Genie Z-45/22 Workshop Repair Service Manual

Technical Publications Second Edition, First Printing Part No. 32960 ® Service Manual Z - 45 22

Genie Z-45/22 Part No. 32960 Service Manual - Second Edition ii 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 Copyright © 1994 by Genie Industries 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.

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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Part No. 32960 Genie Z-45/22 Service Manual - Second Edition v 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.

Genie Z-45/22 Part No. 32960 Service Manual - Second Edition SAFETY RULES vi 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.

Part No. 32960 Genie Z-45/22 Service Manual - Second Edition Table of Contents vii Introduction Important Information ..................................................................................................... ii 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

Genie Z-45/22 Part No. 32960 Service Manual - Second Edition 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

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 ix

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 x

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Genie Z-45/22 Workshop Repair Service Manual

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