Genie Z-45/22 Manuale utente

Technical

Publications

Second Edition, First Printing

Part No. 32960

Service

Manual

Z-45 22

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Genie Z-45/22 Part No. 32960

Service Manual - Second Edition

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie Z-45/22

Operator's Manual

before attempting any

maintenance or repair procedure.

This service manual covers the Genie Z-45/22

2WD and 4WD models introduced in 1994.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting 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 a Genie dealer service center.

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 other manuals. Please

write to the technical publications team in care of

Genie Industries, PO Box 69, Redmond WA

98073-0069 USA.

If you have any questions, call Genie Industries.

Genie North America

Telephone (206) 881-1800

Toll Free in U.S.A. 800 536-1800

Toll Free in Canada 800 426-8089

Fax (206) 883-3475

Genie Europe

Telephone (44) 0636-813943

Fax (44) 0636-815270

Introduction

Second Edition: First Printing, August 1994

Genie® is a registered trademark

of Genie Industries Registered 2009987

These machines comply with

ANSI/SIA 92.5-1992

Printed on recycled paper

Patents Pending

Printed in U.S.A.

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Part No. 32960 Genie Z-45/22

Service Manual - Second Edition

Important

Verify Correct Manual

Do not read any further until you

have verified that this is the

correct manual for this machine.

Contact Genie Industries if you

have any questions.

iii

This manual covers the Genie

Z-45/22 2WD and 4WD models produced from

May 1994, starting with serial number

Z-45-001523.

The serial number plate is

located under the engine

side turntable cover. It is

secured to the bulkhead

near the hydraulic pump.

Use the

Genie Z-45/22 Service Manual

, First

Edition, part number 29487, to service machines

not covered in this second edition.

Do not use this

manual with the

Genie Z-45/22 DC,

Bi-fuel, Tri-fuel, Diesel

and Gas/LPG models.

Compare turntable

cover size and shape.

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Genie Z-45/22 Part No. 32960

Service Manual - Second Edition

This page intentionally left blank.

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Part No. 32960 Genie Z-45/22

Service Manual - Second Edition

Safety Rules

Section 1 - Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual, and the Genie Z-45/22 Operating

Instruction Manual will result in death or serious

injury.

Many of the hazards identified in the operating

instruction 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

You have the appropriate tools, lifting

equipment and a suitable workshop.

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Genie Z-45/22 Part No. 32960

Service Manual - Second Edition

SAFETY RULES

Section 1 - Safety Rules

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 get into machine components

and cause damage.

Be sure that your workshop or work area

is properly ventilated and well lit.

Be sure any forklift, overhead crane or

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 that 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.

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 number one priority.

Read each procedure thoroughly. This

manual and the decals, on the machine,

use signal words to identify the following:

Indicates the presence of

a hazard that will cause

death or serious injury.

Indicates the presence of

a hazard that may cause

death or serious injury.

Indicates the presence of

a hazard that will or may

cause serious injury or

damage to the machine.

Indicates special

operation or maintenance

information.

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, and lifting or

placing loads. Always wear approved steel-toed

shoes.

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Part No. 32960 Genie Z-45/22

Service Manual - Second Edition

Table of Contents

vii

Introduction

Important Information .....................................................................................................

Section One Safety Rules

General Safety Rules ....................................................................................................

iii

Section Two Specifications

Machine Specifications............................................................................................. 2 - 1

Performance Specifications...................................................................................... 2 - 2

Hydraulic Specifications ........................................................................................... 2 - 2

Ford LSG 423 Engine Specifications........................................................................ 2 - 5

Deutz F3L Engine Specifications.............................................................................. 2 - 7

Section Three Scheduled Maintenance Inspections

Introduction............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C..................................................................................................................... 3 - 5

Table D..................................................................................................................... 3 - 6

Maintenance Inspection Report................................................................................ 3 - 7

Section Four Scheduled Maintenance Procedures

Introduction............................................................................................................... 4 - 1

A-1 Inspect the Manuals........................................................................................ 4 - 2

A-2 Inspect the Decals and Placards .................................................................... 4 - 2

A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2

A-4 Check the Engine Oil Level............................................................................. 4 - 3

A-5 Check the Engine Coolant Level - Gasoline/LPG Models............................... 4 - 3

A-6 Check for Fuel Leaks...................................................................................... 4 - 3

A-7 Check the Hydraulic Oil Level......................................................................... 4 - 4

A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4

A-9 Check Tire Pressure ....................................................................................... 4 - 5

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Genie Z-45/22 Part No. 32960

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Section Four Scheduled Maintenance Procedures, continued

A-10 Test the Platform and Ground Controls .......................................................... 4 - 5

A-11 Test Auxiliary Power Operation ...................................................................... 4 - 5

A-12 Test the Tilt Level Sensor ............................................................................... 4 - 6

A-13 Test the Limit Switches................................................................................... 4 - 6

A-14 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................. 4 - 8

A-15 Change the Engine Air Filter......................................................................... 4 - 10

B-1 Check the Engine Belt(s) .............................................................................. 4 - 11

B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 11

B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 11

B-4 Check the Exhaust System........................................................................... 4 - 12

B-5 Check the Battery ......................................................................................... 4 - 12

B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 13

B-7 Inspect the Electrical Wiring.......................................................................... 4 - 13

B-8 Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 14

B-9 Confirm Proper Brake Configuration............................................................. 4 - 14

B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 15

B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 15

B-12 Check and Adjust the Engine RPM............................................................... 4 - 15

B-13 Test the Key Switch ...................................................................................... 4 - 17

B-14 Test the Emergency Stop Buttons ................................................................ 4 - 18

B-15 Test the Ground Control Override................................................................. 4 - 18

B-16 Test the Oscillate Lock-out ........................................................................... 4 - 18

B-17 Test Platform Self-leveling ............................................................................ 4 - 19

B-18 Test the Service Horn ................................................................................... 4 - 19

B-19 Test the Foot Switch ..................................................................................... 4 - 20

B-20 Test the Engine Idle Select ........................................................................... 4 - 20

B-21 Test Fuel Select Operation - Gasoline/LPG Models ..................................... 4 - 21

B-22 Test the Turntable Rotation Stop .................................................................. 4 - 21

TABLE OF CONTENTS

iix

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Part No. 32960 Genie Z-45/22

Service Manual - Second Edition

Section Four Scheduled Maintenance Procedures, continued

B-23 Test the Drive Enable System ...................................................................... 4 - 21

B-24 Test the Drive Brakes ................................................................................... 4 - 22

B-25 Test Drive Speed - Stowed Position ............................................................. 4 - 23

B-26 Test the Alarm Package (optional equipment) .............................................. 4 - 23

B-27 Perform Hydraulic Oil Analysis ..................................................................... 4 - 24

B-28 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 24

C-1 Check the Primary Boom Wear Pads ........................................................... 4 - 26

C-2 Check the Turntable Rotation Bearing Bolts................................................. 4 - 26

C-3 Check the Free-wheel Feature ..................................................................... 4 - 27

C-4 Grease the Worm Drive Gear ....................................................................... 4 - 28

C-5 Replace the Torque Hub Oil ......................................................................... 4 - 29

C-6 Replace the Hydraulic Tank Filter................................................................. 4 - 29

C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 30

C-8 Replace the Diesel Fuel Filter....................................................................... 4 - 30

C-9 Replace the Gasoline Fuel Filter................................................................... 4 - 31

C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 32

C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models..... 4 - 32

C-12 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 33

C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models ............. 4 - 33

C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models...................... 4 - 34

C-15 Check the Engine Valve Clearances - Deutz Diesel Models......................... 4 - 34

D-1 Test or Replace The Hydraulic Oil ................................................................ 4 - 35

D-2 Change or Recondition the Engine Coolant.................................................. 4 - 36

D-3 Change the Fuel Lines.................................................................................. 4 - 38

D-4 Check Engine Valve Clearance - Gasoline/LPG Models .............................. 4 - 39

D-5 Check Engine Cylinder Compression - Gasoline/LPG Models ..................... 4 - 39

D-6 Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models................... 4 - 40

D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models.......... 4 - 41

D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 41

D-9 Replace The Timing Belt - Gasoline/LPG Models......................................... 4 - 41

TABLE OF CONTENTS

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Genie Z-45/22 Part No. 32960

Service Manual - Second Edition

Section Five Troubleshooting Flow Charts

Introduction............................................................................................................... 5 - 1

1 Engine Will Not Crank Over ............................................................................ 5 - 3

2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5

3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12

4 Engine Will Not Start On LPG, But Will Start On Gasoline

- Gasoline/LPG Models................................................................................. 5 - 15

5 Engine Will Not Start On Gasoline, But Will Start On LPG

- Gasoline/LPG Models................................................................................. 5 - 17

6 Engine High Idle Inoperative - Gasoline/LPG Models................................... 5 - 19

7 Engine Low Idle Inoperative - Gasoline/LPG Models.................................... 5 - 22

8 Engine High Idle Inoperative - Deutz Diesel Models..................................... 5 - 23

9 Engine Low Idle Inoperative - Deutz Diesel Models...................................... 5 - 25

10 All Functions Inoperative, Engine Starts and Runs....................................... 5 - 26

11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 27

12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 28

13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 29

14 Secondary Boom Up Function Inoperative ................................................... 5 - 30

15 Secondary Boom Down Function Inoperative............................................... 5 - 32

16 Primary Boom Up Function Inoperative ........................................................ 5 - 34

17 Primary Boom Down Function Inoperative ................................................... 5 - 36

18 Primary Boom Extend Function Inoperative ................................................. 5 - 38

19 Primary Boom Retract Function Inoperative ................................................. 5 - 40

20 Turntable Rotate Function Inoperative.......................................................... 5 - 41

21 Turntable Rotate Left Function Inoperative................................................... 5 - 43

22 Turntable Rotate Right Function Inoperative ................................................ 5 - 44

23 All Platform Leveling Functions Inoperative.................................................. 5 - 45

24 Platform Level Up Function Inoperative........................................................ 5 - 46

25 Platform Level Down Function Inoperative ................................................... 5 - 47

TABLE OF CONTENTS

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