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Genie Z-45/25 Z-45/25J IC Power Service & Repair Manual 1268548 – PDF
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Description
Genie Z-45/25 Z-45/25J IC Power Service & Repair Manual 1268548 – PDF DOWNLOAD
Language : English
Pages : 255
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J IC Power Service & Repair Manual 1268548 – PDF DOWNLOAD
Front Cover........................................................................................................ 1 Important Information.............................................................................................. 2 Find a Manual for this Model....................................................................................... 2 Revision History................................................................................................... 3 Serial Number Legend............................................................................................... 4 General Safety Rules............................................................................................... 5 Table of Contents.................................................................................................. 7 Specifications..................................................................................................... 15 Machine Specifications......................................................................................... 15 Performance Specifications..................................................................................... 16 Hydraulic Specification........................................................................................ 17 Hydraulic Component Specifications............................................................................. 19 Ford MSG-425 EFI Engine Specifications......................................................................... 21 Deutz D2011 L03i Engine Specifications......................................................................... 23 Deutz D 2.9 L4 Engine Specifications........................................................................... 25 Perkins 404D-22 Engine Specifications.......................................................................... 27 Perkins 404F-22 Engine Specifications.......................................................................... 29 Machine Torque Specifications.................................................................................. 30 Hydraulic Hose and Fitting Torque Specifications............................................................... 31 Torque Procedure............................................................................................... 32 SAE and Metric Fasteners Torque Charts......................................................................... 34 Repair Procedures.................................................................................................. 35 Introduction................................................................................................... 35 Platform Controls.............................................................................................. 37 1-1 ALC-500 Circuit Board.................................................................................. 37 1-2 Joysticks.............................................................................................. 38 How to Adjust the Joystick Max-out Setting............................................................. 39 How to Adjust the Joystick Ramp Rate Setting........................................................... 40 How to Adjust the Joystick Threshold Setting........................................................... 41 Platform Components............................................................................................ 43 2-1 Platform Leveling Slave Cylinder....................................................................... 43 How to Bleed the Slave Cylinder........................................................................ 44 2-2 Platform Rotator....................................................................................... 45 2-3 Platform Overload System............................................................................... 46 Jib Boom Components............................................................................................ 48 3-1 Jib Boom............................................................................................... 48 3-2 Jib Boom Lift Cylinder................................................................................. 49 Primary Boom Components........................................................................................ 51 4-1 Cable Track............................................................................................ 51 How to Remove the Cable Track, Z-45/25................................................................. 51 How to Remove the Cable Track, Z-45/25J................................................................ 53 How to Repair the Primary Boom Cable Track............................................................. 55 4-2 Primary Boom........................................................................................... 55 How to Disassemble the Primary Boom.................................................................... 57 4-3 Primary Boom Lift Cylinder............................................................................. 58 4-4 Primary Boom Extension Cylinder........................................................................ 59 4-5 Platform Leveling Master Cylinder...................................................................... 60 Secondary Boom Components...................................................................................... 61 5-1 Secondary Boom......................................................................................... 62 5-2 Secondary Boom Lift Cylinders.......................................................................... 67 Engines........................................................................................................ 69 6-1 RPM Adjustment - Deutz D2011L03i Models................................................................ 69 6-2 RPM Adjustment - Perkins 404D-22 Models................................................................ 69 6-3 Flex Plate............................................................................................. 69 How to Install the Flex Plate.......................................................................... 71 How to install the Pump and Bell Housing Assembly...................................................... 72 6-4 Ford MSG-425 Engine Fault Codes........................................................................ 73 6-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models......................................... 73 Hydraulic Pumps................................................................................................ 74 7-1 Lift/Steer Pump........................................................................................ 74 7-2 Drive Pump............................................................................................. 75 How to Prime the Pump.................................................................................. 76 Manifolds...................................................................................................... 78 8-1 Function Manifold Components........................................................................... 78 8-2 Valve Adjustments - Function Manifold.................................................................. 82 How to Adjust the System Relief Valve.................................................................. 82 How to Adjust the Secondary Boom Down Relief Valve..................................................... 83 8-3 Jib Boom / Platform Rotate Manifold Components......................................................... 84 8-4 Turntable Rotation Manifold Components................................................................. 85 8-5 Directional Valve Manifold Components.................................................................. 86 How to Set Up the Directional Valve Linkage............................................................ 87 8-6 Traction Manifold Components, 2WD...................................................................... 88 8-7 Valve Adjustments, 2WD Traction Manifold............................................................... 90 8-8 Traction Manifold Components, 4WD...................................................................... 91 8-9 Valve Adjustments, 4WD Traction Manifold............................................................... 93 8-10 Hydraulic Generator Manifold Components, 2.2kW........................................................ 94 8-11 Valve Coils........................................................................................... 95 How to Test a Coil Diode............................................................................... 95 Turntable Rotation Components.................................................................................. 97 9-1 Turntable Rotation Assembly............................................................................ 97 Axle Components................................................................................................ 99 10-1 Hub and Bearings, 2WD Models.......................................................................... 99 How to Remove the Hub and Bearings..................................................................... 99 How to Install the Hub and Bearings.................................................................... 99 10-2 Oscillating Axle Cylinders............................................................................100 Fault Codes........................................................................................................101 Introduction...................................................................................................101 Control System Fault Codes.....................................................................................102 How to Retrieve Control System Fault Codes.................................................................102 Control System Fault Codes.................................................................................103 Fault Code Display - Deutz and Perkins Models..................................................................107 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models........................107 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models..................108 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models...................................109 Main Menu Structure - Deutz D 2.9 L4 Models................................................................110 Main Menu Structure - Perkins 404F-22 Models...............................................................111 Deutz D 2.9 L4 Engine Fault Codes..............................................................................112 Perkins 404F-22 Engine Fault Codes.............................................................................123 Ford MSG-425 Engine Fault Codes................................................................................125 How to Retrieve Ford MSG-425 Engine Fault Codes............................................................125 Ford MSG-425 Engine Fault Codes............................................................................126 Schematics.........................................................................................................131 Introduction...................................................................................................131 Electrical Symbol Legend.......................................................................................132 Hydraulic Symbols Legend.......................................................................................133 Electrical Component and Wire Color Legends....................................................................134 Ford Engine Relay Layout.......................................................................................137 Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22.......................................................138 Electrical Schematics – Options................................................................................139 Ford MSG-425 EFI Engine Wire Harness.......................................................................140 Deutz D 2.9 L4 Engine Wire Harness.........................................................................141 Perkins 404F-22 Engine Wire Harness........................................................................144 Electrical Schematic, Options (All Models).................................................................145 Ground Control Box Terminal Strip Wiring Diagram, Options..................................................148 Platform Control Box Wiring Diagram, Options...............................................................149 Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options......................................152 Wiring Diagram, 2.2kW Hydraulic Generator..................................................................153 Hydraulic Schematics...........................................................................................155 Hydraulic Schematic, 2WD Models............................................................................156 Hydraulic Schematic, 4WD Models............................................................................157 Electrical Schematics – ANSI and CSA Models....................................................................159 Electrical Schematic, Ford MSG-425 EFI Models (ANSI/CSA)...................................................160 Ground Control Box Terminal Strip Wiring Diagram - Ford MSG-425 EFI Models (ANSI/CSA)......................164 Ground Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (ANSI/CSA)........................165 Platform Control Box Wiring Diagram - Ford MSG-425 EFI Models (ANSI/CSA)...................................168 Platform Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (ANSI/CSA)......................169 Electrical Schematic, Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA).................................172 Ground Control Box Terminal Strip Wiring Diagram - Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)....176 Ground Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)......177 Platform Control Box Wiring Diagram - Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA).................180 Platform Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i / Perkins 404D-22 Models (ANSI/CSA)....181 Electrical Schematics – ANSI Models............................................................................183 Electrical Schematic, Deutz D 2.9 L4 Models (ANSI).........................................................184 Ground Control Box Terminal Strip Wiring Diagram - Deutz D 2.9 L4 Models (ANSI)............................188 Ground Control Box Switch Panel Wiring Diagram - Deutz D 2.9 L4 Models (ANSI)..............................189 Platform Control Box Wiring Diagram - Deutz D 2.9 L4 Models (ANSI).........................................192 Platform Control Box Switch Panel Wiring Diagram - Deutz D 2.9 L4 Models (ANSI)............................193 Electrical Schematic, Perkins 404F-22 Models (ANSI).......................................................196 Ground Control Box Terminal Strip Wiring Diagram - Perkins 404F-22 Models (ANSI)...........................200 Ground Control Box Switch Panel Wiring Diagram - Perkins 404F-22 Models (ANSI).............................201 Platform Control Box Wiring Diagram Perkins 404F-22 Models (ANSI)..........................................204 Platform Control Box Switch Panel Wiring Diagram - Perkins 404F-22 Models (ANSI)...........................205 Electrical Schematics – AS Models..............................................................................207 Electrical Schematic, Ford MSG-425 EFI Models (AS).........................................................208 Ground Control Box Terminal Strip Wiring Diagram - Ford MSG-425 EFI Models (AS)............................212 Ground Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (AS)..............................213 Platform Control Box Wiring Diagram - Ford MSG-425 EFI Models (AS).........................................216 Platform Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (AS)............................217 Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (AS)........................................220 Ground Control Box Terminal Strip Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (AS)...........224 Ground Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (AS).............225 Platform Control Box Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (AS)........................228 Platform Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (AS)...........229 Electrical Schematics – CE Models..............................................................................231 Electrical Schematic, Ford MSG-425 EFI Models (CE).........................................................232 Ground Control Box Terminal Strip Wiring Diagram - Ford MSG-425 EFI Models (CE)............................236 Ground Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (CE)..............................237 Platform Control Box Wiring Diagram - Ford MSG-425 EFI Models (CE).........................................240 Platform Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models (CE)............................241 Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (CE)........................................244 Ground Control Box Terminal Strip Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (CE)...........248 Ground Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (CE).............249 Platform Control Box Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (CE)........................252 Platform Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models (CE)...........253 Back Cover.........................................................................................................255
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