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Genie Z-45/25 Z-45/25J Service Manual 52709 – PDF DOWNLOAD
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Description
Genie Z-45/25 Z-45/25J Service Manual 52709 – PDF DOWNLOAD
Language : English
Pages : 440
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45/25 Z-45/25J Service Manual 52709 – PDF DOWNLOAD
Front Cover.pdf.................................................................................................... 1 Safety Rules....................................................................................................... 3 Table of Contents.................................................................................................. 5 Specifications..................................................................................................... 19 Machine Specifications......................................................................................... 19 Performance Specifications..................................................................................... 20 Hydraulic Specifications....................................................................................... 22 Ford Engine LRG-425 EFI........................................................................................ 23 Deutz Engine F3L 1011F......................................................................................... 25 Perkins Engine 104-22 (KR model)............................................................................... 26 Hydraulic Hose and Fitting Torque Specifications............................................................... 27 Theory of Operation................................................................................................ 29 Scheduled Maintenance Procedures................................................................................... 31 Maintenance Inspection Report.................................................................................. 33 Table A Procedures............................................................................................. 35 A-1 to A-2................................................................................................. 35 A-3........................................................................................................ 36 A-4........................................................................................................ 37 A-5 to A-6................................................................................................. 38 A-7........................................................................................................ 39 A-8 to A-9................................................................................................. 40 A-10 to A-11............................................................................................... 41 A-12....................................................................................................... 42 A-13....................................................................................................... 43 A-14....................................................................................................... 44 A-15....................................................................................................... 48 A-16....................................................................................................... 49 A-17....................................................................................................... 50 A-18....................................................................................................... 51 A-19....................................................................................................... 52 A-20....................................................................................................... 53 A-21....................................................................................................... 54 A-22....................................................................................................... 56 A-23....................................................................................................... 58 Table B Procedures............................................................................................. 59 B-1 to B-2................................................................................................. 59 B-3........................................................................................................ 60 B-4........................................................................................................ 61 B-5 to B-6................................................................................................. 62 B-7........................................................................................................ 63 B-8 to B-9................................................................................................. 64 B-10....................................................................................................... 65 B-11 to B-12............................................................................................... 67 B-13 to B-14............................................................................................... 68 B-15....................................................................................................... 69 B-16 to B-17............................................................................................... 70 B-18....................................................................................................... 71 B-19....................................................................................................... 72 B-20....................................................................................................... 73 B-21....................................................................................................... 74 B-22....................................................................................................... 75 B-23....................................................................................................... 76 B-24....................................................................................................... 77 B-25 to B-26............................................................................................... 78 B-27....................................................................................................... 79 B-28....................................................................................................... 81 B-29....................................................................................................... 82 B-30....................................................................................................... 83 Table C Procedures............................................................................................. 85 C-1........................................................................................................ 85 C-2........................................................................................................ 86 C-3........................................................................................................ 87 C-4........................................................................................................ 88 C-5........................................................................................................ 89 C-6........................................................................................................ 90 Table D Procedures............................................................................................. 91 D-1........................................................................................................ 91 D-2........................................................................................................ 92 D-3........................................................................................................ 93 D-4........................................................................................................ 95 D-5........................................................................................................ 96 D-6........................................................................................................ 97 D-7........................................................................................................ 98 D-8........................................................................................................ 99 Table E Procedures.............................................................................................100 E-1........................................................................................................101 E-2........................................................................................................102 E-3........................................................................................................104 E-4 to E-8.................................................................................................107 E-9........................................................................................................108 Troubleshooting Flow Charts........................................................................................111 Fault Codes....................................................................................................113 Chart 1........................................................................................................116 Chart 2........................................................................................................118 Chart 2A.......................................................................................................120 Chart 3........................................................................................................121 Chart 4........................................................................................................124 Chart 5........................................................................................................126 Chart 6........................................................................................................127 Chart 7........................................................................................................128 Chart 8........................................................................................................129 Chart 9........................................................................................................131 Chart 10.......................................................................................................132 Chart 11.......................................................................................................133 Chart 12.......................................................................................................134 Chart 13.......................................................................................................135 Chart 14.......................................................................................................136 Chart 15.......................................................................................................139 Chart 16.......................................................................................................142 Chart 17.......................................................................................................145 Chart 18.......................................................................................................148 Chart 19.......................................................................................................151 Chart 20.......................................................................................................153 Chart 21.......................................................................................................155 Chart 22.......................................................................................................159 Chart 23.......................................................................................................163 Chart 24.......................................................................................................164 Chart 25.......................................................................................................166 Chart 26.......................................................................................................168 Chart 27.......................................................................................................171 Chart 28.......................................................................................................174 Chart 29.......................................................................................................176 Chart 30.......................................................................................................178 Chart 31.......................................................................................................179 Chart 32.......................................................................................................180 Chart 33.......................................................................................................181 Chart 34.......................................................................................................184 Chart 35.......................................................................................................185 Chart 36.......................................................................................................186 Chart 37.......................................................................................................187 Chart 38.......................................................................................................188 Chart 39.......................................................................................................189 Schematics.........................................................................................................191 Electrical Schematics.......................................................................................... 0 Electrical Components......................................................................................192 Electrical Symbols Legend..................................................................................194 Abbreviation Legend........................................................................................195 Ford Models................................................................................................ 0 Engine Wire Harness (before serial number 13099).......................................................198 Engine Wire Harness (after serial number 13098)........................................................199 Electrical Schematic Z-45/25(before serial number 13099)...............................................202 Ground Control Box Wiring Z-45/25 (before serial number 13099).........................................206 Platform Control Box Wiring Z-45/25 (before serial number 13099).......................................207 Electrical Schematic Z-45/25 (from serial number 13099 to 16303).......................................210 Ground Control Box Wiring Z-45/25 (from serial number 13099 to 16303)..................................214 Platform Contol Box Wiring Z-45/25 (from serial number 13099 to 16303).................................215 Electrical Schematic Z-45/25J (before serial number 13099).............................................218 Ground Control Box Wiring Z-45/25J (before serial number 13099)........................................222 Platform Control Box Wiring Z-45/25J (before serial number 13099)......................................223 Electrical Schematic Z-45/25J (from serial number 13099 to 16303)......................................226 Ground Control Box Wiring Z-45/25J (from serial number 13099 to 16303).................................230 Platform Control Box Z-45/25J (from serial number 13099 to 16303)......................................231 Electrical Schematic Z-45/25 (after serial number 16303)...............................................234 Ground Control Box Wiring Z-45/25 (after serial number 16303)..........................................238 Platform Control Box Wiring Z-45/25 (after serial number 16303)........................................239 Electrical Schematic Z-45/25J (after serial number 16303)..............................................242 Ground Control Box Wiring Z-45/25J (after serial number 16303).........................................246 Platform Control Box Wiring Z-45/25J (after serial number 16303).......................................247 Deutz Models............................................................................................... 0 Electrical Schematic Z-45/25 (before serial number 13099)..............................................250 Ground Control Box Wiring Z-45/25 (before serial number 13099).........................................254 Platform Control Box Wiring Z-45/25 (before serial number 13099........................................255 Electrical Schematic Z-45/25 (from serial number 13099 to 16303).......................................258 Ground Control Box Wiring Z-45/25 (from serial number 13099 to 16303)..................................262 Platform Control Box Wiring Z-45/25 (from serial number 13099 to 16303)................................263 Electrical Schematic Z-45/25J (before serial number 13099).............................................266 Ground Control Box Wiring Z-45/25J (before serial number 13099)........................................270 Platform Control Box Wiring Z-45/25J (before serial number 13099)......................................271 Electrical Schematic Z-45/25J (from serial number 13099 to 16303)......................................274 Ground Control Box Wiring Z-45/25J (from serial number 13099 to 16303).................................278 Platform Control Box Wiring Z-45/25J (from serial number 13099 to 16303)...............................279 Platform Control Box Wiring - Lift/Drive Select Option Z-45/25J (from serial number 13099 to 16303)....281 Electrical Schematic Z-45/25 (after serial number 16303)...............................................284 Ground Control Box Wiring Z-45/25 (after serial number 16303)..........................................288 Platform Control Box Wiring Z-45/25 (after serial number 16303)........................................289 Platform Control Box Wiring - Lift/Drive Select Option Z-45/25 (after serial number 16303).............291 Electrical Schematic Z-45/25J (after serial number 16303)..............................................294 Ground Control Box Wiring Z-45/25J (after serial number 16303).........................................298 Platform Control Box Wiring Z-45/25J (after serial number 16303).......................................299 Platform Control Box Wiring - Lift/Drive Select Option Z-45/25J (after serial number 16303)............301 Perkins Models............................................................................................. 0 Electrical Schematic Z-45/25 (before serial number 16304)..............................................304 Ground Control Box Wiring Z-45/25 (before serial number 16304).........................................308 Platform Control Box Wiring Z-45/25 (before serial number 16304).......................................309 Electrical Schematic Z-45/25J (before serial number 16304).............................................312 Ground Control Box Wiring Z-45/25J (before serial number 16304)........................................316 Platform Control Box Wiring Z-45/25J (before serial number 16304)......................................317 Platform Control Box Wiring - Lift/Drive Select Z-45/25J (before serial number 16304)..................319 Electrical Schematic Z-45/25 (after serial number 16303)...............................................322 Ground Control Box Wiring Z-45/25 (after serial number 16303)..........................................326 Platform Control Box Wiring Z-45/25 (after serial number 16303)........................................327 Platform Control Box Wiring - Lift/Drive Select Z-45/25 (after serial number 16303)....................329 Electrical Schematic Z-45/25J (after serial number 16303)..............................................332 Ground Control Box Wiring Z-45/25J (after serial number 16303).........................................336 Platform Control Box Wiring Z-45/25J (after serial number 16303).......................................337 Platform Control Box Wiring - Lift/Drive Select Z-45/25J (after serial number 16303)...................339 Platform Control Box Wiring - Load Sensor Option, All Models (after serial number 16303)...................342 Hydraulic Schematics...........................................................................................193 Hydraulic Symbols Legend...................................................................................343 2WD Hydraulic Schematic....................................................................................345 4WD Hydraulic Schematic....................................................................................347 Repair Procedures..................................................................................................349 Platform Controls..............................................................................................350 1-1........................................................................................................350 1-2........................................................................................................356 1-3........................................................................................................358 1-4........................................................................................................359 Platform Components............................................................................................361 2-1........................................................................................................361 2-2........................................................................................................362 2-3........................................................................................................363 Jib Boom Components............................................................................................366 3-1........................................................................................................366 3-2........................................................................................................367 3-3........................................................................................................369 Primary Boom Components........................................................................................370 4-1........................................................................................................370 4-2........................................................................................................375 4-3........................................................................................................378 4-4........................................................................................................379 4-5........................................................................................................380 Secondary Boom Components......................................................................................382 5-1........................................................................................................382 5-2........................................................................................................387 Turntable Covers...............................................................................................388 6-1........................................................................................................388 Deutz Engine F3L 1011F.........................................................................................389 7-1 to 7-2.................................................................................................389 7-3........................................................................................................390 Perkins 104-22 Engine..........................................................................................391 8-1 to 8-2.................................................................................................391 8-3........................................................................................................392 Ford LRG-425 EFI Engine........................................................................................393 9-1 to 9-3.................................................................................................393 9-4........................................................................................................394 Ground Controls................................................................................................396 10-1.......................................................................................................396 10-2 to 10-3...............................................................................................397 10-4.......................................................................................................398 Hydraulic Pumps................................................................................................400 11-1.......................................................................................................400 11-2.......................................................................................................401 Manifolds......................................................................................................404 12-1.......................................................................................................404 12-2.......................................................................................................410 12-3.......................................................................................................412 12-4.......................................................................................................413 12-5.......................................................................................................416 12-6.......................................................................................................418 12-7.......................................................................................................420 12-8.......................................................................................................424 Fuel and Hydraulic Tanks.......................................................................................425 13-1 to 13-2...............................................................................................425 Turntable Rotation Components..................................................................................428 14-1.......................................................................................................428 2WD Steering Axle Components...................................................................................430 15-1.......................................................................................................430 15-2.......................................................................................................432 15-3.......................................................................................................433 4WD Steering Axle Components...................................................................................434 16-1.......................................................................................................434 16-2 to 16-3...............................................................................................436 Oscillating Axle Components....................................................................................437 17-1.......................................................................................................437 Non-steering Axle Components...................................................................................438 18-1.......................................................................................................438 18-2.......................................................................................................439
S.S 05/24
