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Genie Z-45 XC Z-45 HF Service & Repair Manual 1268197 – PDF DOWNLOAD
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Genie Z-45 XC Z-45 HF Service & Repair Manual 1268197 – PDF DOWNLOAD
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Description
Genie Z-45 XC Z-45 HF Service & Repair Manual 1268197 – PDF DOWNLOAD
Language : English
Pages : 197
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-45 XC Z-45 HF Service & Repair Manual 1268197 – PDF DOWNLOAD
Front Cover................................................................................................................ 1 Important Information...................................................................................................... 2 Find a Manual for this Model............................................................................................... 2 Revision History........................................................................................................... 3 General Safety Rules....................................................................................................... 4 Table of Contents.......................................................................................................... 6 Specifications............................................................................................................. 13 Machine Specifications................................................................................................. 13 Performance Specifications............................................................................................. 14 Hydraulic Oil Specifications........................................................................................... 14 Hydraulic Component Specifications..................................................................................... 17 Deutz D 2.9 L4 Engine Specifications................................................................................... 19 Deutz TD 2.2 L3 Engine Specifications.................................................................................. 20 Deutz D2011 L03i Engine Specifications................................................................................. 21 Perkins 404D-22 Engine Specifications.................................................................................. 22 Perkins 404F-E22T Engine Specifications................................................................................ 23 Ford MSG-425 EFI Engine Specifications................................................................................. 24 Machine Torque Specifications.......................................................................................... 25 Hydraulic Hose and Fitting Torque Specifications....................................................................... 25 Torque Procedure....................................................................................................... 27 Repair Procedures.......................................................................................................... 29 Introduction........................................................................................................... 29 Platform Controls...................................................................................................... 31 1-1 ALC-500 Circuit Board.......................................................................................... 31 1-2 Joysticks...................................................................................................... 32 How to Adjust the Joystick Max-out Setting..................................................................... 32 How to Adjust the Joystick Ramp Rate Setting................................................................... 33 How to Adjust the Joystick Threshold Setting................................................................... 35 Platform Components.................................................................................................... 36 2-1 Platform Leveling Slave Cylinder............................................................................... 36 How to Bleed the Slave Cylinder................................................................................ 37 2-2 Platform Rotator............................................................................................... 37 2-3 Platform Overload System....................................................................................... 38 How to Replace the Platform Overload Load Cell................................................................. 41 2-4 Platform Overload Recovery Fault............................................................................... 41 Jib Boom Components.................................................................................................... 42 3-1 Jib Boom....................................................................................................... 42 3-2 Jib Boom Lift Cylinder......................................................................................... 43 Primary Boom Components................................................................................................ 45 4-1 Cable Track.................................................................................................... 45 How to Remove the Cable Track.................................................................................. 45 How to Repair the Primary Boom Cable Track..................................................................... 47 4-2 Primary Boom................................................................................................... 47 How to Disassemble the Primary Boom............................................................................ 49 4-3 Primary Boom Lift Cylinder..................................................................................... 50 4-4 Primary Boom Extension Cylinder................................................................................ 51 4-5 Platform Leveling Master Cylinder.............................................................................. 52 Secondary Boom Components.............................................................................................. 53 5-1 Secondary Boom................................................................................................. 54 5-2 Secondary Boom Lift Cylinders.................................................................................. 58 Engines................................................................................................................ 59 6-1 RPM Adjustment - Deutz D2011L03i Models........................................................................ 59 6-2 RPM Adjustment - Perkins 404D-22 Models........................................................................ 59 6-3 Flex Plate..................................................................................................... 59 How to Install the Flex Plate.................................................................................. 61 How to install the Pump and Bell Housing Assembly.............................................................. 62 5-4 Engine Fault Codes............................................................................................. 63 6-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3.......................................................... 64 Hydraulic Pumps........................................................................................................ 65 7-1 Lift/Steer Pump................................................................................................ 65 7-2 Drive Pump..................................................................................................... 66 How to Prime the Pump.......................................................................................... 67 Manifolds.............................................................................................................. 68 8-1 Function Manifold Components - CE (to Z4525XCM-1500)........................................................... 68 8-1.1 Function Manifold Components - ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501)............................ 71 8-2 Valve Adjustments - Function Manifold.......................................................................... 76 How to Adjust the System Relief Valve.......................................................................... 76 How to Adjust the Secondary Boom Down Relief Valve............................................................. 76 8-3 Jib Boom / Platform Rotate Manifold Components................................................................. 77 8-4 Turntable Rotation Manifold Components......................................................................... 78 8-5 Directional Valve Manifold Components.......................................................................... 79 How to Set Up the Directional Valve Linkage.................................................................... 80 8-6 Traction Manifold Components, 4WD.............................................................................. 82 8-7 Valve Adjustments, 4WD Traction Manifold....................................................................... 84 8-8 Hydraulic Generator Manifold Components, 2.2kW................................................................. 85 8-8.1 Generator Manifold Components................................................................................ 86 8-9 Valve Coils.................................................................................................... 87 How to Test a Coil Diode....................................................................................... 87 Turntable Rotation Components.......................................................................................... 89 9-1 Turntable Rotation Assembly.................................................................................... 89 Axle Components........................................................................................................ 90 10-1 Oscillating Axle Cylinders.................................................................................... 90 Fault Codes................................................................................................................ 91 Introduction........................................................................................................... 91 Control System Fault Codes............................................................................................. 92 How to Retrieve Control System Fault Codes......................................................................... 92 Control System Fault Codes......................................................................................... 93 How to Retrieve Platform Overload System Fault Codes - Deutz D2011L03i, Perkins 404D-22 and Ford MSG-425 Models.... 96 Platform Overload System Fault Codes............................................................................... 97 Fault Code Display - Deutz and Perkins Models.......................................................................... 99 How to Retrieve Active Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-E22T Models............................ 99 How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3 Models.................................................100 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-E22T Models........................101 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-E22T Models.........................................102 Soft Key Functions and Icons - Deutz TD 2.2 L3 Models..............................................................103 Main Menu Structure - Deutz D 2.9 L4 Models........................................................................104 Main Menu Structure - Deutz TD 2.2 L3 Models.......................................................................105 Main Menu Structure - Perkins 404F-E22T Models.....................................................................106 Deutz TD 2.2 L3 Engine Fault Codes.....................................................................................107 Deutz D 2.9 L4 Engine Fault Codes......................................................................................117 Perkins 404F-E22T Engine Fault Codes...................................................................................128 Ford MSG-425 Engine Fault Codes........................................................................................130 How to Retrieve Ford MSG-425 Engine Fault Codes....................................................................130 Schematics.................................................................................................................135 Introduction...........................................................................................................135 Electrical Symbol Legend...............................................................................................136 Hydraulic Symbols Legend...............................................................................................137 Limit Switch Location Legend...........................................................................................138 Electrical Component and Wire Color Legends............................................................................139 Hour Meter Legend......................................................................................................142 Electrical Schematics..................................................................................................143 Electrical Schematic, Ford MSG425..................................................................................144 Electrical Schematic, Deutz D2011L03i and Perkins 404D-22..........................................................145 Electrical Schematic, Deutz D 2.9 L4...............................................................................148 Engine Wire Harness, Deutz D 2.9 L4................................................................................149 Electrical Schematic, Deutz TD 2.2 L3..............................................................................152 Engine Wire Harness, Deutz TD 2.2 L3 - Page 1......................................................................153 Engine Wire Harness, Deutz TD 2.2 L3 - Page 2......................................................................155 Electrical Schematic, Perkins 404F-22T.............................................................................158 Perkins 404F-E22T Engine Wire Harness..............................................................................159 Electrical Schematic, Function Controls - ANSI / CSA...............................................................162 Electrical Schematic, Function Controls - CE.......................................................................163 Electrical Schematic, Platform Overload............................................................................166 Electrical Schematic, Options Wiring Diagram.......................................................................167 Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i and Perkins 404D-22 - ANSI / CSA...................170 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i and Perkins 404D-22 - ANSI / CSA.................171 Ground Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA..................174 Ground Control Box Terminal Strip Wiring Diagram, Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA................175 Ground Control Box Switch Panel Wiring Diagram, Ford MSG425 - ANSI / CSA...........................................178 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG425 - ANSI / CSA.........................................179 Ground Control Box Switch Panel Wiring Diagram - CE................................................................182 Ground Control Box Terminal Strip Wiring Diagram - CE..............................................................183 Platform Control Box Switch Panel Wiring Diagram...................................................................186 Platform Control Box Terminal Strip Wiring Diagram.................................................................187 Platform Control Box Relayl Wiring Diagram - ANSI / CSA............................................................190 Platform Control Box Relay Wiring Diagram- CE......................................................................191 Hydraulic Schematics...................................................................................................193 Hydraulic Schematic - CE (to Z4525XCM-1500)........................................................................194 Hydraulic Schematic - ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501)...........................................195 Back Cover.................................................................................................................197
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