Service Manual Genie Lift-Books Download

Service Manual Genie lift
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Introduction June 2012,Introduction,Important Serial Number Information. Read understand and obey the safety rules and Genie Industries offers the following Service. operating instructions in the Genie Z 45 25 and Manuals for these models . Genie Z 45 25J Operator s Manual before, attempting any maintenance or repair procedure Title Part No . This manual provides detailed scheduled, Z 45 25 and Z 45 25J Service Manual 52709. maintenance information for the machine owner, From serial number 9998 to 21179. and user It also provides troubleshooting fault, codes and repair procedures for qualified service Z 45 25 and Z 45 25J Service Manual 77809.
professionals Deutz models from 21180 to 23040, Basic mechanical hydraulic and electrical skills Ford models from 21180 to 23189. Perkins models from 21180 to 23008,are required to perform most procedures . However several procedures require specialized, Z 45 25 and Z 45 25J Service Manual 107846. skills tools lifting equipment and a suitable Deutz models from 23041 to 34010. workshop In these instances we strongly Ford models from 23190 to 34010. recommend that maintenance and repair be Perkins models from 23009 to 34010. performed at an authorized Genie dealer service All models from A34011 to A47000. center All models from B101, Compliance Z 45 25 and Z 45 25J Service Manual 219418. From serial number 13A 47001,Machine Classification.
Group B Type 3 as defined by ISO 16368,Machine Design Life. Unrestricted with proper opeation inspection and,scheduled maintenance . Technical Publications, Genie 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 Copyright 2011 Terex Corporation. and send in suggestions for improvement All 107846 Rev C August 2006. communications will be carefully considered for Third Edition Third Printing. future printings of this and all other manuals Genie and Z are registered trademarks of. Terex South Dakota Inc in the USA and many, other countries . Contact Us , Printed on recycled paper,http www genielift com. Printed in U S A ,e mail awp techpub terex com,ii Z 45 25 Z 45 25J Part No 107846. June 2012, INTRODUCTION,Serial Number Legend, Serial number Z452506 12345. Model year 2006 Manufacture date 04 12 06, Electrical schematic number ES0274.
Machine unladen weight , Rated work load including occupants 500 lb 227 kg. Maximum number of platfrm occupants 2, Maximum allowable side force 150 lb 670 N. Maximum allowable inclination of the chassis , 0 deg Z4525 06 12345. Maximum wind speed 28 mph 12 5 m s, Maximum platform height 45 ft 6 in 13 8 m. Model Sequence, Maximum platform reach 25 ft 3 in 7 7 m.
Gradeability N A, Country of manufacture USA Model year. This machine complies with , ANSI A92 5, CAN B 354 4. Genie Industries Serial label, 18340 NE 76th Street located under cover . Redmond WA 98052 Serial number, USA stamped on chassis. PN 77055,Part No 107846 Z 45 25 Z 45 25J iii, June 2012.
This page intentionally left blank ,iv Z 45 25 Z 45 25J Part No 107846. June 2012 Section 1 Safety Rules, Safety Rules, 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, 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 ,Part No 107846 Z 45 25 Z 45 25J v.
Section 1 Safety Rules June 2012,SAFETY RULES, Personal Safety Be sure to wear protective eye wear and. other protective clothing if the situation, Any person working on or around a machine must warrants it . be aware of all known safety hazards Personal, safety and the continued safe operation of the Be aware of potential crushing hazards. machine should be your top priority such as moving parts free swinging or. unsecured components when lifting or, placing loads Always wear approved steel toed. Read each procedure thoroughly This, manual and the decals on the machine.
use signal words to identify the following , Workplace Safety. Be sure to keep sparks flames and, Safety alert symbol used to alert. lighted tobacco away from flammable, personnel to potential personal. and combustible materials like battery, injury hazards Obey all safety. gases and engine fuels Always have an approved, messages that follow this symbol.
fire extinguisher within easy reach , to avoid possible injury or death . Be sure that all tools and working areas, Used to indicate the presence of. are properly maintained and ready for, an imminently hazardous situation. use Keep work surfaces clean and free, which if not avoided will result in. death or serious injury of debris that could get into machine components. and cause damage , Used to indicate the presence of a.
potentially hazardous situation Be sure any forklift overhead crane or. which if not avoided could result other lifting or supporting device is fully. in death or serious injury capable of supporting and stabilizing the. weight to be lifted Use only chains or straps that. With safety alert symbol used to are in good condition and of ample capacity . indicate the presence of a, potentially hazardous situation Be sure that fasteners intended for one. which if not avoided may result in time use i e cotter pins and self locking. minor or moderate injury nuts are not reused These components. may fail if they are used a second time , Without safety alert symbol used. to indicate the presence of a Be sure to properly dispose of old oil or. potentially hazardous situation other fluids Use an approved container . which if not avoided may result in Please be environmentally safe . property damage , Be sure that your workshop or work area. Used to indicate operation or is properly ventilated and well lit . maintenance information ,vi Z 45 25 Z 45 25J Part No 107846. June 2012, Table of Contents,Introduction, Important Information ii.
Serial Number Information ii, Serial Number Legend iii. Section 1 Safety Rules, General Safety Rules v,Section 2 Rev Specifications. H Machine Specifications 2 1, Performance Specifications 2 2. Hydraulic Specifications 2 3, Manifold Component Specifications 2 5. Ford LRG 425 EFI Engine Specifications 2 6, Ford DSG 423 EFI Engine Specifications 2 7.
Deutz F3L 2011 D2011 L03i Engine Specifications 2 8. Perkins 404 22 Engine Specifications 2 10, Machine Torque Specifications 2 12. Hydraulic Hose and Fitting Torque Specifications 2 13. SAE and Metric Fastener Torque Chart 2 14,Part No 107846 Z 45 25 Z 45 25J vii. June 2012,TABLE OF CONTENTS,Section 3 Rev Scheduled Maintenance Procedures. Introduction 3 1, Pre Delivery Preparation 3 3, Maintenance Inspection Report 3 5. D Checklist A Procedures, A 1 Perform Pre operation Inspection 3 7.
A 2 Perform Function Tests 3 7, A 3 Perform Engine Maintenance 3 8. A 4 Check the High Pressure Hydraulic Filter Condition Indicator 3 9. A 5 Test the Oscillate Axle if equipped 3 9, A 6 Perform 30 Day Service 3 10. A 7 Perform Engine Maintenance Ford Models 3 10, A 8 Inspect the Fuel Filter Water Separator Diesel Models 3 11. A 9 Grease the Turntable Rotation Bearing and Rotate Gear 3 13. A 10 Perform Engine Maintenance Ford Models 3 13, C Checklist B Procedures. B 1 Inspect the Battery 3 14, B 2 Inspect the Electrical Wiring 3 15.
B 3 Check the Exhaust System 3 16, B 4 Inspect the Engine Air Filter 3 17. B 5 Check the Oil Cooler and Cooling Fins Deutz Models 3 17. B 6 Inspect the Tires Wheels and Lug Nut Torque 3 18. B 7 Confirm the Proper Brake Configuration 3 19, B 8 Check the Oil Level in the Drive Hubs 3 19. viii Z 45 25 Z 45 25J Part No 107846, June 2012, TABLE OF CONTENTS. Section 3 Rev Scheduled Maintenance Procedures continued. B 9 Check and Adjust the Engine RPM All Models 3 20. B 10 Test the Ground Control Override 3 22, B 11 Check the Directional Valve Linkage 3 23. B 12 Test the Platform Self leveling 3 23, B 13 Test the Engine Idle Select 3 24.
B 14 Test the Fuel Select Operation Ford Models 3 25. B 15 Test the Drive Brakes 3 26, B 16 Test the Drive Speed Stowed Position 3 26. B 17 Test the Drive Speed Raised or Extended Position 3 27. B 18 Test the Alarm Package if equipped 3 28, B 19 Perform Hydraulic Oil Analysis 3 29. B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 29. B 21 Replace the Fuel Filter Element Perkins Models 3 30. B 22 Perform Engine Maintenance Perkins Models 3 32. B 23 Replace the Engine Air Filter Element Ford Models 3 32. B 24 Perform Engine Maintenance Ford Models 3 33, D Checklist C Procedures. C 1 Perform Engine Maintenance Deutz Models 3 34, C 2 Grease the Platform Overload Mechanism if equipped 3 34. C 3 Test the Platform Overload System if equipped 3 35. C 4 Replace the Fuel Filter Water Separator Perkins Models 3 38. C 5 Replace the Engine Air Filter Element Deutz and Perkins Models 3 40. C 6 Perform Engine Maintenance Perkins Models 3 40. C 7 Perform Engine Maintenance Ford Models 3 41,Part No 107846 Z 45 25 Z 45 25J ix.
June 2012,TABLE OF CONTENTS, Section 3 Rev Scheduled Maintenance Procedures continued. D Checklist D Procedures, D 1 Check the Boom Wear Pads 3 42. D 2 Check the Turntable Rotation Bearing Bolts 3 42. D 3 Inspect for Turntable Bearing Wear 3 44, D 4 Replace the Drive Hub Oil 3 46. D 5 Check the Free wheel Configuration 3 46, D 6 Replace the Hydraulic Filters 3 48. D 7 Perform Engine Maintenance Deutz Models 3 49, D Checklist E Procedures.
E 1 Test or Replace the Hydraulic Oil 3 50, E 2 Grease the Steer Axle Wheel Bearings 2WD Models 3 52. E 3 Perform Engine Maintenance Deutz Models 3 53, E 4 Perform Engine Maintenance Deutz Models 3 54. Section 4 Rev Repair Procedures, Introduction 4 1, B Platform Controls. 1 1 ALC 500 Circuit Board 4 2, 1 2 Joysticks 4 3, C Platform Components. 2 1 Platform Leveling Slave Cylinder 4 7, 2 2 Platform Rotator 4 8.
2 3 Platform Overload System 4 10,x Z 45 25 Z 45 25J Part No 107846. June 2012, TABLE OF CONTENTS,Section 4 Rev Repair Procedures continued. B Jib Boom Components Z 45 25J, 3 1 Jib Boom 4 12. 3 2 Jib Boom Lift Cylinder 4 13, B Primary Boom Components. 4 1 Cable Track 4 15, 4 2 Primary Boom 4 19, 4 3 Primary Boom Lift Cylinder 4 21.
4 4 Primary Boom Extension Cylinder 4 23, 4 5 Platform Leveling Master Cylinder 4 24. B Secondary Boom Components, 5 1 Secondary Boom 4 27. 5 2 Secondary Boom Lift Cylinders 4 32, B Engines. 6 1 RPM Adjustment Ford and Deutz Models 4 33, 6 2 RPM Adjustment Perkins Models 4 33. 6 3 Flex Plate 4 33, 6 4 Engine Fault Codes Ford Models 4 37.
B Hydraulic Pumps, 7 1 Lift Steer Pump 4 38, 7 2 Drive Pump 4 39. Part No 107846 Z 45 25 Z 45 25J xi, June 2012,TABLE OF CONTENTS. Section 4 Rev Repair Procedures continued, E Manifolds. 8 1 Function Manifold Components, before serial number 27001 4 42. 8 2 Valve Adjustments Function Manifold, before serial number 27001 4 46.
8 3 Function Manifold Components, after serial number 27000 4 48. 8 4 Valve Adjustments Function Manifold, after serial number 27000 4 52. 8 5 Jib Boom Platform Rotate Manifold Components, before serial number 27001 4 53. 8 6 Jib Boom Platform Rotate Manifold Components, after serial number 27000 4 54. 8 7 Turntable Rotation Manifold Components, before serial number 27001 4 55.
8 8 Turntable Rotation Manifold Components, after serial number 27000 4 56. 8 9 Directional Valve Manifold Components 4 57, 8 10 Traction Manifold Components 2WD. before serial number 27001 4 60, 8 11 Traction Manifold Components 2WD. after serial number 27000 4 62, 8 12 Valve Adjustments 2WD Traction Manifold 4 64. 8 13 Traction Manifold Components 4WD, before serial number 27001 4 66.
8 14 Traction Manifold Components 4WD, after serial number 27000 4 68. 8 15 Valve Adjustments 4WD Traction Manifold 4 70. 8 16 Valve Coils 4 70,xii Z 45 25 Z 45 25J Part No 107846. June 2012, TABLE OF CONTENTS,Section 4 Rev Repair Procedures continued. C Turntable Rotation Components, 9 1 Turntable Rotation Assembly 4 72. C Axle Components, 10 1 Hub and Bearings 2WD Models 4 73.
10 2 Oscillate Lock out Cylinders 4 74,Section 5 Rev Fault Codes. Introduction 5 1, A Fault Codes Control System 5 2. B Fault Codes Ford LRG 425 EFI Models 5 6, A Fault Codes Ford DSG 423 EFI Models 5 12. Section 6 Rev Schematics, Introduction 6 1, A Electrical Symbols Legend 6 2. A Hydraulic Symbols Legend 6 3, A Ford Engine Relay Layout 6 4.
Ford models, A Ford LRG 425 EFI Engine Harness 6 5. A Ford DSG 423 EFI Engine Harness 6 6, C Electrical Schematic Z 45 25. Ford LRG 425 EFI before serial number 30142 6 7, A Electrical Schematic Z 45 25. Ford DSG 423 EFI after serial number 30141 6 9,Part No 107846 Z 45 25 Z 45 25J xiii. June 2012,TABLE OF CONTENTS,Section 6 Rev Schematics continued.
Ford models continued, A Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 11. B Ground Control Box Switch Panel Wiring Diagram Z 45 25 6 12. A Platform Control Box Terminal Strip Wiring Diagram Z 45 25 6 13. A Platform Control Box Switch Panel Wiring Diagram Z 45 25 6 14. C Electrical Schematic Z 45 25J, Ford LRG 425 EFI before serial number 30142 6 15. A Electrical Schematic Z 45 25J, Ford DSG 423 EFI after serial number 30141 6 17. A Ground Control Box Terminal Strip Wiring Diagram Z 45 25J 6 19. B Ground Control Box Switch Panel Wiring Diagram Z 45 25J 6 20. A Platform Control Box Terminal Strip Wiring Diagram Z 45 25J 6 21. A Platform Control Box Switch Panel Wiring Diagram Z 45 25J 6 22. Deutz F3L 2011 models, C Electrical Schematic Z 45 25 6 23. C Electrical Schematic Z 45 25, CE models 6 25, A Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 27.
B Ground Control Box Switch Panel Wiring Diagram Z 45 25 6 28. A Ground Control Box Terminal Strip Wiring Diagram Z 45 25. CE Models 6 29, B Ground Control Box Switch Panel Wiring Diagram Z 45 25. CE Models 6 30, A Platform Control Box Terminal Strip Wiring Diagram Z 45 25 6 31. A Platform Control Box Switch Panel Wiring Diagram Z 45 25 6 32. xiv Z 45 25 Z 45 25J Part No 107846, June 2012, TABLE OF CONTENTS. Section 6 Rev Schematics continued, Deutz F3L 2011 models continued. C Electrical Schematic Z 45 25J 6 33, C Electrical Schematic Z 45 25J.
CE models 6 35, A Ground Control Box Terminal Strip Wiring Diagram Z 45 25J 6 37. B Ground Control Box Switch Panel Wiring Diagram Z 45 25J 6 38. A Ground Control Box Terminal Strip Wiring Diagram Z 45 25J. CE Models 6 39, B Ground Control Box Switch Panel Wiring Diagram Z 45 25J. CE Models 6 40, A Platform Control Box Terminal Strip Wiring Diagram Z 45 25J 6 41. A Platform Control Box Switch Panel Wiring Diagram Z 45 25J 6 42. Perkins 404 22 models, C Electrical Schematic Z 45 25 6 44. A Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 48. B Ground Control Box Switch Panel Wiring Diagram Z 45 25 6 49. A Platform Control Box Terminal Strip Wiring Diagram Z 45 25 6 52. A Platform Control Box Switch Panel Wiring Diagram Z 45 25 6 53. C Electrical Schematic Z 45 25J 6 56, B Ground Control Box Terminal Strip Wiring Diagram Z 45 25J 6 60.
B Ground Control Box Switch Panel Wiring Diagram Z 45 25J 6 61. A Platform Control Box Terminal Strip Wiring Diagram Z 45 25J 6 63. A Platform Control Box Switch Panel Wiring Diagram Z 45 25J 6 65. Hydraulic Schematics, D Hydraulic Schematic 2WD Models before serial number 27001 6 67. B Hydraulic Schematic 2WD Models after serial number 27000 6 69. C Hydraulic Schematic 4WD Models before serial number 27001 6 71. B Hydraulic Schematic 4WD Models after serial number 27000 6 73.

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