Genie Z-45/22 Service Manual

219 pages

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Technical

Publications

Second Edition, First Printing

Part No. 32960

®

Service

Manual

Z

-

45

2

2

800-610-4101

ActionRental.com

Table of Contents

Default Chapter2
- Introduction2
- Table of Contents7
Specifications15
- Machine Specifications15
- Performance Specifications16
- Hydraulic Specifications16
- Ford LSG 423 Engine Specifications19
Scheduled Maintenance Inspections23
- Maintenance Inspection Report29
- Part30
Scheduled Maintenance Procedures31
- Inspect the Manuals32
- Inspect the Decals and Placards32
- Inspect for Damage, Loose or Missing Parts32
- Check the Engine Oil Level33
- Check the Engine Coolant Level - Gasoline/Lpg Models33
- Check for Fuel Leaks33
- Check the Hydraulic Oil Level34
- Check for Hydraulic Leaks34
- Test the Platform and Ground Controls35
- Test Auxiliary Power Operation35
- Test the Tilt Level Sensor36
- Test the Limit Switches36
- Replace the Engine Oil and Filter - Gasoline/Lpg Models38
- Check the Engine Belt(S)41
- Check the Radiator - Gasoline/Lpg Models41
- Check the Oil Cooler and Cooling Fins - Deutz Diesel Models41
- Check the Exhaust System42
- Check the Battery42
- Check the Hydraulic Tank Filter Condition Indicator43
- Inspect the Electrical Wiring43
- Inspect the Tires and Wheels (Including Lug Nut Torque)44
- Confirm Proper Brake Configuration44
- Check the Oil Level in the Torque Hubs45
- Check and Adjust the Engine Idle Mixture - Gasoline/Lpg Models45
- Check and Adjust the Engine RPM45
- Test the Key Switch47
- Test the Emergency Stop Buttons48
- Test the Ground Control Override48
- Test the Oscillate Lock-Out48
- Test Platform Self-Leveling49
- Test the Service Horn49
- Test the Foot Switch50
- Test Fuel Select Operation - Gasoline/Lpg Models51
- Test the Turntable Rotation Stop51
- Test the Drive Enable System51
- Test the Drive Brakes52
- Test Drive Speed - Stowed Position53
- Test the Alarm Package (Optional Equipment)53
- Perform Hydraulic Oil Analysis54
- Replace the Engine Oil and Filter - Deutz Diesel Models54
- Check the Primary Boom Wear Pads56
- Check the Turntable Rotation Bearing Bolts56
- Check the Free-Wheel Feature57
- Replace the Torque Hub Oil59
- Replace the Hydraulic Tank Filter59
- Replace the Drive Loop Hydraulic Filter60
- Replace the Diesel Fuel Filter60
- Replace the Gasoline Fuel Filter61
- Replace the PCV Valve - Gasoline/Lpg Models62
- Clean or Replace the Distributor Cap and Rotor - Gasoline/Lpg Models62
- Replace the Spark Plugs - Gasoline/Lpg Models63
- Check and Adjust the Ignition Timing - Gasoline/Lpg Models64
- Check the Engine Valve Clearances - Deutz Diesel Models64
- Test or Replace the Hydraulic Oil65
- Change or Recondition the Engine Coolant66
- D-2 Change or Recondition the Engine Coolant66
- Change the Fuel Lines68
- Check Engine Valve Clearance - Gasoline/Lpg Models69
- Check Engine Cylinder Compression - Gasoline/Lpg Models69
- Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models71
- Check the Toothed Belt - Deutz Diesel Models71
- Replace the Timing Belt - Gasoline/Lpg Models71
  - Gasoline/Lpg Models71
  - Gasoline/Lpg Models77
- Engine Cranks over but will Not Start - Deutz Diesel Models84
  - Engine will Not Start on LPG, but will Start on Gasoline Gasoline/Lpg Models87
  - Engine will Not Start on Gasoline, but will Start on LPG Gasoline/Lpg Models89
- Engine High Idle Inoperative - Gasoline/Lpg Models91
- Engine Low Idle Inoperative - Gasoline/Lpg Models94
- Engine High Idle Inoperative - Deutz Diesel Models95
- Engine Low Idle Inoperative - Deutz Diesel Models97
- All Functions Inoperative, Engine Starts and Runs98
- All Lift and Steer Functions Inoperative, Drive Functions Operational99
- Ground Controls Inoperative, Platform Controls Operate Normally100
- Platform Controls Inoperative, Ground Controls Operate Normally101
- Secondary Boom up Function Inoperative102
- Secondary Boom down Function Inoperative104
- Primary Boom up Function Inoperative106
- Primary Boom down Function Inoperative108
- Primary Boom Extend Function Inoperative110
- Primary Boom Retract Function Inoperative112
- Turntable Rotate Function Inoperative113
- Turntable Rotate Left Function Inoperative115
- Turntable Rotate Right Function Inoperative116
- All Platform Leveling Functions Inoperative117
- Platform Level up Function Inoperative118
- Platform Level down Function Inoperative119
- Platform Rotate Left Function Inoperative120
- Platform Rotate Right Function Inoperative121
- Oscillate Function Inoperative122
- Steer Left Function Inoperative123
- Steer Right Function Inoperative124
- All Drive Functions Inoperative, All Other Functions Operate Normally125
- Drive Forward or Reverse Function Inoperative128
- High Range Drive Function Inoperative129
- Low Range Drive Function Inoperative132
- Traction Function Inoperative133
- Machine will Not Drive at Full Speed134
- Machine Drives at Full Speed with Platform Raised or Extended135
- Drive Enable System Is Malfunctioning136
- Auxiliary Functions Inoperative137
Platform Controls155
- Joystick Controllers155
- Horsepower Limiter Board159
- Foot Switch161
- Resistors161
- Toggle Switches162
Platform Components163
- Platform163
- Platform Leveling Slave Cylinder163
- Platform Rotator164
Primary Boom Components166
- Plastic Cable Track166
- Primary Boom166
- Primary Boom Lift Cylinder169
- Extension Cylinder171
- Platform Leveling Master Cylinder172
Secondary Boom Components174
- Secondary Boom174
- Secondary Boom Lift Cylinders179
Turntable Covers180
Deutz Engine F3L 1011181
- RPM Adjustment181
- Flex Plate181
Ford LSG 423 Engine182
- Governor Actuator182
- Choke Adjustments183
- Timing Adjustment183
- Carburetor Adjustment183
- RPM Adjustment183
- Flex Plate184
- Water Temperature and Oil Pressure Switches185
- Vacuum Switch186
Ground Controls187
- Control Relays187
- Wago Components188
- Resistors188
- Power Relay189
Hydraulic Pumps190
- Lift/Steer Pump190
- Drive Hydraulic Pump191
Function Manifold193
- Function Manifold Components193
- Valve Adjustments195
Fuel and Hydraulic Tanks197
- Hydraulic Tank197
- Fuel Tank198
Turntable Rotation Components199
- Rotation Hydraulic Motor199
- Rotation Bearing and Worm Drive199
2WD Steering Axle Components204
- Yoke and Hub204
- Steering Cylinders205
- Tie Rod206
4WD Steering Axle Components207
- Yoke and Hub207
Oscillating Axle Components209
- Oscillating Axle Lock-Out Cylinder209
Steer and Oscillate Manifold210
- Steer and Oscillate Manifold Components210
- Valve Adjustments211
Non-Steering Axle Components212
- Drive Motor212
- Torque Hub212
2WD Drive Manifold213
- 2WD Drive Manifold Components213
- Valve Adjustments215
4WD Drive Manifold217
- 4WD Drive Manifold Components217
- Valve Adjustments219

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Genie Z-45/22 Specifications

General

Brand	Genie
Model	Z-45/22
Category	Boom Lifts
Language	English

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