Professional Documents
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Z45:25
Z45:25
Z®-45/25
from Z452513A
to Z452516N-57199
This manual includes:
Repair procedures
Fault Codes
Z®-45/25J
from Z4525N-57200
Electrical and
Hydraulic Schematics
Bi-Energy Power
Introduction
Intr oducti on Intr oducti on
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 9/2016 Repair 12-1
A3 11-2017 Specifications Machine Specifications
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Introduction
Safety Rules
Section 1 Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Safety Rules
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
Indicates a potentially hazardous
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Table of Contents
Engines ................................................................................................................40
6-1 Timing Adjustment ..........................................................................................40
6-2 RPM Adjustment ............................................................................................40
6-3 Engine Drive Pulley ........................................................................................40
How to Remove the Engine Drive Pulley ........................................................40
How to Install the Engine Drive Pulley ............................................................41
Table of Contents
Generator ............................................................................................................ 43
7-1 Generator Pulley ............................................................................................ 43
How to Remove the Generator Pulley ............................................................ 43
How to Install the Generator Pulley ................................................................ 43
7-2 Generator Belts .............................................................................................. 44
7-3 Generator Voltage Regulator ......................................................................... 44
How to Adjust the Generator Voltage Regulator ............................................. 44
How to Replace the Voltage Regulator ........................................................... 45
Manifolds ............................................................................................................. 49
9-1 Function Manifold Components ..................................................................... 49
9-2 Valve Adjustments - Function Manifold .......................................................... 51
How to Adjust the System Relief Valve ........................................................... 51
How to Adjust the Secondary Boom Down Relief Valve ................................. 51
9-3 Jib Boom / Platform Rotate Manifold Components ........................................ 52
9-4 Turntable Rotation Manifold Components ..................................................... 53
9-5 Valve Coils ..................................................................................................... 54
How to Test a Coil Diode ................................................................................ 54
Table of Contents
Specifications
Section 2 Specific ati ons
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Kubota Z482-E3B Engine For fuel requirements, refer to the engine Operator
Manual for your engine.
Displacement 29.23 cu in Injection system
0.48 liters
Injection pump make Bosch MD
Number of cylinders 2
Injection timing 21° BTDC
Bore and Stroke 2.64 x 2.68 inches
Injection pump pressure 1991 psi
67 x 68 mm
137 bar
Horsepower 13.3 @ 3600 rpm
Starter motor
9.9 kW
Brush length, new 0.5188 in
Firing order 1-2
13 mm
Low idle 2000 rpm Brush length, minimum 0.3346 in
High idle 3000 rpm 8.5 mm
Governor centrifugal mechanical Alternator
Valve clearance, cold 0.0057 to 0.0072 in Alternator output 12V DC, 150 watts
0.145 to 0.185 mm Fan belt deflection 1/4 to 3/8 inch
Compression ratio 23:1 7 to 9 mm
Compression pressure 412 to 469 psi Battery
28.4 to 32.3 bar Type 12V DC, Group 70
Lubrication system Quantity 1
Oil pressure 36 to 64 psi Cold cranking ampere 450A
2.48 to 4.41 bar
Reserve capacity @ 25A rate 125 minutes
Oil capacity (including filter)
Z482-E2B 2.2 quarts
2.1 liters
Z482-E3B 2.6 quarts
2.5 liters
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Specifications
Specifications
Specifications
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
Specifications
Repair Procedures
Machine Configuration:
Section 3 Repair Pr oc edures
Repair Procedures
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.
Platform Controls
Platform Controls
Platform Components
Platform Components
How to Bleed the Sl av e Cylinder
9 Use a soft metal drift to drive the rod-end pivot How to Bleed the Slave Cylinder
pin out.
Note: This procedure will have to be preformed
Crushing hazard. The platform outside.
could fall when the slave cylinder
rod-end pivot pin is removed if 1 Z45/25J: Raise the jib to a horizontal postion
not properly supported. and raise the secondary boom 3 feet.
Z45/25: Raise the secondary boom 4 feet.
Component damage hazard.
The slave cylinder rod may 2 Move the function enable toggle switch to
become damaged if it is allowed either side. Simultaneously activate and hold
to fall if not properly supported the primary boom up and platform level up
by the lifting device. toggle switches until the primary boom is fully
raised.
10 Use a soft metal drift and drive the barrel-end The platform should be facing in an upward
pin out. position. As shown.
11 Carefully pull the cylinder out of the primary
boom.
Z45/25 Z45/25J
Platform Components
Platform Components
2 Disconnect the electrical connector from the 12 Attach a lifting strap from an overhead crane
jib boom/platform rotate select valve manifold to the jib boom.
mounted to the platform support. 13 Support the barrel end of the jib boom lift
3 Tag, disconnect and plug all of the hydraulic cylinder with a suitable lifting device.
hoses from the jib boom/platform rotate select 14 Tag, disconnect and plug the jib boom lift
valve manifold. Cap the fittings on the cylinder hydraulic hoses. Cap the fittings on
manifold and pull the hoses out through the the cylinder.
platform rotator.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.
15 Remove the pin retaining fastener from the jib
4 Remove the platform mounting weldment. boom lift cylinder barrel-end pivot pin.
5 Attach a lifting strap from an overhead crane
to the platform rotator for support.
6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
16 Use a soft metal drift to remove the pin and let 3-2
the cylinder hang down.
Jib Boom Lift Cylinder
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not How to Remove the Jib Boom Lift
properly supported by the Cylinder
overhead crane.
Note: Perform this procedure with the boom in the
17 Remove the pin retaining fastener from the jib stowed position.
boom pivot pin. Use a soft metal drift to Note: When removing a hose assembly or fitting,
remove the pin, then remove the jib boom from the O-ring (if equipped) on the fitting and/or hose
the bellcrank. end must be replaced. All connections must be
Crushing hazard. The jib boom torqued to specification during installation. Refer to
may become unbalanced and fall Specifications, Hydraulic Hose and Fitting Torque
when it is removed from the Specifications.
machine if it is not properly
1 Raise the jib boom slightly and place blocks
supported by the overhead
under the platform mounting weldment. Then
crane.
lower the jib boom until the platform is resting
on the blocks just enough to support the
18 Attach a lifting strap from an overhead crane
platform.
to the lug on the rod end of the jib boom lift
cylinder. Note: Do not rest the entire weight of the boom on
the blocks.
19 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pivot pin, then remove the 2 Tag, disconnect and plug the jib boom lift
jib boom lift cylinder from the bellcrank. cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Crushing hazard. The jib boom
lift cylinder may become Bodily injury hazard. Spraying
unbalanced and fall when it is hydraulic oil can penetrate and
removed from the machine if it is burn skin. Loosen hydraulic
not properly supported by the connections very slowly to allow
overhead crane. the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
from the "PR1" and "PR2" ports on the
Z-45/25 counterbalance valve manifold located on the
Note: When removing a hose assembly or fitting, platform rotator. Cap the fittings on the
the O-ring (if equipped) on the fitting and/or hose manifold.
end must be replaced. All connections must be Bodily injury hazard. Spraying
torqued to specification during installation. Refer to hydraulic oil can penetrate and
Specifications, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
the oil pressure to dissipate
1 Locate the cables from the primary boom
gradually. Do not allow oil to
cable track to the platform control box.
squirt or spray.
Number each cable and its entry location at
the platform control box.
7 Tag, disconnect and plug the hydraulic hoses
2 Disconnect the cables from the platform from the platform leveling master cylinder.
control box. Cap the fittings on the cylinder.
3 Pull all of the electrical cables out of the plastic Bodily injury hazard. Spraying
cable track. Do not pull out the hydraulic hydraulic oil can penetrate and
hoses. burn skin. Loosen hydraulic
connections very slowly to allow
4 Raise the primary boom to a horizontal
the oil pressure to dissipate
position.
gradually. Do not allow oil to
squirt or spray.
8 Tag and disconnect the hydraulic hoses from 13 Remove the mounting fasteners from the
the platform leveling slave cylinder and upper cable track at the platform end of the
connect them together using a connector. Cap extension boom.
the fittings on the cylinder.
14 Remove the cable track mounting fasteners
Bodily injury hazard. Spraying that attach the lower cable track to the primary
hydraulic oil can penetrate and boom.
burn skin. Loosen hydraulic
connections very slowly to allow 15 Remove the cable track from the machine and
the oil pressure to dissipate place it on a structure capable of supporting it.
gradually. Do not allow oil to
Crushing hazard. The cable
squirt or spray.
track could become
unbalanced and fall if not
9 Pull the four hydraulic hoses toward the
properly attached to the
platform to clear the rod end of the primary
overhead crane.
boom lift cylinder.
10 Place blocks in between the upper and lower Component damage hazard.
cable tracks and secure the upper and lower Cables and hoses can be
tracks together. damaged if they are kinked or
pinched.
Crushing hazard. If the upper
and lower cable tracks are not
properly secured together, the
cable track could become
unbalanced and fall when
removed from the machine.
11 Raise the boom to a horizontal position. 21 Raise the rod end of the primary boom lift
cylinder back into position and install the
12 Place blocks between the upper and lower rod-end pivot pin. Install the pin retaining
cable tracks and secure the upper and lower fasteners.
tracks together.
22 Attach a strap from an overhead crane to the
Crushing hazard. If the upper cable track.
and lower cable tracks are not
properly secured together, the 23 Remove the mounting fasteners from the
cable track could become upper cable track at the platform end of the
unbalanced and fall when extension boom.
removed from the machine.
24 Remove the cable track mounting fasteners
that attach the lower cable track to the primary
13 Attach a lifting strap from an overhead 5 ton /
boom.
5,000 kg capacity crane to the platform end of
the primary boom for support. Do not lift it. 25 Remove the cable track from the machine and
place it on a structure capable of supporting it.
14 Remove all hose and cable clamps from the
underside of the primary boom. Crushing hazard. The cable
track could become
15 Support the rod end of the primary boom lift
unbalanced and fall if not
cylinder with a suitable lifting device.
properly attached to the
16 Remove the pin retaining fasteners from the overhead crane.
primary boom lift cylinder rod-end pivot pin. Do
not remove the pin. Component damage hazard.
Cables and hoses can be
17 Raise the primary boom slightly with the
damaged if they are kinked or
overhead crane to relieve the pressure on the
pinched.
primary boom lift cylinder rod-end pivot pin.
18 Use a soft metal drift to remove the primary
boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary
boom lift cylinder could become
unbalanced and fall if not
properly supported by the lifting
device.
6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead crane to
master cylinder barrel-end pivot pin. Use a soft the center point of the primary boom.
metal drift to remove the pin. Then lower the
15 Attach a similar lifting device to the primary
cylinder and let it hang down.
boom lift cylinder.
Component damage hazard.
16 Place support blocks under the primary boom
When lowering the master
lift cylinder.
cylinder down, be sure not to
damage the master cylinder 17 Remove the pin retaining fasteners from the
hoses or fittings. primary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin.
7 Locate the primary boom drive speed limit
switch inside of the upper pivot. Crushing hazard. The boom lift
cylinder and primary boom will
8 Remove the primary boom drive speed limit fall if not properly supported.
switch mounting fasteners. Do not disconnect
the wiring. 18 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
9 Locate the primary extension boom drive
speed limit switch inside of the extension cylinder rod from damage.
boom. 19 Remove the pin retaining fasteners from the
primary boom pivot pin.
10 Remove the primary extension boom drive
speed limit switch mounting fasteners. Do not 20 Remove the primary boom pivot pin with a soft
disconnect the wiring. metal drift, then carefully remove the primary
boom from the machine and place it on a
11 Pull the limit switch and the wiring out of the
extension tube and move it out of the way. structure capable of supporting it.
12 Tag, disconnect and plug the primary boom Crushing hazard. The primary
extension cylinder hydraulic hoses. Cap the boom could become unbalanced
fittings on the cylinder. and fall when removed from the
machine if not properly attached
Bodily injury hazard. Spraying to the overhead crane.
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.
How to Disassemble the Primary 6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
Boom platform end of the extension tube. Use a soft
Complete disassembly of the boom is only metal drift to remove the pin.
necessary if the outer or inner boom tube must be
7 Support and slide the extension cylinder out of
replaced. The extension cylinder can be removed
the base end of the extension tube. Place the
without completely disassembling the boom. Refer
extension cylinder on blocks for support.
to Repair Procedure, How to Remove the Primary
Boom Extension Cylinder. Crushing hazard. The extension
cylinder could become
1 Remove the primary boom. Refer to Repair unbalanced and fall when
Procedure, How to Remove the Primary
removed from primary boom
Boom. extension tube if not properly
2 Place blocks under the barrel end of the supported.
primary boom extension cylinder for support.
Note: During removal, the overhead crane strap will
3 Remove the pin retaining fastener from the need to be carefully adjusted for proper balancing.
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom. Use a soft
metal drift to remove the pin.
4 Remove and label the location of the wear
pads from the platform end of the primary
boom.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
How to Remove the Primary 5 At the platform end of the boom, remove the
Boom Extension Cylinder external snap rings from the extension
cylinder rod-end pivot pin. Use a soft metal
Bodily injury hazard. This drift to remove the pin.
procedure requires specific repair
6 Remove the barrel-end pivot pin retaining
skills, lifting equipment and a
fasteners.
suitable workshop. Attempting
this procedure without these skills 7 Place a rod through the barrel-end pivot pin
and tools could result in death or and twist to remove the pin.
serious injury and significant
component damage. Dealer 8 Support and slide the extension cylinder out of
service is strongly recommended. the upper pivot.
Crushing hazard. The extension
Note: When removing a hose assembly or fitting, cylinder could fall when removed
the O-ring (if equipped) on the fitting and/or hose from the extension boom if not
end must be replaced. All connections must be properly supported.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications. Component damage hazard. Be
careful not to damage the
1 Raise the primary boom to a horizontal counterbalance valves on the
position. primary boom extension cylinder
when removing the cylinder from
2 Extend the primary boom until the primary the primary boom.
boom extension cylinder rod-end pivot pin is
accessible in the primary boom extension
Component damage hazard.
tube. Hoses and cables can be
3 Remove the hose and cable guard from the damaged if the primary boom
upper pivot. extension cylinder is dragged
across them.
1 Remove the platform. 9 Tag, disconnect and plug the hydraulic hoses
on both of the secondary boom lift cylinders.
2 Z-45/25J: Remove the jib boom. Refer to Cap the fittings on the cylinders.
Repair Procedure, How to Remove the Jib
Boom. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
3 Remove the primary boom. Refer to Repair burn skin. Loosen hydraulic
Procedure, How to Remove the Primary connections very slowly to allow
Boom. the oil pressure to dissipate
4 Remove the master cylinder. Refer to Repair gradually. Do not allow oil to
Procedure, How to Remove the Master squirt or spray.
Cylinder.
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 17 Attach a lifting strap from a second overhead
lug on the rod end of one of the secondary crane to the number 1 arm at the mid-point
boom lift cylinders for support. Do not apply between the upper pivot and mid-pivot.
any lifting pressure.
18 Remove the pin retaining fasteners from the
12 Use a soft metal drift to drive the barrel-end number 1 arm pivot pins at the mid-pivot and
pivot pin half way out. Lower the barrel end of the upper pivot. Do not remove the pins.
the secondary boom lift cylinder and let it hang
down. 19 Use a soft metal drift to drive both pins out.
13 Use a soft metal drift to drive the rod-end pivot 20 Remove the number 1 arm from the machine.
pin half way out. Crushing hazard. The number 1
14 Remove the secondary boom lift cylinder from arm could become unbalanced
the machine. and fall when removed from the
machine if not properly attached
15 Repeat steps 11 through 14 for the other to the overhead crane.
secondary boom lift cylinder.
Crushing hazard. The secondary Crushing hazard. The upper
boom lift cylinder could become pivot could fall when the number
unbalanced and fall when 1 arm is removed from the
removed from the machine if not machine if not properly
properly attached to the supported by the overhead
overhead crane. crane.
16 Attach a lifting strap from an overhead crane Crushing hazard. The secondary
to the upper pivot for support. Do not lift it. boom assembly could fall if not
properly supported by the4 x 4 x
11 inch / 10 x 10 x 28 cm block.
23 Pull all of the cables and hoses out through 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
the upper pivot. block between the number 3 arm and the
number 4 arm at the mid-pivot end.
Component damage hazard.
Cables and hoses can be 32 Attach a lifting strap from the overhead crane
damaged if they are kinked or to the mid-pivot for support. Do not lift it.
pinched.
33 Remove the pin retaining fasteners from the
number 2, 3 and 4 arm pivot pins at the
24 Remove the hose and cable covers from the
mid-pivot. Do not remove the pins.
top of the number 2 arm.
34 Use a soft metal drift to drive each pin out.
25 Pull all of the hoses and cables out of the
Then remove the mid-pivot from the
upper pivot and out through the mid-pivot. Lay
secondary boom assembly.
the hoses and cables on the ground.
Crushing hazard. The mid-pivot
Component damage hazard.
could become unbalanced and
Cables and hoses can be
fall when removed from the
damaged if they are kinked or
secondary boom assembly if not
pinched.
properly supported by the
overhead crane.
26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use
35 Attach the lifting strap from an overhead crane
a soft metal drift to remove the pin.
to the center point of the number 2 arm for
27 Remove the upper pivot from the machine. support. Do not lift it.
Crushing hazard. The upper 36 Remove the pin retaining fasteners from both
pivot could become unbalanced compression link pivot pins. Do not remove
and fall when removed from the the pins.
machine if not properly attached 37 Use a soft metal drift to remove the lower
to the overhead crane. compression link pivot pin at the number 3
arm.
28 Attach the lifting strap from an overhead crane
to the number 2 arm at the upper pivot end. 38 Support the compression link with an
appropriate lifting device.
29 Raise the number 2 arm slightly and remove
the 4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest
pad.
39 Use a soft metal drift to remove the upper 45 Using an approved hand-operated pump,
compression link pivot pin from the number 2 drain the fuel tank into a container of suitable
arm. Remove the compression link from the capacity. Refer to Specifications, Machine
machine. Specifications.
Crushing hazard. The number 2 Explosion and fire hazard.
arm could fall when the Engine fuels are combustible.
compression link is disconnected Perform this procedure in an
from the number 2 arm if not open, well-ventilated area away
properly supported by the from heaters, sparks, flames and
overhead crane. lighted tobacco. Always have an
approved fire extinguisher within
Crushing hazard. The easy reach.
compression link may fall if not
properly supported when Explosion and fire hazard. When
removed from the secondary transferring fuel, connect a
boom assembly. grounding wire between the
machine and pump or container.
40 Remove the number 2 arm from the machine.
Note: Be sure to only use a hand-operated pump
Crushing hazard. The number 2 suitable for use with gasoline and diesel fuel.
arm could become unbalanced
and fall when removed from the 46 Tag, disconnect and plug the fuel hoses from
secondary boom assembly if the fuel tank. Clean up any fuel that may have
not properly supported by the spilled.
overhead crane.
47 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the
41 Remove the upper and lower hose and cable
machine.
covers from the number 3 arm.
42 Pull all of the cables and hoses from the Component damage hazard.
number 3 arm and lay them over the turntable The fuel tank is plastic and may
counterweight. become damaged if allowed to
fall.
Component damage hazard.
Cables and hoses can be Note: Clean the fuel tank and inspect for cracks
damaged if they are kinked or and other damage before installing it onto the
pinched. machine.
48 Remove the retaining fastener from the 56 Remove the secondary boom drive speed limit
ground control box and function manifold pivot switch mounting fasteners from the number 4
plate. arm at the mid-pivot end. Do not disconnect
the wiring.
49 Lower the ground control box and function
manifold pivot plate to access the number 3 57 Remove the pin retaining fasteners from the
arm pivot pin. number 4 arm at the turntable riser. Do not
remove the pin.
50 Attach the lifting strap from the overhead
crane to the centerpoint of the number 3 arm 58 Attach a lifting strap from the overhead crane
for support. Do not lift it. to the center point of the number 4 arm. Do not
lift it.
51 Remove the mounting fasteners from the
cover located in the boom storage area to 59 Use a slide hammer to remove the number 4
access the number 3 and number 4 arm pivot arm from the turntable riser through the
pin retaining fasteners at the turntable riser. ground controls side bulkhead.
52 Remove the pin retaining fasteners from the 60 Remove the number 4 arm from the machine.
number 3 arm at the turntable riser. Do not
remove the pin. Crushing hazard. The number 4
arm could become unbalanced
53 Use a slide hammer to remove the number 3 and fall when removed from the
arm pivot pin from the turntable pivot through machine if not properly
the access hole behind the ground control supported by the overhead
box. crane.
54 Remove the number 3 arm from the machine.
Crushing hazard. The number 3
arm could become unbalanced
and fall when removed from the
machine if not properly
supported by the overhead
crane.
Engines
6-1 6-3
Timing Adjustment Engine Drive Pulley
How to R emove the Engi ne Drive Pulley
Engines
How to Ins tall the Engi ne Drive Pull ey
7 Carefully tighten each bolt evenly until the How to Install the Engine Drive
engine drive pulley slides off the shaft.
Pulley
Component damage hazard. Note: The generator pulley must already be
The engine drive pulley and/or installed before performing this procedure. Refer to
shaft can be damaged if the bolts Repair Procedure, How to Install the Generator
are not tightened evenly. Pulley.
8 Loosen the set screw on the pulley bushing, 1 Align the woodruff key on the engine shaft with
then slide the pulley bushing off of the engine the slot in the pulley bushing and slide the
shaft. pulley bushing onto the engine shaft. Do not
tighten the set screw.
2 Align the flywheel side of the pulley bushing on
the engine shaft with the outer face of the
generator pulley using a straightedge.
1 gap
2 shaft
3 set screw
4 engine drive pulley
5 engine drive pulley bolt
6 shaft bushing
7 woodruff key
1 pulley shaft
2 pulley bushing
3 engine flywheel
4 straightedge
5 generator pulley
6 generator
Engines
3 Tighten the set screw on the pulley bushing 6 Check the alignment between the engine drive
hand tight. pulley and the generator pulley using a
straightedge. Refer to Specifications,
4 Slide the engine pulley onto the pulley
Generator.
bushing.
Note: If the pulley alignment is not within
5 Install the pulley mounting bolts and tighten specification, remove the engine pulley and repeat
them to specification. Refer to Specifications, steps 2 through 6. Refer to Repair Procedure, How
Generator Specifications. to Remove the Engine Drive Pulley.
Component damage hazard. Do
not overtighten the pulley
mounting bolts. There must be a
gap visible between the engine
drive pulley and the pulley
bushing.
1 gap
2 shaft
3 set screw
4 engine drive pulley
5 engine drive pulley bolt
6 shaft bushing
7 woodruff key
Generator
How to Ins tall the Generator Pull ey
Generator
7-2 7-3
Generator Belts Generator Voltage Regulator
w to Adjus t the Gener ator Voltage R egul ator
1 engine pulley
2 generator belts
3 generator pulley
Generator
How to R eplac e the Voltage Regulator
4 Start the engine from the ground controls and How to Replace the Voltage
move the rpm select toggle switch to the
maintained high idle position. Check the
Regulator
voltage on the generator. 1 Disconnect the battery packs from the
Result: The voltage should be 54V DC. machine.
Component damage hazard. Be 2 Remove the engine pivot plate latch retainer.
sure that the screwdriver is
properly inserted into the 3 Open the engine pivot plate latch and swing
potentiometer or the generator the engine out away from the machine to
and/or voltage regulator may access the generator.
become damaged. 4 Tag and disconnect the positive and negative
battery cables from the generator.
6 Carefully adjust the potentiometer to obtain a
54V DC voltage reading. Turn the 5 Loosen the tension adjustment bolt on the
potentiometer clockwise to increase the generator.
voltage or counterclockwise to decrease the 6 Pull the generator away from the machine and
voltage. Do not rotate the potentiometer past remove the belts from the generator pulley.
the internal stops.
7 Remove the generator mounting fasteners
Component damage hazard. then remove the generator from the machine.
The voltage regulator inside the
generator will become 8 Remove the 3 nuts from the battery cable
damaged if the potentiometer is terminal posts.
rotated past the internal stops. 9 Remove the 3 screws that hold the plastic
cover onto the generator. Carefully remove
Note: The maximum range of motion of the
the cover.
potentiometer on the voltage regulator is 280° and
the maximum allowed torque is 5 oz-in / 0.035 Nm.
Generator
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 rectifier 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 Specifications,
Machine Torque Specifications.
1 white wires (#10 nuts) 19 Torque all other fasteners to specification.
2 negative rectifier assembly Refer to Specifications, Machine Torque
3 black wire (#10 screw) Specifications.
4 black wire (#4 nut) 20 Install the plastic cover onto the generator
5 voltage regulator mounting fastener (#8 then install the generator onto the machine.
screw)
6 voltage regulator 21 Adjust the generator belts. Refer to repair
procedure, How to Adjust the Generator Belts.
7 red wire (#10 screw)
8 positive rectifier assembly 22 Adjust the voltage regulator. See How to
Adjust the Voltage Regulator.
11 Remove the nuts on those 3 wires from the
negative rectifier assembly, then remove the Component damage hazard.
wires. The voltage regulator and/or
generator may become
Note: Do not remove the spacers from the damaged if the voltage
underneath the wires on the negative rectifier regulator is not properly
assembly. adjusted after replacement
Hydraulic Pumps
Hydraulic Pumps
Manifolds
9-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 3 way A Primary boom retract 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way B Primary boom up/down 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way C Secondary boom up/down 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way D Turntable rotate left/right 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way E Platform rotate left/right andjib 25 ft-lbs / 34 Nm
boom up/down (Z-45/25J)
6 Solenoid valve, 3 position 4 way F Platform level up/down 25 ft-lbs / 34 Nm
7 Shuttle valve G Platform level circuit 4-5 ft-lbs / 5.5-6.7
Nm
8 Solenoid valve, 3 position 4 way H Steer left/right 25 ft-lbs / 34 Nm
9 Proportional solenoid valve I Controls flow to functions 27 ft-lbs / 37 Nm
10 Pressure switch J Brake circuit
11 Solenoid valve, 2 position 3 way K Primary boom extend 20 ft-lbs / 27 Nm
12 Flow regulator valve, 0.4 gpm / 1.5 L/min L Platform rotate and 20 ft-lbs / 27 Nm
turntablerotate circuits
13 Needle valve M Platform level circuit 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar N Platform level circuit 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar O System relief 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar P Brake circuit 12-14 ft-lbs / 16-19
Nm
17 Orifice, 0.060 inch / 1.5 mm Q Steer circuit
18 Orifice, 0.030 inch / 0.76 mm R Proportional valve circuit
19 Solenoid valve, 2 position 3 way S Brake circuit 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm(located under T Brake circuit
item S)
20 Orifice, 0.037 inch / 0.94 mm U
21 Check valve, pilot operated V Platform level circuit 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar W Secondary boom down circuit 20 ft-lbs / 27 Nm
Manifolds
Manifolds
How to Adj ust the Sec ondary Boom D own R elief Valv e
Manifolds
9-3
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 3 way AA Jib boom / platform rotate select 20 ft-lbs / 27 Nm
Manifolds
9-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Schematic
Index No. Description Function Torque
Item
1 Shuttle valve 2 position 3 way X Turntable rotation brake 10-13 ft-lbs / 14-18 Nm
release
2 Counterbalance valve Y Turntable rotate right 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve Z Turntable rotate left 30-35 ft-lbs / 41-47 Nm
Manifolds
How to T est a Coil Di ode
Manifolds
1 multimeter
2 9V DC battery
3 10Ω resistor
4 coil
Note: When removing a hose assembly or fitting, 9 Tag, disconnect and plug the fuel hoses from
the O-ring (if equipped) on the fitting and/or hose the fuel tank.
end must be replaced. All connections must be 10 Remove the fuel tank strap fasteners and
torqued to specification during installation. Refer to remove the tank strap.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 11 Remove the fuel tank from the machine.
1 Raise the secondary boom until the upper 12 Tag, disconnect and plug the hydraulic hoses
pivot is above the turntable covers. Turn the from the turntable rotation motor manifold.
machine off. Cap the fittings on the manifold.
2 Secure the turntable from rotating with the Bodily injury hazard. Spraying
turntable rotation lock. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Tip-over hazard. The machine connections very slowly to allow
could tip over when the turntable the oil pressure to dissipate
rotation assembly is removed if gradually. Do not allow oil to
the turntable rotation lock is not squirt or spray.
in the locked position.
13 Attach a lifting strap from and overhead crane
3 Remove the engine pivot plate latch retainer. or other suitable lifting device to the turntable
rotator assembly.
4 Open the engine pivot plate latch and swing
the engine out and away from the machine to 14 Remove the turntable rotation assembly
access the turntable rotation assembly. mounting fasteners.
5 Remove the retaining fasteners from the 15 Carefully remove the turntable rotation
center turntable cover. Remove the cover from assembly from the machine.
the machine.
Tip-over hazard. The machine
6 Disconnect the battery backs from the could tip over when the turntable
machine rotation assembly is removed if
the turntable rotation lock is not
Electrocution/burn hazard.
in the locked position.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings, Crushing hazard. The turntable
watches and other jewelry. rotation assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Motor Controllers
1 Loosen the wheel lug nuts. Do not remove 1 Be sure that both bearings are packed with
them. clean, fresh grease.
2 Block the non-steer wheels and place a lifting 2 Place the large inner bearing into the rear of
jack under the steer axle. the hub.
3 Raise the machine. Place blocks under the 3 Install a new bearing grease seal into the hub
drive chassis for support. by pressing it evenly into the hub until it is
flush.
4 Remove the lug nuts. Remove the tire and
wheel assembly. Note: Always replace the bearing grease seal when
removing the hub.
5 Remove the dust cap, cotter pin and castle
nut. 4 Slide the hub onto the yoke spindle.
Note: Always use a new cotter pin when installing a Component damage hazard. Do
castle nut. not apply excessive force or
damage to the lip of the seal may
6 Pull the hub off the yoke spindle. The washer occur.
and outer bearing should fall loose from the
hub. 5 Fill the hub cavity with clean, fresh grease.
7 Place the hub on a flat surface and gently pry 6 Place the outer bearing into the hub.
the grease seal out of the hub. Remove the
inner bearing. 7 Install the washer and castle nut.
Note: When removing a bearing, always use a new 8 Tighten the castle nut to 158 ft-lbs / 214 Nm to
inner bearing seal. seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
Fault Codes
Section 4 Faul t Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall Read each appropriate fault code thoroughly.
be completed by a person trained and qualified Attempting short cuts may produce hazardous
on the repair of this machine conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Electrocution/burn hazard.
before operating the machine. Contact with electrically charged
circuits could result in death or
Unless otherwise specified, perform each serious injury. Remove all rings,
procedure with the machine in the following
watches and other jewelry.
configuration:
• Machine parked on a firm, level surface Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
Fault Codes
Fault Codes
Faul t Code C harts
Fault Codes
Fault Codes
Schematics
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Repair any machine damage or malfunction
burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
the oil pressure to dissipate
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor
Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve
Solenoid operated 2
Directional valve Pilot operated 3 position, 3
Flow divider/combiner valve position, 3 way directional
(mechanically activated) way shuttle valve
valve
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