Genie Z-45/25 function issues from platform (schematics needed)

[Midnightmoon]

Hello,

Looking for some help mainly looking for service manual with schematics before I pay Genie's high prices.

genie
model Z-45/25
sn# Z4525-20880
year 2002
electrical schematic# E0253

My issue is all functions from the lower controls are working fine but from the upper platform only some functions work.

Sometimes everything works fine other times only up down and switches function. Rotate and drive wont work.

Odd thing is these functions work without pressing the foot pedal.

When the foot pedal is pressed it activates the relay under the controls and sends 12 volts to the relay but all other posts on the relay doesn't have 12 volts.

i'm swapping out the relay today but need to rule out the main board that sends voltage to the control valve.

All the electrical looks to be original and nothing has been bypassed under the platform controls.

There are some wires that have been repaired with electrical tape in the boom cat track which I will be investigating today along with swapping out the relay.

Has anyone had similar issues?

Hoping to find a service manual but will buy one if needed.

Thanks for the help.

 

[excavator]

Genie has all their manuals online for free.

 

[Mr. Wrench]

I would start by identifying the output terminals in the basket and checking voltage at them when each function is actuated. You need to try to determine if it is a problem in the basket or a problem with the wiring going to or from the basket. If there is not voltage at the output wire when that function is activated, you can use a jumper wire to put voltage to it to see if it will work. Just remember that function will be at full speed. The switches will be on/off and the joysticks will be PWM. Spend some time with the wiring diagram and it should be easier to make some since of it.

 

[willie59]

Ok, I've been working on aerial lifts for over 40 years, and although I don't claim to be an expert, I think I can safely say that if you have functions working even without depressing the foot pedal? Then you have some serious *** up wiring issues that I don't think we can even begin to troubleshoot over the internet, that flat out is not supposed to happen. When platform controls is selected at the lower control key switch, no function at the platform controls should have power until you depress the footswitch, full stop. And you mention a circuit board. In Genie models of that vintage it was typical for them to have a horsepower limiter board in the platform box, but that only controls the drive function. The only other circuit board I'm familiar with in Genie platform boxes is the ALC500 circuit board, which controls all functions, but I don't recall any relays used at the platform with the ALC500. Functions sometimes working and sometimes not from the platform controls, that's typically a low voltage issue or breaking wires in the cable between platform and lower controls, but that does not explain functions working even if footswitch isn't depressed. As mentioned previously, the Genie service manual is available at the Genie website for free, no charge. The wiring diagrams are in the service manual. And the Genie wiring diagrams are well made, fairly easy to follow. With the issues that you have I wager you're going to be doing some serious study of those diagrams. We'll help you as best we can, but we're a long way from that.