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Genie Z-45/25 Z-45/25J IC Power Service Manual 107846 – PDF DOWNLOAD
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Genie Z-45/25 Z-45/25J IC Power Service Manual 107846 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J IC Power Service Manual 107846 – PDF DOWNLOAD
Language : English
Pages : 287
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J IC Power Service Manual 107846 – PDF DOWNLOAD
Cover................................................................................................ 1 Introduction......................................................................................... 2 Serial Number Legend................................................................................. 3 Safety Rules......................................................................................... 5 Table of Contents.................................................................................... 7 Section 2 Specifications............................................................................. 17 Machine Specifications........................................................................... 17 Performance Specifications....................................................................... 18 Hydraulic Specifications......................................................................... 19 Manifold Component Specifications................................................................ 21 Ford LRG-425 EFI Engine.......................................................................... 22 Ford DSG-423 EFI Engine.......................................................................... 23 Deutz F3L 2011 and D2011L03i Engines............................................................. 24 Perkins 404-22 Engine............................................................................ 26 Machine Torque Specifications.................................................................... 28 Hydraulic Hose and Fitting Torque Specifications................................................. 29 SAE and Metric Fastener Torque Chart............................................................. 30 Section 3 Scheduled Maintenance Prodedures........................................................... 31 Pre-Delivery Preparation......................................................................... 33 Maintenance Inspection Report.................................................................... 35 Checklist A Procedures........................................................................... 37 A-1 Perform Pre-operation Inspection......................................................... 37 A-2 Perform Function Tests................................................................... 37 A-3 Perform Engine Maintenance............................................................... 38 A-4 Check the High Pressure Hydraulic Filter Condition Indicator............................. 39 A-5 Test the Oscillate Axle (if equipped).................................................... 39 A-6 Perform 30 Day Service................................................................... 40 A-7 Perform Engine Maintenance - Ford Models................................................. 40 A-8 Inspect the Fuel Filter/Water Separator - Diesel Models.................................. 41 A-9 Grease the Turntable Rotation Bearing and Rotate Gear.................................... 43 A-10 Perform Engine Maintenance - Ford Models................................................ 43 Checklist B Procedures........................................................................... 44 B-1 Inspect the Battery...................................................................... 44 B-2 Inspect the Electrical Wiring............................................................ 45 B-3 Check the Exhaust System................................................................. 46 B-4 Inspect the Engine Air Filter............................................................ 47 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models..................................... 47 B-6 Inspect the Tires, Wheels and Lug Nut Torque............................................. 48 B-7 Confirm the Proper Brake Configuration................................................... 49 B-8 Check the Oil Level in the Drive Hubs.................................................... 49 B-9 Check and Adjust the Engine RPM - All Models............................................. 50 B-10 Test the Ground Control Override........................................................ 52 B-11 Check the Oscillate Directional Valve Linkage........................................... 53 B-12 Test the Platform Self-leveling......................................................... 53 B-13 Test the Engine Idle Select............................................................. 54 B-14 Test the Fuel Select Operation - Ford Models............................................ 55 B-15 Test the Drive Brakes................................................................... 56 B-16 Test the Drive Speed - Stowed Position.................................................. 56 B-17 Test the Drive Speed - Raised or Extended Position...................................... 57 B-18 Test the Alarm Package (if equipped).................................................... 58 B-19 Perform Hydraulic Oil Analysis.......................................................... 59 B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems................................. 59 B-21 Replace the Fuel Filter Element - Perkins Models........................................ 60 B-22 Perform Engine Maintenance - Perkins Models............................................. 62 B-23 Replace the Engine Air Filter Element - Ford Models..................................... 62 B-24 Perform Engine Maintenance - Ford Models................................................ 63 Checklist C Procedures........................................................................... 64 C-1 Perform Engine Maintenance - Deutz Models................................................ 64 C-2 Grease the Platform Overload Mechanism (if equipped)..................................... 64 C-3 Test the Platform Overload System (if equipped).......................................... 65 C-4 Replace the Fuel Filter/Water Separator - Perkins Models................................. 68 C-5 Replace the Engine Air Filter Element - Deutz and Perkins Models......................... 70 C-6 Perform Engine Maintenance - Perkins Models.............................................. 70 C-7 Perform Engine Maintenance - Ford Models................................................. 71 Checklist D Procedures........................................................................... 72 D-1 Check the Boom Wear Pads................................................................. 72 D-2 Check the Turntable Rotation Bearing Bolts............................................... 72 D-3 Inspect for Turntable Bearing Wear....................................................... 74 D-4 Replace the Drive Hub Oil................................................................ 76 D-5 Check the Free-wheel Configuration....................................................... 76 D-6 Replace the Hydraulic Filters............................................................ 78 D-7 Perform Engine Maintenance - Deutz Models................................................ 79 Checklist E Procedures........................................................................... 80 E-1 Test or Replace the Hydraulic Oil........................................................ 80 E-2 Grease the Steer Axle Wheel Bearings, 2WD Models......................................... 82 E-3 Perform Engine Maintenance - Deutz Models................................................ 83 E-4 Perform Engine Maintenance - Deutz Models................................................ 84 Section 4 Repair Prodedures.......................................................................... 85 Platform Controls................................................................................ 86 1-1 ALC-500 Circuit Board.................................................................... 86 1-2 Joysticks................................................................................ 87 Platform Components.............................................................................. 91 2-1 Platform Leveling Slave Cylinder......................................................... 91 2-2 Platform Rotator......................................................................... 92 2-3 Platform Overload System................................................................. 94 Jib Boom Components, Z-45/25J.................................................................... 96 3-1 Jib Boom................................................................................. 96 3-2 Jib Boom Lift Cylinder................................................................... 97 Primary Boom Components.......................................................................... 99 4-1 Cable Track.............................................................................. 99 4-2 Primary Boom.............................................................................103 4-3 Primary Boom Lift Cylinder...............................................................105 4-4 Primary Boom Extension Cylinder..........................................................107 4-5 Platform Leveling Master Cylinder........................................................108 Secondary Boom Components........................................................................110 5-1 Secondary Boom...........................................................................111 5-2 Secondary Boom Lift Cylinders............................................................116 Engines..........................................................................................117 6-1 RPM Adjustment - Ford and Deutz Models...................................................117 6-2 RPM Adjustment - Perkins Models..........................................................117 6-3 Flex Plate...............................................................................117 6-4 Engine Fault Codes - Ford Models.........................................................121 Hydraulic Pumps..................................................................................122 7-1 Lift/Steer Pump..........................................................................122 7-2 Drive Pump...............................................................................123 Manifolds........................................................................................126 8-1 Function Manifold Components (before serial number 27001)................................126 8-2 Valve Adjustments - Function Manifold (before serial number 27001).......................130 8-3 Function Manifold Components (after serial number 27000).................................132 8-4 Valve Adjustments - Function Manifold (after serial number 27000)........................136 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 27001)..............137 8-6 Jib Boom / Platform Rotate Manifold Components (after serial number 27000)...............138 8-7 Turntable Rotation Manifold Components (before serial number 27001)......................139 8-8 Turntable Rotation Manifold Components (after serial number 27000).......................140 8-9 Directional Valve Manifold Components....................................................141 8-10 Traction Manifold Components, 2WD (before serial number 27001)..........................144 8-11 Traction Manifold Components, 2WD (after serial number 27000)...........................146 8-12 Valve Adjustments, 2WD Traction Manifold................................................148 8-13 Traction Manifold Components, 4WD (before serial number 27001)..........................150 8-14 Traction Manifold Components, 4WD (after serial number 27000)...........................152 8-15 Valve Adjustments, 4WD Drive Manifold...................................................154 8-16 Valve Coils.............................................................................154 Turntable Rotation Components....................................................................156 9-1 Turntable Rotation Assembly..............................................................156 Axle Components..................................................................................157 10-1 Hub and Bearings, 2WD Models............................................................157 10-2 Oscillating Axle Lock-out Cylinders.....................................................158 Section 5 Fault Codes................................................................................159 Fault Codes - Control System.....................................................................160 Fault Codes - Ford LRG-425 EFI Engine............................................................164 Fault Codes - Ford DSG-423 EFI Engine............................................................170 Section 6 Schematics.................................................................................175 Electrical Symbols Legend........................................................................176 Hydraulic Symbols Legend.........................................................................177 Ford Engine Relay Layout.........................................................................178 Electrical Schematics............................................................................175 Ford Gasoline/LPG powered models.............................................................180 Ford LRG-425 EFI Engine Wiring Harness...................................................180 Ford DSG-423 EFI Engine Wiring Harness...................................................181 Electrical Schematic, Z-45/25, Ford LRG-425 EFI Models (before serial number 30142)......184 Electrical Schematic, Z-45/25, Ford DSG-423 EFI Models (after serial number 30141).......188 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Ford Models...................192 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Ford Models.....................193 Platform Control Box Wiring Diagram, Z-45/25, Ford Models................................196 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Ford Models...................197 Electrical Schematic, Z-45/25J, Ford LRG-425 EFI Models (before serial number 30142).....200 Electrical Schematic, Z-45/25J, Ford DSG-423 EFI Models (after serial number 30141)......204 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Ford Models..................208 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford Models....................209 Platform Control Box Wiring Diagram, Z-45/25J, Ford Models...............................212 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford Models..................213 Deutz diesel-powered models..................................................................216 Electrical Schematic, Z-45/25, Deutz F3L-2011 Models.....................................216 Electrical Schematic, Z-45/25, CE Models, Deutz F3L-2011.................................220 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Deutz F3L-2011 Models.........224 Ground Control Box Switch Panel Diagram, Z-45/25, Deutz F3L-2011 Models..................225 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models, Deutz F3L-2011.....228 Ground Control Box Switch Panel Diagram, Z-45/25, CE Models, Deutz F3L-2011..............229 Platform Control Box Wiring Diagram, Z-45/25, Deutz F3L-2011 Models......................232 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Deutz F3L-2011 Models.........233 Electrical Schematic, Z-45/25J, Deutz F3L-2011 Models....................................236 Electrical Schematic, Z-45/25J, CE Models, Deutz F3L-2011................................240 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Deutz F3L-2011 Models........244 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-2011 Models..........245 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models, Deutz F3L-2011....248 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models, Deutz F3L-2011......249 Platform Control Box Wiring Diagram, Z-45/25J, Deutz F3L-2011 Models.....................252 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-2011 Models........253 Perkins diesel-powered models................................................................256 Electrical Schematic, Z-45/25, Perkins 404-22 Models.....................................256 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Perkins 404-22 Models.........260 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Perkins 404-22 Models...........261 Platform Control Box Wiring Diagram, Z-45/25, Perkins 404-22 Models......................264 Platform Control Box Switch Panel, Z-45/25, Perkins 404-22 Models........................265 Electrical Schematic, Z-45/25J, Perkins 404-22 Models....................................268 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Perkins 404-22 Models........272 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 404-22 Models..........273 Platform Control Box Wiring Diagram, Z-45/25J, Perkins 404-22 Models.....................276 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 404-22 Models........277 Hydraulic Schematics.............................................................................279 Hydraulic Schematic, 2WD Models (before serial number 27001).................................279 Hydraulic Schematic, 2WD Models (after serial number 27000)..................................281 Hydraulic Schematic, 4WD Models (before serial number 27001).................................283 Hydraulic Schematic, 4WD Models (after serial number 27000)..................................285
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