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Genie Z-45/25 Z-45/25J IC Power Service Manual 77809 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J IC Power Service Manual 77809 – PDF DOWNLOAD
Language : English
Pages : 337
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J IC Power Service Manual 77809 – PDF DOWNLOAD
Cover..................................................................................................................... 1 Safety Rules.............................................................................................................. 3 Table of Contents......................................................................................................... 5 Section 2 Specifications.................................................................................................. 17 Machine Specifications................................................................................................ 17 Performance Specifications............................................................................................ 17 Hydraulic Specifications.............................................................................................. 18 Manifold Component Specifications..................................................................................... 20 Ford LRG-425 EFI Engine............................................................................................... 21 Deutz F3L 1011F Engine................................................................................................ 23 Perkins 104-22 Engine (KR model)...................................................................................... 24 Machine Torque Specifications......................................................................................... 26 Hydraulic Hose and Fitting Torque Specifications...................................................................... 27 SAE and Metric Fastener Torque Chart.................................................................................. 28 Section 3 Scheduled Maintenance Prodedures................................................................................ 29 Pre-Delivery Preparation.............................................................................................. 31 Maintenance Inspection Report......................................................................................... 33 Checklist A Procedures................................................................................................ 35 A-1 Perform Pre-operation Inspection.............................................................................. 35 A-2 Perform Function Tests........................................................................................ 35 A-3 Perform Engine Maintenance - Deutz Models..................................................................... 36 A-4 Perfrom Engine Maintenance - Ford Models...................................................................... 36 A-5 Perform Engine Maintenance - Perkins Models................................................................... 37 A-6 Check the High Pressure Hydraulic Filter Condition Indicator.................................................. 37 A-7 Test the Oscillate Axle (if equipped)......................................................................... 38 A-8 Perform 30 Day Service........................................................................................ 38 A-9 Perform Engine Maintenance - Ford and Perkins Models.......................................................... 39 A-10 Replace the Fuel Filters - Ford Models....................................................................... 39 A-11 Inspect the Fuel Filter/Water Separator - Diesel Models...................................................... 41 A-12 Check and Adjust the Engine RPM - Perkins Models............................................................. 43 A-13 Grease the Turntable Rotation Bearing and Rotate Gear........................................................ 44 A-14 Perform Engine Maintenance - Ford Models..................................................................... 44 A-15 Perform Engine Maintenance - Perkins Models.................................................................. 45 Checklist B Procedures................................................................................................ 46 B-1 Inspect the Battery........................................................................................... 46 B-2 Inspect the Electrical Wiring................................................................................. 46 B-3 Test the Key Switch........................................................................................... 47 B-4 Perform Engine Maintenance - Ford Models...................................................................... 48 B-5 Check the Exhaust System...................................................................................... 48 B-6 Check the Oil Cooler and Cooling Fins - Deutz Models.......................................................... 49 B-7 Check the Lug Nut Torque (including tires and wheels)......................................................... 50 B-8 Confirm the Proper Brake Configuration........................................................................ 50 B-9 Check the Oil Level in the Drive Hubs......................................................................... 51 B-10 Check and Adjust the Engine RPM - Ford and Deutz Models...................................................... 51 B-11 Test the Ground Control Override............................................................................. 52 B-12 Check the Directional Valve Linkage.......................................................................... 53 B-13 Test the Platform Self-leveling.............................................................................. 53 B-14 Test the Engine Idle Select.................................................................................. 54 B-15 Test the Fuel Select Operation - Ford Models................................................................. 54 B-16 Test the Drive Brakes........................................................................................ 55 B-17 Test the Drive Speed - Stowed Position....................................................................... 56 B-18 Test the Drive Speed - Raised or Extended Position........................................................... 56 B-19 Test the Alarm Package (if equipped)......................................................................... 57 B-20 Perform Hydraulic Oil Analysis............................................................................... 58 B-21 Replace the Fuel Filter/Water Separator Element - Perkins Models............................................. 59 B-22 Replace the Fuel Filter Element - Perkins Models............................................................. 61 B-23 Perform Engine Maintenance - Deutz Models.................................................................... 62 B-24 Perform Engine Maintenance - Ford Models..................................................................... 63 B-25 Perform Engine Maintenance - Perkins 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 Perform Engine Maintenance - Perkins Models................................................................... 67 C-5 Perform Engine Maintenance - Ford Models...................................................................... 67 Checklist D Procedures................................................................................................ 68 D-1 Check the Boom Wear Pads...................................................................................... 68 D-2 Check the Turntable Rotation Bearing Bolts.................................................................... 68 D-3 Check the Free-wheel Configuration............................................................................ 70 D-4 Replace the Drive Hub Oil..................................................................................... 71 D-5 Check and Adjust the LPG Mixture - Ford Models................................................................ 72 D-6 Perform Engine Maintenance - Deutz Models..................................................................... 73 D-7 Inspect for Turntable Bearing Wear............................................................................ 73 D-8 Calibrate the Platform Overload System (if equipped).......................................................... 75 D-9 Replace the Hydraulic Filters................................................................................. 76 Checklist E Procedures................................................................................................ 78 E-1 Test or Replace the Hydraulic Oil............................................................................. 78 E-2 Change the Fuel Hoses - Ford Models........................................................................... 80 E-3 Perform Engine Maintenance - Deutz Models..................................................................... 81 E-4 Grease the Steer Axle Wheel Bearings, 2WD Models.............................................................. 81 Section 4 Repair Prodedures............................................................................................... 83 Platform Controls..................................................................................................... 84 1-1 ALC-500 Circuit Board......................................................................................... 84 1-2 Joysticks..................................................................................................... 85 Platform Components................................................................................................... 89 2-1 Platform Leveling Slave Cylinder.............................................................................. 89 2-2 Platform Rotator.............................................................................................. 90 Jib Boom Components, Z-45/25J......................................................................................... 92 3-1 Jib Boom...................................................................................................... 92 3-2 Jib Boom Lift Cylinder........................................................................................ 93 Primary Boom Components............................................................................................... 94 4-1 Cable Track................................................................................................... 94 4-2 Primary Boom.................................................................................................. 98 4-3 Primary Boom Lift Cylinder....................................................................................100 4-4 Primary Boom Extension Cylinder...............................................................................101 4-5 Platform Leveling Master Cylinder.............................................................................102 Secondary Boom Components.............................................................................................104 5-1 Secondary Boom................................................................................................104 5-2 Secondary Boom Lift Cylinders.................................................................................109 Engines...............................................................................................................110 6-1 RPM Adjustment - Ford and Deutz Models........................................................................110 6-2 RPM Adjustment - Perkins Models...............................................................................110 6-3 Flex Plate....................................................................................................110 6-4 Engine Fault Codes - Ford Models..............................................................................111 Hydraulic Pumps.......................................................................................................113 7-1 Lift/Steer Pump...............................................................................................113 7-2 Drive Pump....................................................................................................114 Manifolds.............................................................................................................116 8-1 Function Manifold Components (before serial number 22050).....................................................116 8-2 Valve Adjustments - Function Manifold (before serial number 22050)............................................120 8-3 Function Manifold Components (after serial number 22049)......................................................122 8-4 Valve Adjustments - Function Manifold (after serial number 22049).............................................126 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 22050)...................................127 8-6 Jib Boom / Platform Rotate Manifold Components (after serial number 22049)....................................128 8-7 Turntable Rotation Manifold Components........................................................................129 8-8 Directional Valve Manifold Components.........................................................................130 8-9 Drive Manifold Components, 2WD................................................................................132 8-10 Valve Adjustments, 2WD Drive Manifold........................................................................134 8-11 Drive Manifold Components, 4WD...............................................................................136 8-12 Valve Adjustments, 4WD Drive Manifold........................................................................138 Turntable Rotation Components.........................................................................................139 9-1 Turntable Rotation Assembly...................................................................................139 Axle Components.......................................................................................................140 10-1 Hub and Bearings, 2WD Models.................................................................................140 10-2 Oscillating Axle Lock-out Cylinders..........................................................................141 Section 5 Fault Codes.....................................................................................................143 Fault Codes - Control System..........................................................................................144 Fault Codes - Ford Models.............................................................................................148 Section 6 Schematics......................................................................................................161 Electrical Symbols Legend.............................................................................................162 Hydraulic Symbols Legend..............................................................................................163 Ford LRG-425 EFI Engine Wiring Harness (before serial number 22050)...................................................165 Ford LRG-425 EFI Engine Wiring Harness (after serial number 22049)....................................................167 Electrical Schematic, Z-45/25, Ford LRG-425 EFI Models (before serial number 22050)...................................170 Electrical Schematic, Z-45/25, Ford LRG-425 EFI Models (after serial number 22049)....................................174 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (before serial number 22050).......178 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (before serial number 22050).........179 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (after serial number 22049)........182 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (after serial number 22049)..........183 Platform Control Box Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (before serial number 22050)....................186 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (before serial number 22050).......187 Platform Control Box Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (after serial number 22049).....................190 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Ford LRG-425 EFI Models (after serial number 22049)........191 Electrical Schematic, Z-45/25J, Ford LRG-425 EFI Models (before serial number 22050)..................................194 Electrical Schematic, Z-45/25J, Ford LRG-425 EFI Models (after serial number 22049)...................................198 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (before serial number 22050)......202 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (before serial number 22050)........203 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (after serial number 22049).......206 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (after serial number 22049).........207 Platform Control Box Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (before serial number 22050)...................210 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (before serial number 22050)......211 Platform Control Box Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (after serial number 22049)....................214 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Ford LRG-425 EFI Models (after serial number 22049).......215 Electrical Schematic, Z-45/25, Deutz F3L-1011F Models (before serial number 22050)....................................218 Electrical Schematic, Z-45/25, Deutz F3L-1011F Models (after serial number 22049).....................................222 Electrical Schematic, Z-45/25, CE Models, Deutz F3L-1011F (after serial number 22049).................................226 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (before serial number 22050)........230 Ground Control Box Switch Panel Diagram, Z-45/25, Deutz F3L-1011F Models (before serial number 22050).................231 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (after serial number 22049).........234 Ground Control Box Switch Panel Diagram, Z-45/25, Deutz F3L-1011F Models (after serial number 22049)..................235 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE Models, Deutz F3L-1011F (after serial number 22049).....238 Ground Control Box Switch Panel Diagram, Z-45/25, CE Models, Deutz F3L-1011F (after serial number 22049)..............239 Platform Control Box Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (before serial number 22050).....................242 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (before serial number 22050)........243 Platform Control Box Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (after serial number 22049)......................246 Platform Control Box Switch Panel Wiring Diagram, Z-45/25, Deutz F3L-1011F Models (after serial number 22049).........247 Electrical Schematic, Z-45/25J, Deutz F3L-1011F Models (before serial number 22050)...................................250 Electrical Schematic, Z-45/25J, Deutz F3L-1011F Models (after serial number 22049)....................................254 Electrical Schematic, Z-45/25J, CE Models, Deutz F3L-1011F (after serial number 22049)................................258 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (before serial number 22050).......262 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (before serial number 22050).........263 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (after serial number 22049)........266 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (after serial number 22049)..........267 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE Models, Deutz F3L-1011F (after serial number 22049)....270 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE Models, Deutz F3L-1011F (after serial number 22049)......271 Platform Control Box Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (before serial number 22050)....................274 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (before serial number 22050).......275 Platform Control Box Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (after serial number 22049).....................278 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Deutz F3L-1011F Models (after serial number 22049)........279 Electrical Schematic, Z-45/25, Perkins 104-22 Models (before serial number 22050).....................................282 Electrical Schematic, Z-45/25, Perkins 104-22 Models (after serial number 22049)......................................286 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Perkins 104-22 Models (before serial number 22050).........290 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Perkins 104-22 Models (before serial number 22050)...........291 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, Perkins 104-22 Models (after serial number 22049)..........294 Ground Control Box Switch Panel Wiring Diagram, Z-45/25, Perkins 104-22 Models (after serial number 22049)............295 Platform Control Box Wiring Diagram, Z-45/25, Perkins 104-22 Models (before serial number 22050)......................298 Platform Control Box Switch Panel, Z-45/25, Perkins 104-22 Models (before serial number 22050)........................299 Platform Control Box Wiring Diagram, Z-45/25, Perkins 104-22 Models (after serial number 22049).......................302 Platform Control Box Switch Panel, Z-45/25, Perkins 104-22 Models (after serial number 22049).........................303 Electrical Schematic, Z-45/25J, Perkins 104-22 Models (before serial number 22050)....................................306 Electrical Schematic, Z-45/25J, Perkins 104-22 Models (after serial number 22049).....................................310 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Perkins 104-22 Models (before serial number 22050)........314 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 104-22 Models (before serial number 22050)..........315 Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, Perkins 104-22 Models (after serial number 22049).........318 Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 104-22 Models (after serial number 22049)...........319 Platform Control Box Wiring Diagram, Z-45/25J, Perkins 104-22 Models (before serial number 22050).....................322 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 104-22 Models (before serial number 22050)........323 Platform Control Box Wiring Diagram, Z-45/25J, Perkins 104-22 Models (after serial number 22049)......................326 Platform Control Box Switch Panel Wiring Diagram, Z-45/25J, Perkins 104-22 Models (after serial number 22049).........327 Hydraulic Schematic, 2WD Models (before serial number 22050)..........................................................329 Hydraulic Schematic, 2WD Models (after serial number 22049)...........................................................331 Hydraulic Schematic, 4WD Models (before serial number 22050)..........................................................333 Hydraulic Schematic, 4WD Models (after serial number 22049)...........................................................335 Back Cover................................................................................................................337 Return to Index........................................................................................................... 0
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