2 WENN LE 9 P 10 vo aa O 2 22 109135 dWnd 12 x 2 100 151 cix 12 gt iz uasna 92 aay 22 e 1 14 el BS aasann 521 2 5 1 I xicjujz S ol s3 a o i o aasnnn 2 2 54 __ o 9 58 z IHWG3H ga 1HM 22 9 1 OL 5 LO 12 ma PER IZ LHM Sod F4 lt E o e 2 61 6L a EI 6LT LHWNHO ann 61 IHWNHO Oj 6L 14 6 61 LHWNHO OK nmn E lt lt 3i IHNWNHO IHWNHO gt zx s saw O 317109 WHOdIvid 81 9 gt 2 O 28 NMOGSIZIHSIH SIVIOH Zi mE Qs E 0 1109 JAHA 9 x ii ipu a 0 seu O NMOG13AS1WHOdIvid
111. secre 0 298 ale wee mA jas 54 6 66 6 Ed EN aja CABLE CABLE CABLE POWER Pici JB TILT p FS ALARM 5 gt 2 I ME 2 0 2 m 9 SiS m S RIR 8 DP1 S 9 21522 lt Ju 1 218 RES 5 8942 m 2 5 B 5J B g 8 20k GRN 1 gi PED WHT 29 z 55 ER X m T 5 5 bs 3191415 x 8 5 a 1 WHT RED 32 9 a o RO t M 22 51900 S WHT 1 WHT 30 6 23 2 9 BLK 1 WHT BLK 31 21552 4 94 5 REV 1 512 RED sex WHT GRN WHT 24 5 GREEN YEL 1956 17 71 9 RED PRPL lt a Coe BLK RED LIFT Q7 ale g A prive e BLU D8 8 m e p Sp e Tog BLU BLK 37 WHT RED BLU 36 gt 7 TS12 TS10 511 TS13 1009 SECONDARY BOOM PRIMARY BOOM EXT RETR S mm BLK WHT 999 A RED BLK WHT RED 2 PEE o 8 o e Tsis 4 5 2 S od SA 5 8 DRIVE ENABLE po J 2 ite AUXILIARY TS6 ENGINE TS4 lt HORN POWER 4 n C GLOW PLUG START RPM P2 uS JIBBOOM
112. y T 2 2 5 oo Q 8 8 is dau dau 5 0951 a dau 10 lt orma lt x OAO 5 2951 gia ale woos air 9 8951 6I LHWNHS 1951 9951 TIHM mmm ve LHM a 1 TWNINYAL OL 3SV8 ya WH fONALXA eds 9 woog wood d a 1951 21 1 aau 2 2 i ei a OOO x a SSL a E a Q 22 034 zaa S 5 PNO am E H3MOd d3u dau HOLIMS 4018 LSJ 1981 bd 6 76 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 from serial number 14079 to 14650 Section 6 Schematics June 2005 _____________ Ground
113. 1 1 1 1 1 1 1 1 1 1 enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 22 PartNo 106488 June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 14079 to 14650 REVA June 2005 Electrical Schematic 2 45 25 from serial number 14651 to 16839 Section 6 Schematics WHT ORG RED 42 RED RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 BLUMHT 12 RED START RELAY TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN BATTERY IGNITION START MODULE 1 2 3 4 5 6 7 8 9 GRN BLK BATT RED 5 6 WHT BATT WHT 23 WHT GROUND WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH BRN FOOT SWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 B ALTERNATOR FIELD RELAY CR16 TP35 HIGH TB35 Ye BRN L LOW RPM TS4 RPM RPM CUTOUT RELAY CR13 BLK RED 35 HIGH RPM RPM RELAY CR14 T 1 1 1 BRN E 1 BLK RED BLK WHT 34 5 lt lt 8 RPM SOLENOID ENGINE START TS2 30 R1
114. 133131V1OH v HR HM 1120 7890 OSLAT V2 d NAKOCTWOOR d 9 2 860 nav vaa 2 899 1951 44 9 nadto 1859 nadlo 1892 v g 1 81 TVNIINH3 L PartNo 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 83 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 21181 to 22050 G F E D B A BK RD 35 __ C45JSV GR WH C2B 7 7 x 1 BK WH 8A GR 17A BK e WEBKSA o GR BK 1 RD LO 59 RD E Ore T GR 8 emma lt 5 5 85 EST BK 4 id 9853525 FER RD BK 2 Wer RD gt RD RD 27A x a lt E gt x 5 m ope OR BK RD BK 2A OR 14A OR RD 1A gt 3 200 GR BK 44A _
115. 2 29 RED WHT 1 TB29 RED WHT 29 POT HI lt 2 aon lt 16 ie CURTIS 1244 SEPEX CONTROLLER B TP32 WHT RED 1 TB32 WHT RED 32 GROUND 1 POT LOW 44 TP31 WHT BLK 1 1 WHT BLK 31 REVERSE 11 i8 TP30 _ WHT 1 TB30 WHT 30 FORWARD 10 ORG GEN NEG ORG GEN POS DIODE RETURN 9 F2 24 POWER ORG RED 42 R 48V INPUT 1 WHT LOAD BLK 48V DC CHARGER CHARGER 1 ORG LOAD 48V ALTERNATOR LOAD SENSOR BOX 10 ALTERI of ORG RED R2 GND PRIMARY LIFT PUMP 1 1 AUXILIARY E UR 1 PUMP B FS 10A F2 200A WHT FS TB20 24V DC BLK 26 LOAD 2 LOAD SENSOR OPTION AP1 F4 500 A F3 424V DC GROUND pec 48V DC 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 45 lt 3 DRIVE ENABLE LIMIT SWITCH BRN 2 220
116. F4 500 A pe 48V DC 24V 1 GROUND LIFT PUMP AUXILIARY LIFT PUMP 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 39 lt 3 DRIVE ENABLE LIMIT SWITCH BRN 2 220 TB13 TP13 BLU RED 3 BLK 7 Section 6 Schematics c2 4 e BLU WHT 12 TP12 BLU WHT 3 WHT 7 di T WHT 24 Electrical Schematic Z 45 25J C from serial number 14079 to 14650 12 13 14 8 A2 16 16 __ TP16 ORG RED 3 i 86 85 BRN PLATFORM BRAKE RELEASE 1 1 CONTROL BOX g zl 4 TRAVEL ALARM A2 GROUND a 5 CR6 TB48 ORG BLK 1 gt B RED WHT 48 87 fe 5 30 5 7 BRAKE RELEASE eee N C COIL 8 TP41 h 3t BRAKE RELEASE N O COIL RED BLK R6 TS15 DRIVE ENABLE BRAKE RELEASE PRESSURE SWITCH 1 RELEASE J1 2 BRAKE STEER MANIFOLD GROUND BLU 1 BLU 36 JP1 REMOVE FOR CE VERSION RED STEER LEFT COIL 4 BLU BLK 37 TB37 BLU BLK 1 1 STEER RIGHT COIL TP37 RED
117. HIGH LOW RPM TOGGLE SWITCH _ _ o CN oe E GA 9 TS6 GLOW PLUG TOGGLE SWITCH NO A Dd J S TR GAS 62 2 e PLATFORM ROTATE TOGGLE SWITCH 8 T8 o TS9 PLATFORM LEVEL TOGGLE SWITCH P3 AUXILIARY ance ENGINE TS4 m TS10 SECONDARY BOOM TOGGLE SWITCH HORN POWER L TS9 START RPM TS7 EC po 511 PRIMARY BOOM DOWN TOGGLE SWITCH PLATFORM ROTATE EMERGENCY STOP TS12 TURNTABLE ROTATE TOGGLE SWITCH RED TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORGIED 2 TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH enie A TEREX COMPANY 6 95 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA June 2005 D
118. v zw 1HOIH 31VLOH STAVINEAL Q TM LO H3MOd 100 IHWG3H za 2 z NMOG STET uc 273 4 18 q3u rau WOO8 fF 81 TVNIINH3L Z 45 25 Z 45 25J Bi Energy 6 55 Section 6 Schematics from serial number 13361 to 14078 Ground Control Box Switch Panel Wiring Diagram Z 45 25 June 2005 REVA 100109 IHM INOIND Av ue 13 31 NHOH 90 99 759 ML NN og 4 4 og z 0g og zen 18
119. 010 33 5 2 22 25 nm lt lt 2 lt lt 2 zm RED LR15 0221 9265 gt 29575 95 71260 515 A 243 4 5 075 9 x ol jo 25 2 lt m 2 8 D T m BRN LJ 5 5 915 BRN J1 NOTES 2 1010 10 0 Y 1010 10 10 0 0 RED BLK 28 93898 ALL WIRES WITHOUT LABELS ARE 919 19 5 S amp amp S 5 2 2 2 9 3 SIE 9 2 EITHER RED OR BLACK JUMPER WIRES oBz2osszesgegsse ssoss do RIB xx 50 FOR LIFT DRIVE SELECTOR OPTION dk ra jaja om Lu 25 25 jM TAKE OFF JUMP BETWEEN 6 amp 7 CABLE CABLE CABLE 1 COMPONENT INDEX A1 TILT ALARM e e 006 00060 66 1 OUTLET BOX 8 2 2 m 2 8 2 8 B 2 ORI 3 8 2 S BCI BATTERY CHARGE INDICATOR 3 9 5 5 5 5 525 5 3 ok GRN PEDWHT 29 BP1 ROTARY FLOW CONTROL DIAL lt
120. 63 08 L _ _ 3 Q JIB BOOM ve MANIFOLD v SLAVE CYLINDER BRAKES STEER CYLINDERS TURNTABLE ROTATE P PRIMARY CYLINDER EXTENSION CYLINDER M i oy 4 aa SU i i bap 1 pes 1 laore 1 1 r1 1 1 1 1 or Ws th DS Z 7 SO pae mA enm i ATMOS m 3500 psi f L 1 1o90 pal gt 241 10 030 inch si ATMOS 0 76 mm BT __ gt 5 MASTER GM Nn S 1 after serial v v number 17735 1 571 before serial 65 number 17736 1 STi ST2 1 PR2 PL1 PL2 sw2 SEC2 P1 P2 EXT RET 9 3200 E 0 046 inch AUXILIARY PRIMARY 6 PUMP d mali 117 0 5 24 1 1 1 9 Limin 7 9 Limin NT H Xi 771 1800 psi ran i 124 bar 63 2 Y ATMOS ___ Lk T EHE 1 M d t1 0060 inh LXI 6 69 69 t i 0 6 _ 69 __ 0 030 inch 06 7 RESERVOIR 69 0 76 mm al T FUNCTION MANIFOLD
121. O20 190 94 ee 5 ome 12 2 17 10 14 Bolt torque sequence after serial number 23331 Part No 106488 COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 3 31 CHECKLIST D PROCEDURES 3 Lower the boom to the stowed position 4 Remove drive chassis covers from both the steer end and the non steer end of the machine 5 Check to be sure that each bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Section 2 Specifications 2 8 Bolt torque sequence before serial number 23332 9 mn id O 7 16 1 4 3 30 104 14 a O O 2 Bolt torque sequence after serial number 23331 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 3 5 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without REV Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands operator knowledge could result in death or serious AWARNING Collision hazard Failure to injury and property dama
122. V g DRIVE ENABLE LIMIT SWITCH LS3 BOOM EXTEND BOOM CABLE 2 BOOM CABLE 3 C O LIMIT SWITCH LS2 PRIMARY BOOM CABLE 5 LIMIT SWITCH LS1 T CABLE 6 LIMIT SWITCH 184 SECONDARY BOOM CABLE 4 SPARE PLUGGED C Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 53 Section 6 Schematics June 2005 Ground Control Box Switch Panel Wiring Diagram Z 45 25 REVA before serial number 13361 v0LHO TUM 110419 100119 SHO Av 13H WHOSLW d NHOH 08 E 06 I 0 og U 24 98 98 98 98 8 2 8 2 8 2 8 NH8 48 48 48 48 lt 1 ON 5 i 8 3 we 8 8 g n d a g dg g 2 22 g s
123. WHT WHT 30 e 6 FWD WHT BLK 31 4 fev 42 BE COMPONENT INDEX RED m wHranw 125 4 WHT 24 s GREEN amp mn 1 TILT ALARM RED lt i 1 AC OUTLET BOX BLK RED E 7 ale BATTERY CHARGE INDICATOR ET M 9 4 DRIVE e 80 BP1 BOOM PROPORTIONAL ROTARY CONTROLLER 2 lt gt e HIEL CRE DRIVE ENABLE RELAY 7 TE WHT RED eol BLU 36 DP1 DRIVE JOYSTICK 7 TS12 TS10 TSI T L1 DRIVE ENABLE LED BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 S 2 n BLK WHT 5155 2 EMERGENCY STOP BUTTON A RED P3 HORN TS1 AUXILIARY TOGGLE SWITCH p m BLK WHT TS2 START ENGINE TOGGLE SWITCH 5 O_O dum 2 TS4 HIGH LOW RPM TOGGLE SWITCH y 9 OO 756 GLOW PLUG TOGGLE SWITCH Cad 999 QO oad LW SEG TS7 PLATFORM ROTATE TOGGLE SWITCH 8 DRIVE ENABLE Ta 7 TS9 PLATFORM LEVEL TOGGLE SWITCH EN AUXILIARY dowr Ue ENGINE NN TS10 SECONDARY BOOM TOGGLE SWITCH T TS7 PUE UE SARE B TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH PLATFORM ROTATE EMERGENCY TS12 TURNTABLE ROTATE TOGGLE SWITCH RED STOP TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 99 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 REVA June 2
124. 1 aaunria m 8 IHMW r18 z Nua Nua ie OOO g o 7981 8 Eg 22 8 22 9 NG 2 wamoa aau 9 2 HOLIMS 4018 LSJ 1951 be 6 56 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 13361 to 14078 Section 6 Schematics June 2005 ______________ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 14079 to 14650 REVA June 2005 45 25 ing Diagram Ir Ground Control Box Terminal Strip W from serial number 14079 to 14650 Section 6 Schematics
125. 6L IHWNHO 6I IHWNHO anod in 8r hmn E 3i IHWNHS 5 8L 8L z lt saw 9171397 1 1 9 2 NMOGSI ZHOIHSIVIOHWHOdIVid 21 Q NE NHO 9i oW 709 AV BH 9L Q 5 1 xi 258 2 sas O ft WHOdLV 1d 56 l t gi a vL WHOSLV1d vL zs 3 THOM 1 lt EE l 2i H3MOd HOLIMSLOOS 24 1HM IHN ma z 558 Aaa m Q 925 T aa WOO8 01 018 na Lu 52 016 NHOH 6 ma z 83 9 E LO WOOG 8 gayana 9 woe 20 ima OLC 1 WOOG AHVINIHd n 955 Qao 9 2 MOTH 131 aaa LO 1457 SLVLOU S 1HOIH 31VLOH 318 y THN THM x H3MOd 109 2 ana
126. 93 BLK WHT 1 PLUGS 00090 E E 4 m I amp z z 5 8 E a 8 5 YEL E 727 4 BLK lt 4 5 a 5 A ox amp 8 im 19 ORG RED 42 ORGIRED 1 ORG RED 4 c a 6668 da 114 52 ofS V RED 2 WHT REDWH 3 REDMHT 3 cre m E d pie ee 2 IE RED WHT 23 ae 45 4 8 19 y RED BLK 1 RED BLK 28 E E 19 WHT2 8 23 IB g uj S 9 5 if i 9 I 5 g L 874 aa BLK RED 3 BLK RED CR4 8 8 de o a 5 BLK 22 8 25 19 E g 3 a N 29 REDS 7 o z T amp 2 2 EN x m e x SQEE na 4 CONTROLLER FAULT 5 INDICATOR LED 12 ORG RED 42 b ORG RED ___ 5 RED BLK R5 20 5 2 g ORG RED 42 COIL PR1 GRN 5 17 8 BLU RED m BLU RED 39 FAULT LED te _
127. CONTROLLER FAULT LED 48 DC POWER RELAY CR2 RED WHT 3 RED WHT 3 RED amp WHT 3 o I 48V DC POWER RELAY CR1 i8 RED FS WHT FS FLASHING BEACON OPTION RED WHT 23 FS1 p TILT ALARM RED 1 RED BLK 1 RED BLK 28 WHT 2 RED WHT 23 BLK FS TILT SENSOR 8 26 23 ENABLE BLK HOUR METER LOAD SENSOR OPTION SEE DETAIL BLK RED 9 RED amp I BLK RED 9 BLK RED 3 ut HORN RELAY BLK 22 BASE CONTROL BOX GROUND TB22 SEC GROUND LS4 BLK8 RED 6 TB50 o E o m 2 9 5 ad 21 22 2 2 PLATFORM RED 8 INDICATOR LED L2 KS1 i i CONTROLLER FAULT 1 1 ORG RED 42 BLK TB40 B BRAKE RELEASE RELAY CR5 ORG RED CR5 RED BLK R5 8 8 ORG RED 42 COIL PRI GPN 17 B MOTOR MAIN CONTACTOR RELAY ORG 40 BLUIRED 1 BLU RED 39 T FAULTLED Je 1 maan TP39 TB39 E1 OFF LIMIT SPEED INPUT F1 RED 20 BLU WHT 12 INTERLOCK E2 2 29 RED WHT 1 TB29 RED WHT 29 POT HI lt 2 aon lt 16 ie CURTIS 1244
128. ee ee wg noo 99 3uvds WOO8 raga 9 81 3Sva IWNINYAL 10 Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 77 Section 6 Schematics from serial number 14651 to 16839 Ground Control Box Switch Panel Wiring Diagram Z 45 25J June 2005 REVA N Ke 100109 IHM ay an INOIND T3A31 NHOH 5 THO ee R og E 4 og 0 zoo 48 48 8 Nog 18 18 18 18 mm 2 st e P x a 3 8 8 g g 5 GG 5 m 26 a a
129. gt a C3B 6 WH RD C6B 6 WH RD BK RD BRN 85 BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP C23 1 522 C6B 17 GR C22 1 22 2 3 s z o 9 25 55 CR19B E TB17 C2P 6 C44JDA GR BK C2B 6 1844 6 C18PRR C4B 6 5 C17PRL GR C4B 5 GR C44DA 6 33 JIB MANIFOLD GR WH C2P 7 C45JSV GR WH C2B 7 PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL 20 1 20 2 C6B 14 OR 520 R d C6B 15 OR BK pe C21 1 C21 2 PLATFORM LEVEL es TB15 PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B C4P 2 C14PLU OR C4B 2 4 3 C15PLD OR BK C4B 3 TB7 EXTEND 4 PRIMARY BOOM EXTEND COIL PRIMARY BOOM
130. i i LO 0 H3MOd El 141 5 6LI LIHWNHO 61 LHWNHO zi PPO Q C TM simu E si avo lt 1 1HWNHO lt 257 HOLIMS 8L 2 5 NMOG SIP LHDIY 31VLOH WHOSLV 1d a SI3HSNUS 2 iw df 81 1331 31 109 WHOS 1d Q i 9 Off 100 INYA a NES LO 6 NMOG WHOSLV1d Q j 9i avo 157 5 su op z Q 2 QN31X3 WOO Off 1 L GL H3MOd HOLIMSLOOS SN HM O n NMOG WOOd 5 Longa a T a mama gt 751 HOLIMS O p WOO8 5 Q Sima ma Lo 6 6 ENIE 9 Qo 8 8 1 WOOS 8 Q MEME LO 2 WOO8 2 9 i a Ls 1 1 14 9 Q 4 4 ammm 190 31V1OH STSVINYNL ME X18
131. lt lt 5 5 2 2 5 2 2 EsssBPBES C eg95s 9s5 2 x9s5s 9 ele RED LR15 22 nM 5 55 5515 lt 5191512006 9 SE m lt 244 4 zm d 4 RED TILT m 2 5 m o Q S 2 GRND BROWN REDNET 6 CO CO AJAJAJA m 11 1 15 9 58 5 1818 SG BROWN J1 NOTES 1010 10 0 0 1010 10 10 0 RED BLK 28 999 09 22 2 2198 99195 8 ALL WIRES WITHOUT LABELS ARE S 2 S154 9 18 2 22 EITHER RED OR BLACK JUMPER WIRES os BS 2 Z kid io S E m i io xu 8 xk B RI FOR LIFT DRIVE SELECTOR OPTION AC 6 o b I Ax Ln nA aja TAKE OFF JUMP BETWEEN A amp B m CABLE CABLE CABLE POWER Foor 5 3 2 1 JIB TILT FS ALARM COMPONENT INDEX TILT ALARM ACI AC OUTLET BOX S S 9 m E m B 2 B9 9 m 9 2 B E 519 BCI BATTERY CHARGE INDICATOR 9 o 2 9 2 o 3 6
132. 0 18 186012 01 860 18 01 8 O 018 JOVHISMINGOS Aava 9 8 8 99 amp 3 ess 19 2 WOO8 n 5 2 A 38925 7890 2 9 141 9 HNWHO O 93799 9 8 5 GU HM 93799 9 895 9 018 HH1SO 9 8 0 6 rezo SHIM 1431 v 78120 1 899 lt NOC NOE 9 g au 2 80 nav vya g dH 2 990 JO L o 1 85 Nadto 1 890 V 5 1 8585 2 81 asva IYNINHIL 28795761 N 10 N Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 67 REVA June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 ANSI and CSA Models from serial number 22051 to 23235 BK RD e C45JSV GR WH C2B 7
133. 1 uvas 8 GL E amimawug 5 42815 1 dana lt Le 1 1 6 0 o 1437 82315 96 6LI LHWNHO 9enms MOVHOIH he i eau 9 259 bd fon izi 12 MOTO ve IHME E seo 18 3NION3 LEVIS 15 Izi 19 Ole MOTHALINWOILNILOd MOLLSAOP 26 jm 9 18 X 18 1HM 85 b t O fe 0 8 MOLLSAOP 62 au ici 62 I2 9 HOLIMS TA i2 T KOL O 8 ue 15 Q i9 98 IB PHO 2 Z 109195 22 Q O 100 8 2 os gt Jo O fs alal amp 2 lt 2 21 aasann o 2 3 s 5348845 ru EZ LHM 2 HOLIMSASDI Q coo Wuviva3H zona OL LIOA ve Q wok Te 8 YILIN azu lt 9 m 6L a E 6LI LHWNHO
134. 1 I lt ME 0 j WHT BLK J 5 1125 ORG Loap yoy E 118 a 4 838 88 g gt 5 9 a 1 ene 1 a 1 x o 25 dios e ii pee voa amp a 1 ie g EM 9 EB 9 1 S o a 222 3 9 a E 28 2 5 E x EE a 1 lt 9 5 gt 1 gt lt T 10 N WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY 13 RPM RELAY 14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12 VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON
135. 2 9 8 5 5 5 5 9 5 M ORG WHT RED 32 iig diei 5 CR6 DRIVE ENABLE RELAY LI a M o R 2 dux a 5 t 7 wor ree 8 9 m CR17 LOAD SENSOR RELAY 2 m oe 9 CRI9A LOW VOLTAGE INTERRUPT BCI RELAY A FWD BLK TS WHT BLK 31 us 5 CR19B LOW VOLTAGE INTERRUPT BCI RELAY B REV RED 25 gu a zi DP1 DRIVE JOYSTICK WHT GRN MEINE N 8 DRIVE ENABLE LED GREEN YEL 6 RED EIS 13 CONTROLLER FAULT LED PRPL lt BLK RED 127 ale 14 OVERLOAD LED a 9 e BHU 28 Wm LDS LOAD SENSOR MODULE Lol BLU BLK 37 3 5 4 J right og 5 IM LOW VOLTAGE INTERRUPT MODULE e eo BLU 36 BATTERY CHARGE INDICATOR FOR LVI OPTION TS10 TS 1513 TS12 SECONDARY PRIMARY EXTEND r S P2 EMERGENCY STOP BUTTON LVI BCI OPTION BOOM BOOM RETRACT BLK WHT 000 HORN 1 TIME DELAY 1 BANGS TS1 AUXILIARY TOGGLE SWITCH HORN Hen BLK WHT TS2 ENGINE START TOGGLE SWITCH T gt HIGH LOW RPM TOGGLE SWITCH TS15 i 5 m TS6 GLOW PLUG TOGGLE SWITCH NO UN z 2 ZA 01 TS7 PLATFORM ROTATE TOGGLE SWITCH 9 Es DRIVE ENABLE FAULT LED Ta 4 TS9 PLATFORM LEVEL TOGGLE SWITCH AUXILIARY TS6 ENGINE TS
136. 5 2981 31V1OH 6ss113A31 viz WHOL ld WHOS4LW1d 189 dau dau 5 1 951 318VN3 NOILLONNA N Eus 4 1 c Qe 319 940 d 2 ya LLNHO x 8 a dau dau 3 0951 WOOS a T AHVQNOO3S orma 5 STEVLNYNL 9951 8951 MO19 WOO amp TXHM mmc TWNINHAL OL mu 36 8 2951 m 19 LOVHLAY e of woog AuVIWIHd 2 Laura 8 2 Nua wu OOO EN 7951 x a a momon PRO zea EZ LHM m 42 T 5 zo dau 2 O O 1951 5 1 HOLIMS 9015 6 72 PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25J before s
137. 92 ENGINE START TOGGLE SWITCH HORN BED BLK WHT HIGH LOW RPM TOGGLE SWITCH 9 L3 TS6 GLOW PLUG TOGGLE SWITCH gt eS 4 POS Ds OM P iON 5 TS7 PLATFORM ROTATE TOGGLE SWITCH NO RM LY TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 DRIVE ENABLE 109 FACED ED L4 Ts9 PLATFORM LEVEL TOGGLE SWITCH TS2 AUXILIARY TS6 ENGINE TS4 FOAD D TS10 SECONDARY BOOM TOGGLE SWITCH POWER GLOW PLUG RPM LED i TS8 TS7 TS9 START PRIMARY BOOM UP DOWN TOGGLE SWITCH JIBBOOM PLATFORM ROTATE PLATFORM LEVEL 80 TURNTABLE ROTATE TOGGLE SWITCH EMERGENCY STOP 7513 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORG RED 42 TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH Z Z Z Z z Z Z Z x Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z DRIVEENAPEEJOGGEEISMITOH PartNo 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 108 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option from serial number 13361 to 14078 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram Z 45 25J from serial number 14079 to 14650 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J REV from serial number 14079 to 14650
138. WATER 25 TEMPERATURE 99 1 SWITCH x E 1 J OIL 5 41 PRESSURE 8 BEN SWITCH og 9 C35HRPM BK RD 1 9 zz Oe E 1 B 4 9 4 1 ALTERNATOR 5 8 FIELD RELAY CR16 I D Co E cM A 1 E LM E 9 E i BRN i RPM CUTOUT pu 6 RELAY CR13 88 rd r 8 o BRN RPM RELAY CR14 E 4 2 8 8 E ui 8 E 9 BKRD Lot 55 ENGINE RPM SOLENOID DZE 7 C33STR 187 START Pu E FiO 4 5 E gt 1 1 Al 5 5 2 E gt C5B 22 4 GLOW PLUG s 44 RELAY CR15 1 o d 8 j 1 GLOW PLUGS 893 8 BK WH 1 8 PLUGS 8 bd FOL i au T 3 8 12V DC ALERNATOR bg 1 1 1 4 4 1 a eg 4 TV DC VOLTAGE REGULATOR 1 1 lt 1 E 2E 8 4 BRN 4 ENGINE POWER RELAY CR12 S 2 e bg 3 amp bg pod T WH 4 ray ENGINE RUN SOLENOID 5 bg BAN 4 STARTER RELAY CR11 1 3 878 8 NN gt Pel 1 bah 2 bg 5 E i EN ma
139. a m TS10_ SECONDARY BOOM TOGGLE SWITCH HORN AUXILIARY PLATFORM PLATFORM LEVEL START Apa EMERGENCY PRIMARY BOOM UP DOWN TOGGLE SWITCH POWER ROTATE STOR 7612 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH eee 515 DRIVE ENABLE TOGGLE SWITCH Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 118 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 21181 to 22050 Section 6 Schematics June 2005 fT Platform Control Box Wiring Diagram Z 45 25J from serial number 22051 to 23235 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 22051 to 23235
140. 4 a Hanama vi avo j ania gt 757 HOLIMS omg for WOO8 5 Q Orma 2 LO 6 6 ENIE 9 Qo 8 8 1 1 8 a FIRME LO Z 1 WOO8 4 9 ya Ls 1 1 14 9 Q 5 9 onam 1 31V1OH 318vINHn L Q S3F IHM O v 1431 1 1 318vINHnL v T 1HM Q T LHM O H3MOd 1109 A 87 dd IHWG3H 9 Q 9 NMOG 2 Q E mE 2 sar 3uvds n WOO8 a E v g NS 81 TVNIIWH3 L YT N iO Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 81 Section 6 Schematics June 2005 Ground Control Box Switch Panel Wiring Diagram Z 45 25J REVA from serial number 17975to 21180
141. 440 Q 20 980 1110 4 6 980 Q 9 uvas 8 a im 1 emimwwuo MTO 0 Jess IS Q 4 o na segaupng 9 36 MOVAS Se aaunna 2 EQ LO MOTD ve gayaa is 2 Q 5 euo 3NION3 1591 Q zi 9i N3LOd MOILSAOP 8 HALSWOLLNALOd XOLLSAO Ze G3UAHM 2 8 Q3H 1HM mi Ou 5 Ofte RE lt I tr o 5 0 E 8 Ole 104 XOLLSAOP 62 IM 9 I3Nvd HOLIMS gt 2 oissoosum 82 Navi LILL 8c 8219 038 D 21 g day O 22 193115 dWnd 22 2 3i cys 2 2 gt Jo 9 5 2 2 3i olg 65 s 5515 aasnnn 1 2 suma o e H3MOd HOLIMSAS Q T T 1HM LO INHOd1Vd OL LOA ver 22 2 5 OFE STaVN
142. 7 C33STR C1B 7 BK ISM1 BL ISM2 5 5 C33STR BK HIGH TB35 C5B 3 C23PWR WH 5 18 C35HRPM 5 8 8 4 BRN 26 85 iS CR13 30 Pi ENGINE START TS52 TS6 GLOW PLUGS 1 8 C34SA BK WH C1B 8 C5B 22 C34SA BK WH uc i TB34 GLOW TS56 PLUGS P25BAT RD P24BAT WH C9P 3 C9P 2 RD FS WH FS RD 1 5 C9P 1 LOAD SENSOR OPTION SEE DETAIL P2 1 C2P 4 R42BAT OR RD C2B 4 WH J4 30 1 87 B RD E gt RD J10 12GA BRN 85 86 CR12 4 85 86 o 2 STARTER C3P 3 C3BAT RD WH C3B 3 5 11 C21IGN2 WH C23PWR WH 2 2 C28TTA RD BK 1 2 gt lt E 85 2 2 RD BK C6B 28 P23SWBAT WH C7B 2 WH C6B 34 C3P 9 C9HRN BK RD C3B 9 BK RD 4 P3 HORN TB22 BK 8 BRN oe WH LOAD 8 2 5 gt 5 PLATFORM GROUND C6B 20 RD 10 2 5 Y 8 22 5 C6B 9 BK RD D 5 11 2 WH 6 5 WATER TEMPERATURE SWITCH OIL PRESSURE SW
143. 8 48 48 18 18 lt eo x x 8 5 n i 5 29 I zi X 9 9 So a a z 66 26 a a 5 2 o aau ouo E E Ve 2 az 6 E a ot 18 48 48 38 98 98 98 Dr 228 228 a a z oe og PE 1 H3MOd 90 180 LHWG3H E 4 X a 1 St LHWNHO St LHWNHO 2 aLVLOY 933 WHOSLW1d WHOALWId PE 2581 6951 1 qay alo NOILONNA u 180 5551 S 319 940 TROL z x m 8 5 m woog dau AHVONOO3S dau 0981 _ orma 454 5 2951 Hong 4 S mr 2 gema gema YE LHMANE la dIHLS TVNINYAL OL dau a WH QN31X3 H313W noos Ct AuvWIHd 060 a 9991 1951 21 wu zng aau
144. BH 9 Solenoid valve 2 position 2 way Bl 10 Solenoid valve 2 position 3 way BJ 11 Flow regulator valve 0 6 2 27 12 Counterbalance valve 13 Flow control valve BM 14 Relief valve 3200 psi 220 6 bar BN 15 Diagnostic nipple 16 Check valve 17 Orifice 0 060 inch 1 5 2 18 Differential sensing valve BR 19 Pressure switch 5 20 Solenoid valve 2 position 2 way poppet BT Orifice 0 030 inch 0 76 mm located under item ue 21 Orifice 0 046 inch 1 17 BV 22 Counterbalance valve BW 23 Relief valve 1800 psi 124 bar BX 4 40 Genie EM Function Primary boom retract Primary boom up down Secondary boom up down Turntable rotate left right Platform rotate left right and jib boom up down Z 45 25J Platform level up down Steer left right C
145. F ge 9 PEG ggg 828 a 25 3 DO 8 8 5 52 4 P20BAT RD C6B 23 5 RD 2 RD C7B 4 BL 10A RD T BK 22A BL BK 11A 56 5 Box 20 WH 23A GR WH 19A BK Or gt 8 oz P20BAT RD 5 1 E 8 RD z 85 SE RD RD RD a a 6 c RD WH 5 BRN 855 8 y gt 5 i 7 2 8 e a gt 294 gt 2 lt 9 RD 58 8 2 lt I a 2 ay Genie Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 84 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 from serial number 21181 to 22050 Section 6 Schematics June 2005 _________ Ground Control Box Terminal Strip Wiring Diagram 2 45 25 ANSI and CSA Models from serial number 22051 to 23235 REVA June 2005
146. Nf 5 rt lt 3 lt ra 1 1 48V DC 8 28 WH CHARGER e D EE FE 55 ee 49V DC 929 5 1 ALTERNATOR a gt eb roy d 5 r 3 PRIMARY oe LIFT PUMP 85 2 ELE 1 AUXILIARY 1 LIFT PUMP 5 4058 P20BAT RD C7B 4 RD 20 is a 10 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED NOTES 1 Part No 106488 gt ADD 040 ONLY IF UNIT HAS L4 AND 148 TEREX COMPANY Z 45 25 Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 51 Section 6 Schematics from serial number 22051 to 23235 6 52 lt 3 DRIVE ENABLE LED L1 DRIVE ENABLE LIMIT SWITCH BRN C7P 3 BATGND BRN C7B 3 BATGND BRN 22 21 y d 1 C13DREL BL RD C4B 1 BURD C6B 13 C13DREL BK 8 BRN 8 C6B 21 DREGND BRN C3P 12 C12DRE C3B 12 BL WH C6B 26 C12DRE RD 8 4 4 C16DRE OR RD C4B 4 OR RD C6B 16 C16DRE BRN A2 BRAKE RELEASE RD WH TRAVEL ALARM A2 26 1 26 2 C6B 35 RD WH e BRAKE RELEASE 27 OR BK C2B 3 g caps ews RD WH N C COIL RD
147. TEREX COMPAN Z 45 25 Bi Energy Z 45 25J Bi Energy 2 7 Section 2 Specifications June 2005 SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade Black Oxide Bolts LUBED DRY LUBED in Ibs in lbs Nm 100 11 3 80 9 130 14 7 10 1 120 120 LUBED DRY LUBED DRY LUBED feos Nm Nm is Nm 76 17 18 15 19 20 312 53 85 I 2 gt 352 37 50 55 60 813 80 1084 68 91 80 85 90 122 120 730 EB 176 780 270 366 280 379 298 300 310 480 583 450 610 510 274 270 500 560 759 640 867 680 922 770 1044 78 710 750 1016 990 1342 840 7139 7 790 1071 970 1315 1090 1477 908 890 1080 1220 1654 7 1120 1518 1360 1844 1530 2074 1240 1510 1700 1950 2370 2670 3000 e e o o 5 EE 18 16 24 20 13 20 12 18 18 34 __10 ___16 9 14 8 12 7 12 mE GNE 12 6 12 7 75 91 10 3 116 155 5 2 1 95 260 DRY LUBED ft lbs Nm ft lbs Nm 36 5 23 6 32 31 4 42 6 2 467 62 3 81 108 129 172 202 269 278 371 394 535 536 8 1055 682 E wo 4 N ATO
148. e TT Wr WESS CR6 DRIVE ENABLE RELAY 6 2 m BUE LL A CR7A JIB CUTOUT RELAY 2 x 4 Qj 8 5 CR7B JIB VALVE RELAY HEY RED 955 CR19A LOW VOLTAGE INTERRUPT BCI RELAY a n wHriGRN 1258 SI GREEN 58 CR19B LOW VOLTAGE INTERRUPT BCI RELAY B 6 RED lt a BEC 1 DRIVE JOYSTICK 5 Uer PRPL 26 9 o BLK RED 7 DRIVE ENABLE LED BLU R6 j CM DRIVE 8 LOW VOLTAGE INTERRUPT MODULE 3 5 4 29 LVW BCI BATTERY CHARGE INDICATOR FOR LVI OPTION gue BLU 36 P2 EMERGENCY STOP BUTTON 7 Rie SECONDARY HORN PRIMARY EXTEND mimm ROTATE LVI BCI OPTION BOOM BOOM RETRACT BLK WHT 9 SS TIME DELAY 1 RED 91 AUXILIARY TOGGLE SWITCH 92 ENGINE START TOGGLE SWITCH HORN BLK WHT HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH OT wi Qoo PN 29 8 C TS7 PLATFORM ROTATE TOGGLE SWITCH E LY TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 9 TS DRIVE ENABEE 711 T je 59 PLATFORM LEVEL TOGGLE SWITCH i 6 AUXILIARY CX GLOW PLUG ENGINE TS4 gt TS10 SECONDARY BOOM TOGGLE SWITCH POWER RPM TS8 TS7 TS9 START TS PRIMARY BOOM UP DOWN TOGGLE SWITCH HN JIB BOOM PLATFORM LEVEL PLATE ORM ROTATE 2 512 TURNTABLE ROTATE TOGGLE SWITCH
149. 9 9 9 9 9 9 9 9 9 9 I D zm CENE m z Eimomio im QIS 3 eld DP1 S E I 3 5 5 52 BaS le COMPONENT INDEX a x iz 55 4 iig g A1 TILT ALARM 2 e 5 a 9 ORG pa WHTRED 32 58 9 9 gt t 7 P AC1 AC OUTLET BOX WHT 30 6 D BCI BATTERY CHARGE INDICATOR 4 k p NHTBUCST BP1 BOOM PROPORTIONAL ROTARY CONTROLLER DEM RED eso wes CR6 DRIVE ENABLE RELAY DE CR7A JIB BOOM CUTOUT RELAY RED E lt a 8c CR7B JIB BOOM VALVE RELAY Dy OOo BLK RED 27 pium DP1 DRIVE JOYSTICK pave e BLU m L1 DRIVE ENABLE LED X9 night e MHTYEL 129 BEUBEKCF L3 CONTROLLER FAULT LED H WHT RED BLU 36 B P2 EMERGENCY STOP BUTTON 7 TS12 TS10 TS11 TS13 TELS eo P3 HORN BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 G m m m T TIME DELAY 1 BLK WHT ag x RED TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH BLK WHT HIGH LOW RPM TOGGLE SWITCH p O bA B mE lego TS6 GLOW PLUG TOGGLE SWITCH 9 TS7 PLATFORM ROTATE TOGGLE SWITCH 56d gt wee CAD C 5
150. Platform Control Box Wiring Diagram Z 45 25J REV A from serial number 14651 to 16839 RED BLK R6 TIME DELAY 1 ORG BLK R6 Ti ORG BLK 41 BRN J4 3 B 3 o 5 58 o a E 2 RED TIME RED TIME 2 z ORG RED 16 ORG RED 16 0 2 ORG BLK 41 ORG BLK 41 3 d 3 3 2 amp N D D Y 313 2 D oD D gt
151. RED BLK 2 amp PRIMARY BOOM TB2 TP1 UP RED 3 RED BLK 3 PRIMARY BOOM 8 2 TB10 BLU 10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL BLU BLK 11 B SECONDARY TB11 DESCENT ALARM OPTION A3 UP BLU 3 t BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY TB5 WHT BLK 5 WHT 4 TURNTABLE ROTATE TB4 TP5 RED WHT BLK 3 WHT 3 Su zu 56 a 7 FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED BLU WHT 12 RED TS55 GND GND BRN RED WHT 24 ORG RED 42 PAST EITHER NON STEER WHEEL NOTES 3 SWITCH SHOWN WITH BOOM ROTATED 6 20 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 13361 to 14078 REVA RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 June 2005 WHT 24 ORG RED 42 TS4 RPM FOOTSWITCH HIGH RPM BLK RED 1 RED BLU WHT 12 RED RED 5 6 IGNITION START MODULE START RELAY TACH INPUT START INPUT NOT USED GROUND BATTERY KEY SWITCH POWER NOT USED IGNITION ON WHT 2 AUXILIARY 1 2
152. Ss ee aaa Wuviv d38 6 aaunna 61 IHWNHO H3MOd Q3H 2 p n Zu a3u ouo 422 039 12 d3H or LLL SEW pa 1HM ig Re e eene onse pepe ae aaa es Ee ERR a ee eee 18 580 SOS 18 580 12 2 Ganva NOLLdO LNOLNO 13A31 AINO ASN 9 NOILONAL 61 261 09 B 261 151 xog TOWLNOD P O 8 8r1HWG3H LO INVA alr Sy amp lt o a O AE 239 1HMNHO X z z S O Gyvas E alg AE 226 ret 99 5 slo is o io 5 HOLIM EZ 24 So SUMS Qe 12 1 o Ov as o 03345
153. bog NOILONAP 257 157 6b Q SS3NHVH 7OHINOO 8v 8v erimwasu O S IN 9 1 8v p bog rt 9 E LO INVA Sy O gt Guvas 51915 NE bog a ols 5 NOLLONN Is uf lt E ha M FA LARS ai o z i a o u o6 Oo m LO 87 HOLIMS 1 Je SN bg Ga E LO ok 1 a Eis AE E m ol daadS LINIT 440 Ov X rt if H3TIOHLNOO 6 6c asuma 2 rt E Gyvas 8 O bog Fd IHN ma EN 8 APON amp 9 engm lt snam dans bog jo O AAHS 36 o 9e na 4 ma LO MEE s d PTO SMEMO at r3 zo Off 3NION3 19 15 53 SEE ziasvo Wood T2 8 CN Y 1 19
154. p PO 12 mE oe 02 O dWnd 6 O 6L LHWNHO i SN gt 1HWNHO9 8L z 19 1391 31 10 WHOd1V1d 2 TH 3IVLOH WHOd1V 1d NUS ols 109 91 c Si aeweu 19 NMOG WHOSLV1d u 18 9H a mas OOO Q 5 THOM eit TUNNE HOIIMSIOOd Q E 54 G nem NMOG RE O WOOS OL ma 2 06 NOH 8 a O 8 aaunga a 8 8 THIGH OLE ON3DG 2 019 131 9 Q CERRAR 6 S Suum 1431 Q X18 1HM 1 1 THA THM x cimwau O QE A87 e 2 5 e MEM o NMOG WOO8 WOOS
155. 22 NMOGIN 55 GE Q V 91 WNIWHAL Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 73 Section 6 Schematics from serial number 13361 to 14078 Ground Control Box Switch Panel Wiring Diagram Z 45 25J June 2005 REVA N 110179 an TBATIWHOdIY Td WHOALWId 3svaau NHOH vOLHO 40 42 SHO 20006250 joe lt 4 og og sna 8 228 228 ele 58 98 58 58 48 48 48 48 9 l lt Os 3 3 9 7 x x a E a a a m 3 a a c g gg g 8 z a a m
156. 28 2 42 ___ CIAWI 1 Ob LHM 22 THM 12 02120 2 lt 2 lt 2 i BENE TRIN PN c UO bd 9 Fd dazr a3u youo 1 1001012 13A31 HOS AINO HOLIMS fos 571 257 05 6b 251 151 6b aa SS3NHVH oos imwa O Qe 8b LHWGSd bd O zr 5 EN aasann i bd 9 Fd Ole a INVA AIr E O O Qo t 5 2 bd 1HWNHS 1 21 7 Feu Gyvas vi Pa fel fod Pe 221 lt 2 lt Gyvas sis g N 485 534 Sv SEIOASIEHOLMS IN 9 bog 1 4 mamao PO O Q 09345 330 Ov _ s uj bd 5 6 1 BSTIOHINOO a G 3 z
157. 29 6 739 jad 05 Mi CABLE CABLE CABLE POWER E E n 3 2 1 oe FS NOTES ALARM 1 ALL WIRES WITHOUT LABELS EITHER RED OR BLACK JUMPER WIRES FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS 6 amp 7 ON THE DRIVE JOYSTICK oo 9 oo 9 2 7 9 0 0 0 9 2 5 B Bs 8 3 5 2 pp mm pig 9 x a 5 or n z 2 2 5 B E lew 5 34 gle COMPONENT INDEX Teal WHT30 SES x 5 6 TILT ALARM 2 NN e 40 ACI AC OUTLET BOX REY RED CR R BATTERY CHARGE INDICATOR 2 GREEN A BOOM PROPORTIONAL ROTARY CONTROLLER RED PAPI CR6 DRIVE ENABLE RELAY OOO N E O BLK RED pi 7 JIB BOOM CUTOUT RELAY a 271 e PLU ees CR7B JIB BOOM VALVE RELAY Q e WHEL BEU BEK Ur E DP1 DRIVE JOYSTICK 7 e 1200 BLU 36 L1 DRIVE ENABLE LED TS12 TS10 TS11 TS13 BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 S 222 L3 CONTROLLER FAULT LED BLK WHT S P2 EMERGENCY STOP BUTTON x P3 HORN TS1 AUXILIARY TOGGLE SWITCH ses BLKWHT TS2 ENGINE START TOGGLE SWITCH O 6 1 on
158. 4 BLK 3 BLK WHT 3 PRIMARY BOOM PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM 1 RED 3 RED BLK 3 gt lt a BOOM TP2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL SECONDARY BOOM 11 DESCENT ALARM OPTION A3 UP BLU 3 BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY TB5 RIGHT WHT BLK 5 it WHT 4 LEFT TURNTABLE ROTATE RED 5 WHT BLK 3 WHT 3 8 5 ROTATE TP4 FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED RED BLU WHT 12 RED TS55 GND GND BRN WHT 24 ORG RED 42 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL NOTES 6 40 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics SE Electrical Schematic Z 45 25J from serial number 14079 to 14650 REVA June 2005 Electrical Schematic Z 45 25J from serial number 14651 to 16839 Section 6 Schematics WHT ORG RED 42 RED RED RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 BLUMHT 12 RED START RELAY
159. 5 27 8 2x m 5 GRN WHT R12 2 lt GRND RED STOP 0 5 RsssERERSEEEPPEERPSSSSss WHT x IS NOTES RED JIB 12 lt lt Aui TIS 2 2 gt gt 25 aw a fo oS Sq l 2 55 2 B ALL WIRES WITHOUT LABELS ARE BRN GRND 5 5 gt m i 5 5 m RI to 0 5 x m i ES 5 m EI EITHER RED OR BLACK JUMPER WIRES 7 1 i FooT 5 7 IE eB ey FOR LIFT DRIVE SELECTOR OPTION Al SARE POWER SWITCH TAKE OFF JUMP BETWEEN 6 amp 7 5 TILT Es ALARM COMPONENT INDEX e 999 eee Al TILT ALARM gt o 2 mo 0 o 2 2 0 2 0 o ACC 8 2 5 8 2 p DP 1 OUTLET BOX 5 S S 5 2255 5 528 s x 4 8 5 GRN 29 5 5 5 SR 5 BCI BATTERY CHARGE INDICATOR lt lt 22 5 6 3 m
160. 9 2 2 x 1 5 9 9 265 291 gt x 2 g RED PISM6 lt lt 49 1 25 69 1 zu x g x ag E T i zz 2 BRN 82 23 BLK RED 1 8718 n amp a E a 1 Tx Be 8 Hu 8 8 BRN 5 E p oF E rc 1 a 8 59 BRN 1 m EN t 958 B 1 8 BLKRED 456 8 ENGINE B25 START 8 d 5 BLK WHT 34 p lt 1 Hh re 5 im a 8 8 BLKWHT PLUGS 5 00000 x 5 5 3 T 8 5 YEL SN ae at lt amp BRN 1 x 5 oe 5 a x 5 N WHT 21 WHT ox lo E lt te SIEGE E ORG RED 42 ORG RED 1 ORG RED 19 9 E 1 Ta E 5 E E S 8 A 5 8 A 8 L BRN H I T i g g RED amp REDWHT 3 REDAWHT 3 Fi WHT 3 o o BRN Ae ji 1 zs i 8 8 1 Tle 1 1 BE i i 2 RED WHT 23 iar
161. ALTERI of ORG RED R2 GND PRIMARY LIFT PUMP B 1 1 AUXILIARY E UR 1 PUMP FS 10A F2 200A n 5 WHT FS TB20 24V DC BLK 26 LOAD 2 LOAD SENSOR OPTION AP1 F4 500 A F3 424V DC GROUND pec 48V DC 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 43 lt 3 DRIVE ENABLE LIMIT SWITCH BRN 2 220 TB13 TP13 BLU RED 3 BLK 7 Section 6 Schematics c2 4 e BLU WHT 12 TP12 BLU WHT 3 WHT 7 di T WHT 24 Electrical Schematic Z 45 25J C from serial number 16840 to 17974 12 13 14 8 A2 16 16 __ TP16 ORG RED 3 i 86 85 BRN PLATFORM BRAKE RELEASE 1 1 CONTROL BOX g zl 4 TRAVEL ALARM A2 GROUND a 5 CR6 TB48 ORG BLK 1 gt B RED WHT 48 87 fe 5 30 5 7 BRAKE RELEASE eee N C COIL 8 TP41 h 3t BRAKE RELEASE N O COIL RED BLK R6 TS15 DRIVE ENABLE BRAKE RELEASE PRESSURE SWITCH 1 RELEASE J1 2 BRAKE STEER MANIFOLD
162. Bl TP4 RED FUNCTION ENABLE BLU WHT 12 TS55 RED ROTATE LEFT GND GND BRN enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 18 Part No 106488 June 2005 Section 6 Schematics Electrical Schematic 2 45 25 before serial number 13361 REVA RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 June 2005 WHT WHT 24 ORG RED 42 RED BLU WHT 12 RED START RELAY TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN IGNITION START MODULE BATTERY 1 2 3 4 5 6 7 8 9 GRN BLK BATT WHT BATT RED 5 6 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH IGINE WHT 23 WHT 2 GROUND FOOTSWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 ALTERNATOR FIELD RELAY CR16 HIGH TB35 85 CRt6 86 2 2 TS4 RPM RPM CUTOUT RELAY CR13 HIGH LOW RPM RPM BLK RED 35 RPM RELAY CR14 RPM SOLENOID Ze Ze TS2 12V DC GLOW PLUG RELAY CR15 BLK WHT 34 ar lt lt 00000 BLKWHT GLOW PLUGS BN 00000 TB34 BLK WHT 1 1 30 GLOW PLUGS TP34 1 ALT TS6 12V DC ALERNATOR WHT J4
163. LO 8 5 27 Jp SED wonmgeuo INdINO Ov E O 03395 330 6 GS1ITWVdH3TIOHINOO 66 GBINO9 9 e Q gaeng 1 Ze O AONE Heals SN Zeonaima LO 9 1397 9331 96 1 Q 9e ma ma S P 01 MOVASIH G 6 ve ve 9 IHME amO Off 3NION31HVIS 55 Q sea ze MOTHSISWOILNSLOd MOLLSAOP 9 OLENALOd 9 0 8 Off 16 Q E 06 Q x A THM a HOIH MOILSAOP 62 9 HOLIMS NT 9 9 82 821 Ge 8719 038 a 2 12 103195 dWnd 12 x 5 1z d3u dau gt Off aasann 92 0 la I Zia aasann s SIS EZ LHM LO Ll lo 2 LO e WHOJlvd OL e 22
164. TB13 TP13 BLU RED 3 BLK 7 Section 6 Schematics c2 4 Be BLU WHT 12 TP12 BLU WHT 3 WHT 7 di T WHT 24 Electrical Schematic Z 45 25J C from serial number 17975 to 21180 12 13 14 8 A2 16 16 __ TP16 ORG RED 3 i 86 85 BRN PLATFORM BRAKE RELEASE 1 1 CONTROL BOX g zl 4 TRAVEL ALARM A2 GROUND a 5 CR6 TB48 ORG BLK 1 gt B RED WHT 48 87 fe 5 30 5 7 BRAKE RELEASE eee N C COIL 8 TP41 h 3t BRAKE RELEASE N O COIL RED BLK R6 TS15 DRIVE ENABLE BRAKE RELEASE PRESSURE SWITCH 1 RELEASE J1 2 BRAKE STEER MANIFOLD GROUND BLU 1 BLU 36 JP1 REMOVE FOR CE VERSION RED STEER LEFT COIL 4 BLU BLK 37 TB37 BLU BLK 1 1 STEER RIGHT COIL TP37 RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 1 2 3 4 5 6 7 8 9 10 GRN WHT 19 AUXILIARY PUMP RED 8 AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 z RED RED 27 RELAY CR3 TB27 RED AUXILIARY LIFT PUMP RELAY COIL PR3 GRN WHT 8 9 GRNAWHT 2 6 85 RELAY COIL PR2 WHT RED 3 WHT RED
165. TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 1 DAIVEENABLE 29 PAUELEED um TS9 PLATFORM LEVEL TOGGLE SWITCH P3 AUXILIARY Bow DH ENGINE i TS10 SECONDARY BOOM TOGGLE SWITCH HO POWER TS8 TS7 TS9 START RUM A PRIMARY BOOM UP DOWN TOGGLE SWITCH 1 JiB BOOM PLATFORM ROTATE PLATFORM LEVEL 2 EMERGENCY STOP TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TEREX COMPANY 6 111 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA June 2005 F D Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 14651 to 16839 B A
166. UP ORG 3 MANIFOLD FUNCTION GROUND ORG BLK 3 PLATFORM LEVEL EXTEND p PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM St 2 gt 4 BLK 3 BLK WHT 3 PRIMARY BOOM PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM 1 RED 3 RED BLK 3 gt lt a BOOM TP2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL SECONDARY BOOM 11 DESCENT ALARM OPTION A3 UP BLU 3 BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY TB5 RIGHT WHT BLK 5 it WHT 4 LEFT TURNTABLE ROTATE RED 5 WHT BLK 3 WHT 3 8 5 ROTATE TP4 FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED RED BLU WHT 12 RED TS55 GND GND BRN WHT 24 ORG RED 42 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL NOTES 6 44 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 June 2005 Section 6 Schematics ET Electrical Schematic Z 45 25J from serial number 16840 to 17974 REVA June 2005 El
167. WHT 21 ENGINE RUN SOLENOID 25 TP24 STARTER RELAY CR11 15A STARTER WHT 23 WHT 21 ORG RED 42 ORG RED 1 m ORG RED B 4 e TP42 TB42 48V DC POWER RELAY CR2 TB3 RED WHT 3 RED WHT 3 RED amp WHT 3 o I 48V DC POWER RELAY CR1 i8 RED FS WHT FS FLASHING BEACON OPTION RED WHT 23 FS1 p TILT ALARM RED 1 RED BLK 1 WHT 2 RED BLK 28 RED WHT 23 BLK FS TILT SENSOR 8 TP26 TP23 ENABLE BLK HOUR METER LOAD SENSOR OPTION SEE DETAIL BLK RED 9 RED 8 1 BLK RED 9 BLK RED 3 ut HORN RELAY BLK 22 BASE CONTROL BOX GROUND TB22 SEC GROUND 154 BLK 8 RED 6 TB50 o 2B o TB49 2 9 5 lt 21 22 2 2 PLATFORM RED 8 INDICATOR LED L2 KS1 ORG RED 42 BLK i CONTROLLER FAULT 40 B BRAKE RELEASE RELAY CR5 ORG RED RED BLK R5 8 8 ORG RED 42 COIL PR1 gt 17 BLU WHT 12 INTERLOCK 5 T 1 1 B MOTOR MAIN CONTACTOR RELAY ORG 40 OFF LIMIT SPEED INPUT 3 F1 RED 20
168. a 8 g Es gig g 9 m m m P 2 2 Nua n I 2 Ve 8 Ge o 2 aau ouo cL 2 18 5 18 18 18 98 58 98 1 S8 98 98 8 28 228 828 N 0 0 J 1 OG 1311 0280 Ho 1 LHIWG3H x m 1 9 ggg 434 WHOL 1d WHOSLW1d 1561 6951 Javna 45 dau 18 580 180 SSSL 4 4 5 dau TROL gx 8 ILNHO 08 8 a c woog dau AHVONOO3S dau 0951 dau 31v10H orma 9 5 2951 5 OOO Ne 2 N 2 xa diH LS TVNIIWH3 L OL mE SS3NuVH 3SV8 wa LOWHLSY 5 WH QN31X3 woog Oe AWN 290 5 g noos col AHVIAIHd 1951
169. w 6 85298256556 55285 mum E E 23 le Ale 53 mE 50 mv 280 66 eX A L AES jays At CABLE CABLE CABLE POWER 1 C o o 2 0 o 2 2 2 2 im 212 819 mm RIR S 5 DP1 S amp 2 924 i 3 5 3 E ale N GRN RED WHT 29 SESS m ES m Bug 2 is 20k 21 9m Sg T jo ja y x u o E 5 5 A T lt 17 518 a i a ORG WHT RED 32 im 8 a gt t e e qe WHT 1 WHT 30 23 iS FWD lt e loa WHT BLK 31 8 A REV E RED L WHT GRN N 6 GREEN YEL 6 RED PRPL lt J O BLK RED ag 4 4 BLU RED BLK R6 3 5 4 WHTYEL Tog BLU BLK 37 Ie 7L 8 e MHTRED Top BLU 36 TS10 TS TS13 SECONDARY PRIMARY EXTEND ROTATE LVI BCI OPTION BOOM BOOM RETRACT 1 BLK WHT lt 090 A RED P3 HORN PES BLK
170. 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 AWARNING boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 19 Lower the rod end of the primary boom lift cylinder approximately 12 inches 30 cm Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy PRIMARY BOOM COMPONENTS 20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder 21 Raise the rod end of the primary boom lift cylinder back into position and install the rod end pivot pin Install the pin retaining fasteners 22 Attach a strap from an overhead crane to the cable track 23 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 24 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom 25 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING 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 CAUTION Section 4 Repair Procedures
171. 2 2 4 RA2BAT OR RD C2B 4 1 OR RD bg E 1 E 8 8 1 pod 5 g 5 bd aw 8 5 8 5 pg 55 1 88 E Ud RD WH 558 48V DC POWER RELAY CR2 219 C7P 2 P23BAT WH C7B 2 TI o 5 BRN 71 48V POWER RELAY CRI 8 8 1 bg ee 1 1 E g FLASHING BEACON OPTION 2 i 14 5 cx A NE EN M 2 to C1P 2 C28TTA RD BK C1B 2 C6B 28 RD BK WH oe B caps ci34PwRGR C2B 5 C6B 34 RD RD 1BK BRN TILT SENSOR 2 lt BR L 3 Fd S SSS 1 HOUR METER M ned C3P 9_ COHRN BK RD C3B 9 BK RD bg bg bg bg 2 P23BAT WH C7B 2 red AB EN a 1 5 T 1 5 a m 22 gi C7B 1 1 e bg i HN 8 2 5 HORN RELAY gt 85 8 BRN T T 1 BK 8 25 C6B 9 BK RD 4 HORN 8 3 E 2 C6B 20 RD 10 2 WH 5 RD 5 2 i Oe 5 7 5 iR 10 1 5 11 1 BK6 BASE CONTROL x GROUND a 5 10 4 WH 4 11 4 WH7 5 5 C6B 40 OR 10 3 4 BK7
172. 55 3 a a 3 E 8 E m 3 22 f a co c a 6 36 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics SS See Electrical Schematic Z 45 25J before serial number 13361 REVA RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 June 2005 WHT 24 ORG RED 42 TS4 RPM RED FOOTSWITCH HIGH RPM BLK RED 1 RED BLU WHT 12 RED RED 5 6 IGNITION START MODULE START RELAY TACH INPUT START INPUT NOT USED GROUND BATTERY KEY SWITCH POWER NOT USED IGNITION ON WHT 2 AUXILIARY 1 2 3 4 5 6 7 8 9 10 ENGINE FAULT GND GND BRN GRN BLK BATT WHT BATT WHT 23 WHT IGINE GROUND EN BLK ISM1 BLU ISM2 BLK 33 HIGH LOW RPM RPM Ze TS2 BLK 1 TB35 BLK RED 35 BRN TP33 BLK WHT 34 12V DC BLK WHT 1 GLOW PLUGS TS56 TB34 TS6 GLOW PLUGS TP25 TP24 ORG RED 42 TP34 ORG RED 1 ORG RED BRN lt lt BLK WHT BN 30 WHT J4 RED J10 12GA 85 86 WHT 21 BRN CR12 12V gj 21 WHT 23 WHT 21
173. C30FWD WH 4 C29JSH RD WH C1P 3 al 5 OR BK 2 C28TTARD BK OR BK R6 C27AUX RD C1P 1 RD AUX 31 xi lt 7 5 2 38 RD STOP Hou C J 9 27 RD HRN i i R42BAT OR RB 1 gt 8 25 f gt z BRN BCI 4 3 i i C9HRN BK RD 1 1 gt zz i 1 1 1 a 1 1 1 MSN Oy eee cc PRESE E ERE TORRES 2 55 22 cn el A Platform Control Box Wiring Diagram Z 45 25 from serial number 21181 to 22050 Section 6 Schematics PartNo 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 101 June 2005 Section 6 Schematics REV A Platform Control Box Wiring Diagram Z 45 25 with LVI BCI Option from serial number 21181 to 22050 N M K J F E D B A
174. C6B 4 WH i 14 1 142 E TURNTABLE ROTATE RD RIGHT 5 C4TRR C3B 5 lt 2 2 4 C4TRLWH C3B 4 P24BAT WH R42BAT OR RD FUNCTION ENABLE C40LS OR RD C12DRE BL WH P42BAT OR RD RD TS55 GND BK PR2 PR3 soso June 2005 Section 6 Schematics p Electrical Schematic Z 45 25 CE Models from serial number 22051 to 23235 June 2005 Section 6 Schematics REVA Electrical Schematic Z 45 25J before serial number 13361 i N N Q Q a 66 2 9992 2 518 5 E 5 E a 1 5 a uz z 5 _ a Ssa Siz wy
175. gt Guvas 51915 NE bog a ols 5 NOLLONN Is uf lt E ha M FA LARS ai o z i a o u o6 Oo m LO 87 HOLIMS 1 Je SN bg Ga E LO ok 1 a Eis AE E m ol daadS LINIT 440 Ov X rt if H3TIOHLNOO 6 6c asuma 2 rt E Gyvas 8 O bog Fd IHN ma EN 8 APON amp 9 engm lt snam dans bog jo O AAHS 36 o 9e na 4 ma LO MEE s d PTO SMEMO at r3 zo Off 3NION3 19 15 53 SEE ziasvo Wood T2 8 CN Y 1 19 lt ole 5 18 X18 1HM 0 SN G O IHM THM ic 8 HOIHH3IJWOLN3IOdMOHNSAOh 10 ANWd nes I 5 121 9 oissoo3uwm 0 8 ZIA 5 wads mo 2 4 109135
176. 1 AC OUTLET BOX 19 8B 8 6 Be BATTERY CHARGE INDICATOR 5 5 S8 5 55555 25 8 5 51 218 8 a GRN REDIWHT 29 ls 3298 BP1 ROTARY FLOW CONTROL DIAL lt E N m A 5 9 5 1 2 9 4 7 9 3 9 5 9 gg WHTIRED 32 9i Js CR6 DRIVE ENABLE RELAY m lt 8 a gt TY a CR7A JIB CUTOUT RELAY Teu e a VHT P CR7B JIB VALVE RELAY 6 FWD m x e PK HTIBLKST CR19A LOW VOLTAGE INTERRUPT BCI RELAY A REV RED waruves CR19B LOW VOLTAGE INTERRUPT BCI RELAY B zl E GREEN eer 9 DP1 DRIVE JOYSTICK RED lt a L1 DRIVE ENABLE LED 9 9 BLK RED PEPE 58 7 13 CONTROLLER FAULT LED BLU RED BLK R6 EN 5 DRIVE e LOW VOLTAGE INTERRUPT MODULE 3 5 4 log SES BATTERY CHARGE INDICATOR FOR LVI OPTION WHT RED BLU 36 P2 EMERGENCY STOP BUTTON 7 LEFT DMB tele SECONDARY PRIMARY HORN EXTEND LVI BCI OPTION TE ROTATE BOOM BOOM RETRACT BLK WHT 9 mmm TIME DELAY 1 x TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH P3 BLK WHT TS4 HIGH LOW RPM TOGGLE SWITCH HORN RED 12 hs TS6 GLOW PLUG TOGGLE SWITCH 9
177. 38383 2855 5 38425 2890 2 019 JOBINOO MOT 2 9 QU HM 23190 9 860 QH HM 23199 9 890 5 5 9 HH1SO 9 80 ae X8 HM HHISO 58 892 4 eum 1431 19170 899 srw 2 9 2 80 Wav Wa 2 895 19 1 o i 9 da nadito 1 80 1 895 V 5 1 2288 42 81 36 8 TVNIIWNH3 L 2 1879 9 8 0 N H6 Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 69 TS51 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 CE Models from serial number 22051 to 23235 BK RD C45JSV GR WH C2B 7 BK 7A SRBK 18A 1 ___ GR 7A BK WH BK 5A 5 5 Pot 5 LS GR T wo 5 Stat BK
178. 5 a 22 24 FEKO lt BK RD 2 RD gt RD RD 27A x dd OR BK RD BK2A 4 OR MA OR RD 1A gt gt ET 090 a a a 950 A 2 8 pfo ga RD C23 6 4 22 NEM 2 RD C7B 4 BL 10A RD lt 592 BLIBK 11A EI 500 58 S Box 3609 GR WH 19A BK oz 5 902 P20BAT RD 5 1 4 lt RD EE RD 134A 920 B8 RD RD RD e C297 RD 6 v RD WH 23 e gt 6 WH 7 e LE ala n BRN 81 5 B e z 5 833 e HrU 9 8 IE X 5 8 a aV Genie Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 70 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 CE Models from serial number 22051 to 23235 Section 6 Schematics June 2005 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J before serial number 13361 REVA June 2005 45 25J
179. 8 2 o 2 5 m lt 5 2 gt 5 2 5 8 8 5 2 9 amp Sl 5 5 gt i 5 n 5 8 e o 2 ux gt a 9 9 5 g T xz i 910 1910 9101910 9 0 T m 4 I x a WH BATT 5 e 8 9 25 4 WH R14 7 7 7 8 4 9 BK ISM1 BK ISM1 m a BRN VOLT BL ISM2 BL ISM2 C33STR BK BRN J5 BRN ISM5 BRN ISM5 P20BAT RD C23PWR WH 3 ge 5 6 lt ENGINE HARNESS TO DRIVE CHASSIS GR BK BATT ENGINE HARNESS ENGINE WH ISM10 ENGINE HARNESS TO GROUND CONTROL BOX Q gt 7 C v 5 x z c z m e a tr lt m a iD 2 5 8 S8 amp 8 e 2 e e m Q a e 12V DC S S8 38 8 8 8 8 VOLTAGE REGULATOR 2 C5B MALE DEUTSCH CONNECTOR 6 15 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics
180. 9 Tag disconnect and plug the fuel hoses from the fuel tank 10 Remove the fuel tank strap fasteners and remove the tank strap 11 Remove the fuel tank from the machine 12 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold and the brake Cap the fittings on the manifold and the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the turntable rotation motor mounting fasteners Remove the motor from the brake 14 Remove the brake mounting bolts Remove the turntable rotation brake from the machine AWARNING Crushing hazard The machine Genie could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 49 Section 4 Repair Procedures June 2005 TURNTABLE ROTATION COMPONENTS 10 2 Turntable Rotation Assembly from serial number 18367 to 23235 How to Remove the Turntable Rotation Assembly When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom unti
181. BK 2GA E BK 2GA T 1 i 1 3 RD 2GA 5 RD 20 12GA e WH FROM CHARGER 1 i P42BAT OR RD i 500 0 5 lt BK 2GA 10A BK 2GA ii BK 2GA BK 2GA 4 x E a RD 2GA TOP VIEW OF DRIVE CONTACTOR DRIVE CONTACTOR AUXILIARY POWER UNIT 2 CONTACTOR 1 LT IT i H AMMETER c AP 2 DIODE gt DIODE 330 x DIODE PLUG 330 5 H 4 2 5 PRA HH CONTROLLER PR 3 UC g LIFT b R42BAT OR RD lt 2 OR RD R42BAT OR RD 5 BRN J8 BRN J8 3 z lt a lt lt 5 lt lt i R27AUX RD RD SSES 2 BK BK BK BK RD 2GA 5 RD 20 12GA 6 RD 2GA RD 2GA 5 RD 10GA RD 10GA amp 24V DC a asv DC 1 200 2004 RD 10GA 5 RD 10GA RD 2GA 5 z F2 4 206 5 E ALA 7 2 8 i 24123 2221120 19118 17116 15 1413 12 11 holo 18 17 1615 2 1 9 RD 2GA S 1S F1 c rtc c F2 Q RD 10GA z 5 A1 EE A2 5 9 9 8 513 BK 2GA cr BK 2GA E 4 RIGHT SIDE 8 LEFT SIDE BK FROM CHARGER RD 10GA 2 FN DRIVE MOTOR DRIVE MOTOR 5 92 BRN J8
182. BRNJ3 olo RED LVI 2 v 5 5 z4 c z e gt SCIS mm 5 mim 20 61505 BIB 9 ZIZISSZABS CYS SPSS 5 2 555 d 3 5 E SS 2 2 Zo 2272 25552 26 5 gt 5 2 315 gt 2 __ 9 Sale 5 5 258882544 SSHZSS SSS sh 82225 2828006 T n m 2 2 2 5 RED LR15 S 829m 54 m RED TIME 93181715 YP Or ul lo GRN WHT JOYS A m 3 5157 4 GRNWHT R12 a NOTES ic ALL WIRES WITHOUT LABELS ARE BROWN J7 RED STOP EITHER RED OR BLACK JUMPER WIRES BROWN LJ 5 5 aa usos 5 2 5 5 55 8 22 2 39585 FOR LIFT DRIVE SELECTOR OPTION 6 mmm O o o o og TAKE OFF JUMP BETWEEN 8 B 28 RED JIB PISS 25 5 5 5 2 6 5885 5 5 55 5 BLK ogzomso sz5pss sso ss BROWN GAND km 16 SS 10 RSS xm RE
183. CONTROLLER 5 2 NA RED WHT 3 B RED WHT 3 TB42 TB3 STARTER 251 RED FS TP26 TILT ALARM RED BLK 1 i RED WHT 23 RED BLK 28 WHT 2 RED WHT 23 RED TP23 5 BLK RED 3 TB23 B ENABLE BLK RED 9 BLK 2 BLK RED 9 li BLK 22 TB22 RED FS FS1 WHT FS PLATFORM GROUND KS1 Ls4 SEC BLK 8 Ls2 RED 6 BLK 6 RED 8 D RED 20 BLU RED 1 21 ORG RED 42 I 50 21 PRI CONTROLLER FAULT INDICATOR LED L2 BLK 9 TB49 TB40 ORG RED i RED BLK RS 8 ORG RED 42 8 COIL PR1 GRN ORG 40 BLU RED 39 FAULT LED 9 29 RED WHT 1 TB39 OFF LIMIT SPEED INPUT BLU WHT 12 INTERLOCK RED WHT 29 POT HI TP32 WHT RED 1 WHT RED 32 POT LOW TP31 iz WHT BLK 1 WHT BLK 31 REVERSE TP30 WHT 30 FORWARD BLK LSTOP LOAD SENSE OPTION a RED 17 LOAD SENSE PCB 2 4 z s
184. DRIVE ENABLE LIMIT SWITCH C7B 3 BATGND BRN C4B 1 BURD C6B 13 C13DREL 22 21 BK 8 BRN 8 C6B 21 DREGND BRN C3P 12 C12DRE BL WH BL WH C6B 26 C12DRE 1 153 WH 8 4 4 C16DRE OR RD C3B 12 gt 12 C4B 4 OR RD C6B 16 CT6DRE 13 14 86 BRN CE VERSION REMOVE JUMPER AND ADD RELAY 77 CR6 OR BK C2B 3 RD WH C27 1 C27 2 A2 RD BK R6 TS15 C2P 3 DRIVE 30 ENABLE I 87 C36STCC BL C1B 10 l C6B 36 BL tht 26 1 26 2 10 C37STC BL BK C1B 11 C6B 37 BL BK 1 11 C32JSL WH RD C32JSL WH RD C30FWD WH LVI BCI OPTION C30FWD WH C31REV WH BK C31REV WH BK C40LS OR C40LS OR P24BAT WH P24BAT WH OR BK R6 5 6 FWD e e 4 REV AUXILIARY PUMP C27AUX RD C1P 1 C6B 23 2 RD C1B 1 C6B 38 GR WH GR WH OR RD R42BAT OR RD CR3 85 86 BCI OPTION OR RD C4P 7 C19LPMP GR WH ON 2 Ie z ase C4B 7 GR WH 30 C3P 6 C 6LFC WH RD C3B 6 WH RD RD t
185. GR WH E C6B 27 2 8 1 Sistas Sates MI C6B 6 WH RD RD BRN BK RD CONTROL P ROTARY OEM FLOW BP1 4 6 C18PRR GR BK PLATFORM ROTATE C4B 6 GR BK C6B 18 GR BK C23 1 C232 C6B 17 GR TB17 PLATFORM C4P 5 C17PRLGR C4B 5 GR PLATFORM LEVEL 2 C14PLU PLATFORM LEVEL TB15 C4B 2 14 C6B 14 OR 22 1 22 2 C6B 15 OR BK 20 1 20 2 C4P 3 C15PLD OR BK C4B 3 C3P 7 C7PBE BK PRIMARY BOOM C3B 7 m 5 TB7 C6B 7 BK 5 4 21 1 21 2 16 1 16 2 C6B 8 BK WH TB8 C3P 8 C8PBR BK WH C3B 8 PRIMARY C3P 1 RD PRIMARY BOOM C3B 1 TB1 C6B 1 RD 17 1 18 2 12 1 C6B 2 RD BK C12 2 TB2 2 C2PBD RD BK C3B 2 SECONDARY 10 C10SBU BL SECONDARY C3B 10 TB10 C6B 10 BL Fly C13 1 13 2 18 1 C6B 11 BL BK C3P 11 115 0 C3B 11 TURNTABLE C3P 5 C4TRR WH BK TURNTABLE RD C3B 5 TBS C6B 5 WH BK C6B 4 WH TB4 C3B 4 4 y C4TRL WH P20BAT ne C12DRE BL WH P42BAT OR R
186. June 2005 PRIMARY BOOM COMPONENTS How to Repair the Primary Boom Cable Track Component damage hazard The CAUTION primary boom cable track can be damaged if it is twisted A 7 link repair section of cable track is available through the Genie Industries Service Parts Department a link separation point b lower clip 1 Use a slotted screwdriver to pry down the lower clip 2 To remove a single link open the lower clip and then use a screw driver to pry the link to the side 3 Repeat steps 1 and 2 for each link Genie REV 4 2 Primary How to Remove the Primary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Z 45 25 Remove the platform rotator and platform mounting weldment Z 45 25J Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the cable track See 4 1 How to Remove the Cable Trac
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188. PRIMARY BOOM COMPONENTS REV 4 4 3 Remove the hose and cable guard from the upper pivot Primary Boom Extension PEREA Cylinder 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The AWARNING Bodily injury hazard Spraying primary boom extension cylinder is equipped with hydraulic oil can penetrate and counterbalance valves to prevent movement in the burn skin Loosen hydraulic event of a hydraulic line failure connections very slowly to allow the oil pressure to dissipate How to Remove the Primary gradually Do not allow oil to Boom Extension Cylinder ui 5 Atthe 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 AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and 6 Remove the barrel end pivot pin retaining tools could result in death or fasteners serious injury and significant component damage Dealer Service is strongly recommended 7 Placea rod through the barrel end pivot pin and twist to remove the pin 8 Support and slide the extension cylinder out of When removing a hose assembly the upper pivot or fitting the O ring on the fitting an
189. Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED lt SWITCH SHOWN WITH BOOM EXTENDED 6 19 SWITCH DRIVE ENABLE LIMIT BRN 2 TB13 BLU RED 3 BLK 7 1 z TP12 BLU WHT 12 m BLU WHT 3 WHT 7 Section 6 Schematics WHT 24 Electrical Schematic Z 45 25 from serial number 13361 to 14078 ORG RED 3 1 TB12 13 14 7816 16 16 fet 86 85 BRN un PLATFORM 1 BRAKE RELEASE 1 CONTROL BOX TRAVEL ALARM A2 x ORG BLK 1 GROUND E ter CR6 5 RED WHT 48 8 TP41 3t 7 7 M v m ks BRAKE RELEASE e N C COIL BRAKE RELEASE N O COIL RED BLK R6 DRIVE 30 ENABLE BRAKE RELEASE PRESSURE SWITCH PS1 TS15 BRAKE RELEASE JACK 9 BRAKE STEER MANIFOLD GROUND BLU 1 BLU 36 JP1 REMOVE FOR CE VERSION STEER LEFT COIL BLU BLK 1 BLU BLK 37 TB37 T STEER RIGHT COIL TP37 ORG BLK R6 GRN WHT 19 4 5 DRIVE 1 STEER AUXILIARY June 2005 WHT
190. Result All boom functions should operate Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 10 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 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 TEREX COMPANY REV B B 11 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol Low idle and slow battery charging High idle rabbit symbol High idle and quickest battery charging Foot switch activated high idle rabbit and foot switch symbols Activates high idle only when the foot switch is pressed down 1 Start the engine f
191. Sea 89453555 5 2 90 2 m 2 2 9 2934 lt T zoo 4 Hm lt RED TIME 20209 gm 9 rely m 4 GRNWHTJOYS lt m 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES GRN WHT R12 D 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp B GROUND RED STOP o ON THE DRIVE JOYSTICK 6161551415 55 82 15 5 5 2 8 8 2 2 gt RED BLK 28 B B B olo lo DIS S D 2 gt B BED WHT RHE BLK a B S BO BS Ble 55 als 9 a 2 29 lt 2 5 gt BROWN GRND kB xz kB 36 2225 60 Eee SE 2 5 E fala COMPONENT INDEX GABLE CABLE CABLE y SWITCH A1 TILT ALARM 5 ar i FS OUTLET BOX BCI BATTERY CHARGE INDICATOR gt BP1 BOOM PROPORTIONAL ROTARY CONTROLLER DRIVE ENABLE RELAY 5 2 82 28 23 E BB BEES 5 5 g als CR7A JIB BOOM CUTOUT RELAY 5 875 24588253 5 2 BS 255516 CR7B JIB BOOM VALVE RELAY 5 2 3 9 5 4 a
192. gt 2 1 ales i P26BAT BK agg BK LOAD 1 y RD HRN 1 1 i 1 ji x 1 255 p 2 d d 5 8 8 8 55255288888 8 i i i PAPE A 66 SS 1 e 160 919 9 9 919 9 9 ____ 1 1 1 1 B 1 1 1 1 ot 1 5 Rl 1 i 5 55 d s f 3 1 1 1 els BK RD A wok 2 2 o 1 1 1 1 D 1 1 1 I RD RPM BRN LOAD RD AUX eee BRN J1 BRN BC lt C33STR BK 1 p y 61 age 1 5 1 1 8 Ww C34SA 2 3 1 oo 8 P25BAT RD C9P 3 J E PE P24BAT WH lt 9 2 C6LFC WH RD 26 C9P 1 C19LPMP 25 RD RD SW BRN BATGND C7P 3 5 P23SWBAT WH C7P 2 i
193. s 7 s fo n e Electrical Schematic Z 45 25J from serial number 13361 to 14078 Section 6 Schematics 10A iN CBI amp ORG RED 42 DIODE RETURN 48V INPUT ORG RED R2 11 10 MOTOR CONTROLLER WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY BASE CONTROL BOX GROUND B CR16 30 87 ORG GEN NEG ORG GEN POS AC POWER BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 lt aon CHASSIS GROUND 48V CHARGER 48V DC ALTERNATOR PRIMARY TB20 F4 500 A pe 48V DC 24V 1 GROUND LIFT PUMP AUXILIARY LIFT PUMP 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC
194. 106488 Rev B COMPANY A TERI
195. 2 WS 1 Nua Nua O uus OOO g 5 79951 a ou 8 R tg z 22 T aay O 2 wamoa aau 29 HOLIMS 9018 LSJ 1951 ta a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 62 PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 16840 to 17974 Section 6 Schematics June 2005 _______________ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 17975 to 21180 REVA June 2005 Diagram Z 45 25 ing Ground Control Box Terminal Strip Wir from serial number 17975 to 21180 Section 6 Schematics DASHED LINES INDICATE OPTION WIRES
196. 2 EMERGENCY STOP BUTTON 7 TS10 TS11 TS12 TS13 P3 HORN SECONDARY PRIMARY EXTEND m m T T ROTATE LVI BCI OPTION BOOM BOOM BLK WHT 9 Ti TIME DELAY 1 BED TS AUXILIARY TOGGLE SWITCH BANLI TS2 ENGINE START TOGGLE SWITCH P3 5 HORN AED BLK WHT TS4 HIGH LOW RPM TOGGLE SWITCH 13 TS6 GLOW PLUG TOGGLE SWITCH x 5 b EN Sav Oo 9 4 8 TS7 PLATFORM ROTATE TOGGLE SWITCH NO ud H o y Iu amp C TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 9 DRIVE ENABLE 1209 FAULT LED T2 14 Ts9 PLATFORM LEVEL TOGGLE SWITCH m TS6 AUXILIARY Giow PLUG ENGINE LOAD gt lt TS10 SECONDARY BOOM TOGGLE SWITCH POWER START RPM LED HE TS8 TS7 TS9 TS PRIMARY BOOM UP DOWN TOGGLE SWITCH JIB BOOM PLATFORM ROTATE PLATFORM LEVEL 2 512 TURNTABLE ROTATE TOGGLE SWITCH RED ric dd TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 514 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH PartNo 106488 TEREX COMPANY enie Z 45 25 Bi Energy Z 45 25J Bi Energy 6 110 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option from serial number 14079 to 14650 Section 6 Schematics June 2005 ___________ Platform Control Box Wiring Diagram Z 45 25J from serial number 14651 to 16839 Section 6 Schematics June 2005
197. 3 4 5 6 7 8 9 10 ENGINE FAULT BLK ISM1 BLU ISM2 BLK 33 HIGH LOW RPM RPM Ze GE TS2 TB35 GND GND BRN GRN BLK BATT WHT BATT WHT 23 WHT IGINE GROUND EN BLK RED 35 BRN BLK WHT 1 BLK WHT 34 12V DC GLOW PLUGS TS56 TB34 TS6 GLOW PLUGS TP25 TP24 ORG RED 42 TP34 ORG RED 1 ORG RED BRN lt lt BLK WHT BN 30 WHT J4 RED J10 12GA WHT 21 85 86 BRN CR12 12V gj 21 CONTROLLER 5 2 7 NA RED WHT 3 B TB42 TB3 RED WHT 3 WHT 23 WHT 21 STARTER 251 RED FS TP26 TILT ALARM RED BLK 1 i RED WHT 23 RED BLK 28 WHT 2 RED WHT 23 TP23 5 BLK RED 3 TB23 B ENABLE BLK RED 9 BLK 2 BLK 22 RED FS FS1 WHT FS TB22 PLATFORM GROUND KS1 Ls4 SEC BLK 8 RED 6 Ls2 BLK 6 RED 8 RED 20 D 21 ORG RED 42 I 50 21 PRI 9 TB49 C
198. 310 3 Ss s 3 CR17 LOAD SENSOR RELAY LOAD SENSOR OPTION ONLY X X X 2 a 8 8 3 5 5 e 5 CR19A LOW VOLTAGE INTERRUPT BCI RELAY A LVI OPTION ONLY 6 g Dpi CR19B LOW VOLTAGE INTERRUPT BCI RELAY B LVI OPTION ONLY S DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED GREEN 9 105 L3 CONTROLLER FAULT LED __ RED L4 OVERLOAD LED LOAD SENSOR OPTION NI 1 26 LDS LOAD SENSOR MODULE 2 130 LVI LOW VOLTAGE INTERRUPT MODULE lt gt Or RN ern aS LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP 2 7 TURNTABLE SECONDARY PRIMARY BOOM EXTEND 5 P3 HORN BCI ROTATE TS12 BOOM TS10 TS11 RETRACT gt LI TS13 7 Ti TIME DELAY 1 TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH BI ENERGY ONLY BLK WHT HIGH LOW RPM SWITCH BI ENERGY ONLY OO TS15 id 5 4 13 8 TS6 GLOW PLUG SWITCH BI ENERGY ONLY SSD poo ZA TS7 PLATFORM ROTATE SWITCH P3 NO Cid Quos 3 EE Od 2 9 Cad Cov LW 5 01 TS8 JIB BOOM UP DOWN SWITCH JIB ONLY 8 AUXILIARY J FRUEHEED J TS9 PLATFORM LEVEL SWITCH HORN GLOW PLUG START RPM TS10 SECONDARY BOOM SWITCH ay JIBBOOM PLATFORM ROTATE PLATFORM LEVEL ie PRIMARY BOOM UP DOWN SWITCH 198 187 159 TS12 TURNTABLE ROTATE SWITCH TS1
199. 5 WHT BLK 3 WHT 3 8 5 ROTATE TP4 FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED RED BLU WHT 12 RED TS55 GND GND BRN WHT 24 ORG RED 42 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL NOTES 6 42 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 June 2005 Section 6 Schematics Electrical Schematic Z 45 25J from serial number 14651 to 16839 REVA June 2005 Electrical Schematic Z 45 25J from serial number 16840 to 17974 Section 6 Schematics WHT RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG RED 42 RED RED BLUMHT 12 RED START RELAY TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN BATTERY IGNITION START MODULE 1 2 3 4 5 6 7 8 9 GRN BLK BATT WHT BATT RED 5 6 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH WHT 23 WHT GROUND BRN FOOT SWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 B ALTERNATOR FIELD RELAY CR16 HIGH TB35 TP35 Ye BRN is Low RPM TS4 RPM
200. 6 108 Genie beh PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy xvii June 2005 TABLE OF CONTENTS Section6 Rev Schematics continued Platform Control Box Wiring Diagram 2 45 25 from serial number 14079 to 14650 6 109 Platform Control Box Wiring Diagram 2 45 25 with platform load sense and LVI BCI option from serial number 140791014650 6 110 A Platform Control Box Wiring Diagram Z 45 25J from serial number 14651 1016839 6 111 A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI option from serial number 14651 1016839 6 112 A Platform Control Box Wiring Diagram Z 45 25J from serial number 168401017970 6 113 A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI option from serial number 16840 to 17974 6 114 A Platform Control Box Wiring Diagram Z 45 25J from serial number 17975 to 21180 6 115 A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI option from serial number 17975 to 21180 sse 6 116 A Platform Control Box Wiring Diagram Z 45 25J from serial number 21181 1022050 asnarin ainsana 6 117 A Platform Control Box Wiring Diagram Z 45 25J with LVI BCI option from serial number 211811022050 6 118 A Platform Control Box Wiring Diagram Z 45 25J from serial number 2205110 23235
201. 6 87 A Ground Control Box Switch Panel Wiring Diagram Z 45 25J CE Models from serial number 22051 to 23235 6 88 Platform Control Box Wiring Diagrams Z 45 25 Platform Control Box Wiring Diagram Z 45 25 before serial number 13361 6 89 Platform Control Box Wiring Diagram Z 45 25 with platform load sense and LVI BCI option before serial number 13361 200400 0 6 90 Platform Control Box Wiring Diagram Z 45 25 from serial number 13361 to 14078 6 91 A Platform Control Box Wiring Diagram Z 45 25 with platform load sense and LVI BCI option from serial number 13361 to 14078 6 92 A Platform Control Box Wiring Diagram Z 45 25 from serial number 14079 to 14650 6 93 A Platform Control Box Wiring Diagram Z 45 25 with platform load sense and LVI BCI option from serial number 14079 to 14650 6 94 Xvi Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Rev A TABLE OF CONTENTS Schematics continued Platform Control Box Wiring Diagram Z 45 25 from serial number 14651 1016839 0 6 95 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI option from serial number 14651 16839 6 96 Platform Control Box Wiring Diagram Z 45 25 from serial number 168401017970 0 20 400 000
202. 9 ORG BLK 41 ORG BLK 41 3 EL 8 BLU L10 BLU L10 WHT LV24 J WHT L6 WHT L6 S 3 3 RED LVI lt 5 5 5 2 715 3 3 1 8 IRE gt gt On m E 8 315 0515555 9 5 2 2 1575 2 2 gt lt lt 200501051553 E zm 5 99 lt 34 1985 1 2 5 DSTI 25 RED LR19B gt Amm Oz v 5951266 SemS mg g rp 3m lt 255474 n zB Q 5 4 alt 8 2 lt n RED TILT GRND 35 5 5 PssspapassseERRPRPRSSSSSs IS ISIE ISIS S 2 415 95 0 0 15 A IS 2 I rm CD T m I rm 239 2919 jag 919 2519 AN Y jojo 66
203. BK 7A GR BK 18A e A 1 BK WH 8A GR 17A gt BK WH BK 5A 4522 BIE gt WH 4A GR Bee PEO gt oak Siac BK zs90 0525 a LEZA BK 2 rakl RD gt RD RD 27A a 845 x a 5 Zz x CRBK 15A OR BK RD BK 2A OR 14A OR RD 1A gt gou 3 9 9 BEG 9509 T T T gp ps RD RD C23 6 4 BK 22A 2 RD C78 4 a1 BL 10A RD S gt T 5 2 i 7 2 EE BL BK 11A 7 A 58 7509 1 GR WH 19A BK 5 P20BAT RD 5 1 e 5 RD 134 25 1 1 RD RD i RD i RD 23 7 RD 6 RD 4 GR BK H6 WH 23A Rog G 5 BRN 2 D 8 y x amp ira 8 5 RD 855 GM 8 E gt 2 A TEREX COMPANY PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 68 June 2005 Section 6 Schematics 2 2 2 2 Ground Control Box Switch Panel Wiring Diagram 2 45 25 ANSI and CSA Models from serial number 22051 to 23235 Section 6 Schematics June 2005 ___________ Ground Control Box Terminal Strip W
204. Engine Panel Diagram from serial number 21181 to 22050 Section 6 Schematics June 2005 Engine Panel Diagram from serial number 21181 to 22050 f NOTE RD CB CIRCUT BREAKER RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE 1 CB3 RD CB 12V 12V 15A C21IGN2 WH C21IGN2 WH C35HRPM BK RD C35HRPM BK RD WH J5 WH J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 T ae WH J4 WH J4 WH J6 BK RD BK RD oe a 2282 2 2 98 87 87 87 87 87 87 on GND BRN ov 87a 86 les 87a s 85 86 85 s 87a 87a zi 5 RD CB a 30 30 30 30 CR16 CR12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WH J4 RELAY RELAY C34SA BK WH WH J4 WH J6 WH J6 3 RD J6 RD J6 lt 3
205. FS BK FS C9P 1 BK P2 52 C7P 1 BK P25BAT RD P24BAT WH C9P 2 22 2 4 R42BAT OR RD C2B 4 WH J4 3 C3B 3 C5B 11 C21IGN2 WH o 2 2 o C23PWR WH 87 30 87 gt STARTER C7P 2 P23BAT WH C7B 2 gt A1 TILT ALARM 48 A C1P 2 C28TTA RD BK C1B 2 RD BK C6B 28 P26BAT RD RD P3 RD C2P 5 C134PWR GR C2B 5 C6B 34 HORN C3P 9 C9HRN BK RD C3B 9 BK RD 1518 12 H C7B 2 P23BAT WH gt _ lt GR BK C7B 1 TB134 C132 PLI BL WH coe gt gt v 5 8 gt gt 4 6 gt gt 12 BK 30 87 C6B 9 BK RD TB22 GROUND PLATFORM KS1 C2P 2 C40LS OR C2B 2 OR C29JSH RD WH C1B 3 TB40 OR C6B 20 RD 10 2 WH 5 RD 5 11 2 WH 6 BK 5 WH 4 C10 1 lt a C10 4 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID S
206. Genie Service Manual Refer to inside cover for additional serial number information Tasse 2 45 25 2 45 25 Bi Energy Power from serial number 9996 to 23235 Introduction June 2005 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie 2 45 25 Bi Energy and Genie Z 45 25J Bi Energy Operator s Manualbefore attempting any maintenance repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us
207. KS1 i i CONTROLLER FAULT 1 1 ORG RED 42 BLK TB40 B BRAKE RELEASE RELAY CR5 ORG RED CR5 RED BLK R5 8 8 ORG RED 42 COIL PRI GPN 17 B MOTOR MAIN CONTACTOR RELAY ORG 40 BLUIRED 1 BLU RED 39 T FAULTLED Je 1 maan TP39 TB39 E1 OFF LIMIT SPEED INPUT F1 RED 20 BLU WHT 12 INTERLOCK E2 2 29 RED WHT 1 TB29 RED WHT 29 POT HI lt 2 aon lt 16 ie CURTIS 1244 SEPEX CONTROLLER B TP32 WHT RED 1 TB32 WHT RED 32 GROUND 1 POT LOW 44 TP31 WHT BLK 1 TB31 WHT BLK 31 REVERSE 11 i8 TP30 _ WHT 1 TB30 WHT 30 FORWARD 10 i ORG GEN NEG ORG GEN POS F2 24 POWER ORG RED 42 R 48V INPUT 1 a DIODE RETURN g 1 1 1 1 WHT LOAD 9 BLK 48V DC CHARGER CHARGER 1 ORG LOAD 48V ALTERNATOR LOAD SENSOR BOX 10 ALTERI of ORG RED R2 GND PRIMARY LIFT PUMP 1 1 AUXILIARY fom 1 PUMP B FS 10A F2 200A WHT FS TB20 24V DC B
208. REVA C6B 38 GR WH Z 45 25 Bi Energy Z 45 25J Bi Energy 9 10 2 3 4 5 7 OR BK R6 4 4 FWD REV 2 DRIVE STEER P24BAT WH DP1 20K AUXILIARY PUMP 1 C27AUX RD gt TS1 RD AUX GR WH 330 PR2 OR RD 8 5 C6B 19 4 PRIMARY LIFT PUMP RELAY COIL PR2 BCI OPTION BK AUXILIARY POWER 85 OR RD TS51 2 5 v IH 2 RELAY COIL 1 1 PartNo 106488 1 AUXILIARY LIFT 6 27 EX PUMP RELAY COIL 5 1 E 1 1 4 LIFT PUMP ms GR WH 8 NA bg 5 m 86 4 CRS 4 7 C19LPMP GR WH C4B 7 GR WH CONTACTOR RELAY CR20 81765432 C3P 6 C6LFC WH RD x a C3B 6 WH RD C6B 6 WH RD efje FLOW CONTROL COIL RD BRN PLATFORM ROTATE RIGHT C23 1 23 2 18 C6B 18 GR BK m C6B 17 GR PLATFORM ROTATE LEFT ROTARY CONTROL OEM FLOW 22 1 C22 2 TB17 4 6 C18PRR GR BK C4B 6 GR BK 5 C17PRL GR C4B 5 GR PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL 20 1 20 2 C6B 14 OR 2 6 15 OR BK E C21 1 21 2 15 PLATF
209. d id B 5 ENGINE HARNESS E xls E TO ENGINE S 9 9 8 gt 9 85 4 amp t 5 8 E 7 E E 25 2 2 E Ej S u ri 5 5 MALE DEUTSCH 3 5 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR BROWN J3 BLACK 33 RED PISM6 WHITE BATT WHITE 21 BLK RED 35 WHITE 23 BLK WHT 34 GRN BLK BATT CHASSIS HARNESS PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy enie A TEREX COMPANY 6 10 June 2005 Section 6 Schematics n Q u Engine Panel Diagram from serial number 13361 to 14078 Section 6 Schematics June 2005 ETC Engine Panel Diagram from serial number 14079 to 14650 Section 6 Schematics June 2005 Engine Panel Diagram from serial number 14079 to 14650 A B C D E F G H J M
210. eer EM RP m AIRE 919 jaya COMPONENT INDEX FOOT uu Ea POWER TILT ALARM 5 1 AC OUTLET BOX C lt BCI BATTERY CHARGE INDICATOR E BP1 ROTARY FLOW CONTROL DIAL oe o o o o o DRIVE ENABLE RELAY z 919 IS m Bm Bg S CR7A JIB CUTOUT RELAY 9 2 2 3 99 2 o 3 9 18 16 5 25555 278 8 3 les g GRN gf REDWHT 29 CR7B JIB VALVE RELAY lt 2 PI m a 5 5 318 z CR17 LOAD SENSOR RELAY POR E ES 5 9 9 WHURED 32 5 5 m WHESO E B 5 5 CR19A LOW VOLTAGE INTERRUPT BCI RELAY A 6 Ly 9 CR19B LOW VOLTAGE INTERRUPT BCI RELAY 2 2 x BLK WHTBLKS1 5 EHE DP1 DRIVE JOYSTICK REV 3 RED 252 1 DRIVE ENABLE LED La WHT GRN WHT LV24 Nag 5 2 13 CONTROLLER FAULT LED GREEN YEL 596 a a lt A 25 4 OVERLOAD LED 000 9 N 7 ale LDS LOAD SENSOR MODULE BLU DRIVE e LVI LOW VOLTAGE INTERRUPT MODULE 3 5 4 e WHIVEL log LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION WHTRED BLU 36
211. i 56 x 1 pp PLATFORM LEVEL a p Sa DOWN 73 DOWN 8 a 8 5 JB MANIFOLD ez a 20 2 PLATFORM LEVEL m ORGS 2 258 DOWN CUTOUT 48 RELAY ORG BLK 3 gS DOWN au EXTEND B BLK 7 PRIMARY BOOM a 5 EXTEND m AES PRIMARY BOOM zo RETRACT m RETRACT 1 a EXTEND 7 B puc iz z 29 UP RED 1 PRIMARY BOOM nm 1 UP E p z m RED LK 2 b PRIMARY BOOM 25 3 a DOWN a oa RED 3 E I g DOWN TO gt UP s BLU 10 SECONDARY BOOM lt 1 T amp m BLUBLK 1 1 SECONDARY BOOM 8 DOWN DOWN 8 wy o 2 Ve eee ee ee 1 SC DESCENT ALARM gt OPTION x UP BLU 3 i 5 at gt 222 BLU BLK 3 9 DOWN m 8 P E 5 WHT BLK 5 TURNTABLE ROTATE RIGHT WHT 4 i TURNTABLE 55 LERT 5 ROTATE LEFT a 1 1 WHT BLK 3 T j T t WHT 3 zc ft LEFT m i
212. 14 6 Nm 25 Pressure switch Y ass Brake circuit 4 36 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV O OOO Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 37 MANIFOLDS 00 G9 GD 9 9 Section 4 Repair Procedures June 2005 MANIFOLDS 9 2 REV C Function Manifold Components from serial number 17841 to 20379 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index Schematic No Description Item 1 Solenoid valve 2 position way 2 Solenoid valve 2 position way AB 3 Solenoid valve position 4 way AC 4 Solenoid valve 3 position 4 way AD 5 Solenoid valve position 4 way AE 6 Solenoid valve position 4 way AF 7 Counterbalance valve AG 8 Solenoid valve 3 position 4 way AH 9 Solenoid valve position 4 way Al 10 Proportional solenoid valve AJ ues 11 Differential sensing valve AK 12 Solenoid valve 2 position 2 way N C 13 Relief valve 1800 psi 124 bar AM 14 Flow regulator valve 0 6 2 2
213. 25 ft lbs 34 Nm 20 25 ft lbs 27 34 Nm 20 ft lbs 27 Nm Platform level down System relief Testing Brake 12 14 ft lbs 16 19 Nm Steer circuit Brake circuit 20 ft lbs 27 Nm Brake circuit Secondary boom up Part No 106488 MANIFOLDS Section 4 Repair Procedures OO OOOO 2 c J 0 3 dad 0 CA 9 64 9 June 2005 a a 2 2 a 6 39 enie Z 45 25 Bi Energy Z 45 25J Bi Energy TERI G Part No 106488 Section 4 Repair Procedures J M su MANIFOLDS 9 3 June 2005 REV C Function Manifold Components from serial number 20380 to 22565 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index Schematic No Description Item 1 Solenoid valve 2 position 3 way BA 2 Solenoid valve position 4 way BB 3 Solenoid valve position 4 way BC uus 4 Solenoid valve 3 position 4 way BD 5 Solenoid valve position 4 way 6 Solenoid valve 3 position 4 way BF 7 Solenoid valve position 4 way BG aus 8 Proportional solenoid valve
214. 261 161 sumwauP e 8 a 8r O ur 5 aasnnn O 2n TINN LO 5 SANA Sy Q E 2 gt 215 SS3NHVH wes i NEVA INHOSI SN S G 1O3INVW 29 amp NOLLONRd Gyvas sis 2 JP SEIONSEHOUMS id 9 O a Lt Woo8 3348 LINIT 440 Q e UO 6 3uvas 6 a 88 88799 8 LO 28 28 3 d 6LMLHWNH9 9 a 9 2881 gma 6LI IHWNHO 01 SAS s a 9 UH ro 8 SN 9 swa 9 8 Dil MOT EN o ee 3NION3 LYVLS a WOOS 8 O O e MOTH3IJWOLIN3l1Od MOILSAOP 26 18 lt 18 Q Q SA X18 1HM ee 05 0 1HM 8 6 HOSIHH3ISWOLN3IOdMOHSAOh a Q HOLIMS HAV 3 4 SUM O Ojs 82 SN o 828 038 LO 22 1909135 dWnd Auvriixnv 22 Q cix 2
215. 45 seconds 12 2 meters 45 seconds 5 2 Z 45 25 Bi Energy Z 45 25J Bi Energy REVA 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 Part No 106488 June 2005 Section 5 Fault Codes Fault Code Chart REVA Fault Code Programmer Condition Possible Causes 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 COMM NICATION button s was cycled on seconds Pull out the 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 blinking sensed an internal error out to the ON position If during start up problem persists replace the motor controller 12 HW FAILSAFE 1 2 3 Machine will not drive motar controller the motor failed self test controller The motor controller has a internal short motor M SHORTED M
216. 6 97 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI option from serial number 16840 to 17974 6 98 Platform Control Box Wiring Diagram Z 45 25 from serial number 179751021180 6 99 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI option from serial number 17975 to 21180 essen 6 100 Platform Control Box Wiring Diagram Z 45 25 from serial number 211811022050 6 101 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI option from serial number 21181 1022050 6 102 Platform Control Box Wiring Diagram Z 45 25 from serial number 22051 023235 6 103 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI option from serial number 22051 to 23235 6 104 Platform Control Box Wiring Diagrams Z 45 25J Platform Control Box Wiring Diagram Z 45 25J before serial number 13361 6 105 Platform Control Box Wiring Diagram Z 45 25J with platform load sense and LVI BCI option before serial number 13361 2 2 2 0 000 6 106 Platform Control Box Wiring Diagram Z 45 25J from serial number 13361 to 14078 sse 6 107 Platform Control Box Wiring Diagram Z 45 25J with platform load sense and LVI BCI option from serial number 13361 to 14078
217. A TEREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 This page intentionally left blank Genie iv Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Genie beh PartNo 106488 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie 2 45 25 Bi Energy and Genie Z 45 25J Bi Energy 5 Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority messages that follow this symbol to avoid possible injury or death ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in dea
218. BOS Es Opo 55 gt 2 228 CES apo 28 95 LF M RD BK C23 6 a 4 RD BK 22A e 2 RD C78 4 p URDU ee T BL 10A RD 592 BL BK 11A g ood 35085 GR WH 19A BK oz 5 ERA 5 1 i P20BAT RD C5B 1 4 232 BD RD 134A 266 i 1 1 e RD RD ENS RD r8 a e 80237 RD 6 v RD GR BK H6 a are ee D eta eese eh bep UA WH 23A 862 Fah 5 6 WH 7 IN 2 go 5 5 BRN 2 e z 2 999 9 HOUR METER H M BASE BOX HARNESS Genie TEREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 88 June 2005 Section 6 Schematics 5 Ground Control Box Switch Panel Wiring Diagram Z 45 25J CE Models from serial number 22051 to 23235 Section 6 Schematics June 2005 Sa Sess Platform Control Box Wiring Diagram Z 45 25 before serial number 13361 Section 6 Schematics aes See June 2005
219. C 3 Test platform overload if equipped Perform every 800 hours C 4 Perform engine maintenance A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Section 3 Scheduled Maintenance Procedures _ SS MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes acceptable no remove from service R repaired Comments Checklist D Rev June 2005 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 D 6 Turntable bearing wear 0 7 Calibrate platform overload system if equipped Perform every 1000 hours D 8 Perform engine ma
220. HARNESS lt FUNCTIOI MANIFOLD HARNESS BOOM CABLE 1 91 ASV 1VNII H3 5 r4 x Nua 9 d Nua Nua 5 Nua 5 2 o 5 5 918 uc Wdvivoria 6 d3unria U IHWNHO 6I LHWNHO 9INSId d3H U3MOd d3u ert ne A e UL IM M 22 940 eh A ee E DHOR ae 558 A PL iei 0 12 INOLND 13A31 WHOd1Y 1d AINO 05 61 251 08 0 51 2571 6r 267 167 257 15 Q 8 DIVE 8 cra 4 aasann nin LO INVA Qo A 213 Guvds s Guvas Q ou
221. PET a WHT J4 WHTJA WHT J6 BLK RD BLK RD 555 5 ESS 2 8 87 87 87 87 87 87 85 86 85 86 BROWN CH H ov gt 87 87a 86 85 87a 87 87 87 86 oo RED CB om 30 30 30 30 CR16 CH12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WHT J4 RELAY RELAY BLK WHT 34 WHT J4 WHT J6 WHT J6 ei rE gt 6 RED J6 RED J6 amp 2 3 gt o 2 5 lt ie gt tr m 5 9 g 9 2 5 Q 5 8 gt 5 o 95 406 5 gz Y I t I 5 a a i 58 232 3 4 WHT R14 a g i EZ 2 E 5 X E a a m c BLK ISM 1 BLK ISM 1 2 BRN VOLT 5 BLU ISM2 BLU ISM2 BLK 33 BRN J5 5 BRN ISM5 BRN ISM5 RED ISM6 WHT 23 a Zrze 55455 3 22538 GRN BLK BATT 6 WHT ISM10 ENGINE HARNESS TO CHASSIS HARNESS 2a 45885 9 ENGINE HARNESS Se x 51804 o rt Q X S q 5 2 7 t S 5 S 2 S MALE DEUTSCH CONNECTOR 12V DC 2 VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR
222. RED 3 PRIMARY BOOM TB1 RED 1 RED BLK 2 TB2 8 RED BLK 3 BLU 3 SECONDARY TB11 TB10 BLU 10 BLU BLK 11 BLU BLK 3 5 WHT BLK 3 TURNTABLE ROTATE RED 5 WHT BLK 5 WHT 4 TB4 WHT 3 BLU WHT 12 RED FUNCTION ENABLE TS55 GND GND RELAY COIL PR2 FLOW CONTROL COIL LATFORM ROTATE RIGHT LATFORM ROTATE LEFT PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT ALARM OPTION A3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL BRN enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 28 Part No 106488 June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 17975 to 21180 REVA June 2005 Electrical Schematic 2 45 25 from serial number 21180 to 22050 Section 6 Schematics C31REV WH BK C29JSH RD WH C32JSL WH RD C40LS OR C30FWD WH P24BAT WH R42BAT OR RD FOOT SWITCH HIGH RPM 9 C35HRPM BK RD C1B 9 P20BAT RD P42BAT O
223. Schematics from serial number 14651 to 16839 Ground Control Box Switch Panel Wiring Diagram Z 45 25 June 2005 REVA e 100109 1HM way Lnoino TENTIWUOdIY Md NHOH 801 2 SHO THO 4 0 08 ze 48 48 8 Nog 18 18 18 18 2 e 9 i E a n n zo a ZA I Eu n 26 a a 5 2 E Nua Rn S8 Ve 2 6 6 2 9 no 5 5 48 48 48 58 98 98 98 Sg 5 2 8 ezg 2 8 E oe 0 XE P 1 OG 280 H3MOd 199 1
224. Se lt E TP29 RED WHT 29 _ REDAWHTH290 POT H Jig amp 59 8 9 TP32 WHT RED 1 2 _ WHT RED 32 POT LOW 44 88 oH te T TP31 WHT BLK 1 WHT BLKHS1 REVERSE 2 2 1 _ WHT 1 TB30 _ WHT 30 FORWARD o bg m gt DIODE RETURN g 9 42 48V INPUT 2 o 8 59 1 WHT BLK 4 9 CHARGER I gt 5 5 lt t 3 In 48V 1 ALTERNATOR T Bega bese See E 2 gt 9 3 P Y PRIMARY 3 LIFT PUMP ez at Al 5 us 7 700 ep ee gt gt amp AUXILIARY 5 B PUMP lt a 5 D E a wa m am rz 5 15 E 2 929 RM DU e oz gest 3 2 zo lt 9 wal 0 lt da SS 5 lt lt 5 2 N e enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 6 35 Section 6 Schematics before serial number 13361 Electrical Schematic Z 45 25J 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 2 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED NOTES
225. Tastee 22 103135 dWnd 72 LH shod ea o HM 1V8MSEZd 7 820 22 WHOdLW 1d OL Ave 22 NIAS E 5 a EM si 51220 02 890 6r 13r 6r 0951 9 id dd 1610 2 80 HIWHO 1454612 86 892 gt E p WHOdIYld 81 Suo 989 81 899 lt 5 yO OF 81 1337 WHOSIV Id n UON HO 1HdZLO 11 899 esu OP st 014910 aro 8 80 074910 91 890 WHOSLW1d 2390 1 890 2 H3MOd HOLIMSLOOA ie 1 21 890 OSEXG S e 9 E ABVENG 3S H 9 Wav 8510 11 890 WOO AHVONOO3S 0 0 5 78085019 01 890 asrama 9 OL 8 e 8 869 Q e 3890 amp ess ON3DG 7 orem 5 Seo MAUD 38425 2890 2 019 JOBINOO 2 9 QU HM 23192 9 860 93799 9 490 sspe 18 31v1OH S 190 58 892 eum 1431 19170 899 9 2
226. Z 45 25J 13 to 23 seconds Turntable rotate 359 76 to 82 seconds primary boom retracted Platform rotate 180 Z 45 25 6 to 10 seconds Platform rotate 160 Z 45 25J 6 to 10 seconds Genie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 2 Specifications REV Hydraulic Specifications Before serial number 20926 Hydraulic oil type Shell Donax TG Dexron After serial number 20925 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax Dexron oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 18 C Use S
227. aE ele 5 Q Y S lt i Pg m S vod 25 GAN RED WHT 29 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS amp E 2 S 5 B B8 20k ON THE DRIVE JOYSTICK p 9 a lt 8 ME 9 Y ORG WHT RED 32 55 5 a 5 nwo 222 228 EI V eso WHT 30 Sik 2 ME 6 FWD WHT BLK 31 As x A 9s REY RED BU COMPONENT INDEX 252 WHT 24 5 E TILT ALARM GREEN VEL 196 RED BARL lt lt 1 AC OUTLET BOX BLK RED LIFT 107 BATTERY CHARGE INDICATOR 571 9 7 DRIVE Sm BP1 BOOM PROPORTIONAL ROTARY CONTROLLER d 22 2 lt e HTYEL BLUBLK S7 S DRIVE ENABLE RELAY o __ 12 02 BLU 36 DP1 DRIVE JOYSTICK 7 TS12 7810 1513 L1 DRIVE ENABLE LED BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 G E 2 E BLK WHT 5155 P2 EMERGENCY STOP BUTTON RED P3 HORN TS1 AUXILIARY TOGGLE SWITCH p RES BLK WHT TS2 ENGINE START TOGGLE SWITCH ol O_O Tsis i zat TS4 HIGH LOW RPM TOGGLE SWITCH tS bo Sa oes 9 OO 2 TS6 GLOW PLUG TOGGLE SWITCH O A 2 lt lt 5 TS7 PLATFORM ROTATE TOGGLE SWITCH 8 DRIVE ENABLE TS2 7 59 PLATFORM LEVEL TOGGLE SWITCH P3 AUXILIARY 756 ENGINE TS4 TS10 SECONDARY BOOM TOGGLE SWITCH HORN P
228. aici 25 30 ft lbs 34 41 Nm 8 Solenoid valve position 4 way Eus Platform level up down 20 25 ft lbs 27 34 Nm 9 Counterbalance valve Die Platform level up 35 40 ft lbs 47 54 Nm 10 Solenoid valve position 4 way Jib boom up down Platform rotate left right 20 25 ft lbs 27 34 Nm 11 Solenoid valve position 4 way Turntable rotate left right 20 25 ft lbs 27 34 Nm 12 Solenoid valve 3 position 4 way L uus Secondary boom up down 20 25 ft lbs 27 34 Nm 13 Solenoid valve position 4 way M Primary boom up down 20 25 ft lbs 27 34 Nm 14 Solenoid valve 2 position 3 way Primary boom extend 20 25 ft lbs 27 34 Nm 15 Orifice 0 037 inch 0 94 Qs Secondary boom up 16 Solenoid valve 2 position 3 way Primary boom retract 20 25 ft lbs 27 34 Nm 17 Relief valve 2300 psi 158 7 bar before serial number 11819 Quis Primary boom down 25 30 ft Ibs 34 41 Nm 18 Relief valve 1800 psi 124 1 bar Huan Secondary boom down 25 30 ft Ibs 34 41 Nm 19 Flow regulator valve 0 6 2 27 L min S sinus Turntable rotate left right pre
229. bog a ols 5 NOLLONN Is uf lt E ha M FA LARS ai o z i a o u o6 Oo m LO 87 HOLIMS 1 Je SN bg Ga E LO ok 1 a Eis AE E m ol daadS LINIT 440 Ov X rt if H3TIOHLNOO 6 6c asuma 2 rt E Gyvas 8 O bog Fd IHN ma EN 8 APON amp 9 engm lt snam dans bog jo O AAHS 36 o 9e na 4 ma LO MEE s d PTO SMEMO at r3 zo Off 3NION3 19 15 53 SEE ziasvo Wood T2 8 CN Y 1 19 lt ole 5 18 X18 1HM 0 SN G O IHM THM ic 8 HOIHH3IJWOLN3IOdMOHNSAOh 10 ANWd nes I 5 121 9 oissoo3uwm 0 8 ZIA 5 wads mo 2 4 109135 22 Q O 15 ac 12 gt 999
230. 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 4x 4x11 inch 10 x 10 x 28 cm block 30 Lower the number 2 arm onto the boom rest pad Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy SECONDARY BOOM COMPONENTS 31 Insert a 4 x 4 x 81 2 inch 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid pivot end 32 Attach a lifting strap from the overhead crane to the mid pivot for support Do not lift it 33 Remove the pin retaining fasteners from the number 2 3 and 4 arm pivot pins at the mid pivot Do not remove the pins 34 Use a soft metal drift to drive each pin out Then remove the mid pivot from the secondary boom assembly Crushing hazard The mid pivot AWARNING 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 Section 4 Repair Procedures June 2005 SECON
231. 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 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 17 Check the Electrical Contactors Maintaining the electrical contactors in good condition is essential to safe machine operation Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage 1 Remove the drive chassis cover from the non steer end of the machine and locate the electrical contactors mounted on the component mounting panel 2 Visually inspect the contact points of each contactor for the following items Excessive burns Excessive arcs Excessive pitting AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Replace the contactors if any damage is found A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV 18 P
232. v1 89 2 zr HOLIMSLOOS Cote 21 890 b oss Leia V2 NMOGWOOE AHVONOOSS H 9 Wav 99 _ 09651 18 or 18 185012 01 859 a NASOLD 01 992 8 8 961 8 9 8 860 8 890 2 Z TET QN31X3 WOO8 rue 8 39920 2890 PTO 9 704109 131 9 23790 9 899 ZS 31V1OH 5 SO 9 99 133131V1OH v HR 1 7890 OSLAT V2 d NAKOCTWOOR d 9 2 860 nav vaa 2 899 1951 44 9 nadto 1859 nadlo 1892 v g 1 81 TVNIINH3 L PartNo 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 65 June 2005 Section 6 Schematics REVA Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 21181 to 22050
233. y m LO 87 HOLIMS bg Je IN bg Ga dau ou E LO ok 1ndlno INYA Wy G voyo Havoda E m 0 daadS LINIT 440 Ov Q X rt if bog 6 3uvds 6 d N A rt Gyvas 8 Q bd 1 FO 8 APON HALS amp 9 Zeonama lt snam dans bog jan O AAHS 36 o 9e na 4 ma ru LO MEE s d 1 PTO SMEMO at 2 Pt O ee 3NION3 1HVIS 55 c SCOPE zi hnavoviood T2 ioi O MO1HSISWOILNALOd AOILSAOF 26 CN Y 1 19 lt ole 5 18 X18 1HM 0 SN G O IHM THM ig 8 HOIHH3IJWOLN3IOdMOHNSAOh 10 ANWd nes I 5 121 9 oissoo3uwm 0 8 ZIA 8219 038 5 wads mo 2 4 103195 Z 15 ac 124 gt zi 999 Ole E aasnnn ES ERES 9V0 e 53 mi d bog bd
234. 1 2 NHH6H 6 499 T3 26252 66890 88 QH HOlVgZvd 890 92 890 61 890 7 XNVZ2 72 890 9055 cic ES J 8V avro 55 899 9855 55 92 890 71070 0 899 c 6 ae A VUNG 22 88888 8 Nua WHNHG 1 820 SS3NuvH OH1NOO HM ZN IIZO 11 850 92 890 em 1 1 859 Snivis HM HMdEZO 850 vel vel dI UWGVEID 9H 5 89 8951 4849 C4 9 820 Wavavoia 87 HOLIMS 2 arao 9 820 1 0 22 89 77 03395 330 9 51070 2 820 81092 72 990 Ofe E 9 915 59 915 69 28 490 9 o 18 2015962 01 810 Q 2215960 96 892 7951 01 0 4 WdHHSEO 6 810 IdHHSEO 81 852 95S1 HW ld 9 VSYEO 8 819 8 22 980 o 25518 o amp 513559 2810 5 8669 9 850
235. 12 BLU WHT 3 ni 2 WHT 7 m 2 DRIVE ENABLE LIMIT SWITCH 1 REMOVE FOR CE VERSION ORG RED 16 TB12 ORG RED 3 e 85 TP16 BRN CR6 86 ORG BLK 1 t CONTROL BOX PLATFORM x GROUND B BRAKE RELEASE TB48 RED WHT 48 1 TRAVEL ALARM RED BLK R6 DRIVE ENABLE TS15 30 87 41 ih BLU 1 m 51 BLU 36 BRAKE RELEASE N C BRAKE RELEASE N O 4a BRAKE RELEASE PRESSURE SWITCH PS1 BRAKE STEER MANIFOLD GROUND BLU BLK 1 TB37 BLU BLK 37 STEER LEFT 1 STEER RIGHT STEER FWD REV 1 2 3 4 5 DP1 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG RED 42 RED RED 37 g ORG BLK R6 AUXILIARY PUMP TS1 WHT 24 PLATFORM ROTATE PLATFORM LEVEL gt x lt 2 gt x lt 2 a BOOM gt lt a a lt So ORG RED 42 19 RED 27 9 AUXILIARY CONTROL TB27 9 go GRN WHT 8 1 BRN BLK RED WHT RED 3 WHT RE
236. 2 PRIMARY BOOM RED BLK 3 TB2 PRIMARY BOOM TP2 ni BLU 3 TB10 BLU 10 BLU BLK 11 SECONDARY BLU BLK 3 11 SECONDARY 5 WHT BLK 3 TBS WHT BLK 5 RELAY COIL PR2 FLOW CONTROL COIL PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B PRIMARY BOOM EXTEND COIL RETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT ALARM WHT 4 TURNTABLE ROTATE RED i WHT 3 TB4 2 2 gt ROTATE 4 WHT 24 ORG RED 42 RED FUNCTION ENABLE BLUAWHT 12 RED TS55 GND GND BRN OPTION A3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL i 1 1 1 1 1 1 1 1 1 1 1 1 PRIMARY BOOM 1 1 1 1 1 1
237. 20V DC 25 to 28 0 schematic items F LL and Solenoid valve N O poppet 20V DC 25 to 28 Q schematic items B VV and BT Genie TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 REVA Kubota 7482 Engine Displacement Number of cylinders Bore and stroke Horsepower Gross intermitent Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold Engine coolant 29 23 cu in 0 48 liters 2 2 64 x 2 68 inches 67 x 68 mm 12 5 3600 rpm 1 2 23 1 412 to 469 psi 28 4 to 32 3 bar 2000 rpm 3000 rpm centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 185 mm Capacity 2 9 quarts 2 8 liters Lubrication system Oil pressure 36 to 64 psi 2 48 to 4 41 bar Oil capacity 2 6 quarts including filter 2 5 liters Oil viscosity 10W 30 requirements Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Part No 106488 A TEREX COM Section 2 Specifications Injection system SPECIFICATIONS Injection pump make Bosch MD Injection timing 21 BTDC Injection pump pressure 1991 psi 137 bar Fuel requirement Starter motor diesel number 2 D Brush length new 0 5188 in 13 mm Brush length minimum 0 3346 in 8 5 mm Battery Type 12V DC Group 70 Quantity 1 Cold cranking ampere 450A Reserve capacity 2
238. 21 1 aau 2 2 i ei a OOO x a SSL a E a zea Q 22 034 0 9 5 V 5 8 5 A H3MOd d3u dau HOLIMS 4018 LSJ 1981 bd 6 74 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 from serial number 13361 to 14078 Section 6 Schematics June 2005 __________ Ground Control Box Terminal Strip Wiring Diagram 2 45 25 from serial number 14079 to 14650 REVA June 2005 45 25J D iring Ground Control Box Terminal Strip W from serial number 14079 to 14650 Section 6 Schematics
239. 21180 to 22050 Section 6 Schematics June 2005 Ss Power Cable Diagram REV from serial number 21180 to 22050 TO ENGINE PANEL TO GROUND CONTROL BOX CONNECTOR 6 1 POWER CABLE LEFT SIDE DC AMMETER CABLE BATTERY PACK RIGHT SIDE fo MM 48V DC ALTERNATOR i AC 1 1 2 5 BATTERY PRIMARY CHARGER LIFT PUMP EE 1 lt 1 B2 AUXILIARY LIFT GE RUMP 5 i
240. 24 ORG RED 42 PUMP RED 1 TS1 nj 6 RED 85 RED RED 27 8 2 AUXILIARY CONTROL 8 1 RELAY COIL i 27 4 TS51 AUXILIARY POWER TB27 E AUXILIARY LIFT HED PUMP RELAY COIL 19 19 GRNWHT 8 i H GRNWHT 4 LIFT PUMP m RELAY COIL PR2 FLOW CONTROL COIL WHT RED 3 WHT RED 6 5 TP6 RED BRN PLATFORM ROTATE RIGHT GRN WHT 19 2 GRN BLK 18 GRN 17 PLATFORM ROTATE LEFT CONTROL BLK RED ROTARY OEM FLOW 1 PLATFORM ROTATE 17 18 GRN BLK 3 WHT RED 6 GRN 3 PLATFORM ROTATE 17 PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE MODELS ONLY E 1 TB14 PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL kos PLATFORM LEVEL ORG 15 14 PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B FUNCTION MANIFOLD GROUND UP ORG 3 ORG BLK 3 1 8 PLATFORM LEVEL 15 EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM St 2 E E 2 4 TP7 EXTEND BLK 3 BLK WHT 3 ale TB1 RED 1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM TP8
241. 4 1 5 3 a a lt 0122 Zu 2 a 85 9 2 52 gt gt 5 5 9g ES 9 2 9 o 9 g T 2 5 2238 3 2 2 l 55 Yt a al a G cs E 2 Z gt 5 S lt 0 ENGINE HARNESS CHASSIS HARNESS lt 7 E 8 2456 7 c x a S a E E 5 E S al S S c 3 S a REGULATOR CONNECTOR WHITE BATT GRN BLK BATT RED PISM7 BLK WHT 34 BLK RED 35 WHITE 23 BLACK 33 WHITE 21 BROWN CHASSIS HARNESS Genie TEREX COMPANY 6 9 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA ORG GEN POS G June 2005 Section 6 Schematics Engine Panel Diagram from serial number 13361 to 14078 C B A
242. 4 x WH BATT E o g c z E lt 3 E 20 lt gt WH R14 o BK ISM1 9 9 N m i BK ISM1 mo al 5 BRN VOLT BL ISM2 BL ISM2 C33STR BK 5 BRN J5 BRN ISM5 BRN ISM5 E P20BAT RD a C23PWR WH 5 z 5 6 S 22585 E ENGINE HARNESS TO DRIVE CHASSIS GR BK BATT zi a ENGINE HARNESS TO ENGINE WH ISM10 ENGINE HARNESS TO GROUND CONTROL BOX d 5 7 9 I I 5 2 a e tr 2 lt lt oO o d a 5 9 2 8 8 S 8 a N gt d a al c 8 8 8 8 S S 8 4 VOLTAGE REGULATOR 13 2 2 C5B MALE DEUTSCH CONNECTOR 7 mE 4 Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 16 June 2005 Section 6 Schematics D n Engine Panel Diagram from serial number 22051 to 23235 June 2005 Section 6 Schematics REVA Electrical Schematic 2 45 25 before serial number 13361 RED WHT 29 LOAD SENSE OPTION WHT RED 32 WHT 30 WHT BLK 31
243. 5 2 E Nua E I M I Ve 2 r4 B 5 5 aau ouo ao gy a 48 48 48 58 98 S8 98 278 2 8 2 8 yz 0 0 X P 1 H3MOd 280 H3MOd 199 1 LHIWG3H m 1 St LHWNHO Si LIHWNHO I aLVLOY ggg 933 WHOL 1d WHOSLW1d 2 2551 cet 1 aay ac NOILONNA 180 SSSL d 5 fag Q a z cz 2 9 B 9 wooa dau AHVONOO3S a 0951 a dau L6 31viOH orma STAVINEAL oho E 5 4 6 291 J woos air 3 8951 6I LHWNHO xa diH LS TVNIIWH3 L OL dau SS3NHVH wa WH ONAL weed woog rams OOO 1951 1 qd3d 2 4 m 8 IHW r
244. 5 C4TRR WH BK C3B 5 2 2 E C3P 4 C4TRL WH C3B 4 P24BAT WH R42BAT OR RD FUNCTION ENABLE C12DRE BL WH TS55 C40LS OR RD P42BAT OR RD RD GND BK PR2 mo EE June 2005 Section 6 Schematics 4 Electrical Schematic Z 45 25J CE Models from serial number 22051 to 23235 Section 6 Schematics June 2005 S Ground Control Box Terminal Strip Wiring Diagram 2 45 25 before serial number 13361 REVA June 2005 Diagram 2 45 25 Ground Control Box Terminal Strip Wiring before serial number 13361 Section 6 Schematics HOLIMS OL xoa TOHLNOD 2 2 RED ALARM USED ONLY FOR FLASHING BEACON OPTION eh BLK ALARM USED ONLY FOR TRAVEL ALARM OPTION
245. 55 E NE E 5 52 51555 Fi S gc cr m ola 5 wl 5 8 8 58 A S zale sou 00 ESE S 1 29 lt lt 5 lt Sa 5 ol we sa x sE C5B 1 RD 99 WATER 25 TEMPERATURE 99 1 SWITCH x E 1 J OIL 5 41 PRESSURE 8 BEN SWITCH og 9 C35HRPM BK RD 1 9 zz Oe E 1 B 4 9 4 1 ALTERNATOR 5 8 FIELD RELAY CR16 I D Co E cM A 1 E LM E 9 E i BRN i RPM CUTOUT pu 6 RELAY CR13 88 rd r 8 o BRN RPM RELAY CR14 E 4 2 8 8 E ui 8 E 9 BKRD Lot 55 ENGINE RPM SOLENOID DZE 7 C33STR 187 START Pu E FiO 4 5 E gt 1 1 Al 5 5 2 E gt C5B 22 4 GLOW PLUG s 44 RELAY CR15 1 o d 8 j 1 GLOW PLUGS 893 8 BK WH 1 8 PLUGS 8 bd FOL i au T 3 8 12V DC ALERNATOR
246. 6 6 CONTROL COIL RED BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP GRN WHT 19 2 GRN BLK 18 GRN 17 CONTROL BLK RED ROTARY OEM FLOW 1 JIB BOOM 17 a GRN BLK 3 WHT RED 6 h GRN 3 JIB BOOM CR7A 30 eel 17 CR7A 86 gt 85 RED PLATFORM ROTATE PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY GROUND PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL JIB MANIFOLD PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B UP ORG 3 MANIFOLD FUNCTION GROUND ORG BLK 3 PLATFORM LEVEL EXTEND p PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM St 2 gt 4 BLK 3 BLK WHT 3 PRIMARY BOOM PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM 1 RED 3 RED BLK 3 gt lt a BOOM TP2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL SECONDARY BOOM 11 DESCENT ALARM OPTION A3 UP BLU 3 BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SEC
247. 6 WHT ISM10 ENGINE HARNESS TO CHASSIS HARNESS 2 45885 ENGINE HARNESS E ET E TO ENGINE 5 e oj j 8 gt lt 5 2 898 50 9 E 8 X S 5 3 4 E 2 il S 5 S 2 d zi c 7 MALE DEUTSCH comecron 1 2 3 4 5 el 12V DC 2 VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR e e T e gt e bi e 9 8 21 3 E 3 3 8 E s amp 8 alg E sss m a 2 C gt 5 CHASSIS HARNESS dee 6 11 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA REVA ORG GEN POS G June 2005 B Section 6 Schematics Se Engine Panel Diagram from serial number 14651 to 16839 RED CB CIRCUT BREAKER RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE Hed 1 RED CB 12V WHT BATT WHT BATT WHT BATT WHT 21 WHT 21 BLK RED 35 BLK RED 35 WHT J5 WHT J5 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4
248. 8688 2 pioa PP99 999 9 a jajo ole lR Jo r Jo T T 1 i d Q Q Q gt S 4 2 2 3 2 C7P JIB 1618 U O 9 wW 1 lt D 2 2 E i S D40 1 HET ALARA 19 18 CONTROL CABLE 12V DC BATTERY SWITCH c ERR dee PC DR KA Cope 25 221 435 454525 22 45 55 7 25225 4252 1 i GR LFC 1 20k t GR 10 C29JSH RD WH GR S C32JSL WH RD 2 7812 7810 EM TS13 a WH C30FWD WH TURNTABLE SECONDARY BOOM EXTEND PWD bi ROTATE BOOM RETRACT ae 4 Qj CSIREV WHIBK 6 REV OR BK R6 1 RD RD DRE 51 x 3 re rect 1080 E 1 u M 126 RD RPM L E LIFT PRPL 7 i BL RD BK R6 B E ppi DRIVES BKWH DRE D 1 T OPTION S 9 Q 9 9 9 9 m 5 RIGHT WH YL 90 C37STC BL BK gt 4 TU S e 212 e 1 2 2 0 0 0 Bc WH RD C36STCC BL 1 2 52 2 ajs LEFT e 1 2 o 52 7 8 88 Ha HE S BH 1 g 2 D NM 0 a gt i A AB H
249. A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes acceptable no remove from service R repaired Comments A 2 Function tests A 3 Generator belts and pulleys Perform after 50 hours A 4 30 Day Service Perform every 50 hours A 5 Perform engine maintenance Perform every 75 hours A 6 Perform engine maintenance Perform every 100 hours A 7 Grease rotation bearing A 8 Perform engine maintenance Perform every 150 hours A 9 Perform engine maintenance Perform every 200 hours A 10 Perform engine maintenance Part No 106488 B 3 Batteries B 4 Electrical wiring B 5 Lug nut torque B 6 Brake configuration B 7 Drive hub oil level B 8 Engine RPM B 9 Ground control override B 10 Platform leveling B 11 Engine idle select B 12 Drive brakes B 13 Drive speed stowed B 14 Drive speed raised B 15 Alarm package if equipped B 16 Turntable rotation stop B 17 Electrical contactors B 18 Hydraulic oil analysis Checklist C Rev B Y NR C 1 Perform engine maintenance C 2 Grease platform overload if equipped
250. Boss Port SPECIFICATIONS Seal Lok fittings Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal LokQ fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Lok Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 27 ft lbs 36 6 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft lbs 85 4 Nm 12 140 ft lbs 190 Nm 12 90 ft lbs 122 Nm 16 210 ft lbs 284 7 Nm 16 120 ft lbs 162 7 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Part No 106488
251. C6B 31 SEPEX CONTROLLER REVERSE GND B BK P25BAT WHFS 2 P24BAT WH BK 26 LOAD BK FS 25 P26BAT C9P 1 BK LOAD SENSOR OPTION s A 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED P22BAT BK 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED NOTES COPS y 4 C1B 4 C6B 30 FORWARD e e 10A CB1 P20BAT RD C7B 4 PR1 EM DIODE RETURN 9 48V INPUT 4 F2 OR GEN NEG OR GEN POS AC POWER BK P42BAT OR RD C6B 3 PR2 a Ru eT E 1 F3 500A AP1 BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 48V DC CHARGER 48V DC ALTERNATOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 6 29 Section 6 Schematics June 2005 Electrical Schematic 2 45 25 from serial number 21180 to 22050 REVA C29JSH RD WH C29JSH RD WH C4P 1 C13DREL BL RD BRN C7P 3 BATGND BRN
252. COIL PR1 GRAN 17 BLU RED 1 0 39 _ FAULT LED D B MOTOR MAIN CONTACTOR ORG 40 RED FS FS1 RELAY PR1 4139 OFF LIMIT SPEED INPUT RED 20 BLU WHT 12 INTERLOCK WHT FS CR16 30 87 TP29 RED WHT 1 TB29 RED WHT 29 POT lt Xo aon CHASSIS GROUND 2 WHT RED 7832 WHT RED 32 POT LOW T E e 5 TP31 WHT BLK 1 TB31 WHT BLK 31 REVERSE m a MOTOR CONTROLLER 11 9 _ WHT 1 TB30 WHT 30 FORWARD 10 ORG GEN NEG ORG GEN POS DIODE RETURN g P 48V INPUT 1 ORG RED 42 EI AC POWER 48V CHARGER BLK LSTOP 48V DC ALTERNATOR 10A CB1 LOAD SENSE OPTION ORG RED R2 PRIMARY LIFT PUMP REDL1 AUXILIARY 1 PUMP TB20 24 DC RED 17 1 LOAD SENSE PCB GROUND 24V 2 4 2 s 4s s 7 s n e 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED NOTES Electrical Schematic Z 45 25 from serial number 13361 to 14078 Section 6 Schematics
253. Control Box Terminal Strip Wiring Diagram 2 45 25 ANSI and CSA Models from serial number 22051 to 23235 REVA June 2005 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 ANSI and CSA Models from serial number 22051 to 23235 Section 6 Schematics AWTS Av HH NHOH SHO oe 4 oe sm y t E als T
254. DOWN SWITCH STOP TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT SWITCH ORG RED 42 TS14 DRIVE RANGE HIGH LOW SWITCH TS15 DRIVE ENABLE SWITCH PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy enie A TEREX COMPANY June 2005 Section 6 Schematics SSS Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option before serial number 13361 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram 2 45 25 from serial number 13361 to 14078
255. EXCEPT WHERE NOTED 6 37 lt lt 3 DRIVE ENABLE LIMIT SWITCH BRN 2 DRIVE ENABLE LED L1 TB13 22 21 o 2 Rd BLU RED 3 BLK 7 Section 6 Schematics 22 m 1 1 153 12 BLU WHT 12 BLU WHT 3 WHT 7 RED 7 gt ae Sis 5 NIAE 3 ORG RED 16 TP16 ORG RED 3 E 86 85 BRAKE RELEASE 1 TRAVEL ALARM A2 BRN PLATFORM CONTROL BOX GROUND CR6 6 38 June 2005 Electrical Schematic Z 45 25J from serial number 13361 to 14078 REVA RED WHT 29 WHT 24 REMOVE FOR CE VERSION ORG BLK 1 TB48 RED WHT 48 RED BLK R6 87 TP41 DRIVE 30 ENABLE b TS15 BLU 1 RELEASE JACK PS1 BLU 36 BRAKE STEER MANIFOLD GROUND BLU BLK 1 BLU BLK 37 TB37 5 TP37 LIFT DRIVE fuk STEER ORG BLK R6 FWD REV WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG RED 42 RED PLATFORM ROTATE TS1 RED pS AUXILIARY PUMP RED 1 JIB BOOM TP17 CR7A 86 gt 85 PLATFORM LEVEL TP15 PRIMARY BOOM TP8 PRIMARY BOOM TP2 SECONDARY TP11 TURNTABLE ROTATE WHT 24 ORG RED 42 GRN WHT 1
256. GRN WHT JOYS m 4 D gt 5 5 9 4 GRN WHT R12 2 GRND RED STOP olo el ele 5 5 6 mmm 10 10 O O O O UD wat RED JIB 5 50 SIS lt lt 2 FSS 2 2 555535999524 gt gt lt BAN GAND EE RBS RB BB PPP RR BS RSS RB 3 A AC FOOT oj jaye CABLE CABLE CABLE POWER NOTES uc 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES ALARM FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp B S ON THE DRIVE JOYSTICK 2 2 EE mio 5 2 8 88833 5 B B 5 2g B 58 20k Toy gp ET 582659 5 8 5 31 5 Y ORG WHT RED 32 9 COMPONENT INDEX a EN do 22 5 8 amp a t 1 m pm TILT ALARM 6 23 ACI AC OUTLET BOX d 4 e WHTBLK BATTERY CHARGE INDICATOR REV R
257. GROUND BLU 1 BLU 36 JP1 REMOVE FOR CE VERSION RED STEER LEFT COIL 4 BLU BLK 37 TB37 BLU BLK 1 1 STEER RIGHT COIL TP37 RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 1 2 3 4 5 6 7 8 9 10 GRN WHT 19 AUXILIARY PUMP RED 8 AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 z RED RED 27 RELAY CR3 TB27 RED AUXILIARY LIFT PUMP RELAY COIL PR3 GRN WHT 8 9 GRNAWHT 2 6 85 RELAY COIL PR2 WHT RED 3 WHT RED 6 6 CONTROL COIL RED BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP GRN WHT 19 2 GRN BLK 18 GRN 17 CONTROL BLK RED ROTARY OEM FLOW 1 JIB BOOM 17 a GRN BLK 3 WHT RED 6 h GRN 3 JIB BOOM CR7A 30 eel 17 CR7A 86 gt 85 RED PLATFORM ROTATE PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY GROUND PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL JIB MANIFOLD PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B
258. LOW VOLTAGE INTERRUPT BCI RELAY A LVI OPTION ONLY 6 5 CR19B LOW VOLTAGE INTERRUPT BCI RELAY B LVI OPTION ONLY 1 DP1 DRIVE JOYSTICK m L1 DRIVE ENABLE LED GREEN S 20k 10 L3 CONTROLLER FAULT LED RED Y L4 OVERLOAD LED LOAD SENSOR OPTION VETRO O C BLK RED met 20 LDS LOAD SENSOR MODULE 1 e130 LVI LOW VOLTAGE INTERRUPT MODULE a REV 3 5 4 et X9 Or BATTERY CHARGE INDICATOR FOR LVI OPTION 7 P2 EMERGENCY STOP 2 TURNTABLE SECONDARY PRIMARY BOOM EXTEND OL HORN LVI BCI OPTION ROTATE TS12 BOOM TS10 TS11 RETRACT BP1 TS13 V 2 TIME DELAY 1 TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH BI ENERGY ONLY BLK WHT TS4 HIGH LOW RPM SWITCH BI ENERGY ONLY O_O T 5 E TS6 GLOW PLUG SWITCH BI ENERGY ONLY 3 LON Spo TS7 PLATFORM ROTATE SWITCH O 27 ge O N Ls 01 TS8 JIB BOOM UP DOWN SWITCH JIB ONLY 8 9 AUXILIARY DRIVE ENABLE TS9 PLATFORM LEVEL SWITCH TS1 GLOW PLUG START RPM HORN Hes a gt TS10 SECONDARY BOOM SWITCH 11 1 JIB BOOM PLATFORM ROTATE PLATFORM LEVEL TS11 PRIMARY BOOM UP DOWN SWITCH T97 A TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT SWITCH TS14 DRIVE RANGE HIGH LOW SWITCH 7 7 2 2 2 2 2 2 2 2 z Z Z Z Z Z 2 Z Z Z Z Z Z Z Z Z Z Z 1515 DRIVE ENABLE SWITCH
259. NMOG m 25 Q monga vi mama gt 57 HOLIMS LO 8 orma orma 5 ma 8 mamma O 016 NHOH 6 Q 5 saw 18 WOO 8 Q ee ie Bm OL n JOULNOD 141 9 inmwwuo P 9 G3H IHM GSH IHM LO QOIS 31VLOH 5 Sor 1HM v 1457 SLVLOW 7 1HM 9 IN 9 T LHM IHM 8 H3MOd 100 AV HH A 8 Q O 2 WOOG Q ee ee wg noo 99 3uvds WOO8 raga 9 81 3Sva IWNINYAL 10 Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 75 Section 6 Schematics from serial number 14079 to 14650 Ground Control Box Switch Panel Wiring Diagram Z 45 25J June 2005 REVA
260. NOTES E 9 EN FIP E 5 705 i 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES iE ja AC N foot Ido ha 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp CABLE CABLE CABLE POWER ON THE DRIVE JOYSTICK Al SWITCH TILT ae T 5 ALARM m gt s 2 COMPONENT INDEX amp 3 3 5 5 E 2 S 5 57255 955 5 2 1 S 5 15 B P 3 83 hia 5228853 2551514 TILTALARM 9 i vim 5 22 9 ACI AC OUTLET BOX T E X 7 EN i SIR BATTERY CHARGE INDICATOR 6 BP1 BOOM PROPORTIONAL ROTARY CONTROLLER 4 i CR6 DRIVE ENABLE RELAY CR7A JIB BOOM CUTOUT RELAY Glencen S E 1 9 CR7B JIB BOOM VALVE RELAY RED DP1 DRIVE JOYSTICK OOO 9 BLK RED lt 20 L1 DRIVE ENABLE LED 47 gt 33 L3 CONTROLLER FAULT LED REV lt TO a BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON 7 512 1510 TS TS18 5 3H P3 HORN BCI T T ROTATE SECONDARY BOOM EXT RETR BP1 A Ti TIME DELAY 1 A TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWIT
261. No 106488 June 2005 Section 4 Repair Procedures REV 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 AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder barrel end pivot pin is above the turntable covers 3 Attach a 5 ton 5000 kg overhead crane to the primary boom for support 4 Raise the primary boom with the overhead crane slightly to take the pressure off the primary boom lift cylinder pivot pins Genie be eth PRIMARY BOOM COMPONENTS 5 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 6 Tag disconnect and p
262. OPTION NI 9 BLK RED as 5 LDS LOAD SENSOR MODULE 47 ove LVI LOW VOLTAGE INTERRUPT MODULE 29 gt Hem ere 40 BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP 2 7 TURNTABLE SECONDARY PRIMARY EXTEND LEFT 5 HORN BCI ROTATE TS12 BOOM TS10 BOOM TS11 RETRACT TS13 BP1 J Ti TIME DELAY 1 TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH BI ENERGY ONLY BLK WHT HIGH LOW RPM SWITCH BI ENERGY ONLY OO Cl n TS6 GLOW PLUG SWITCH BI ENERGY ONLY c TS15 L3 gt B5 N B 515 9 A TS baw 9 9 9 157 PLATFORM ROTATE SWITCH Ss C TS8 JIB BOOM UP DOWN SWITCH JIB ONLY 8 9 AUXILIARY DRIVE ENABLE FAULT LED 59 PLATFORM LEVEL SWITCH HORN TS1 SLOW PLUG START gt e T TS10 SECONDARY BOOM SWITCH G ROTATE PLATFORM LEVEL EMERG STOP TS11 PRIMARY BOOM UP DOWN SWITCH P2 TS12 TURNTABLE ROTATE SWITCH SCHEME TS13 PRIMARY BOOM EXTEND RETRACT SWITCH TS14 DRIVE RANGE HIGH LOW SWITCH TS15 DRIVE ENABLE SWITCH 6 89 Z 45 25 Bi Energy Z 45 25J Bi Energy No 106488 June 2005 Section 6 Schematics 655 ______________56_______________________________________ aM
263. OPTION TILT SENSOR HOUR METER HORN RELAY BASE CONTROL BOX GROUND PartNo 106488 BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY BLK 2GA CHASSIS GROUND A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 48V DC CHARGER 48V DC ALTERNATOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 1 ALLLIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt J SWITCH SHOWN WITH BOOM EXTENDED 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED NOTES 6 27 Section 6 Schematics June 2005 Electrical Schematic 2 45 25 from serial number 17975 to 21180 REVA RED WHT 29 RED WHT 29 WHT 24 DRIVE ENABLE LED L1 BRN 2 DRIVE ENABLE LIMIT SWITCH BLU RED 3 BLK 7 TB13 BLU WHT 12 12 BLU WHT 3 WHT 7 JP1 REMOVE FOR CE VERSION RED yy d TB12 ORG RED 3 ORG RED4e TP16 3 BRN 15 86 ORG BLK 1 PLATFORM CONTROL BOX GROUND TB48 h RED WHT 48 30 87 DRIVE ENABLE RED BLK R6 TS15 8 a BLU 1 E BLU 36 BRAKE STEER MANIFOLD GROUND 55 WHT RED 32 WHT RED 32 WHT 30 WHT 30
264. PLATFORM ROTATE PLATFORM LEVEL EMERGENCY RED STOP 10 6 115 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 REVA June 2005 Section 6 Schematics m nn Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 17975 to 21180 D B A
265. RIGHT WHT BLK 3 a WHT 3 5 56 5 Fa a ul FUNCTION ENABLE TS55 RED BLU WHT 12 RED GND GND BRN RED Y g o June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 14651 to 16839 REVA June 2005 Electrical Schematic 2 45 25 from serial number 16840 to 17974 Section 6 Schematics WHT RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG RED 42 RED BLUMHT 12 RED START RELAY TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN BATTERY IGNITION START MODULE 1 2 3 4 5 6 7 8 9 GRN BLK BATT WHT BATT RED 5 6 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH WHT 23 WHT GROUND BRN FOOT SWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 B ALTERNATOR FIELD RELAY CR16 HIGH TB35 TP35 Ye BRN is Low RPM TS4 RPM RPM CUTOUT RELAY CR13 BLK RED 35 HIGH RPM RPM RELAY CR14 T 188 1 BRN quc 2 1 BLK RED BLK WHT 34 5 lt lt RPM SOLENOID ENGINE START n TS2 30 R15
266. S 5 5 9 55 513 9 9 5 8 2 Bale 25 9 REDIWHT 29 5 B B 25 Bs gis BRB t SAREE 8 i 2 9 ORG 2 WHTIRED 22 zig E 9 Ai TILT ALARM a 8 5 RIS t t ne 220 Wido spe e AC1 AC OUTLET BOX 6 eut BATTERY CHARGE INDICATOR 4 x Q4 HUBLKST 8 585 BOOM PROPORTIONAL ROTARY CONTROLLER RED DRIVE ENABLE RELAY WHTGAN 125 WHT 24 S vee DE 5 CR7A JIB BOOM CUTOUT RELAY RED lt A BIE Ie CR7B JIB BOOM VALVE RELAY 5 19 BLK RED pil 27 BET DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED lt gt aight e T9 BEUBENSS 13 CONTROLLER FAULT LED 7 H MHTIRED 1502 BLU 36 P2 EMERGENCY STOP BUTTON TS12 TS10 TS11 TS13 BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 6 222 HORN BLK WHT Ti TIME DELAY 1 x BED TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH n BLK WHT TS4 HIGH LOW RPM TOGGLE SWITCH O E TS6 GLOW PLUG TOGGLE SWITCH E Qoo 89 G Tad 459 TS7 PLATFORM ROTATE TOGGLE SWITCH NO ree A o S TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS15 FAULT LED 8 RY m e TS9 PLATFORM LEVEL TOGGLE
267. SEPEX CONTROLLER B TP32 WHT RED 1 TB32 WHT RED 32 GROUND 1 POT LOW 44 TP31 WHT BLK 1 TB31 WHT BLK 31 REVERSE 11 i8 TP30 _ WHT 1 TB30 WHT 30 FORWARD 10 i ORG GEN NEG ORG GEN POS F2 24 POWER ORG RED 42 R 48V INPUT 1 a DIODE RETURN g 1 1 1 1 WHT LOAD 9 BLK 48V DC CHARGER CHARGER 1 ORG LOAD 48V ALTERNATOR LOAD SENSOR BOX 10 ALTERI of ORG RED R2 GND PRIMARY LIFT PUMP 1 1 AUXILIARY fom 1 PUMP B FS 10A F2 200A WHT FS TB20 24V DC BLK 26 LOAD 2 LOAD SENSOR OPTION AP1 F4 500 A F3 424V DC GROUND pec 48V DC 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 41 lt 3 DRIVE ENABLE LIMIT SWITCH BRN 2 DRIVE ENABLE LED L1 TB13 TP13 BLU RED 3 BLK 7 Section 6 Schematics c2 4 Be BLU WHT 12 BL
268. SET TO B 9 99 o o lo DISCHARGE IS SET Is le M z 8 2 m3 BRN LVJ dE 8 5 5 5 lt lt m BE 2 N S o gt R R o E 9 5 7 8 s D RED TIME 2 8 ORG RED 16 ORG RED 16 BLU LR19A ORG RED LV42 o 2 8 2 9 ORG BLK 41 ORG BLK 41 E 9 2 2 gt D 9 gt 3 BLU L10 BLU L10 WHT LV24 2 lt WHT L6 WHT L6 S S bad 3 BRNJ3 olo RED LVI 22 2 0 5 5 1 66 lt is 3 o 2 555 999 52 99 E t 2 lt 55 1002000 R lt 58 lt 31615 lt lt gt 55 lt RED TILT 81 55 E 2 gt 2515 5 m 2 lt 2 ee 251050 Olz mmm 5 6 5 59 2 5229 2 m lt lt m 2 lt lt 2599 4 2 5 zm m f B seanma 2329 36551 5 9 lt 5 RED LR19B 2 52 2 5 D 9191 d Am m RED TIME 29414 L 93m mr lt GRNMWHT JOYS ma m 3 E 5 4 GRNMWHT R12 2 a GRND RED STOP
269. SL c quedo i 55 Q vL 5 E a THOM Q Sg 3 lt M HOLIMSLOOS e a mi LO m NMOG wid 25 8s 5 gis N Tama eue NS 5 01 meine orna IN ma 2 83 O 006 NHOH 8 gt LO 8 1 1 8 8 TAMAS IHME oru n WOOSAHVWIHd Z 00 e x9 555 9 9 mwm HO J0H4LNO9 MOTH 147 G AR G3H IHM 8 IJS131VIOH SHIM 19 1HM LO ol LHWO3H SN D 2 _ NMO WOOS AYINA 5 5 NH AHVWIHd 1 Maay ics raga V 81 asva 6 71 Section 6 Schematics June 2005 Ground Control Box Switch Panel Wiring Diagram Z 45 25J REVA before serial number 13361
270. SOD 0 RD 148 f TS15 1 DRIVE ENABLE HORN HN Moe ENGINE P2 GLOW PLUG RPM TS1 uN TS8 TS7 TS9 START EMERGENCY AUXILIARY JIB BOOM PLATFORM PLATFORM STOP POWER ROTATE LEVEL REV NOTES lt 1 FOR LVI BCI OPTION REMOVE INDICATED WIRES COMPONENT INDEX BCI BATTERY CHARGE INDICATOR BP1 ROTARY FLOW CONTROL DIAL DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED LVI LOW VOLTAGE INTERRUPT MODULE LVI BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON P3 HORN TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH H1 TITL ALARM LS18 PLATFORM OVERLOAD LIMIT SWITCH L4 PLATFORM OVERLOAD LED L48 TILT ALARM LED 6 119 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics
271. SPEED INPUT BLU WHT 12 INTERLOCK RED WHT 29 POT HI TP32 WHT RED 1 WHT RED 32 POT LOW TP31 iz WHT BLK 1 WHT BLK 31 REVERSE TP30 WHT 30 FORWARD BLK LSTOP LOAD SENSE OPTION a RED 17 LOAD SENSE PCB 2 4 z s s 7 s fo n e Electrical Schematic Z 45 25J from serial number 14079 to 14650 Section 6 Schematics 10A iN CBI amp ORG RED 42 DIODE RETURN 48V INPUT ORG RED R2 11 10 MOTOR CONTROLLER WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY BASE CONTROL BOX GROUND B CR16 30 87 ORG GEN NEG ORG GEN POS AC POWER BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 lt aon CHASSIS GROUND 48V CHARGER 48V DC ALTERNATOR PRIMARY TB20
272. TACH INPUT START INPUT NOT USED GROUND BATTERY KEY SWITCH POWER NOT USED 1 2 3 4 5 6 7 8 9 IGNITION ON 10 ENGINE FAULT C5B 1 P20BAT RD WH AUXILIARY GND GR BK WH BATT WH ENGINE GROUND D LOW RPM __ E TS4 RPM HIGH RPM TS2 ENGINE C1P 7 C33STR BK C1B 7 BK ISM1 BL ISM2 C5B 5 C33STR BK HIGH TB35 TS54 RPM LOW S C5B 18 C35HRPM C5B 3 C23PWR WH gt CR16 BRN ENGINE START TS52 TB33 START TS6 GLOW C1P 8 C34SA BK WH 1 8 C5B 22 C34SA BK WH C5B 2 GLOW PLUGS TS56 TB34 PLUGS C9P 3 RD FS WH FS FS BK FS C9P 1 BK P2 52 C7P 1 BK P25BAT RD P24BAT WH C9P 2 22 2 4 R42BAT OR RD C2B 4 WH J4 3 C3B 3 C5B 11 C21IGN2 WH o 2 2 o C23PWR WH 87 30 87 gt STARTER C7P 2 P23BAT WH C7B 2 gt A1 TILT ALARM 48 A C1P 2 C28TTA RD BK C1B 2 RD BK C6B 28 P26BAT RD RD P3 RD C2P 5 C134PWR GR C2B 5 C6B 34 HORN C3P 9 C9HRN BK RD C3B 9 BK RD 1518
273. WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 1 2 3 4 5 6 7 8 9 10 GRN WHT 19 AUXILIARY PUMP RED 8 AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 z RED RED 27 RELAY CR3 TB27 RED AUXILIARY LIFT PUMP RELAY COIL PR3 GRN WHT 8 9 GRNAWHT 2 6 85 RELAY COIL PR2 WHT RED 3 WHT RED 6 6 CONTROL COIL RED BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB UP GRN WHT 19 2 GRN BLK 18 GRN 17 CONTROL BLK RED ROTARY OEM FLOW 1 JIB BOOM 17 a GRN BLK 3 WHT RED 6 h GRN 3 JIB BOOM CR7A 30 eel 17 CR7A 86 gt 85 RED PLATFORM ROTATE PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY GROUND PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL JIB MANIFOLD PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B UP ORG 3 MANIFOLD FUNCTION GROUND ORG BLK 3 PLATFORM LEVEL EXTEND p PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM St 2 gt
274. WHT BLK 31 WHT 24 WHT BLK 31 WHT 24 ORG BLK R6 BLU BLK 1 TB37 BLU BLK 37 5 TP37 10 RED AUXILIARY PUMP 5 RED 1 ORG RED 42 RED PLATFORM ROTATE PLATFORM LEVEL gt lt 2 a BOOM 8 PRIMARY BOOM TP2 SECONDARY 2 2 2 E ROTATE WHT 24 ORG RED 42 GRN WHT 19 RED 27 8 TB27 TB19 GRN WHT 6 85 30 WHT RED 6 BRAKE RELEASE TRAVEL ALARM A2 BRAKE RELEASE N C COIL BRAKE RELEASE N O COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL AUXILIARY CONTROL RELAY COIL CR3 AUXILIARY LIFT PUMP RELAY COIL PR3 IFT PUMP 87a 8 5 5 RED BRN CONTROL BLK RED ROTARY OEM FLOW 1 18 GRN BLK 3 PLATFORM ROTATE GRN WHT 19 18 GRN BLK 18 GRN 17 17 r1 GRN 3 WHT RED 6 17 PLATFORM LEVEL PLATFORM LEVEL CUTOUT CE VERSION ONLY 1 TB14 g ach ORG 15 ORG BLK 3 TP7 BLK 3 PRIMARY BOOM FUNCTION MANIFOLD GROUND BLK WHT 3 8 1
275. WHT R12 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp d ONTHE DRIVE JOYSTICK GROUND BROWNE RED STOP 5 w CO CO I BROWN LJ 558 BROWN J1 RED BLK 28 5 5 0 DD S V V 1 RED JIB WHT 93255225 5656008222 4 IS SIA Ss S S S SIS 558222 BROWN GRND BER 2 li B B I m 2 m m M B m a 7 up X I 55 825 29 9 BE EXE COMPONENT INDEX do a At case CABLE case POWER SWITCH A1 TILT ALARM 2 1 JIB FS 5 ACI AC OUTLET BOX BCI BATTERY CHARGE INDICATOR BP1 ROTARY FLOW CONTROL DIAL CR6 DRIVE ENABLE RELAY 8 8 2 8 818 zig EE 2 CR7A JIB BOOM CUTOUT RELAY E B 5 52555 gt g 5 9 8585283 igi 9 3 CR7B JIB VALVE RELAY 2 22 55 82223 5 41216 17 LOAD SENSOR RELAY LOAD SENSOR OPTION ONLY a gt 8 5 2 s 418 5 19
276. Z 45 25 Bi Energy Z 45 25J Bi Energy 6 124 June 2005 Section 6 Schematics U Hydraulic Schematic from serial number 22566 to 23235 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual Z 45 25 e Z 45 25J Bi Energy Power from serial number 9996 to 23235 Part No
277. 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy PRIMARY BOOM COMPONENTS 3 Attach overhead crane or similar lifting device to the master cylinder 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 5 Place a rod through the barrel end pivot pin and twist to remove the pin 6 Remove the pin retaining fastener from the rod end pivot pin 7 Place rod through the rod end pivot pin and twist to remove the pin 8 Remove the master cylinder from the machine Crushing hazard The master AWARNING cylinder could become unbalanced and fall if not properly attached to the overhead crane Section 4 Repair Procedures June 2005 Secondary Boom Components REV B Secondary Boom components upper secondary boom number 1 arm b upper tension link number 2 arm lower tension link number
278. available in the Kubota Z482 E Operator s Manual Kubota part number 16676 89163 Kubota Z482 E Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures Checklist Procedures B 1 B 2 Check the Radiator Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engi
279. http www genieindustries com e mail techsup genieind com Genio li Z 45 25 Bi Energy Z 45 25J Bi Energy Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Z 45 25 Bi Energy and Z 45 25J Bi Energy Service Manual after serial number 23235 110188 Copyright 1999 by Genie Industries 106488 Rev B June 2005 Second Edition Second Printing Genie and Z are registered trademarks of Genie Industries in the USA and many other countries Printed on recycled paper Printed in U S A PartNo 106488 June 2005 INTRODUCTION Serial Number Legend Genie Model 7 45 25 Serial number 2452505 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number ES0274 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 Maximum allowable inclination of the chassis 0 deg 24525 05 1 2345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 45 ft 6 in 13 8 m Dua m Maximum platform reach 25 ft 3 in 7 7 m Sequence Gradeability N A number Country of manufacture USA Model year This machine complies with ANSI A92 5 CAN B 354 4 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Genie
280. i 9 A fi 9 TS7 PLATFORM ROTATE TOGGLE SWITCH NO Cid 5 VY 5 JIB BOOM UP DOWN TOGGLE SWITCH 8 xm DRIVE ENABLE po FAULT LED 555 TS9 PLATFORM LEVEL TOGGLE SWITCH TS6 AUXILIARY EN GLOW PLUG ENGINE TS4 TS10 SECONDARY BOOM TOGGLE SWITCH POWER T 5 TS8 TS7 TS9 C START BRM PRIMARY BOOM UP DOWN TOGGLE SWITCH JIB BOOM PLATFORM ROTATE PLATFORM LEVEL P2 TS12 TURNTABLE ROTATE TOGGLE SWITCH RED A TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 112 June 2005 Section 6 Schematics Q JU Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 14651 to 16839 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram Z 45 25J from serial number 16840 to 17974 Section 6 Schematics June 2005 a Sey
281. i aoi l NI 8 1 4 92118118119 5 2 5 2 1518 1 i D39 5 5 2 d 2 FOOT SWITCH 1 TILT ALARM 19 18 CONTROL CABLE 12V DC BATTERY 5 uec NOTES i i 1 LOAD SENSE WIRES SHOWN WITH DASHED LINES 1 20k GR FOR OPTION REMOVE JUMPER JOYSTICK BETWEEN 1 212 TERMINALS 6 amp 7 AND ADD 8 1518 AND L4 OR TS12 TS10 1511 1513 222 TURNTABLE SECONDARY PRIMARY EXTEND 232 COMPONENT INDEX BOOM RETRACT FWD ue 6 DAD BATTERY CHARGE INDICATOR n eso 1 ROTARY FLOW CONTROL DIAL 3 5 4 D P24BAT WH DP1 DRIVE JOYSTICK OOO a lt 4 pow ju DRIVE ENABLE LED i 7 LOAD SENSE LED LOW VOLTAGE INTERRUPT MODULE le lo 129 0 BATTERY CHARGE INDICATOR FOR LVI OPTION 5 8 is E e euo P2 EMERGENCY STOP BUTTON 7 B 2 5 P3 HORN lt lt g 8 S _ AUXILIARY TOGGLE SWITCH TS2 START ENGINE TOGGLE SWITCH 8 HIGH LOW RPM TOGGLE SWITCH 9 GLOW PLUG TOGGLE SWITCH g TS7 PLATFORM ROTATE TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH
282. indicator light turns on and the alarm sounds 8 Test all machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate Machine functions should still operate with auxiliary power at the ground controls A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV 11 Lift the test weights off the platform floor using a suitable lifting device Result The platform overload indicator light and alarm should turn off at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light and alarm turn off 12 Test all machine functions from the ground controls Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All platform control functions should operate If the platform overload system is not operating properly see D 6 Calibrate the Platform Overload System Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV C 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 800 hours Proper engine maintenance following the engi
283. lt ole 5 18 X18 1HM 0 SN G O IHM THM ic 8 HOIHH3IJWOLN3IOdMOHNSAOh 10 ANWd nes I 5 121 9 oissoo3uwm 0 8 ZIA 5 wads mo 2 4 109135 22 Q O 15 ac 12 gt 999 gay 3 2 2994 ols aasnnn o WOO e 53 d bog 2 8 EZIHM yo H3MOd HOLIMSA3M ee 7 O WHOSLV1d OL 22 a H3I3N zag A vet Zlo zi 6L 6L 6I LHWNHO Oi 6L i 9 OT sino E s amavo 5 5 67 81 31VLOH WHOdlVid 81 ai 8 9 e 9 9 81 Si 2 m 2 81 1331 317109 WHOd1V 1d X 5 1100 AV 3H 91 gt zi zi NMO 13 31 WHOALV 1d
284. m Ble e Ble 5 5155 82g 2 CR7B JIB BOOM VALVE RELAY 2 Z 2 pA ES ME SIS 2 Eu 5 5 CR17 LOAD SENSOR RELAY LOAD SENSOR OPTION ONLY M 5 8 5 g S 3 N 813 g m CR19A LOW VOLTAGE INTERRUPT BCI RELAY A LVI OPTION ONLY Boi CR19B LOW VOLTAGE INTERRUPT BCI RELAY B LVI OPTION ONLY 4 9 DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED Ho GREEN S 20k t 1 7 13 CONTROLLER FAULT LED tH RED L4 OVERLOAD LED LOAD SENSOR OPTION 5 Uo 20 LDS LOAD SENSOR MODULE ee LVI LOW VOLTAGE INTERRUPT MODULE 3 5 4 29 REV 4 BATTERY CHARGE INDICATOR FOR LVI OPTION 40 P2 EMERGENCY STOP 2 TURNTABLE SECONDARY PRIMARY BOOM EXTEND A OL 50 P3 HORN ROTATE TS12 BOOM TS10 OPTION TS13 7 TIME DELAY 1 TS1 AUXILIARY SWITCH 52 START ENGINE SWITCH BI ENERGY ONLY BLK WHT TS4 HIGH LOW RPM SWITCH BI ENERGY ONLY TS15 DIE ho 2 TS6 GLOW PLUG SWITCH BI ENERGY ONLY 900 Y ZN TS7 PLATFORM ROTATE SWITCH P3 1 6 Od C 7 NF TS8 JIB BOOM UP DOWN SWITCH JIB ONLY AUXILIARY DRIVE ENABLE j KOAD LED TS9 PLATFORM LEVEL SWITCH TS1 GLOW PLUG START RPM HORN ids 2 gt _ TS10 SECONDARY BOOM SWITCH ux y PLATFORM ROTATE PLATFORM LEVEL c TS11 PRIMARY BOOM UP
285. machine 10 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 11 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 12 Attach a lifting strap from an overhead crane to the jib boom 13 Support the barrel end of the jib boom lift cylinder with a suitable lifting device 14 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Section 4 Repair Procedures June 2005 JIB BOOM COMPONENTS Z 45 25J 15 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 16 Use a soft metal drift to remove the pin and let the cylinder hang down Crushing hazard The jib boom AWARNING 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 AWARNING Cushing hazard The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 18 Attach a lifting strap from an overhead crane to the l
286. may cause severe burns 4 Remove the engine pivot plate latch retainer 5 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine 6 Tag disconnect and plug the hydraulic hoses from the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the function pump mounting bolts Carefully remove the pump Section 4 Repair Procedures June 2005 Manifolds REV 9 1 Function Manifold Components before serial number 17841 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index Schematic No Description Item Function Torque 1 Differential sensing valve All 20 25 ft lbs 27 34 Nm 2 Solenoid valve Bus Brake circuit 20 25 ft lbs 27 34 Nm 3 Orifice 0 050 inch 1 27 mm C assis Brake circuit 4 Orifice 0 060 inch 1 5 mm Dun Steer circuit 5 Solenoid valve position 4 way E 265 Steer 20 25 ft lbs 27 34 Nm 6 Solenoid valve Figs Brake 20 25 ft lbs 27 34 Nm 7 Proportional solenoid valve All fUnCtions ices
287. not properly attached to the overhead crane Crushing hazard The upper pivot ACAUTION 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 4x 11 inch 10 x 10 x 28 cm block between the number 2 arm and the boom rest Then lower the secondary boom assembly onto the block AWARNING Crushing hazard The secondary boom assembly could fall if not properly supported by the 4 4 11 inch 10 x 10x 28 cm block Part No 106488 June 2005 Section 4 Repair Procedures REV 23 Pull all of the cables and hoses out through the upper pivot CAUTION 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 CAUTION 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 AWARNING Crushing hazard The upper pivot could become unbalanced and fall when removed from the machine if
288. number 14079 to 14650 B RED BLK R6 BRN LVJ LVI LOAD SENSOR ORG BLK R6 8 7 6 5 4 3 2 1 123456789101112 99 OOOO RED L7 3 BLK LSTOP sss 2 B 3 B BRN LVJ idus oo 5 gt lt Y ES 5 N RED L1 5s 55 9 e 9 9 lt 2 ORG RED LED e lt S 5 m m BLK 26 BLK 26 5 2 ORG RED 16 ORG RED 16 BLU LR15 RED L7 RED L7 ORG RED LV42 5 RED L1 RED L1 2 9 ORG BLK 41 ORG BLK 41 2 m 2 BLU L10 BLU L10 WHT LV24 gt j WHT L6 WHT L6 8 45 7155 6 5 2 2999 5 BIS 2 2 lt 12 5 1 2 gt 2 gt 2154 5 5 g
289. operate If the platform overload system is not operating properly repeat steps 1 through 4 CHECKLIST D PROCEDURES D 8 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota Z482 E Operator s Manual Kubota part number 16676 89163 Kubota Z482 E Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine Genie Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 9 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Require
290. properly attached to the overhead crane 9 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder 10 Place blocks in between the upper and lower How to Remove the Cable Track cable tracks and secure the upper and lower 2 45 25 tracks together When removing a hose assembly AWARNING Ctushing hazard If the upper and or fitting the O ring on the fitting lower cable tracks are not properly and or hose end must be replaced secured together the cable track and then torqued to specification could become unbalanced and fall during installation Refer to when removed from the machine Section 2 Hydraulic Hose and 11 Remove all hose and cable clamps from the Fitting Torque Specifications Beer one primary Daam 1 Locate the cables from the primary boom cable 12 Attach a strap from an overhead crane to the track to the platform control box Number each cable track cable and its entry location at the platform control box 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension Disconnect the cables from the platform control boom box 3 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators Genie Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 11 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS 4 Remove the hose clamp on the primary boom bellcran
291. quio H 19880 8EO NHH6H 6 899 55 174 2 52152 SHO 65 899 55 899 H HIWQH 55 899 ala 61 899 1818 72 890 1 62 892 Varro 55 899 ANJ M M 92 892 55906686 S100 07 890 ee ek E YY Houme Nua WH NHS ASPSPO 2820 B SS3NHVH H OHINOO HM 1 850 sz a90 1 1 490 aW HM HMdEZO 869 snivis 1 325300 alf rnv l 8561 id 2 9 820 naviva LO Ws HOLIMS O Q 9 1V8ZvH 1H0 Qu HO 1V8zrH 22 9 ow 3345 340 Or Q ao Sas 99 S109 2 892 1 1 O a 9 915 59 OLSZED 16 890 9 9 anm HO SN 18 9018960 01 10 2 a 18 201590 96 890 SE SE 551 0 a 4 dama WdHHSEO 6 82 5 WdHHSEO 81 850 ve ve 9551 MOTD HME 8 810 5 VSVEO 22 850 9 2951739 JNIONCIHVIS ee a 9 5665 2810 1 9 95 2 22 103135 dux 2980
292. rabbit symbol from the ground controls Result High idle should be 3000 rpm Skip to step 7 if the high idle rpm is correct Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV B 6 Loosen the lock nut on the solenoid then turn the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle 7 Swing the engine back to its original position and close the engine pivot plate latch 8 Install the engine pivot plate latch retainer Part No 106488 A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy CHECKLIST PROCEDURES B 9 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the oN or position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin 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
293. the container to the boom 3 Open the top bleed valve on the rotator but do not remove it a top bleed valve b bottom bleed valve container d clear hose Section 4 Repair Procedures June 2005 PLATFORM COMPONENTS 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Cushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks Genie broth REV B 4 6 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures Jib Boom Components Z 45 25J 3 1 5 Attach a lifting strap from an overhead crane to Jib Boo
294. toggle switch in the down direction with the primary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 3 the machine off Hold the primary boom down relief valve with a wrench and remove the cap item Q 4 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 5 Repeat steps 2 through 4 and recheck relief valve pressure Part No 106488 June 2005 Section 4 Repair Procedures REV How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold Move and hold the function enable toggle switch to either side and hold the secondary boom up down toggle switch in the down direction with the secondary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications Turn the machine off Hold the secondary boom down relief valve with a wrench and remove the cap item R AM BX or CW Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING hazard Do not adjust t
295. 005 D B Section 6 Schematics i ee Platform Control Box Wiring Diagram Z 45 25 with LVI BCI Option from serial number 17975 to 21180 A RED BLK R6 BRN LVJ 1 RESET IS SET ORG BLK R6 8 7 6 5 4 3 2 1 DISCHARGE IS SET N ORG BLK 41 90 009 0 g 8 BRN LVJ 9 9 5 bi m 9 N 5 n o gt 2 E E lt 99 lt 8 5 8 3 2 ORG RED 16 ORG RED 16 BLU LR19A ORG RED LV42 2
296. 1090 2 820 HO 51070 72 892 1 1 9 915 59 915 69 890 arama 9 18 2215962 01 910 18 201590 96 895 SE a vSS1 Qu t8 WdHHSEO 6 810 WdHHSEO 81 850 E ve MOT ve 95S1 HW ld o B Ee 9 8 8 810 HMMA 22 852 9 259158 LAVIS 5 515559 2810 550 5 96 ISSrau 22 193156 dnd 1929 HM 1 2 820 ios WHOALVId OL OG zz 222 02 89 A AUS er 131 Q 06 980 i wsruwo 6 a ae 2870 MSd6LO 85 899 8 31VLOH WHOSLV 1d 5 HHd8LO 81 892 5 133731109 WHOd1V 1d HOT SH THdZLO 21 892 mbeu WHOSLV1d 515 W O 51 892 71890 2i 9 9 4 21 80 5 21 990 H o nav 11 990 WOO
297. 1180 Section 6 Schematics DASHED LINES INDICATE OPTION WIRES Nua Nua Nua 2 lt TANWd Ze 31VNIWH3L 32 3S3HL 2 19 OL 1 H LHWNHO 61 LHWNHO bg PA 9INSId Q3H E H3MOd d3H t SS3NuvH id Sura aag 5 N 2 22 1 Y 61 LHWNHO SS3NHVH ee ee ie ee ee tee SISSVHO am os NOILONNP 761 251 09 a 8
298. 12 H C7B 2 P23BAT WH gt _ lt GR BK C7B 1 TB134 C132 PLI BL WH coe gt gt v 5 8 gt gt 4 6 gt gt 12 BK 30 87 C6B 9 BK RD TB22 GROUND PLATFORM KS1 C2P 2 C40LS OR C2B 2 OR C29JSH RD WH C1B 3 TB40 OR C6B 20 RD 10 2 WH 5 RD 5 11 2 WH 6 BK 5 WH 4 C10 1 lt a C10 4 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 11 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY HORN Bko 9 BK 11 4 WH 7 gt C6B 40 OR 10 3 4 11 3 BK 7 CONTROLLER FAULT INDICATOR LED L2 JOR RD gt C6B 25 CFIL BK 154 4 4 CT C6B 39 CR5 RD BK 21 22 SEC a GR X COIL PR1 OR RD 4 C6B 22 OFF LMT SPD INP 17 C6B 29 24 1 C6B 12 BL WH INTERLOCK RD WH POT C32JSL WH RD C1B 6 C6B 32 WH RD POT LOW C31REV WH BK C1B 5 C6B 31
299. 14 Place the large inner bearing into the rear of the hub Part No 106488 A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy CHECKLIST E PROCEDURES 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 17 Place the outer bearing into the hub 18 Install the washer and castle nut 19 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 20 Loosen the castle nut and re tighten to 8 ft lbs 11 21 Install a new cotter pin Bend the cotter pin to lock it in Always use a new cotter pin when installing a castle nut 22 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and compone
300. 16 30 87 ORG GEN NEG ORG GEN POS AC POWER BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 lt aon CHASSIS GROUND 48V CHARGER 48V DC ALTERNATOR PRIMARY TB20 F4 500 A pe 48V DC 24V 1 GROUND LIFT PUMP AUXILIARY LIFT PUMP 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 21 Section 6 Schematics June 2005 Electrical Schematic 2 45 25 from serial number 14079 to 14650 REVA RED WHT 29 RED WHT 29 WHT 24 DRIVE ENABLE LED L1 BRN 2 DRIVE ENABLE LIMIT SWITCH BLU RED 3 TB13 BLK 7 BLU WHT 12 12 BLU WHT 3 a WHT 7 JP1 REMOVE FOR CE VERSION eT d TB12 ORG RED 3 ORG RED4e _ TP16 3 BRN Ye ORG BLK 1 86 PLATFORM CONTROL BOX GROUND BRAKE RELEASE TB48 h RED WHT 48 1 9 DRIVE ENABLE 30 87 TP41 RED BLK R6 TS15 L1 BLU 1 H RED BLU 36 BRAKE STEER MANIFOLD GROUND BLU BLK 1 TB37 BLU BLK 3
301. 18 L Nua Nua O uus OOO E vSSL PRO m a t de c f 42 T aay zaa 5 9 NG wamoa aau 248 HOLIMS 9018 LSJ 1551 ld 6 78 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 2 45 25 from serial number 14651 to 16839 Section 6 Schematics June 2005 ___________ Ground Control Box Terminal Strip Wiring Diagram 2 45 25 from serial number 16840 to 17974 REVA June 2005 45 25J D iring Ground Control Box Terminal Strip W from serial number 16840 to 17974 Section 6 Schematics
302. 1HM 1431 SLVLOY STAVINENL T 1HM Q T LHM O H3MOd 1109 A 87 p dd IHWG3H 9 Q 9 NMOG 2 Q E mE sar 3uvds WOO8 Q E v g NS 81 TVNIIWH3 L YT N iO Part No 106488 TEREX COMPANY 2 45 25 Bi Energy Z 45 25J Bi Energy G 6 63 Section 6 Schematics June 2005 Ground Control Box Switch Panel Wiring Diagram Z 45 25 REVA from serial number 17975 to 21180 N NHOH vHO Zea 22 8 Sg Nua 18 8 fa ON i E x gE 2 a g D 8 E a A 3 g 3 2 az 5 g 85 2 28 5 28 18 18 58 9
303. 2 C2PBD RD BK C3B 2 SECONDARY 10 C10SBU BL C3B 10 TB10 C6B 10 BL C13 1 13 2 C18 1 C182 C6B 11 BL BK I s SECONDARY 11 C11SBD BL BK C3B 11 C3P 5 C4TRR WH BK C3B 5 TBS C6B 5 WH BK L C19 1 C6B 4 WH TURNTABLE ROTATE RD TURNTABLE C3P 4 CATRL C3B 4 P24BAT WH R42BAT OR RD C12DRE BL WH P42BAT OR RD RD E IN RD FUNCTION ENABLE TS55 GND BK PR2 et BRAKE RELEASE 1 TRAVEL ALARM 2 BRAKE RELEASE N C COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL PRIMARY LIFT PUMP RELAY COIL PR2 AUXILIARY CONTROL RELAY COIL CR3 AUXILIARY LIFT PUMP RELAY COIL LIFT PUMP NEL eM TIC ee 6 32 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G CONTACTOR RELAY CR20 FLOW CONTROL COIL PartNo 106488 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT ALARM OPTION A3 TURNTABLE ROTATE RIGHT C
304. 2 34 gt aasnnn o 21 Fa a fal T lt gasnnn E 2 8 E 2 O 5 EZ LHM 44 318v9 H3MOd HOLIMSA3M 257 HOLIMS MNA 1HM 2 WHO4LV1d OL 22 O r4 Wala r4 LZ LHM LO H3MOd El 141 5 6LI LIHWNHO 61 LHWNHO gt 61 61 PPO Q C TM simu E si avo lt 1 1HWNHO lt 257 HOLIMS 8L 2 5 NANAS tO O 31VLOH WHO1Y 1d a SNANG AWW Ol df 1431 WHOL 1d m Q i 9 Off 1100 AVISY INYA 91 a NES 2 LO 6 NMOG 13 31 WHOSLV1d 91 Q 9 318vO 157 5 Q SEOUO 2 a Off 1 L a ong aau ma H3MOd HOLIMSLOOS SN 1HM ale O n WOOS8 uns b
305. 25 aX za gt ou a2 1 oo 2 lt lt 5 25 2 2 6 RED PISM6 WATER TEMPERATURE 25 SWITCH Se OIL PRESSURE SWITCH 5 T n 3 BRN 2 25 98 _ BLK RED 1 zi 4 9 8 8 i aE 2 5 5 sps 8 RELAY X T x ES 8 BO RPM RELAY CR14 pe 9 8 8 8 ENGINE BLK RED RPM SOLENOID BLK 1 START 86 8 5 tg 5 5 BLKIWHT 4 GLOW PLUG RELAY CR15 j 5 udo GLOW PLUGS 8 BLKWHT 55 700900 az 29 m 7 5 6 12V ALTERNATOR a lt 1 12V VOLTAGE gt REGULATOR i BLK 5 ENGINE POWER RELAY CR12 E G ENGINE RUN SOLENOID STARTER RELAY CR11 A E ORG RED 42 PORED P ORG RED i 5 gu E 1 BS oi SRA I 48 POWER RELAY CR2 WHT RED WHT 3 RED WHT 3 5 4 POWER RELAY CRI 8 8 eder IS a n I ig ule i658 28
306. 3 PLATFORM LEVEL PRIMARY BOOM EXTEND COIL i i i i i i i PRIMARY BOOM i BLK WHT 8 EXTEND BLK 7 i 1 PRIMARY BOOM TP7 BLK 3 a BLK WHT 3 t1 TB1 RED 1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL gt E 38 a z RED BLK 2 8i dimi PRIMARY BOOM TB2 TP1 UP RED 3 RED BLK 3 H TB10 BLU 10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL PRIMARY BOOM 2 al BLU BLK 11 8 8 SECONDARY DESCENT ALARM OPTION A3 UP BLU 3 t BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY TBS WHT 4 WHT BLK 5 TURNTABLE 4 L Hi 152 ROTATE RED TB4 5
307. 3 HE 9 2 RS le TS SSAC assise ass o3 5 lt 515 gt gt 8 gt 12 lt 200 2 0245000 RED TILT 3 55 E 3 56 lt gt 55 m 23 2 525 a G gt gt 0 gt lt 2 5 5 9 2 5 50 e amp 519 151 2 20 6 55 JF RED LR15 7 gt x mom 92 95 12960 mme 72 mom Am m m RED TIME 215911141715 5 lt GRN WHT JOYS 5 5 gt 5 4 2 8 2 lt m 2 NOTES GRN WHT R12 2 ALL WIRES WITHOUT LABELS J7 RED STOP EITHER RED OR BLACK JUMPER WIRES 07 BRNALI 2a w eeleeszmsszssusssSNNSESSNSSSSSSSESSSSS8S5ss525ES BENI FOR LIFT DRIVE SELECTOR OPTION RED BLK 28 Bpz ismeosprozszszpppssesspooosooo TAKE OFF JUMP BETWEEN 6 amp 7 559 1 5 8 8 2 2 2 525223 RED JIB S Wi lg 3685 ZIP LIVI lt lt 5 FS Sle 599 lt gt gt lo w a a BRN GRND km d
308. 3 PRIMARY BOOM EXTEND RETRACT SWITCH TS14 DRIVE RANGE HIGH LOW SWITCH TS15 DRIVE ENABLE SWITCH yenie 6 105 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics a Ss ee Se REV A Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option before serial number 13361
309. 3 arm mid pivot compression link secondary boom lift cylinder 2 lower secondary boom number 4 arm turntable pivot i boom rest j upper pivot EM Genio 4 20 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV B 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING 991 injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Z 45 25J Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the primary boom See 3 2 How to Remove the Primary Boom Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy SECONDARY BOOM COMPONENTS 4 Remove the master cylinder See 4 5 How to Remove the Master Cylinder 5 Attach a lifting strap from an overhead cr
310. 37 RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 1 2 3 4 5 6 7 8 9 10 Z 45 25 Bi Energy Z 45 25J Bi Energy GRN WHT 19 AUXILIARY PUMP AUX ON 85 RED RED 8 AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 RED 27 4 RELAY COIL CR3 TS51 TB27 RED AUXILIARY LIFT PUMP RELAY COIL 6 gt 1 GRN WHT 8 GRN WHT LIFT PUMP 4 RELAY COIL PR2 WHT RED 3 WHT RED 6 RED BRN 19 PartNo 106488 PLATFORM ROTATE RIGHT GRN WHT 19 1 18 GRN BLK 18 ne GRN 17 PLATFORM ROTATE LEFT CONTROL BLK RED BP1 ROTARY OEM FLOW PLATFORM ROTATE TB17 TP18 GRN BLK 3 WHT RED 6 GRN 3 PLATFORM ROTATE 17 RED PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL v 8 TB14 PLATFORM LEVEL ORG TB15 14 PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B MANIFOLD GROUND ORG 3 m fet ORG BLK 3 PLATFORM LEVEL 15 EXTEND BLK 7 PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL BLK W
311. 37 inch ead removedafter AUXILIARY PRIMARY 5 127 mm 4 0 94 mm serial number PUMP PUMP Q tee 0 5 2 1 ej M 2300 psi 11618 1 9 7 9 L min n d 1800 psi 159 bar 3500 x ar TE SEEE cp NNI ii 9 B ei D P Wo 1 J gI LI SELLERS SHE DOS HIE TX 1 L A 2 0 6 gpm 0 6 gpm 117 2 3 L min RESERVOIR Genie A TEREX COMPANY 6 121 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics ee See REV Hydraulic Schematic from serial number 16962 to 20379 N M L K J H G F E D B A JIB BOOM PLATFORM ROTATE joe een Eee Hees joe eee G cupide 0 026 inch 0 025 inch 4 i 1 1 4 1 3000 q ph 9 207 bar i B S 15401 hood 3800 psi Me ke OY 262 bar 1 1 1 44 st
312. 4 Er TS10 SECONDARY BOOM TOGGLE SWITCH POWER 157 199 C SIART 511 PRIMARY BOOM DOWN TOGGLE SWITCH L1 PLATFORM PLATFORM ROTATE LEVEL P2 TS12 TURNTABLE ROTATE TOGGLE SWITCH RED TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH enie Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 Section 6 Schematics E n Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option from serial number 14079 to 14650 Section 6 Schematics June 2005 ____________ Platform Control Box Wiring Diagram 2 45 25 from serial number 14651 to 16839 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25 REV A from serial number 14651 to 16839
313. 488 June 2005 Section 3 Scheduled Maintenance Procedures REV B CHECKLIST A PROCEDURES A 7 A 8 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the front turntable cover 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Perform Engine Maintenance Engine specifications require that this procedure be performed every 100 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota Z482 E Operator s Manual Kubot
314. 5 87 12V GLOW PLUG RELAY CR15 GLOW PLUGS 0000 TB34 GLOW BLK WHT PLUGS IS 9707 GLOW PLUGS TS56 2 TP34 BLK WHT 1 TS6 12V DC ALERNATOR WHT J4 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 12V 21 RED J10 12GA E ast 6 2 2 WHT 21 ENGINE RUN SOLENOID 25 TP24 STARTER RELAY CR11 15A STARTER ORG RED 42 ORG RED 1 4 m ORG RED WHT 23 WHT 21 B 4 e TP42 TB42 CONTROLLER FAULT LED 48 DC POWER RELAY CR2 RED WHT 3 RED WHT 3 RED amp WHT 3 o I 48V DC POWER RELAY CR1 i8 RED FS WHT FS FLASHING BEACON OPTION RED WHT 23 FS1 p TILT ALARM RED 1 RED BLK 1 RED BLK 28 WHT 2 RED WHT 23 BLK FS TILT SENSOR 8 26 23 ENABLE BLK HOUR METER LOAD SENSOR OPTION SEE DETAIL BLK RED 9 RED amp I BLK RED 9 BLK RED 3 ut HORN RELAY BLK 22 BASE CONTROL BOX GROUND TB22 SEC GROUND LS4 BLK8 RED 6 TB50 o E o m 2 9 5 ad 21 22 2 2 PLATFORM RED 8 INDICATOR LED L2
315. 5 2 E 8 lt u X BE a m C a 8 g 6 CHASSIS HARNESS 6 13 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA REVA ORG GEN POS June 2005 H G F E D B Section 6 Schematics Engine Panel Diagram from serial number 17975 to 21180 A NOTE RED CB CIRCUT BREAKER RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE A RED CB 12V 2 WHT BATT WHT BATT WHT BATT WHT 21 WHT 21 BLK RED 35 BLK RED 35 WHT J5 WHT J5 E BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 BRN J4 ow WHT J4 WHTJ4 WHT J6 BLK RD BLK RD 22 gt as 1 1 1 m 1 ESS 9 529 87 87 87 87 87 87 t 85 86 85 86 BROWN CH H ov p 87a 86 les 87a 86 87 86 87 87 les 87a 86 RED CB 30 30 30 CR16 CR12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WHT J4 REL
316. 5 2 Secondary Boom Lift Cylinders A Kubota Z482 E Engine 6 1 Timing 22 2 22 2 2 6 2 4 4 412 6 3 Engine Drive Pulley 22222 422 2 Genie x Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued A Generator 7 1 GeneratorPulley 4 29 7 2 GeneratorBellts 2 440 0 0 0 0 00000 4 30 7 3 Generator Voltage Regulator 2222 00 00 0 4 30 B Hydraulic Pumps 81 Auxiliary 55 2 4 6 int 4 33 8 22 4 33 Manifolds 9 1 Function Manifold Components before serial number 17841 4 34 9 2 Function Manifold Components from serial number 17841 to 20379 4 38 9 3 Function Manifold Components from serial number 20380 to 22565 4 40 9 4 Function Manifold Components from serial number 22566 to 23235 4 42 95 Valve Adjustments Function 4 44 9 6 Jib Boom Platform Rotate Manifold Component 4 46 9 7 Turntable Rotation Manifold Components 4 47 B Turntable Rotation Components 10 1 Rotation H
317. 5 Bi Energy Z 45 25J Bi Energy 43 Part No 106488 Section 4 Repair Procedures June 2005 MANIFOLDS 9 5 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Move and hold the function enable toggle switch to either side and hold the primary boom extend retract toggle switch in the retract direction with the primary boom fully retracted Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 3 Turn the machine off Hold the system relief valve with a wrench and remove the cap item V AQ BN or CO 4 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 5 Repeat steps 2 through 4 and recheck relief valve pressure Z 45 25 Bi Energy Z 45 25J Bi Energy REV C How to Adjust the Primary Boom Down Relief Valve before serial number 11819 Perform this procedure with the boom in the stowed position 1 Connect 0 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Move and hold the function enable toggle switch to either side and hold the primary boom up down
318. 5 ft lbs 34 Nm 4 5 ft lbs 5 5 6 7 Nm 25 ft lbs 34 Nm 27 ft Ibs 37 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm 20 ft lbs 27 Nm 20 ft Ibs 27 Nm 20 ft lbs 27 Nm Index Schematic No Description Item Function 1 Solenoid valve 2 position 3 way CA Primary boom retract 2 Solenoid valve position 4 way Primary boom up down 3 Solenoid valve position 4 way uus Secondary boom up down 4 Solenoid valve position 4 way CD Turntable rotate left right 5 Solenoid valve position 4 way GE 2 Platform rotate left right and jib boom up down 2 45 25 6 Solenoid valve 3 position 4 way CELL Platform level up down Shuttle valve CG us Platform level circuit 8 Solenoid valve position 4 way COH Steer left right 9 Proportional solenoid valve CI Controls flow to functions 10 Pressure switch Brake circuit 11 Solenoid valve 2 position 3 way uus Primary boom extend 12 Flow regulator valve 0 4 1 5 L m
319. 58585454520 1 amp 8 8 5 8 1 o 02 S NI 9 2 9 9 9 9 9 9 9 06 0 ____ C EN 8 5 5 x 1 wok C35HRPM BK RD gt 1 ER x ec jd a 3g OIN e i RD RPM BRN LOAD J RD AUX BRN J1 p BRN BCI lt i C33STR BK 1 nea 1 PSs a fr m 2 GR WH 45 i a Ww GR WH 45 ros BRN JIBGND oca C34SA BK WH 6 1 l oa P25BAT RD 3 9 rz P24BAT WH lt 1 9 2 gt WH RD P26BAT BK C9P 1 C19LPMP P25BAT RD RD SW 1 BRN BATGND C7P 3 5 A P23SWBAT WH 2 OR LOAD P22BAT BK C7P 1 2 2 RS po RELOAD ____ gt 191 GRWH __ C4P 5 7 ER ae C18PRR GR BK 6 p BS p amp C7PBE BK C17PRLGR 5 ARBRE CI6DRE OR RD 4 i C15PLD OR BK 3 C14PLU OR 2 gt C13DREL BURD 1 gt d 1 Qu gt aaO oi C12DRE BUWH C3P 12 229 C11SBD BL BK 11 9 C2PBD C14PLU OR CIOSBUBE alca ciPBURD lt i C15PLD C9HRN BK RD 9 C8PBR BK WH C3P 8 GR WH 45 C7PBE BK C3P 7 EL 1 gt
320. 5A rate 125 minutes Alternator Output 12V DC 150 watts Fan belt deflection 1 4 to 3 s inch 7 to 9 mm 2 5 Z 45 25 Bi Energy Z 45 25J Bi Energy Section 2 Specifications June 2005 SPECIFICATIONS Generator Generator output with engine 3000 rpm 54V DC 100A Generator pulley to engine 1 16 inch pulley offset maximum 1 6 mm Belt deflection maximum 1 4 inch 6 5 mm Generator Torque Specifications Generator pulley retaining nut torque 80 90 ft lbs 108 122 Nm Engine pulley retaining bolts 108 in Ibs 12 2 Nm 10 screw 25 in Ibs 2 8 Nm 10 nut 25 in Ibs 2 8 Nm 4 nut 8 10 in lbs 0 9 1 1 Nm Voltage regulator 25 in Ibs mounting fasteners 2 8 Nm G 2 6 Z 45 25 Bi Energy Z 45 25J Bi Energy ATER COMPANY REVA Part No 106488 June 2005 Section 2 Specifications REVA Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring
321. 7 55 WHT RED 32 WHT RED 32 WHT 30 WHT 30 WHT BLK 31 WHT 24 WHT BLK 31 WHT 24 ORG BLK R6 TP37 10 RED AUXILIARY PUMP 5 RED 1 ORG RED 42 TP27 BCI V 00 GRN WHT 19 RED 27 8 1 TRAVEL ALARM 2 BRAKE RELEASE N C COIL BRAKE RELEASE N O COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL AUXILIARY CONTROL TB27 19 GRN WHT 30 6 85 19 TP6 WHT RED 6 RELAY COIL AUXILIARY LIFT PUMP RELAY COIL LIFT PUMP 87a 8 5 5 RED BRN CONTROL BLK RED ROTARY OEM FLOW BP1 TP18 GRN BLK 3 GRN WHT 19 18 GRN BLK 18 GRN 17 PLATFORM ROTATE 17 r1 GRN 3 WHT RED 6 PLATFORM ROTATE RED 2 TP17 ORG 3 PLATFORM LEVEL CUTOUT CE VERSION ONLY 8 TB14 ach PLATFORM LEVEL ORG TB15 ORG BLK 3 PLATFORM LEVEL TP7 BLK 3 FUNCTION MANIFOLD GROUND PRIMARY BOOM St 2 E gt BLK WHT 3 gt lt 2 BOOM 8 1 RED 3 TB1 RED 1 RED BLK
322. 7 L MIN AN 15 Flow control valve 0 1 0 38 L min AO 16 Counterbalance valve 17 Relief valve 3200 psi 220 6 bar AQ 18 Diagnostic nipple 19 Check 20 Orifice 0 060 inch 1 5 AT 21 Pressure switch AU 22 Solenoid valve 2 position 2 way poppet AV Orifice 0 030 inch 0 76 mm located under item VV AW 23 Orifice 0 046 inch 1 17 mm AX 4 38 Z 45 25 Bi Energy Z 45 25J Bi Energy Function Torque 20 ft lbs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm Primary boom retract Primary boom extend Primary boom up down Secondary boom up down Turntable rotate left right Platform rotate left right and jib boom up down Z 45 25J Platform level up 25 ft lbs 34 Nm 20 25 ft lbs 27 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 27 ft lbs 37 Nm 25 ft lbs 34 Nm Platform level up down Steer left right Controls flow to functions All functions 20 ft lbs 27 Nm 20 ft lbs 27 Nm Brake circuit Secondary boom down Platform rotate turntable rotate and jib boom circuits 2 45 25 20 ft lbs 27 Nm
323. 8 6 55 Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 13361 to 14078 6 56 Ground Control Box Terminal Srip Wiring Diagram Z 45 25 from serial number 140791014650 6 57 Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 14079 to 14650 6 58 Ground Control Box Terminal Srip Wiring Diagram 2 45 25 from serial number 14651 16839 6 59 Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 14651 to 16839 6 60 Ground Control Box Terminal Wiring Diagram Z 45 25 from serial number 16840 to 17974 eee eee eters 6 61 Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 16840 017974 222002444 0 000000 6 62 Ground Control Box Terminal Srip Wiring Diagram 2 45 25 from serial number 1797510 21180 6 63 Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 179751021180 6 64 A Ground Control Box Terminal Srip Wiring Diagram Z 45 25 from serial 211811022050 6 65 xiv Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 TABLE OF CONTENTS Section6 Rev Schematics continued Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 211811022050 6 66 Ground Control Box Termin
324. 8 Sg 98 S8 98 s8 se 928 228 278 v8 e z z D og 5 0 5 0 oe E J 5 1 3 141 0280 Nua IHWG3H 1HIWI3H 1 gt 2 31v10H E WHOSLW1d X 2 E JNE 25 SL 18 980 LNI 195 9951 G L INHOA1V ld 600 6951 dau 8 a a a a LI NHO 8 wooa 5 dau 0951 dau Q Ol a 9 O 2951 3NION3 zu 1 18 8 T LHM gea OL 3SV8 OBS Aud T AHVMWIHd WH cost POY 1961 NH8 Laura 8 LHMNE IZ LHM 9 7981 2 8 dau 22 039 aay 4 2 5 H3M
325. 86 8 187 GR WH 8 pis 6 87 C6B 6 WH RD 2 C6B 18 GR BK 23 1 ni C23 2 C6B 17 GR TB17 C4P 6 C18PRR GR BK 7844 C4B 6 GR BK 5 C17PRLGR C4B 5 GR JIB MANIFOLD 2 7 C45J8V GR WH 2 C14PLU OR C4B 2 PLATFORM ROTATE 57 33 C44DA 6 C6B 14 OR ils 22 1 22 2 20 1 20 2 C6B 15 OR BK B TB15 3 C15PLD OR BK C4B 3 7 C7PBE C3B 7 EXTEND TB7 C6B 7 BK C21 1 C21 2 C16 1 5 C16 2 C6B 8 4 PRIMARY BOOM C3P 8 C8PBR BK WH C3B 8 C3P 1 CiPBU RD C3B 1 C6B 1 RD Cie C12 1 5 12 2 C6B 2 RD BK PRIMARY BOOM 9 3 T TB2 C3P 2 C2PBD RD BK C3B 2 C3P 10 C10SBU BL C3B 10 TB10 C6B 10 BL 13 1 13 2 18 1 18 2 gt 1 C6B 11 SECONDARY 11 C3P 11 C11SBD BL BK C3B 11 C3P 5 WH BK C3B 5 TBS C6B 5 WH BK 15 1 15 2 C6B 4 WH TURNTABLE ROTATE C3P 4 C4TRL WH C3B 4 P20BAT 2 06
326. 87 12V GLOW PLUG RELAY CR15 GLOW PLUGS 8 0000 TB34 GLOW BLKWHT PLUGS 87 55 90090 GLOW PLUGS TS56 2 TP34 BLK WHT 1 TS6 12V DC ALERNATOR WHT J4 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 21 RED J10 12GA E ast 6 2 2 12V WHT 21 ENGINE RUN SOLENOID 25 TP24 STARTER RELAY CR11 15A STARTER WHT 23 WHT 21 ORG RED 42 ORG RED 1 Bm ORG RED 4 m e B TP42 TB42 48V DC POWER RELAY CR2 TB3 RED WHT 3 RED WHT 3 RED WHT 3 o I 48V DC POWER RELAY CR1 i8 RED FS WHT FS FLASHING BEACON OPTION RED WHT 23 FS1 p TILT ALARM RED 1 RED BLK 1 WHT 2 RED BLK 28 RED WHT 23 BLK FS TILT SENSOR 8 TP26 TP23 ENABLE BLK HOUR METER LOAD SENSOR OPTION SEE DETAIL BLK RED 9 RED 8 1 BLK RED 9 BLK RED 3 ut HORN RELAY BLK 22 BASE CONTROL BOX GROUND TB22 SEC GROUND 154 BLK 8 RED 6 TB50 o 2B o TB49 2 9 5 lt 21 22 2 2 PLATFORM RED 8 INDICATOR LED L2 KS1 ORG RED 42 BLK
327. 9 RED 27 TB27 TB19 GRN WHT gt WHT RED 3 WHT RED 6 gt GRN WHT BRAKE RELEASE N C COIL BRAKE RELEASE N O COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL AUXILIARY CONTROL RELAY COIL CR3 AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP 87a RED BRN CONTROL BLK RED ROTARY OEM FLOW 18 GRN BLK 3 m JIB BOOM GRN WHT 19 2 GRN BLK 18 GRN 17 2 4 17 1 89 GRN 3 WHT RED 6 PLATFORM ROTATE JIB MANIFOLD ORG 3 GROUND PLATFORM LEVEL PLATFORM LEVEL CUTOUT 1 TB14 CE VERSION ONLY 15 ORG BLK 3 TP7 BLK 3 PRIMARY BOOM EXTEND RETRACT BLK WHT 3 a TP1 RED 3 PRIMARY BOOM UP ED 1 2 D ED BLK 2 DOWN RED BLK 3 TP10 BLU 3 SECONDARY TB10 BLU BLK 3 g TB11 5 WHT BLK 3 TURNTABLE ROTATE RED WHT BLK 5 WHT 4 WHT 3 RED RED BLU WHT 12 RED FUNCTION ENABLE TS55 GND GND RELAY COIL PR2 FLOW CONTROL COIL PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT J
328. 9 t 1 t ti tj 4 0 060 inch CL Al a 6 0060 in UAX X 12 65 69 5 0 6 gpm Jc S 2 27 L min 0 030 inch 7 RESERVOIR W em MM pum X FUNCTION MANIFOLD Genie A TEREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 122 June 2005 Section 6 Schematics Hydraulic Schematic from serial number 16962 to 20379 Section 6 Schematics June 2005 Hydraulic Schematic from serial number 20380 to 22565 Section 6 Schematics June 2005 Hydraulic Schematic from serial number 20380 to 22565 A B G H J K L M N REV PLATFORM ROTATE 262 uns M an i DX
329. 9 ME ct RED WHT 23 FLASHING BEACON iab 1 OPTION ig oA m cse ee el 18 83 255 R 8 E RED BLK 1 RED BLK 28 1 te T ie E T Wr 5 RED WHT 23 TILT SENSOR a 15 e g ul iu 2 i P 5 lo a ote ol HOUR METER m g p i manae cad I o m BLKRED9 _ BLK RED 3 BLK RED CR4 8 HORN RELAY m E g 8 i E BLK 22 gis m 7 2 m 5 GROUND CONTROL 9 iu 8 5 BOX GROUND sia aw a a gt N J Bike 9 BlK6 RED7 gt BLK7 58 B BN 578 Domus iro SOEE 4 a X OSE 25 mH a CONTROLLER FAULT 255 5 2 INDICATOR LED 12 5 lt d al gt I S Vas 248 ORG RED 42 BLK 2838 elit 5 2658 E Se ge PRUDENS amp ORG RED RED BLK R5 59 x s at 9 ORG RED 42 COIL PR1 GRN E amp amp BLU RED 1 m BLU RED 39 FAULT LED 6 29 8 E TB39 95 fa ___ SPEED INPUT 4 x9 1 ul i ee BLUWHT 2 INTERLOCK x 3 9 g
330. 9 5 5 25 5 5 8 5 5 s zs 5156 3 8 BPI ROTARY FLOW CONTROL DIAL lt au T 5 2 5 3 5 2m 1 8 5 110 CR6 DRIVE ENABLE RELAY lt a 5 9 S 8 jx amp i Rig 4121518 S 9 CR17 LOAD SENSOR RELAY 6 DER CR19A LOW VOLTAGE INTERRUPT BCI RELAY A 2 9 CR19B LOW VOLTAGE INTERRUPT BCI RELAY B 1 lt DP1 DRIVE JOYSTICK v GREEN A 1 L1 DRIVE ENABLE LED N RED L3 CONTROLLER FAULT LED A BLK RED B t 7 209 14 OVERLOAD LED _ FWD 9 49 5 LDS LOAD SENSOR MODULE REV 3 5 4 LVI LOW VOLTAGE INTERRUPT MODULE gt 5 Gi BATTERY CHARGE INDICATOR FOR LVI OPTION _ TS12 TS10 TS TS13 L 3 P2 EMERGENCY STOP BUTTON LVI BCI OPTION T T ROTATE SECONDARY PRIMARY EXTEND 1 HORN 4 1 TIME DELAY 1 Ba BENI TS1 AUXILIARY TOGGLE SWITCH HORN BLK WHT TS2 ENGINE START TOGGLE SWITCH G dom 5 HIGH LOW RPM TOGGLE SWITCH b 2 GN z bow 9 TS6 GLOW PLUG TOGGLE SWITCH NO E m 01 TS7 PLATFORM ROTATE TOGGLE SWITCH 8 DRIVE ENABLE FAULT LED L4 TS9 PLATFORM LEVEL TOGGLE SWITCH TS1 L TS2 AUXILIARY TS6 ENGINE TS4 LOAD P TS10 SECONDARY BOOM TOGGLE SWITCH POWER GN GLOW PLUG RPM LE
331. 98 BK 5 2 bag al 5 5 amp SR a 9 bg 6 CONTROLLER FAULT 5 i bog NDIGATOREEDI2 JE 2 S 4 C6B 25 CFILBK 5 BK2GA a pe E 4OR RD 885 C6B 39 CRS 59 1 BRAKE RELEASE C2P 2 C40LS OR C2B 2 4 z 3 RELAY CRS lt 1 bg p qnem 5 MOTOR MAIN Se T OR RD Pe CONTACTOR RELAY PRI 8 _ 5 OFF LMT SPD _ g 8 Fd A E bg E ul 6 12 1 BLWH INTERLOCK E a bog 2 9 9 E 3 C29JSH RD WH C1B 3 C6B 29 RD WH 1 Jig lt 5 Dd 5 1 59 1 6 4 C32JSL WH RD 6 C6B 32 WH RD POT LOW 14 i o 5 C31REV WH BK C1B 5 C6B 31 WH BK REVERSE 5 1 1 4 C30FWD WH C1B 4 C6B 30 WH FORWARD DIODE RETURN 9 8 OR RD 48V DC INPUT bg Nf 5 rt lt 3 lt ra 1 1 48V DC 8 28 WH CHARGER e D EE FE 55 ee 49V DC 929 5 1 ALTERNATOR a gt eb roy d 5 r 3 PRIMARY oe LIFT PUMP 85 2 ELE 1 AUXILIARY 1 LIFT PUMP 5 4058 P20BAT RD C7B 4 RD 20 is a
332. AD SENSOR OPTION AP1 F4 500 A F3 424V DC GROUND pec 48V DC 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 25 6 26 DRIVE ENABLE LIMIT SWITCH BRN 2 DRIVE ENABLE LED L1 22 21 2 2 kr BLK 7 TB13 Section 6 Schematics n 1 i 1 BLU RED 3 2 153 Electrical Schematic 2 45 25 from serial number 16840 to 17974 WHT 24 Em fet BLU WHT 12 12 BLU WHT 3 WHT 7 TB12 13 14 ORG RED 3 ORG RED 16 TP16 86 8 BRN 1 PLATFORM BRAKE RELEASE 17 CONTROL BOX TRAVEL ALARM A2 5 8 ORG BLK 1 GROUND B E gt BRAKE RELEASE a a N C COIL CR6 ES TB48 RED WHT 48 30 87 ka i TP41 BRAKE RELEASE N O COIL DRIVE ENABLE RED BLK R6 TS15 BRAKE RELEASE PRESSURE SWITCH PS1 RELEASE BRAKE STEER MANIFOLD GROUND BRAKE JACK BLU 1 8 P BLU 36 H RED STEER LEFT COIL JP1 REMOVE FOR CE VERSION BLU BLK 37 TB37 BLU BLK 1 7 STEER RIGHT COIL A TEREX COMPANY G TP
333. AY RELAY BLK WHT 34 E WHT J4 WHT J6 WHT J6 2 gt Se gt RED J6 RED J6 5 5 5 2 lt 2 3 gt gt t LE a E x 5 2 g 9 9 z amp 5 x 8 9 o o 5 5 oz xx a Y I p 55 T a N e 10 10 e 3 5 8 3 S amp WHT R14 2 5 52 8 5 BE a a a a BLK ISM 1 BLK ISM 1 gt BRN VOLT 5 BLU ISM2 BLU ISM2 BLK 33 BRN J5 BRN ISMS BRN ISMS RED ISM6 WHT 23 Ed arze u 59585 5 gt 55 GRN BLK BATT WHT ISM10 ENGINE HARNESS TO CHASSIS HARNESS a a 5 Soa ENGINE HARNESS nm E TO ENGINE e 5 8 e 29 lt MALE DEUTSCH 213 CONNECTOR 12V DC VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR RED PISM6 BLK WHT 34 BLK RED 35 CHASSIS HARNESS enie Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 14 June 2005 Section 6 Schematics P we _ Engine Panel Diagram from serial number 17975 to 21180 Section 6 Schematics June 2005 ETC
334. BK 2GA BK 2GA Sx BK 2GA RD 2GA M Be NOTES UND 4 1 ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED MOTOR CONTROLLER TEREX COMPANY 6 7 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics REV Power Cable Diagram from serial number 22051 to 23235 N M L K J F E D TO ENGINE PANEL TO GROUND CONTROL BOX CONNECTOR C6B 1 AC POWER CABLE LEFT SIDE DC AMMETER CABLE BATTERY PACK RIGHT SIDE BATTERY PACK DC ALTERNATOR g 2 2 BATTERY 5 lt CHARGER PRIMARY NEG E z LIFT PUMP 9 A1 7 SL E
335. BK R6 a BRAKE RELEASE PRESSURE SWITCH PS1 24 1 24 2 Rm C6B 36 BL STEER LEFT COIL CE VERSION DEI ee PS1 A TEREX COMPANY C36STCC BL C1B 10 lt C1P 10 G 7 C37STC BUBK 1 P oen m gt gt C6B 37 BL BK a Sy STEER RIGHT COIL 25 1 25 2 Electrical Schematic Z 45 25J CE Models C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK C40LS OR LVI BCI OPTION June 2005 C29JSH RD WH C32JSLWH RD C31REV WH BK C30FWD WH REVA C6B 38 GR WH OR BK R6 Z 45 25 Bi Energy Z 45 25J Bi Energy 1 2 3 4 5 6 7 9 10 lt 4 FWD e 2 DRIVE LR STEER P24BAT WH AUXILIARY PUMP 1 1 C27AUX RD C1B 1 TS1 RD AUX GR WH 330 PR2 OR RD C6B 19 PRIMARY LIFT PUMP 5 27 GRWH RELAY COIL PR2 BK OR RD RELAY COIL CR3 BCI OPTION AUXILIARY LIFT PUMP RELAY COIL 71771 LIFT PUMP gi GR WH 8 5 PartNo 106488 2 5 go z0 RD RD AUXILIARY CONTROL E 1 1 1 4 7 C19LPMP GR WH C4B 7 GR WH gt CONTACTOR RELAY 20 FLOW CONTROL COIL 87684431211 6 C6LFC WH RD
336. CH ae BLK WHT 784 HIGH LOW RPM TOGGLE SWITCH TS15 5 Sos 756 GLOW PLUG TOGGLE SWITCH nd SES du Sob OO TS7 PLATFORM ROTATE TOGGLE SWITCH 66 Jo TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 DRIVE ENABLE o9 TS9 PLATFORM LEVEL TOGGLE SWITCH Eg AUXILIARY ee Glow nie ENGINE gt TS10 SECONDARY BOOM TOGGLE SWITCH TI TS8 TS7 PLATFORM LEVEL START TS PRIMARY BOOM UP DOWN TOGGLE SWITCH JIBIBOOM ROTATE EMERGENGY TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH OFGINED 42 TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH yenie 6 107 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA F June 2005 5 Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option from serial number 13361 to 14078 E D
337. Contact with AWARNING electrically charged circuits could Pin 17 to B 500kQ or more result in death or serious injury Remove all rings watches and Pin 20 to B 500k or more other jewelry 4 52 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 5 Fault Codes 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 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 106488 TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 2 45 25 Bi Energy and Genie 2 45 25 Bi Energy Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate fault code thoroughly Attempting s
338. Control Box Terminal Strip Wiring Diagram 2 45 25 from serial number 14651 to 16839 REVA June 2005 45 25J D iring Ground Control Box Terminal Strip W from serial number 14651 to 16839 Section 6 Schematics Nua 2 Nua lt Nua 1 Zr NH8 2g i 9 5 50 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau eo 1 vru aau na 6 aau na V d U IHWNHO 61 IHWNHO bd 1 Suorig aau SS3NHVH d SISSVHO
339. D TS8 TS7 TS9 START PRIMARY BOOM UP DOWN TOGGLE SWITCH JIB BOOM PLATFORM ROTATE PLATFORM LEVEL 2 TS12 TURNTABLE ROTATE TOGGLE SWITCH vee TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORG RED 42 TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH Z Z 2 Z gt Z Z Z Z Z Z Z Z Z Z Z Z 2 Z Z Z Z Z Z Z gt DRIVE ENABLE TOGGLE SWITCH enie Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 Section 6 Schematics Y Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option from serial number 13361 to 14078 Section 6 Schematics June 2005 ___________ Platform Control Box Wiring Diagram 2 45 25 from serial number 14079 to 14650 Section 6 Schematics June 2005 mEm Q Platform Control Box Wiring Diagram Z 45 25 REVA from serial number 14079 to 14650
340. D 6 RELAY COIL AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP GRN AWHT 5 RELAY COIL PR2 PROPORTIONAL ROTARY OEM FLOW CONTROL TP18 GRN BLK 3 PLATFORM ROTATE GRN BLK 18 VALVE PLATFORM GRN 17 ROTATE RIGHT PLATFORM TB17 n GRN 3 WHT RED 6 TP17 ORG 3 PLATFORM LEVEL GRN WHT 19 PLATFORM LEVEL CUTOUT CE VERSION ONLY MAMA ROTATE LEFT PLATFORM LEVEL UP CUTOUT RELAY CR10A PLATFORM LEVEL TB14 UP PLATFORM LEVEL ORG 15 ORG BLK 3 TP7 BLK 3 PRIMARY BOOM BLK 7 DOWN PLATFORM LEVEL DOWN CUTOUT RELAY CR10B FUNCTION MANIFOLD GROUND PRIMARY BOOM d BLK WHT 8 EXTEND PRIMARY BOOM 1 a BLK WHT3 TP8 TP1 RED 3 PRIMARY BOOM RED 1 RETRACT PRIMARY BOOM RED BLK 2 UP PRIMARY BOOM 03 RED BLK 3 TP2 BLU 3 SECONDARY 11 10 BLU 10 DOWN SECONDARY BLU BLK 11 BOOM UP SECONDARY wank B BLU BLK 3 TP11 TP5 WHT BLK 3 TURNTABLE ROTATE RED TB5 WHT BLK 5 BOOM DOWN DESCENT ALARM OPTION TURNTABLE ROTATE RIGHT WHT 4 TURNTABLE TB4 n WHT 3
341. D RD TS55 FUNCTION ENABLE 14 1 14 2 GND BK BRAKE RELEASE TRAVEL ALARM BRAKE RELEASE N C COIL BRAKE RELEASE N O COIL BRAKE RELEASE PRESSURE SWITCH PS1 STEER LEFT COIL STEER RIGHT COIL AUXILIARY CONTROL 6 30 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PRIMARY LIFT PUMP RELAY COIL PR2 RELAY COIL CR3 AUXILIARY LIFT PUMP RELAY COIL PR3 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL Part No 106488 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B i i i PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL i i i i i PRIMARY BOOM UP COIL PRIMARY B
342. DARY BOOM COMPONENTS 39 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm Remove the compression link from the machine Crushing hazard The number 2 AWARNING arm could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane ACAUTION Crushing hazard The compression link may fall if not properly supported when removed from the secondary boom assembly 40 Remove the number 2 arm from the machine Crushing hazard The number 2 AWARNING 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 CAUTION Cables and hoses can be damaged if they are kinked or pinched Genie Z 45 25 Bi Energy Z 45 25J Bi Energy REV B 43 Open the ground controls side turntable cover 44 Remove the fuel tank filler cap 45 Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an
343. E DRIVE JOYSTICK GRND RED TET 35 N RED BLK 28 22120 S S mmm IEE IE IE 55 55552 PRSIESECESESESCRRss PS RA SE ee Ea ee cab BS BB SS RSS B AG 6 68 jg Ee ES 25 219 COMPONENT INDEX P CABLE CABLE TILT ALARM MET ui AC1 AC OUTLET BOX 5 ALARM gt BATTERY CHARGE INDICATOR BP1 BOOM PROPORTIONAL ROTARY CONTROLLER CR6 DRIVE ENABLE RELAY w m m 5 DdD 2 S o 00250 5 2 5 23 5 585 3 5 5 2 2 5 JIB BOOM CUTOUT RELAY 5 3 2 3 8 zs ME 2 22 2158 CR7B JIB BOOM VALVE RELAY S 9 x FEES 3 3 aoje 5 82 9 17 LOAD SENSOR RELAY LOAD SENSOR OPTION ONLY m 8 5 e le N 8 48 8 5 CR19A LOW VOLTAGE INTERRUPT BCI RELAY A LVI OPTION ONLY 6 DPI CR19B LOW VOLTAGE INTERRUPT BCI RELAY B LVI OPTION ONLY 4 4 n DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED S GREEN 5 10 L3 CONTROLLER FAULT LED RED Y 14 OVERLOAD LED LOAD SENSOR
344. E SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 Section 6 Schematics 2 Platform Control Box Wiring Diagram 7 45 25 with LVI BCI Option from serial number 14651 to 16839 Section 6 Schematics June 2005 _____________ Platform Control Box Wiring Diagram 2 45 25 from serial number 16840 to 17974 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25 REV A from serial number 16840 to 17974
345. ED oso BP1 BOOM PROPORTIONAL ROTARY CONTROLLER f WHT GRN WHT 24 55 DRIVE ENABLE RELAY GREEN 8 YEL 16 6 RED JIB BOOM CUTOUT RELAY 0 BLK RED pou 7 ES ale CR7B JIB BOOM VALVE RELAY 9 5 77 e PLU 28 1 DRIVE JOYSTICK 4 amp 9 WHT VEL eas fa DRIVE ENABLE LED 7 e MHURED Toy BLU 36 2 2 EMERGENCY STOP BUTTON TS12 TS10 TS11 TS13 Se BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 S mimm P3 HORN BLK WHT 006 TIME DELAY 1 x TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH BLK WHT HIGH LOW RPM TOGGLE SWITCH o gt TS6 GLOW PLUG TOGGLE SWITCH TS15 Do 5 Gd 2 1 EN Bad 9 OO R TS7 PLATFORM ROTATE TOGGLE SWITCH 6 Al a 7 989 pd YY 5 JIB BOOM UP DOWN TOGGLE SWITCH DRIVE ENABLE 29 TS2 7 LL TS9 PLATFORM LEVEL TOGGLE SWITCH T ON AUXILIARY CR eon ENGINE M lt TS10 SECONDARY BOOM TOGGLE SWITCH POWER uu 9 T5 TS ms C START PRIMARY BOOM UP DOWN TOGGLE SWITCH JIB BOOM PLATFORM ROTATE EMERGENCY TS12 TURNTABLE ROTATE TOGGLE SWITCH RED STOP TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TEREX COMPANY 6 113 Z 45 25 Bi Energy Z 45 25J Bi Energy Pa
346. G Part No 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 14651 to 16839 Section 6 Schematics June 2005 _____________ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 16840 to 17974 REVA June 2005 45 25 ing Diagram Ir Ground Control Box Terminal Strip W from serial number 16840 to 17974 Section 6 Schematics Nua 2 Nua lt Nua Z 2g i 9 59 68 Nua 934 Eola DR e eo SLND ee EAE 28 Weve 55 waviv dau eo 1 vru aau na 6 aau na V d U IHWNHO 6L IHWNHO bd
347. GA NOTES CHASSIS B M 1 ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED GROUND MOTOR CONTROLLER PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 8 June 2005 Section 6 Schematics I Power Cable Diagram from serial number 22051 to 23235 Section 6 Schematics June 2005 J fvi Engine Panel Diagram before serial number 13361 Section 6 Schematics June 2005 Engine Panel Diagram REV before serial number 13361 A B D E F G H WHT BATT 1 WHT 21 BLK RED 35 RED J1 BLK WHT 34 BRN VOLT ENGINE RPM START POWER CUTOUT RPM GLOW PLUG UL _ CR12 CR13 CR14 CR15 RED CB CIRCUT BREAKER ____ BLK ISM 1 i BROWN CHH CB3 2 24V 24V 24V 24V 24V 12V 15A BRN J1 BRN J2 BRN J3 BRN J4 WHT J1 BLK RD dM IGNITION START WHT J2 WHT J3 MODULE T 3 8 5 5 12 24V DC T 5 8 5 X I a a a 3 a 5 5 21 o a a zi dis
348. HT 8 5 1 PRIMARY BOOM St E o 4 7 EXTEND BLK 3 BLK WHT 3 RED 1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM 8 RED BLK 2 PRIMARY BOOM 1 RED 3 8 RED BLK 3 rele a TB10 BLU 10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL PRIMARY BOOM 2 BLU BLK 11 SECONDARY 11 DESCENT ALARM OPTION UP BLU 3 BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY WHT 4 RIGHT WHT BLK 5 TURNTABLE ROTATE 5 RED WHT BLK 3 WHT 3 2 2 ROTATE FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED BLU WHT 12 RED TS55 GND GND BRN WHT 24 ORG RED 42 June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 16840 to 17974 June 2005 Section 6 Schematics REVA Electrical Schematic 2 45 25 from serial number 17975 to 21180 8 5 3 E E El 1 5 E 1 gt s Eg d 8 i MERE E 5 JEBE 5 EE g 2 o 28 AE E
349. I ER SE Ad CABLE CABLE SWITCH E TIT m 2 1 en FS NOTES ALARM 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS 6 amp 7 ON THE DRIVE JOYSTICK t stet 9 eo e o 9 9 e9 9 9 9 9 9 9 2 m o 2 2 o lt 5 9 2 2 6 3 5 3 dE 9 9 2 955 5 8 ai GRN RED WHT 29 559558 8 3 8 R58 E RS 8 1515 PUB 5 84 9 9 9 WHT RED 32 ri a 8 e t 5 88 86 COMPONENT INDEX 7 4 WHT 6 a 23 1 TILT ALARM 4 e a gi 8 ACI AC OUTLET BOX REY RED 25 Sia x BATTERY CHARGE INDICATOR WHT GRN WHT 24 N 5 we De Soy BP1 BOOM PROPORTIONAL ROTARY CONTROLLER 9 RED lt a CR6 DRIVE ENABLE RELAY 5 PRPL 2 55 BLK RED 7 ARE ak CR7A JIB BOOM CUTOUT RELAY x d a e BLU Qs CR7B JIB BOOM VALVE RELAY A aight fogg BEUBER ST s DP1 DRIVE JOYSTICK o WHT RED BLU 36 L1 DRIVE ENABLE LED 7 7510 150 9 en L3 CONTROLLER FAULT LED BCI T T ROTATE SECONDARY BOOM PRIMARY BOOM EXT RETR BP1 S 222 BLK WHT S P2 EMERGENCY STOP BUTTON A RED P3 HORN TS1 AUXILIARY TOGGLE SWITCH BLK WHT TS2 ENGINE START TOGGLE SWITCH 13
350. IB UP PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL UP COIL DOWN COIL DESCENT ALARM OPTION A3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL BRN SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL NOTES 3 SECONDARY BOOM SECONDARY BOOM enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics Electrical Schematic Z 45 25J from serial number 13361 to 14078 REVA RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 June 2005 WHT 24 ORG RED 42 TS4 RPM RED FOOTSWITCH HIGH RPM BLK RED 1 RED BLU WHT 12 RED RED 5 6 IGNITION START MODULE START RELAY TACH INPUT START INPUT NOT USED GROUND BATTERY KEY SWITCH POWER NOT USED IGNITION ON WHT 2 AUXILIARY 1 2 3 4 5 6 7 8 9 10 ENGINE FAULT GND GND BRN GRN BLK BATT WHT BATT WHT 23 WHT IGINE GROUND EN BLK ISM1 BLU ISM2 BLK 33 HIGH LOW RPM RPM Ze TS2 BLK 1 TB35 BLK RED 35 BRN TP33 BL
351. ITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 11 48V DC POWER RELAY CR2 48V DC POWER RELAY 1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY HORN 14 E 11 1 6 10 1 m 10 4 WH 4 11 4 WH 7 KS1 o C2P 2 C40LS OR C2B 2 C6B 40 OR 10 3 BK 4 11 3 BK 7 21 M 22 OR SEC CONTROLLER FAULT INDICATOR LED L2 154 BK 5 OR RD C6B 25 CFIL BK P20BAT RD C1P 3 C29JSH RD WH C1B 3 a TB40 o 2 2 gt 7 CR5 9 RD BK 20 8 X COIL PR1 GR 4 17 OR RD C6B 24 OFF LIMIT SPEED INPUT C6B 22 OR C6B 12 BL WH INTERLOCK POT HI C6B 29 RD WH 16 C1P 6 C32JSL WH RD C1B 6 C6B 32 WH RD POT LOW 14 LOAD SENSOR MODULE BRN C1P 5 C31REV WH BK C1B 5 C6B 31 WH BK 1 REVERSE 11 GND 4 C30FWD WH C1B 4 C6B 30 WH 1 FORWARD B BK P25BAT WH FS __ 9 2 lt P24BAT WH BK 26 LOAD BK FS de P26BAT C9P 1 BK LOAD SENSOR OPTION P22BAT BK 1 ALLLIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3
352. K WHT 34 12V DC BLK WHT 1 GLOW PLUGS TS56 TB34 TS6 GLOW PLUGS TP25 TP24 ORG RED 42 TP34 ORG RED 1 ORG RED BRN lt lt BLK WHT BN 30 WHT J4 RED J10 12GA 85 86 WHT 21 BRN CR12 12V gj 21 WHT 23 WHT 21 STARTER CONTROLLER 5 2 NA RED WHT 3 B RED WHT 3 TB42 TB3 251 RED FS TP26 TILT ALARM RED BLK 1 i RED WHT 23 RED BLK 28 WHT 2 RED WHT 23 RED TP23 5 BLK RED 3 TB23 B ENABLE BLK RED 9 BLK 2 BLK RED 9 li BLK 22 TB22 RED FS FS1 WHT FS PLATFORM GROUND KS1 Ls4 SEC BLK 8 Ls2 RED 6 BLK 6 RED 8 D RED 20 BLU RED 1 21 ORG RED 42 I 50 21 PRI CONTROLLER FAULT INDICATOR LED L2 BLK 9 TB49 TB40 ORG RED i RED BLK RS 8 ORG RED 42 8 COIL PR1 GRN ORG 40 BLU RED 39 FAULT LED 9 29 RED WHT 1 TB39 OFF LIMIT
353. LE SWITCH JIB BOOM PLATFORM ROTATE PLATFORM LEVEL EMERGENCY TS12 TURNTABLE ROTATE TOGGLE SWITCH m STOP TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 7514 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Part No 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 116 June 2005 Section 6 Schematics SC ______ Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 17975 to 21180 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 21181 to 22050 REVA June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 21181 to 22050 Section 6 Schematics x 5 E g Ii Q 5 SE 2 5 lt 550
354. LK 26 LOAD 2 LOAD SENSOR OPTION AP1 F4 500 A F3 424V DC GROUND pec 48V DC 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 3 SWITCH SHOWN WITH BOOM EXTENDED NOTES Part No 106488 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 6 23 6 24 lt 3 ENABLE LIMIT DRIVE SWITCH BRN 2 22 BLU RED 3 TB13 21 I 2 z kr BLK 7 Section 6 Schematics d 1 1 153 BLU WHT 12 BLU WHT 3 WHT 7 RED 7 Electrical Schematic 2 45 25 from serial number 14651 to 16839 WHT 24 ORG RED 16 ORG RED 3 Bl TB12 13 14 Ao 16 PLATFORM BRAKE RELEASE CONTROL BOX TRAVEL ALARM A2 GROUND 85 2 CRG RED WHT 48 2 784 h 7 30 87 BRAKE RELEASE DARAANAN N C COIL BRAKE RELEASE N O COIL DRIVE ENABLE RED BLK R6 TS15 BRAKE RELEASE PRESSURE SWITCH PS1 RELEASE J BRAKE STEER MANIFOLD GROUND BRAKE JACK BLU 1 BLU 36 RED STEER LEFT COIL JP1 REMOVE FOR CE VERSION a TB37 BLU BLK 1 BLU BLK 37 5 1 STEER RIGHT COIL A TEREX COMPANY G TP37 RED WH
355. LK RD 55 5 m 1 1 ESS 2 529 87 87 87 87 87 87 85 86 85 86 BROWN CH H ov gs 87a 86 87 86 po 87a 86 87a 87 es 87a RED CB oe 30 30 30 30 CR16 CH12 CR13 CR14 CR15 FIELD RELAY START RELAY ENGINE POWER RPM CUTOUT RPM RELAY GLOW PLUG RELAY WHT J4 RELAY RELAY BLK WHT 34 g WHT J4 WHT J6 WHT J6 gt 4 zi RED J6 RED J6 5 5 Eu 3 Tr 22092 E 21215151512 5 2 a tr m lt 5 6 a 2 fe D 3 m amp x 5 E 9 2 5 526 5 B 8 oz xx Y I t I 6 8 N e 2 8 8 4 WHT R14 20905 55 2 E 5 a mc m c BLK ISM 1 BLK ISM 1 5 BRN VOLT 5 BLU ISM2 BLU ISM2 BLK 33 BRN J5 5 BRN ISMS BRN ISMS RED ISM6 WHT 23 5855 gt 2558 GRN BLK BATT 6 WHT ISM10 ENGINE HARNESS TO CHASSIS HARNESS 45885 ar ENGINE HARNESS PM E TO ENGINE x 51804 ELS X 5 8 q E 8 2 5 5 gt x r is 7 2 S MALE DEUTSCH 12V DC 2 VOLTAGE REGULATOR FEMALE DEUTSCH CONNECTOR 8
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358. NS Manifold Component REV Machine Torque Specifications Specifications Platform rotator Plug torque 1 8 center bolt grade 2 200 ft lbs 271 Nm SRE Nee Nm 1 8 center bolt grade 8 480 ft lbs SAE No 4 10 ft lbs 13 Nm 651 Nm SAE No 6 14 ftlbs 19Nm 3 8 16 bolts GR 8 44 ft lbs 60 Nm SAE No 8 38 ft lbs 51 Nm Turntable rotate assembly SAE No 10 41 ft lbs 55 Nm Rotate bearing mounting bolts lubricated 180 ft Ibs SAE No 12 56 ft lbs 76 Nm 244 Nm Drive motor brake mounting bolts dry 110 ft Ibs 149 Nm Valve Coil Resistance Specification Drive motor brake mounting bolts lubricated 80 ft Ibs Description Specification 108 Nm Solenoid valve 3 position 4 way 20V 251029 OQ Drive motor and hubs schematic items E H J K L M CC DD EE FF HH BB BD BE BF BG CB Drive hub mounting bolts lubricated 180 ft Ibs CD CE CF and CH 244 Nm Solenoid valve 2 position 3 way 20V DC 25 to 29 0 Drive motor mounting bolts lubricated 55 ft lbs schematic items N P AA BB BA Bu 75 Nm CA CK and CR Solenoid valve 2 position 3 way 20V DC 17 to 21 Q schematic item CR Solenoid valve 2 position 3 way 20V DC 25 to 28 Q schematic item DC Solenoid valve 2 position 2 way 20V DC 22 to 26 Q schematic items DA and DB Proportional solenoid valve 24V DC 17 to 21 0 schematic items G JJ BH and Cl Solenoid valve N C poppet
359. NTROL BOX GROUND TB22 SEC GROUND 154 BLK 8 RED 6 TB50 o 2B o TB49 2 9 5 lt 21 22 2 2 PLATFORM RED 8 INDICATOR LED L2 KS1 ORG RED 42 BLK i CONTROLLER FAULT 40 B BRAKE RELEASE RELAY CR5 ORG RED CR5 RED BLK R5 8 8 ORG RED 42 COIL PR1 gt 17 B MOTOR MAIN CONTACTOR RELAY ORG 40 1 OFF LIMIT SPEED INPUT F1 RED 20 INTERLOCK BLU WHT 12 E2 2 29 RED WHT 1 TB29 RED WHT 29 POT HI lt 2 aon lt 16 ie CURTIS 1244 SEPEX CONTROLLER B GROUND 14 TP31 WHT BLK 1 1 WHT BLK 31 REVERSE 11 i8 TP30 _ WHT 1 TB30 WHT 30 FORWARD 10 ORG GEN NEG ORG GEN POS F2 ORG RED 42 T TP32 32 WHT RED 32 POT LOW AC POWER R 48V INPUT 1 EL 24 DIODE RETURN g 1 1 1 1 WHT LOAD 9 BLK 48V DC CHARGER CHARGER 1 ORG LOAD 48V ALTERNATOR LOAD SENSOR BOX 10
360. OIL TURNTABLE ROTATE LEFT COIL June 2005 Section 6 Schematics eee See Electrical Schematic Z 45 25 ANSI and CSA Models from serial number 22051 to 23235 REVA C29JSH RD WH June 2005 Electrical Schematic Z 45 25 CE Models from serial number 22051 to 23235 Section 6 Schematics pg 1 1 1 z r o 2995 55 E NE E 5 52 51555 Fi S gc cr m ola 5 wl 5 8 8 58 A S zale sou 00 ESE S 1 29 lt lt 5 lt Sa 5 ol we sa x sE C5B 1 RD 99
361. ONDARY TB5 RIGHT WHT BLK 5 it WHT 4 LEFT TURNTABLE ROTATE RED 5 WHT BLK 3 WHT 3 8 5 ROTATE TP4 FUNCTION ENABLE RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED RED BLU WHT 12 RED TS55 GND GND BRN WHT 24 ORG RED 42 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL NOTES 6 46 a A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G Part No 106488 June 2005 Section 6 Schematics ae SEE Electrical Schematic Z 45 25J from serial number 17975 to 21180 June 2005 Section 6 Schematics REVA Electrical Schematic Z 45 25J from serial number 21180 to 22050 C29JSH RD WH C32JSL WH RD C31REV WH BK C40LS OR P24BAT WH C30FWD WH R42BAT OR RD FOOT SWITCH HIGH RPM TS2 9 C35HRPM BK RD C1B 9 P20BAT RD C12DRE BL WH P42BAT OR RD CRS START RELAY TACH INPUT START INPUT NOT USED GROUND BATTERY WH AUXILIARY GND KEY SWITCH POWER AP2 NOT USED RD IGNITION START MODULE 1 2 3 4 5 6 IGNITION ON 10 ENGINE FAULT 7 8 9 C5B 1 P20BAT RD GR BK WH BATT WH Ra ENGINE GROUND BRN ENGINE lt 7 lt
362. ONTROLLER FAULT INDICATOR LED L2 BLK TB40 ORG RED i RED BLK RS 8 ORG RED 42 8 COIL PR1 17 ORG 40 BLU RED 1 BLU RED 39 FAULT LED 9 29 OFF LIMIT SPEED INPUT BLU WHT 12 INTERLOCK RED WHT 1 RED WHT 29 POT HI TP32 WHT RED 1 WHT RED 32 POT LOW iz TP31 WHT BLK 1 WHT BLK 31 REVERSE a MOTOR CONTROLLER 11 TP30 WHT 30 FORWARD BLK LSTOP LOAD SENSE OPTION a RED 17 LOAD SENSE PCB 2 4 z s s 7 s fo n e Electrical Schematic 2 45 25 from serial number 14079 to 14650 Section 6 Schematics 10A CB1 amp ORG RED 42 DIODE RETURN g 10 ORG RED R2 48V INPUT 1 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH ALTERNATOR FIELD RELAY CR16 RPM CUTOUT RELAY CR13 RPM RELAY CR14 RPM SOLENOID GLOW PLUG RELAY CR15 GLOW PLUGS 12V DC ALERNATOR 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 ENGINE RUN SOLENOID STARTER RELAY 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY BASE CONTROL BOX GROUND B CR
363. OOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT ALARM OPTION A3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL June 2005 Section 6 Schematics Electrical Schematic 2 45 25 from serial number 21181 to 22050 June 2005 Section 6 Schematics REVA Electrical Schematic Z 45 25 ANSI and CSA Models from serial number 22051 to 23235 C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK C40LS OR P24BAT WH R42BAT OR RD FOOTSWITCH HIGH RPM 1 9 5 BK RD 1 9 C12DRE BL WH P42BAT OR RD RD RD IGNITION START MODULE START RELAY TACH INPUT START INPUT NOT USED GROUND BATTERY KEY SWITCH POWER NOT USED 1 2 3 4 5 6 7 8 9 IGNITION ON 10 ENGINE FAULT C5B 1 P20BAT RD WH AUXILIARY GND GR BK WH BATT WH ENGINE GROUND D LOW RPM __ E TS4 RPM HIGH RPM TS2 ENGINE C1P 7 C33STR BK C1B 7 BK ISM1 BL ISM2 C5B 5 C33STR BK HIGH TB35 TS54 RPM LOW S C5B 18 C35HRPM C5B 3 C23PWR WH gt CR16 BRN ENGINE START TS52 TB33 START TS6 GLOW C1P 8 C34SA BK WH 1 8 C5B 22 C34SA BK WH C5B 2 GLOW PLUGS TS56 TB34 PLUGS C9P 3 RD FS WH FS
364. OR LOAD P22BAT BK C7P 1 3 2 PAG C BKLOAD 8 oli C19LPMP GR WH 7 C18PRR GR BK 6 ug x 2 C17PRLGR 5 E C8PBR BK WH C16DRE OR RD 4 4 is C15PLD OR BK C4P 3 C14PLU OR 2 C13DREL BURD 1 i gt E Su gee C12DRE 12 9 ak 229 i C11SBD BLBK 11 d as 71 Teen groma poma C9HRN BK RD 9 C8PBR BK WH 8 7 7 x 1 1 gt 1 C6LFC WH RD C3P 6 C4P BR gt C17PRLGR C5TRR WH BK 5 amp e C4TRL WH 4 558 C18PRRGRIBK 5 Se RD WH C3P 3 SEN ga C OR RD C2PBD RD BK 2 C3P GR C11SBD BL BK C1PBU RD lt 1 cap 1 C10SBU BL lt 4 C4TRL WH C2P BK 6 aw R42BATOR RD _ lt 2 4 55 R41DRE OR BK 2 3 5 FEO E 1 C37STC C1P 11 CIP GY 71 1 1 5 WH BK C36STCC BL 10 _ 1 9 CIDBEUBURD C34SA C1P 8 6 C33STR BK 7 C32JSL WH RD C1P 6 1 BK WH DRE rs C31REV WH BK 5 RD DRE nis
365. ORM LEVEL PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B 2 C4B 2 4 3 C15PLD OR BK C4B 3 m 2 5 7 PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL 16 1 16 2 C6B 7 BK 0 C6B 8 BK WH IA t PRIMARY BOOM C17 1 C182 TB8 C3P 7 C7PBE BK C3B 7 C3P 8 C8PBR BK WH C3B 8 TB1 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL C6B 1 RD C12 1 12 2 i C6B 2 RD BK C13 1 13 2 PRIMARY BOOM TB2 PRIMARY C3P 1 C1PBU RD C3B 1 C3P 2 C2PBD RD BK C3B 2 TB10 C18 1 C18 2 4 SECONDARY BOOM UP COIL I SECONDARY BOOM DOWN COIL UP a C6B 10 BL C6B 11 BL BK amp C19 1 C192 SECONDARY TB11 DESCENT ALARM OPTION A3 SECONDARY 10 C10SBU BL C3B 10 11 C11SBD BUBK C3B 11 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL TBS 9 9 S C6B 5 WH BK
366. OWER TS9 GLOW PLUG START RPM 57 911 PRIMARY BOOM DOWN TOGGLE SWITCH PLATFORM ROTATE EMERGENCY TS12 TURNTABLE ROTATE TOGGLE SWITCH RED TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH A TEREX COMPANY 6 97 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 REVA June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25 with LVI BCI Option from serial number 16840 to 17974 D RED BLK R6 B
367. Od Q3H Q PT HOLIMS 15 1951 6 64 Z 45 25 Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 17975 to 21180 Section 6 Schematics June 2005 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 21181 to 22050 REVA June 2005 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 21181 to 22050 Section 6 Schematics
368. P GRN WHT 19 2 GRN BLK 18 GRN 17 CONTROL BLK RED ROTARY OEM FLOW 1 JIB BOOM 17 a GRN BLK 3 WHT RED 6 h GRN 3 JIB BOOM CR7A 30 eel 17 CR7A 86 gt 85 RED PLATFORM ROTATE PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY GROUND PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PLATFORM LEVEL JIB MANIFOLD PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B UP ORG 3 MANIFOLD FUNCTION GROUND ORG BLK 3 PLATFORM LEVEL EXTEND p PRIMARY BOOM EXTEND COIL PRIMARY BOOM RETRACT COIL PRIMARY BOOM St 2 gt 4 TP7 BLK 3 BLK WHT 3 PRIMARY BOOM 8 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL PRIMARY BOOM 1 RED 3 RED BLK 3 PRIMARY BOOM 2 TB10 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL SECONDARY BOOM 11 DESCENT ALARM OPTION A3 UP BLU 3 BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL SECONDARY TB5 RIGHT WHT BLK 5 it WHT 4 LEFT TURNTABLE ROTATE RED
369. POS RD 2GA aig lt 2 Bs 5 AUXILIARY LIFT PUMP 5 BK 2GA amp D1 BK 2GA E 3 RD 2GA 1 RD 20 12GA 1 i WH FROM CHARGER P42BAT OR RD 4 25 F5 10 BK 2GA BK 2GA 4 BK 2GA BK 2GA zz TOP VIEW OF AUXILIARY POWER UNIT DRIVE DRIVE CONTACTOR CONTACTOR c a CY 4 BATTERY 5 U d H AMMETER zl L 2 W DIOD DIODE 5 H m F H CHARGER i M5 e PLUG 5 g c H 5 HH CONTROLLER PR 3 KO E 9 LIFT 4 R42BAT OR RD 5 lt CONTACTOR R42BAT OR RD R42BAT OR RD 3 5 BRN J8 BRN J8 55 F4 Papas lt lt 8 lt i R27AUX RD RD BK BK BK BK RD 2GA RD 2GA RD 2GA lt 6 A RD 10GA RD 10GA 24V DC lt 2 i o 4 DI F1 NPS 200 200 RD 10GA 5 RD 2GA re 4 204 4 7 N e A2 o 24 23 2221 20 19 18 17 16 15 14 13 11 9 18 17 16 5 14 131211 RD 2GA amp o F1 T T F2 Q RD 10GA Es i 5 E 5 5 9 2 3 885 B 852 BK 2GA RIGHT SIDE 8 LEFT SIDE BK FROM CHARGER RD 10GA DRIVE MOTOR DRIVE MOTOR E E eX RD 10GA BRN J8 BK 2GA BK 2GA amp RD 2
370. Part No 106488 Genie ee CHECKLIST D PROCEDURES Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub Repeat steps 1 through 5 for the other drive hub Z 45 25 Bi Energy Z 45 25J Bi Energy 3 33 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 5 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 1 Locate the hydraulic return filter next to the hydraulic tank 2 Place a suitable container under the hydraulic filter 3 Remove the filter with an oil filter wrench 4 Apply a thin layer of oil to the new oil filter gasket 5 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 6 Turn the key switch to ground controls and pull out the red Emergency Stop button out to the on position at both the ground and pl
371. QW p i 2 BRAKE RELEASE RD WH TRAVEL ALARM A2 26 1 26 2 C6B 35 RD WH s 1 BRAKE RELEASE e e OR BK C2B 3 o caps ews RD WH N C COIL 6 BRAKE RELEASE PRESSURE SWITCH PS1 24 1 24 2 C6B 36 BL STEER LEFT COIL CE VERSION PS1 A TEREX COMPANY C36STCC BL C1B 10 gt lt 4 C1P 10 G 7 C37STC BUBK 1 m gt gt C6B 37 a So STEER RIGHT COIL 25 1 25 2 C29JSH RD WH C32JSL WH RD C30FWD WH C31REV WH BK C40LS OR Electrical Schematic Z 45 25J ANSI and CSA Models LVI BCI OPTION June 2005 C29JSH RD WH C32JSLWH RD C31REV WH BK C30FWD WH REVA C6B 38 GR WH OR BK R6 Z 45 25 Bi Energy Z 45 25J Bi Energy n 2 3 4 5 6 7 9 10 4 4 4 v FWD e 2 DRIVE STEER P24BAT WH AUXILIARY PUMP 1 1 C27AUX RD gt TS1 RD AUX GR WH 330 a PR2 OR RD C6B 19 PRIMARY LIFT PUMP 5 27 GRWH RELAY COIL PR2 D AUXILIARY CONTROL RELAY COIL CR3 OR RD AUXILIARY LIFT PUMP RELAY COIL 771 LIFT PUMP CONTACTOR RELAY CR20 FLOW CONTROL COIL BCI OPTION
372. R RD C12DRE BL WH RD C5B 1 P20BAT d IGNITION START MODULE START RELAY TACH INPUT KEY SWITCH POWER START INPUT NOT USED GROUND BATTERY NOT USED 2 3 4 5 6 7 8 9 IGNITION ON 10 ENGINE FAULT WH GND BK AUXILIARY PR2 AP2 C1B 7 HIGH TB35 BK ISM1 BL ISM2 GR BK WH BATT WH I ENGINE GROUND BRN 5 5 C33STR 7854 RPM LOW 5 858 4 BRN 4 C5B 3 C23PWR WH 5 18 C35HRPM Pi 2 8 ENGINE START TS52 C1P 8 C1P 7 gt C33STR C34SA BK WH C1B 8 C5B 22 C34SA BK WH 12V DC C5B 2 2 GLOW PLUGS TS56 TB34 C2P 4 R42BAT OR RD C2B 4 WH J4 ALT BRN RD J10 1264 12V DC P24BAT WH 9 2 C3P 3 C3BAT RD WH C3B 3 C5B 11 C21IGN2 WH C23PWR WH gt WH FS ALARM TILT Al C1P 2 C28TTA RD BK 2 P23SWBAT WH C1B 2 lt RD BK RD WH C6B 28 RD BK WH C7B 2 C6B 34 RD RD le HORN C3P 9 C9HRN BK RD C3B 9 BK RD C8 A 1 ers BRN 1 1 1 BRN H TB22 BK lt GROUND
373. RLOAD LIMIT SWITCH L4 PLATFORM OVERLOAD LED L48 TILT ALARM LED enie 6 103 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics REV A Platform Control Box Wiring Diagram Z 45 25 with LVI BCI Option from serial number 22051 to 23235 N L K J H G F E D C B A Ce ey WH gt i OR RD LVI 1 1 _ OR 92 a ens OR BK ES ORRD 5 1 1 WH WH 96 RESET IS SET TO B BRN RELAY LaL DISCHARGE IS SET Lol CR6 CR7 CR19A CR19B 2 88 982658 bd EIE ZS SS EE ols 5 3 gt 9 lt lt Dr I 2 H i E i A 1 d 3 MEN NT 9 9 8 1 1 Q ie olo ala ed IS 1 19 EX 4 1 gt 515 gt 5 E
374. RN LVJ RESET IS SET ORG BLK R6 8 7 6 5 4 3 2 1 DISCHARGE IS SET TO ORG BLK 41 Om 9 19 9 BRN LVJ 88 E 9 p 5 5 5 ss B BE i 88 E E lt lt 8 c e DS m 3 2 ORG RED 16 ORG RED 16 BLU LR19A ORG RED LV42 8 2 0 9 ORG BLK 41 ORG BLK 41 3 9 BLU L10 BLU L10 WHT LV24 J WHT L6 WHT L6 S lt 557 49952 2 222 9 2 8 gt gt m rr mmc zi gt m mm 21 22czsagomm fm ald S r 2 7 90 5 5 Seeka 5 5 5 5 25 6 aces 8 5165 15 15 0 x 62 2 8 22024 RED LR19B lt 15 2 9 2 5 4 25201250 E dm lt aay al ig B SB 2 E 5 D 5 2 m 2 5 RED TILT D GRND BRNA VI RED BLK 28 20 m um l l lololo 0 0 w IJ w om
375. RPM CUTOUT RELAY CR13 BLK RED 35 HIGH RPM RPM RELAY CR14 T 188 1 BRN quc 2 1 BLK RED BLK WHT 34 5 lt lt RPM SOLENOID ENGINE START TS2 30 R15 87 12V GLOW PLUG RELAY CR15 GLOW PLUGS 8 0000 TB34 GLOW BLKWHT PLUGS 87 55 90090 GLOW PLUGS TS56 n TP34 BLK WHT 1 TS6 12V DC ALERNATOR WHT J4 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 21 RED J10 12GA E ast 6 2 2 12V WHT 21 ENGINE RUN SOLENOID 25 TP24 STARTER RELAY CR11 15A STARTER WHT 23 WHT 21 ORG RED 42 ORG RED 1 m ORG RED 4 m e B TP42 TB42 48V DC POWER RELAY CR2 TB3 RED WHT 3 RED WHT 3 RED WHT 3 o I 48V DC POWER RELAY CR1 i8 RED FS WHT FS FLASHING BEACON OPTION RED WHT 23 FS1 p TILT ALARM RED 1 RED BLK 1 WHT 2 RED BLK 28 RED WHT 23 BLK FS TILT SENSOR 8 TP26 TP23 ENABLE BLK HOUR METER LOAD SENSOR OPTION SEE DETAIL BLK RED 9 RED 8 1 BLK RED 9 BLK RED 3 ut HORN RELAY BLK 22 BASE CO
376. S 10 BLACK 2GA BLACK 2GA BLACK 2GA RED 2GA bd rj DIODE SH DIODE AP 1 aca AMMETER 2 LIFT CONTACTOR DRIVE CONTACTOR Send rs CHARGER 5 PR 2 PR 1 contactor PH 3 PLUG BI ENERGY 5 H MODELS ONLY 2 t i ORG RED 42 2 ORG RED 42 ORG RED 42 lt amp amp 5 BRN J9 BRN J9 5 9 8 5 i RED 27 RED 27 al a 9999 RED 2GA dada BRNIE RED 20 12GA 6 RED 2GA RED 2GA 5 2 RED 10GA RED 10GA a 24V DC 48V n 85 E F2 200A 1 200 RED 10GA 8 RED 10GA RED 2GA 5 1 eek 5 At 9 24123 22121 20 19 18 17 16 15 14 13 12 111019 8 7 6 5 4 3 2 1 955 RED 2GA 5 E2 1 S RED 10GA 5 3 a 3 288 2 1 9 x g z g 2 BI ENERGY MODELS ONLY 2 5 8 J BU GE z a BLK 2GA 8 BLACK FROM CHARGER HED 0G 21 RIGHT SIDE DRIVE MOTOR BLK 2GA m 9 BRN J8 BLK 2GA BLK 2GA e BLACK 2GA EM RED 2GA W eI NOTES CHASSIS GROUND 9 M B MOTOR CONTROLLER 1 ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED Genie PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 6 June 2005 Section Schematics eee Power Cable Diagram from serial number 16840 to 21179 Section 6 Schematics June 2005 Power Cable Diagram from serial number
377. SCHARGE 4 O SET TO N E BCI 7 C19LPMP GR WH OR RD C6B 38 GR WH GR WH OR RD 25 1 25 2 330 PR2 C6B 19 x 5 x 5 z POWER 2 86 85 GR WH C4B 7 GR WH eS CR3 30 2 5 21 RESET TO CR19A 85 BRN 86 CR19B 1 RD BRN cA C3P 6 C6LFC WH RD C3B 6 WH RD 1 TB19 TB6 C6B 27 PR3 RD GR WH C6B 6 WH RD ROTARY OEM FLOW CONTROL 4 6 C18PRR GR BK TB18 1 C6B 18 GR BK C6B 17 GR PLATFORM ROTATE 17 C4B 6 GR BK C4P 5 C17PRL GR C4B 5 GR 2 C14PLU OR C4B 2 TB14 C6B 14 OR 6 15 OR BK 20 1 B 20 2 PLATFORM LEVEL 15 4 3 C15PLD OR BK 4 3 PRIMARY C3P 7 C7PBE BK C3B 7 EXTEND TB7 C6B 7 BK C21 1 C21 2 d C6B 8 BK WH C16 1 C162 BOOM _1863 8 C3B 8 CR19A 1 C1PBU RD C3B 1 TB1 C6B 1 RD C17 1 C18 2 C6B 2 RD BK C12 1 C12 2 PRIMARY BOOM TB2 30
378. SES SSS Ole zee 8 222 la D h S 1515 2 1 B SB BP RS RS RA RIS 56 N Foor 60 64 JEJE AY XE 23 1 CABLE CABLE POWER SWITCH 5 T 2 my ES ALARM NOTES S 1 ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES 2 FOR LIFT DRIVE SELECT OPTION REMOVE JUMPER BETWEEN TERMINALS A amp B ON THE DRIVE JOYSTICK m m 5 lt lt 2 jojo o lp w 2 5 5 1213238 i 5 5 Es 8 54 2 5 9 B S 3 215 i3 BIBIT 2 58 gt 5 55 5 5 EIB EROS 5 a amp 9 bi 8 5 5 Big 6 55 COMPONENT INDEX 4 4 L TILT ALARM lt ACI AC OUTLET BOX o GREEN see 16 BATTERY CHARGE INDICATOR 9 RED BP1 BOOM PROPORTIONAL ROTARY CONTROLLER OPO 2O BLK RED B to DRIVE ENABLE RELAY ENS c DPI DRIVE JOYSTICK pop 9 P lt gt 1 DRIVE ENABLE LED 7 R 5 CONTROLLER FAULT LED TS12 TS10 TS11 TS13 L LEFT 5 e BCI T T ROTATE SECONDARY BOOM PRIMARYBOOM EXT RETR BP1 BATTERY CHARGE INDICATOR FOR EVEOPTION J P2 EMERGENCY STOP BUTTON HORN TS1 AUXILIAR
379. SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 4 ALLSOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 6 31 Section 6 Schematics June 2005 Electrical Schematic Z 45 25 ANSI and CSA Models REVA from serial number 22051 to 23235 C29JSH RD WH C29JSH RD WH C13DREL BURD C4B 1 BRN C7P 3 BATGND BRN SWITCH DRIVE ENABLE LIMIT 3 BATGND BRN BL RD C6B 13 C13DREL 22 21 BK 8 BRN 8 Cel B 21 DREGND BRN C12DRE C3B 12 BL WH C6B 26 C12DRE 1 153 WH 8 RD 8 C16DRE OR RD C4B 4 12 OR RD C6B 16 C16DRE 13 14 BRN D CE VERSION R41DRE OR BK C2B 3 C6B 35 RD WH RD WH C26 1 C26 2 RD BK R6 C32JS8L WH RD C32JSL WH RD C30FWD WH LVI BCI OPTION C30FWD WH C31REV WH BK C31REV WH BK C40LS OR C40LS OR OR BK R6 C2P 3 C36STCC BL C1B 10 RD WH PS1 C6B 36 BL C1P 10 C37STC BL BK C1B 11 C6B 37 BL BK C24 1 Il C24 2 P24BAT WH DP1 20K ew moea AUXILIARY PUMP 1 1 11 C27AUX D BCI OPTION OR RD DI
380. SWITCH AUXILIARY ane 1 GLOW PLUG ENGINE i TS10 SECONDARY BOOM TOGGLE SWITCH POWER TS9 START NN EU B TS PRIMARY BOOM UP DOWN TOGGLE SWITCH EMERGENCY STOP TS12 TURNTABLE ROTATE TOGGLE SWITCH RED TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORG RED 42 TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH enie TEREX COMPANY 6 109 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA June 2005 F E C Section 6 Schematics J J 5 Platform Control Box Wiring Diagram Z 45 25J with Platform Load Sense and LVI BCI Option from serial number 14079 to 14650 D B A
381. SWITCH SHOWN WITH BOOM EXTENDED 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED NOTES RD FS C9P 8 oe 10 P20BAT RD 10 DIODE RETURN 48V INPUT 4 OR RD 152 21 PRI BK2GA 1 BASE CONTROL BOX GROUND Part No 106488 CHASSIS GROUND F1 30 CR16 CURTIS 1244 SEPEX CONTROLLER B OR GEN NEG OR GEN POS F2 AC POWER P42BAT OR RD C6B 3 C7B 4 BK AP1 BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 48V DC CHARGER 48V DC ALTERNATOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 6 47 Section 6 Schematics June 2005 Electrical Schematic Z 45 25J from serial number 21180 to 22050 REVA C29JSH RD WH C29JSH RD WH lt 1 C13DREL C4B 1 BRN C7P 3 BATGND BRN DRIVE ENABLE LIMIT SWITCH C7B 3 BATGND BRN BURD C6B 13 C13DREL BRN 8 C6B 21 DREGND BRN C3P 12 C12DRE BL WH C3B 12 lt lt 4 4 C16DRE OR RD C4B 4 C6B 26 C12DRE BLWH gt TB12 OR RD C6B 16 C16DRE 86 CE VERSION RD BK R6 TS15 CR6 R41DRE OR BK ws C2B 3 RD WH 35 RD WH C27 1 27 2
382. T 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 10 Z 45 25 Bi Energy Z 45 25J Bi Energy GRN WHT 19 AUXILIARY PUMP RED 1 6 85 RED Bi AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 REVA RED 27 ey d TP27 AUXILIARY LIFT RED PUMP RELAY COIL TB19 9 a A RELAY COIL 1 i 1 1 1 19 GRN WHT 8 LIFT PUMP RELAY COIL PR2 FLOW CONTROL COIL WHT RED 3 WHT RED 6 TP6 RED BRN 187 Part No 106488 PLATFORM ROTATE RIGHT GRN WHT 19 2 GRN BLK 18 GRN 17 PLATFORM ROTATE LEFT OEM FLOW CONTROL BLK RED PLATFORM ROTATE 17 18 GRN BLK 3 WHT RED 6 GRN 3 PLATFORM ROTATE 17 PLATFORM LEVEL CUTOUT UP RELAY COIL CR10A PLATFORM LEVEL CUTOUT CE VERSION ONLY PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL 1 TB14 qmi PLATFORM LEVEL ORG 15 PLATFORM LEVEL CUTOUT DOWN RELAY COIL CR10B FUNCTION MANIFOLD GROUND UP ORG 3 i ORG BLK 15 ORG BLK
383. T 811 2 1221 Tom m gt 4 5 RIS 8 gt gt io ie cic 2 lt 2 22 919 2 8 lt 5 288 354 1985 1815 5 2 m c 8 5 J Ox B Rens 555 65 lt 2 RED TIME 9 4223 45 zr z m 2 lt GRN WHT JOYS S 5 5 Q 4 GRN WHT R12 g 2 x zi BRN J7 RED STOP add 5 5 5 55 5 2 55 28 NOTES 10 10 0 10 0 RED BLK 28 apasssppesssseoopoooo BszmspmmmssssessssePPBISSO9SS99 9 ALL WIRES WITHOUT LABELS ARE pere WHT 5 55 5 2 2 5255 IS S 2S ISIE IS ISS 5 5 5 22 9255 EITHER RED OR BLACK JUMPER WIRES BLK S D 5 B 5 9 gt gt km ES m RES FOR LIFT DRIVE SELECTOR OPTION ES AC N 2 54 60 eer ng SE M TAKE OFF JUMP BETWEEN 6 amp 7 CABLE 5 e T m INS ALARM COMPONENT INDEX gt TILT ALARM
384. TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN BATTERY IGNITION START MODULE 1 2 3 4 5 6 7 8 9 GRN BLK BATT RED 5 6 WHT BATT WHT 23 WHT GROUND WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH BRN FOOT SWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 B ALTERNATOR FIELD RELAY CR16 TP35 HIGH TB35 Ye BRN L LOW RPM TS4 RPM RPM CUTOUT RELAY CR13 BLK RED 35 HIGH RPM RPM RELAY CR14 T 1 1 1 BRN E 1 BLK RED BLK WHT 34 5 lt lt 8 RPM SOLENOID ENGINE START TS2 30 R15 87 12V GLOW PLUG RELAY CR15 GLOW PLUGS 0000 TB34 GLOW BLK WHT PLUGS IS 9707 GLOW PLUGS TS56 n TP34 BLK WHT 1 TS6 12V DC ALERNATOR WHT J4 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 12V 21 RED J10 12GA E ast 6 2 2 WHT 21 ENGINE RUN SOLENOID 25 TP24 STARTER RELAY CR11 15A STARTER ORG RED 42 ORG RED 1 ORG RED WHT 23 WHT 21 B 4 e TP42 TB42
385. TARTER RELAY 11 48V DC POWER RELAY CR2 48V DC POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR HOUR METER HORN RELAY HORN Bko 9 BK 11 4 WH 7 gt C6B 40 OR 10 3 4 11 3 BK 7 CONTROLLER FAULT INDICATOR LED L2 JOR RD gt C6B 25 CFIL BK 154 4 4 CT C6B 39 CR5 RD BK 21 22 SEC a GR X COIL PR1 OR RD 4 C6B 22 OFF LMT SPD INP 17 C6B 29 24 1 C6B 12 BL WH INTERLOCK RD WH POT C32JSL WH RD C1B 6 C6B 32 WH RD POT LOW C31REV WH BK C1B 5 C6B 31 REVERSE C30FWD WH C1B 4 C6B 30 FORWARD P20BAT RD CB1 10A e re P20BAT RD C7B 4 P42BAT OR RD C6B 3 DIODE RETURN ev INPUT OR RD PR1 U6A MOTOR CONTROLLER 5 BASE CONTROL BOX GROUND CHASSIS GROUND 2 F1 30 cR16 OR GEN NEG OR GEN POS F4 500A AC POWER WH BRAKE RELEASE RELAY CR5 MOTOR MAIN CONTACTOR RELAY PR1 SWITCH SHOWN WITH BOOM EXTENDED 48V DC CHARGER PRIMARY F5 10A F2 200A 24V DC BK AP2 AP1 GROUND LIFT PUMP AUXILIARY PUMP NOTES gt ADD 040 ONLY IF UNIT HAS 14 AND 148 gt ANSI CSA 1 ALL LIMIT SWITCHES
386. TIME DELAY 1 ORG BLK R6 Ti ORG BLK 41 BRN J4 8 B 2 5 5 v s 5 RED TIME I 2 ORG RED 16 ORG RED 16 7 4 2 5 ORG BLK 41 ORG BLK 41 5 2 5 E 2 amp cs 9 3 3 oo 22 Do gt gt 5 565 x 59 92 2 8 RED TIET a 55 aS 5 2 E a 55 8 9 54 55 519 m 3 Sg 5 8595195 2 Fla RED TIME 21511121009 4 am m ms E m I 5 GRN WHT JOYS 3 3 9 4 GRNAWHT R12 GRND RED STOP DDD dW mmm 28 S S 589 im im SSSR RED JIB wi VISRARRS SS 5 222 5 51445 55256 55999 lt lt BROWN GRND mes 2B
387. TOR T DRIVE CONTACTOR 2 AUXILIARY POWER bp 3 CHARGER 5 PR 1 UNIT CONTACTOR i EPUG le 5 BI ENERGY x MODELS ONLY M 9 lt 4 ORG RED 42 lt ORG RED 42 ORG RED 42 8 lt 55953 BRN J9 BRN J9 xig amp 5 g RED 27 RED 27 CN Q e 0999 RED 2GA mur zog BANS RED 20 12GA 6 5 RED 2GA RED 2GA 5 6 RED 10GA RED 10GA n 24V DC o 2 200 F1 200A RED 10GA 8 RED 10GA RED 2GA E 8 7 dk 8 X E A2 1 9 24 23 22 21 20 19 18 17 16 15 14 13 S 8 12 11 10 9 8 7 6 5 32 1 955 RED 2GA 1 9 8 E2 Q RED 10GA 213 89 288 9 1 1 e 2 BI ENERGY MODELS ONLY Ele Se 586 25 J BLK 2GA 4 BLK 2GA 8 BLACK FROM CHARGER FAN RIGHT SIDE DRIVE MOTOR BLK 2GA 22 92 BRN J8 BLK 2GA BLK 2GA C BLACK 2GA RED 2GA 9 o NOTES CHASSIS GROUND B M OJ MOTOR CONTROLLER 1 ALL WIRE IS 16 GAUGE UNLESS OTHERWISE SPECIFIED Geni 6 5 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics
388. TS 13 Remove the hose clamp at the pivot end of the boom 14 Attach a 5 ton 5 000 kg overhead crane to the center point of the primary boom 15 Attach a similar lifting device to the primary boom lift cylinder 16 Place support blocks under the primary boom lift cylinder 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom lift cylinder and primary boom will fall if not properly supported 18 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 19 Remove the pin retaining fasteners from the primary boom pivot pin 20 Remove the primary boom pivot pin with a soft metal drift then carefully remove the primary boom from the machine and place it on a structure capable of supporting it Crushing hazard The primary AWARNING boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS How to Disassemble the Primary 6 Boom Complete disassembly of the REV B Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube Use a soft metal drift to remove the pin boom is only necessary 7 Support and slide the extension cylinder out of if the outer or inn
389. TS Z 45 25J 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The jib boom AWARNING 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 AWARNING 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 Genie Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 9 Section 4 Repair Procedures June 2005 Primary Boom Components 4 1 Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables
390. TS10 TS TS13 12 SECONDARY PRIMARY EXTEND S zz P2 EMERGENCY STOP BUTTON LVI BCI OPTION BOOM BOOM RETRACT BLK WHT P3 HORN A RED Ti TIME DELAY 1 TS1 AUXILIARY TOGGLE SWITCH BLK WHT TS2 ENGINE START TOGGLE SWITCH 55 6 amp HIGH LOW RPM TOGGLE SWITCH 2 TS6 GLOW PLUG TOGGLE SWITCH Sad C O 2 TS7 PLATFORM ROTATE TOGGLE SWITCH 8 DRIVE ENABLE 16 0 TS9 PLATFORM LEVEL TOGGLE SWITCH P3 AUXILIARY TS6 ENGINE TS10 SECONDARY BOOM TOGGLE SWITCH HORN POWER 157 192 C START 511 PRIMARY BOOM DOWN TOGGLE SWITCH L1 PLATFORM PLATFORM P2 ROTATE LEVEL EMERGENCY TS12 TURNTABLE ROTATE TOGGLE SWITCH RED STOP TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 4 Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 100 June 2005 Section 6 Schematics ___________ Platform Control Box Wiring Diagram 2 45 25 with LVI BCI Option from serial number 17975 to 21180 Section 6 Schematics June 2005 mEEE Ja Platform Control Box Wiring Diagram Z 45 25 from serial number 21181 to 22050 REVA June 2005
391. TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH PartNo 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy 6 114 June 2005 Section 6 Schematics Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 16840 to 17974 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram Z 45 25J from serial number 17975 to 21180 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25J from serial number 17975 to 21180
392. Test the Drive Speed Raised or Extended Position 3 22 B 15 Testthe Alarm Package if equipped 3 22 B 16 Testthe Turntable Rotation 2 40 4 0 0 3 23 B 17 Check the Electrical 3 24 B 18 Perform Hydraulic Oil 3 24 B 19 Perform Engine sess resurssoinnin 3 25 Checklist C Procedures C 1 Perform Engine Maintenance 00 3 26 C 2 Grease the Platform Overload Mechanism if equipped 3 26 C 3 Test the Platform Overload Mechanism if equipped 3 27 4 Perform Engine Maintenance 10 3 29 Checklist D Procedures D 1 Check the Primary Boom Wear 3 30 0 2 Check the Turntable Rotation Bearing Bolts 3 30 0 3 Checkthe Free wheel Configuration 22 20 3 32 0 4 Replace the Drive Hub 2 2 2 04040 0 00 0 00 3 33 05 Replace the Hydraulic Tank Return Filter 3 34 D 6 Inspect for Turntable Bearing Wear 3 34 D 7 Calibrate the Platform Overload System if equipped 3 36 D 8 Perf
393. Too BLU 36 TS10 TS TS13 SECONDARY PRIMARY EXTEND 9 ROTATE LVI BCI OPTION BOOM BOOM RETRACT BLK WHT ggg A RED P3 HORN BLK WHT TS15 Ls PO 8 Gd D 3H oR 6 90 NO 7 gt 2 FAULT LED p P m DRIVE ENABLE AUXILIARY 56 ENGINE 154 gt lt POWER TS7 TS9 GLOW PLUG START RPM L1 PLATFORM PLATFORM ROTATE LEVEL 2 RED EMERGENCY STOP Section 6 Schematics 2 Platform Control Box Wiring Diagram Z 45 25 with LVI BCI Option from serial number 14651 to 16839 B A NOTES ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES FOR LIFT DRIVE SELECTOR OPTION TAKE OFF JUMP BETWEEN 6 amp 7 COMPONENT INDEX Al TILT ALARM AC1 AC OUTLET BOX BCI BATTERY CHARGE INDICATOR BP1 ROTARY FLOW CONTROL DIAL CR6 DRIVE ENABLE RELAY CR19A LOW VOLTAGE INTERRUPT BCI RELAY A CR19B LOW VOLTAGE INTERRUPT BCI RELAY B DP1 DRIVE JOYSTICK El DRIVE ENABLE LED 13 CONTROLLER FAULT LED LOW VOLTAGE INTERRUPT MODULE LVI BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON P3 HORN Ti TIME DELAY 1 TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGL
394. U WHT 3 WHT 7 24 Electrical Schematic Z 45 25J from serial number 14651 to 16839 12 13 14 8 A2 16 ORG RED 16 16 ORG RED 3 86 85 BRN PLATFORM BRAKE RELEASE 1 1 CONTROL BOX g zl 4 TRAVEL ALARM A2 GROUND a 5 CR6 TB48 ORG BLK 1 gt B RED WHT 48 87 fe 5 30 5 7 BRAKE RELEASE eee N C COIL 8 TP41 h 3t BRAKE RELEASE N O COIL RED BLK R6 TS15 DRIVE ENABLE BRAKE RELEASE PRESSURE SWITCH 1 RELEASE J1 2 BRAKE STEER MANIFOLD GROUND BLU 1 BLU 36 JP1 REMOVE FOR CE VERSION STEER LEFT COIL 4 BLU BLK 37 TB37 BLU BLK 1 1 STEER RIGHT COIL TP37 RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG BLK R6 1 2 3 4 5 6 7 8 9 10 GRN WHT 19 AUXILIARY PUMP RED 8 AUXILIARY CONTROL June 2005 WHT 24 ORG RED 42 z RED RED 27 RELAY CR3 TB27 RED AUXILIARY LIFT PUMP RELAY COIL PR3 GRN WHT 8 9 GRNAWHT 2 6 85 RELAY COIL PR2 WHT RED 3 WHT RED 6 6 CONTROL COIL RED BRN PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE LEFT JIB U
395. WHOdlVid 81 ai 8 9 e 9 9 81 Si 2 m 2 81 1331 317109 WHOd1V 1d X 5 1100 AV 3H 91 gt zi zi NMO 13 31 WHOALV 1d 5 SL 18 680 IN Siongiouo gt y 318vo 187 HOLIMS i vL Q aoe e 5 anaba nodi Bas zi pr THOM EL 2 a lt M H3MOd HOLIMSLOOS THA ala a 4 LO NMOG m 25 Q monga vi mama gt rS HOLIMS LO 8 orma orma 5 ma 8 mamma O 016 NHOH 6 Q 5 saw 18 WOO 8 Q ee ie Bm OL n JOULNOD 141 9 inmwwuo P 9 G3H IHM GSH IHM LO QOIS 31VLOH 5 Sor 1HM v 1457 SLVLOW 7 1HM 9 IN 9 T LHM IHM 8 H3MOd 100 AV HH A 8 Q O 2 WOOG Q
396. WHT fn 5 Sao 68 my No 989 B amp C Tai DRIVE ENABLE AUXILIARY TS6 ENGINE TS4 POWER TS7 TS9 GLOW PLUG START RPM L1 PLATFORM PLATFORM ROTATE LEVEL P2 RED EMERGENCY STOP NOTES ALL WIRES WITHOUT LABELS ARE EITHER RED OR BLACK JUMPER WIRES FOR LIFT DRIVE SELECTOR OPTION TAKE OFF JUMP BETWEEN 6 amp 7 COMPONENT INDEX A Al TILT ALARM AC1 AC OUTLET BOX BCI BATTERY CHARGE INDICATOR BP1 ROTARY FLOW CONTROL DIAL CR6 DRIVE ENABLE RELAY CR19A LOW VOLTAGE INTERRUPT BCI RELAY A CR19B LOW VOLTAGE INTERRUPT BCI RELAY B DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED LVI LOW VOLTAGE INTERRUPT MODULE LVI BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON P3 HORN Ti TIME DELAY 1 TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH PartNo 106488 enie A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy June 2005 S
397. Y TOGGLE SWITCH m aED BLK WHT TS2 ENGINE START TOGGLE SWITCH e 7515 hs 2 TS4 HIGH LOW RPM TOGGLE SWITCH 4 OOO So S TS6 GLOW PLUG TOGGLE SWITCH C a X E 220 TS7 PLATFORM ROTATE TOGGLE SWITCH 8 Ts DRIVE ENABLE m RD TS9 PLATFORM LEVEL TOGGLE SWITCH E AUXILIARY gt 1510 SECONDARY BOOM TOGGLE SWITCH 7 PLATFORM atFOnM LEVEL O START P2 TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH ROTATE ENG TS12 TURNTABLE ROTATE TOGGLE SWITCH TS18 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORGHED AR TS14 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH 6 91 Z 45 25 Bi Energy Z 45 25J Bi Energy PartNo 106488 June 2005 Section 6 Schematics E Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option from serial number 13361 to 14078 N M L K J H G F E D REVA
398. __OFF LIMIT SPEED INPUT 4 S BLUWHT 2 INTERLOCK 9 SE TP29 _ REDWHT 1 29 9 POT HI 2 T x TP32 wHT REDi 32 WHT REDH32 POT LOW 88 ul T TP31 WHT BLKHS1 REVERSE 2 TP30 TB30 WHT WHT 30 FORWARD g DIODE RETURN m 8 ORG RED 42 48V INPUT 2 g dE 8 BLK lm 1 268 Br 4 9 8 gt S3 Lab ne lt lt ez ag amp lt 8 gt RED 20 a amp 5 5 5 a 8 g c BRN 8 5 CHASSIS GROUND 48V CHARGER 48V ALTERNATOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 1 ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION EXCEPT AS NOTED 2 ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED NOTES enie G A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 6 17 Section 6 Schematics June 2005 Electrical Schematic 2 45 25 REVA before serial number 13361 RED WHT 29 1 ALLLIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 2 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED NOTES WHT 24 BRN 2 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL BLU RED 3 BLK 7 TB13 BLU WHT
399. a A sA ba 1 gt 6 1 Q E E 5 9 ag 9 8805 Ed 9 2 a du Sz 5 8 8 io N 5 9 5 3 3 5 E 25 3 ogg gt g 8 9 2 g z m E ze S pP 5 2 5 A 8 s 8 Oo AX 54 8 OOO SOD CR RD 1 Q L48 18 TS15 DRIVE ENABLE HORN TS6 TS2 TS4 PS GLOW PLUG ENGINE RPM 1 757 TS9 START EMERGENCY i AUXILIARY PLATFORM PLATFORM STOP LEVEL 5 lt 1 FOR LVI BCI OPTION REMOVE INDICATED WIRES COMPONENT INDEX BCI BATTERY CHARGE INDICATOR BP1 ROTARY FLOW CONTROL DIAL DP1 DRIVE JOYSTICK L1 DRIVE ENABLE LED LVI LOW VOLTAGE INTERRUPT MODULE LVI BCI BATTERY CHARGE INDICATOR FOR LVI OPTION P2 EMERGENCY STOP BUTTON P3 HORN TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH 513 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 515 DRIVE ENABLE TOGGLE SWITCH H1 TITL ALARM 1518 PLATFORM OVE
400. a YILIN 5 zu lt vot 02 o o 02 E o 2 GAMGEE O 131 SN 9 3 1HWNHO 1HWNHO 5 gt lt O Og 8 1397 WHOdIVId 81 8 5 21 an 0 8 WHOdLV Td Q NUD 85 gt 59 5 100 STEVNA JAHA 9L Q gt lt NMOG 3 31 WHOSLV 1d a 2565 a LO WHOSLV Id 5 zs 3 SN G 2 2 DHO HOM lt 25 5 2 ETT HOLIMSLOOS THM sis EN 5 4 54 cba lt qe NMOG 5 C mama 925 OM AHVONOO3S OF m 6 NHOH 6 me 2 5 4 0 9 8 BI LO 8 1OVHI3H WOO8 8 8 Q a E 1 ofa me 2 1 WOO ni 585 ii mmg 01 9 OHINOO 141 9 G3H 1IHM 9 OL 1 31 1 10 STAVINEAL INIAM
401. a part number 16676 89163 Kubota Z482 E Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Openthe engine pivot plate latch and swing the engine out away from the machine Genie Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Engine specifications require that this procedure be performed every 150 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 REV A 10 Perform Engine Maintenance Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are
402. achine will not drive controller see the between M and B 2 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 OR motor controller has the defective drive an internal short motor OR test the motor controller See the Repair Section ARM SENSOR Machine will not drive Defective motor Replace the motor controller controller FLD SENSOR Machine will not drive Defective motor Replace the motor controller controller FIELD OPEN Machine will not drive 287 Continued next Genie EREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 5 3 Section 5 Fault Codes June 2005 FAULT CODE CHART Fault Code Code Scanner Displa THROTTLE FAULT 1 THROTTLE FAULT 2 CONT DRVR OC MAIN CONT WELDED PRECHARGE FAULT Genie Machine will not drive Machine will not drive Machine will not drive Machine will not drive Machine will not drive Open in wht red wire 32 at pin 14 or red wht wire 29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick defective Pin 14 wht red 32 is shorted to power or ground OR the potentiometer on the drive joystick is defective Main contactor PR1 coi
403. ad indicator light and alarm turn on There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds The platform will need to be moved up and down and allowed to settle in between adjustments Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV Confirm the setting 5 Turn the key switch to platform control 6 Lift the test weight off the platform floor using a suitable lifting device 7 Place the test weight back onto the center of the platform floor using a suitable lifting device Result The alarm should be off The platform overload indicator light should be off at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light and alarm turn off 8 Add an additional 10 Ib 4 5 kg test weight to the original test weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 9 all machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls Result All ground control functions should not
404. ailable in the Genie 2 45 25 Bi Energy and Genie Z 45 25J Bi Energy Operator s Manual your machine Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES REV A 3 3 Check to be sure the engine pulley and the Check the Generator Belts and Pulleys Maintaining the generator belts and the pulleys is essential to good engine performance and service life The generator will not operate properly with loose or defective belts and continued use may cause component damage AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns Charging the batteries with the engine does not fully charge the batteries Periodically use the AC battery charger to fully charge the batteries 1 sure that all fasteners and cables on the generator are tight 2 Be sure that the pulley mounting fasteners tight and that the pulleys show no signs of damage or unusual wear TEREX COMPANY generator pulley are aligned within specification using a straightedge Refer to Section 2 Specifications CD S M RN engine pulley straightedge maximum pulley offset generator pulley If alignment does not meet specification refer to Repair Procedure 6 3 How to Install the E
405. al Srip Wiring Diagram 2 45 25 ANSI and CSA Models from serial number 22051 to 23235 6 67 Ground Control Box Switch Panel Wiring Diagram Z 45 25 ANSI CSA Models after serial number 22050 6 68 Ground Control Box Terminal Wiring Diagram Z 45 25 CE Models from serial number 22051 23235 6 69 Ground Control Box Switch Panel Wiring Diagram Z 45 25 CE Models from serial number 22051 to 23235 6 70 Ground Control Box Wiring Diagrams 2 45 25 A Ground Control Box Terminal Wiring Diagram 2 45 25 before serial 13361 6 71 Ground Control Box Switch Panel Wiring Diagram Z 45 25J beforeserialnumber 13361 er iate rr ace pag 6 72 A GroundControl Box Terminal Srip Wiring Diagram Z 45 25J from serial number 13361 to 14078 6 73 A Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 13361 to 14078 6 74 A Ground Control Box Terminal Wiring Diagram Z 45 25J from serial number 14079 to 14650 6 75 A Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 140791014650 6 76 A Ground Control Box Terminal Srip Wiring Diagram Z 45 25J from
406. amage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures June 2005 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 See the Troubleshooting section of this manual for a list of fault codes and additional information There are no adjustments needed on the drive joystick controller For further information or assistance consult the Genie Industries Service Department OO O00 0 99 fec loo 52 20 ojo 5 EE 0 0 0 a boom function speed controller b drive joystick Genio 4 2 Z 45 25 Bi Energy Z 45 25J Bi Energy REV B Boom Function Speed Controller Adjustmen
407. 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 2 45 25 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 2 Disconnect the cables from the platform control box 3 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 4 Raise the primary boom to a horizontal position Genie REV 5 disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder Cap the fittings on the unions AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can pen
408. and swing the engine out away from the machine CHECKLIST B PROCEDURES Genie Part No 106488 Z 45 25 Z 45 25J Bi Energy 3 25 Section 3 Scheduled Maintenance Procedures June 2005 Checklist C Procedures C 1 Perform Engine Maintenance Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV 2 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased pla
409. ane to to the lug on the rod end of the primary boom lift cylinder Then raise the primary boom lift cylinder with the crane to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder AWARNING 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 slide hammer to remove the pin Remove the primary boom lift cylinder from the machine AWARNING C eshing 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 AWARNING 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 Section 4 Repair Procedures June 2005 SECONDARY BOOM COMPONENTS 10 Remove the pin retaining fasteners from both sides of the secondary boom lift cylinder rod end pivot pin and barrel end pivot pin Do not remove the pins 11 Attach a strap from an overhead crane to the lug on the
410. approved fire extinguisher within easy reach ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or contrainer Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel 46 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled 47 Remove the fuel tank mounting fasteners Carefully remove the fuel tank from the machine CAUTION Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine Part No 106488 June 2005 Section 4 Repair Procedures REV 48 Remove the retaining fastener from the ground control box and function manifold pivot plate 49 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin 50 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support Do not lift it 51 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser 52 Remove the pin retaining fasteners from the number 3 arm at the turntable riser Do not remove the pin 53 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through t
411. ard 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 CAUTION 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 App marks on the hydraulic tank Do not overfill 16 Clean up any oil that may have spilled Properly discard of oil 17 Operate all machine functions through a full cycle and check for leaks TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV 2 Grease the Steer Axle Wheel Bearings Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels then center a lift
412. at the ground controls and on the motor controller See the Troubleshooting section of this manual for a list of fault codes and additional information There are no adjustments needed on the drive joystick controller For further REVA 4 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller 5 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below and check for resistance Result All desired results must be 500 kilohms or more If any test has a result less than 500 kilohms replace the motor controller information or assistance consult the Genie Test Brine e Industries Service Department in kilohms How to Test the Motor Controller 92 Use the following procedure test F1 to B 500kQ or more the motor controller If the motor controller is found to be faulty F1 to M 500 or more note which test failed and which fault code if any was present at 500 or more the time of failure F2 to B np 1 Turn the key switch to the off position and disconnect the battery packs from the machine F2 to M 500kQ or more 2 Remove the chassis cover from the non steer F2 to B 500kQ or more end of the machine 3 and disconnect all power cables from the 500 or more motor controller M to B or more Electrocution hazard
413. atform controls 7 Activate any boom function and inspect the filter and related components to be sure that there are no leaks 8 Use permanent ink marker to write the date and number of hours from the hour meter on the oil filter A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV D 6 Inspect for Turntable Bearing Wear Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 7 Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turn
414. care wir comer T 2 C4TRL WH 4 uj 5 8 5 9 RD WH 3 8 a OR RD C2PBD RD BK 2 C3P GR C11SBD BL BK GR WH R7 C1PBU RD 1 BL lt lt GR WH 45 CATRL WH GR WH 7 GR WH C45JSV GR WH C2P 7 z C44JDA GRIBK C2P 6 C2P BK 8 Im 8 RD J7 R42BATOR RD lt 1 C2P 4 E 88 R41DRE OR EK C2P 3 15 gt 2 2 E 1P GY x 5 CS7STC BLIBK 5 WH BK C44JDA GR BK C36STCC BL C1P 10 C35HRPMBK RD 9 C34SA C1P 8 ou _ 86 C33STR BK 7 C32JSL WH RD C1P 6 BK WH DRE Psy C31REV WH BK C1P 5 RD DRE 5 ur UL C30FWD WH C1P 4 C29JSH RD WH C1P 3 9 OR BK C28TTA RD BK s OR BK R6 C27AUX RD 1 1 RD AUX 5 lt gt 1 co RD STOP 080 5 5 C27AUX RD lt i RD HRN Oo R42BAT OR RB 1 O uol 9 5 gt 22 1G BRN BCI__ lt 1 4 58 C9HRN BK RD T 595 4 21212 1 a v N
415. ce Inspection Report to use for each inspection Store completed forms for three years Part No 106488 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev B Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record t
416. ch 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 Setthe max out Press down the foot switch then move the primary boom toggle switch in the down position Adjust the amperage to 0 54 to 0 55A Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 9 Before serial number 21180 Remove the temporary wire from TP6 and install the wht red wire into TP6 Boom function speed controller specifications Threshold 0 17 to 0 18A Max out 0 54 to 0 55A Genie Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 3 Section 4 Repair Procedures June 2005 Platform Components 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered bl
417. ch is held down Turn the key switch to platform control Result The flashing beacon should be on and flashing 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 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 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 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Part No 106488 ATE Z 45 25 Bi Energy Z 45 25J Bi Energy 3 23 COMPANY B 16 Test the Turntable Rotation Stop The turntable is capable of rotating the boom 355 degrees and is stopped midpoint between the steer wheels by the rotation stop Detecting a rotation stop malfunction is essential to safe operation and good machine performance If the turntable rotates
418. d 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 tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION 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 AWARNING 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 ACAUTION 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 AWARNING 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 Genie Part No 106488 A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST E PROCEDURES 8 Remove the hydraulic tank from the machine CAUTION Component damage haz
419. d maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine REV B TEREX COMPANY 3 38 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures Checklist E Procedures REV E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose an
420. d or hose end must be replaced AWARNING Crushing hazard The extension and then torqued to specification cylinder could fall when removed during installation from the extension boom if not Refer to Section 2 Hydraulic Hose properly supported and Fitting Torque Specifications PR CAUTION Component damage hazard Be 1 Raise the primary boom to a horizontal position careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube Component damage hazard CAUTION Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them Note the length of the cylinder after removal The cylinder must be at the same length for installation Genio 4 18 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base of the primary boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced
421. der 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 AWARNING 991 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hyaraulic 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 Genio Z 45 25 Bi Energy Z 45 25J Bi Energy REV B 3 Tag disconnect and plug the hydraulic hoses on the secondary boom lift cylinder AWARNING e injury hazard Spraying ydraulic 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 appl
422. e assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until the upper pivot is above the turntable covers Turn the machine off 2 Secure the turntable from rotating with the turntable rotation lock pin AWARNING 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 o Unlocked position Locked position 3 Remove the engine pivot plate latch retainer 4 Open the engine pivot plate latch and swing the engine out away from the machine to access the turntable rotation motor and brake 6 TURNTABLE ROTATION COMPONENTS Remove the retaining fasteners from the center turntable cover Remove the cover from the machine Disconnect the battery backs from the machine AWARNING Electrocution hazard Contact with 7 electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Place a suitable container under the engine plate 8 Tag and disconnect the fuel hose from the fuel filter and drain the fuel tank into a suitable container See capacity specifications
423. e off 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 After serial number 21180 Inspect for a liberal coating of dielectric grease at the following location All wire harness connectors to the platform control box Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 3 15 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 5 Check the Lug Nut Torque including the tires and wheels Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage also result if problems are not discovered and repaired in a timely fashion ADANGER Tip over hazard An over inflated tire can explode which will compromise machine stability and and cause the machine to tip over AWARNING Bodily injury hazard An over inflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products The tires on some machines are foam filled and do not need air added to them 1 Check the tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug n
424. e release 10 13 ft Ibs 14 18 Nm 2 Counterbalance valve not Turntable rotate right 30 35 ft lbs 41 47 Nm Counterbalance valve OZ ue Turntable rotate 30 35 ft lbs 41 47 Nm Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 47 Section 4 Repair Procedures June 2005 Turntable Rotation Components 10 1 Rotation Hydraulic Motor before serial number 18367 How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until the upper pivot is above the turntable covers Turn the machine off 2 Secure the turntable from rotating with the turntable rotation lock pin AWARNING 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 Clo Unlocked position Locked position Genie REV Remove the engine pivot plate latch retainer 4 Open the engine pivot plate latch and swing the engine out away from t
425. ection 6 Schematics ___________ Platform Control Box Wiring Diagram 2 45 25 with LVI BCI Option from serial number 16840 to 17974 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram 2 45 25 from serial number 17975 to 21180 Section 6 Schematics aes See June 2005 Platform Control Box Wiring Diagram 2 45 25 MEVA from serial number 17975 to 21180 RED BLK R6 1 ORG BLK R6 ORG BLK 41 gt m p m 8 E oem 2 3 ORG RED 16 ORG RED 16 ORG BLK 41 ORG BLK 41 5 5 1512 S S B 515 5
426. ectrical Schematic Z 45 25J from serial number 17975 to 21180 Section 6 Schematics WHT RED WHT 29 WHT RED 32 WHT 30 WHT BLK 31 WHT 24 ORG RED 42 RED RED BLUMHT 12 RED START RELAY TACH INPUT START INPUT NOT USED GROUND KEY SWITCH POWER NOT USED IGNITION ON 10 ENGINE FAULT AP2 AUXILIARY GND GND BRN BATTERY IGNITION START MODULE 1 2 3 4 5 6 7 8 9 GRN BLK BATT WHT BATT RED 5 6 WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH WHT 23 WHT GROUND BRN FOOT SWITCH HIGH RPM BLK ISM1 BLU ISM2 BLK 33 BLK RED 1 B ALTERNATOR FIELD RELAY CR16 HIGH TB35 TP35 Ye BRN is Low RPM TS4 RPM RPM CUTOUT RELAY CR13 BLK RED 35 HIGH RPM RPM RELAY CR14 T 188 1 BRN quc 2 1 BLK RED BLK WHT 34 5 lt lt RPM SOLENOID ENGINE START TS2 30 R15 87 12V GLOW PLUG RELAY CR15 GLOW PLUGS 8 0000 TB34 GLOW BLKWHT PLUGS 87 55 90090 GLOW PLUGS TS56 n TP34 BLK WHT 1 TS6 12V DC ALERNATOR WHT J4 12V DC VOLTAGE REGULATOR ENGINE POWER RELAY CR12 21 RED J10 12GA E ast 6 2 2 12V
427. ectrical Schematics Z 45 25J A Electrical Schematic Z 45 25J before serial number 13361 6 35 A Electrical Schematic Z 45 25J from serial number 13361 to 14078 6 37 A Electrical Schematic Z 45 25J from serial number 14079 to 14650 6 39 A Electrical Schematic Z 45 25J from serial number 14651 to 16839 6 41 A Electrical Schematic Z 45 25J from serial number 16840 to 17974 6 43 A Electrical Schematic Z 45 25J from serial number 17975 to 21180 6 45 A Electrical Schematic Z 45 25J from serial number 21181 to 22050 6 47 A Electrical Schematic Z 45 25J ANSI and CSA Models from serial number 22051 to 23235 seem 6 49 A Electrical Schematic Z 45 25J CE Models from serial number 22051 to 23235 6 51 PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy xiii June 2005 TABLE OF CONTENTS Section 6 Rev Schematics continued Ground Control Box Wiring Diagrams Z 45 25 A GroundControl Box Terminal Srip Wiring Diagram Z 45 25 before serial number 13361 024 0040000 nennen 6 53 Ground Control Box Switch Panel Wiring Diagram Z 45 25 before serial 13361 6 54 Ground Control Box Terminal Srip Wiring Diagram 2 45 25 from serial number 13361 to 1407
428. eed the slave cylinder to be sure there is no air in the closed loop When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 1 Z 45 25J Extend the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 4 4 Z 45 25 Bi Energy Z 45 25J Bi Energy Genie hsec d REV B 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector Connect the hoses from the cylinder together using a connector AWARNING 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 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 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
429. eee 1 5 Mert QE E S PE ee ee aive e Vig ee Poe NOTI ST UM Xi I MI eG EGO ee gE cV 1 1 5 O GR S 2 SECOND HM TS13 jm 2 FOR CE OPTION TAKE OFF JUMPER ON JOYSTICK ROTATE BOOM BOOK BETWEEN TERMINALS 6 8 7 AND ADD CR8 6 O O i P24BAT WH COMPONENT INDEX amp BATTERY CHARGE INDICATOR BP1i ROTARY FLOW CONTROL DIAL JOYSTICK o 1290 DRIVE ENABLE LED Poj D w 2 oe 1 3 8 12 LOAD SENSE LED 7 5 LOW VOLTAGE INTERRUPT MODULE gt 8 LV BCI BATTERY CHARGE INDICATOR FOR LVI OPTION EMERGENCY STOP BUTTON P3 HORN 131 AUXILIARY TOGGLE SWITCH 762 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH 3 TS6 GLOW PLUG TOGGLE SWITCH 0 O 167 PLATFORM ROTATE TOGGLE SWITCH 8 i Q e he TS8 JIBBOOM UP DOWN TOGGLE SWITCH O OJ o o TS9 PLATFORM LEVEL TOGGLE SWITCH DRIVE ENABLE TS6 TS2 zu n Ea m
430. eer 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 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy 4 1 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence ofa potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property d
431. els or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this procedure after fully charging the batteries Charging the batteries with the engine does not fully charge the batteries Periodically use the AC battery charger to fully charge the batteries The engine battery is a maintenance free battery and does not require the replenishing of electrolyte For a more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion REV B 3 Be sure that the cable connections are tight Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced Check the battery acid level of the battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overf
432. engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 REV A 6 Perform Engine Maintenance Engine specifications require that this procedure be performed every 75 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota Z482 E Operator s Manual Kubota part number 16676 89163 Kubota Z482 E Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine Part No 106
433. er boom tube must be replaced The extension cylinder can be removed without the base end of the extension tube Place the extension cylinder on blocks for support completely disassembling the AWARNING Crushing hazard The extension boom See 4 4 How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom See How to Remove the Primary Boom 2 Place blocks under the barrel end of the primary boom extension cylinder for support 3 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin at the pivot end of the primary boom Use a soft metal drift to remove the pin 4 Remove and label the location of the wear pads from the platform end of the primary boom Pay careful attention to the location and amount of shims used with each wear pad 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube AWARNING C shing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing Genie cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 4 16 Z 45 25 Bi Energy Z 45 25J Bi Energy Part
434. er the finish line Refer to Section 2 Specifications A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy MPANY 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 turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The flashing beacon should be on and flashing 2 Move the function enable switch to either side and activate the primary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down 3 Move the function enable switch to either side and activate the secondary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures SSS SSS REV CHECKLIST B PROCEDURES 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 swit
435. erform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV B B 19 Perform Engine Maintenance Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch
436. erial number 13361 Section 6 Schematics June 2005 Ground Control Box Terminal Strip Wiring Diagram 2 45 25 from serial number 13361 to 14078 REVA June 2005 Diagram 2 45 25 iring Ground Control Box Terminal Strip W from serial number 13361 to 14078 Section 6 Schematics e o i I x 8 Nua Nua Nua 5 3 5 9 9 6I IHWNHO Waviona m MELDE 7 E E d 6 bd H LHWNHO 61 IHWNHO e U3MOd d3H 2 1 Suorig aau
437. es 4 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 5 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Genie Part No 106488 A TEREX COMPANY Z 45 25 Z 45 25J Bi Energy Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES REV B B 14 B 15 Test the Drive Speed Raised or Test the Alarm Package Extended Position if equipped Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Raise the platform more than 5 feet 1 5 m 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 4 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 5 Continue at full speed and note the time when the machine reference point passes ov
438. es Tire ply rating 6V DC Sidewall 6 Quantity 8 Tire contact area 43 5 911 350 280 sq Reserve capacity 25A rate 750 minutes Overall tire diameter 28 in 71cm Tire pressure 100 psi 6 89 bar Continuous improvement of our products is For operational specifications refer to the Operator s Manual Part No 106488 A TEREX COM Z 45 25 Bi Energy Z 45 25J Bi Energy PANY Genie policy Product specifications are subject to change without notice Section 2 Specifications June 2005 SPECIFICATIONS Performance Specifications Drive speeds maximum Drive speed stowed 3 mph All models 4 8 km h 40 ft 9 sec 12 2 m 9 sec Drive speed boom 0 6 mph raised or extended 1 km h all models 40 ft 45 sec Braking distance maximum 12 2 m 45 sec High range on paved surface Gradeability boom stowed Boom function speeds maximum from platform controls REV Jib boom up 2 45 25 30 to 40 seconds Jib boom down Z 45 25J 18 to 23 seconds Primary boom up 30 to 36 seconds Primary boom down 26 to 32 seconds Secondary boom up 38 to 42 seconds Secondary boom down 32 to 36 seconds Primary boom extend 2 45 25 25 to 30 seconds 5to7ft boom extend Z 45 25J 16 to 24 seconds 1 5to2m ado Primary boom retract Z 45 25 21 to 30 seconds Primary boom retract
439. etrate 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 disconnect and plug the hydraulic hoses from the platform leveling master cylinder Cap the fittings on the cylinder AWARNING 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 10 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures s M S r Y REV B PRIMARY BOOM COMPONENTS 8 Tag and disconnect the hydraulic hoses from 14 Remove the cable track mounting fasteners that the platform leveling slave cylinder and connect attach the lower cable track to the primary them together using a connector Cap the boom onthe cylinder 15 Remove the cable track from the machine and AWARNING injury hazard Spraying place it on a structure capable of supporting it ydraulic 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 Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched AWARNING Crushing hazard The cable track could become unbalanced and fall if not
440. ge AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the CAUTION machine must be towed do not exceed 2 mph 3 2 km h 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub hoo brake disengaged position EN arg an brake engaged position A TEREX COMPANY engage the drive hubs could result in death or serious injury and property damage 3 32 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV D 4 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees a models with o ring plugs
441. get into machine components and cause damage Be sure any forklift overhead crane or A 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 rs 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 8 properly ventilated and well lit Taine PartNo 106488 June 2005 Table of Contents Introduction Important Serial Section 1 Safety Rules General Safety Rules Section2 Rev Specifications gt gt gt gt gt gt Section 3 Rev Scheduled Maintenance Procedures Pre delivery Preparation Maintenance Inspection Report B Checklist A Procedures A 1 Perform Pre operation Inspection 2 Perform Function
442. have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor pump or engine will be required to perform this procedure Bl 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 zr A TEREX 3 2 Z 45 25 Bi Energy Z 45 25J Bi Energy MPANY 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 Maintenan
443. he access hole behind the ground control box 54 Remove the number 3 arm from the machine AWARNING Crushing hazard The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 55 Remove the upper and lower hose and cable covers from the number 3 arm 56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid pivot end Do not disconnect the wiring Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy SECONDARY BOOM COMPONENTS 57 Remove the pin retaining fasteners from the number 4 arm at the turntable riser Do not remove the pin 58 Attach a lifting strap from the overhead crane to the center point of the number 4 arm Do not lift it 59 Use a slide hammer to remove the number 4 arm from the turntable riser through the ground controls side bulkhead 60 Remove the number 4 arm from the machine AWARNING Crushing hazard The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Section 4 Repair Procedures June 2005 SECONDARY BOOM COMPONENTS 5 2 Secondary Boom Lift Cylinders There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly These cylinders operate in parallel and require hydraulic pressure to extend and retract Each secondary boom lift cylin
444. he machine to access the turntable rotation motor 5 Remove the retaining fasteners from the center turntable cover Remove the cover from the machine 6 Disconnect the battery backs from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Place a suitable container under the engine plate 8 Tag and disconnect the fuel hose from the fuel filter and drain the fuel tank into a container of suitable capacity See capacity specifications 9 Tag disconnect and plug the fuel hoses from the fuel tank 10 Remove the fuel tank strap fasteners and remove the tank strap 11 Remove the fuel tank from the machine 12 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the turntable rotation motor mounting fasteners Remove the motor from the brake 14 Remove the turntable rotation motor from the machine 4 48 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV How to Remove the Turntable Rotation Brake before serial number 18367 When removing a hos
445. he relief valve higher than specified 5 Repeat steps 2 through 4 and recheck relief valve pressure Part No 106488 Genie MANIFOLDS Z 45 25 Bi Energy Z 45 25J Bi Energy Section 4 Repair Procedures June 2005 M Q V M M sS MANIFOLDS REV C 9 6 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to platform support Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 way Jib boom platform rotate select 8 10 ft lbs 11 14 Nm 2 Solenoid valve 2 position 2 way Jib boom platform rotate select 8 10 ft lbs 11 14 Nm Solenoid valve 2 position 3 way DC Jib boom platform rotate select 20 ft lbs 27 Nm From serial number Before serial number 16963 16963 to 22565 eg 0 Q 0 R 4 From serial number 22566 to 23235 4 46 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures SS Sy REV MANIFOLDS 9 7 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position way Turntable rotation brak
446. he results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments 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 Section 3 Scheduled Maintenance Procedures June 2005 ss SSS aor SS This page intentionally left blank TEREX COMPANY 3 4 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev B YNR Checklist B Rev B YNR 5 1 Pre operation B 1 Radiator Serial number inspection B 2 Exhaust system Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection
447. hell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Function pump Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy SPECIFICATIONS Function pump Type Fixed displacement gear pump Displacement 0 183 cu in 3 cc Flow rate 2 1 gpm 7 9 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold Function relief valve pressure 3200 psi 220 6 bar Primary boom down 2300 psi relief valve pressure 158 6 bar before serial number 11819 Secondary boom down 1800 psi relief valve pressure 124 bar before serial number 22566 Secondary boom down 2000 psi relief valve pressure 138 bar from serial number 22566 to 23235 Platform level flow regulator 0 1 gpm before serial number 20380 0 38 L min Platform level flow regulator 0 6 gpm from serial number 20380 to 23235 2 27 L min Jib boom platform rotate flow regulator 0 6 gpm before serial number 22566 2 27 L min Jib boom platform rotate flow regulator 0 4 gpm from serial number 22566 to 23235 1 5 L min Auxiliary pump Type fixed displacement gear pump Displacement 0 5 gpm 1 9 L min 2 3 Section 2 Specifications June 2005 SPECIFICATIO
448. hichever comes first Yearly calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Perform this procedure with the machine on a firm level surface 1 Level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy REV Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle O Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off The platform will need to be moved up and down and allowed to settle in between adjustments There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds O Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overlo
449. hortcuts may produce hazardous conditions aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Section 5 Fault Codes June 2005 FAULT CODES ADANGER Tip over hazard When adjusting the raised drive speed settings the maximum raised drive speed must not exceed 0 6 mph 1Km h or 40 feet 45 seconds 12 2 meters 45 seconds If the machine is allowed to drive faster than specification the machine could become unstable and will tip over Additional troubleshooting of the fault codes may by accomplished by using the hand held pendant motor controller programmer Genie part number 56303 S When using the hand held pendant motor controller programmer the M1 MAX SPEED needs to be set to 33 If needed adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed of 0 6 mph 1Km h or 40 feet
450. i mama gt rS HOLIMS LO 8 orma orma 5 ma 8 mamma O 016 NHOH 6 Q 5 saw 18 WOO 8 Q ee ie Bm OL n JOULNOD 141 9 inmwwuo P 9 G3H IHM GSH IHM LO QOIS 31VLOH 5 Sor 1HM v 1457 SLVLOW 7 1HM 9 IN 9 T LHM IHM 8 H3MOd 100 AV HH A 8 Q O 2 WOOG Q ee ee wg noo 99 3uvds WOO8 raga 9 81 3Sva IWNINYAL 10 Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G 6 57 Section 6 Schematics from serial number 14079 to 14650 Ground Control Box Switch Panel Wiring Diagram Z 45 25 June 2005 REVA
451. i CONTROLLER FAULT 40 B BRAKE RELEASE RELAY CR5 ORG RED CR5 RED BLK R5 8 8 ORG RED 42 COIL PR1 gt 17 B MOTOR MAIN CONTACTOR RELAY ORG 40 1 OFF LIMIT SPEED INPUT F1 RED 20 INTERLOCK BLU WHT 12 E2 2 29 RED WHT 1 TB29 RED WHT 29 POT HI lt 2 aon lt 16 ie CURTIS 1244 SEPEX CONTROLLER B GROUND 14 TP31 WHT BLK 1 1 WHT BLK 31 REVERSE 11 i8 TP30 _ WHT 1 TB30 WHT 30 FORWARD 10 ORG GEN NEG ORG GEN POS F2 ORG RED 42 T TP32 32 WHT RED 32 POT LOW AC POWER R 48V INPUT 1 EL 24 DIODE RETURN g 1 1 1 1 WHT LOAD 9 BLK 48V DC CHARGER CHARGER 1 ORG LOAD 48V ALTERNATOR LOAD SENSOR BOX 10 ALTERI of ORG RED R2 GND PRIMARY LIFT PUMP B 1 1 AUXILIARY E UR 1 PUMP FS 10A F2 200A n 5 WHT FS TB20 24V DC BLK 26 LOAD 2 LO
452. ill Install the battery vent caps Be sure the battery packs are wired correctly TEREX COMPAN 3 14 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV B 4 6 Inspect the Electrical Wiring 7 Maintaining electrical wiring in good condition is essential to safe operation and good machine 8 performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Power units Inside of the ground control box Turntable manifold wiring Generator and power units Engine wiring harness 2 After serial number 21180 Inspect for a liberal coating of dielectric grease at the following location All wire harness connectors to the ground control box 3 Raise the secondary boom until the mid pivot is approximately 10 feet 3 m off the ground 4 Remove the center turntable cover Inspect the turntable center area for burnt chafed and pinched cables A TEREX COMPANY CHECKLIST B PROCEDURES Install the center turntable cover Lower the boom to the stowed position and turn the machin
453. in CL iis Platform rotate and turntable rotate 13 Needle valve GM us Platform level circuit 14 Relief valve 2500 psi 172 bar CN Platform level circuit 15 Relief valve 3200 psi 220 6 bar System relief 16 Check valve 5 psi 0 3 bar Brake circuit 17 Orifice 0 060 inch 1 5 mm CQ Steer circuit 18 Orifice 0 030 inch 0 76 mm CR Proportional valve circuit 19 Solenoid valve 2 position 3 way CS Brake citCult eren Orifice 0 030 inch 0 76 mm from serial number 22566 to 22628 and after serial number 23235 located under item CS Clase Brake circuit 20 Orifice 0 037 inch 0 94 CU 21 Check valve pilot operated CM Platform level circuit 22 Relief valve 2100 psi 145 bar Secondary boom down circuit 4 42 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 Section 4 Repair Procedures June 2005 MANIFOLDS REV 0 9 9 9 06 Genie Z 45 2
454. ing 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 Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 8 Loosen the castle nut and re tighten to 8 ft lbs 11 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 10 and grease the wheel bearings Result If there is side to side or up and down movement continue to step 10 and replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease
455. intenance Perform every 1500 hours D 9 Perform engine maintenance ChecklistE RevB E 1 Hydraulic oil E 2 Wheel bearings E 3 Perform engine maintenance A TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures Checklist A Procedures REV A 1 Perform Pre operation Inspection Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the Genie 2 45 25 and Genie 2 45 25 Bi Energy Operator s Manual your machine Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is av
456. iring Diagram Z 45 25 CE Models from serial number 22051 to 23235 REVA June 2005 Ground Control Box Terminal Strip Wiring Diagram 2 45 25 CE Models from serial number 22051 to 23235 Section 6 Schematics D anis asy3734 ayvua NHOH SHO 05 lt 4 ss 9 8 m 58 Nua t 9 gt 6 g uo Nua Nua
457. ith pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub Repeat steps 1 through 4 for the other drive hub Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications Z 45 25 Bi Energy Z 45 25J Bi Energy 3 17 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 8 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine 3 Connectan rpm gauge to the engine and then start the engine from the ground controls Result Low idle should be 2000 rpm Skip to step 5 if the low idle rpm is correct TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy MPANY REV B 4 Loosen the lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the lock nut and recheck the rpm a low idle adjustment screw not shown b high idle adjustment nut rpm solenoid d fuel shut off solenoid 5 Move the engine idle control switch to high idle
458. k 4 Raise the primary boom to a horizontal position 4 14 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV 5 Remove the hose and cable cover from the upper pivot 6 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin Then lower the cylinder and let it hang down Component damage hazard CAUTION When lowering the master cylinder down be sure not to damage the master cylinder hoses or fittings 7 Locate the primary boom drive speed limit switch inside of the upper pivot 8 Remove the primary boom drive speed limit switch mounting fasteners Do not disconnect the wiring 9 Locate the primary extension boom drive speed limit switch inside of the extension boom 10 Remove the primary extension boom drive speed limit switch mounting fasteners Do not disconnect the wiring 11 Pull the limit switch and the wiring out of the extension tube and move it out of the way 12 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy PRIMARY BOOM COMPONEN
459. k 5 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 6 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING 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 AWARNING ecd injury hazard Spraying ydraulic 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 REV B 8 Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate manifold Cap the fittings on the manifold AWARNING 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 AWARNING Bodily inj
460. l 8561 id 2 9 820 naviva LO Ws HOLIMS O Q 9 1V8ZvH 1H0 Qu HO 1V8zrH 22 9 ow 3345 340 Or Q ao Sas 99 S109 2 892 1 1 O a 9 915 59 OLSZED 16 890 9 9 anm HO SN 18 9018960 01 10 2 a 18 201590 96 890 SE SE 551 0 a 4 dama WdHHSEO 6 82 5 WdHHSEO 81 850 ve ve 9551 MOTD HME 8 810 5 VSVEO 22 850 9 2951739 JNIONCIHVIS ee a 9 5665 2810 1 9 95 2 22 103135 dux 2980 1S HM Jp SN HM 1V8MSEZd 2 819 HM WHYVEZO 96 892 T IS Jp 22 WHOALV Id OL 22 vHO 8 51220 02 890 IIAW 131 6r UO HIWHO ossruwus f er annan Sr 9 lt dd 1619 7 80 HW H9 MSd6LO 86 899 TRIANO 31V1OH WHOALW1d 8 uro 81 899 5 133131V10H WHOSLW1d 1951 99 19920 5 199210 21 899 6 lt 51 NMO TRAAT WHOA S 0714910 074910 51 899 WHOSLW 1d vb so Tana ayo
461. l defective OR brake release relay CR5 defective Main contactor PR1 contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has a internal short to ground External short between B terminal on motor controller and ground OR motor controller is defective REVA Consult Genie Industries Service Department Consult Genie Industries Service Department Replace main contactor or brake release relay CR5 OR replace the motor controller Consult Genie Industries Service Department Repair short between B terminal on motor controller and ground OR replace motor controller Note Short can be on any part of circuit connected to the B terminal on the motor controller TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 5 Fault Codes REVA Fault Code 34 Code Scanner Displa MISSING CONTACTOR Machine will not drive MAIN CONT DNC LOW BATTERY VOLTAGE OVERVOLTAGE THERMAL CUTBACK Machine will not drive Machine will not drive Machine will not drive Machine will not drive Genie Part No 106488 Motor controller does not detect the main contactor PR1 or brake release relay 5 Main contactor PR1 or brake release relay CR5 did not close OR open in org red wire to PR1 and or CR5 OR main contactor and or brake re
462. l the upper pivot is above the turntable covers Turn the machine off 2 Secure the turntable from rotating with the turntable rotation lock pin AWARNING 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 Cle 9 Unlocked position Locked position Genie Z 45 25 Bi Energy Z 45 25J Bi Energy REV B Remove the engine pivot plate latch retainer 4 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation assembly 5 Remove the retaining fasteners from the center turntable cover Remove the cover from the machine 6 Disconnect the battery backs from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Place a suitable container under the engine plate 8 Tag and disconnect the fuel hose from the fuel filter and drain the fuel tank into a suitable container See capacity specifications 9 Tag disconnect and plug the fuel hoses from the fuel tank 10 Remove the fuel tank strap fasteners and remove the tank strap 11 Remove the fuel tank from the machine 12 Tag disconnect and plug the hydraulic hose
463. latform controls Carefully move the test weight to each remaining location Result The platform overload indicator light should be off at both the ground and platform controls Add an additional 10 Ibs 4 5 kg of weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 6 Calibrate the Platform Overload System There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 3 27 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST C PROCEDURES 7 Carefully move the test weights to each remaining location in the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 6 Calibrate the Platform Overload System There may be an approximate 2 second delay before the overload
464. lease relay is defective Battery supply voltage to motor controller less than 32V DC Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in Machine being operated outside of temperature range of 13 F to 185 F 25 C to 85 C OR machine being driven under excessive load OR motor controller is not being cooled sufficently FAULT CODE CHART Consult Genie Industries Service Department Consult Genie Industries Service Department Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller Be sure the battery charger is disconnected OR check for loose battery cables or poor connections Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy Section 5 Fault Codes June 2005 SS This page intentionally left blank 5 6 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from se
465. lug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 AWARNING Cushing hazard The primary boom will fall if not properly supported when the primary boom rod end pivot pin is removed Place a support block across both turntable covers under the primary boom lift cylinder Lower the rod end of the lift cylinder onto the block Protect the cylinder rod from damage AWARNING Cushing 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 AWARNING Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device Part No 106488 Z 45 25 Z 45 25J Bi Energy 4 17 Section 4 Repair Procedures June 2005
466. m the platform rotator for support How to Remove the Jib Boom Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Tagand disconnect the electrical connectors from the jib boom platform rotate select manifold mounted to the platform support 3 Tag disconnect and plug all of the hydraulic hoses from the jib boom platform rotate select valve manifold Cap the fittings on the manifold and pull the hoses out through the platform rotator AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the platform mounting weldment Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy 6 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 7 Remove the pin retaining fasteners from both platform rotator pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down 9 Use a soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the
467. machine is not in free wheel or partial free wheel configuration Refer to B 4 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Lower the boom into the stowed position 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 4 Bring the machine to maximum drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 5 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb CHECKLIST B PROCEDURES B 13 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Lower the boom into the stowed position 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lin
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469. ne manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine CHECKLIST C PROCEDURES Genie Part No 106488 Z 45 25 Z 45 25J Bi Energy 3 29 Section 3 Scheduled Maintenance Procedures June 2005 Checklist D Procedures D 1 Check the Primary Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the primary boom through the entire range of motion to check for
470. ne pivot plate out away from the machine to access the radiator 3 Inspect the radiator for leaks and physical damage 4 Clean the radiator fins of debris and foreign materials 5 Swing the engine back to its original position and close the engine pivot plate latch 6 Install the engine pivot plate latch retainer Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust System can cause component damage and unsafe operating conditions AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine pivot plate latch retainer 2 Openthe engine pivot plate latch and swing the engine pivot plate out away from the machine to access the exhaust system Be sure that all nuts and bolts are tight 4 Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints Genie Part No 106488 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 3 Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid lev
471. ngine Drive Pulley to adjust the pulley alignment 3 8 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV CHECKLIST A PROCEDURES 4 Inspect the generator belts for A 4 Cracking Perform 30 Day Service Glazing Separation Breaks The 30 day maintenance procedure is a one time 5 Replace both belts if any damage is found sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 6 Check the generator belts for proper tension Refer to Section 2 Specifications If the belt deflection is not within specification see repair procedure 1 Perform the following maintenance procedures 7 2 How to Adjust the Generator B 5 Check the Lug Nut Torque Belts including tires and wheels D 2 Check the Turnable Rotation Bearing Bolts D 5 Replace the Hydraulic Tank Return Filter engine pulley b generator belts c generator pulley 7 Checkthe torque of the pulley retaining nut on the generator Refer to Section 2 Specifications TEREX COMPANY Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 3 9 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES A 5 Perform Engine Maintenance Engine specifications require that this procedure be performed every 50 hours Proper
472. ngine shaft Do not mounting bolts There must be a tighten the set screw gap visible between the engine drive pulley and the pulley 2 Align the flywheel side of the pulley bushing on bushing the engine shaft with the outer face of the generator pulley using a straightedge i b shaft EA C Setscrew G engine drive pulley e pulley mounting bolt f pulley bushing g woodruff key pulley shaft 6 Check the alignment between the engine drive pulley bushing pulley and the generator pulley using a engine flywheel straightedge generator pulley generator straightedge Refer to Section 2 Specifications If the pulley alignment is not within specification remove the engine pulley and repeat steps 2 through 6 See 6 4 How to Remove the Engine Drive Pulley 4 28 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures Generator REVA 7 1 How to Install the Generator Generator Pulley Pulley The pulley on the generator must How to Remove the Generator be installed before installing the Pulley engine drive pulley 1 Remove the engine pivot plate latch retainer 1 Align the woodruff key on the generator shaft with the slot in the pulley and slide the pulley all 2 Open the engine pivot plate latch and swing the the way onto the generator shaft engine out away from the machine to access the generator
473. nnect terminal BLK 21 4 rot T T circuits connect at terminal T circuits connect Connection terminal Circuits crossing no connection Diode Battery 15 Lers Circuit breaker Solenoid or relay coil Horn Tilt sensor Ag NC 1 Limit switch normally closed held open P1 a Red Emergency Stop button normally closed Relay contact normally open TB17 e Ground supression circuit NC ie Ls3 Limit switch 151 NO Limit switch normally open held closed PLAT go GRND Key switch HORN DP Horn button normally open s Relay panel contactor TS3 zz Toggle switch SPDT Boom function speed controller REVA TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 6 Schematics REVA Pressure gauge lt Filter e Fixed displacement pump li Spring applied hydraulically released brake gt Bi directional motor 1 Pump prime mover motor Oylinder zT 0 035 Orifice with size RS Variable orifice or shut off valve Check valve gt M 2 221 Relief valve
474. nt damage Required maintenance procedures and additional engine information are available in the Kubota 2482 Operator s Manual Kubota part number 16676 89163 Kubota 7482 Operator s Manual Genie part number 52958 To access the engine 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine REV B TEREX COMPANY 3 42 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie Z 45 25 Bi Energy and Genie Z 45 25J Bi Energy Operator s Manual on your machine Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non st
475. o 106488 A TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of ADANGER imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures June 2005 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols
476. ontrols flow to functions Brake circuit Primary boom extend Platform rotate and turntable rotate circuits System relief ene Testing Brake circuit Steer circuit Brake circuit Secondary boom up Platform level up Secondary boom down Torque 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 27 ft lbs 37 Nm 20 ft Ibs 27 Nm 20 ft Ibs 27 Nm 20 ft lbs 27 Nm 20 25 ft lbs 27 34 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 20 25 ft lbs 27 34 Nm 20 ft lbs 27 Nm Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 Section 4 Repair Procedures June 2005 MANIFOLDS REV 0 5 0000 Genie Z 45 25 Z 45 25J Bi Energy Part No 106488 Section 4 Repair Procedures pr M Mu uM d MANIFOLDS 9 4 June 2005 REV C Function Manifold Components from serial number 22566 to 23235 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Torque 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 2
477. oog dau AHVONOO3S dau 0951 2 31viOH orna lt STaVLNYNL dau 29811 A magma x bs A 1 N mr o z lt 18 gema 1 xa diH LS TVNIIWH3 L OL mE SS3NuVH 3SV8 LOWHLSY 5 WH QN31X3 woog Oe Qoo 5981 1951 2 WS 1 8 1 Nua Nua O uus OOO 7951 a ou 8 R 8 22 08 22 T aay zana 5 9 NG wamoa aau 248 HOLIMS 4018 LSJ 1951 ta 6 58 TEREX COMPANY Z 45 25 Bi Energy Z 45 25J Bi Energy G PartNo 106488 June 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 from serial number 14079 to 14650 Section 6 Schematics June 2005 _______________ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 from serial number 14651 to 16839 REVA June 2005 45 25 ing Diagram Ir Ground Control Box Terminal Strip W from serial number 14651 to 16839 Section 6 Schematics
478. or towards the machine and tighten the adjustment bolt 6 Check the generator belts for proper tension Refer to Section 2 Specifications If the belt deflection is not within specification perform Steps 4 and 5 and re check the belt tension engine pulley b generator belts c generator pulley Z 45 25 Bi Energy Z 45 25J Bi Energy REVA 7 8 Generator Voltage Regulator How to Adjust the Generator Voltage Regulator The voltage regulator regulates the output voltage of the generator A properly adjusted voltage regulator is essential to good generator performance and service life A defective or improperly adjusted voltage regulator could result in component damage Be sure the batteries are fully charged before performing this procedure 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator 3 Connectthe positive lead of a voltmeter to the Pos terminal on the generator and the negative lead of the voltmeter to the terminal on the generator AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 106488 June 2005 Section 4 Repair Procedures REVA GENERATOR 4 Start the engine from the ground controls and How to Replace the Voltage move the rpm select toggle switch
479. orm Engine 3 37 09 Perform Engine Maintenance 3 38 B Checklist E Procedures Testor Replace the Hydraulic 3 39 E 2 Grease the Steer Axle Wheel Bearings 22 3 40 PerformEngine 3 42 Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy ix June 2005 TABLE OF CONTENTS Section4 Rev IMTOO UCTIOMN NERO Platform Controls 1344 Controllers 06 Platform Components 2 1 Platform Leveling Slave Cylinder 2 2 PlattormbEOotator oorr oce dad B Jib Boom Components Z 45 25J Models 2 1 Jib BOOM 3 2 Jib Boom Lift Primary Boom Components 41 8 4 80 4 2 43 Primary Boom Lift Cylinder 4 4 Primary Boom Extension Cylinder 4 5 Platform Leveling Master Cylinder B Secondary Boom Components 51 Secondary BOOM
480. p 8 N 3 BRN J3 olo D D 22 2 5 55 095 lt lt 011 19 4 2959 2 lt 55 18 8915 gt 5 22 S S RED TILT 3 55 a E E 2 1 915 m c 2 gC lee 8992 33 lala lola lal 121 f P 8 55 16 B 218258265 2 5 lt l3 19 600 50 gt RED TIME 915 mz GRN WHT JOYS ma m 5 5 E 5 5 9 gt 4 GRN WHT R12 2 GRND RED STOP w 5 aRREEEEERPR ee esssseel WHT DIS B S S B 0 2 212 ISIE ISIS 2 2 TIS IS Z D Q Q Z 5 gt gt lt 5 2 IE Sia
481. pulley 2 Loosen the tension adjustment bolt on the generator Pull the generator away from the machine and remove the belts from the generator pulley Disconnect the battery cables from the engine battery AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Remove the engine battery hold down then remove the battery from the machine Remove the generator pulley retaining nut from the generator shaft Slide the pulley off of the generator shaft Genie Part No 106488 Install the flat washer and pulley retaining nut onto the generator shaft then torque the nut to specification Refer to Section 2 Specifications Adjust the tension of the generator belts See 7 2 How to Adjust the Generator Belts Z 45 25 Bi Energy Z 45 25J Bi Energy 4 29 Section 4 Repair Procedures June 2005 GENERATOR 7 2 Generator Belts How to Adjust the Generator Belts 1 Disconnect the battery packs AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Remove the engine pivot plate latch retainer 3 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator belts 4 Loosen the tension adjustment bolt on the generator 5 Push the generat
482. remove the pin Place a block under the slave cylinder for support Protect the cylinder rod from damage Part No 106488 June 2005 Section 4 Repair Procedures REV B 8 Use soft metal drift to drive the rod end pivot pin out AWARNING Cushing 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 CAUTION 9 Use a soft metal drift and drive the barrel end pin out 10 Carefully pull the cylinder out of the primary boom How to Bleed the Slave Cylinder 1 Raise the primary boom to a horizontal position 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy 4 5 PLATFORM COMPONENTS 2 2 Platform Rotator How to Bleed the Platform Rotator This procedure will require two people 1 Move the function enable toggle switch to either side and activate the platform rotate toggle Switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Connecta clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure
483. 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 AWARNING 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 CAUTION 16 Attach a lifting strap from an overhead crane to the upper pivot for support Do not lift it Genie Z 45 25 Bi Energy Z 45 25J Bi Energy REV B 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid point between the upper pivot and mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid pivot and the upper pivot Do not remove the pins 19 Use a soft metal drift to drive both pins out 20 Remove the number 1 arm from the machine AWARNING Crushing hazard The number 1 arm could become unbalanced and fall when removed from the machine if
484. rom the ground controls Move the engine idle select toggle switch to high idle rabbit symbol Result The engine should change to high idle Release the engine idle select toggle switch Result The engine should return to low idle Turn the key switch to platform controls ar At the platform controls move the engine idle select toggle switch to high idle rabbit symbol Result The engine should change to high idle 6 Move the engine idle select toggle switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine idle select toggle switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change to high idle 3 20 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV B 12 Test the Drive Brakes Proper brake action is essential to safe machine operation The machine uses drive motor regenerative braking to stop the machine Hydraulically released individual wheel brakes hold the machine once it has stopped The drive motor regenerative braking should operate smoothly free of hesitation and jerking Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Collision hazard Be sure that the AWARNING
485. rom the machine and remove the belts from the generator pulley Remove the 3 bolts that attach the engine drive pulley to the shaft bushing Install the same 3 bolts that were removed in step 5 into the threaded holes of the engine drive pulley Carefully tighten each bolt evenly until the engine drive pulley slides off the shaft CAUTION Component damage hazard The engine drive pulley and or shaft can be damaged if the bolts are not tightened evenly Loosen the set screw on the pulley bushing then slide the pulley bushing off of the engine shaft gap shaft set screw engine drive pulley engine drive pulley bolt shaft bushing woodruff key Z 45 25 Bi Energy Z 45 25J 4 27 Section 4 Repair Procedures June 2005 uM M cy KUBOTA Z482 E ENGINE REVA How to Install the Engine Drive 3 Tighten the set screw on the pulley bushing hand tight Pulley 4 Slide the engine pulley onto the pulley bushing The generator pulley must already be installed before performing this 5 Install the pulley mounting bolts and tighten procedure See 7 1 How to Install them to specification Refer to Section 2 the Generator Pulley Specifications 1 Align the woodruff key on the engine shaft with CAUTION Component damage hazard Do the slot in the pulley bushing and slide the not overtighten the pulley pulley bushing onto the e
486. rtNo 106488 REVA June 2005 D Section 6 Schematics a se eee See Platform Control Box Wiring Diagram Z 45 25J with LVI BCI Option from serial number 16840 to 17974 C B RED BLK R6 BRN LVJ 1 TIME DELAY 1 ORGIBEK RE 8 7 8 4 2 MN 1 ORG BLK 41 RESET IS
487. rvice a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 2 45 25 Bi Energy and Genie Z 45 25J Bi Energy Operator s Manualon your machine Be sure that all necessary tools and test equipment are available and ready for use TEREX COMPANY Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Perform repair Return to service problem solved PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 6 1 Section 6 Schematics June 2005 Electrical Symbols Legend 1318940 Wire color with cable number 1820 Terminal Quick disco
488. s from the turntable rotation motor manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 106488 June 2005 Section 4 Repair Procedures REV TURNTABLE ROTATION COMPONENTS 13 Attach a lifting strap from and overhead crane or other suitable lifting device to the turntable rotation assembly 14 Remove the turntable rotation assembly mounting fasteners 15 Carefully remove the turntable rotation assembly from the machine AWARNING 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 AWARNING rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Genie 106488 2 45 25 Bi Energy Z 45 25J Bi Energy 4 51 Section 4 Repair Procedures June 2005 Motor Controller 11 1 Motor Controller The drive motor controller is located under the non steer end drive chassis cover The drive motor controller can recognize machine drive malfunctions and display controller fault codes by flashing a LED
489. serial number 14651 1016839 6 77 A Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 14651 to 16839 6 78 A GroundControl Box Terminal Srip Wiring Diagram Z 45 25J from serial number 168401017974 6 79 A Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 16840 to 179740 6 80 PartNo 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy XV June 2005 TABLE OF CONTENTS Section6 Rev Schematics continued Ground Control Box Terminal Srip Wiring Diagram 2 45 25 from serial number 179751021180 6 81 Ground Control Box Switch Panel Wiring Diagram Z 45 25J from serial number 179751021180 6 82 Ground Control Box Terminal Srip Wiring Diagram 2 45 25 from serial 211811022050 6 83 Ground Control Box Switch Panel Wiring Diagram 2 45 25 from serial 211811022050 6 84 Ground Control Box Terminal Srip Wiring Diagram Z 45 25J ANSI CSA Models from serial number 22051 to 23235 6 85 Ground Control Box Switch Panel Wiring Diagram Z 45 25J ANSI and CSA Models from serial number 22051 to 23235 6 86 A Ground Control Box Terminal Srip Wiring Diagram Z 45 25J CE Models from serial number 22051 to 23235
490. table rotation bearing 9 turntable b dial indicator c drive chassis d turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom TEREX COMPANY CHECKLIST D PROCEDURES 7 Note the reading on the dial indicator O Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Ww Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 3 35 Section 3 Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 7 Calibrate the Platform Overload System if equipped Genie specifications require that this procedure be performed every 1000 hours or annually w
491. tform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control 2 Level the platform from the platform controls 3 Determine the maximum platform capacity Refer to the machine serial plate Genie CHECKLIST PROCEDURES 4 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown Result The platform overload indicator light should be off at both the ground and p
492. th LVI BCI Option from serial number 21181 to 22050 Section 6 Schematics June 2005 __________ Platform Control Box Wiring Diagram 2 45 25 after serial number 22051 to 23235 Section 6 Schematics June 2005 Platform Control Box Wiring Diagram Z 45 25 from serial number 22051 to 23235 i 1 BRN RELAY 98 5 8 1 AA 1 2 2 1 o o 2 2 BN SBERBERSS 2222822 RSE SES gt 2 lt ooo 3 ABS 5 255505 2g s a 2225 8 623728 O5 3 gy o g 3 A 215 AE AX A E BRN BATGND A A g 992999999 299999999999 eeegeege
493. th or serious injury 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 AWARNING Used to indicate the presence ofa potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information vi Z 45 25 Bi Energy Z 45 25J Bi Energy 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
494. the hydraulic tank 2 Remove the drain plug from the hydraulic tank 3 Completely drain the hydraulic tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 4 Remove the engine pivot plate latch retainer 5 Open the engine pivot plate latch and swing the engine pivot plate out away from the machine 6 Tag disconnect and plug the hydraulic hoses from the auxiliary pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the auxiliary pump mounting bolts Carefully remove the pump Part No 106488 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy Hydraulic Pumps 8 2 Function Pump How to Remove the Function Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Place a suitable container under the hydraulic tank 2 Remove the drain plug from the hydraulic tank 3 Completely drain the hydraulic tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil
495. the positive and negative battery cables from the generator Loosen the tension adjustment bolt on the generator Pull the generator away from the machine and remove the belts from the generator pulley Remove the generator mounting fasteners then remove the generator from the machine Remove the 3 nuts from the battery cable terminal posts Remove the 3 screws that hold the plastic cover onto the generator Carefully remove the cover Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 31 Section 4 Repair Procedures June 2005 GENERATOR REVA 10 Locate the 3 white wires that lead from the 12 Locate the red wire that leads from the voltage voltage regulator to the negative rectifier regulator to the positive rectifier assembly assembly 13 Remove the screw that attaches the red wire to the positive recitfier assembly 14 Remove the 4 nut that attaches the black wire to the voltage regulator 15 Remove the voltage regulator mounting screws 16 Remove the voltage regulator while carefully guiding the red and black wires from underneath the bottom support of the positive and negative rectifier assembly 17 Install the new voltage regulator by following the previous steps in reverse order 18 Apply Loctite removable thread sealant onto the voltage regulator mounting fasteners and torque to specification Refer to Section 2 Specifications 19 Torque all fasteners
496. tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Primary boom wear REV B D 2 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the primary boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from cylinder and all moving parts when lowering the boom A lift cylinder safety chock is available through Genie part number 33484 pad specifications New Minimum Top bottom and side wear pads 3 4 inch 5 8 inch platform end of boom 19 mm 15 9 mm Side and bottom wear pads 5 8 inch 1 2 inch pivot end of boom 15 9 mm 12 7 mm Top wear pads 3 4 inch 5 8 inch pivot end of boom 19 mm 15 9 mm Genie TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV 2 Check to be sure that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 6 A 9 Bolt torque sequence before serial number 23332 18 1 9 11 6 O 7 T Q 16 13
497. to specification Refer to a white wires 10 nuts Section 2 Specifications b negative rectifier assembly c black wire 10 screw 20 Install the plastic cover onto the generator then d black wire 4 nut install the generator onto the machine e voltage regulator mounting fastener 8 screw 21 Adjust the generator belts See 7 2 How to f voltage regulator Adjust the Generator Belts g redwire 10 screw positive rectifier assembly 22 Adjust the voltage regulator See 7 3 How to 11 Remove the nuts on those 3 wires from the Adjust the Voltage Regulator negative rectifier assembly then remove the CAUTION Component damage hazard The wires voltage regulator and or generator may become damaged if the voltage regulator is not properly adjusted after replacement Do not remove the spacers from the underneath the wires on the negative rectifier assembly When the voltage regulator is replaced the voltage regulator must be adjusted See 7 3 How to Adjust the Voltage Regulator 4 32 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV B 8 1 Auxiliary Pump How to Remove the Auxiliary Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Place a suitable container under
498. to the maintained high idle position Check the voltage on the generator 1 Regulator Disconnect the battery packs from the machine Result The voltage should be 54V DC AWARNING Electrocution hazard Contact with 5 If the voltage reading is not 54V DC insert a small flat blade screwdriver into the potentiometer located inside of the generator Use the access hole on the back of the generator labeled ADJ CAUTION Component damage hazard Be sure that the screwdriver is properly inserted into the potentiometer or the generator and or voltage regulator may become damaged 6 Carefully adjust the potentiometer to obtain a 54V DC voltage reading Turn the potentiometer clockwise to increase the voltage 6 or counterclockwise to decrease the voltage Do not rotate the potentiometer past the internal stops Component damage hazard The CAUTION voltage regulator inside the generator will become damaged if the potentiometer is rotated past 9 the internal stops The maximum range of motion of the potentiometer on the voltage regulator is 280 and the maximum allowed torque is 5 oz in 0 035 Nm Genie electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Remove the engine pivot plate latch retainer 3 Open the engine pivot plate latch and swing the engine out away from the machine to access the generator Tag and disconnect
499. ts Do not adjust the controllers unless the static battery supply voltage is above 24V DC at the platform red Emergency Stop button AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Open the platform control box lid and locate the boom function speed controller Of oza threshold adjustable trimpot max out adjustable trimpot white red wire to TP6 boom function speed controller ao oo Part No 106488 June 2005 Section 4 Repair Procedures REV B PLATFORM CONTROLS Before serial number 21180 3 Remove the wht red wire from TP6 Temporarily insert a short piece of stripped wire into TP6 4 Connect the red lead from an amp meter to the wht red wire Connect the black lead to the piece of wire at TP6 From serial number 21180 to 23235 3 Disconnect the blk red wire of the boom function speed controller from the wht red wire 4 Connect the red lead from an amp meter to the blk red wire Connect the black lead to the wht red wire All models 5 Turn the boom function speed controller to the CREEP position 6 Setthe threshold With the boom in the stowed position press down the foot swit
500. u wires Biz 8 BP1 ROTARY FLOW CONTROL DIAL IN 2 TS gt ges CR6 DRIVE ENABLE RELAY 5 WHT WHT 30 RS 6 RUE CR7A JIB CUTOUT RELAY A 2 1 x e e WHT BLK 31 5 CR7B JIB VALVE RELAY REV RED im CR19A LOW VOLTAGE INTERRUPT BCI RELAY A p prm WHT GRN 2 Apo at ims 58 CRI9B LOW VOLTAGE INTERRUPT BCI RELAY B 9 RED lt 1 1 DRIVE JOYSTICK A O O BLK RED E 7 PEBRA Li DRIVE ENABLE LED BLU R6 a DRIVE LVI LOW VOLTAGE INTERRUPT MODULE 3 5 4 24 9 log BLUBUST 5 BATTERY CHARGE INDICATOR FOR LVI OPTION e _WHT RED De BLU 36 2 EMERGENCY STOP BUTTON 7 TS12 1510 1511 TS13 P3 HORN SECONDARY PRIMARY EXTEND 2220 ROTATE OPTION BOOM BOOM RETRACT mE BLK WHT 9 1 TIME DELAY 1 TS1 AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH RER BLK WHT TS4 HIGH LOW RPM TOGGLE SWITCH 2 0 m 6 _ o TS6 GLOW PLUG TOGGLE SWITCH P eau fae 9 TS7 PLATFORM ROTATE TOGGLE SWITCH a P SS TS8 JIB BOOM UP DOWN TOGGLE SWITCH 8 LL DRIVE ENABLE 1s EN Fo 5 07 TS9 PLATFORM LEVEL TOGGLE SWITCH 6 HORN GLOW PLUG ENGINE TSA gt S TS10 SECONDARY BOOM TOGGLE SWITCH POWER RPM qH TS8 TS7 TS9 START ES PRIMARY BOOM UP DOWN TOGG
501. ug on the rod end of the jib boom lift cylinder 19 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the bellcrank AWARNING 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 Genie Z 45 25 Bi Energy Z 45 25J Bi Energy REV B 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 106488 June 2005 Section 4 Repair Procedures SS Sy REV B JIB BOOM COMPONEN
502. ury 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 AWARNING 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 Genie 4 12 Z 45 25 Z 45 25J 106488 June 2005 Section 4 Repair Procedures REV 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 AWARNING 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
503. ut for proper torque Refer to Section 2 Specifications 4 Check the pressure in each air filled tire Refer to Section 2 Specifications TEREX Z 45 25 Bi Energy Z 45 25J Bi Energy MPANY REV B B 6 Confirm the Proper Brake Configuration 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 arf arg E brake engaged position Part No 106488 June 2005 Section 3 Scheduled Maintenance Procedures REV B 7 Check the Oil Level in the Drive Hubs Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees models with pipe plugs CN a models with o ring plugs Part No 106488 Genie ee CHECKLIST B PROCEDURES Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Models w
504. vents overflowing the proportional valve 10 12 ft Ibs 14 6 Nm This list continues Please turn the page 4 34 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 June 2005 Section 4 Repair Procedures REV O OOO Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy 4 35 MANIFOLDS 00 G9 GD 9 9 Section 4 Repair Procedures June 2005 w QV X M 1M sw t MANIFOLDS REV C Function Manifold Components before serial number 17841 continued The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index Schematic No Description Item Function Torque 20 Flow regulator valve 0 6 2 27 L min Jib boom up down platform rotate left right and platform level up down prevents overflowing the proportional valve 10 12 ft lbs 14 6 Nm 21 Counterbalance valve Platform level down 35 40 ft lbs 47 54 Nm 22 Relief valve 3200 psi 220 6 bar System 35 40 ft lbs 47 54 Nm 23 Diagnostic nipple Testing 24 Check niece etes Pressure switch circuit 10 12 ft Ibs
505. y 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 Usea soft metal drift to drive the rod end pivot pin half way out 8 Remove the secondary boom lift cylinder from the machine AWARNING 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 CAUTION Part No 106488 June 2005 Section 4 Repair Procedures REVA 6 1 Timing Adjustment Complete information to perform this procedure is available in the Kubota 2482 Workshop Manual Kubota part number 97897 01165 Kubota Z482 E Workshop Manual Genie part number 52956 6 2 RPM Adjustment See the scheduled maintenance procedure B 8 Check and Adjust the Engine RPM 6 3 Engine Drive Pulley How to Remove the Engine Drive Pulley 1 Remove the engine pivot plate latch retainer 2 Open the engine pivot plate latch and swing the engine out away from the machine to access the engine drive pulley 3 Loosen the tension adjustment bolt on the generator Part No 106488 Genie Kubota 2482 Engine Pull the generator away f
506. ydraulic Motor before serial number 18367 4 48 10 2 Turntable Rotation Assembly after serial number 18366 4 50 A Motor Controller 11 1 MotorCornitroller iiie Gon ar aden RED teddies lattes 4 52 Part No 106488 Z 45 25 Bi Energy Z 45 25J Bi Energy xi June 2005 TABLE OF CONTENTS Section5 Rev FaultCodes INTPOCUCHON 5 1 A pecu co ctu 5 3 Section6 Rev Schematics nurse ETE 6 1 A Electrical Symbols 6 2 A Hydraulic Symbols legend tee Rice 6 3 Power Cable Diagrams A Power Cable Diagram before serial number 16839 6 5 A Power Cable Diagram from serial number 168401021179 6 6 A Power Cable Diagram from serial number 21180 to 22050 6 7 A Power Cable Diagram from serial number 22051 to 23235 6 8 Engine Panel Diagrams A Engine Panel Diagram before serial number 13361 6 9 A EnginePanelDiagram from serial number 13361 to 14078 6 10 A Engine Panel Diagram from serial number 14079 to 14650 6 11 A EnginePanelDiagram from serial number 14651 to 16839
507. zat HIGH LOW RPM TOGGLE SWITCH 990 oS 2 TS6 GLOW PLUG TOGGLE SWITCH Gm 6 C A GAY M 7 157 PLATFORM ROTATE TOGGLE SWITCH TB FO 5 5 FAULT LED 8 1 DRIVE ENABLE es T TS9 PLATFORM LEVEL TOGGLE SWITCH E AUXILIARY Grow Bild ENGINE 1 gt TS10 SECONDARY BOOM TOGGLE SWITCH POWER Hu T TS7 Duy C SIART p2 1811 PRIMARY BOOM UP DOWN TOGGLE SWITCH PLATFORM ROTATE EMERGENCY STOP TS12 TURNTABLE ROTATE TOGGLE SWITCH RED TS13 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH ORGIED 42 7614 DRIVE RANGE HIGH LOW TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH enie A TEREX COMPANY 6 93 Z 45 25 Bi Energy Z 45 25J Bi Energy Part No 106488 REVA June 2005 F E D Section 6 Schematics I Platform Control Box Wiring Diagram Z 45 25 with Platform Load Sense and LVI BCI Option from serial

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

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