Genie Z-45/25 Manuale utente

Service Manual

Z-45/25

Z-45/25J

IC Power

Part No. 77809

Rev C2

August 2005

Serial Number Range

Deutz models: from 21180 to 23040

Ford models: from 21180 to 23189

Perkins models: from 21180 to 23008

Z-45/25 • Z-45/25J Part No. 77809

March 2005

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the Genie Z-45/25 and

Genie Z-45/25J Operator's Manual before

attempting any maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes 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 an authorized Genie dealer service

center.

Technical Publications

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 all other manuals.

http://www.genieindustries.com

e-mail: [email protected]

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title PartNo.

Z-45/25 and Z-45/25J Service Manual ................. 52709

From serial number 9998 to 21179

Z-45/25 and Z-45/25J Service Manual ................. 77809

Deutz models: from 21180 to 23040

Ford models: from 21180 to 23189

Perkins models: from 21180 to 23008

Z-45/25 and Z-45/25J Service Manual ............... 107846

Deutz models: from 23041 to 34010

Ford models: from 23190 to 34010

Perkins models: from 23009 to 34010

All models: from A34011 to A47000

All models: from B101

Z-45/25 and Z-45/25J Service Manual ............... 219418

From serial number 13A-47001

77809 Rev C March 2005

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J

March 2005

iii

Safety Rules

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual, and the

Genie Z-45/25 and

Genie Z-45/25J Operator's Manual

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.

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.

Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005

SAFETY RULES

Section 1 • Safety Rules

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 top priority.

Read each procedure thoroughly. This

manual and the decals on the machine

use signal words to identify the following:

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.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Without safety alert symbol—used

to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

Used to indicate 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 when lifting or

placing loads. Always wear approved steel-toed

shoes.

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 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.

Be sure that your workshop or work area

is properly ventilated and well lit.

Part No. 77809 Z-45/25 • Z-45/25J

August 2005

Table of Contents

Introduction

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

Section 1 Safety Rules

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

iii

Section 2 Rev Specifications

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

B Performance Specifications ................................................................................... 2 - 1

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

B Manifold Component Specifications ...................................................................... 2 - 4

A Ford LRG-425 EFI Engine Specifications .............................................................. 2 - 5

A Deutz F3L-1011F Engine Specifications................................................................ 2 - 7

A Perkins 104-22 Engine Specifications ................................................................... 2 - 8

A Machine Torque Specifications............................................................................ 2 - 10

B Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 11

A SAE and Metric Fastener Torque Chart .............................................................. 2 - 12

Section 3 Rev Scheduled Maintenance Procedures

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

Pre-Delivery Preparation ....................................................................................... 3 - 3

Maintenance Inspection Report ............................................................................. 3 - 5

EChecklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................ 3 - 7

A-2 Perform Function Tests ............................................................................... 3 - 7

A-3 Perform Engine Maintenance - Deutz Models .............................................. 3 - 8

A-4 Perform Engine Maintenance - Ford Models ................................................ 3 - 8

A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9

Z-45/25 • Z-45/25J Part No. 77809

June 2005

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

A-6 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 9

A-7 Test the Oscillate Axle (if equipped) .......................................................... 3 - 10

A-8 Perform 30 Day Service ............................................................................. 3 - 10

A-9 Perform Engine Maintenance - Ford and Perkins Models .......................... 3 - 11

A-10 Replace the Fuel Filters - Ford Models ...................................................... 3 - 11

A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 13

A-12 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 15

A-13 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 16

A-14 Perform Engine Maintenance - Ford Models.............................................. 3 - 16

A-15 Perform Engine Maintenance - Perkins Models ......................................... 3 - 17

DChecklist B Procedures

B-1 Inspect the Battery ..................................................................................... 3 - 18

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18

B-3 Test the Key Switch ................................................................................... 3 - 19

B-4 Perform Engine Maintenance - Ford Models .............................................. 3 - 20

B-5 Check the Exhaust System ........................................................................ 3 - 20

B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21

B-7 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 22

B-8 Confirm the Proper Brake Configuration .................................................... 3 - 22

B-9 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23

B-10 Check and Adjust the Engine RPM - Ford and Deutz Models .................... 3 - 23

B-11 Test the Ground Control Override .............................................................. 3 - 24

Part No. 77809 Z-45/25 • Z-45/25J

June 2005

TABLE OF CONTENTS

vii

Section 3 Rev Scheduled Maintenance Procedures,continued

B-12 Check the Directional Valve Linkage ......................................................... 3 - 25

B-13 Test the Platform Self-leveling ................................................................... 3 - 25

B-14 Test the Engine Idle Select ........................................................................ 3 - 26

B-15 Test the Fuel Select Operation - Ford Models ........................................... 3 - 26

B-16 Test the Drive Brakes ................................................................................ 3 - 27

B-17 Test the Drive Speed - Stowed Position .................................................... 3 - 28

B-18 Test the Drive Speed - Raised or Extended Position ................................. 3 - 28

B-19 Test the Alarm Package (if equipped) ........................................................ 3 - 29

B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 30

B-21 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 31

B-22 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 33

B-23 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34

B-24 Perform Engine Maintenance - Ford Models.............................................. 3 - 35

B-25 Perform Engine Maintenance - Perkins Models ......................................... 3 - 35

CChecklist C Procedures

C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 36

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 36

C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 37

C-4 Perform Engine Maintenance - Perkins Models ......................................... 3 - 39

C-5 Perform Engine Maintenance - Ford Models.............................................. 3 - 39

Z-45/25 • Z-45/25J Part No. 77809

June 2005

Section 3 Rev Scheduled Maintenance Procedures,continued

DChecklist D Procedures

D-1 Check the Boom Wear Pads ..................................................................... 3 - 40

D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 40

D-3 Check the Free-wheel Configuration .......................................................... 3 - 42

D-4 Replace the Drive Hub Oil ......................................................................... 3 - 43

D-5 Check and Adjust the Air/LPG Mixture - Ford Models ................................ 3 - 44

D-6 Perform Engine Maintenance - Deutz Models ............................................ 3 - 45

D-7 Inspect for Turntable Bearing Wear ........................................................... 3 - 45

D-8 Calibrate the Platform Overload System (if equipped) ............................... 3 - 47

D-9 Replace the Hydraulic Filters ..................................................................... 3 - 48

BChecklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 50

E-2 Change the Fuel Hoses - Ford Models ...................................................... 3 - 52

E-3 Perform Engine Maintenance - Deutz Models ............................................ 3 - 53

E-4 Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 53

Section 4 Rev Repair Procedures

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

CPlatform Controls

1-1 ALC-500 Circuit Board ................................................................................. 4 - 2

1-2 Joysticks ...................................................................................................... 4 - 3

APlatform Components

2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7

2-2 Platform Rotator........................................................................................... 4 - 8

viii

TABLE OF CONTENTS

Part No. 77809 Genie Z-45/25 and Genie Z-45/25J

March 2005

Section 4 Rev Repair Procedures, continued

BJib Boom Components, Z-45/25J

3-1 Jib Boom .................................................................................................... 4 - 10

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11

APrimary Boom Components

4-1 Cable Track ............................................................................................... 4 - 12

4-2 Primary Boom ............................................................................................ 4 - 16

4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 18

4-4 Primary Boom Extension Cylinder ............................................................. 4 - 19

4-5 Platform Leveling Master Cylinder ............................................................. 4 - 20

ASecondary Boom Components

5-1 Secondary Boom ....................................................................................... 4 - 22

5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 27

BEngines

6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 28

6-2 RPM Adjustment - Perkins Models ............................................................ 4 - 28

6-3 Flex Plate ................................................................................................... 4 - 28

6-4 Engine Fault Codes - Ford Models ............................................................ 4 - 29

AHydraulic Pumps

7-1 Lift/Steer Pump .......................................................................................... 4 - 31

7-2 Drive Pump ................................................................................................ 4 - 32

TABLE OF CONTENTS

Genie Z-45/25 and Genie Z-45/25J Part No. 77809

March 2005

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

BManifolds

8-1 Function Manifold Components (before serial number 22050) ................... 4 - 34

8-2 Valve Adjustments - Function Manifold (before serial number 22050) ....... 4 - 38

8-3 Function Manifold Components (after serial number 22049) ...................... 4 - 40

8-4 Valve Adjustments - Function Manifold (after serial number 22049) .......... 4 - 44

8-5 Jib Boom / Platform Rotate Manifold Components

(before serial number 22050) ..................................................................... 4 - 45

8-6 Jib Boom / Platform Rotate Manifold Components

(after serial number 22049) ........................................................................ 4 - 46

8-7 Turntable Rotation Manifold Components .................................................. 4 - 47

8-8 Directional Valve Manifold Components .................................................... 4 - 48

8-9 Drive Manifold Components, 2WD ............................................................. 4 - 50

8-10 Valve Adjustments, 2WD Drive Manifold ................................................... 4 - 52

8-11 Drive Manifold Components, 4WD ............................................................. 4 - 54

8-12 Valve Adjustments, 4WD Drive Manifold ................................................... 4 - 56

.ATurntable Rotation Components

9-1 Turntable Rotation Assembly ..................................................................... 4 - 57

BAxle Components

10-1 Hub and Bearings, 2WD Models ................................................................ 4 - 58

10-2 Oscillate Lock-out Cylinders ...................................................................... 4 - 59

Section 5 Rev Fault Codes

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

B Fault Codes - Control System ............................................................................... 5 - 2

B Fault Codes - Ford Models .................................................................................... 5 - 6

Altri manuali per Z-45/25

Questo manuale è adatto per i seguenti modelli

Indice

Altri manuali Genie Sistema di sollevamento

Genie

Genie GTH-1048 Manuale utente

Genie

Genie S-60 HC Manuale utente

Genie

Genie GS-2032 Guida all'installazione

Genie

Genie DPL-25S Manuale utente

Genie

Genie Load Lifter 5.5 Manuale utente

Genie

Genie GS-1530 Manuale utente

Genie

Genie GS-2646 AV Manuale utente

Genie

Genie GTH-1544 Manuale di installazione e funzionamento

Genie

Genie S-100 Manuale di installazione e funzionamento

Genie

Genie Z-45/22 Manuale utente

Genie

Genie S-85 Manuale utente

Genie

Genie S-40 TRAX Manuale utente

Genie

Genie S-40 TRAX Manuale utente

Genie

Genie gS-1530/32 Manuale utente

Genie

Genie GTH-844 Manuale di installazione e funzionamento

Genie

Genie GS-1930 Manuale utente

Genie

Genie Super Tower ST-20 Guida rapida

Genie

Genie GS-3384 Manuale utente

Genie

Genie S-65 Manuale utente

Genie

Genie SUPERLIFT Contractor SLC-6 Guida rapida

Genie

Genie S-65 Manuale utente

Genie

Genie SUPER HOIST Manuale utente

Genie

Genie S-100 Manuale utente

Genie

Genie GCL-MT Manuale utente

Manuali Sistema di sollevamento popolari di altre marche

morse

morse 82H-124 Manuale utente

Braun

Braun NL955 Series Manuale utente

haacon

haacon 1889.10 Manuale utente

Protekt

Protekt AT 252 Manuale utente

R. Beck Maschinenbau

R. Beck Maschinenbau HS 600 Manuale utente

Nova Technology International, LLC

Nova Technology International, LLC NAS Series Manuale utente

Screen Technics

Screen Technics INTERFIT Vertical Up Lift Manuale utente

Mortuary Lift

Mortuary Lift ULTIMATE 1000 Manuale utente

Custom Equipment

Custom Equipment Hy-Brid 3 Series Manuale di programmazione

Custom Equipment

Custom Equipment Hy-Brid Lifts 2 Series Manuale di programmazione

Hy-Brid Lifts

Hy-Brid Lifts HB-P3.6 Manuale di programmazione

BERG

BERG BeNomic EasyLeaf Manuale utente

Powermate

Powermate LiftGate LG-3 Manuale utente

Snorkel

Snorkel TM12 Series Manuale utente

Terberg

Terberg OMNIDEKA Manuale utente

Harmar Mobility

Harmar Mobility AL625 Istruzioni operative

Rotary

Rotary SPO16 Manuale utente

Ricon

Ricon Mirage F9T Manuale utente