Genie Z-45/25, Z-45/25J Workshop Service Repair Manual 52709

First Edition Second Printing Part No. 52709 Service Manual

Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing ii Introduction ® Copyright © 1998 by Genie Industries First Edition: Second Printing, September 2000 "Genie" and "Z" are Registered Trademarks of Genie Industries in the USA and many other countries. These machines comply with ANSI/SIA 92.5-1992. Printed on recycled paper Printed in U.S.A. Important Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 & Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure. This service manual covers the Genie Z-45/25 & Genie Z-45/25J 2WD and 4WD models introduced in 1998. 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 97030, Redmond WA 98073-9730 U.S.A. If you have any questions, please call Genie Industries. Contact us: http://www.genielift.com e-mail: techpub@genieind.com

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J First Edition • Second Printing 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 & 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 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing SAFETY RULES iv 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. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Green—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 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 .

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J First Edition • Second Printing Table of Contents v 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 - 4 Ford LRG-425 EFI Engine Specifications ................................................................. 2 - 5 Deutz F3L 1011F Engine Specifications ................................................................... 2 - 7 Perkins 104-22 Engine Specifications ....................................................................... 2 - 8 Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 9 Section Three Theory of Operation Power Source ........................................................................................................... 3 - 1 Hydraulic System ...................................................................................................... 3 - 1 Electrical System ...................................................................................................... 3 - 1 Limit Switches ........................................................................................................... 3 - 2 Machine Controls ...................................................................................................... 3 - 2

Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing TABLE OF CONTENTS vi Section Four Scheduled Maintenance Procedures Introduction ............................................................................................................... 4 - 1 Maintenance Inspection Report ................................................................................ 4 - 3 A-1 Inspect the Operator's and Safety Manuals .................................................... 4 - 5 A-2 Inspect the Decals and Placards ..................................................................... 4 - 5 A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6 A-4 Check the Engine Oil Level ............................................................................. 4 - 7 A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8 A-6 Check for Fuel Leaks ...................................................................................... 4 - 8 A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9 A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10 A-9 Check the Tire Pressure ............................................................................... 4 - 10 A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11 A-11 Test the Platform and Ground Controls ......................................................... 4 - 11 A-12 Test the Auxiliary Power Operation ............................................................... 4 - 12 A-13 Test the Tilt Sensor ....................................................................................... 4 - 13 A-14 Test the Limit Switches ................................................................................. 4 - 14 A-15 Check the Engine Belt - Perkins Diesel Models ............................................ 4 - 18 A-16 Inspect the Engine Air Filter Element ............................................................ 4 - 19 A-17 Replace the Fuel Filters - Ford Models ......................................................... 4 - 20 A-18 Inspect the Radiator - Perkins Models .......................................................... 4 - 21 A-19 Perform 30 Day Service ................................................................................ 4 - 22 A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models ............ 4 - 23 A-21 Inspect the Fuel Filter/Water Separator - Diesel Models ............................... 4 - 24 A-22 Check and Adjust the Engine RPM - Perkins Diesel Models ......................... 4 - 26 A-23 Check the Engine Belt - Ford Models ............................................................ 4 - 28

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J First Edition • Second Printing TABLE OF CONTENTS vii Section Four Scheduled Maintenance Procedures, continued B-1 Check the Battery ......................................................................................... 4 - 29 B-2 Inspect the Electrical Wiring .......................................................................... 4 - 29 B-3 Check the Radiator - Ford Models ................................................................ 4 - 30 B-4 Check the Exhaust System ........................................................................... 4 - 31 B-5 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32 B-6 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32 B-7 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33 B-8 Confirm the Proper Brake Configuration ....................................................... 4 - 34 B-9 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34 B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models ............ 4 - 35 B-11 Test the Key Switch ...................................................................................... 4 - 37 B-12 Test the Emergency Stop Buttons ................................................................. 4 - 37 B-13 Test the Ground Control Override ................................................................. 4 - 38 B-14 Check the Directional Valve Linkage ............................................................. 4 - 38 B-15 Test the Platform Self-leveling ...................................................................... 4 - 39 B-16 Test the Horn ................................................................................................ 4 - 40 B-17 Test the Foot Switch ..................................................................................... 4 - 40 B-18 Test the Engine Idle Select ........................................................................... 4 - 41 B-19 Test the Fuel Select Operation - Ford Models ............................................... 4 - 42 B-20 Test the Drive Enable System ....................................................................... 4 - 43 B-21 Test the Drive Brakes ................................................................................... 4 - 44 B-22 Test the Drive Speed - Stowed Position ........................................................ 4 - 45 B-23 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46

Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing Section Four Scheduled Maintenance Procedures, continued B-24 Test the Alarm Package - Optional Equipment .............................................. 4 - 47 B-25 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48 B-26 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 48 B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 49 B-28 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 51 B-29 Replace the Spark Plugs - Ford Models ........................................................ 4 - 52 B-30 Replace the Engine Air Filter Element ........................................................... 4 - 53 C-1 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55 C-2 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57 C-3 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57 C-4 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58 C-5 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 59 C-6 Replace the PCV Valve - Ford Models .......................................................... 4 - 60 D-1 Check the Boom Wear Pads ......................................................................... 4 - 61 D-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62 D-3 Check the Free-wheel Configuration ............................................................. 4 - 63 D-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 65 D-5 Replace the Drive Hub Oil ............................................................................. 4 - 66 D-6 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67 D-7 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68 D-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models ......... 4 - 69 viii TABLE OF CONTENTS

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J First Edition • Second Printing Section Four Scheduled Maintenance Procedures, continued E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 70 E-2 Change or Recondition the Engine Coolant - Ford Models ........................... 4 - 72 E-3 Change the Fuel Hoses ................................................................................ 4 - 74 E-4 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 77 E-5 Check the Engine Valve Clearance - Ford Models ........................................ 4 - 77 E-6 Check the Engine Cylinder Compression - Ford Models ............................... 4 - 77 E-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ........... 4 - 77 E-8 Replace the Timing Belt - Ford Models ......................................................... 4 - 77 E-9 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 78 Section Five Troubleshooting Flow Charts Introduction ............................................................................................................... 5 - 1 Fault Codes .............................................................................................................. 5 - 3 1 Engine Will Not Crank Over ............................................................................ 5 - 6 2 Engine Cranks Over But Will Not Start - Ford Models ..................................... 5 - 8 2A Engine Runs While Cranking Then Dies ....................................................... 5 - 10 3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 11 4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models ..... 5 - 14 5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models ..... 5 - 16 6 Engine High Idle Inoperative - Ford Models .................................................. 5 - 17 7 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 18 8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 19 9 Engine Low Idle Inoperative - Diesel Models ................................................. 5 - 21 10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 22 11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 23 ix TABLE OF CONTENTS

Genie Z-45/25 & Genie Z-45/25J Part No. 52709 First Edition • Second Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts, continued 12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 24 13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 25 14 Primary Boom Up Function Inoperative ........................................................ 5 - 26 15 Primary Boom Down Function Inoperative (before serial number 13099) ..... 5 - 29 16 Primary Boom Down Function Inoperative (after serial number 13098) ........ 5 - 32 17 Secondary Boom Up Function Inoperative .................................................... 5 - 35 18 Secondary Boom Down Function Inoperative ............................................... 5 - 38 19 Primary Boom Extend Function Inoperative .................................................. 5 - 41 20 Primary Boom Retract Function Inoperative .................................................. 5 - 43 21 Turntable Rotate Left Function Inoperative ................................................... 5 - 45 22 Turntable Rotate Right Function Inoperative ................................................. 5 - 49 23 All Platform Leveling Functions Inoperative .................................................. 5 - 53 24 Platform Level Up Function Inoperative ........................................................ 5 - 54 25 Platform Level Down Function Inoperative .................................................... 5 - 56 26 Platform Rotate Left Function Inoperative ..................................................... 5 - 58 27 Platform Rotate Right Function Inoperative ................................................... 5 - 61 28 Jib Boom Up Function Inoperative, Z-45/25J Models .................................... 5 - 64 29 Jib Boom Down Function Inoperative, Z-45/25J Models ............................... 5 - 66 30 Steer Left Function Inoperative ..................................................................... 5 - 68 31 Steer Right Function Inoperative ................................................................... 5 - 69 32 Oscillate Function Inoperative ....................................................................... 5 - 70 33 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 71 34 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 74 35 Traction Function Inoperative ........................................................................ 5 - 75 36 Machine Will Not Drive At Full Speed ............................................................ 5 - 76 37 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 77 38 Drive Enable System Is Malfunctioning ......................................................... 5 - 78 39 Auxiliary Functions Inoperative ..................................................................... 5 - 79 x

Genie Z-45/25, Z-45/25J Workshop Service Repair Manual 52709

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