Genie Z-45/25 - Service Manual

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First Edition

Second Printing

Part No. 52709

Service Manual

From Serial number 9998 to 21179

Main Page

Table of Contents5
Specifications19
Machine Specifications19
Performance Specifications20
Hydraulic Specifications22
Ford LRG-425 EFI Engine Specifications23
Deutz F3L 1011F Engine Specifications25
Hydraulic Hose and Fitting Torque Specifications27
Theory of Operation29
Power Source29
Hydraulic System29
Electrical System29
Limit Switches30
Machine Controls30
Maintenance Inspection Report33
Inspect the Operator's and Safety Manuals35
Inspect the Decals and Placards35
Inspect for Damage and Loose or Missing Parts36
Check the Engine Oil Level37
Check the Engine Coolant Level - Liquid Cooled Models38
Check for Fuel Leaks38
Check the Hydraulic Oil Level39
Check for Hydraulic Leaks40
Check the Tire Pressure40
Test the Oscillate Axle (if Equipped)41
Test the Platform and Ground Controls41
Test the Auxiliary Power Operation42
Test the Tilt Sensor43
Test the Limit Switches44
Check the Engine Belt - Perkins Diesel Models48
Replace the Fuel Filters - Ford Models50
Inspect the Radiator - Perkins Models51
Perform 30 Day Service52
Inspect the Fuel Filter/Water Separator - Diesel Models54
Check and Adjust the Engine RPM - Perkins Diesel Models56
Check the Engine Belt - Ford Models58
Check the Battery59
Inspect the Electrical Wiring59
Check the Radiator - Ford Models60
Check the Exhaust System61
Check the Hydraulic Return Filter Condition Indicator62
Check the Oil Cooler and Cooling Fins - Deutz Diesel Models62
Inspect the Tires and Wheels (Including Lug Nut Torque)63
Confirm the Proper Brake Configuration64
Check the Oil Level in the Drive Hubs64
Test the Key Switch67
Test the Emergency Stop Buttons67
Test the Ground Control Override68
Check the Directional Valve Linkage68
Test the Platform Self-Leveling69
Test the Horn70
Test the Foot Switch70
Test the Engine Idle Select71
Test the Fuel Select Operation - Ford Models72
Test the Drive Enable System73
Test the Drive Brakes74
Test the Drive Speed - Stowed Position75
Test the Drive Speed - Raised or Extended Position76
Test the Alarm Package - Optional Equipment77
Replace the Hydraulic Tank Return Filter78
Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models79
Replace the Fuel Filter Element - Perkins Diesel Models81
Replace the Spark Plugs - Ford Models82
Replace the Engine Air Filter Element83
Check the Engine Belt- Deutz Diesel Models85
Replace the Engine Oil and Filter - Deutz Diesel Models86
Check the Engine Valve Clearances - Deutz Diesel Models87
Change or Recondition the Engine Coolant - Liquid Cooled Models88
Check the Engine Valve Clearances - Perkins Diesel Models89
Replace the PCV Valve - Ford Models90
Check the Boom Wear Pads91
Check the Turntable Rotation Bearing Bolts92
Check the Free-Wheel Configuration93
Grease the Turntable Rotation Bearing and Rotate Gear95
Replace the Drive Hub Oil96
Replace the Drive Loop Hydraulic Filter97
Check and Adjust the Air/Lpg Mixture - Ford Models98
Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models99
Test or Replace the Hydraulic Oil100
Change or Recondition the Engine Coolant - Ford Models102
Change the Fuel Hoses104
Check the Toothed Belt - Deutz Diesel Models107
Check the Engine Valve Clearance - Ford Models107
Grease the Steer Axle Wheel Bearings, 2WD Models108
Troubleshooting Flow Charts111
Fault Codes113
Engine will Not Crank over116
Engine Cranks over but will Not Start - Ford Models118
Engine Runs While Cranking then dies120
Engine Cranks over but will Not Start - Diesel Models121
Engine will Not Start on LPG, but will Start on Gasoline - Ford Models124
Engine will Not Start on Gasoline, but will Start on LPG - Ford Models126
Engine High Idle Inoperative - Ford Models127
Engine Low Idle Inoperative - Ford Models128
Engine High Idle Inoperative - Diesel Models129
Engine Low Idle Inoperative - Diesel Models131
All Functions Inoperative, Engine Starts and Runs132
All Lift and Steer Functions Inoperative, Drive Functions Operational133
Ground Controls Inoperative, Platform Controls Operate Normally134
Platform Controls Inoperative, Ground Controls Operate Normally135
Primary Boom up Function Inoperative136
Primary Boom down Function Inoperative (before Serial Number 13099)139
Primary Boom down Function Inoperative (after Serial Number 13098)142
Secondary Boom up Function Inoperative145
Secondary Boom down Function Inoperative148
Primary Boom Extend Function Inoperative151
Primary Boom Retract Function Inoperative153
Turntable Rotate Left Function Inoperative155
Turntable Rotate Right Function Inoperative159
All Platform Leveling Functions Inoperative163
Platform Level up Function Inoperative164
Platform Level down Function Inoperative166
Platform Rotate Left Function Inoperative168
Platform Rotate Right Function Inoperative171
Jib Boom up Function Inoperative, Z-45/25J Models174
Jib Boom down Function Inoperative, Z-45/25J Models176
Steer Left Function Inoperative178
Steer Right Function Inoperative179
Oscillate Function Inoperative180
All Drive Functions Inoperative, All Other Functions Operate Normally181
Drive Forward or Reverse Function Inoperative184
Traction Function Inoperative185
Machine will Not Drive at Full Speed186
Machine Drives at Full Speed with Platform Raised or Extended187
Drive Enable System Is Malfunctioning188
Auxiliary Functions Inoperative189
Electrical Components192
Electrical Symbols Legend194
Abbreviation Legend195
Electrical Schematic, Z-45/25 Ford Models (before Serial Number 13099)202
Ground Control Box Wiring Diagram-Z-45/25 Ford Models (before Serial Number 13099)205
Platform Control Box Wiring Diagram-Z-45/25 Ford Models (before Serial Number 13099)208
Electrical Schematic, Z-45/25 Ford Models (from Serial Number 13098 to 16303)210
Ground Control Box Wiring Diagram, Z-45/25 Ford Models213
Platform Control Box Wiring Diagram, Z-45/25 Ford Models216
Electrical Schematic, Z-45/25J Ford Models (before Serial Number 13099)218
Ground Control Box Wiring Diagram-Z-45/25J Ford Models (before Serial Number 13099)221
Platform Control Box Wiring Diagram-Z-45/25J Ford Models (before Serial Number 13099)223
Electrical Schematic, Z-45/25J Ford Models (from Serial Number 13098 to 16303)226
Ground Control Box Wiring Diagram, Z-45/25J Ford Models229
Platform Control Box Wiring Diagram, Z-45/25J Ford Models232
Electrical Schematic, Z-45/25 Ford Models (after Serial Number 16303)234
(After Serial Number 16303)235
Ground Control Box Wiring Diagram-Z-45/25 Ford Models (after Serial Number 16303)237
Platform Control Box Wiring Diagram-Z-45/25 Ford Models (after Serial Number 16303)240
Electrical Schematic, Z-45/25J Ford Models (after Serial Number 16303)242
(After Serial Number 16303)243
Ground Control Box Wiring Diagram-Z-45/25J Ford Models (after Serial Number 16303)245
Platform Control Box Wiring Diagram-Z-45/25J Ford Models248
Electrical Schematic, Z-45/25 Deutz Models (before Serial Number 13099)250
Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (before Serial Number 13099)253
Platform Control Box Wiring Diagram-Z-45/25 Deutz Models (before Serial Number 13099)256
Electrical Schematic, Z-45/25 Deutz Models (from Serial Number 13098 to 16303)258
Ground Control Box Wiring Diagram, Z-45/25 Deutz Models261
Platform Control Box Wiring Diagram, Z-45/25 Deutz Models264
Electrical Schematic, Z-45/25J Deutz Models (before Serial Number 13099)266
Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (before Serial Number 13099)269
Platform Control Box Wiring Diagram-Z-45/25J Deutz Models (before Serial Number 13099)272
Electrical Schematic, Z-45/25J Deutz Models (from Serial Number 13098 to 16303)274
Ground Control Box Wiring Diagram, Z-45/25J Deutz Models277
Platform Control Box Wiring Diagram, Z-45/25J Deutz Models280
Platform Control Box Wiring Diagram - Lift Drive Select Option281
Platform Control Box Wiring Diagram - Lift/Drive Select Option281
Platform Control Box Wiring Diagram- Lift/Drive Select Option282
Electrical Schematic, Z-45/25 Deutz Models (after Serial Number 16303)284
Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (after Serial Number 16303)287
Platform Control Box Wiring Diagram-Z-45/25 Deutz Models (after Serial Number 16303)290
Z-45/25 Deutz Models (after Serial Number 16303)290
Electrical Schematic, Z-45/25J Deutz Models (after Serial Number 16303)294
Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (after Serial Number 16303)297
Platform Control Box Wiring Diagram- Lift/Drive Selectoption, Z-45/25J Deutz Models (after Serial Number 16303)301
Electrical Schematic, Z-45/25 Perkins Models (before Serial Number 16304)304
Ground Control Box Wiring Diagram, Z-45/25 Perkins Models (before Serial Number 16304)307
Platform Control Box Wiring Diagram-Z-45/25 Perkins Models (before Serial Number 16304)310
Electrical Schematic, Z-45/25J Perkins Models (before Serial Number 16304)312
Ground Control Box Wiring Diagram-Z-45/25J Perkins Models (before Serial Number 16304)315
Platform Control Box Wiring Diagram-Z-45/25J Perkins Models (before Serial Number 16304)318
Platform Control Box Wiring Diagram- Lift/Drive Selectoption319
Z-45/25J Perkins Models (before Serial Number 16304)319
Electrical Schematic, Z-45/25 Perkins Models (after Serial Number 16303)322
Ground Control Box Wiring Diagram-Z-45/25 Perkins Models (after Serial Number 16303)325
Platform Control Box Wiring Diagram-Z-45/25 Perkins Models (after Serial Number 16303)328
Electrical Schematic, Z-45/25J Perkins Models (after Serial Number 16303)332
Ground Control Box Wiring Diagram-Z-45/25J Perkins Models (after Serial Number 16303)335
Platform Control Box Wiring Diagram-Z-45/25J Perkins Models (after Serial Number 16303)338
Z-45/25J Perkins Models (after Serial Number 16303)338
Platform Control Box Wiring Diagram- Load Sensor Option, All Models341
Hydraulic Symbols Legend343
2WD Hydraulic Schematic345
4WD Hydraulic Schematic347
Repair Procedures349
Platform Controls350
Joystick Controllers350
Horsepower Limiter Board356
Foot Switch358
Toggle Switches359
Platform Components361
Platform361
Platform Leveling Slave Cylinder362
Platform Rotator363
Jib Boom Components, Z-45/25J Models366
Jib Boom, Z-45/25J Models366
Jib Boom Lift Cylinder, Z-45/25J Models367
Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models369
Primary Boom Components370
Plastic Cable Track370
Primary Boom375
Primary Boom Lift Cylinder378
Primary Boom Extension Cylinder379
Platform Leveling Master Cylinder380
Secondary Boom Components382
Secondary Boom382
Secondary Boom Lift Cylinders387
Turntable Covers388
Deutz Engine F3L 1011F389
RPM Adjustment389
Flex Plate389
Perkins 104-22 Engine391
RPM Adjustment391
Flex Plate391
Coolant Temperature and Oil Pressure Gauages392
Ford LRG-425 EFI Engine393
Timing Adjustment393
RPM Adjustment393
Flex Plate393
Ground Controls396
Control Relays396
Wago Components397
Engine Fault Codes - Ford Models398
Hydraulic Pumps400
Lift/Steer Pump400
Drive Pump401
Manifolds404
Function Manifold Components404
Valve Adjustments - Function Manifold410
Turntable Rotation Manifold Components412
Directional Valve Manifold Components413
2WD Drive Manifold Components416
Valve Adjustments, 2WD Drive Manifold418
4WD Drive Manifold Components420
Valve Adjustments, 4WD Drive Manifold424
Fuel and Hydraulic Tanks425
Fuel Tank425
Hydraulic Tank425
Turntable Rotation Components428
Rotation Hydraulic Motor428
2WD Steering Axle Components430
Yoke and Hub430
Steering Cylinders432
Tie Rod433
4WD Steering Axle Components434
Yoke and Hub434
Oscillating Axle Components437
Oscillating Axle Lock-Out Cylinders437
Non-Steering Axle Components438
Drive Motor438
Drive Hub439

Genie Z-45/25 - Service Manual

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