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Service Manual - Genie Industries

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1. 6 73 A TEREX COMPANY Z 45 25 2 45 25 G Part No 107846 H m H o sQ m 4 55 95 g Q
2. E t 2o d 2985 NH8 3 SES 0 2269 E SEE 18 2381 HWHO ASTELD HMO 2870 z ra 6 Wuvivoia 61 90 8 5 INUYTV QU HM ESO rs 424050042 aca Sese e __ __ E T a lt 2 o b 5 1 89 QH HM a Q q ER 9 z sa Tr 5 d Spee 522 05 1 z i 5 d a 213 gal i is 5 85 1 gt 5885 lt guon 6 90 auma 6 469 iu 2 99 i 99 o HM 9 90 gt 8 HM 9 95 1 92 7801 959 E NP 5 5 ee E D
3. DESCRIPTION Sc HH HOLSISSY NMOQ dn WOO8 5 FLH z 318vN3 d TAS Wer teed YSL S1OHINOO NOLLONN4 WHOd1V 1d WHO31V 1d H3xv3ug 7951 1551 6951 vse auma zao gt uo o T Cr 1 a 902 vre au IN o vsixauo T ANIONS uayvaua 21 49 VZI 4D au al g HVYD AST61O HAWHO 2870 t99 T i co 8 3NION3 wood air g 1HVlS MO19 E 9951 vesa 2551 9951 pios See Lx Ee 8 aon 5 P DEEN 5 en 3ivioH viyana 318v1NHnL a a 1260 1 2951 fe Gum eee ed Q 9 QH HM V9 QH HM MT WEE UW THM YARN 5 Q SAHM WEN ee 002 YALSISSY 43385 MOUNT V9Z QH HM ve HmmMa I MESS Q ag Sla woos 99 Bc 1951 0
4. Electrical Schematic Z 45 25J CE Models Section 6 Schematics Deutz F3L 2011 Models xx x 28 za a 5 HE E SIS 5 ops BK RD 018 9 HGHRPM ENGINE Low neu SPEED 5 B e LOWRPM EuNcTiON 8 HIGH RPM ENABLE P C35RPM BK RD BRN e HIGH IDLE RELAY C518 HIGH RPM SOLENOID 2 in a ek ee wrt a 7277754 777762277577 0700 3 i e CHE C2P 7 CASGEN GRWH C287 CASGEN GRWH C5 12 lt 1 GENERATOR OPTION 1 ee Se Benni MC CELOS a u El 1 4 DLITE C3B 4 4 ig DRIVE LIGHTS E e v8 14 WORK LIGHTS 06 39 RD 5 iim E NA i 9 DRIVE LIGHT OPTION 1 12 ala 2 2 8 1 H
5. Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J August 2006 Section 6 Schematics r1 Ground Control Box Switch Panel Wiring Diagram Z 45 25J Ford Models Section 6 Schematics August 2006 EEE Platform Control Box Wiring Diagram Z 45 25J Ford Models REV A August 2006 Platform Control Box Wiring Diagram Z 45 25J Section 6 Schematics Ford Models c zl Se ea 5 2 Eug Zn z 02 Onn gt 5 2 6 2 lt 55 29622 Ces eE E 92 9 915 5 E gt 5
6. Ground Control Box Terminal Strip Wiring Diagram Z 45 25 CE Models Section 6 Schematics Deutz F3L 2011 Models and 28824 Nu8 Nya 1 5 228 o 2650 Sea 1SFHM fr 4 4951 ASP610 HWUB Z r esha SSOH vSrau ZSE Te wave Weg 61 50 8 5 VZE QH HM WHV1V GH HM 85 95 a MENS RM siHonaAHdo0cdd 2 T SEHMWau 2 m 2 b ur 8 E 8 assem 8255 Es 5 Sree Saag S28 Ne z z z z 7 E BE 88 518 AR I ME 5 28 o als 5 5983 lt 2988 6 95 6 8 ung 6 869 T 2 90 r E aureo 7 90 2 9 0 11 80 1801 92 z gj 5 1 a B 4 4 4 2 3 i EE 86 90 25 eem 5 b E O i e 9 E a 5 g 9 2 Y ER ii 5 E 2 2 amp SH i
7. N p BATGND eres eres e GROUND OR EK Copa 5 C30FWD WH 9 614 C1B 4 C521 C30FWD WH BK RD S BRN A Ges FORWARD ops WH BK ops 5 20 REV WH BK RD 3 s BRN bi lt es 1 DRIVE EDC REVERSE ON SS SS nn CC C DI S Een i RDIWH e C6 33 2 WHIRD i 2 TRAVELALARM OPTION ne qu ETE N BURD ZR g C26 1 C262 n CDE1 BL 6 C32BRK WH RD C1B 6 C6 32 C32BRK WH RD P der o gt ES KS BRAKE RELEASE VALVE bd N PAVE ENABLE ees PE 5 C1P 3 C29MS RD WH C1B 3 c6 29 C29MS RD WH BLIBK EX Me MOTOR STROKE ei esse 2 1 8 fel e lt s s 4 amp amp ig c25 1 C252 IS 5 Ja 18 m 5 1 11 C37SCW BL BK 1 11 37 C37SCW BUBK 815 4 2 5 5 STEER RIGHT ewe po 2 13 BRN 1 10 C36SCC BL 10 C6 36 C36SCC BL 16 2 gt gt 18 STEER LEFT C244 0242 lt 4 Cape WH RD Cape lt
8. Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J 8 gt BK WH 8A RD E Z O 8b RD RD RD G i d 7 RD 4 a RD Zu S ask T 5 RD SEE D4 859 gt 5 5 5 x gt De RD 2 5 6 2 gt oz Sg KEE BD 5 5 2 88 ins z n PERS a c A 99 3 e que A 858 E o ERR Pro lt lt P 8 s 8 5 5 Bi B8 5 5 218 amp B HIE 8 g BL 5 z c m c T c 225 d T 5 6 RD RD 22 lt 4 5 E a i 8 amp lt n 0 5 5 a di c P BOX ER ER 640 55 82 WH 23 2 A _ z a 855 NPD 826 xu Fon x LL PER ale G BOX 5505 5 RD g m 8 8 b lt 400 RD RD gg E E 8 amp lt WH CR2 8 5 8 3 5 5 8 g BRN lt A 58 8 5 lt Eu E SE n z 5 CG ono 555 5 7 a gg PEC 658 ELM 1 RD SE a 50 222 RD EE E coc CES RD gt P amp z es
9. e fe 6 E m our RD LS18 BK C7P 1 2 BK J3 3 a SE WH 2 C9P 1 AER BL J1 5 s WH J1 4 9 BL J1 5 Bo OR 1 13 E to a BRN J1 14 i B BK BK C39LP BL RD C2P 1 PDLITE RD i etc BD B U oO NI rm EO d pr 5 mou v e a uc Bu g 2 2I y O ra 4 c a gt P24FS C9 2 55 o ADO BK 12815 OR RD C2P 4 RD e C35RPM BK RD C1P 9 1 RD ____ OPTION SS ue CWLITE RD C2P 12 gt tod x a op bd zi TE DIJE i E 50090 Usi aiU 8 u CA bd ee ee NER CWLITE RD 2 11_ i RD BK H1 C33STR BK C1P 7 CD T DE ol Ee BS P25FS RD C9 3 25 IE N d C45GEN GR WH 2 7__ x J 5 wo GER 5 98 m lt 22 Faz iu u t J1 16 BL DE1 J1 6 C v BL BK DE2 J1 7 t P BK YEL J1 3 2a OR J1 9 ER i BRN 1 10 C29MS RDAWH J1 8 Fes a SP n oliv tT OLN m K D C27AUX RD 1 1 8 Hovo tr SE
10. Section 6 Schematics after serial number 27000 B A MEDIUM HIGH 7 45 25 MODELS 1 PRESSURE PRESSURE FILTER FILTER JIB BOOM PLATFORM ROTATE m SECONDARY rd ELEVATE CYLINDERS i Vai D GENERATOR SELECT NU NM Se weed QI MANIFOLD i P NN PLATFORM LEVEL ai gt 1117 TURNTABLE ROTATE m E gt SE 1 0 GPM Pre nn 0 60 GPM SLAVE 2 3750 psi i Di d ee
11. August 2006 BK ALARM BK Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Ford Models Section 6 Schematics Ki 5 SEH 2 coz 2981 HWHO AST6LO HGB 2 80 D o c Wuvivoa 61 59 u a VeE QH HM WHYTV QH HM 92 9 lt o a z a aray gt n 89 QH HM 2 8 8 g EES DO 285 com orc a i 5 5 8 Wel i 5 Ir Jua E lt a y 5 E 5 lt gt o 822 Ss 933 m o 5855 8204 auma 6 80 gugu Speg z Gage 290 K q o 1 99 i E E d nr HM 90 Feo 9 0 11 90 1901 99 1 8 2 85 95 S n RD 9 28
12. D TURNTABLE ROTATE Hydraulic Schematic 2WD Models before serial number 27001 C B A r M Fd RB 0 070 inch 1 78 ji 50 LA t A nuc 50 1 LB T 250psi 17 2 bi u Ths 0 030 inch BRK d I bo 0 76 mm 2SPD 69 JIB BOOM PLATFORM ROTATE PRIMARY BOOM 0 6 gpm 2 27 PRIMARY EXTENSION 4251 151 3625 3800 psi 1 262 M L 12 EET e E E a0 psi O UM 1 1 4 282 Ce me 1 L 1 SLAVE C
13. D TURNTABLE ROTATE Hydraulic Schematic 4WD Models before serial number 27001 C B A 77 1 JIB BOOM after serial number 224491 PRIMARY 0 6 9pm 2 27 Umin PRIMARY BOOM LEM i EXTENSION onse LE SH 42521 151 1 m I 3625 psi 3800 psi H lu 1 i 250 bar mes MIS Dv Dno s AL ie Hi MI Le Bee NEN purses an wal a1 jl ia et STi me Aos SLAVE CYLINDER mr eabar 1500 psi 2 0 030 inch QU I 4 101 1 103 bar 0 76 mm C SECONDARY BOOM AERE RAS J1 J2 PR2 PR1 CYLINDERS
14. N co N Yl WYO 5 4 Sc Hd HOISIS3H 9334 NMOQ dN INOO8 5 vH E gen 8148 0 Rum VeL 18 49 SSESSOUINGS Md NE WHOJ1v1d SSL 6951 vse auma PN vsr gHO YSL 3NION3 T uayvaua 2 49 a 21 AST6LO 7 872 185 a c S 18916 2 E une VEEOIG 2991 9551 e GRO 999 O 38viNHunL L 20 2951 ey Er a a WOO8 ee AHVONOO3S San VS Ig HM 0951 002 93151999 318VIHVA a 3395 NOLLONNA vH 92 Ve HMME p NMOQ dN MAH La woos vo ica AHVIAIHd d 1951 m c n SS LOVHL3U 9 VEHIWGH a QN31X3 o woog E EN a Er g E 3 9 20 o SH HEAD dIHLS TWNINHAL OL SS3NHVH VSZ X8 HM am ee 3unssaud NI _ 110 7 s Se sr NH8
15. CN Lo BATGND 7 3 C7B 3 GROUND CA1RPM OR BK C2P 3 BK 3 4 C30FWD WH 4 C521 C30FWD WH BK RD 15 15 ae eNe DRIVE EDC FORWARD P C31REV WH BK 7 Ex 1 5 C1B 5 C5 20 C31REV WH BK RD 7 BK dree NL u _DRIVEMODE SET SSS SSeS Ss SS RS SS eee SS ni 4 gt RD WH 1 d CSZTAWHIRD TRAVELALARMOPTION 3 Dee Ee ENT CDE3 BURD 5 5 C26 1 C262 3 1 BL 1 6 C32BRK WH RD C1B 6 P C6 32 C32BRK WH RD 5 am 7 19 BRAKE RELEASE VALVE t DRIVE ENABLE C284 C282 CDE2 BUBK EX 1 3 C29MS RD WH C1B 3 mE BRD DA MOTOR STROKE p 1 a 1 g g pr C25 1 C252 alt ales 1 11 C37SCW BUBK 1 11 06 37 C37SCW BUBK h 8 5 17 gt STEER RIGHT ju 13 1P 10 C36SCC BL 1B 10 5 C36SCC BL 5 14 18 S 5 08 36 Al STEER LEFT C241 C242 4 P4 C6TRF WH RD Ex 6 C3B 6 lt lt 8 5 5 C3B 5 2 4 TURNTABLE ROTATE 9 lt 9 SELECT RELAY e TURNTABLE ROTATE WE TURNTABLE ROTATE RIGHT C151 C152 FATREWH TURNTABLE ROTATE LEFT 1 E C141 C14 2 i BR sc 3 BS 5 5 PRIMARY BOOM 152 58 SELECT RELAY 8 8 E 1 y aino C121 C122 5 PRIMARY
16. Electrical Schematic Z 45 25 Models Section 6 Schematics Deutz F3L 2011 Models lt Z CE and platform overload option x x z x olo 88 5 u a 3 HE N zog 8 1 9 BK RD 018 9 HGHRPM ENGINE Lowrrm SPEED x 8 c 2 o e LOWRPM FUNCTION 8 ENABLE d HIGH RPM C35RPM BK RD n BRN p ei HIGH IDLE RELAY _ BK RD C5 18 Le HIGH RPM SOLENOID 62 8 a pee 2724277077552051 52011 ee ee gee 1 3 ET GENERATOR C2P 7 GR WH ak u CASGEN GR WH este D GENERATOR OPTION 1 H 4 4 4 4 4 4 g 3 C3P 4 DLITE WH C3B4 DRIVELIGHTS 5 e a 5 WORK LIGHTS c6 39 RD 5 5 u FR D DRIVE LIGHT OPTION ale 8 z v8 06 38 RD 5 D ne 5 C2P 12 C2P 10 pets 1 WORK LIGHT OPTION 5
17. 2 BATGND c7P 3 e GROUND C41RPM OR BK C2P 3 lt gt 5 P C30FWD WH ra Ex 1 4 C1B 4 C521 C30FWD WH 9 RD ABAN A DRIVE FORWARD 1 5 C31REV WH BK C1B 5 C5 20 REV WH BK RD BK BRN 5 lt DRIVE EDC REVERSE DRIVE MODE 5 5 EEGENEN a E R pe i gt RD WH 06 33 2 WHRD L TRAVEL ALARM OPTION 1 Ester imc eC cto eI MN ye ee wee ey p BLAD Sab D C261 C262 E CDE1 BL C1P 6 C32BRK WH RD C1B 6 Zi 06 32 C32BRK WH RD 5 7 19 e BRAKE RELEASE VALVE e PPE ENABLE gt 2282 pre 55 C29MS RD WH C1B 3 06 29 C29MS RD WH CDE BUBK Me MOTOR STROKE uc el x mur og o 5 s 5721 C25 C252 BL 5 1 11 C37SCW 1 11 37 C37SCW 815 lt gt 5 vec mE STEER RIGHT own se s gt C36SCC BL 5 C36SCC BL ao r Sx 5 ge DE C1B 10 C6 36 il A SERIER lt 024 1 024 2 Bear 4 C3P 6 C6TRF WH RD C3B 6 lt ERS 2 5 CSTRR WH BK C3B 5 8 TURNTABLE ROTATE D s gt SELECT RELAY 5 e Sp RIGHT TURNTABLE ROTATE MET BEIER TURNTABLE ROTATE RIGHT e C154 C152 d TURNTABLE ROTATE LEFT 8 peer 4 C64 C144 c142 74 Is F EZ 5 k z g PRIMARY BOOM 159 your i m gt gt 2 E
18. BRN GND GR BK H6 RD TS52 RD TS51 BK C7B 1 8 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Section 6 Schematics Deutz F3L 2011 Models 2 t BER 2824 Nua 2 j 520 E SSES SECH eran ff 4SS1 5 6192 HAVE 2 87 z aeea SE SCH VIDEO ESEL Wave Wuere ag 61 80 V2E QH HM WHV IV QH HM 85 95 2 UU 9 amp a lt gt C Sen 8 5 z geo 885 8255 E 5 St Sree 522 o Nua z i 8 7 E gd Q 3 8 HE I S g 8 5 Ke ez lt E 6 90 a auma 6 869 T 2 20 T 1 80 HM 90 A X8 HM S 90 11 80 d 1801 92 LEM NEN le 5 ARDEN 5 EE 2 4 25 m zairiaevg 66 95 a Fog oi Fog a Fog o 2 bd a 2 2 2 D 2 Y E B E amp S 6SFHM z 2 88 818 5 5 e 8 355 1 5 52 Sek II als ale 1 8 nm 5 5
19. gt Ww amp cc z o a A I 5 u 1 9 C35RPM BK RD C1B 9 Foorsw HIGH e FOOTSW LOW 2 4 C128RPM OR RD C2B 4 5 a x 2 28g A Lo 3 LOW RPM e FUNCTION ENA HIGH RPM H E 3 2 7 C45GEN GR WH C2B 7 C5 12 C45GEN GRWH In 4 GENERATOR OPTION MUR MES MM LI 1 9 e 1 5 g SZ 4 WH 6384 5 1 1 DRIVE LIGHT a work 19879 RD 5 i 422 DRIVE LIGHT OPTION gt lt i I 5 gg WE ls C4B 11 RD X 4 lt C2P 12 2 10 u is 29 FEN WORK LIGHTS OPTION rs T cz ul 1 4 1 Du C2P 9 2 nrc x zc x cc cx sog rss ee a age Si vB E a P134BAT RD C6 34 FLASHING BEACONS 5 M OPTION Nea Sele eye er ee i N Re ae TRU 1 C128RPM OR RD 2 C2P 1 C39LP BURD C2B 1 xs LP FUEL SELECT GAS l C21IGN WH HOUR METER 2 N lpo oP FUEL CHECK ENGINE LED e Gas SELECT C108ESL BL WH ol 8g 85 g eie
20. 5 Add D40 only if unit has L4 and L48 z Si 22 5 5 ob u a 28 N zz x 9 1 9 C35RPM BK RD lt C1B 9 HIGH RPM ENGINE Lowrpm SPEED i 2 5 5 SONEM Funonon 8 ENABLE HIGH RPM i BK RD BRN e HIGH IDLE RELAY C518 HIGH RPM SOLENOID 2 8 ee Leesan ees Hace Eee HES Hl LERNEN EEE i I 5 GENERATOR i C2P 7 C45GEN GR WH C2B 7 C45GEN GR WH C5 12 GENERATOR OPTION 1 1 1 Sl 1 a o ee oM 8 CEA DLITE WH C3B 4 DRIVE LIGHTS re i WORK LIGHTS 1 i 5 E i 8 DRIVE LIGHT OPTION 8 3 WS SIS 8 DE ut ere NT C2P 12 C2P 10 i amp res WORK LIGHT OPTION 8 xcd icem dus E ET EE J i i 8 C2P 11 C2P 9 ad peces rcu idle eeu e CLR e nace lee Matra
21. z x x x ala SS 5 22 S 5 g TTE E 5 5 ops BK RD ces HIGH RPM ENGINE Lowrrm SPEED 8 8 Es LOWRPM 8 ENABLE HIGH RPM e COSREM BRAD HIGH IDLE RELAY 1 3 e BORD este HIGH RPM SOLENOID 52 8 f eU LEI i 5 Ba 8 GENERATOR 7 GRWH C2B 7 GR WH C512 DA GENERATOR OPTION 1 1 EE NEE EE EE Das ne SE EE en ee C3P 4 DLITE WH C3B4 ril 5 DRIVE LIGHTS 2 e i 3 1 WORK LIGHTS C6 39 RD e 8 g C 8 I DRIVE LIGHT OPTION 3 8 SIS 8 u C638 E T C2P 12 C2P 10 SEN 5 e WORK LIGHT OPTION f E 3 C2P 11 C2P 9 EEN jg 8 1 Bi C6 34 134 RD 8 8 years X FLASHING BEACONS OPTION i Me 1 cete ete cest ta 5 5 B 8 1 8 C34SA BKWH CiB 8 C34SA BK WH C522 e 2 4 stow PLUG B GLOW 9 6 P
22. C28TTA RD BK REV A GROUND CATRPM C2P 3 ze ea 5 4 P C30FWD WH EE C1B 4 C521 C30FWD WH BK q RDA BAN onse FORWARD 1 5 C31REV WHBK C1B 5 5 20 WHIBK RD 3 BRN lt DRIVE EDC REVERSE e DRIVE 5 Se BEE EE ei RD WH 06 33 C32TA WH RD TRAVELALARM OPTION CH CM cU ES PF MH eS HS BURD gt C26 1 C262 g CDE1 BL 6 C32BRK WH RD C1B 6 E C6 32 C32BRK WH RD 5 m 2 7 19 KS BRAKE RELEASE VALVE LEFT e I PRIVE ENABLE cai eee gt CIP 3 C29MS RD WH 1 06 29 C29MS RD WH CDE2 GE MOTOR STROKE I a ERI E aL 8 N lt o 12 ZS gt C25 1 C252 2 E E BL I Copa C37SCW BUBK Copa 66 37 C37SCW BUBK 815 ER gt 515 17 STEER RIGHT ju pwr s IE BRN C1P 10 C36SCC BL C1B 10 C6 36 C36SCC BL GND 2 gt 14 18 STEER LEFT lt C24 1 C242 a C3P 6 C6TRF WHIRD C3B 6 lt ERC 8 3 5 WHBK C3B 5 8 TURNTABLE ROTATE D s SELECT RELAY e RIGHT TURNTABLE ROTATE RETA e TURNTABLE RO
23. e CDE3 BURD gt 026 1 C262 E CDE1 BL C1P 6 C32BRK WH RD C1B 6 ei 06 32 C32BRK WH RD D 7 19 e BRAKE RELEASE VALVE e I mega PRIVE ENABLE iba gt C1P 3 C29MS RD WH C1B 3 C629 C29MS RD WH CDE2 BUBK EX MOTOR STROKE ULM TIC us BL 5 s o Your s gt 4 C25 1 025 2 BL 5 1 11 C37SCW C1B 11 37 C37SCW 815 ER gt s s lt ces STEER RIGHT is Gm H ie 10 C36SCC BL C1B 10 C6 36 C36SCC BL il BRN ono 2 lt STEER LEFT 24 1 C24 2 lt 4 C3P 6 WH RD C3B 6 lt ERS 2 C3P 5 CSTRR WH BK C3B 5 8 S TURNTABLE ROTATE D s SELECT RELAY 4 Sp 8 RIGHT TURNTABLE ROTATE FOTRRWIIER TURNTABLE ROTATE RIGHT ces 9 E EN c152 TURNTABLE ROTATE LEFT 4 C64 i C14 1 C14 2 4 7 is 5 lt g 5 5 PRIMARY 155 EHS 22 2 B SELECT RELAY 8184 pe 1 C124 Ci22 2192 OR 5 PRIMARY a RIPBUIRD PRIMARY izg Pw sg n E 316 ER BRN t g C6 1 E 2 4 ee 5 R2PBD RD BK E 8 d PRIMARY BOOM DOWN lt C62 oan 2 isse d L en 1 C1PBU RD C3B 1 EE C2PBD RD BK C3B 2
24. 25 30 ft lbs 34 41 Nm 18 Check Sins Non steer end drive motor circuit 10 12 ft lbs 14 16 Nm 19 Check AA Non steer end drive motor circuit 10 12 ft Ibs 14 16 Nm Genie TEREX COMPANY 4 68 2 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures REV E MANIFOLDS SG DM RS E Y T 2 PartNo 107846 Z 45 25 Z 45 25J 4 69 Section 4 Repair Procedures June 2012 MANIFOLDS 8 15 Valve Adjustments 4WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Holdthe charge pressure relief valve and remove the cap item AH or AD 3 Turn the internal hex socket clockwise fully until it stops Install the cap 4 Startthe engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turnthe engine off Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Hold the charge pressure relief valve and remove the cap item AH or AD 8 Startthe engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position 9 A
25. 2 DEER E 2960 Lu g 8 8 1 z 9 Q 9 1951 81 35 8 TWNINYSL 49098 3 InGOW 1 15 FZL amp gt gt i 2 2 On o uo 2d Drei SSHd WAL OL rer 8 g 9 5 5 6 pap ae aie s TUHM Low see e sl oO 85588 5 4 D 8 g AINO 795310 MS ASNOL 2 ES a Aual ya 9 DEET s s SO v 1 indNilMVIS pue e lt q Anued usnd MEC AvmHiHVIS 1 3AOWAH OL CN Lo Part No 107846 2 45 25 Z 45 25J G 6 37 August 2006 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25J Deutz F3L 201 1 Models REV B N M L K LABEL DESCRIPTION CB1 CIRCUIT BREAKER ENGINE 15A CB2 CIRCUIT BREAKER CONTROLS 15A CR1 IGNITION START RELAY CR2 IGNITION POWER RELAY HIGH IDLE RELAY CR5 HORN RELAY HM HOUR METER KS1 KEY SWITCH L42 OIL PRESSURE LED 43 OIL TEMPERATURE LED L45 PLATFORM O
26. BO Turntable rotate Check valve 5psi 0 3 BQ Differential sensing circuit turntable rotate Check valve 5psi 0 3 CB Differential sensing circuit primary boom retract Check valve 5psi 0 3 BC us Differential sensing circuit platform rotate left and Jib boom conces 2 This list continues Please turn the page Genie TEREX COMPANY Torque 25 ft lbs 34 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 16 20 ft lbs 22 27 Nm 25 ft lbs 34 Nm 16 20 ft lbs 22 27 Nm 16 20 ft lbs 22 27 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm 25 ft lbs 34 Nm 12 14 ft lbs 16 19 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 12 14 ft lbs 16 19 Nm 12 14 ft lbs 16 19 Nm 12 14 ft lbs 16 19 Nm 25 ft lbs 34 Nm Z 45 25 Z 45 25J Part No 107846 MANIFOLDS Section 4 Repair Procedures June 2012 REVE BO BA BB BS 17 16 15 14 G Na Im 2 5 0 9277 DER o z 49 a enie Z 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012 MANIFOLDS REVE Function Manifold Components afte
27. 5 ra LLL I2 PRIMARY BOOM PRIMARY BOOM 601 1 to R LIFT CYLINDER EXTENSION CYLINDER T H 3 2 2 4 GPM 4 1 regen 2 1 GPM L qe mni J2 PR2 i E T NAUES 310 psi ei 3200 BH at H oi bet par EI 3 i JIB SELECT jt L FUNCTION N E MANIFOLD 8 E PUMP V vi MASTER 7 EEN EEN 7 7 Sg ied DRIVE PUMP AUR o e ee Ste ee 2 BI 25 PSI TEST1 3 4 iz zl 7 di de 2500 172 4 bar um i 1 PSI SET ncc es BC BD 6 mE A amer 2 0 TANK PT 7 H E AL E e TESTI e EDS v 11 ref TRACTION MANIFOLD TU DEEN J Q au ee HET e E SC 5 hed 0 4 gpm O 4 0 4 80 2 5 L t JN 1 R 1 1 GEN zech gt d wt x v 1 B 5 7 L min el BM 1 gpm sl Jose n Ji Umin 5 7 X IL A foe PO Sc zz 1 A BN 20 mr TEST T1 X J an 2 bar 1 1 i i T f 6 FI AD 5 GA sa
28. 2 45 25 Z 45 25J G RD P2 RD H1 C19JSV WH 9 D gt gt ES a zi HO C32BRK WH RD CIPS ________________ MEE C32BRK WH RD 2 19 _________ z i T nos i o 1 __ CAOLSSORJ24 P24FS WH C9P 2 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH C4P 7 C18JD GR BK C4P 6 C17JU GR 5 C15PLD OR BK C4P 3 C14PLU OR 2 C9HRN BK RD C3P 9 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9 1 P25FS RD C9 3 P24FS 9 2 CDUTEGR ll don EH o O C45GEN GR WH 2 7 ME C44JDALARM GR BK C2P 6 P26ESTP LL e e WH RD C3P 6 gt e e C10SBU BL C3P 10 LU C16DRE OR RD 4 e e gt C11SBD BL BK 11 lt N C40LSS OR C2P 2 M oo C12SBF BL WH 12 O 5 P24FS WH e C41RPM OR BK C2P 3 C30FWD WH 4 Q BRN e RD C3P 1 gt a C31REV WH BK C1P 5 al of of N e C2PBD RD BK C3P 2 9 4 C37STC BUBK C1P 11 e C3PBF RD WH C3P 3 C36STCC BK 10 e wi C32BRK WH RD C1P 6 C4 B 5 WH BK C3P 5 o e a C29MS RD WH 1 3 Se lt lt C3P GR O C35HS BK RD C1P 9 C33STR 1 7 C27AUX RD C1P 1 C2P BK d o sl P E d JC1 3 OR e bg JC2 4 RD Eu bg
29. e Se 1 LAVAS Wi pue G pem 4 queb z You Am AUIS OL waa 3 N Lo Part No 107846 2 45 25 Z 45 25J G 6 39 August 2006 Section 6 Schematics REV B Ground Control Box Switch Panel Wiring Diagram Z 45 25J CE Models Deutz F3L 201 1 Models N M L K J G F E D C B A LABEL DESCRIPTION o 1 CIRCUIT BREAKER ENGINE 15A 25 3 BER E 1 99 8 aS 42 RD RD GR BK SS CB2 CIRCUIT BREAKER CONTROLS 15A 2 23 Se BEE CR1 IGNITION START RELAY 25039 gees E D ee HD RD RD RD Me 2 IGNITION POWER RELAY Bee De m 79 CR4 HIGH IDLE RELAY 57 4 91 d d ils CR5 HORN RELAY I 8 RD 1 1 RD G o HM HOUR METER BD i RD FEM 9 2 KS1 KEY SWITCH sz RD RD 142 OIL PRE
30. 8 11 Traction Manifold Components 2WD after serial number 27000 8 12 Valve Adjustments 2WD Traction Manifold 8 13 Traction Manifold Components 4WD before serial number 27001 8 14 Traction Manifold Components 4WD after serial number 27000 8 15 Valve Adjustments 4WD Traction Manifold 8 16 Valve cree a Xii Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Rev Section 5 Rev Section 6 Rev TABLE OF CONTENTS Repair Procedures continued Turntable Rotation Components 9 1 Turntable Rotation Assembly 4 72 Axle Components 10 1 Hub and Bearings 2WD Models nennen nnnnnn 4 73 10 2 Oscillate Lock out Cylinders AAA 4 74 Fault Codes rr EE 5 1 Fault Codes Control System 5 2 Fault Codes Ford LRG 425 EFI Models 0 5 6 Fault Codes Ford 056 423 EFI Models 5 12 Schematics 6 1 Electrical Symbols Legend are bein 6 2 Hydraulic Symbols Legend sse nennen nnns 6 3 Ford Engine Relay TEE 6 4 Ford models Ford LRG 425 Engine 6 5 Ford DSG 423 EFI Engine Harness 6 6
31. ET EE J i i 8 C2P 11 C2P 9 ad peces rcu idle eeu e CLR e nace lee Matra t E Doce i i 8 2 FLASHING BEACONS OPTION NOT VE kere EDS i E eae ee ee iei o EE 5 5 B 8 C34SA C34SA C5 22 E efa PLUG 8 8 Sr 555 6 GLOWPLUG g 8 3 EE OIL TEMPERATURE LED 5 8 566 C25PSR WH BK OIL PRESSURE LED Zu 858 5 o 2 8 52 8 C33STR BK 8 85 8 dE 8 5 m OIL TEMPERATURE SWITCH E88 352228 Ed e H ENGINE g START g BEBEBEBREIH 9 m 2 3 START e SES e 9 OIL PRESSURE SWITCH j ES E 2 m I 28 a mim E 5 55 u SE AUXILIARY C1P 1 C27AUX RD 1 e POWER RELAY 1 3 el KE EE ES FUEL SOLENOID 55 N 52 SUPRESSION DIODE x pr TONS 1 a 2 C21IGN WH 5 i HOUR METER as j 8 pto zi 735 gs IGNITION START RELAY 1 S D 1 M x EH 33666656655 i 2 R33STR BK 55 2 8 t A T ig 2 2 LN a 019 8 e 6 STARTER MOTOR 1 8 ES E EE
32. Electrical Schematic Z 45 25 Section 6 Schematics Deutz F3L 2011 Models 5 Add D40 only if unit has L4 and L48 z Si 22 5 5 ob u a 28 N zz x 9 1 9 C35RPM BK RD lt C1B 9 HIGH RPM ENGINE Lowrpm SPEED i 2 5 5 SONEM Funonon 8 ENABLE HIGH RPM i BK RD BRN e HIGH IDLE RELAY C518 HIGH RPM SOLENOID 2 8 ee Leesan ees Hace Eee HES Hl LERNEN EEE i I 5 GENERATOR i C2P 7 C45GEN GR WH C2B 7 C45GEN GR WH C5 12 GENERATOR OPTION 1 1 1 Sl 1 a o ee oM 8 CEA DLITE WH C3B 4 DRIVE LIGHTS re i WORK LIGHTS 1 i 5 E i 8 DRIVE LIGHT OPTION 8 3 WS SIS 8 DE ut ere NT C2P 12 C2P 10 i amp res WORK LIGHT OPTION 8 xcd icem dus E
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50. 6 73 Part No 107846 Z 45 25 Z 45 25J June 2012 9 This page intentionally left blank Genie A TEREX xvi Z 45 25 Z 45 25J Part No 107846 January 2011 Section 2 Specifications REVH Specifications Tires and wheels Hi flotation Machine Specifications option Ti and wheels Rough terrain Industrial 3 Tire size 33 16LL500 Tire size 355 55 D625 9 14 5 LT Tire ply rating 10 Tire ply ratin 14 Tread 8 PS Sidewall 6 Overall tire diameter 33 in 84 cm Tire weight new foam filled minimum 390 Ibs sche enes 177 kg 79 kg suem Overall tire diameter 36 9 in 28 in Wheel width 14 inches 93 7 cm 71 35 6 cm Wheel diameter 24 5 inches 14 5 inches Wheel lugs 9 5 8 18 62 2 cm 36 8 cm Lug nut torque Wheel width 11 75 inches 7inches lubricated 94 pus 29 8 cm 17 8 cm 127 4 Nm dry 125 ft lbs Wheel lugs 9 5 8 18 9 5 s 18 169 5 Nm Lug nut torque Tire pressure 38 psi lubricated 94 ft lbs 94 ft lbs 2 6 bar 127 4 Nm 127 4 Nm dry 125 ft lbs 125 ft lbs 169 5 Nm 169 5 Nm Tire pressure air filled tires 50 psi 100 psi 3 45 bar 6 9 bar For operational specifications refer to the Operator s Manual Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 107846 Z 45 25 Z 45 25J 2 1 Section
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55. TRAVELALARMOPTION 8 v he ee pj BLAD Jels 026 1 C262 g E CDE1 BL C1P 6 C32BRK WH RD C1B 6 ei 06 32 C32BRK WH RD TT ES EN BRAKE RELEASE VALVE e I e PF E ENABLE gt CIP 3 C29MS C1B 3 C629 C29MS RD WH CDE2 BUBK EX MOTOR STROKE S fo 1 I EIS us 8 HE mour 6 2 8 amp amp o wH Your s gt 4 C25 1 025 2 BL 1 11 C37SCW C1B 11 37 C37SCW 815 ER gt s s lt ces STEER RIGHT E m s H ie 10 C36SCC BL C1B 10 C6 36 C36SCC BL il BRN e ono 2 lt STEER LEFT lt 024 1 024 2 sica 4 C3P 6 WH RD C3B 6 lt ERS 2 5 CSTRR WHIBK C3B 5 8 3 TURNTABLE ROTATE D s SELECT RELAY e FIGHT TURNTABLE ROTATE 2 lees pera week TURNTABLE ROTATE RIGHT e C154 C152 m TURNTABLE ROTATE LEFT 4 C64 i C14 1 C14 2 74 Is E lt g IBE Sp gt 5 4 PRIMARY BOOM 15 E 373 SELECT RELAY 8184 xw pe C124 Ci22 5188 5 PRIMARY BOOM a mE PRIMARY izg Pw lt n E 815 ER BRN t g C6 1 E 2 4 ee 5 R2PBD RD BK d d PRIMARY BOOM DOWN lt C62 oan 2 25225 4 e 1 CIPBU RD C3B 1 CS 1 r geara C2PBD RD BK C3B 2 i Copa
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57. SELECT RELAY 8154 amp 1 C124 Ci22 8158 5 PRIMARY BOOM a ae PRIMARY BOOM UP izg Pw s lt 316 ER BRN e 5 C6 1 E evo 2 4 ee 5 R2PBD RD BK d d e PRIMARY BOOM DOWN lt C62 oan 2 i 4 cR IN ex 1 C1PBU RD C3B 1 lt e C2PBD RD BK 2 C3P 3 RD WH C3B 3 i lt gt zen m 1 d T 12 125 12 lt EE IT m Is 2 2 11 115 0 BUBK C3B 11 5 8 4 lt 91 gt d 3 98 E C3P 10 C10SBU BL C3B 10 18 12 gt 5 16 28 5 SECONDARY E if Dep SELECT RELAY sur e 1 mm C18 1 2 10SBU BL d e e SECONDARY BOOM WS Ye SECONDARY BOOM UP DOWN l 145 e Gs C6 10 5 R11SBD BUBK eS 1 5 i SECONDARY DOWN Si a E Com C194 2 P24FS WH 2 dd 8 ej 5 i 24 WH gt 2 2 ax 4 C16PDRE OR RD 4 6 16 BK6 zo C6 13 T 26 BK 8 2 D 153 DRIVE ENABLE 3 8 y LIMIT SWITCH E b gt C2P 2 LS1 PRIMARY BOOM EXTEND 61 lt 4 DRIVE LIMIT SWITCH cna BK 6 T WH6 wus C102 RD C6 20 5 x 5 g D amp 8 cna WH 7 Ae BK 7 cia LS2 PRIMARY BOOM UP 1 DRIVE LIMIT SWI
58. TEREX BRAND Genie Service Manual 2 45 25 2 45 25J IC Power Serial Number Range Deutz models from 230441 to 34010 Ford models from 23190 to 34010 Perkins models from 23009 to 34010 models from A34011 to 47000 models from B101 to B3300 Part No 107846 Rev C5 June 2012 Introduction June 2012 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie Z 45 25 and Genie Z 45 25J Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper opeation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product sp
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61. 4 ee E m TANK AUXILIARY iT bd POWER UNIT Ji ATMOS bd Lc N ee all 1000 psi 69 bar FRONT RFA RIGHT PA EEN EIS LFB STEER CYLINDERS Y 1 y TE OPTIONAL OSCILLATE 7 AD DIRECTIONAL VALVE D 4 FRONT d gpm 5 T 3 8 L min LEFT De ire eee ERE 1 1 1 LFA rt oem GD pores gpm 250 1 7 6 L min n TANK 1 2 a o 030 inch 8 0 76 6 enie Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J 6 71 June 2012 Section 6 Schematics Hydraulic Schematic 4WD Models before serial number 27001 Section 6 Schematics after serial number 27000 Hydraulic Schematic 4WD Models June 2012 REV B
62. A RU us d 5 an n LEFT sn TEST2 REAR COUNTERBALANCE VALVES 9 A RATIO PRESSURE AJ LAK 5 0 1 1000 psi 69 b 4 STEER CYLINDERS 69 7 BOT 81 1000 psi 69 bar lt HS0081D 1 1 3 1 1500 psi 103 bar Ld LA 0 030 inch A 03 us X 31 3300 psi 228 bar Al e l AK 3 1 3500 psi 241 vf Hin Hes CT me M N 4 53 3500 psi 241 bar BRK 7T ad 1 di m Lt 4 25 1 3626 250 28PD vU vU i SE 151 3800 262 COUNTERBALANCE VALVE CD CHANGED FROM 3000 PSI TO 1000 PSI AFTER SERIAL NUMBER 31414 gt lt n 4 Al 4 3 1 3800 psi 262 bar 8 H er HH OSCILLATE AXLE CYLINDERS 1 enie Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J 6 69 June 2012 Section 6 Schematics 1 Hydraulic Schematic 2WD Models after serial number 27000 REAR 5 RIGHT REAR 71 LEFT June 2012 Section 6 Schematics
63. A 185 gt a PRIMARY UP 158 BRN 6 1 13P aw 24 Dr de R2PBD RD BK le 1 gt PRIMARY BOOM DOWN lt C181 C132 un 1 el s C3P 1 CIPBURD C3B 1 2 C2PBD RD BK C3B 2 C3P 3 RD WH C3B 3 1 gt lt 1 C3P 12 C12SBF BUWH C3B 12 18 sq 4 lt ts YEL i E err ge DE C11SBD BUBK C3B 11 818 L lt _ pm so sl 2 10 C10SBU BL C3B 10 18 P 16 288 10 2 B SECONDARY BOOM B Ens SELECT RELAY e e 2 pte 2 e SECONDARY BOOM Lie HiOSBUBL SECONDARY n 6 10 5 RITSBD BL BK Y B E o SECONDARY DOWN e a i Cen C194 19 2 P24FS WH 2 1 8 da g 5 P24FS WH we s 6004 C16PDRE OR RD 4 C6 16 BK 6 3 wie 06 13 P26ESTP 8 2 Be LS3 DRIVE ENABLE 2 LIMIT SWITCH E 5 5 C2P 2 2 151 PRIMARY BOOM EXTEND ERG o gt 4 DRIVE LIMIT SWITCH cna 6 2 wus 2 WHS 1 2 RD 06 20 5 1 iss amp amp M a 1 8 ae ee E 11 4 WH7 1 BK 7 11 3 152 PRIMARY BOOM UP E amp DRIVE LIMIT SWITCH mE 2 5 59 Look Bo u 8 C2B 2 C640 Do 04 Co 5 LS4 SECONDARY BOOM UP 4 Qe 1 DRIVE LIMIT SWITC
64. C16 1 162 g C7PBE 8 T 1 BOOM EXTEND EXTEND e BOOM T RETRACT Ces CaPBR BKIWH RETRACT B C174 c17 2 2 C4P 2 C14PLU OR C4B 2 8 DOWN gt lt e PLATFORM LEVEL e uP C4P 3 C15PLD OR BK 3 i 1 C20 1 C202 8 06 4 Ke PLATFORM LEVEL UP Down e PLATFORM LEVEL eur 06 15 C15PLD OR BK e 1 e PLATFORM LEVEL DOWN i 021 1 C212 x GRIBK 44 C2P 6 129 GRIBK C2B 6 i 2 gt 9 i 6 C18 D GR BK C4B 6 DOWN e sie oe JIB BOOM ow 5 C17JU GR C4B 5 1 E C231 C232 N g i 618 C18JD GR BK 8 i PLATFORM ROTATE RIGHT AR BOOK JIB BOOM DOWN 1 ev 1 1 06 17 17 JU GR 1 PLATFORM ROTATE LEFT JIB BOOM UP 5 1 022 1 22 2 ivy 6 RIGHT 5 e e eoe PLATFORM g i C525 10 LEFT ROTATE RIGHT PLATFORM e 221 f DoM ROTATE i 5 e 1 C129DA BK C6 19 e e DESCENT ALARM OPTION e 2 DE E EE 1 7 C19JSV GR WH con d z P zE 5 z 08 5 Ho o gz a 5 ro 3 5
65. Comments Part No 107846 B 10 Ground control override B 11 Directional valve B 12 Platform leveling B 13 Engine idle select B 14 Fuel select Ford models B 15 Drive brakes B 16 Drive speed stowed position B 17 Drive speed raised position B 18 Alarm package B 19 Hydraulic oil analysis B 20 Fuel and hydraulic tank cap venting B 21 Replace fuel filter Perkins models B 22 Engine maintenance Perkins models B 23 Air filter Ford models Perform every 400 hours B 24 Engine maintenance Ford models TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures 1 S M MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of both pages to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection Six Month or 500 hour Inspection Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn
66. Genie A TEREX COMPANY 5 6 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 5 Fault Codes G REV B FAULTCODES Code Problem Cause Solution 111 Closed loop multiplier high iQ Repair wiring and or connections OR replace LPG sensor OR repair vacuum and exhaust leaks vacuum leaks or exhaust leaks 11 2 HO2S open inactive Heated oxygen sensor wiring and or connections Repair wiring and or connections OR replace bank 1 open or shorted OR sensor is faulty sensor 11 3 HO2S open inactive Heated oxygen sensor wiring and or connections Repair wiring and or connections OR replace bank 2 open or shorted OR sensor is faulty sensor The post cat heated oxygen sensor wiring and or 114 Post cat oxygen sensor connections are open or shorted OR sensor is Repair wiring and or connections OR replace open cold non responsive or inactive for 60 seconds or the post cat oxygen sensor longer Heated oxygen sensor wiring and or connections Repair wiring and or connections OR replace Closed loop multiplier high open or shorted OR sensor is faulty OH there are sensor OR repair any vacuum and exhaust 121 vacuum leaks or exhaust leaks OR fuel pressure OR test the fuel OR dl gasoline is low OR the fuel injectors need cleaning or Se s h i pressure Ra replacing replace the fuel injectors MAP IAT or ECT sensors not in correct position OR wiring a
67. HOLSIS3H 85 WOCH 8 FLH z an 81 49 48 8 9 9 YSL 51041409 ACTON WHOd1V 1d WHO1V 1d H3xv3ug 7951 1551 6951 vse auma G edo voz d gt VrI H0 a 1 4 5 902 vre au rN T 3NION3 T 21 49 VZL HD 110949 gt 2 6 610 2870 189 2 a gy 3NION3 frd LYVIS MO19 Q KG 2951 9951 E cos a c c SES RO 26 DY 31v10H B 38viNunL a a 7 829 a 2951 V2L HN 18 1 9 V9 QH HM 7727717 PHM AHVONOO3S Q S J8 HM VS I8 HM 0951 002 3151599 JN9VIHYA 9334 NOILONNA vH V9c QH HM NT VUM NMOG dn wea a Sla woog Ed o 1951 0 21 n 1 gy 7 am QN31X3 ovi WOCH 110 5951 28 2 4 I 9 22 ELLE p HN 91915 1VNIINH3 L OL SS3NHVH 3S v8 c H3ldW VSe E HM am aunssaud _ i O s d Sp Nua 5 ESA z e VEZ HM I2 esce coo Yid au au ao a a
68. gt on 25 8 54 S RD Y 58 KEE 85 i 896 96 Le ae RD Se RD 6 12 2006 Section 6 Schematics g Ground Control Box Switch Panel Wiring Diagram Z 45 25 Ford Models Section 6 Schematics August 2006 EE Platform Control Box Wiring Diagram Z 45 25 Ford Models REV A August 2006 Platform Box Wiring Diagram Z 45 25 Section 6 Schematics Ford Models PLATFORM CONTROL HARNESS TO SWITCH PANEL RD P2 RD H1 OPT C32BRK WH RD C1P 6 LS18 CE OPTION ONLY C40LSS OR C2P 2 P24FS WH C9P 2 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C9HRN BK RD C3P 9 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9 1 P25FS RD C9 3 P24FS WH C9 2 CDLITE GR C45GEN GR WH C2P 7 C3P ES C128LS OR RD C2P 4 C39LP BL RD C2P 1 C9 P26ESTP BK 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALA
69. gu Q VE HIWdH 1 1 J am QN31X3 ovi 2 INV1009 aval en dl 2951 cc c g I 9 20 dIHLS TWNINYSL OL SS3NHVH 3578 c VSe E HM am en 3unssaud 5 _ 10 i C Q S sr Nua i ESA Ti vez HM I2 E RH pete I au au ao al a c E 9 8 x 22 5 EECH Toi e HW OO 8 Beien pe HOLIMS dOLS 1951 Id o E o 2 z O u zio o M E 9 ae d 9 65 5 285 a 2 95 5 2 02 2 962 j 6 2 2 64 S F 6 51 ug usc SE w adugoocsomusatoms 5 2 PSPs So ayes SQ ele x z zu x 595 gt CGO MES 255 gt em gt ui APE gt gt gt 042 lt gt gt tr 5 gt a gt 0 gt ETO gt S35 2 2 16 5 gt lt 2 lt gt a 25
70. t Ground Control Box Switch Panel Wiring Diagram Z 45 25J Deutz F3L 201 1 Models Section 6 Schematics August 2006 EEE Ground Control Box Terminal Strip Wiring Diagram Z 45 25J CE Models Deutz F3L 2011 Models August 2006 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Models Deutz 2011 Models Section 6 Schematics t ao 2945 Nua Nua EFFET o5 2 amp 2 CEET ZSFHM tr 1561 5610 2 80 azau Sagan DEES DESCH 8 ver aumm WUYIV QW HM
71. 13 Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Section 2 Specifications 9 4 30 Oe 8 2 Bolt torque sequence before serial number 23332 10 15 000 7 Bolt torque sequence after serial number 23331 REVD D 3 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Greasethe turntable bearing See A 10 Grease the Turntable Bearing and Rotate Gear 2 Torquethe turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Startthe machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 4 Place a dial indicator between the drive chassis and the turntable at a point that is dir
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73. 9 Remove the center turntable cover retaining fasteners Remove the center turntable cover from the machine 10 Inspect the turntable area for burnt chafed and pinched cables 11 Lower the boom to the stowed position and turn the engine off 12 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Cables on the primary and jib booms Jib boom Platform rotate manifold Inside of the platform control box 13 Inspect for a liberal coating of dielectric grease at the following location All wire harnesses connectors to the platform control box 14 Swing the engine back to its original position and close the engine pivot plate latch 15 Install the engine pivot plate safety pin 16 Install the center turntable cover and tighten the retaining fasteners REVC B 3 Check the Exhaust System Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns
74. C214 C212 i 1 gt C4P 6 C18JD GR BK C4B 6 RIGHT PLATFORM gt ROTATE caps C17JU GR CABS 8 023 1 023 2 g 06 18 18 0 GR BK RIGHT gt PLATFORM ROTATE RIGHT E PLATFORM JIB BOOM DOWN 5 eer ROTATE 06 17 C17 JUGR PLATFORM ROTATE LEFT JIB BOOM UP B C224 C222 Yt ES 1 C525 CLE CU p E 22542 22 1 129DA BK C6 19 ee m 1 DESCENT ALARM OPTION 2 2 E EE 1 9 e b 59 zz SZ Ho a E E zz oo ERO SE xou or gu ozo 2 82 Karine 559 54 2555 95 2 5964 e 828 5 5554 lt Ex 2500 E Se 205 9066 55 KEE T ES ele E 6 24 Nenie 2 45 25 Z 45 25J PartNo 107846 August 2006 Section 6 Schematics Electrical Schematic 2 45 25 Deutz F3L 201 1 Models REVC C28TTA RD BK C28TTA RD BK August 2006
75. FAULT CODES MIL Malfunction Indicator Light control ground short MIL Malfunction Indicator Light open MIL Malfunction Indicator Light control short to power For further engine fault code troubleshooting and diagnostic information refer to the Ford DSG 423 EFI Service Manual EDI part number 1060040 Ford DSG 423 EFI Service Manual Genie part number 119494 Genie PartNo 107846 A TEREX COMPANY Z 45 25 Z 45 25J Section 5 Fault Codes August 2006 esses This page intentionally left blank Genie TEREX COMPANY 5 16 2 45 25 Z 45 25J PartNo 107846 August 2006 Section 6 Schematics Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Observe and Obey Electrocution hazard Contact with AWARNING electrically charged circuits could Troubleshooting and repair procedures shall be result in death or serious injury completed by a person trained and qualified on Remove all rings watches and the repair of this machine other jewelry Immediately tag and remove from service Hydraulic Schematics damaged or malfunctioning machine AWARNING Bodily injury hazard Spraying Repair any machine damage or malfunction hydraulic oil can penetrate and before operating the machine burn skin Loosen hydraulic connections very slowly to allow B
76. S Sl 1 5 5 Els 8 Le 5 n ed 5 T He 2 8 i o9 E CA1RPM OR BK c52 so 5 CA1RPM OR BK C2B 3 EE ja Oo 4 S E 2 107 WH LB Le el 1 Ca oe 1 x lt 1021 7 g Fl ot 5 EG ol a T pp 1 918 6 a 2 OCH ALTERNATOR 2 6 S i GEAR n 5 lt ee eee Oe SS og bec 4 N 5 1 T i 81754 1 IB 8 50 0 M Ek aigc o 2 S817 4 5 1292 d lt 4 8 By C7B4 P20BAT RD RD 2 e ors N e iO Part No 107846 A TEREX COMPANY Z 45 25 2 45 25 G 6 56 Section 6 Schematics Perkins 404 22 Models C28TTA RD BK Electrical Schematic Z 45 25J P26ESTP BK August 2006 P26ESTP BK C28TTA RD BK REVC
77. t C2P 7 C45GEN GR WH C2B 7 C5 12 GRWH p 4 GENERATOR OPTION d cc 4 yes ates e Sce EE ee ar a zi 2 ig g ig S C3P 4 DLITE WH C3B 4 x DRIVE LIGHT E work HIT 8 C 4 DRIVE LIGHT OPTION AIR D 1 LS lt g 6 S RF C4B 11 RD oe 5 C2P 12 C2P 10 u Q gt UM WORK LIGHTS OPTIO cz E E 2 11 2 9 Z A amp NT i g 8i C6 34 FLASHING BEACONS OPTION EK MDC EN Rene SA EE siga E E cae E EE en EN C128RPM OR RD H C2P 1 C39LP BL RD C2B 1 FUEL 3 HOUR METER Gas SELECT 3 2 N CHECK ENGINE LED Lie FUEL n GY RD e GAS SELECT C108ESL BUWH GYYL Z GASOLINE SENSOR RD o0 u BK BL 2 2 92 81 RD GN ex d Sir E cn 0 LPG LOCKOUT a BR e wo D E 1 7 C33STRBK CIB 7 4 Test RUN TEST SWITCH ENGINE i START a b ZG vo amp iue 4 E ojejo w nnt 3 AUXILLARY POWER 4 zs C5 19 P23BAT WH FEH 16 PIN1 89
78. 0523 BRN c 1 BURD oem E LEVEL SENSOR mom UA acc 548 A z lt a oo 4 Copa BK RD 9 C46HRN BK RD Inl 6 HORN RELAY gt 201 95 o5 o5 KE 52 37 0 e 7 1 22 C784 P22BAT BK i mam ne LI HORN NO A VW SIE gt 8 amp y 1 2 BLWH 12 N gt 8 A E C2P 5 C134PWR GN 0285 Ee 8 o E 8 a X BI T e 10 BRN e w e B x 9 oa 5 e 6 5845 u 4 83 o e c0 amp gt 5 5 o9 E 8 Ox C41RPM OR BK C52 Go 41 OR BK C2B 3 EE So S i o C107AF WH 1 Cox 9 e Oe 5 9 g 5 pE pagas i g i E ALTERNATOR 8 na amp og 5 IU 52 9 0 8159 S o Se 29258 E e c elo co an a og ee 8 c lt lt RD C7B 4 P20BAT RD gt e ors 2 1 N Section 6 Schematics August 2006 Electrical Schematic Z 45 25 REVC Perkins 404 22 Models C28TTA RD BK C28TTA RD BK
79. 2 2 5 5 BB WH zu Tc ozo sr Omom ks 5 JIB BOOM VALVE JIB BOOM VALVE 20 lt GG ER x Se mm OTEO raga 58 x 526 0006 2 g TH WES z D 8 SIS wv 6 36 Mane 2 45 25 Z 45 25J PartNo 107846 August 2006 Section 6 Schematics n r Electrical Schematic Z 45 25J CE Models Deutz F3L 201 1 Models Section 6 Schematics August 2006 EE Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Deutz F3L 201 1 Models GROUND BK ALARM August 2006 BK ALARM BK
80. 8 C33STR BK C1B 7 8 Teer RUN TEST SWITCH STAAT P 2 25 amp 8 a ENGINE 888 stant 9 Y e SR 5 19 P23BAT WH FEH 16 PIN AUXILLARY RELAY o9 82 5 c5 11 C21GN WH FEH 71 PIN21 6 OR RD FEH 306 PIN24 x 5 1 5 BL WH FEH 658 PING 9 GR FEH 458 PIN18 9 o 52 E o 2 65 10 BURD FEH 72 05 18 BK RD FEH 307A 23 2 a 2 5 z P20BAT RD FEH 361 PIN9 3 N GND BR FEH 570 PIN34 C52 CA1RPM OR BK FEH 11 PIN2 3 E 5 2 e Ces R33STR BK FEH 32 PIN15 IGNITION START RELAY e C33STR BK FEH 32 5 oz C135FP BL WH FEH 787A PINS BLUWH BK FUEL PUMP 5 amp e RE a 5 ele 3 EIS 2 8 amp amp C33STR BK E e o y 2 ae D T 88 TEE e DTD e 1 STARTER MOTOR e e AUXILIARY POWER B 0627 AUXILIARY POWER RELAY C27AUX RD BAT RD C2BTTA RD BK AUXILIARY PUMP 1 2 C28TTA RD BK CiP2 0524 C28TTA RD BK 5 lt TILT ALARM z P C2P 5 C184PWR GR C2B5 0547 134TTS RD WEEN x a 5 gt 5 8 5 SE Copa C46HRN BK RD C3B 9 z C46HRN BK RD 2 amp lt 2 o HORN RELAY c wo amp on TUER E n e C7P 2 P23BAT WH C7B2 N 9 7 1 P22BAT P22HRN BK FA6HRN BK RD C69 59 92 SCH Horn a m gt
81. AUXILIARY 5 m P C27AUX RD er 49 AUXILIARY POWER RELAY 8 2 P23BAT WH C7B 2 2 e AUXILIARY PUMP 4 xx RA 3 a4 5 m RD o 1 gt x e 1 2 C28TTA RD BK C1B 2 C5 17 C28TTARDIBK WH TILT ALARM lt i a lt cu A RD 1BK BRN C133PLABL RD C4B 1 P9478 WH H 5 LEVE i En E DEN 4 x lt m z 25 g 8 RT Copa C46HRN BKIRD cao 9 C46HRN BK RD Inl HORN RELAY E e 95 o5 C7P 1 P22BAT BK C7B 1 22 C6 9 am HORN RA E OO gt 5 1 2 BUWH 018 12 2 gt gt 8 caps C134PWR GN 2 5 8 o o N BRN i x 8 D 5 JE 5 gt 8 88 oz amp e e5 5 D x 2 8 OR BK C52 Go C41RPM C2B 3 8 Pus C107AF WH a o 921 za 9 55 n g si p 5 1 77 i m S i ALTERNATOR i amp a oe 9 i ed n 9 88 23 2 8 MEM 1 M Uu EDEN T 94 8 lt lt P20BAT RD E RS RD C7B 4 gt e e ors 2 CN Lo Part No 107846 GREEN BROWN C3B amp C3P amp Mane 2 45 25 Z 45 25J lt 6 ANSI CSA Domestic machine add L48 6 23 Section 6 Schematics C28TTA
82. C33STR C1P 7 C27AUX RD C1P 1 E C2P BK 5 e 34 JC1 3 OR 5 E x JC2 4 RD Pd bg 1 mE zs JC1 2 e n C1P GY JC2 3 OR ME y JC1 5 YEL ME al JC2 2 BRN e N JC3 5 WH E o JC3 3 OR ME JC3 4 BL 2 JC3 2 BRN 5 d DRE ABLWH Pu C28TTA RD BK H1 x D Ti DRE B BL BK lt 88 d C13LED BL RD e E 5 i C29MS RD WH mam p zi o SE E Ld d RD BK L48 bd GR BK 1 bd GR BK L4 T bd lt RED TILT RED TILT C2P 5 Ld RED 1518 z Ld E Der BRN Ly BRN Xl LLL N 6 31 Section 6 Schematics August 2006 Platform Control Box Switch Panel Wiring Diagram Z 45 25 REV A Deutz F3L 201 1 Models TS13 PRIMARY BOOM C8PBR BK WH 8 C7PBE BK C3P 7 White wire replaced by CR27 and CR30 on CE models EXTEND RETRACT N c C17PRL GR 5 WH CN LO E 20 RD 1518
83. E e re 06 38 RD 5 1 3 C2P 12 207 C2P 10 ji i 3 9 WORK LIGHT OPTION 5 5 EN ET T ELE EE SEE i ow 7 C2P 11 C2P 9 JJ Reale ee en a x lt al x VB 81 C6 34 P134FB RD 8 FLASHING BEACONS OPTION L pt pH VER EN cde dtt ot eee Ste che E 2 B 2 8 C34SA BK WH C1B8 C34SA C5 22 Z MN e Caw PLUG 8 2 GLOW Tre PLUG 5 GLOWPLUG 2 g 8 C26TSR WH RD OIL TEMPERATURE LED CINES E 8 5 oa 29 C25PSR WH BK OIL PRESSURE LED gu 8 3 859 5 2 g 39 BE 7 C33STR BK 7 3 Er 5 3 5 gt OIL TEMPERATURE SWITCH ENGINE SES amp Zem k EE 8 8 E B 16 7 SAT 55 OIL PRESSURE SWITCH BK 8 69 DIE 2 gle mx 5 u AUXILIARY POWER 1 1 C27AUX RD C1B POWER RELAY gt Ile i 8 o y WH en M FUEL SOLENOID 55 Se SUPRESSION DIODE x 1 amp C21IGN WH m 1 gt HOUR METER gi 8 ba ab 1 LI 6 IGNITION START RELAY 1 4 D R El z 5 AOE 1
84. Ford models 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine 2 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine to access the exhaust system models 3 Be sure that all nuts and bolts are tight 4 Inspect all welds for cracks 5 Inspect for exhaust leaks i e carbon buildup around seams and joints Ford models 6 Swing the engine back to its original position and close the engine pivot plate latch 7 Install the engine pivot plate safety pin Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC CHECKLIST B PROCEDURES B 4 B 5 Inspect the Engine Air Filter Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine air filter in good condition is essentialto good engine performance and service life Failure to perform this procedure can lead to poorengine performance and component damage Perform this procedure with the engine off 1 Release the latches from the air cleaner canister end cap Remove the end cap 2 Remove the filter element 3 Clean the inside of the canister and the end cap with a damp cloth 4 Inspect the air filter element If needed blow
85. GR WH D d GeheRATOR OPTION 1 1 E I c 1 an c ar nn mU 1 C3P 4 DLITE WH C3B 4 DRIVE LIGHTS 8 8 WORK LIGHTS 06 39 RD Ke 5 1 g i amp a EIN 19 DRIVE LIGHT OPTION 1 ala 8 8 9 3 06 38 RD 12 44 7 C2P 12 10 2 BER WORK LIGHT OPTION 5 18 9 C2P 11 gt 2 9 VW cea ws he teh ates el EE EE EE E Cice E Ou A i x Sos B 81 C6 34 P134FB RD 1 gg FLASHING BEACONS OPTION ee FEN u 2 8 Eg 8 Copa C34SABKWH 5 22 Z MN e 9 PLUG 2 e e Gre GLOWPLUG GeGTSR WHIHD COOLANT TEMPERATURE LED Fe 3 5 3 gt oa aer C25PSR WH BK OIL PRESSURE LED gt 2 6 4 En SES 5 g oe C33STR BK BER 18 81 i 5 14 5 gt e COOLANT TEMPERATURE SWITCH 2 on S START S 5852515
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87. HOUR METER Gas SELECT 3 E E N CHECK ENGINE LED Lie FUEL n GY RD e GAS SELECT C108ESL BUWH GYYL OU B hb Z GASOLINE SENSOR xu D BK BL gu a 2 HS SIE 22 Et RD GN 25 a Ev ie LPG LOCKOUT a ja BR e I 918 7 C33STR CIB 7 4 Test RUN TEST SWITCH ENGINE i START 8 5 2 2 p amp Bl ole 4 5 ENGINE E 51818 START 3 nl AUXILLARY POWER 4 zs C5 19 P23BAT WH FEH 16 PIN1 5 5 11 C21IGN WH FEH 71 16 amp 6 OR RD FEH 306 PIN24 a 5 E BL WH FEH 658 PING u ai o N GR FEH 458 52 o 9o 58 EE C5 10 BURD FEH 72 PIN7 5 18 BK RD FEH 307A PIN23 II ai N GND BR FEH 570 PIN34 a 5 2 C41RPM OR BK FEH 11 PIN2 5 IGNITION START 5 5 5 R33STR BK FEH 32 PIN15 RELAY C135FP BL WH FEH 787A PINS E x BL WH Je B 8 FUEL PUMP a ale 3 Qe 5 START D N NIN aja Mn ala A 88 PATRE mo STARTER MOTOR 01 b Fl Meee cael AUXILIARY BS e POWER E C6 27 C27AUX RD AUXILIARY POWER DI AUXILIARY RELAY POWER p CIP C27AUX RD 1 1 Eg COBTTARD BK g BAERD ele 4 AUXILIARY PUMP tL s 2 gt WH SV ciP2 C28TTA RD BK 1 2 C5 24 C28TTA RD BK wi 77
88. REVD 15 Install the new filter elements into the housings and tighten them securely The medium and high pressure filters use the same elements 16 Clean up any oil that may have spilled during the installation procedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 18 Start the engine from the ground controls 19 Inspect the filter housings and related components to be sure that there are no leaks CHECKLIST D PROCEDURES D 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 201 1 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie Part No 107846 TERE
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90. bag P23SWBAT WH 2 EN P22BAT C7P 1 E E 1 1 1 1 1 1 a Fd C15PLD OR BK C4P 3 72 C14PLU OR C4P 2 1 m C9HRN BK RD C3P 9 pd BK WH C3P 8 151 7 1 P26BAT BK C9 1 P25FS RD C9 3 1 P24FS WH 2 Fg 2 d CWLITE RD C2P 12 d Sp oro LUI 252 2r RR ke SETEN VE 0 _______________________ BER 5 4 o C45GEN GR WH C2P 7 1 o Fd Ne E P26ESTP BK 5 1 gt WH RD C3P 6 pd gt 2 m C10SBU BL C3P 10 d C16DRE OR RD C4P 4 gt C11SBD BUBK 11 RE a x 1 F F ij N C40LSS OR C2P 2 e N emn C12SBF BUWH 12 O 5 P24FS WH C41RPM OR BK C2P 3 W e C30FWD WH C1P 4 BRN C1PBU RD C3P 1 gt C31REV WH BK 5 ai af af e C2PBD RD BK C3P 2 SI 6 T a C37STC C1P 11 RD WH C3P 3 W e C36STCC BK 10 e C32BRK WH RD 1 6 e CA 1 5 WH BK C3P 5 26 amp C29MS RD WH C1P 3 gt E m lt lt C3P GR C35HS BK RD 9 O
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92. 1 3500 psi 241 bar LLL 1 JIB BOOM MANIFOLD u 3 ii I 4 5 PM H atmos 3500 psi HIGH MASTER CYLINDER 241 bar CHARGE PRESSURE FILTER FILTER ME ici N 1 50 psi 13 4 bar ST1 ST2 PR1 PR2 S1 52 P1 P2 EXTEN RETRACT u Geesen 0 037 inch 09mm y 4 i bano 2500 psi 172 bar L 1 I Zem em Zem set at 0 6 y FAXO Me 1 H TP2 7 yee chen 21 7 poo Mee TO AO cet at 25 gpm EN es pi W amp 5 CE 7 PRESS ry PEST pes 1 1 1 5 1 Las 2500 pal OM 4 15 7 Sch i 241 0 4 gpm HH FUNCTION PUMP AUX 1 5 Lmin T 0 1 7 gpm 26 5 L min fd 2m Lj 5 dca i 1 1 DRIVE MANIFOLD EI pn L p mmm cc 1 t 1 t 220 6 bar set at 7 D POM Sp TCR PN de celat Pam ORAL C RA Parl PNEU IPIE 1 vi B 26 5 L min at 1 995 1 mam 1 s mm gu See 7 FUNCTION MANIFOLD OSCILLATE e apes ce UNCTIO T CYLINDERS 3200 psi i bd 2206 wa poi 25psi e 17bar 6 T Li 9
93. 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump Part No 107846 Z 45 25 Z 45 25J HYDRAULIC PUMPS 2 Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Component damage hazard The CAUTION engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 3 Tag and disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures August 2006 HYDRAULIC PUMPS REV B 4 Supportthe pump with a lifting device and How to Prime the Pump remove the two drive pump mounting fasteners 1 Connecta 0 to 600 psi 0 to 41 bar pressure 5 Carefully pull the drive pump out until the pump gaug
94. 10 12 ft Ibs 14 16 Nm Genie A TEREX COMPANY 4 62 Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures REV E MANIFOLDS PartNo 107846 2 45 25 2 45 25 4 63 Section 4 Repair Procedures EE MANIFOLDS 8 12 Valve Adjustments 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump Hold the charge pressure relief valve and remove the cap item PP or AD Turn the internal hex socket clockwise fully until it stops Install the cap Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turnthe engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold Hold the charge pressure relief valve and remove the cap item PP or AD Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 bar less than the pressure reading on the pump Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 10 Turn the engine off and remove the pressure
95. 16 e RICHT PLATFORM G eer ee eee VEREIN N euer ROTATE i 5 129 c6 19 DESCENT ALARM OPTION eoe 7 C19JSV GR WH con z 45 mE 5 z 08 I 6s Ho 5 ga 2 z 8 Iz 3 Ex o SE 598 8 BK WH zu azo Sb ks o ddot JIB BOOM VALVE JIB BOOM VALVE Sog ZAS gage sf 5092 j BB oy i 5 Zem mmm 55 z SEN SEY 6484 e 23S 900 AE 8 8 amp SIS Gei 6 16 Nenie 2 45 25 Z 45 25J 107846 2006 Section 6 Schematics u n Electrical Schematic Z 45 25J Ford LRG 425 EFI Models before serial number 30142 REVA C28TTA RD BK C41RPM OR BK C28TTA RD BK August 2006 C Electrical Schematic
96. 23 Check Valve eie eere pets MN 244 24 Check 25 Shuttle valve Y x 26 Check 27 Check 28 Check AB 29 Relief valve 2100 psi 145 bar AC Function Platform level flow control Platform level circuit Differential sensing circuit platform level up Differential sensing circuit platform level down Platform level circuit Differential sensing circuit boom retract Differential sensing circuit turntable rotate right Differential sensing circuit turntable rotate left Secondary boom down REV E Torque 20 ft lbs 27 Nm 25 ft lbs 34 Nm 12 14 ft lbs 16 19 Nm 12 14 ft Ibs 16 19 Nm 4 5 ft lbs 5 7 Nm 12 14 ft lbs 16 19 Nm 12 14 ft lbs 16 19 Nm 12 14 ft lbs 16 19 Nm 25 ft lbs 34 Nm TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012 MANIFOLDS REV E AoA KA ere SIE XG AC AB amp 9 AA EM D DM ay 9 45 Z 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012
97. 6 RIGHT 5 10 LEFT RIGHT d e PLATFORM pee LEFT ROTATE i Bl C129DA BK Cem jet DESCENT ALARM OPTION 1 e c 1 7 C19JSV GR WH Z u zE z o8 I 5 Ho 69 2 og as 2 rz zz 8 855 SE 2385 Era E BK WH zu RER 020 SF 586 ks o ud dat JIB BOOM VALVE JIB BOOM VALVE Sog ia nase 9685 wags 88 a Ean PED mmm 55 OTE H SEH 588 5 zt 2 5 aes u z zv 38 8 ale y 5 6 18 2 45 25 2 45 25 G Part No 107846 2006 Section 6 Schematics u i Electrical Schematic Z 45 25 Ford DSG 423 EFI Models after serial number 30141 Section 6 Schematics August 2006 ___________________________ _________6 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Ford Models REV A GROUND CONTROL BK ALARM
98. E GENERATOROPTION 7 3 L_ _L_________CWLITE RD 2 12 __ SE am _____ _________ __ Le a E gt 9690 M 5 Dd dE I qu z 265 26 GR BKH 039 E UB OWLITE RD CPI RD BK H1 C33STR 7 RD RD C34SA BKANH 1 8 BL DE1 J1 6 TS15 DRIVE BUBK DE2 J1 7 ENABLE YEL J1 3 OR J1 9 BRN J1 10 RD C29MS RD WH J1 8 TS6 GLOW PLUG JC1 SECONDARY BOOM UP DOWN C8PBR BK WH 8 C27AUX RD C1P 1 bag TS14 HIGH LOW 2WD AWD DRIVE SPEED C7PBE BK C3P 7 O TS13 PRIMARY BOOM EXTEND RETRACT BK J1 2 C17PRL GR C4P 5 TS1 AUXILIARY PUMP WH WH C19JSV GR WH C19JSV GR WH 7 RD J1 1 C18PRR GR BK 6 SS eun E OR J1 11 BRN J1 12 7 C14PLU 2 WH 6 53 RD DASHED LINES INDICATE OPTION WIRES NOTE enie A TEREX COMPANY Z 45 25 Z 45 25J G RD RD Part No 107846 RD RD TS7 PLATFORM ROTATE RD LEVEL d TS9 PLATFORM PRIMARY BOOM UP DOWN amp TURNTABLE ROTATE LEFT RIGHT REVA C15PLD C4P 3 C9HRN BK RD C3P 9 RD
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100. MANIFOLDS 8 2 Valve Adjustments Function Manifold before serial number 27001 How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge to the 1 port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the high rpm position and activate and hold the primary boom retract switch with the boom fully retracted 4 ObDservethe pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item P 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeatsteps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge A TEREX CON Z 45 25 Z 45 25J REV E How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the 1 port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the high rpm position and activate and hold the secondary boom down switch with the secondary boom f
101. Perkins 404 22 Models JC3 TS47 GENERATOR OPTION Platform Control Box Switch Panel Wiring Diagram Z 45 25J August 2006 TS15 REVA 6 65 DASHED LINES INDICATE OPTION WIRES NOTE TEREX COMPANY 2 45 25 Z 45 25J G Part No 107846 5 ER D ER RD LS18 2 BK C7P 1 BK J3 3 g 55 7 2 or wo BK C9P 1 27 BL J1 5 SC gt WH J1 4 BL J1 5 Im u g 1 13 Si BRN J1 14 BK BK i RD PDLITE RD 1 _____________ DD 0 OLN se ES O g 800 B oL ENT 8 uto 9 a gt E P24FS 9 2 tr RD C35RPM BK RD C1P 9 amp MS GENERATOR OPTION fg AE CWLITERDC2PJ2 Ss B __________ _ EIS x 25 90990 69a S 690 3 5 2 meh S E 3 Puxa 269 26 039 re E B E CW
102. Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings W Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones Whenreplacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14 Pack both bearings with clean fresh grease 15 Place the large inner bearing into the rear of the hub Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush 17 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the slotted nut to 35 ft lbs 47 Nm to seat the bearings 21 Loosen the castle nut and re tighten to 8 ft lbs 11 Nm 22 Install a new cotter pin Bend the cotter pin
103. SAE No 10 41 ft Ibs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve Coil Resistance Specification Proportional directional solenoid valve 10V DC 6 to 8Q schematic items A C D BP BU and BY 3 position 4 way directional valve 10V DC 6 to 80 schematic items B F H BF BM CG 2 position 3 way solenoid valve 10V DC 6 to 80 schematic items E G CA CC AD OO XX AF AG Al and AK Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice TEREX COMPANY Part No 107846 Z 45 25 e Z 45 25J 2 5 Section 2 Specifications January 2011 SPECIFICATIONS Ford LRG 425 EFI Engine Displacement 153 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke Horsepower 70 2500 rpm 52 kW 2500 rpm Firing order 1 3 4 2 Low function idle computer controlled 1600 rpm 27 Hz High function idle computer controlled 2500 rpm 42 Hz Compression ratio 9 4 1 Compression pressure approx Pressure psi or bar of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure operating temperature 2500 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 4 5 quarts including filter 4 3 liters Cil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Cil visc
104. Serial Number Legend Genie A TEREX COMPANY Serial number Z452506 12345 Model year 2006 Manufacture date 04 12 06 Electrical schematic number 50274 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 16 670 Maximum allowable inclination of the chassis 0 deg 24525 06 12345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 45 ft 6 in 13 8 m m Maximum platform reach 25 ft 3 in 7 7 m Sequence Gradeability N A number Country of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Model year Genie Industries Serial label 18340 NE 76th Street located under cover Redmond WA 98052 Serial number USA stamped on chassis 77055 TEREX COMPANY Part No 107846 Z 45 25 e Z 45 25J lii June 2012 p u This page intentionally left blank Genie A TEREX iv Z 45 25 Z 45 25J Part No 107846 2012 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z 45 25 and Genie Z 45 25J Operator s Manual will result in death or serious injury Many of the hazards identified in the operato
105. Turn the key switch to platform control Result The flashing beacon should be on and flashing Press down the foot switch Move the primary boom control handle to the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down Press down the foot switch Move the secondary boom control handle to the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down Z 45 25J Press down the foot switch Activate the jib boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC CHECKLIST B PROCEDURES B 19 B 20 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction s
106. Z 45 25J Ford DSG 423 EFI Models after serial number 30141 Section 6 Schematics al ala I Ga m z o a 1 9 5 BK RD C1B 9 FOOTSW HIGH t FOOTSW LOW C2P 4 C128RPM OR RD C2B 4 5 a Ka a 28 8 4 3 LOW RPM vele UNOTION B c 5 a ee eee crew SR REESEN t C2P 7 C45GEN GR WH C2B 7 C5 12 GRIWH 4 GENERATOR OPTION d cc RI RE CH ERBEN WENN i gc ie fl man EN E 2 une ne ix 5 19 g amp C3P 4 DLITE WH 4 9 IE DRIVELIGHT gt eo work CHTS RD 5 iS C 4 DRIVE LIGHT OPTION FS 672 2 i 5 8 8 RF C4B M RD 3 4 1 emn lt C2P 12 C2P 10 15 9 WORK LIGHTS OPTIO FTIR D cz H 13 Cor C2P 9 2 i d 5 i g P134BAT RD C6 34 FLASHING BEACONS 4 m OPTION eg DE Fr te Fe e j 1 ee Be rece P mele C128RPM OR RD H C2P 1 C39LP BURD C2B 1 FUEL Br
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108. bag 1 1 1 nog Da e C15PLD OR BK C4P 3 2 4 C9HRN BK RD C3P 9 2 C8PBR BK WH C3P 8 7 NW P26BAT BK C9 1 Ld P25FS RD C9 3 24 5 WH C9 2 EE on essen PE ERN PS CWLITE RD C2P 12 1 MEME d erst cken ATE RECRE eege EE WEN 55 GR WH C2P 7 Q if 1 bg i P26ESTP BK d Fd oe e e C6TRF WH RD C3P 6 gt 1 1 o C10SBU BL C3P 10 e C16DRE OR RD 4 Is C11SBD BUBK 11 na lt F N e C40LSS OR C2P 2 e N C12SBF BL WH 12 O P24FS WH e C41RPM OR BK C2P 3 T Se C30FWD WH 1 4 Q i BRN e C1PBU RD C3P 1 gt C31REV WH BK 5 of of a a CN 1 T Ry 5 T e C2PBD RD BK C3P 2 Of C37STC BUBK 1 11 e RD WH C3P 3 C36STCC BK 10 T C32BRK WH RD C1P 6 e CAP BR S e C5TRR WH BK C3P 5 M 2 2 a C29MS RD WH C1P 3 29 lt C3P GR S J i C35HS BK RD C1P 9 C34SA BK WH 8 C33STR BK 7 C27AUX RD 1 1 2 4 J 5 a JC1 8 OR x
109. boom extend retract and turntable rotate 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Part No 107846 August 2006 Section 4 Repair Procedures REVC 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Z 45 25J Extend the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raisethe primary boom slightly and place blocks under the platform for support Part No 107846 Geni
110. con i 15 5952 airy 4 8 i oe a 29 lt Ea mon os 1 nD 4150 gt o 812 8 a 8 0 lt RD C7B4 P20BAT RD e e ors CN Lo Part No 107846 2 45 25 Z 45 25J G 6 35 Section 6 Schematics Deutz F3L 201 1 Models 2 RD BK P26ESTP BK Electrical Schematic Z 45 25J CE Models August 2006 P26ESTP BK C28TTA RD BK REVC CN z BATGND c7P 3 GROUND OR BK Copa lt 5 P C30FWD WH Ex 1 4 C1B 4 C521 C30FWD WH BK N RD A FORWARD C31REV WH BK x 64 9188 1 5 C5 20 C31REV WH BK 1 8 ASEAN a DRIVE EDC REVERSE DEME ES SS SS m tenis ii een i riter mz 2 C638 WHRD am TRAVEL ALARM OPTION n
111. d E TILT ALARM 1 a RD BK BRN E 4 RD C2P 5 C134PWR GR C2B 5 4 C5 17 P134TTS RD H 5 E 3 al en amp e P S Neb Copa CA6HRNBK RD C3B 9 C46HRN BK RD I BOB RELAY gt g NA C7P 2 P23BAT WH C7B2 qs CN 1 a 7 1___ 22 C7B 1 P22HRN BK PAGHRN BKIRD C6 9 a T 3 5 g oz o m e o c 42477 g z 8 ALTERNATOR 5 gt FIELD FEH o als i 4 BAT RD C41RPM OR BK C2B 3 2 8 lalo i d 8 i 1 19 1 5 1 E c 45 gled clad zig o 8 84 88 xr d ANE 2 E 1 g EE 3 ba a u 2 Zb gt Oc 20 1 5 wore Part No 107846 Z 45 25 Z 45 25J in the stowed position and the keyswitch off 6 17 C7P 8 BATGND Ces Section 6 Schematics 2 RD BK Electrical Schematic Z 45 25J Ford DSG 423 EFI Models after serial number 30141 August 2006
112. g 08 1 Ee 228 zQ 5 R2PBD RD BK ER Ble lt lt lt H gt PRIMARY BOOM DOWN 1 lt Leg g 1 06 2 13 1 13 2 A e s lt C3P 1 C1PBU RD C3B 1 d ER 2 C2PBD RD BK C3B 2 ars RD WH C3B 3 pee i R C3P 12 125 BL WH C3B 12 18 lt Dee lt lt SE 2 11 CT1SBD BUBK C3B 11 1 518 lt Tw 1 1 5 C3P 10 C10SBU BL C3B 10 18 E d D e EE 16 cop cm gt e SECONDARY BOOM 8 SELECT RELAY Ke 858 H 5 R10SBU BL on en n 10 PR A e oo DOWN SECONDARY BOOM lt lt Ze A gt SECONDARY BOOM UP a 1 8 re e t C6 10 5 BRN x 2 5 5 115 0 BUBK d Se B d e SECONDARY BOOM DOWN 1 Com 19 1 19 2 24 5 if few 8 5 N P24FS WH i 0 0 gt 418 8 2 E ER 4 4 C16PDRE OR RD CAB 4 c6 16 pre 3 wus Cem P26ESTP BK Ee 8 2 Po z LS3 DRIVE ENABLE 5 LIMIT SWITCH E i gt C2P 2 LS1 PRIMARY EXTEND 5 4 lt 8 DRIVE LIMIT SWITCH lt 11 1 BK 6 WH 6 11 2 WH 5 lt lt 10 2 lt 6 20 5 ji lt 5 Y 1 En Nie cna WH 7 BK 7 11 3 132 PRIMARY BO
113. gauge 4 64 TEREX COMPANY June 2012 REV E Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures lt REVE MANIFOLDS This page intentionally left blank PartNo 107846 Z 45 25 Z 45 25J 4 65 Section 4 Repair Procedures June 2012 S MANIFOLDS REV E 8 13 Traction Manifold Components 4WD before serial number 27001 The traction manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Function Torque 1 Flow divider combiner valve AB Controls flow to non steer end drive motors in forward and 25 30 ft lbs 34 41 Nm 2 Bi directional flow control valve 2 GPM 7 6 AC Non steer end drive motor circuit 25 30 ft lbs 34 41 Nm 3 Bi directional flow control valve 1 3 8 AD Steer end drive motor circuit 25 30 ft Ibs 34 41 Nm 4 Directional control valve AE 2 speed motor shift circuit High speed 10 12 ft Ibs 14 16 Nm Diagnostic fitting s Testing Shuttle valve position way AG Charge pressure circuit that directs
114. injector 2 OR replace fuel injector 2 OR replace the ECM 314 njector driver 2 shorted Wiring and or connections to fuel injector 2 shorted OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 2 OR replace fuel injector 2 OR replace the ECM Genie A TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 August 2006 Section 5 Fault Codes REV B FAULT CODES Code 315 Problem njector driver 3 open Cause Open wiring and or connections to fuel injector OR fuel injector 3 is faulty OR ECM is faulty Solution Repair wiring and or connections to fuel injector 3 OR replace fuel injector 3 OR replace the ECM 316 njector driver 43 shorted Wiring and or connections to fuel injector shorted OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 3 OR replace fuel injector 3 OR replace the ECM 321 njector driver 44 open Open wiring and or connections to fuel injector 4 OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 44 OR replace fuel injector 4 OR replace the ECM 322 njector driver 4 shorted Wiring and or connections to fuel injector 4 shorted OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 44 OR repla
115. level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 4 Press down the foot switch and raise the primary boom above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line CHECKLIST B PROCEDURES 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications 8 Lowerthe boom to the stowed position and extend the boom 1 foot 30 cm 9 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 10 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 11 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST
116. to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the 5 platform during rotation Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Cushing hazard Keep clear of the 7 platform during rotation Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled Rotate the platform fully in both directions and inspect the bleed valves for leaks After serial number 24303 2 Place a suitable container underneath the platform rotator Open the top bleed screw on the rotator but do not remove it AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 107846 Section 4 Repair Procedures PLATFORM COMPONENTS 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left pos
117. x 5 run 3 lt 0 al 10 C10SBU BL C3B 10 5 8 16 cw m a 5 e SECONDARY BOOM E B ENS SELECT RELAY 1 lt e As ur H RIOSBU BL Se Se e licei m SECONDARY BOOM e SECONDARY BOOM UP 5 DOWN 81 e ag C6 10 5 R11SBD 8 EN Me SECONDARY BOOM DOWN 8 81 eo Pp C6 11 C194 19 2 P24FS WH 8 t 5 i bg AES WH 5 8 s ze ete C16PDRE OR RD C4B4 C6 16 BK6 3 wus C6 13 P26ESTP gt 8 y gu DRIVE ENABLE LIMIT SWITCH o i E I b gt 2 151 PRIMARY BOOM EXTEND 8 a lt e gt 4 i DRIVE LIMIT SWITCH E cna BK 6 gt wus enz wus RD 06 20 5 5 m a 1 P 8 rE 11 4 WH 7 1 BK 7 11 3 LS2 PRIMARY UP 4 E ES 2 DRIVE LIMIT SWITCH 1 8 IET 8o 8 C2B 2 05 40 C103 4 zz 104 BK C10 1 5 154 SECONDARY UP 4 oz gt 1 ZE T DRIVE LIMIT SWITCH 1 e e e i ER 1 P22LS BK I 7 S EXTEND 1 e BOOM RETRACT C3P 8 C8PBR BK WH C3B 8 i E 1 p BO 8 I c67 C7PBE BK 9 4 EXTEND RETRACT i C68
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121. 2006 CHECKLIST D PROCEDURES REVD D 4 D 5 Replace the Drive Hub Oil Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Install the plugs 5 Repeat steps 1 through 4 for all the other drive hubs 6 Checkthe torque of the drive hub mounting bolts Refer to Section 2 Specifications Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use ofthe free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage h
122. 36 GY 18 BKW 16 A LGR 18 BI 1 IC It AUX ANA WA 18 18 14 1 LPTEMP AUX ANAPU2 lt DEE IVS AUX ANA 41 18 18 BAG 18 BRAKE AUX DIG 3 BKN 18 BKY 18 TNSW PES BAT GOV2 AUX DIG 4 TY 18 Pow 44 ALG 18 DB W 18 d ETE az GYW 18 14 ame 4 4a YDB 16 FUELSELECT AUX 0161 i Aue i vai BAY 18 23 GOV SELECT 2 C35 RPM DGP 18 KNOCK LB BK 18 ONG 18 29 fpe 14 _ _ DGP 18 Sim KC POTE DG O 18 DG O 18 32 ANA AUX PD1 Pg 11 DB W 18 DB W 18 eR woe Gegen 58 12FPP2 S vearenot ECH aris 5 Gyn 18 H m 33 P wu BR TG BOSCH THROTTLE Weis BATT Ve Was YWIS INISLS IBDG 16 18061 euo pee ERIS Cleans 71 GY R 18 GYIR 18 ARA KS ern 18 1 GYIO 18 3 RY18 RELAY PKILG 18 BKR 16 AUX PWM7 76 WIBK 18 LOCKOFF 18018 FUELPUMP AUX PWM6 ATI ver one H Dew PET BRW 16 So SS 6 REK 18 18 Hw 21AUXPIMS Paa ate AUX PWM4 BK O 18 18 25 1VS AUX PWM2 TY 18 IY 18 2 TACH c nn PRG 18 le FPREC AUX PWM3 REC 6 MiL cto Best pec Pume pet DUIS 18FUEL PUMP C21 IGN Rie wie 38 AUX OUT1 C135 ma 18 7 FUEL SELECT C39 LP PAB 18 10 AUX ANA PD1B YON 18 27 AUXOUT2 WAB 18 4 BRAKE 0
123. 45 25 Z 45 25J SECONDARY BOOM COMPONENTS 5 Attach a lifting strap from an overhead crane to to the lug on the rod end of the primary boom lift cylinder Then raise the primary boom lift cylinder with the crane to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pin retaining fastener from the primary boom lift cylinder barrel end pivot pin 8 Use slide hammer to remove the pin Remove the primary boom lift cylinder from the machine AWARNING Cushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the overhead crane 9 Tag disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders Cap the fittings on the cylinders AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures August 2006 SECONDARY BOOM COMPONENTS 10 Remove the pin retaining fasteners from both sides of the secondary boom lift cylinder rod end pivot pin and barrel end piv
124. 5 RD C27AUX RD char AUXILIARY POWER RELAY o i C7P 2 P23BAT WH C7B2 g tee a gt V z kg 8 S 8 RD Wee oe 1 gt e 1 2 C28TTA RD BK C1B 2 C547 C28TTA RD BK 1 TILT ALARM lt o 8 bd 2 4 wy S C133PLA BURD 4 1 P134TTS WH ER RD 4 BRN On e e Fr LEVEL SENSOR x lt been D z a 2 n z 3 A BK C3P 9 CAGHRN BK RD C3B 9 C46HRN BK RD Jo e HORN RELAY Ka 95 EEN ww GH 22 22 gt PM HORN am g LJ TON d _ 29 29 2 M n o amp C132PLI BL WH C1B 12 Sal ore 8 LOAD SENSE MODULE C2P 5 C134PWR GN C285 5 8 gt Ja a d BRN e 5 cu 2 e amp x 5 Yi 5 ii d HE 5 ses te ME 55 5 8 Ox P CA1RPM OR BK 052 S o 19 CA1RPM OR BK C2B 8 Oo 5 i i bal 2 E C107AF WH 5 a ew 78 2 9c 20 2 o a 1 e 5 RENE a 1 B I 7 2 8 2 ALTERNATOR 1 alrr 2o ige 5 il Rie y ER i 1 BEE 5 I 3 g C BI 5 E 2 8 RD C78 4 20 CN Part No 107846 GREEN BROWN
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127. 9V DC battery 100 resistor coil ao oo Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Seta multimeter to read DC current The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures August 2006 Turntable Rotation Components 9 1 3 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly When removing a hose assembly 4 or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections REVC Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine Remove th
128. B PROCEDURES B 18 Test the Alarm Package if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm Descentalarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls O Result The flashing beacon should be on and flashing 2 Move the function enable switch to either side and activate the primary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Genie A TEREX COMPANY 3 28 Z 45 25 Z 45 25J REVC Move the function enable switch to either side and activate the secondary boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Z 45 25J Move the function enable toggle Switch to either side and activate the jib boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down
129. BR W 18 351 BR W 18 5 VOLT REF 16 R LG 18 16 R LG 18 358 LG BK 18 3 Ke 358 LG BK 18 oe rr CAM 32 ANA AUX PD1 4 361 16 150 DG W 18 150 DG W 18 37 ANA AUX PU1 es cine 5 361 R16 361 14 114 LB Y 18 114185718 BAT 2 392 R LG un 5 y 352 BR LG 18 1 1 ope REG 18 40 EGR PWM 24 74 GY LB 18 2565 360 BR PK 18 EGO 1 41EGR REC dos 26 O2 SENSOR 361 R 14 KC 2 359 GY R 18 359 GY R 18 ana 16 18 32 R LB 16 4 13 STARTER CONTROL SENSOR 355 18 STARTER 357 18 RELAY 151 LB BK 18 1511B BK 18 3170 018 32 RLB 16 D 1 15 STARTER IN INTERUP eran e 351 BR W 18 RIBAR J2 R EY 359 GYR 18 39 STARTER IN AUTOCRANK F 2 MED 342 LG P 18 342 LG P 18 1 850 Y BK 18 Z 361AR 16 COS gt paie 361AR 16 sie 15 BEINEN eaw c gt art 24 LOCKOFF SOLENOID 669 DG W 18 GO 25 458 18 core 22 34216 18 STARTER LOCKOUT FUELLOCKOFF 2 2120618 ae 9 326A LE O 18 926A LB O 18 1
130. Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Tag disconnect and plug the hydraulic hoses from the platform leveling master cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 11 Raise the boom to a horizontal position 12 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 13 Attach a lifting strap from an overhead 5 ton 5 000 kg capacity crane to the platform end of the primary boom for support Do not lift it Genie dee PartNo 107846 2 45 25 Z 45 25J 4 17 Section 4 Repair Procedures August 2006 PRIMARY BOOM COMPONENTS 14 Remove all hose and cable clamps from the underside of the primary boom 15 Support the rod end of the primary boom lift cylinder with a suitable lifting device 16 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Do not remove the pin 17 Ra
131. Crushing hazard The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Crushing hazard The upper pivot ACAUTION could fall when the number 1 arm is removed from the machine if not properly supported by the overhead crane 21 Using the overhead crane attached to the upper pivot raise the secondary boom assembly approximately 30 inches 76 cm 22 Inserta 4 x 4 x 11 inch 10 x 10 x 28 cm block between the number 2 arm and the boom rest Then lower the secondary boom assembly onto the block AWARNING Crushing hazard The secondary boom assembly could fall if not properly supported by the 4 4 11 inch 10x 10x 28 cm block Part No 107846 August 2006 Section 4 Repair Procedures REV B 23 Pull all of the cables and hoses out through the upper pivot CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 24 Remove the hose and cable covers from the top of the number 2 arm 25 Pull all of the hoses and cables out of the upper pivot and out through the mid pivot Lay the hoses and cables on the ground Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 26 Remove the pin retaining fastener from the number 2 arm pivot pin at the upper pivot Usea soft metal drift to remove the pin 27 Remove the upper pivot from the machine AWARNING C
132. EIS 8 e e s Lef ENGINE gt os e OIL PRESSURE SWITCH START BK p g 5 cs ER AUXILIARY RE N POWER C27AUX RD 2 POWER RELAY 1 E z 18 ganienz WH een M FUEL SOLENOID 55 88 52 SUPRESSION DIODE eur 1 E C21GN WH d gt HOUR METER gi 8 E a id DE IGNITION START RELAY D 1 g 1 Pili i R33STR BK P 8 ie gt 5 5 I 1 amp Loe 1 STARTER MOTOR L4 it Bi 2 amp Te AUXILIARY 5 8 5 RDF C27AUX RD Sec 5 AUXILIARY POWER RELAY o C7P 2 P23BAT WH C7B2 4 4 B cl NA 3 Sa 5 QU 5 8 2 gt lt C1P 2 C28TTA RD BK ER 05 17 C28TTARDIBK 25 us EEN TILT ALARM ud cx o N casg C133PLABURD C4B 1 BK BRN gt em t LEVEL SENSOR on p m H D e ee C3P 9 BK RD caa BK RD HORN RELAY ER 95 o5 o5 7 1 P22BAT BK c7B 1 P22BAT BK HORN m m D NA gt KR gt C132PLI BUWH C1B 12 2 Y 2 5 C134PWR GN C o 8 o o a N o i BRN 5 E 4 gw P 2 9 3 c s 9
133. England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures August 2006 rt This page intentionally left blank Genie A TEREX COMPANY 3 4 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of both pages to use f
134. GR GR o c 8 Se 4 3 p 2 mag Q 9 d a que 0 a 200 I lt lt lt 5 55 5 5 9 9 5 2 lt lt 2 SZ f dE T Y E e x lt lt NIN E 2 B 2558 228 38 528 o CC d T Ojo 4 RD RD BK 22A EI is a lt 8 iol 5 lt im x 3 255 amp x bs d del PROX WH 23 WH 23 E 2 I 5 885 H 4584 a 225 Saag 9 __ C z 5 1 e Esc Sot USS Jo Omz 8 Ze G BOX S320 RD RD ar 398 25 a c lt RD m 5 LI c c c za TT e o duc BE RD RD ER 6 gt Sch 96 m zi 5 5 Ee ol 5 S 2 5 5 2 S 8 WH CR4 BRN 58 5 7 T Lo SEI 5 z amp E ul o 2 r q 88 zi grz ien ed Solo BLS GBI Oo cle zm oou DES nr a a 25 0 e 2 255 uz lu mu 290 25 8 21 72 e lt z r2 j ezo 2 S SE v B58 a aa SES 5 58 RD RD g enie A TEREX COMPANY Part No 107846 Z 45 25 Z 45 25J 6 38 August 2006 Section 6 Schematics p
135. Genie Industries Service Department If this fault appears on your machine contact 51 2 ER veniae Genie Industries Service Department ME If this fault appears on your machine contact 51 3 FER higherthan Genie Industries Service Department 514 FPP1 lower than IVS Limit Not used If this fault appears on your machine contact Genie Industries Service Department If this fault appears on your machine contact 521 FPP Morused Genie Industries Service Department 522 FPP2 low voltage Not used If this fault appears on your machine contact Genie Industries Service Department 531 TPS1 signal voltage high The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 TPS1 signal voltage low 532 The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 533 TPS2 signal voltage high The 2 throttle position sensor wiring and or connections open or shorted OR there
136. Models E 4 Perform Engine Maintenance Deutz Models Section4 Rev RepairProcedures IntrOAUCHON PEE B Platform Controls 1 1 ALC 500Circuit Board 122 EE e PlatformComponents 2 1 Platform Leveling Slave Cylinder 2 2 Pl ttormiRotator u a a 2 3 Platform Overload System x Z 45 25 Z 45 25J Part No 107846 June 2012 p M n TABLE OF CONTENTS Section 4 Rev Repair Procedures continued B Jib Boom Components Z 45 25J 3 1 JIBBOOM 4 12 3 2 Jib Boom Lift Cylinder 4 13 Primary Boom Components 4 1 donee deeded 4 15 42 Piman BOOM e avra Ae ee 4 19 4 5 Primary Boom Lift Cylinder c ccccsceceeeeeeeeeeneeeeeneeeeeeeeeeeseeaeeesenaeeeteneees 4 21 4 4 Primary Boom Extension 4 4 23 4 5 Platform Leveling Master Cylinder 4 24 B Secondary Boom Components 5 1 Secondary Boom 4 27 5 2 Secondary Boom Lift Cylinders 4 32 B Engines 6 1 RPM Adjustment Ford and Deutz Models 4 33 6 2 Adjustment Perki
137. N A C40LSS C2P 2 4 N C12SBF BUWH C3P 12 O P24FS WH e C41RPM C2P 3 4 C30FWD WH 4 Q BRN e C1PBU RD C3P 1 gt WH BK 5 of of of of N 1 Ry e C2PBD RD BK C3P 2 of 5 C37STC BUBK C1P 11 RD WH C3P 3 a C36STCC BK 10 i T 9 2 WH RD 1 6 CAP BR 5 WH BK C3P 5 e T C29MS RD WH C1P 3 20 1 lt C35HS BK RD C1P 9 C34SA 1 8 C33STR BK 7 C27AUX RD C1P 1 C2P BK Tog 5 a JC1 3 OR 5 E e TNT JC2 4 RD J dE JC1 2 BRN B JC2 5 BK A bd 1 PY Y d JC2 3 OR e LE E JC1 5 YEL bd 5 E A JC2 2 ra 63 5 WH JC3 3 OR P JC3 4 BL d 1 JC3 2 BRN 5 1 DRE BLWH gt C28TTA RD BK H1 x i 5 ez A S e DRE lt 080 a C13LED BL RD e o C29MS RD WH x oi al E 8 a 8 Fd 11 RD BK L48 bd GR BK 1 a GR BK L4 MN mi m Fog RED TILT bog RED TILT C2P 5 1 RED 1518 iz i BRN Log im bog BRN M BRN A TEREX COMPANY Z 45 25 2 45 25 G TILT ALARM 6 64 Section 6 Schematics PLATFORM CONTROL
138. O 1981 09 Qu 98 v 8 91 36 1VNIWH3 L Part 107846 Mane Z 45 25 Z 45 25J 6 11 REV B M L LABEL DESCRIPTION CB1 CIRCUIT BREAKER ENGINE 15A CB2 CIRCUIT BREAKER CONTROLS 15A CR1 IGNITION START RELAY CR2 INGITION POWER RELAY CR4 HIGH IDLE RELAY CRS HORN RELAY HM HOUR METER KS1 KEY SWITCH 12 1 RED EMERGENCY STOP BUTTON R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS R14 UP DOWN SPEED RESISTER 7 5 OHMS TS51 AUXILIARY TOGGLE SWITCH TS52 ENGINE START TOGGLE SWITCH TS53 FUEL SELECT TOGGLE SWITCH TS54 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS64 RUN TEST TOGGLE SWITCH NOTE DASHED LINES INDICATE OPTION WIRES August 2006 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25 RD C Ford Models A UJ PLATFORM ROTATE
139. OU 5 e JC2 4 RD JC1 2 BRN ee E C1P GY i M E JC2 3 OR e LE JC1 5 YEL i JC2 2 BRN e JC3 5 gt o JC3 3 OR e E JC3 4 BL a JC3 2 gt i 2 9 DRE A BL WH C28TTA RD BK H1 x a 9 T a i DRE B Fad lt 8 C13LED BURD E C29MS RD WH P 8 m B o E zi a i RD BK L48 GR BK 1 GR BK L4 RED TILT RED TILT C2P 5 RED 1518 2 fe BRN itn BRN BRN A TEREX COMPANY Z 45 25 2 45 25 G TILT ALARM 6 52 Section 6 Schematics 55 CONTROL BOX PLATFORM CONTROL Perkins 404 22 Models JC3 DRIVE FORWARD REVERSE amp STEER LEFT RIGHT TS47 GENERATOR OPTION Platform Control Box Switch Panel Wiring Diagram Z 45 25 August 2006 L1 DRIVE ENABLE LED BURD DES3 J1 16 P25FS RD C9 3 RD 1518 BK C7P 1 BK J3 3 7 2 He BK C9P 1 se BL J1 5 2 WH J1 4 n BL J1 5 wu J1 13 BRN J1 14 gt BK li RD PDITERD wt oO x lt e uu gt P24FS WH 9 2 C35RPM BK RD 1 9 5
140. S zx 55 a a gt BR 8 8 MV P 7 C33STR 1 7 TEST RUN TEST SWITCH P ENGINE gt START 8 N e bel Q o ENGINE 5 888 o IT START 8 e 1 AUXILLARY POWER 4 ie C5 19 P23BAT WH FEH 16 PIN1 SE 32 5 5 11 C21IGN WH FEH 71 PIN21 EN _ 5 OR RD FEH 306 PIN24 B 5 5 BL WH FEH 658 PING u Ale E S GR FEH 458 PIN18 2 Ez o o an T 65 10 FEH 72 t 5 18 BK RD FEH 307A PIN23 ac a P20BAT RD FEH 361 PINS az amp GND BR FEH 570 PIN34 B 5 2 CA1RPM OR BK FEH 11 b yl IGNITION START DM C5 5 R33STR BK FEH 32 PIN15 RELAY EI ZE C33STR BK FEH 32 PIN13 oz 1 5 BL WH 787 5 3 a gt BI G a 5 um Gi BK FUEL PUMP a Q lt vga cz e an 5 S S C33STR BK e e ala 4 8 d 88 4 se E Je STARTER MOTOR 51 b ol 1 Ei EE e le 1 AUXILIARY EE EI e POWER A 6 27 C27AUX RD AUXILIARY POWER 210 amp AUXILIARY _ RELAY DE e POWER 1 1 C27AUX RD 1 1 BAT RD C28TTA RD BK BAT aie A AUXILIARY PUMP H 5 gt o 1 2 C28TTA RD BK 1 2 5 24 C28TTA RD BK WH Leo TUR AFABM x M i RD BK _ BRN E 4 RD C2P 5 C134PWR GR C2B 5 C5 17 P134TTS RD 5 LEVEL SENSOR 8 lt lecce ne
141. and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray TEREX Z 45 25 Z 45 25J DEN 2 Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 3 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 4 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The oscillate ACAUTION cylinder may become unbalanced and fall when removed from the machine if not properly attached to the overheadcrane 5 Remove the oscillate cylinder from the machine Part No 107846 August 2006 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boomin stowed
142. bolts Carefully remove the pump Models without hydraulic tank shut off valves Component damage hazard Be CAUTION sure to fill the hydraulic tank to specification and prime the pump after installing the pump Models with hydraulic tank shut off valves CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Part No 107846 August 2006 Section 4 Repair Procedures REV B 7 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electro proportional controller located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications
143. boom lift cylinder for support Do not apply any lifting pressure Use a soft metal drift to drive the barrel end pivot pin half way out Lower the barrel end of the secondary boom lift cylinder and let it hang down Use a soft metal drift to drive the rod end pivot pin half way out Remove the secondary boom lift cylinder from the machine AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Component damage hazard When CAUTION removing a secondary boom lift cylinder from the machine be careful not to damage the counterbalance valve at the barrel end of the cylinder TEREX COMPANY 4 32 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures Engines 6 1 6 3 RPM Adjustment Ford and Flex Plate Deutz Models Refer to Maintenance Procedure B 9 Check and Adjust the Engine RPM All Models 6 2 RPM Adjustment Perkins Models Referto Maintenance Procedure B 9 Check and Adjust the Engine RPM All Models Genie dec Part No 107846 Z 45 25 Z 45 25J The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Disconnect the positive battery cable from the battery AWARNING Electrocution hazard Contact with electrically
144. cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raisethe primary boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder barrel end pivot pin is above the turntable covers 3 Attach a 5 ton 5000 kg overhead crane to the primary boom for support PartNo 107846 Z 45 25 Z 45 25J 4 21 Section 4 Repair Procedures August 2006 PRIMARY BOOM COMPONENTS REV B 4 Raisethe primary boom with the overhead crane 10 Remove the primary boom lift cylinder barrel end slightly to take the pressure off the primary pivot pin retaining fasteners Do not remove the boom lift cylinder pivot pins pin 5 Supportthe rod end and the barrel end of the 11 Usea slide hammer to remove the barrel end primary boom lift cylinder with a second
145. damaged if it is allowed to fall if not properly supported by the lifting device CAUTION 10 Use a soft metal drift and drive the barrel end pin out 11 Carefully pull the cylinder out of the primary boom How to Bleed the Slave Cylinder 1 Simultaneously activate the boom up function and the platform level up function until the boom is fully raised 2 Simultaneously activate the boom down function and the platform level down function until the boom is fully lowered TEREX 4 8 2 45 25 Z 45 25J 2 2 Platform Rotator How to Bleed the Platform Rotator This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle Switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right Before serial number 24304 2 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom 3 Openthe top bleed valve on the rotator but do not remove it a top bleed valve b bottom bleed valve container d clear hose Part No 107846 August 2006 EE Move the function enable toggle switch to either side and hold the platform rotate toggle switch
146. drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level O Result The oil level should be even with the bottom of the side plug hole 3 Ifnecessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Install the plug s into the drive hub 5 Checkthe torque of the drive hub mounting bolts Refer to Section 2 Specifications 6 Repeatthis procedure for each drive hub Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES B 9 Check and Adjust the Engine RPM Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Ford LRG 425 EFI models The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department OR your local Ford dealer Ford DSG 423 EFI models The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contac
147. drive hubs by turning over the drive hub disconnect caps on each steer wheel hub 11 Manually rotate each steer wheel disengaged position engaged position O Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands and lower the machine AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST D PROCEDURES D 6 Replace the Hydraulic Filters Genie requires thatthis procedure be performed yearly or every 1000 hours whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns Perform this procedure with the engine off Hydraulic return filter 1 Openthe ground controls side turntable cover and locate the hydraulic return filter housing on top
148. e AUXILIARY PUMP 4 xx RA 3 a4 5 m RD o 1 gt x e 1 2 C28TTA RD BK C1B 2 C5 17 C28TTARDIBK WH TILT ALARM lt i a lt cu A RD 1BK BRN C133PLABL RD C4B 1 P9478 WH H 5 LEVE i En E DEN 4 x lt m z 25 g 8 RT Copa C46HRN BKIRD cao 9 C46HRN BK RD Inl HORN RELAY E e 95 o5 C7P 1 P22BAT BK C7B 1 22 C6 9 am HORN RA E OO gt 5 1 2 BUWH 018 12 2 gt gt 8 caps C134PWR GN 2 5 8 o o N BRN i x 8 D 5 JE 5 gt 8 88 oz amp e e5 5 D x 2 8 OR BK C52 Go C41RPM C2B 3 8 Pus C107AF WH a o 921 za 9 55 n g si p 5 1 77 i m S i ALTERNATOR i amp a oe 9 i ed n 9 88 23 2 8 MEM 1 M Uu EDEN T 94 8 lt lt P20BAT RD E RS RD C7B 4 gt e e ors 2 CN Lo Part No 107846 GREEN BROWN C3B amp C3P amp 2 45 25 Z 45 25J G lt 6 ANSI CSA Domestic machine add L48 6 33 Section 6 Schematics C28TTA RD BK Deutz F3L 201 1 Models Electrical Schematic Z
149. emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Perform this procedure with the key switch in the off position 1 Locate the run test toggle switch on the side of the ground control box 2 Pullout the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position Result The check engine light should turn on The check engine light should begin to blink REVA 5 Continue to hold the run test toggle switch in the test position and count the blinks Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Once a fault code has been retrieved and the rep
150. engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 Ford LRG 425 EFI Operator Handbook Genie TEREX COMPANY Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Part No 107846 Z 45 25 Z 45 25J CHECKLIST B PROCEDURES Section 3 Scheduled Maintenance Procedures August 2006 Checklist C Procedures C 1 Perform Engine Maintenance Deutz Models Deutz engine specifications require thatthis procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Openthe engine pivot plate latch and swing the engine pivot pl
151. essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover 3 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine Genie TEREX COMPANY 3 38 Z 45 25 Z 45 25J REVD Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Locate the fuel filter water separator mounted to the rear engine mounting bracket Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter water separator Loosen the vent plug located on the fuel filter water separator head vent plug main fuel line drain plug filter bowl filter element separator head Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely dra
152. flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Perkins models 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover 3 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine Genie TEREX COMPANY 2 45 25 Z 45 25J 3 11 Part No 107846 CHECKLIST A PROCEDURES Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Locate the fuel filter water separator mounted to the rear engine mounting bracket Visually inspect the filter bowl for water buildup Result If water is present in the filter bowl continue with steps 7 through 11 7 Loosen the vent plug located on the fuel filter water separator head gt VC H vent plug b drain plug c filter bowl d separator head Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Tighten the vent plug If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine See C 4 Heplace The Fuel Filter Water Separator Element Perkins Models for instructions on how to prime
153. from the underside of the primary boom 12 Attach a strap from an overhead crane to the cable track 13 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 14 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom TEREX Z 45 25 Z 45 25J REV B 15 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched CAUTION How to Remove the Cable Track Z 45 25J When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 2 Disconnect the cables from the platform control box 3 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 4 Remove the hose clamp on the primary boom bellcrank 5 Pull all of the electrical cables out of the plastic cable track Do not pu
154. hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift zu 15 18 ft Ibs 20 24 Nm 7 Relief valve 250 psi 17 2 bar AH Charge pressure circuit 10 12 ft Ibs 14 16 Nm 8 Solenoid valve 2 position 3 way 2 speed motor shift 10 12 ft Ibs 14 16 Nm 9 Orifice 0 030 inch 0 76 mm AJ sis Brake and 2 speed motor shift circuit 10 Solenoid valve 2 position 3 way AK Braking nes 10 12 ft Ibs 14 16 Nm 11 Check AL 2 speed motor shift circuit 10 12 ft Ibs 14 16 Nm 12 Orifice 0 025 inch 0 64 AM 2 speed motor shift circuit 13 Flow divider combiner valve AN Controls flow to flow divider Combiner valves 1 and 17 25 30 ft Ibs 34 41 Nm 14 Check esee AO Steer end drive motor circuit 10 12 ft Ibs 14 16 Nm 15 Orifice 0 052 in 1 32 MM Drive circuit 16 Check valve Steer end drive motor circuit 10 12 ft Ibs 14 16 Nm 17 Flow divider combiner valve AR Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 18 Check AS Non steer end drive motor
155. iei LLL LR REVH SPECIFICATIONS Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25 rate 200 minutes Engine coolant Capacity 7 7 quarts 7 3 liters Coolant temperature sending unit Temperature switch point 221 105 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 107846 Z 45 25 e Z 45 25J 2 11 Section 2 Specifications January 2011 SPECIFICATIONS REVH Machine Torque Specifications Platform rotator 3 4 10 center bolt GR 8 380 ft lbs 515 Nm 3 8 16 bolts GR 8 44 ft Ibs 60 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft Ibs 244 Nm Drive motor brake mounting bolts dry 110 ft Ibs 149 Nm Drive motor brake mounting bolts lubricated 80 ft lbs 108 Nm Drive motor and hubs Drive hub mounting bolts lubricated 180 ft Ibs 244 Nm Drive motor mounting bolts lubricated 55 ft Ibs 75 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY 2 12 Z 45 25 e Z 45 25J Part No 107846 January 2011 Section 2 Specifications REVH Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications requir
156. in the stowed position When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform 2 Disconnect the electrical connector from the jib boom platform rotate select valve manifold mounted to the platform support 3 Tag disconnect and plug all of the hydraulic hoses from the jib boom platform rotate select valve manifold Cap the fittings on the manifold and pull the hoses out through the platform rotator AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Removethe platform mounting weldment A TEREX CON REV B 5 Attach a lifting strap from an overhead crane to the platform rotator for support 6 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 7 Remove the pin retaining fasteners from both platform rotator pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down 9 Usea soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the machine 10 Slide both of th
157. lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence ofa potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J 3 1 Section 3
158. lt gt gt H SCH sis Teen C37SCW BUBK C1B 11 C637 C37SCW BL BK GTEER Sio em s E C36SCC BL C1B 10 6 C36SCC BL L ono pc H 46 0110 m I STEER LEFT 1 5 lt 0241 C242 p C6TRF WH RD C3B 6 n cos s lt lt 8 5 CSTRR WH BK C3B 5 D 4 TURNTABLE ROTATE 9 lt 5 SELECT RELAY e TURNTABLE ROTATE I Bras STAR WHEE He TURNTABLE ROTATE RIGHT e Ks C151 C152 e RATRL WH gt TURNTABLE ROTATE LEFT pase 4 4 c142 lt E E lag E PRIMARY BOOM so ww 5 2 SELECT RELAY g 8154 4 lt gt C124 c122 8154 4 gt gt lt RIPBU RD IER 5 PRIMARY BOOM PRIMARY BOOM UP igg 3 n E 318 ER BRN ce 6 1 12 2 gt 12 R2PBD RD BK LS gt PRIMARY DOWN lt B 062 13 1 0132 REN 4 1 e 1 C1PBU RD C3B 1 1 1 C3P 2 C2PBD RD BK C3B 2 meas RD WH C3B 3 Ados E z 12 C12SBF BLWH C3B 12 5 DEC 1 i 1 13 5 Cap C11SBD BUBK C3B 11 16 13 518 91 1 sl 2 C3P 10 C10SBU BL C3B 10 18 16 10 2 NS e SECONDARY BOOM B Ez SELECT RELAY eur e C181 C182 RIOSBUBL e SECONDARY BOOM 5 Aje SECONDARY UP DOWN gi R11SBD
159. procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie TEREX COMPANY Part No 107846 2 45 25 Z 45 25J 3 41 Section 3 Scheduled Maintenance Procedures August 2006 Checklist D Procedures D 1 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn wear pads may result in component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obta
160. select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle CHECKLIST B PROCEDURES Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position Move the fuel select switch to LPG Restart the engine and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Genie TEREX COMPANY 2 45 25 Z 45 25J 3 25 Part No 107846 Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES B 15 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brake
161. solenoid valve 10V DC 6 to 80 schematic items BP BU and BY 3 position 4 way directional valve 10V DC 6 to 8Q schematic items BF BM and CG 2 position 3 way solenoid valve 10V DC 61080 schematic items CC AF and AG Part No 107846 June 2012 Section 4 Repair Procedures REV E How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connecta 10Q resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 100 Genie part number 27287 The battery should read 9V DC or more when measured across the terminals Part No 107846 Z 45 25 Z 45 25J MANIFOLDS Seat lilh 5 100 9V RESISTOR BATTERY Am A AO METTE VU bea AA dedi d xr OE IUE M QE ac i multimeter
162. t E Doce i i 8 2 FLASHING BEACONS OPTION NOT VE kere EDS i E eae ee ee iei o EE 5 5 B 8 C34SA C34SA C5 22 E efa PLUG 8 8 Sr 555 6 GLOWPLUG g 8 3 EE OIL TEMPERATURE LED 5 8 566 C25PSR WH BK OIL PRESSURE LED Zu 858 5 o 2 8 52 8 C33STR BK 8 85 8 dE 8 5 m OIL TEMPERATURE SWITCH E88 352228 Ed e H ENGINE g START g BEBEBEBREIH 9 m 2 3 START e SES e 9 OIL PRESSURE SWITCH j ES E 2 m I 28 a mim E 5 55 u SE AUXILIARY C1P 1 C27AUX RD 1 e POWER RELAY 1 3 el KE EE ES FUEL SOLENOID 55 N 52 SUPRESSION DIODE x pr TONS 1 a 2 C21IGN WH 5 i HOUR METER as j 8 pto zi 735 gs IGNITION START RELAY 1 S D 1 M x EH 33666656655 i 2 R33STR BK 55 2 8 t A T ig 2 2 LN a 019 8 e 6 STARTER MOTOR 1 8 ES E EE AUXILIARY 5 m P C27AUX RD er 49 AUXILIARY POWER RELAY 8 2 P23BAT WH C7B 2 2
163. the primary boom 15 Attach a similar lifting device to the primary boom lift cylinder 16 Place support blocks under the primary boom lift cylinder 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom lift cylinder and primary boom will fall if not properly supported 18 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 19 Remove the pin retaining fasteners from the primary boom pivot pin 20 Remove the primary boom pivot pin with a soft metal drift then carefully remove the primary boom from the machine and place it on a structure capable of supporting it Crushing hazard The primary AWARNING boom could become unbalanced and fall when removed from the machine if not properly attached to the overheadcrane A TEREX CON Z 45 25 Z 45 25J How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom See How to Remove the Primary Boom 2 Place blocks under the barrel end of the primary boom extension cylinder for support 3 Remove the pin retaining fastener from the ex
164. to lock it in Always use a new cotter pin when installing a castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 201 1 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section Scheduled Maintenance Procedures August 2006 CHECKLIST E PROCEDURES REVD E 4 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 12 000 hours Pro
165. y RD WH C3B 3 1 lt 1 1 PECES C12SBF C3B 12 16 8 1 15 gZ C11SBD BUBK C3B 11 1 518 S gt 1 C3P 10 C10SBU BL C3B 10 18 D gt B 16 cop c 10 a 5 SECONDARY p lt S58 SELECT RELAY T sye C18 1 18 2 ev H R10SBU BL d e SECONDARY BOOM 1 Yo SECONDARY BOOM UP amp DOWN sid e C6 10 E 1 1 5 R11SBD BUBK e ms g 5 gt 1 EN SECONDARY BOOM DOWN a Com C194 19 2 P24FS WH i g 8 5 1 P24FS WH Sa 8 ee eeu C16PDRE OR RD 4 C6 16 BK6 2 Cem 26 BK 5 8 2 T x LS3 DRIVE ENABLE 3 8 I LIMIT SWITCH E 5 5 C2P 2 A 131 PRIMARY BOOM EXTEND EI DRIVE LIMIT SWITCH cna BK 6 Zu WH6 enz wus C102 RD C6 20 5 5 5 8 cna WH7 s 7 S 182 PRIMARY BOOM UP 5 1 UN DRIVE LIMIT SWITCH 1 4 1 D 8o 8 C2B 2 C6 40 OR 70108 2 2 C104 BK C10 1 5 154 SECONDARY BOOM UP oz ia 1 DRIVE LIMIT SWITCH 1 amp 0350 1 1 RER BEFEHL PERS SR 2215 7 C7PBE C3B 7 EXTEND e e BOOM 1 RET
166. 2 Specifications January 2011 SPECIFICATIONS Fluid capacities LPG tank 33 5 pounds 15 2 kg Fuel tank 17 gallons 64 4 liters Hydraulic tank 24 gallons 91 liters Hydraulic system 30 gallons including tank 113 6 liters Drive hubs 2WD models 17 fl oz before serial number 24690 0 5 liters Drive hubs 2WD models 24 fl oz after serial number 24689 0 7 liters Drive hubs Steer end 4WD models 17 fl oz 0 5 liters Drive hubs 48 1 17 fl oz Non steer end 4WD models 0 5 liters before serial number 23812 Drive hubs with brake 57 1 24 fl oz Non steer end 4WD models 0 7 liters after serial number 23811 Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 2 A TEREX COMPANY REV H Performance Specifications Drive speed maximum Stowed position 4 8 mph 7 7 km h 40 ft 5 7 sec 12 2 m 5 7 sec Raised or extended position 0 6 mph 0 98 km h 40 ft 45 sec 12 2 45 sec Raised or extended position narrow models 0 38 mph 0 6 km h 40 ft 70 sec 12 2 m 70 sec Gradeability Braking distance maximum See Operator s Manual High range on paved surface 3 to 6 ft 0 9 to 1 8 Boom function speeds maximum from platform controls Primary boom up 24 to 28 seconds
167. 2 Section 4 Repair Procedures EE MMR REV E MANIFOLDS 8 5 Jib Boom Platform Rotate Manifold Components before serial number 27001 The jib boom platform rotate manifold is mounted to the platform support Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way AD Platform rotate jib boom select 8 10 ft Ibs 11 14 Nm PartNo 107846 Z 45 25 Z 45 25J 4 53 Section 4 Repair Procedures June 2012 S MANIFOLDS REV E 8 6 Jib Boom Platform Rotate Manifold Components after serial number 27000 The jib boom platform rotate manifold is mounted to the platform support Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way Platform rotate jib boom select 8 10 ft Ibs 11 14 Nm G TEREX COMPANY 4 54 Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures ________ REVE MANIFOLDS 8 7 Turntable Rotation Manifold Components before serial number 27001 The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function 1 Counterbalance valve MM Turntable rotate right 2 Counterbalance valve NN Turntable rotate left e a PartNo 107
168. 200A Current draw maximum load 800A Alternator Output 95A 13 8V DC Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 0 900A Reserve capacity 25A rate 200 minutes 2 7 Section 2 Specifications January 2011 SPECIFICATIONS Deutz F3L 2011 Engine Deutz D2011L03i Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio Compression pressure Governor Valve clearance cold 142 cu in 2 33 liters 3 3 7 x 4 4 inches 94 x 112 mm 48 Q 2800 rpm 36 kW 2800 rpm 1 2 3 1500 rpm 25 Hz 2500 rpm 42 Hz 19 1 362 to 435 psi 25 to 30 bar centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COM 2 8 Z 45 25 Z 45 25J PANY REV H Lubrication system Oil pressure 20 to 44 psi 1 4 to 3 bar Oil capacity 8 5 quarts including filter 8 liters Deutz F3L 2011 Engine Oil capacity 9 5 quarts including filter 9 liters Deutz D2011L03i Engine Cil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 20 to 32 10W 40 Above 23 F 5 C 20W 50 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requiremen
169. 25 Z 45 25J Part No 107846 June 2012 p TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 9 Check and Adjust the Engine RPM All Models 3 20 B 10 Test the Ground Control Override 2 3 22 B 11 Check the Directional Valve 3 23 12 Test the Platform Self leveling 00 3 23 B 13 Test the Engine Idle 3 24 B 14 Test the Fuel Select Operation Ford Models 3 25 B 15 Test the Drive Brakes uk 3 26 B 16 Test the Drive Speed Stowed Position 3 26 B 17 Test the Drive Speed Raised or Extended Position 3 27 B 18 Test the Alarm Package if 3 28 B 19 Perform Hydraulic Oil Analysis 3 29 B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 29 B 21 Replace the Fuel Filter Element Perkins Models 3 30 B 22 Perform Engine Maintenance Perkins Models 3 32 B 23 Replace the Engine Air Filter Element Ford Models 3 32 B 24 P
170. 40 ft Ibs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm 6 1 O Component damage hazard When CAUTION installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged Ford LRG 425 EFI models Perkins models TEREX COMPANY 4 36 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures E REV B ENGINES 6 4 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Refer to Section 5 How to Retrieve Engine Fault Codes for your specific model of engine Use the Fault Code Chart within Section 5 to aid in identifying the fault Part No 107846 Z 45 25 Z 45 25J 4 37 Sec
171. 45 25J August 2006 C28TTA RD BK REVC CN ra BATGND e GROUND CA1RPM OR BK C2P 3 KT 3 m z 4 C30FWD WH C1B 4 C521 C30FWD WH BK LAD EDC FORWARD be lt 1 5 C31REV C1B 5 5 20 C31REV WHIBK BO BK BAN DRIVE EDC REVERSE 4 pm DRIVE MODE Si 5 RD WH 06 33 2 WH RD e TRAVEL ALARM OPTION TORO ez ED EDO ose enn Ne CDE3 BURD C26 1 C262 C82BRK WH RD 4 2 WHIRD 8 OPE BL H 19 m pos e cl BRAKE RELEASE VALVE P ierr DRIVE ENABLE FIGHT a C28 1 028 2 CDE2 BUBK Ex C1P 3 y C29MS RD WH 06 29 C29MS RD WH 5 fees EB E 1 g n C25 1 C252 19 E 7SCW giz BE DE C37SCW BUBK C1B 11 06 37
172. 46 Z 45 25 Z 45 25J 5 3 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine OO pump pump shaft pump coupler flex plate with raised spline engine flywheel 3 16 inch 4 8 mm gap Diesel Models 1 16 inch 1 5 mm gap Ford LRG 425 0 080 inch 2 mm gap Ford DSG 423 rop Oo Co 4 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm Section 4 Repair Procedures August 2006 ENGINES REV B 5 Install the pump and bell housing assembly Ford LRG 425 and Deutz models Torque the bell housing mounting bolts labeled C in sequence to 28 ft lbs 38 Nm Then torque the bell housing mounting bolts labeled C in sequence to 40 ft Ibs 54 Nm Ford DSG 423 models Torque the bell housing mounting bolts labeled A and B in sequence to 28 ft Ibs 38 Nm and the mounting bolts labeled C to 49 ft Ibs 66 Nm Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft Ibs 54 Nm and the mounting bolts labeled C to 70 ft Ibs 95 Nm Ford DSG 423 EFI models Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to
173. 4B 5 1 1 023 1 023 2 C18JD GR BK 8 C918 Ibi PLATFORM ROTATE RIGHT DOWN 5 BOOM JIB BOOM DOWN e 1 uP C6 17 C17 JU GR i PLATFORM ROTATE LEFT JIB BOOM UP C224 22 2 Yi RIGHT PLATFORM 6525 ROTATE RIGHT PLATFORM le l Lert ROTATE i Bu C129DABK c6 19 u DESCENTALARMOPTION e g P 1 C19J5V GRWH C4B 7 amp m 29 o Se E z 99 zz o 5 5 92 2 z 5 EZ o SE Equo WH gu ozo Omom Es 6929 tege JIB VALVE zzo aaan JIB BOOM VALVE Eist COGS EU j uljrig 5 Ss KIEO 5500 z sK 205 90600 gt p 2 ala 28 5 6 34 2 45 25 Z 45 25J PartNo 107846 August 2006 Section 6 Schematics Eu O ser Electrical Schematic Z 45 25J Deutz F3L 201 1 Models REVC C28TTA RD BK C28TTA RD BK August 2006
174. 5 I 5 11 C21IGN WH FEH 71 PIN16 N OR RD FEH 306 PIN24 8 5 E E BL WH FEH 658 PING 7 sn ai o a GR FEH 458 gt o On 9 22 C5 10 BL RD FEH 72 PIN7 5 18 BK RD FEH 307A PIN23 ar 2 5 8 A ET N GND BR FEH 570 PIN34 a C5 2 CA1RPM OR BK FEH 11 PIN2 5 IGNITION START C5 5 R33STR FEH 32 PIN15 RELAY E C135FP BL WH FEH 787A PINS E x BL WH 5 E EI BISEINTS FUEL PUMP 8 2 ojo START a N NIN D 1 i g i Nn a I 88 PATRE mo STARTER MOTOR 01 b wl SIEHE AUXILIARY BS e E C27AUX RD AUXILIARY POWER DI AUXILIARY RELAY uu az POWER or C27AUX RD E UOBTTARDIBK BAT RD ele AUXILIARY PUMP tL s 2 g Ka o f rf 2 C28TTA RD BK C1P 2 28 RD BK WH TEE M E RD 5 C134PWR GR C2B 5 4 P134TTS RD gt BAND LEVEL SENSOR m x v 1 lt 5 p P S Neb Copa C46HRN __ 9 C46HRN BK RD I DEREN Bott e NA C7P 2 P23BAT WH 5 m 1 7 1 22 BK C7B 1 P22HRN BK e PAGHRN BKIRD C6 9 g 8 Po gt e a x m alk 0286 5 e o 5 e 5 8 ALTERNATOR 5 4 gt FIELD FEH o i BAT RD CA1RPM OR
175. 5 R Y 18 conmo sies 355 GY W 18 931 avwi TPS2 253 DG W 18 Ma RETTET OIL PRESSURE DEN 29 317 GY O 18 b ERARE SWITCH 6 511 LG R 18 511 LG R 18 511 LG R 18 TERME 7 253 DG W 18 E 253 DG W 18 GREEN 253 DG W 18 OIL PRESSURE 26 OIL PRES 8 11 18 11 18 2 i 27 Sara Be 10258 0678 258067 18 AUX OUTA 5 7101818 710416 18 14 TA 8 __ EEE TZYBK 18 72 Y BK 18 ee 15 ric end GOV SELECT 1 24 GOV SELECT 1 a 17 1 SSC SC 2080798807 T1696 8K 16 SIE DER ROAD SPEED 35 ROADSPEED HOADSPEED 12 172 LE R 18 o E 17218 818 sp ROADSPEED 26 77 DB Y 18 E d 349 DB 18 ern 30 OVERSPEED Se 18 662 DG P 18 see 582 09 18 Se 945901618 lt 15201918 430191 Ze ae 2 epo BE 91205018 ee E 2 4610 18 4610 18 461018 usos L gt 669 DG W 18 aU BS 25k RS 230 FX 35 458 O BK 18 ___ dd 458 O BK 18 L DEA TWR SHD TRIM VALVE WE PLUG GROUND 77 DB Y 18 B B PLUG RELAY POWER 459041018 PLUG CAN 361 16 1 S61AR 16 662 DG P 18 D D PLUG CAN 4 WPTWR2 GY MTRTWR4 MTRSHD4 enie A TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 REVA ENGINE ECM CONNECTOR SPK SPK COILIB SPARK COIL2A GND SPK COIL2B SPK COILSA SPK COILaB UEGOS UE
176. 5 z b i z gE 88 z gl 559 i 5 52 z g gee E H coo 1 Nx o o 5 ii Bl ES oj 88 88 81 511 5 1 of ising 5 ze T2 HM 951 08 828g x BER 83 E E SEE 5 2 UTE SATE On we vell O 9 4 Qu 80 E HM 869 sas 9 wer wamodsy 07 G 55 ez o or cla 9 2 als SS O 598 908 9951 9 9 879 wave m t 820 5 2 sl a EIE d Sg LO ANM HOLWNELIY 1 85 505 ER 2 30 ke 9 avs oF XAHO 6 829 ess auna O O razo 3 Gud s OQ N zrHwa O E SE e Eege O a auma 6 819 o m elc E h h omamo ve 8 9551 HWE 8810 5 556 m 2 HMIG 22 39 Deg EUST ee mons O E i Zug 68 90 HUN OM O 26 99 5 m 9 810 n dnd AHVIIXDV 12 Q QUEE Lo 5 22 90 z 81 9 LC HOLIMS 3HnIVH3dW3lTO 5 a 8 B ald 5 Os HOIIMS3HnSS3Hd O 52 nn 2 SE i 5 M M 8 Ope SN OLSFHM 8 8 KO vz moato O DECH 0 8 g
177. 5A F3 10A F4 15A F5 15A A TEREX COMPANY 6 4 Z 45 25 Z 45 25J Part No 107846 2006 Section 6 Schematics Ford LRG 425 EFI Engine Wire Harness Section 6 Schematics August 2006 1 Ford LRG 425 EFI Engine Wire Harness REV A B C D E F G H J K L M N 6 361 R 16 361R 16 361R 16 361 R 16 361 16 wen 7 555716 555 T 16 FORD 8 557 BR Y 16 557 BR Y 16 road 9 58896 Sss RLB 16 Ej 5 de h 05 42 PIN 10 556 W 16 556 W 16 m Rm INJECTOR 1 INJECTOR 3 INJECTOR 4 INJECTOR 2 CONNECTOR 5 570 BK W 16 39 R W 18 359 GY R 18 16 WATER TEMP INJ6 AUX OUT 2 21 180 18 WATER Fan 19 198 DG O 18 AUX 1 Ge 20 358 LG BK 18 15 151 LB BK 18 151 LE BK 1511BBK 27 743 GY 18 307 BK Y 18 307 BK Y 18 25 IVS EDT 28 354 LG R 18 hl 354 LG R 18 359 GY R 18 17 307 18 570 Bi w 16 18 150 DG W 18 570 BK W 16 570 BK W 12 34 GROUND AUX ANA PU1 FPP2 EGR PWM EGR RECIRC POWER GROUND 16 114 LB Y 18 570 BK W 16 2 352 BR LG 18 23 360 BR PK 18 570 BK W 16 16 R LG 18 16 R LG 18 570 BK W 16 POWER GROUND 2 sn gous Bu _ ANARIN 13 359 GY R 18 _ __ 570 BK W 16 4 351 BR W 18 351
178. 70 270 300 430 470 640 710 790 890 1120 1240 1950 2190 74 5 101 6 115 122 149 120 162 162 176 203 217 230 244 366 379 406 420 13 14 23 37 57 1 3 1 108 4 9 1 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 4 8 12 8 4 8 7 5 3 7 1 1 7 1 m DI ia E METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual i Class 4 6 Class 8 8 Class 10 9 Class 12 9 2 DRY N 3 3 ER el ER c el ile ER ER i 1 m m A gt o ala a Oe Sa eo 15 716 132 155 176 lt Ser o A o EEE 44 N x lo So 9 2 a o N r c 00 8 g H 0 8 21125 81 110 108 147 600 458 622 612 830 536 727 715 970 562 762 583 791 778 1055 682 925 909 1233 2 14 Z 45 25 e Z 45 25J Part No 107846 20 crf co a cof gt lt A gt gt NI o A po NI N N kal od CPP ES O ol OJ 22 N o lal A aL ao E 4 10 09 gt olol A N lt A ayn
179. 818 11 RS 232 gps INJECTOR CYL 42 Rm FUEL PUMP R16 16 LPG WIPK 16 19 START IN AUTOCRANK TEMPERATURE iir 5 FUEL PUMP C135 eva 1 mm ow 4 5 FUEL PUMP RELAY INJECTOR CYL 4 ei STARTER STARTER RELAY CAN LPG oop 18 7 SOLENOID Ha TERMINATION orgs BRA 16 LOCKOFF KNOCK Qnae LBIPKI6 30 CONNECTOR Er Ea SENSOR DIAGNOSTIC CONNECTOR wie wis 18 18 86 R16 gue bes 8 PKEK 16 16 INJECTOR CYL 1 R16 NM R16 RIT 18 POWER RELAY 816 R16 RELAYED POWER Genie Part No 107846 CONNECTOR TEREX COMPANY Z 45 25 Z 45 25J 2006 Section 6 Schematics ___________________ Ge Ford DSG 423 EFI Engine Wire Harness C28TTA RD BK C41RPM C28TTA RD BK August 2006 C Ford LRG 425 EFI Models before serial number 30142 Electrical Schematic Z 45 25 Section 6 Schematics
180. 846 Z 45 25 Z 45 25J 4 55 Section 4 Repair Procedures June 2012 MANIFOLDS REV E 8 8 Turntable Rotation Manifold Components after serial number 27000 The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function 1 Counterbalance valve Turntable rotate right 2 Counterbalance valve Turntable rotate left e a TEREX COMPANY 4 56 Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures REV E 8 9 MANIFOLDS Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description 1 2 Spool valve Function Torque See Breather 20 25 ft lbs 27 33 Nm PartNo 107846 Z 45 25 Z 45 25J 4 57 Section 4 Repair Procedures June 2012 MANIFOLDS How to Set Up the Directional Valve Linkage Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lowerthe boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Failure to perform AWARNING this procedure on a level floor could com
181. 9 X er a SI UE EI BE lt AN Medi ES I 2a 5 L e d L 1 1 a 1 I 1 3 e 1 en 3 z RT R a I eem Tiss u 225 5 85 AE 1 an E greo EE H a si T La i CX 5 T 92 Jo a 5 N E TY e CT jw 5 2 i E H a He pec a lt Meses poene 1 E elo KS m 8511 85 pO ui 5 alej Si g n AD d EE 18 1 5 5 o 4 Pepe 4 5 d x 706 1 c EN 1 E Tet 3 inl 81155 S e 8 E ol 3 kcu i98 x d az E 5 i2 2 pee 1 uiu see lg oz Sem 2 is 5 lt S55 1 4 E 5511 zl 15 IN le er e s E Ke e K I ay Te ER aS pase fers ieee rn E T 8 S e a H 4 d a 1 gl E og z _ amp EE 5 N s I LEO 58 E 8 Soc uj c B di au ite a
182. 9 SIP 7 G2 E gl aala z a SES E x ale y 2 45 25 2 45 25 G Part No 107846 2006 Section 6 Schematics u i Electrical Schematic Z 45 25 Ford DSG 423 EFI Models after serial number 30141 Section 6 Schematics August 2006 ____________________________________________ ___ Ground Control Box Terminal Strip Wiring Diagram Z 45 25 Ford Models REV A GROUND CONTROL BK ALARM August 2006 BK ALARM BK Ground Control Box Terminal Strip Wiring Diagram Z 45 25 Ford Models Sectio
183. BK C2B 3 38 bai g gt 8 E 1 2 19 E c 1 xd dig s N ji m N 9 1 lt iiu S191 4 75 12 0 e 1 2 4 pm 8 2 oo LII P20BATRD F ee lt 5 xo 1 SE ee a N Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J G in the stowed position and the keyswitch off Section 6 Schematics Electrical Schematic Z 45 25 6 10 Ford DSG 423 EFI Models after serial number 30141 August 2006 REV A CN BATGND c7P 3 GROUND C41RPM OR BK C2P 3 lt 5 P C80FWD WH rx C1B 4 C521 CSOFWD WH RD SNBRN d DAVE FORWARD 1 5 WH BK ops 5 20 REV WH BK RD fJ BRN i lt e 1 DRIVE EDC REVERSE D amp e a DRIVE MODE 3 Sa RDWH C6 33 Com WHIRD i a
184. BK J1 2 RD J1 1 C18PRR GRIBK C4P 6 OR J1 11 x 1 12 N o oo t OLN C14PLU OR 2 5 a C15PLD C4P 3 D gt um Bz8t N ZUS RD Tage S ck d e 5 C9HRN BK RD C3P 9 5 250 o A 2006 Section 6 Schematics V M 8 Platform Control Box Switch Panel Wiring Diagram Z 45 25 Ford Models REV C C28TTA RD BK C28TTA RD BK August 2006 amp amp BROWN Electrical Schematic Z 45 25J Ford LRG 425 EFI Models before serial number 30142 Section 6 Schematics x x 55 5 P E 3 975 6 EE 8 1 9 BK RD C1B 9 ENGINE ke SPEED Low C2P 4 C128RPM OR RD C2B 4 9 5 8 8 D e LOWRPM FUNCTI
185. BUBK 5 5 2 2 1 SECONDARY DOWN amp a i ere e 11 2 24 5 WH poem e 1 gt y 8 2 E s ze 04 C16PDRE OR RD C4B4 06 16 BK6 2 C613 P26ESTP BK 8 2 Se 153 DRIVE ENABLE gt x y LIMIT SWITCH E 5 i gt C2P 2 151 PRIMARY EXTEND S lt lt o gt E DRIVE LIMIT SWITCH cua BK 6 wus wus C102 RD C620 2 T 5 x a P Ee 1 11 4 WH7 BK 7 152 PRIMARY UP 5 DRIVE LIMIT SWITCH 1 A 5 1 5 Si H So 8 C2B 2 C640 OR C103 BK 4 D 2 010 4 BK C101 BKS 154 SECONDARY BOOM i oz i DRIVE LIMIT SWITCH with a LA e 03650 Leg EN P22LS BK caP 7 y C7PBE BK 7 6 EXTEND e BOOM RETRACT Copa C8PBR BK WH C3B 8 5 16 1 i 2 e B Kee E eoe BOOM RETRACT e C8PBR BK WH 4 RABEN T 8 C174 2 C4P 2 C14PLU OR C4B 2 DOWN 1 e PLATFORM LEVEL i eur CAP 3 C15PLD OR BK 3 i C20 C202 E B 06 14 C14PLU OR P ipi PLATFORM LEVEL UP DOWN 9 PLATFORM LEVEL eur 0645 CI5PLD OR BK e t PLATFORM LEVEL DOWN 2
186. C37SCW C36SCC BL E 1 10 C36SCC BL 10 06 36 4 1 C241 C242 p 6 WH RD C3B 6 lt lt lt 2 8 CSTAR WH BK C3B 5 D 4 TURNTABLE ROTATE Ex 5 8 5 SELECT RELAY e TURNTABLE ROTATE BARR WIEN fs e TURNTABLE ROTATE RIGHT C151 C152 pee wi TURNTABLE ROTATE LEFT EE c142 BR e lt 18 BK 5 5 PRIMARY BOOM SE vor s 2 E 878 SELECT RELAY 8 igu a P gt 1 PHPSURD C124 C122 3188 5 PRIMARY a i PRIMARY BOOM ig Le gm zm ie 5 PBD E ano 2 lt EES E FRED RDIBK Jd PRIMARY BOOM DOWN lt cea C184 Cas Lesen passe 1 L _ s C3P 1 CIPBURD C3B 1 EES 2 C2PBD RD BK C3B 2 ex 3 Caper RD WH C3B 3 E amp 12 C12SBF BUWH C3B 12 Ek E 1 15 YEL z US 11 CI1SBD C3B 11 o 18 818 lt 91 gt 5 16 ewra so al 10 C10SBU BL C3B 10 15 12 5 15 eno 2c 10 3 ZEE e SECONDARY BOOM 8 A SU m m SELECT RELAY 1 lt sur HIOSBUBL SECONDARY BOOM UP Dic E e SECONDARY BOOM E NDA S DOWN d JE a 1 5 E 5 RITSBD BL BK BEN SECONDARY BOOM DOWN og jJ a ore e a cen 192 P24FS WH 5 5 8 5
187. C8PBR BK WH e T T i C4P 2 C14PLU OR C4B 2 p E Siet PLATFORM LEVEL our CAP 3 C15PLD OR BK CAB 3 i 20 1 C202 2 8 e Lee Lol e PLATFORM LEVEL UP m e o PLATFORM LEVEL i eur Ce15 C15PLD OR BK 16 1 PLATFORM LEVEL DOWN i 21 1 C212 zi 1 z Cape C18JD GR BK Cape FIGHT PLATFORM LET ROTATE caps C17JU GR 5 1 2 023 1 023 2 6618 C18JD GR BK B gaan PLATFORM ROTATE RIGHT E PLATFORM JIB BOOM DOWN ROTATE 1 e LEFT C17 JU GR fe i PLATFORM ROTATE LEFT i JIB BOOM UP B C224 C22 2 v YN x C525 1 GE ps cs cede 1 C129DA 6 19 ee j DESCENT ALARM OPTION 2 eco eure ee EE 1 5 08 Ig 5 a Zo e zz o x SE SOR zu Jrg 2209 8 Kaz 259 sior 90685 aa Ska nons lt Exum Saga 2 z COGS Sa 508 SIS ale 3 amp 5 gg W August 2006 Section 6 Schematics n Electrical Schematic Z 45 25 CE Models Deutz F3L 201 1 Models Section 6 Schematics August 2006 Ground Control Box Term
188. C9P 1 LI BL 01 5 WH J1 4 8 BL J1 5 alo OR J1 13 CE a BRN J1 14 S BK BK C39LP BL RD C2P 1 RD PDLITERD er S NR ee oO Mm ei H lt u 8 m a uim u gt d eeu Sy ni zo t 7 gi P24FS WH C9 2 D 2 RD getan E _ C128LS OR RD C2P 4 RD C C35RPM BK RD C1P 9 RD Ka SUM ____ _________ li 332 CWLITE RD C2P 12 Pic 3 AE RN eee C3P 4 DLITE WH 5 d 8 ES 26660 5 OOO __ 2224 i BE 333 g T ae 5 BS E RD BKH1 C33STR BK 7 ECCE D E EE RD HB Loo 21196 6 P25FS RD C9 3 GR WH GR WH 2 7 ____________________ ______________ 45 7__ x 5 25m 5298 PES D cd T BL RD DES J1 16 BL DE1 J1 6 _ BL BK DE2 J1 7 YEL J1 3 28 a OR 1 9 5 5 9 BRN J1 10 C29MS RD WH J1 8 59 T N OI Ww Fl 2 2 C27AUX RD C1P 1 8 Hovo E az DS gt O D 5 zu lt O UI 7 a a C8PBR BK WH C3P 8 gt oak ot299 C7PBE BK C3P 7 23882 000 Taxu We gt i C17PRL GR C4P 5 5 FEO di tr 19 5 GR WH C4P 7
189. Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES A 3 Perform Engine Maintenance Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good eng
190. E 5 1 C29MS RD WH Copa 66 29 C29MS RD WH CDE2 BUEK zo lt MOTOR STROKE x m I E JE x 8 8 g BL mour s 8 amp amp amp ig m C25 1 C252 yout 5 gt u BL C37SCW C37SCW 8 C1P 11 C1B 11 06 37 815 EZ 515 lt b STEER RIGHT E putet C36SCC BL c C36SCC BL 1P 10 18 10 x 8 GND Be D lt STEER LEFT lt 024 1 C242 1 4 6 C6TRF WH RD C3B 6 lt s lt lt 8 5 5 WH BK C3B 5 8 4 TURNTABLE ROTATE 0 lt e S SELECT RELAY e e TURNTABLE ROTATE s 15 ces EATER WEEE Me TURNTABLE ROTATE RIGHT e m 15 1 c15 2 PATREWH HE TURNTABLE ROTATE LEFT para C64 1 C141 Ci42 DX ig 6 lt g BS voir ES 3 gt 3 PRIMARY BOOM 158 P Sc SELECT RELAY 8158 gt gt 3 PI S EN c122 La ae eg ron ce d e PRIMARY BOOM UP 1 15 E m 12F 2 lt 12 zQ zu R2PBD RD BK ER 8 PRIMARY BOOM DOWN lt 8 06 2 C134 i 4 A T i zec C1PBU RD C3B 1 d 1 C3P 2 C2PBD RDIBK C3B 2 RD WH C3B 3 i ME PEE MI 12 C12SBF BL WH C3B 12 i 18 ec EK 1 15 la s gZ 08 11 C11SBD BUBK C3B 11 518 EZ 51684
191. E 11 1 BK amp _ WHS C102 RD C6 20 A 5 a Na E S E 11 4 WH 7 d BK7 cua LS2 PRIMARY BOOM UP 5 R DRIVE LIMIT SWITCH E 1 8 9 go c2B2 C640 C103 4 WHA C104 C104 5 154 SECONDARY BOOM UP 4 d 2 8 DRIVE LIMIT SWITCH 63506 1 e care ante P22LS C3P 7 C7PBE BK C3B 7 6 EXTEND e oe BOOM RETRACT C3P 8 C8PBR BK WH C3B 8 2 C16 1 16 2 i E g C67 C7PBE BK 8 5 e lpi e e RETRACT Ces BK WH 1 RETRACT C174 17 2 1 2 14 OR C4B 2 D gt lt e PLATFORM LEVEL uP C4P 8 C15PLD OR BK C48 3 20 1 20 2 2 8 m Siemon Il PLATFORM LEVEL UP 6 Down 1 o _ ____e PLATFORM LEVEL 06 15 C15PLD OR BK e PLATFORM LEVEL DOWN i 5 c21 1 c21 2 ET GRIBK 44 C2P 6 C129DA C2B 6 5 9 gt C4P 6 C18JD GR BK Cape oe DOWN Ae BOOM Te 5 C17JU GR C4B 5 2 023 1 023 2 1 g C6 18 C18JD GR BK 8 PLATFORM ROTATE RIGHT BOOK JIB BOOM DOWN ev C6 17 C17 JU GR e PLATFORM ROTATE LEFT JIB BOOM UP C22 1 C222 e
192. EK 8 5 CSTAR WH BK C3B 5 8 TURNTABLE ROTATE D s z 9 SELECT RELAY TURNTABLE BBTHRIWEUBK TURNTABLE ROTATE RIGHT e As C154 C152 d TURNTABLE ROTATE LEFT pee C64 14 1 14 2 4 Is EE X 3 ER 5 5 PRIMARY emis m gt gt 2 Ce SELECT RELAY 8154 xuw p Ee 1 12 1 12 2 5188 OR 5 PRIMARY BOOM See E d e P P ya a i leit RIMARY BOOM Ul ER BRN e 66 1 125 2 2 2 a 5 R2PBD RD BK IE 8 d e PRIMARY BOOM DOWN X o 06 2 C134 132 een 4 NRI s ge ee C1PBU RD C3B 1 lt C2PBD C3B 2 n C3P 3 y RD WH C3B 3 i lt 1 Ee 1 7 lt C3P 12 CI2SBF BLWH C3B 12 B E Ex v ig LE 3 C11SBD Cap 519 a lt 91 gt 5 ren i 10 C10SBU BL C3B 10 E z gt e 5 18 2 888 10 a 5 SECONDARY BOOM 8 E SELECT RELAY 1 1 H C184 18 2 d jefes A s SECONDARY BOOM RIOSSU BL d SECONDARY UP amp DOWN 81 8 UE 5 R11SBD BUBK 5 BRN a 5 11 gt 1 gi T SECONDARY BOOM DOWN ere 08 11 C194 0192 8 ER 5 P24FS WH oe 243 8 E gt ge et C16PDRE OR RD C4B 4 c6 16 BK 6 zo Cem 26 BK 8 2 y 133 DRIVE E
193. EREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES 7 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle 8 Swing the engine back to its original position and close the engine pivot plate latch 9 Install the engine pivot plate safety pin REVC B 10 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform red Emergency Stop button to the off position Start the engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle O Result All boom functions should operate Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 Augu
194. EREX COMPANY 4 40 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures EEE eee REV B HYDRAULIC PUMPS 5 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 Ford models Connect the LPG hose to the LPG tank and open the valve on the tank Perkins models Connectthe engine wiring harness to the fuel solenoid 7 Startthe engine from the ground controls and check for hydraulic leaks PartNo 107846 Z 45 25 Z 45 25J 4 41 Section 4 Repair Procedures June 2012 Manifolds 8 1 REV E Function Manifold Components before serial number 27001 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index Schematic No Description Item Function Torque 1 Proportional directional solenoid valve 3 position 4 way Secondary boom up down 16 20 ft Ibs 22 27 Nm Solenoid valve 3 position 4 way Bus Steer left right AAA 25 ft lbs 34 Nm Proportional directional solenoid valve 3 position 4 way Turntable rotate left right 16 20 ft lbs 22 27 Nm 4 Proportional directional solenoid valve 3 position 4 way E Primary boom up down 16 20 ft Ibs 22 27 Nm 5 Solenoid valve 2 position way E unm Primary boom e
195. EX 4 4 2 45 25 Z 45 25J MPANY REV B 8 Startthe engine from the platform controls and press down the foot switch 9 Startatimer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the machine function time with the function times listed in Section 2 Specifications Determine whether the function time needs to increase or decrease 11 While the joystick is activated adjust the max out setting to achieve the proper function cycle time Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed Each time the drive enable toggle Switch is momentarily moved the function speed will change in 2 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved O Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Part No 107846 August 2006 Section 4 Repair Procedures REV B How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joy
196. Electrical Schematic Z 45 25 Ford LRG 425 EFI before serial number 30142 6 7 Electrical Schematic Z 45 25 Ford 059 423 EFI after serial number 30141 6 9 Genie Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J xiii June 2012 TABLE OF CONTENTS Section 6 Rev Schematics continued Ford models continued A Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 11 B Ground Control Box Switch Panel Wiring Diagram 2 45 25 6 12 A Platform Control Box Terminal Strip Wiring Diagram 2 45 25 6 13 A Platform Control Box Switch Panel Wiring Diagram Z 45 25 6 14 C Electrical Schematic Z 45 25J Ford LRG 425 EFI before serial number 30142 6 15 A Electrical Schematic Z 45 25J Ford 059 423 EFI after serial number 30141 6 17 A Ground Control Box Terminal Strip Wiring Diagram Z 45 25J 6 19 B Ground Control Box Switch Panel Wiring Diagram Z 45 25J 6 20 A Platform Control Box Terminal Strip Wiring Diagram 2 45 25 6 21 Platform Control Box Switch Panel Wiring Diagram Z 45 25J 6 22 Deutz F3L 2011 models Ele
197. FORWARD P C31REV WH BK n s 1 5 C1B 5 05 20 WH BK EDC REVERSE e u ee Eee i DAVE MODE 575 RD WH C6 33 WHIRD i TRAVELALARM OPTION 5 BURD 5 i C261 C262 3 ri CDE1 BL C1P 6 C32BRK WH RD C1B 6 C6 32 C32BRK WH RD E gt 7 lt e il BRAKE RELEASE VALVE P ES lt e RIGHT DRIVE ENABLE 4 C282 px 1 C29MS RD WH CiB a 06 29 C29MS RD WH DEZ zo lt 4 MOTOR STROKE x 1 8 le gt lt 6 5 T d H amp 2 vor a gt 25 1 C252 4 al m gt 5 1 11 C37SCW C1B 11 Can C37SCW BUBK Sio 4 7 STEER RIGHT ra pwr 24 98 13 E 1 10 C36SCC BL 10 C36SCC BL 15 ap 2c 2 D cese k e STEER LEFT lt C241 C242 6 C6TRF WH RD C3B 6 lt lt lt 2 C3P 5 CSTRR WH BK C3B 5 8 TURNTABLE ROTATE 0 lt SELECT RELAY e H E RIGHT E TURNTABLE ROTATE BITRA d e TURNTABLE ROTATE RIGHT LEFT 8145 cos 1 e s 15 1 15 2 Lj MEN 8 a lt lt lt E gt gt e TURNTABLE ROTATE LEFT a 14 1 Ci42 DX is iz Ee 5 k BK a g PRIMARY BOOM 5 15 2 m gt 2 FE 38 SELECT RELAY yzy gt Biga UU D s ou PRIMARY BOOM a d ES RS S e 5 lt lt u d B 2 i g PRIMARY
198. Ford Models Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDIpart number 1060020 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 Checklist B Procedures B 1 Inspect the Battery Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connecti
199. GC 5 31V10H S1SVLNYNL 9 D NEHM 5860 z X8 HM 98 SEO oo GC E 7041409 WOO8 AHVWIHd E 1951 9 0 E HOH 08 2640 geet 9 z Noos 2 O 1981 48 0H 2 89 g 8 1 260 WOOS AHvWiHd 1951 E O raeo 98 81 36 8 TWNIWHSL 5 2 o a gt 49098 N d 3 InGOW LYVLS NOLINDI 30A 2 21 lt E OD E o H 25 LInW4 SS3Hd HO dWAL OL a CEET 8 2 9 8 8 HONS 6 SEBES e E AINO 5 9 201 dwar 8 0000000 95588 a I o AINO 195310 MS 2 4 8 HE 9 aanva s zi 2 um Md om v indNilMVIS wy pue e Z lt AqueB z Via AAY LUVAS HAOW3H OL raya Part No 107846 A TEREX COMPANY Z 45 25 2 45 25 G 6 48 Section 6 Schematics August 2006 Ground Control Box Switch Panel Wiring Diagram Z 45 25 REV B Perkins 404 22 Models
200. GOC UEGOP UEGPR AUX ANA PDI FRP AUX ANA PD2 14 DG P18 WIPK 18 IGNITION COILS August 2006 Section 6 Schematics 816 HO2S 1 Y BK 18 DGP 18 18 oven d 08018 GYN 18 BKLG 18 Ford DSG 423 Engine Wire Harness D HO2S 2 GY R 18 pun es D BRAB 18 Gym 18 TWR GASOLINE gt cani eH CAN2 AUX ANA PD3 715 OLG 18 a eil 19 18 DG P 18 OG 18 LG R18 SVEXT 1 EGO EGO2 MAP AUXANAPUDS Q GYR18 GYLB 18 GYN 18 FH LG BK 18 25 GY18 CRANK p DBL 18 21 GYR 18 a 18 DEE SPEED LB IS 4 GY18 18 man GY R 18 GROUND INTERFACE MTRTWR4 BR16 B A FORD 42 PIN 2 CONNECTOR _ OP RING BR 16 seen 4 gt 3 5VEXT2 LER 48 svATN2 Ben EI LH LGIBK 18 ef 35 ROADSPEED PULSE IN TAB 18 TAB 18 TH DE Govt OIL PRESS
201. Genie Section 5 Fault Codes August 2006 FAULT CODES Control System 3 How to Retrieve Control System Fault Codes At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes Perform this procedure with the 4 engine off the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Open the platform control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious 5 injury Remove all rings watches and other jewelry 2 Locate the red and yellow fault LEDs on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap Genie A TEREX COMPANY REV A Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second When the red LED is f
202. H whee N 8 0360 1 1 EE LP EMEN 4 P22LS 7 S C7PBE BK lt C3B 7 6 EXTEND e RETRACT 8 C3B 8 5 m i C164 c162 8 ez C7PBE 8 BOOM EXTEND P bcEND T eoe BOOM RETRACT ces 11 BOOM RETRACT B C174 C172 a 2 C14PLU OR 2 8 9 DOWN e PLATFORM LEVEL e uP 3 C15PLD OR BK CAB 3 x 20 1 20 2 8 __0014 Jo PLATFORM LEVEL Down eo PLATFORM LEVEL i eur 06 15 C15PLD OR BK i PLATFORM LEVEL DOWN C211 C212 a 1 i C4P 6 C18JD GRIBK C4B 6 RIGHT PLATFORM u g 9 7 ROTATE C17JU GR C4B 5 1 C2341 C232 2 06 18 C18JD GRIBK B daer 191 PLATFORM ROTATE RIGHT E PLATFORM JIB BOOM DOWN LEFT ce Ci7JUGR 1 PLATFORM ROTATE LEFT JIB BOOM UP a C22 1 C222 xe C525 e C129DABK 19 DESCENTALARMOPTION 2 2 1 tr 5 SE o9 2 ro SZ Ho lt E s zz o x Bea gt 6 lt SF gu 2500 ozo 252 559 Z 505 NOx gr 0006 x SEG 2559 lt mm lt
203. I ei 1 een 4029 2 E s ze ona C16PDRE OR RD C4B4 C6 16 BK 6 3 wus C6 13 8 153 DRIVE ENABLE P26ESTP 8 2 gt e gt x LIMIT SWITCH o 2 1 5 C2P 2 151 PRIMARY BOOM EXTEND lt o gt 5 DRIVE LIMIT SWITCH cna BK 6 2 wus 2 1 2 RD 6 20 5 S X 8 E 8 KEE 1 11 4 WH 7 1 Zen BK 7 11 3 152 PRIMARY BOOM UP i E La DRIVE LIMIT SWITCH 1 8 x 5 3 4 5 5 C2B 2 C6 40 OR C10 3 4 1 WH4 1 4 10 1 5 134 SS oz e g i DRIVE LIMIT SWITCH whee 1 amp E e 03650 1 P22LS 7 lt C3B 7 d 6 EXTEND e BOOM RETRACT C3P 8 C8PBR BK WH C3B 8 5 zi i C164 C162 C67 C7PBE BK 8 e BOOM EXTEND EXTEND e BOOM RETRACT ces 11 RETRACT B 017 1 017 2 2 2 C14PLU OR C4B 2 6 DOWN PLATFORM LEVEL uP 3 C15PLD OR BK C4B 3 20 1 C202 8 e LLL DEn EE PLATFORM LEVEL UP PLATFORM LEVEL SE E ORBK PLATFORM LEVEL DOWN i C214 021 2 GRIBK 44 1290 GRIBK C2P 6 C129DAG eme C4P 6 C18JD GRBK C4B 6 DOWN lt ee m o JIBBOOM 1 C4p 5 C17JU GR C
204. IMARY BOOM COMPONENTS 4 Raise the primary boom to a horizontal position 5 Remove the hose and cable cover from the upper pivot 6 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin Then lower the cylinder and let it hang down Component damage hazard CAUTION When lowering the master cylinder down be sure not to damage the master cylinder hoses or fittings 7 Locate the primary boom drive speed limit switch inside of the upper pivot 8 Remove the primary boom drive speed limit switch mounting fasteners Do not disconnect the wiring 9 Locate the primary extension boom drive speed limit switch inside of the extension boom 10 Remove the primary extension boom drive speed limit switch mounting fasteners Do not disconnect the wiring 11 Pull the limit switch and the wiring out of the extension tube and move it out of the way 12 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures August 2006 PRIMARY BOOM COMPONENTS 13 Remove the hose clamp at the pivot end of the boom 14 Attach a 5 ton 5 000 kg overhead crane to the center point of
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206. ISIN die Zu m Al OQ 69 Quae j co A VIN 5 9 DEEN AB E A A A E o S gt a a o A 5 E A N NI A gt gt N August 2006 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Boomin stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation
207. J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 4 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 5 Remove the center turntable cover retaining fasteners Remove the center turntable cover from the machine 6 sure that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 30 80 7 ei 2 9 10 Bolt torque sequence before serial number 23332 10 1 15 18 30 17 OS 2 20 14 16 2 9 Bolt torque sequence from serial number 23332 to 27000 Part No 107846 CHECKLIST D PROCEDURES 1 Counterweight 18 6 13 3 10 4 oe 9S 86 015 o o 169 07 2 9 12 14 5 17 Bolt torque sequence after serial number 27000 7 Startthe engine from the ground controls 8 Raise the secondary boom and remove the safety chocks 9 Lowerthe boom to the stowed position 10 Remove drive chassis covers from both the steer end and the non steer end of the machine 11 Remove the lower chassis cover mounting fasteners from inside of the drive chassis if equipped 12 Remove the lower chassis cover to access the lower turntable bearing bolts under the drive chassis Genie TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST D PROCEDURES
208. K C3P 11 1 a T a e C40LSS OR C2P 2 4 A ae 125 BL WH 12 O 5 P24FS WH m CA1RPM OR BK C2P 3 a C30FWD WH 4 Q BRN C1PBU RD C3P 1 gt WHIBK 5 af of af ef 5 N e C2PBD RD BK C3P 2 of of a v co a C37STC BL BK C1P 11 j N e RD WH C3P 3 C36STCC BK C1P 10 e 1 C32BRK WH RD 1 6 A BR z 5 WH BK C3P 5 a C29MS RD WH C1P 3 73 2 2 C3P GR 6 J C35HS BK RD C1P 9 2 C33STR 1 7 C27AUX RD C1P 1 C2P BK 5 a o y JC1 3 OR e LE 5 JC2 4 RD T JC1 2 BRN e N SC n C1P GY JC2 3 OR e e JC1 5 YEL N JC2 2 BRN e a g 4 JC3 5 T 510 JC3 3 OR e a EN JC3 4 BL Pd d LO JC3 2 BRN 5 DRE ABLWH C28TTA RD BK H1 x NI e 5 a DRE BL BK lt c C13LED BL RD e E o C29MS RD WH o B E lt 2 RD BK L48 GR BK C4P 1 gt BE GR BK L4 r af E lt RED TILT RED TILT C2P 5 RED 1518 BRN CN 1 N N Section 6 Schematics August 2006 Ford Models Platform Control Box Switch Panel Wiring Diagram Z 45 25J REV A
209. LATFORM gp 1 C525 Tp e e MOHT PLATFORM stl LP zn e LEFT ROTATE i 1 C129DA C619 S e peo T DESCENT ALARM OPTION Wil 1 2 scie P cL 1 C4P 7 C19JSV GR WH d 3 E o9 2 z gt Q Ho na az 3 z z 5 ood ET gt lt 5 o BK WH zu oz9 St Omom ES o 2 JIB BOOM VALVE JIB BOOM VALVE 552 5064 x 5 i SB oF oy a mmm OTEO 9a 2 9066 g ons fle z 38 N SIS W 6 57 A TEREX COMPANY Z 45 25 Z 45 25J G Part No 107846 August 2006 Section 6 Schematics A I T Electrical Schematic Z 45 25J Perkins 404 22 Models Section 6 Schematics August 2006 Do M P 3H c Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Perkins 404 22 Models REV B August 2006
210. LITE RD C2P 11 RD BK H1 C33STR BK 7 5 Weil T e ME NK CIEN _ P25FS RD C9 3 e KSE ao NECNON 2 7____ 5 A sag SE E a a rai BURD DES J1 16 C34SA BK WH C1P 8 BL DE1 J1 6 026 KO 93 2 0 oa T 2 BL BK DE2 J1 7 YEL J1 3 O 88 OR J1 9 228 BRN 1 10 C29MS RD WH J1 8 ON F s vn EG P gt C27AUX RD C1P 1 gt m 990 38 gt p 2 lt 8 55 BRN lt 55 9 WH JIB WH JIB gt GR BK 44 C2P 6 M Pz 8 tr a m on P OO Se PS Oc 29 C8PBR BK WH C3P 8 om Ben C7PBE BK C3P 7 m bee S 5 5 2 5 C17PRL GR C4P 5 C19JSV GR WH 67 vo C19JSV GR WH 7 J1 2 RD J1 1 C18PRR GR BK C4P 6 OR J1 11 I BRN J1 12 P24FS QI C14PLU OR 2 208 Fei lt a z Zu C15PLD OR BK C4P 3 zuo gag RD m z lt gt E 9 25 C9HRN BK RD C3P 9 5 9 4 August 2006 Section 6 e Schematics Platform Control Box Switch Panel Wiring Diagram Z 45 25J Perkins 404 22 Models REVD REAR RIGHT DRIVE MANIFOLD June 2012 Section 6 Schematics
211. LUG 505 GLOW PLUG C26TSR WIRD COOLANT TEMPERATURE LED C 3 Sof C25PSR WH BK OIL PRESSURE LED 90 2 u Sg 28 5 55 5 o zo 8 52 385 gla g B E C1P 7 C33STR BK C1B 7 amp 5 ry 0514 amp COOLANT TEMPERATURE SWITCH 2 6 5508 ale 4 ENGINE START g 855 8 8 all e e e e E e 5 16 OIL PRESSURE SWITCH e EN a g 8 2 P I gi a gg 5 5 55 RE AUXILIARY 8 1 C27AUX RD C1B 1 POWER RELAY C21IGN2 WH cen ole gt FUEL SOLENOID 55 N 9 e SUPRESSION DIODE Y x 8 C21IGN WH HOUR METER 2 E ES 8 AE d E gs IGNITION START RELAY 1 8 2 E mop PW 1 R33STR BK 5 5 Sg 8 N 2 E IN 5 52 LA A 1 _ ef 49 STARTER MOTOR zi i g 2 8 tie esc aei AUXILIARY N B C27AUX RD R t 0627 AUXILIARY POWER RELAY D 8 z Gp sient Bie 1 1 E C7P 2 P23BAT WH C78 2 E 16 5 AUXILIARY PUMP 4 B E Lee ee eee 9 d NA 8 a4 E N n 8 8 EE T 3 e 1 2 C28TTARD BK C1B 2 C547 2 RD BK WH TILT ALARM X E TUO pog cic
212. NABLE e gt 1 LIMIT SWITCH E 5 gt C2P 2 E 151 PRIMARY BOOM EXTEND ES 4 DRIVE LIMIT SWITCH cna BK 6 wus C102 RD C6 20 A 8 Va N 1 8 iip or aeo D ge i cna WH 7 7 3 132 PRIMARY BOOM UP 5 1 zen DRIVE LIMIT SWITCH o v 9 5 e 4 f 8 C2B 2 06 40 OR BK 4 C104 BK C10 1 BK 5 LS4 SECONDARY BOOM UP os 1 me DRIVE LIMIT SWITCH whee RON 03650 qe i pue ee P22LS C3P 7 C7PBE BK C3B 7 6 EXTEND e eoe BOOM RETRACT C3P 8 C8PBR BK WH C3B 8 3 m C16 1 c16 2 B C67 C7PBE BK 8 EXTEND o oe BOOM RETRACT Ces C8PBR e RETRACT 17 1 c r2 o C4P 2 C14PLU OR C4B 2 NY D gt lt 9 PLATFORM LEVEL uP C4P 3 C15PLD OR BK C4B 3 T C20 1 C202 B 2 8 4 PLATFORM LEVEL UP DOWN eoe PLATFORM LEVEL eur c6 15 C15PLD OR BK e PLATFORM LEVEL DOWN H C21 1 C212 7 N gt C4P 6 18 0 GR BK C4B 6 e RIGHT PLATFORM g C17JU GR C4B 5 023 1 C232 g C6 18 C18 D GR BK B gt i PLATFORM ROTATE RIGHT re PLATFORM JIB BOOM DOWN eer ROTATE C6 17 C17 JU GR PLATFORM ROTATE LEFT JIB BOOM UP C224 C22 2
213. OM UP 5 1 DRIVE LIMIT SWITCH 1 o a 3 3 ST 59 IET 5 C2B 2 06 40 OR 0103 BK 4 0104 C10 1 5 LS4 SECONDARY BOOM UP 4 oe EZE I CR 1 DRIVE LIMIT SWITCH whoo 1 amp e 0356 Br 2215 C3P 7 C7PBE BK C3B 7 EXTEND e BOOM RETRACT C3P 8 C8PBR BK WH C3B 8 2 1 C16 1 16 2 D m m g C7PBE 8 T f BOOM EXTEND EXTEND RETRACT C68 C8PBR BK WH ICE BOOM RETRACT C174 17 2 8 2 C14PLU OR C4B 2 7 6 DOWN e PLATFORM LEVEL eur C4P 3 C15PLD OR BK C4B 3 I 20 1 C20 2 m 1 B 2 1 i p mE Il PLATFORM LEVEL UP Down e PLATFORM LEVEL 1 C645 C15PLD OR BK e 1 o PLATFORM LEVEL DOWN i a I 21 1 C212 E GR BK 44 C2P 6 C129DA GR BK C2B 6 A i 2 5 9 i gt Cape C18JD GR BK C4B 6 DOWN e Boo pe g ow 5 C17JU GR C4B 5 i C231 C23 2 1 1 1 2 Cem C18JD GR BK 8 t come d PLATFORM ROTATE RIGHT e A3 BOO JIB BOOM DOWN ev 06 17 C17 JU GR e e PLATFORM ROTATE LEFT JIB BOOM UP il 22 1 C22 2 B RIGHT 5 e PLATFORM 2 C5 25
214. ON 8 A HIGH Rpm ENABLE 3 a PIT Ss ee E KIRMES H ee P ra e S a Rom o ru eret eres ka aav s Poe Sv e ethos C Pw Y eire ei ewe e e er ge e PIE 5 o GENERATOR i g C2P 7 GRWH C2B 7 65 12 CASGEN GR WH GENERATOR OPTION EE EE EENAA PAIESE PERRO IE DP AOE NOII AN E i pe ue cop aaa ee E EE 3 C3P 4 DLITEWH CH 5 V ome 8 6 DRIVE LIGHTS lt 15 WORK LIGHTS C4B 12 RD Is e 1 6 DRIVE LIGHT OPTION 2 E V 2 EIS lt C4B 11 RD 3 S ens i 6 C2P 12 HO C2P 10 u ras 1 ig 5 8 2 5 u WORK LIGHT OPTION iow E E N rude pert eet SES HE c vA AN E LE S B C2P 11 C2P 9 NEE E EE EE 1 21 d i 1 1 91 1 P134BAT RD E 8 gu FLASHING BEACONS OPTION p EL eee eee tee eek eee e M nn C128RPM OR RD 2 C2P 1 C39LP BURD C2B 1 2 P e FUEL SELECT m cas 8 C211GN WH e HOUR METER 2 8 CHECK ENGINE 9 FUEL SELECT cs C108ESL BL WH 2 56 B S gt 8 a ai BR amp
215. OOM COMPONENTS Z 45 25J REV B 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Supportthe jib boom lift cylinder with a suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The jib boom AWARNING could fall when the barrel end pivot pin is removed if not properly supported by the overhead crane 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane TEREX COMPANY 4 14 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures REV B 4 1 Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and ho
216. OSE pe ES GR BK C19JSV GR WH BK J1 2 C19JSV GR WH 7 RD J1 1 C18PRR GR BK 6 OR J1 11 BRN J1 12 7 6 5 4 3 P24FS WH GR Vd WH lt TS7 JC2 PRIMARY BOOM UP DOWN C14PLU OR 2 amp TURNTABLE ROTATE LEFT RIGHT C15PLD OR BK C4P 3 C9HRN BK RD 9 PLATFORM ROTATE RD RD RD RD 999 PE 4 RD 3 z e CH I 2 DASHED LINES INDICATE OPTION WIRES Mane 2 45 25 Z 45 25J 6 32 PartNo 107846 August 2006 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Z 45 25 Deutz F3L 201 1 Models REVC C28TTA RD BK C28TTA RD BK August 2006 Electrical Schematic Z 45 25J Section 6 Schematics Deutz F3L 2011 Models
217. Ouen Steer 25 ft lbs 34 Nm 16 Relief valve 3200 psi 220 6 bar Pass System relief AAA 20 ft lbs 27 Nm 17 Flow regulator valve 0 1 0 38 L min Qus Primary boom load sense Circuit 20 ft lbs 27 Nm 18 Shuttle valve Fus Primary boom 4 5 ft lbs 5 7 Nm 19 Flow regulator valve 2 GPM 7 6 Boom extend retract circuit 20 ft lbs 27 Nm 20 Flow regulator valve 0 4 1 5 L min p Jib boom and platform rotate nn ee 20 ft lbs 27 Nm This list continues Please turn the page Genie TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012 MANIFOLDS REV E AoA KA ere SIE XG AC AB amp 9 AA EM D DM ay GIG 43 Z 45 25 Z 45 25J PartNo 107846 Section 4 Repair Procedures June 2012 MANIFOLDS Function Manifold Components before serial number 27001 continued Index Schematic No Description Item 21 Needle valve 22 Relief valve 2500 psi 172 bar
218. P BK 5 S 5 i JC1 3 OR e JC2 4 RD A JC1 2 BRN e JC2 5 BK 1 P GY d JC2 3 OR e E JC1 5 YEL i JC2 2 BRN a i e JC3 5 o JC3 3 OR i JC3 4 BL q n JC3 2 S A DRE ABL WH C28TTA RD BK H1 x S o a DRE B BLIBK A g 5 C13LED BURD e E 5 C29MS RD WH 8 s g i 3 E 5 i RD BK L48 il 1 lm GR BK 1 Cs GR BK L4 RED TILT RED TILT C2P 5 RED 1518 Es BRN BRN BRN Part No 107846 19 18 CONTROL CABLE 2 45 25 Z 45 25J TILT ALARM 6 13 Section 6 Schematics Ford Models PLATFORM CONTROL TS47 Platform Control Box Switch Panel Wiring Diagram Z 45 25 August 2006 REV A HARNESS TO CONTROL BOX 6 14 MeNe 2 45 25 Z 45 25J NOTE DASHED LINES INDICATE OPTION WIRES Part No 107846 RD LS18 BK C7P 1 BK J3 3 STAT 2 MZ ies BK
219. Primary boom down 24 to 28 seconds Secondary boom up 24 to 28 seconds Secondary boom down before serial number 27001 38 to 42 seconds Secondary boom down after serial number 27000 24 to 28 seconds Turntable rotate 359 primary boom retracted 62 to 68 seconds Z 45 25 e Z 45 25J Part No 107846 January 2011 Section 2 Specifications REVH Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Chevron Rykon MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron lll oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index greater than 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below O F 18 Use Shell Tel
220. Proceed to step 9 Result The overload indicator light is off at both the ground and platform controls and the alarm does not sound Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Testall machine functions from the platform controls Result All platform control functions should not operate PartNo 107846 Z 45 25 Z 45 25J PLATFORM COMPONENTS 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls O Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor O Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls O Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls O Result All platform control functions should operate normally Section 4 Repair Procedures August 2006 Jib Boom Components Z 45 25J 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom
221. RACT C3P 8 C8PBR BK WH C3B 8 2 5 C16 1 162 g T 8 T 1 BOOM EXTEND EXTEND 9 BOOM RETRACT C68 C8PBR RETRACT B C174 c17 2 2 C4P 2 C14PLU OR C4B 2 8 DOWN gt lt e PLATFORM LEVEL eur C4P 3 C15PLD OR BK 3 i i 20 1 C202 B 2 8 06 4 Ke PLATFORM LEVEL UP Down eoe PLATFORM LEVEL 06 15 C15PLD OR BK e t e PLATFORM LEVEL DOWN i C214 c21 2 DH 1 E INE gt C4P 6 C18JD GR BK C4B 6 RIGHT PLATFORM ROTATE caps C17JU GR 5 2 d C231 23 2 i 1 g c6 18 C18JD GR BK 8 PLATFORM ROTATE RIGHT RIGHT PLATFORM JIB BOOM DOWN e LEFT ROTATE oe C17JU GR 1 PLATFORM ROTATE LEFT JIB BOOM UP a 1 22 1 22 2 NY e 5 25 N Insassen 1 1 C129DA BK C6 19 106 DESCENT ALARM OPTION H o llLnlluceiiesmescczueccaccecunenimneeieeeeecezmeeLe emecmeeeemnccce 1 Z SE P o 9 Ek I 5 o og a 55 ES 2 gt SE 4942 Sr gu TXTE oz9 St 5 ax 520 GG NOs a lj k 5 wash Sed 9 Bar mmm 8 Ss SES SEU 5588 Z
222. RD BK Deutz F3L 201 1 Models Electrical Schematic Z 45 25 August 2006 C28TTA RD BK REVC CN LO c7P 3 BATGND C7B 3 e GROUND C41RPM OR BK C2P 3 5 FWD WH BK RD 4 BRN m OA C30 C1B 4 5 21 C30FWD WH a de DRVCEDG FORWARD lt DES C31REV C1B 5 5 20 C31REV WH BK BD BK SSBEN A DRIVE EDC REVERSE p 4 DRVEMODE Se SS SS SS SS SS eae SSS SS a mr RD WH 06 33 C32TA WH RD TRAVELALARMOPTION E SAOI E UPPER ON BURD 5 a 026 4 C262 8 C32BRK WH RD op 2 2 WH RD 5 nals 7 CC OPS 6 eos BRAKE RELEASE VALVE ier DRIVE ENABLE B C29MS RD WH C1B 3 C629 C29MS RD WH ODERBUBK ZEPS MOTOR STROKE amp rT E 1 8 le ES g 8 5 6 Z amp d C251 C252 ig
223. RM ITEM H1 7 C9 48 PIN CONNECTOR BLOCK U13 J2 J3 CR27 CR30 1518 FOOT SWITCH SUPPY i i 1 r1 rod Fd 1 1 rd mE 1 E i nid bd 1 Fg 1 bg i e 1 e i gt C6TRF WH RD C3P 6 be 5 i e 9 e E C10SBU BL C3P 10 UI 1 e C16DRE OR RD C4P 4 _ C11SBD C3P 11 Y 1 1 e C40LSS OR C2P 2 4 A lt C12SBF 12 m P24FS WH C41RPM OR BK C2P 3 O i C30FWD WH 4 e BRN e C1PBU RD C3P 1 gt C31REV WH BK 5 a s al e CN e C2PBD RD BK C3P 2 Sf 5 v C37STC BUBK C1P 11 RD WH C3P 3 C36STCC BK 10 c m e WH RD 6 e CA C5TRR WH BK C3P 5 J 1 og a C29MS RD WH C1P 3 1 H x C3P GR C35HS BK RD 1 9 C33STR 7 y C27AUX RD 1 1 C2
224. ROCEDURES E 2 Grease the Steer Axle Wheel Bearings 2WD Models Genie requires thatthis procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosenthe wheel lug nuts Do not remove them 2 Block the non steer wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement REVD 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 ft Ibs 47 Nm to seat bearings 8 Loosen the castle nut and re tighten to 8 ft los 11 Nm 9 Checkfor wheel bearing wear by attempting to move the wheel hub side to side then up and down
225. SSURE LED 558 143 OIL TEMPERATURE LED EB ope tp mH 145 PLATFORM OVERLOAD 52 GR BK GRIBK P1 RED EMERGENCY STOP BUTTON 5 98558 aD gd g 4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS amp 5 5 R14 SECONDARY BOOM SPEED RESISTOR 7 5 OHMS obo i 3 TS51 AUXILIARY POWER TOGGLE SWITCH 50 ooo S TS52 ENGINE START TOGGLE SWITCH aos S TS54 FUNCTION ENABLE TOGGLE SWITCH Si Fas TS56 GLOW PLUG TOGGLE SWITCH OPTION lt ii g 3 i L x 5 i i TS57 PLATFORM ROTATE TOGGLE SWITCH z z 8 B ZS 5 g 85 525 TS58 JIB BOOM UP DOWN TOGGLE SWITCH 4 TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY UP DOWN TOGGLE SWITCH 5 lt fu TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH 8 amp TS62 TURNTABLE ROTATE TOGGLE SWITCH wis E ES tt 25 563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 325 559 WH 23 s380 Sz 5858 C 7 SEM Ze 85 QRO 55 i 5 Ns J S n RD 8 nm 5 RD RD m a 7 2 2 8 QU 8 z gt 50 2626 RD RD RD 5 6 6 85 5 5 d 5 5 s apen e e a B 8 a 8 BRN 5 x i 5 e 8852 _ 7 E a a i ab A BE g II a T c a 5 E D SS Jil E Le 558 E 508 fe Mic E RD S RD 20
226. Scheduled Maintenance Procedures August 2006 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure E Eco Bl Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly every six months annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to performa scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or eve
227. TATE RIGHT C154 152 First Yo TURNTABLE ROTATE LEFT 8 C64 1 C141 C14 2 7 lt 1 is IE lt g BS 5 PRIMARY Eg m i Bye SELECT RELAY 8154 4 2 C124 Ci22 RH 5 PRIMARY BOOM RIPBUIRD GE e PRIMAR P 152 lt n B ME RIMARY BOOM U g E a Ew E R2PBD RD BK 24 5 2 5 21 5 e PRIMARY BOOM DOWN 1 1 lt 2 2 C194 2 c EMT d e 1 1 CIPBU RD C3B 1 lt Ex 2 C2PBD RD BK C3B 2 Copa gt RD WH C3B 3 lt 1 EE 1 C8P 12 125 BLWH 12 13 e LR z s _ 11 C11SBD BUBK C3B 11 518 lt on 5 E Pwa 9 C3P 10 gt C10SBU BL C3B 10 5 24888 10 S i e SECONDARY BOOM IR SELECT RELAY lt e i C181 18 2 g J SECONDARY BOOM EE HE SECONDARY BOOM UP DOWN 06 10 a t 5 5 R11SBD BUBK 8 1 SECONDARY DOWN 8 ER Bos a gt c6 11 C194 C192 B er 5 8 ER P24FS WH 8 8 E Ex C4P 4 C16PDRE OR RD C4B 4 66 16 6 2 C6 13 P26ESTP BK 8 2 WS 133 DRIVE ENABLE hd gt LIMIT SWITCH E 5 gt C2P 2 1 LS1 PRIMARY BOOM EXTEND EHER 4 DRIVE LIMIT SWITCH
228. TCH gt amp Ss 7 4 DH 59 C2B 2 C6 40 1 4 zg 6104 C10 1 5 154 SECONDARY BOOM UP KA 1 SR T DRIVE LIMIT SWITCH whoa amp 0350 1 1 2215 I C3P 7 C7PBE BK C3B 7 EXTEND 1 e e BOOM 1 RETRACT C3P 8 C8PBR BK WH C3B 8 2 5 C16 1 162 8 C7PBE BK 8 EXTEND 9 BOOM RETRACT C68 C8PBR BKIWH ICE T RETRACT B C174 c17 2 2 C4P 2 C14PLU OR C4B 2 i 8 gt lt 1 PLATFORM LEVEL N 1 ur C4P 3 C15PLD OR BK C4B 3 i 20 1 C202 1 8 4 06 4 on PLATFORM LEVEL UP DOWN e PLATFORM LEVEL 06 15 C15PLD OR BK e t e PLATFORM LEVEL DOWN i 1 021 1 021 2 g GR BK 44 C2P 6 C129DA GR BK C2B 6 E T e Eg 6 C18JD GR BK C4B 6 6 DOWN 5 JIB BOOM f 5 C17JU GR C4B 5 2 C231 232 i E g 618 C18JD GR BK 8 gt i PLATFORM ROTATE RIGHT 1 DOWN jiBBOOM JIB BOOM DOWN eur i C17 JU GR 1 PLATFORM ROTATE LEFT JIB BOOM UP 1 22 1 22 2 ivy 6 RIGHT 5 e P
229. UTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL RELAY CE OPTION DESCRIPTION TILT ALARM ALC 500 CONTROL BOARD CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH 1 C4P 48 PIN CONNECTOR BLOCK ITEM H 7 013 J2 J3 CR27 CR30 LS18 FOOT SWITCH SUPPY Part No 107846 19 18 CONTROL CABLE i C15PLD OR BK 3 C9HRN BK RD C3P 9 BK WH C3P 8 7 P26BAT BK C9 1 P25FS RD C9 3 P24FS WH 9 2 S AE E EA ee CWLITE RD C2P 12 MEN enen ez LL nr E ne m MN 5 mi C45GEN GR WH C2P 7 H aus CA4JDALARM GR BK C2P 6 1 TE O bd P26ESTP BK w 1 N 1 Fd E 1 e gt C6TRF WH RD C3P 6 p gt 1 e 9 e bg H 4 C10SBU BL C3P 10 I 1 LLI C16DRE OR RD 4 4 EN C11SBD BL BK 11
230. VERLOAD P1 RED EMERGENCY STOP BUTTON R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS H14 SECONDARY BOOM SPEED RESISTOR 7 5 OHMS TS51 AUXILIARY POWER TOGGLE SWITCH TS52 ENGINE START TOGGLE SWITCH 1554 FUNCTION ENABLE TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH OPTION 557 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 2 zT E 1 22 3 gee Ra 8 Ek 55 225 t 9 RD RD GR BK SEX essay P 356 52288 8280E 22 o rox BK WH 8 2 5 RD RD RD RD 7 Q 79 1 j 5 RD RD g 2 RD RD x Bln 1 d i a d Q mix c RD RD 21212 ggu 855 RD Q 1 i x Et GR BK GR BK E oo 2200 RD RD E
231. X COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 Checklist E Procedures E 1 1 Test or Replace the Hydraulic Oil Genie requires thatthis procedure be performed every 2000 hours or 3 every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced atthe two year inspection test the oil quarterly Replace the oil when it fails the test When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the boom in the stowed position Genie TEREX COMPANY REV D Ford models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank Ford m
232. XTEND RETRACT r 9 RD RD PartNo 107846 RD C19JSV GRWH 2 v C19JSV GR WH C4P 7 EE DIO J1 2 RD J1 1 C18PRR GR BK C4P 6 OR J1 11 I BRN J1 12 z P24FS sti ol a e C14PLU OR 2 Le Ek Fe i 8 C15PLD C4P 3 Sw 55 CN gt O sak D RD eu 3 cc se le g tc C9HRN BK RD C3P 9 5 9 August 2006 Section 6 Schematics TTS Platform Control Box Switch Panel Wiring Diagram Z 45 25J Deutz F3L 2011 Models Section 6 Schematics August 2006 eet Electrical Schematic Z 45 25 Perkins 404 22 Models C28TTA RD BK C28TTA RD BK August 2006 Electrical Schematic Z 45 25 Section 6 Schematics Perkins 404 22 Models
233. YLINDER ple d 1500 psi 4 EINE ie 103 bar 0 76 mm 1 SECONDARY BOOM J1 J2 PR2 PR1 CYLINDERS f pet R it ee d BS ior Im x n 3 3500 psi 1 1 241 bar LLL _ vi ug E JIB MANIFOLD L4 m i PM JH IE atmos 3500 HIGH MASTER CYLINDER C 241 bar CHARGE PRESSURE FILTER FILTER ape 4 s P 1 50 psi n gt 308 pet OPTIONAL 2977 c e T E MOTOR GEN STi 572 pri PR2 PLi PL2 SW2 51 52 1 P2 EXTEN RETRACT 1 X h FM i CM Os Day PS i me cune e T5 2500 psi 172 i RT NN set at 0 6 gpm r 4 4 eer eee 4 ns L _ a 1 1 op dod TIGEN i Iq 0 0 amp amp stmmatTP E 1 ehe PRESS i 2 FE GENERATOR SELECT en a nn Qi Die E FUNCTION PUMP AUX 1 5 7 26 5 L min S p aa 7 SS ie EE N LA 3200 psi een 220 6 bar set at 7 gpm ERROR EE 1 26 5 L min at TP1 EE gt mn pen
234. added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the pressure in each air filled tire Refer to Section 2 Specifications Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC B 7 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect to be sure itis in the engaged position brake disengaged position brake engaged position CHECKLIST B PROCEDURES B 8 Check the Oil Level in the Drive Hubs Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees a
235. adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 107846 A TEREX Z 45 25 Z 45 25J 4 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Used to indicate the presence ofa potentially hazardous situation which if not avoided could result in death or serious injury With safet
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237. air has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Genie A TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 August 2006 Section 5 Fault Codes REVA CL Closed Loop high LPG CL Closed Loop high gasoline bank 1 CL Closed Loop low gasoline bank 1 CL Closed Loop low LPG Gasoline catalyst monitor 1 LPG catalyst monitor 141 AL Adaptive Learn high gasoline bank1 142 AL Adaptive Learn low gasoline bank 1 143 AL Adaptive Learn high LPG 144 AL Adaptive Learn low LPG FAULT CODES Code Description m 211 IAT Intake Air Temperature high E IAT Intake Air Temperature low ae IAT Intake Air Temperature higher than expected 1 IAT Intake Air Temperature higher 214 an expected 2 Oil pressure low ECT CHT Engine Cylinder Head 212 213 Coolant Temperature high voltage 2 CHT En
238. ant level to specification 231 MAP high pressure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 232 MAP low voltage Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 234 BP high pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 235 BP low pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 242 Crank sync noise Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in ace and secure OR repair wiring and or onnections to sensor OR replace sensor 243 Never crank synced at start Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty e sure system ground connections are in ace and secure OR repair wiring and or onnections to sensor OR replace sensor 244 Camshaft sensor loss Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty e sure system ground connections are in ace and secure OR repair wiring and or onnections to sen
239. any response from the Megavector or an incorrect response for 500ms period or longer Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector 361 MegaJector voltage supply high The Megavector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running Repair charging system OR replace the MegayJector 362 MegaJector voltage supply low The Megavector detects voltage less than 9 5 volts for 5 seconds anytime the engine is cranking or running Repair VBAT power or ground circuit to ECM MegaJector OR replace battery OR repair charging system OR replace the MegaJector 363 Megajector internal actuator fault detection The MegayJector detects an internal fault Open or short in power ground or CAN circuits s Check power ground and CAN circuits at and all connections and repair as necessary OR has an internal fault Contact Ford Power Products for assistance 364 Megajector internal circuitry fault detection The Megavector detects an internal circuitry failure Open or short in power ground or CAN circuits Check power ground and CAN circuits at and all connections and repair as necessary OR has an internal fault Contact Ford Power Products for assistance 365 in
240. ate Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle Switch in the left direction to decrease the time Each time the drive enable toggle Switch is momentarily moved the time will change in 1096 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the Z 45 25 Z 45 25J settings to be saved O Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Ramp rate factory settings Primary boom up down accelerate 4 seconds decelerate 0 5 second Secondary boom up down accelerate 2 seconds decelerate 0 5 second Turntable rotate accelerate 2 seconds decelerate 0 5 second Drive accelerate 3 8 seconds accelerate narrow models 3 8 seconds decelerate to neutral 0 5 second decelerate change of direction 0 5 second decelerate coasting 0 75 second decelerate braking 1 second decelerate shift from low to high speed 1 second decelerate shift from high to low speed 2 seconds 4 5 Section 4 Repair Procedures August 2006 PLATFORM CONTROLS How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve
241. ate out and away from the machine REVD 2 Grease the Platform Overload Mechanism if equipped Genie specifications require thatthis procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will resultin component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP 2 lithium based or equivalent Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over The platform overload system is design
242. ater separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Swing the engine back to its original position and close the engine pivot plate latch Install the engine pivot plate safety pin Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD CHECKLIST A PROCEDURES A 9 A 10 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Before serial number 27001 Locate the grease fitting on the front turntable cover After serial number 27000 Locate the grease fitting near the ground control box 2 Pumpgreaseinto the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 18 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located underthe turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Perform Engine Maintenance
243. atics Ground Control Box Switch Panel Wiring Diagram Z 45 25 Perkins 404 22 Models Section 6 Schematics August 2006 Platform Control Box Wiring Diagram Z 45 25 Perkins 404 22 Models REVA August 2006 Platform Control Box Wiring Diagram Z 45 25 Section 6 Schematics Perkins 404 22 Models PLATFORM CONTROL HARNESS TO SWITCH PANEL RD P2 RD H1 LIFT DRIVE OPTION PT C32BRK WH RD C1P 6 B is i 8 ONLY C40LSS OR C2P 2 P24FS WH C9P 2 P23SWBAT WH C7P 2 P22BAT BK C7P 1 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL RELAY CE OPTION DESCRIPTION TILT ALARM ALC 500 CONTROL BOARD CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH C4P 48 PIN CONNECTOR BLOCK ITEM Hi 013 J2 J3 CR27 CR30 LS18 FOOT SWITCH SUPPY Part No 107846 19 18 CONTROL CABLE i i 1 er i
244. attery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 3 14 2 45 25 2 45 25 Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC 10 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 13 W Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled Part No 107846 Genie Z 45 25 Z 45 25J 3 15 CHECKLIST PROCEDURES B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours
245. azard If the CAUTION machine must be towed do not exceed 2 mph 3 2 km h Non steer wheels All models 1 Chockthe steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub 5 Manually rotate each non steer wheel disengaged position engaged position O Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands and lower the machine AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Steer wheels 4WD models 7 Chockthe non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer tires 9 Liftthe wheels off the ground and then place jack stands under the drive chassis for support CHECKLIST D PROCEDURES 10 Disengage the
246. c filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Openthe engine side turntable cover 2 Startthe engine from the ground controls 3 Changethe engine idle to high rpm rabbit symbol 4 Visually inspect the filter condition indicator O Result The filter condition indicator should be operating with the plunger in the green area Wi Result If the indicator displays the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See D 6 Heplace the Hyaraulic Filters CHECKLIST A PROCEDURES A 5 Test the Oscillate Axle if equipped Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1 Startthe engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer ti
247. can open and allow the function to operate Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do press down the foot switch Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 8 times Result There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode 8 Startthe engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold A TEREX 4 6 Z 45 25 Z 45 25J REV B 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the joystick back to the neutral position Just before the function stops moving move the drive enable toggle switch to either side to set the threshold Result The alarm should sound indicating a successful calibration 12 Repeat steps 9 through 11 for each boom joystick controlled machine function up down
248. cate and troubleshoot or repair faulty engine sensor OR replace ECM Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM Locate and repair any engine harness wiring Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor is faulty 631 External 5V DC ref lower than expected Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty 632 External 5V DC ref higher than expected 655 RTI 2loss ege damage or shorts to ECM to be sure they y secure OR replace ECM 7 Locate repair any engine harness wiring 656 RTI 3loss rm Wire conniectioris to ER damage or shorts to ECM to be sure they are secure OR replace ECM TEREX COMPANY PartNo 107846 2 45 25 2 45 25 5 11 Section 5 Fault Codes August 2006 FAULT CODES Ford DSG 423 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust
249. ce fuel injector 4 OR replace the ECM 351 Fuel pump loop open or high side short to ground Open wiring and or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty Repair wiring and or connections to fuel pump OR replace fuel pump 352 Fuel pump high side shorted to power Wiring and or connections to fuel pump shorted to power OR fuel pump is faulty Repair wiring and or connections to fuel pump OR replace fuel pump 353 delivery pressure higher than expected Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector 354 Megajector delivery pressure lower than expected Fuel pressure too low OR LPG lockoff not opening completely OR the line between the Megavector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector 355 MegaJector communication lost The ECM doesn t get
250. charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump Ford LRG 425 EFI and Perkins models 3 Remove the engine starter mounting fasteners Remove the starter from the engine Do not disconnect the wiring 4 Supportthe drive pump with an appropriate lifting device Then remove all of the bell housing to engine mounting bolts Leave the pump connected to the bell housing Section 4 Repair Procedures August 2006 ENGINES 5 Carefully pull the pump and bell housing away from the engine and secure it from moving Component damage hazard Hoses CAUTION can be damaged if they are kinked orpinched 6 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel Ford DSG 423 EFI models 3 Supportthe drive pump assembly with an overhead crane or other suitable lifting device Do not apply any lifting pressure 4 Remove the drive pump retaining fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate Component damage hazard Hoses CAUTION can be damaged if they are kinked orpinched 6 Disconnect the electrical connector from the oxygen sensor at the tailpipe Do not remove the oxygen sensor 7 Supportthe muffler and bracket assembly with a suitable lifting device 8 Remove the
251. circuit 10 12 ft Ibs 14 16 Nm 19 Check AT Non steer end drive motor circuit 10 12 ft Ibs 14 16 Nm Genie TEREX COMPANY 4 66 Z 45 25 Z 45 25J Part No 107846 June 2012 Section 4 Repair Procedures REV E MANIFOLDS 2 gt Se 4 49 n 6 0 2 I AM 0 e QE ft C AN Bw e SCH M 60 Part No 107846 Z 45 25 Z 45 25J 4 67 Section 4 Repair Procedures June 2012 MANIFOLDS REV E 8 14 Traction Manifold Components 4WD after serial number 27000 The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Flow divider combiner valve LU Controls flow to non steer end drive motors in forward and 25 30 ft lbs 34 41 Nm 2 Bi directional flow control valve 2 GPM 7 6 E conss Non steer end drive motor circuit 25 30 ft Ibs 34 41 Nm 3 Bi directional flow control valve 1 gpm 3 8 L MIN NX ciun Steer end drive motor circuit 25 30 ft lbs 34 41 Nm 4 Directional control valve AM sse 2 speed motor shift circuit High speed 10 12 ft Ibs 14 16 Nm Diagnostic EE Te
252. ct normally open Genie HR Horn button normally open 2 52 N O temperature switch normally open ER 81 NO Coolant temperature switch normally open OPS1 N C Oil pressure switch normally closed Gauge sending unit gt gt gt PULL IN iQ HOLD HJ U Fuel or RPM solenoid AL August 2006 REVA FS1 BLK Foot switch P1 a Emergency Stop button normally closed Hydraulic oil cooling fan Auxiliary pump Resistor with ohm value Tilt sensor Deep Key switch after serial number 22050 A TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 August 2006 Section 6 Schematics Hydraulic Symbols Legend REVA 25 psi 1 7 bar ER Og ES Orifice with size pues Solenoid operated operated postion Ss penton 4 way Filter with proportional directional valve bypass valve relief setting Se fixed displacement or bi directional variable displacement Q 9 bi directional aos Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder Check valve 1 200 psi 13 8 bar 1 s E etl Relief valve with pre
253. ctrical Schematics Z 45 25 anne einen 6 23 C Electrical Schematic Z 45 25 CE Models 6 25 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 27 B Ground Control Box Switch Panel Wiring Diagram 2 45 25 6 28 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 GEIMOdGEIS 6 29 B Ground Control Box Switch Panel Wiring Diagram Z 45 25 CE har 6 30 A Platform Control Box Terminal Strip Wiring Diagram 2 45 25 6 31 A Platform Control Box Switch Panel Wiring Diagram Z 45 25 6 32 Z 45 25 Z 45 25J Part No 107846 June 2012 TABLE OF CONTENTS Section6 Rev Schematics continued Deutz F3L 2011 models continued C Electrical Schematic Z A 6 33 Electrical Schematic Z 45 25J ezyuporIc 6 35 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J 6 37 B Ground Control Box Switch Panel Wiring Diagram 2 45 25 6 38 Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Ee EE 6 39 B Ground Control Box Switch Panel Wiring Diagram Z 45 25J 6 40 A Platform Control Box Termina
254. d d 5 1 S O 2 2961 5860 NEHM 984 ECHO 8 260 z Sr ke iz oo D AU I9S HWQH Jp HW E 869 HOH 0 2680 a geet d 2 NMOG WOOS AHVWIHd 2 1951 A O 280 g TOO 8 d LC AWW 1951 04 1 90 985 2280 aL asva TWNINYAL 2 o 48095 N d 31NGOW LYVLS NOLINDI 92 21 amp gt gt i 65 25 SS3Hd HO dWAL OL EE 89055 NO H dHONO 6 e p eoo a ZU HM e x 5 9 201 dun 8 0000000 e O SE 9 2 g gl 5 G E B 3 58 AINO 195310 MSAA OL 2 Sum z 9 D 5 5 e 891298999 p Ke JINN Md v Ud e D 0 ANdNIIUVIS E H313WOHOVL 2 lt Anue mme AYHHiHVIS OL F a sr seujsnpu eiuec Ground Control Box Terminal Strip Wiring Diagram Z 45 25J Section 6 Schematics Perkins 404 22 Models Part No 107846 TEREX COMPANY Z 45 25 2 45 25 G 6 60 Section 6 Schematics Perkins 404 22 Models Ground Control Box Switch Panel Wiring Diagram Z 45 25J August 2006 M REV B Yb WYO
255. d and it could tip over Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor REVC 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 Result The overload indicator lights are flashing atthe platform and ground controls and the alarm is sounding Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 The platform will need to be moved up and down and allowed to settle between each adjustment There may be a 2 second delay before the platform overload indicator light and alarm responds Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicato
256. dgjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 bar less than the pressure reading on the pump Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 10 Turn the engine off and remove the pressure gauge TEREX CON Z 45 25 Z 45 25J REV 8 16 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification before serial number 27001 Proportional directional solenoid valve 10V DC6 to 8Q schematic items A C and D 3 position 4 way directional valve 10V DC 6 to 8Q schematic items B F and H 2 position 3 way solenoid valve 10V DC 6 to 8Q schematic items E AD OO XX Al and Valve Coil Resistance Specification after serial number 27000 Proportional directional
257. ding the thumb rocker steer switch No machine fuction should operate while performing the joystick calibration procedure Part No 107846 Z 45 25 Z 45 25J 4 3 Section 4 Repair Procedures August 2006 PLATFORM CONTROLS How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick controlled machine function Whenever a hydraulic cylinder drive motor or hydraulic pump is replaced the max out setting should be adjusted to maintain optimum performance The max out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do press down the foot switch Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode TER
258. e flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System ifequipped There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie TEREX COMPANY 3 36 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST C PROCEDURES 8 Testall machine functions from the platform 15 Turn the key switch to platform control contrals 16 Test all machine functions from the platform Result All platform control functions should not controls operate Result All platform control functions should 9 Turn the key switch to ground control operate 10 Test all machine funct
259. e m Platform Components 3 Lowerthe primary boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector Connect the hoses from the cylinder together using a connector AWARNING Eodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin Z 45 25J Remove the external snap rings from the slave cylinder barrel end pivot pin Do not remove the pin Z 45 25 Remove the pin retaining fastener from the slave cylinder barrel end pivot pin Do not remove the pin Place a block under the slave cylinder for support Protect the cylinder rod from damage Z 45 25 Z 45 25J 4 7 Section 4 Repair Procedures August 2006 PLATFORM COMPONENTS 8 Z 45 25 Supportthe platform rotator with a suitable lifting device 9 Use a soft metal drift to drive the rod end pivot pin out AWARNING Cushing hazard The platform could fall when the slave cylinder rod end pivot pin is removed if not properly supported Component damage hazard The slave cylinder rod may become
260. e that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SPECIFICATIONS Seal Lok fittings 1 SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft Ibs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal LokQ fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Lok Fittings tube fitting installed into Ste
261. e available in the Perkins 400 Series Operation Manual Perkins part number 14435 Perkins 400 Series Operation Manual REVC B 23 Replace the Engine Air Filter Element Ford Models Engine specifications require that this procedure be performed every 400 hours Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap Remove and discard the filter element Genie part number 94890 4 Cleanthe inside of the canister and the end cap with a damp cloth 5 Install the new filter element 6 Install the air filter canister end cap and secure the end cap latches Be sure the discharge valve is pointing down when the cap is instaled Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC B 24 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor
262. e center turntable cover retaining fasteners Remove the center turntable cover from the machine must be torqued to specification 5 Open the engine pivot plate latch and swing the e engine pivot plate out and away from the during installation Refer to machine Section 2 Hydraulic Hose and Fitting Torque Specifications 6 Tag disconnect and plug the hydraulic hoses 1 Raisethe secondary boom until the upper pivot 1 2 nn an is above the turntable covers Turn the machine 9 off AWARNING Body injury hazard Spraying 2 Secure the turntable from rotating with the Gan 2 and turntable rotation lock TA SAN ROSEN connections very slowly to allow Tip over hazard The machine the oil pressure to dissipate ADANGER could tip over when the turntable gradually Do not allow oil to squirt rotation assembly is removed if the or spray turntable rotation lock i tin th ge SES 7 lifting strap from and overhead crane other suitable lifting device to the turntable rotator assembly 8 Remove the turntable rotation assembly mounting fasteners 9 Carefully remove the turntable rotation assembly from the machine Unlocked position ADANGER Tip over hazard The machine Locked position TEREX COMPANY could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not i
263. e jib boom leveling arms off of the jib boom cylinder rod end pivot pin 11 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 12 Attach a lifting strap from an overhead crane to the jib boom 13 Support the barrel end of the jib boom lift cylinder with a suitable lifting device 14 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 12 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures REV B 15 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 16 Use a soft metal drift to remove the pin and let the cylinder hang down Crushing hazard The jib boom AWARNING could fall when when the barrel end pivot pin is removed if not properly supported by the overhead crane 17 Remove the pin retaining fastener from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the bellcrank AWARNING Cushing hazard The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 18 Attach a lifting strap from an overhead crane to the lug on the rod
264. e to the test port on the drive pump coupler separates from the flex plate 2 Remove the safety pin if equipped from the 6 Remove the drive pump from the machine engine pivot plate latch Component damage hazard The CAUTION hydraulic pump may become unbalanced and fall if not properly supported The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine Component damage hazard When CAUTION installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur 4 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position 3 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine Models without hydraulic tank shut off valves CAUTION Component damage hazard Be Perkins models Disconnectthe engine wiring to fill the hydraulic tank t harness from the fuel solenoid at the injector specification and prime the pump pump after installing the pump Deutz models Hold the manual fuel shutoff Models with hydraulic tank shut off valves valve clockwise to the closed position Component damage hazard Be CAUTION sure to open the two hydraulic tank valves and prime the pump after installing the pump d 1 5 X lage 511 NS LIC a manual fuel shutoff valve T
265. eal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle Component damage Do not CAUTION apply excessive force or damage to the lip of the seal may occur 5 Placethe outer bearing into the hub 6 Install the washer and castle nut 7 Tighten the castle nut to 35 ft Ibs 47 Nm to seat bearing 8 Fully loosen the castle nut then re tighten to 8 ft lbs 11 Nm 9 Install a new cotter pin Bend the cotter pin to secure the castle nut Always use a new cotter pin when installing a castle nut 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Section 4 Repair Procedures August 2006 AXLE COMPONENTS 10 2 Oscillating Axle Lock out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle Cylinder Perform this procedure on a firm level surface with the boom in the stowed position When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect
266. ecifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement communications will be carefully considered for future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com li Z 45 25 e 7 45 25 Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Z 45 25 and Z 45 25J Service Manual 52709 From serial number 9998 to 21179 Z 45 25 and Z 45 25J Service Manual 77809 Deutz models from 21180 to 23040 Ford models from 21180 to 23189 Perkins models from 21180 to 23008 Z 45 25 and Z 45 25J Service Manual 107846 Deutz models from 23041 to 34010 Ford models from 23190 to 34010 Perkins models from 23009 to 34010 All models from A34011 to A47000 All models from B101 Z 45 25 and Z 45 25J Service Manual 219418 From serial number 13A 47001 Copyright O 2011 Terex Corporation 107846 Rev C August 2006 Third Edition Third Printing Genie and Z are registered trademarks of Terex South Dakota Inc in the USA and many other countries 6 Printed on recycled paper Printed in U S A Part No 107846 June 2012 p m INTRODUCTION
267. ections OR fill engine oil level to specification 221 CHT ECT high voltage Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor 222 CHT ECT low voltage Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning and Repair engine cooling system problems OR connections open or shorted OR sensor is faulty OR coolant level is low 223 CHT higher than expected overheating the engine OR sensor wires and or repair open or shorted wiring to sensor OR 1 A replace sensor OR fill engine coolant level to connections open or shorted OR sensor is faulty BAR specification OR coolant level is low Coolant temperature at the cylinder head is 250 E Ven Repair engine cooling system problems OR F Engine cooling system is malfunctioning and e CHT higher than expected repair open or shorted wiring to sensor OR overheating the engine OR sensor wires and or 2 replace sensor OR fill engine cool
268. ectly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing e turntable dial indicator drive chassis turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator 6 Lowerthe secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom CHECKLIST D PROCEDURES 7 Note the reading on the dial indicator O Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Genie TEREX COMPANY Part No 107846 2 45 25 Z 45 25J 3 45 Section 3 Scheduled Maintenance Procedures August
269. ed speed and Value too high Value too low Value at OV direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected Not calibrated Just calibrated Joystick speed and direction frozen at zero and neutral Initiate 1 second beep of alarm Calibrate joystick Self clearing transient Drive flow valve EDC 53 Drive brake valve Value too high Value too low Not calibrated Just calibrated Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Normal function except threshold for one or both directions is zero Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected Calibrate valve thresholds Self clearing Power up controller with problem corrected High speed drive motor Valve Fault Motor speed frozen in the low state Alarm sounds indicating fault Power up controller with problem corrected Steer joystick Value at 5V Value too high Value too low Value at OV Not calibrated Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Joystick speed and direction frozen at zero and neutral Power up controller with problem corrected Calibrate Joystick Just calibrated I
270. ed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When activated the system halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload CHECKLIST C PROCEDURES The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform As weight is added to the platform the spring will compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weigh
271. edures June 2012 MANIFOLDS 8 10 Traction Manifold Components REV E 2WD before serial number 27001 The traction manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item 1 Solenoid valve 2 position 3 way XX us 2 Relief valve 250 psi 17 2 bar Flow divider combiner valve 4 Orifice 0 070 in 1 78 mm RR 5 Check 95 6 Check 7 Shuttle valve position way UU 8 Diagnostic fitting WV 9 Orifice 0 030 0 76 mm WW 10 Solenoid valve 2 position 3 way OO Z 45 25 Z 45 25J Function Torque 10 12 ft lbs 14 16 Nm 10 12 ft Ibs 14 16 Nm Braking Charge pressure circuit Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm Drive circuit zi IDEIVOSCITCUIU en 25 30 ft lbs 34 41 Nm sx DEVO CIECUIU ri deor axe creans 25 30 ft lbs 34 41 Nm Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm Testing Brake circuit 10 12 ft lbs 14 16 Nm TEREX COMPANY Part No 107846 Section 4 Repair Proced
272. een the throttle body and cylinder head 611 COP failure Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 612 Invalid interrupt Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM A D loss 613 Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Genie A TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 August 2006 Section 5 Fault Codes H O meer REV B FAULT CODES Code Problem Cause Solution Locate and repair any engine harness wiring 61 4 1 loss en Wire connections to ECM OR ECM s damage or shorts to ECM to be sure they are secure OR replace ECM A Locate and repair any engine harness wiring 61 5 Flash checksum invalid SE Wire connections To damage or shorts to ECM to be sure they are aulty secure OR replace ECM e Locate and repair any engine harness wiring 616 RAM failure connectionis to EGM ECM is damage or shorts to ECM to be sure they are Locate and repair any engine harness wiring damage or shorts OR lo
273. efore Troubleshooting the oil pressure to dissipate Read understand and obey the safety rules and gradually Do not allow oil to squirt operating instructions in the appropriate Operator s Manual on your machine General Repair Process Be sure that all necessary tools and test equipment are available and ready for use Malfunction Identify Troubleshoot discovered symptoms problem Still exists Return to Perform Service repair problem Solved Genie TEREX COMPANY Part No 107846 Z 45 25 Z 45 25J 6 1 Section 6 Schematics Electrical Symbols Legend l BLK er Quick disconnect terminal WHT 21 S 21 T circuits connect at terminal Ge T circuits connect Connection no terminal Circuits crossing no connection Diode 1 nl Lu 15 Circuit breaker with amperage Coil solenoid or relay H1 Horn or alarm Flashing beacon Hour meter L3 f LED F1 ic 25A Fuse with amperage m Starting aid glow plug or flame ignitor Limit switch KS1 PLATFORM 4 1 GROUND Key switch before serial number 22051 Power relay Em R 19118 3NI9N3 Toggle switch SPDT E E e Dd B B Toggle switch DPDT Control relay conta
274. el hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft Ibs 21 7 Nm 4 18 ft Ibs 25 6 35 ft Ibs 47 5 Nm 6 30 ft Ibs 40 8 60 ft lbs 81 3 Nm 8 40 ft lbs 55 Nm 10 105 ft lbs 142 4 Nm 10 60 ft lbs 80 Nm 12 140 ft lbs 190 Nm 12 85 ft lbs 115 Nm 16 210 ft lbs 284 7 Nm 16 110 ft lbs 150 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 180 ft lbs 245 Nm Part No 107846 A TERI EX COMPANY Z 45 25 e Z 45 25J 2 13 Section 2 Specifications January 2011 SPECIFICATIONS REVH SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Seet LUBED D S 2 o DRY LUBED RY LUBED indbs inibs Nm Nm 11 3 12 4 13 5 13 5 DRY DRY ftibs bs Nm LU ftibs 24 25 7 27 1 42 44 7 47 4 50 31 49 664 43 583 60 80 so 120 100 120 10 1 LUBED ft lbs 17 19 31 35 17 6 19 5 23 35 2 50 1 55 5 77 3 86 7 108 4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 67 8 813 80 1084 _ 68 921 110 120 150 170 210 244 240 271 380 433 420 474 583 610 610 637 678 670 867 922 962 1016 990 1342 _ 840 1139 1071 1315 1206 1464 1518 1844 1681 2047 2643 3213 2969 7 1 55 75 85 110 120 150 1
275. el tank 2 Checkfor proper venting O Result Air passes through the fuel tank cap Proceed to step 4 Result If air does not pass through the cap clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely through the cap Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 8 W Result If air does not pass through the clean or replace the cap Proceed to step 7 When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Genie 7 45 25 Z 45 25J REVC B 21 Replace the Fuel Filter Element Perkins Models Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter
276. enance Inspection Report een 3 5 Checklist A Procedures A 1 Perform Pre operation Inspection 3 7 2 Poron Funcion Tests en 3 7 A 3 Perform Engine Maintenance 3 8 A 4 Check the High Pressure Hydraulic Filter Condition Indicator 3 9 5 Test the Oscillate Axle 3 9 6 Perform 30 Day Service ceret erp euer 3 10 A 7 Perform Engine Maintenance Ford Models nennen 3 10 A 8 Fuel Filter Water Separator Diesel Models 3 11 A 9 Grease the Turntable Rotation Bearing and Rotate Gear 3 13 A 10 Perform Engine Maintenance Ford 3 13 Checklist B Procedures Det INSPect the Battery bam rer a iiec dE EE 3 14 B 2 Inspect the Electrical 8 80 0 3 15 B 3 Checkthe Exhaust System cecinere ea 3 16 B 4 Inspect the Engine Air Filter 3 17 B 5 Check the Cooler and Cooling Fins Deutz Models 3 17 B 6 Inspect the Tires Wheels and Lug Nut Torque 3 18 B 7 Confirmthe Proper Brake Configuration 22 2 2 4 4 00 3 19 B 8 Check the Oil Level in the Drive Hubs 3 19 viii Z 45
277. end of the jib boom lift cylinder 19 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the bellcrank AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Part No 107846 Z 45 25 Z 45 25J JIB BOOM COMPONENTS Z 45 25J 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures August 2006 m ENT JIB B
278. eners from the engine side cover then remove the cover 4 Inspect the oil cooler for leaks and physical damage a ol cooler b cylinder head cooling fins c fan blower fins 5 Clean the oil cooler of debris and foreign material Cooling and fan blower fins 6 Inspectthe fan blower fins for physical damage 7 Clean the fan blower fins of debris and foreign material 8 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 9 Cleanthe cylinder head cooling passages of debris and foreign material 10 Install the engine side cover 11 Swing the engine back to its original position and close the engine pivot plate latch 12 Install the engine pivot plate safety pin REVC B 6 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products The tires on some machines are foam filled and do not need air
279. erform Engine Maintenance Ford 3 33 D Checklist C Procedures C 1 Perform Engine Maintenance Deutz Models nennen 3 34 C 2 Grease the Platform Overload Mechanism if equipped 3 34 C 3 Testthe Platform Overload System if equipped 3 35 C 4 Replace the Fuel Filter Water Separator Perkins Models 3 38 C 5 Replace the Engine Air Filter Element Deutz and Perkins Models 3 40 C 6 Perform Engine Maintenance Perkins Models 3 40 C 7 Perform Engine Maintenance Ford 3 41 A TEREX COMPANY Part No 107846 Z 45 25 Z 45 25J June 2012 TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued D ChecklistD Procedures D 1 Check the Boom Wear 5 D 2 Check the Turntable Rotation Bearing Bolts D 3 Inspect for Turntable Bearing Wear 0 4 Replace the Drive Hub 0 5 Checkthe Free wheel Configuration D 6 Replace the Hydraulic Filters D 7 Perform Engine Maintenance Deutz Models D Checklist E Procedures E 1 Testor Replace the Hydraulic E 2 Grease the Steer Axle Wheel Bearings 2WD Models E 3 Perform Engine Maintenance Deutz
280. etract circuit Solenoid valve 2 position 3 way CA Primary boom extend Proportional directional solenoid valve 3 position 4 way BY Primary boom up down Differential sensing valve 160 psi 11 bar em BG Meters flow to functions Proportional directional solenoid valve 3 position 4 way Turntable rotate left right Proportional directional solenoid valve 3 position 4 way Secondary boom up down Solenoid valve 3 position 4 way BF Steer left right Relief valve 2100 psi 145 bar Secondary boom down Orifice 0 046 inch 1 17 mm Secondary boom down circuit Check valve 5psi 0 3 bar BY Differential sensing circuit secondary boom down Check valve 5psi 0 3 bar Bi Secondary boom Check valve 5psi 0 3 bar Differential sensing circuit secondary boom Priority flow regulator valve 1 5 5 7 L min 2 steer circuit ccn Relief valve 3200 psi 220 6 bar BA System Shuttle valve
281. exhaust pipe fasteners at the muffler 9 Remove the muffler bracket mounting fasteners from the bell housing Carefully remove the muffler and bracket assembly from the engine 10 Support the engine with an overhead crane or other suitable lifting device Do not lift it 4 34 TEREX Z 45 25 Z 45 25J 11 Remove the engine mounting plate to bell housingfasteners 12 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support 13 Remove all of the engine bell housing retaining fasteners 14 Carefully remove the bell housing from the engine 15 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Part No 107846 August 2006 Section 4 Repair Procedures REV B How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump 2 Ford models Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft Ibs 27 Nm Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft Ibs 54 Nm Perkins models Torque the flex plate mounting bolts in sequence to 49 ft lbs 66 Nm Then torque the flex plate mounting bolts in sequence to 70 ft Ibs 95 Nm Perkins models PartNo 1078
282. form and ground personnel 1 Startthe engine from the ground controls and lower the boom into the stowed position 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the primary boom through a full cycle O Result The platform should remain level at all times to within 5 degrees Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES B 13 Test the Engine Idle Select Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are two settings Foot switch activated low idle turtle symbol allows the operator to control individual boom functions Drive functions will operate at low idle but at reduced performance Foot switch activated high idle rabbit symbol should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from the ground controls then move the function enable toggle switch to the high idle rabbit symbol position and hold in the on posit
283. from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed 5 Install the filter element 6 Install the air filter canister end cap and secure the end cap latches Be sure the discharge valve is pointing down when the cap is instaled Check the Oil Cooler and Cooling Fins Deutz Models Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING P dily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may result in severe burns Oil cooler 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES 2 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 3 Remove the fast
284. g oo Bo 62 e 5 8 5 5 C107AF WH joe 510 N BAT RD 8 9 OR BK C2B 3 t ry kal eo o 2 8 IM Z2 OQ lllll 26 ER 5 E PM e Ei ALTERNATOR iE i lg 520 B 8 84 8 83 53 Lie br bes lt g m TE ui 2 a P20BAT RD C7B 4 e e ENGINE HARNESS 2 Part No 107846 2 45 25 Z 45 25J boom in stowed position and the keyswitch off 6 15 Section 6 Schematics C28TTA RD BK Electrical Schematic Z 45 25J Ford LRG 425 EFI Models before serial number 30142 August 2006 C28TTA RD BK REV C BATGND C7P 8 C7B 8 e GROUND CA1RPM OR BK C2P 3 lt 5 C30FWD WH 5 s qc DE C1B 4 05 21 C30FWD WH BK LED A
285. gh idle 2500 rpm 42 Hz Compression ratio 23 371 Compression pressure 426 psi 29 4 bar Pressure psi of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Governor centrifugal mechanical Valve clearance cold Intake 0 008 in 0 2 mm Exhaust 0 008 in 0 2 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 10 A TEREX COM Z 45 25 Z 45 25J PANY REV H Lubrication system Oil pressure cold 60 psi at 2500 rpm 4 1 bar Oil capacity 9 3 quarts including filter 8 8 liters Cil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel injection system Injection pump make Zexel Injection pressure 2133 psi 147 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Alternator output 55A 12V DC Fan belt deflection 3 8 in 10 mm Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Part No 107846 January 2011 Section 2 Specifications iere ee ee
286. gine Cylinder Head Coolant Temperature low voltage CHT higher than expected 1 CHT higher than expected 2 ECT higher than expected 1 ECT higher than expected 2 MAP Manifold Absolute Pressure high pressure MAP Manifold Absolute Pressure low voltage BP Barometric Pressure high pressure BP Barometric Pressure low pressure 46 53 254 1 3 3 3 3 For further engine fault code troubleshooting and diagnostic information refer to the Ford DSG 423 EFI Service Manual EDI part number 1060040 Ford DSG 423 EFI Service Manual Genie part number 119494 Genie PartNo 107846 A TEREX COMPANY Z 45 25 Z 45 25J Section 5 Fault Codes August 2006 FAULT CODES REVA Code FP Fuel Pressure high voltage EE Primary Loop Open or Low Side Short to Ground 2 FP Fuel Pressure low voltage 414 Primary Coil Shorted 2 FT Fuel Temperature gasoline high 271 voltage 415 Primary Loop Open or Low Side Short 272 FT Fuel Temperature gasoline low to Ground 3 voltage 416 Primary Coil Shorted 3 273 FT Fuel Temperature gaseous fuel 421 Primary Loop Open or Low Side Short high voltage to Ground 4 FT Fuel Temperature gaseous fuel 422 Primary Coil Shorted 4 ow vonage TPS1 Throttle Position Sensor high Injector Loop Open or Low Side Short 531 votadas to Ground 1 TPS1 Throttle Position Sensor Low Injector Coil Shorted 1 532 voltage 313 Injector Loop Open or Low Side Short 533 TPS2 T
287. greater than 1500 rpm sensor wiring and or connections are open or 211 IAT high voltage shorted OR sensor is faulty OR engine intake air temperature is too cold sensor wiring and or connections are open or 212 IAT low voltage shorted OR sensor is faulty OR engine intake air temperature is too hot Repair wiring and or connections OR replace sensor OR direct warmer air into air intake Repair wiring and or connections OR replace sensor OR direct cooler air into air intake Continued on next page 5 PartNo 107846 Z 45 25 2 45 25 5 7 Section 5 Fault Codes August 2006 FAULT CODES REV B Code Problem Cause Solution IAT higher than expected Air intake temperature is greater than 200 F with Check air intake system for damage and 21 3 1 9 the engine greater than 1000 rpm OR air intake proper routing of air intake components OR system has leaks OR IAT sensor is faulty replace the sensor Air intake temperature is greater than 210 F with Check air intake system for damage and 21 4 e higher thanmexpected the engine greater than 1000 rpm OR air intake proper routing of air intake components OR system has leaks OR IAT sensor is faulty replace the IAT sensor 215 Oil pressure low Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Replace oil pressure sensor OR repair sensor wiring and or conn
288. hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag disconnect and plug the hydraulic hoses from the platform leveling master cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PartNo 107846 2 45 25 Z 45 25J 4 15 Section 4 Repair Procedures August 2006 PRIMARY BOOM COMPONENTS 8 Tagand disconnect the hydraulic hoses from the platform leveling slave cylinder and connect them together using a connector Cap the fittings on the cylinder AWARNING SC injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Pullthe four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder 10 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 11 Remove all hose and cable clamps
289. he fuel filter housing CHECKLIST B PROCEDURES Prime the fuel system 10 Loosen the vent plug on top of the fuel injection pump a vent plug b fuel injection pump fuel lift pump 11 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 12 Clean up any fuel that may have spilled during this procedure 13 Operate the starter motor for intervals of 15 seconds until the engine starts It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES B 22 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 250 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information ar
290. heck engine light should turn on The check engine light should begin to blink REV B 5 Continue to hold the run test toggle switch in the test position and count the blinks Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery
291. how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service R repaired Checklist C Rev D August 2006 Checklist D RevD YN D Rev D C 1 Engine maintenance Deutz models 2 Grease platform overload if equipped C 3 Test platform overload if equipped 4 Fuel filter separator Perkins models C 5 Air filter Deutz and Perkins models Perform every 600 hours C 6 Perform every 800 hours Engine maintenance Perkins models C 7 Engine maintenance Ford models Comments Genie D 1 Boom wear pads D 2 Turntable bearing bolts D 3 Turntable bearing wear D 4 Drive hub oil D 5 Free wheel configuration D 6 Hydraulic filters D 7 Engine maintenance Deutz models ChecklistE RevD Y NR E 1 Hydraulic oil E 2 Grease steer axle wheel bearings 2WD models Perform every 3000 hours E 3 Engine maintenance Deutz models Perform every 12 000 hours E 4 Engine maintenance Deutz models TEREX COMPANY 2 45 25 2 45 25 Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures Checklist A Procedures REVD A 1 Perform Pre operation Inspection
292. hrottle Position Sensor high to Ground 2 voltage Injector Coil Shorted 2 534 TPS2 Throttle Position Sensor low 315 Injector Loop Open or Low Side Short voltage to Ground 3 535 TPS1 Throttle Position Sensor higher Injector Coil Shorted 3 1PS2 ATEI Injector Loop Open or Low Side Short 536 321 than TPS2 to Ground 4 BE Postionsensen Injector Coil Shorted 4 Position Sensor 538 Unable to reach lower TPS Throttle shorted to ground Position Sensor DEER 539 51 2 simultaneous voltages EPR delivery pressure higher than 541 AUX analog high expected 542 AUX analog PU1 low EPR delivery pressure lower than 543 AUX analog PU high expected EPR comm lost 544 AUX analog PU2 low Fuel run out longer than expected 551 Max govern speed override EPR voltage supply high 552 Fuel rev limit EPR voltage supply low 553 Spark rev limit EPR internal actuator fault detection For further engine fault code troubleshooting and EPR internal circuitry fault detection diagnostic information refer to the Ford DSG 423 EPR internal comm fault detection EFI Service Manual EDI part number 1060040 dbi Open or Low Side Short Ford DSG 423 EFI Service Manual to Groun Genie part number 119494 Primary Coil Shorted 1 Genie TEREX COMPANY 5 14 Z 45 25 2 45 25 PartNo 107846 August 2006 Section 5 Fault Codes REVA
293. i OSCILLATE EN RUNE NIE ee FUNCTION MANIFOLD TP2 DEUS CG 2206bar Fd 25psi 17 ES T M E d EE P uet cir SIE TANK AUXILIARY M An POWER UNIT M eee 5 1 T ATMOS Balearen 1 1000 psi 69 bar STEER CYLINDERS a zx t9 HH ER PTIONAL OSCILLATE IRECTIONAL VALVE 107846 A TEREX COMPANY 2 45 25 Z 45 25J 6 67 June 2012 Section 6 Schematics Hydraulic Schematic 2WD Models before serial number 27001 REV B June 2012 e Hydraulic Schematic 2WD Models
294. ich if not avoided may result in minor or moderate injury CAUTION Without safety alert symbol used to indicate the presence of a Be sure to properly dispose of old oil or potentially hazardous situation 2 other fluids Use an approved container which if not avoided may result in Please be environmentally safe property damage Be sure that your workshop or work area Used to indicate operation or is properly ventilated and well lit maintenance information Cie Genie vi Z 45 25 Z 45 25J Part No 107846 Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards e such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and Ae lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 8 Be sure that all tools and working areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure gos faste
295. in minimum clearance with zero binding 2 Extendandretract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Primary boom wear REVD D 2 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining propertorque onthe turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom and place a safety chock on the lift cylinder rods Carefully lower the boom onto the lift cylinder safety chock AWARNING Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through the Genie Service Parts Department 2 Turnthe engine off 3 Remove the safety pin from the engine pivot plate latch pad specifications Minimum The engine pivot plate latch is located underthe engine turntable Top bottom and side wear pads 5 8 inch pivot plate at the counterweight platform end of boom 15 9 mm end of the machine Side and bottom wear pads 1 e inch pivot end of boom 12 7 mm Top wear pads 5 8 inch pivot end of boom 15 9 mm Genie TEREX COMPANY 2 45 25 Z 45 25
296. in the fuel Rotate the filter bowl counterclockwise and remove it from the element Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 10 Rotate the filter element counterclockwise and remove it from the filter head 11 Install the bowl onto the new filter element 12 Apply a thin layer of oil onto the element gasket Install the filter bowl assembly onto the filter head Tighten the drain plug and vent plug Component damage hazard The CAUTION drain plug and vent plug can be damagedi if they are overtightened 13 Clean up any diesel fuel that may have spilled during the installation procedure 14 Install the fuel supply hose from the fuel tank to the fuel filter water separator Tighten the clamp 15 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter element housing Prime the fuel system 16 Loosen the vent plug on top of the fuel injection pump vent plug b fuel injection pump c fuel lift pump CHECKLIST C PROCEDURES 17 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 18 Clean up any fuel that may have spilled during this procedure 19 Operate the starter motor for intervals of 15 seconds until the engine starts It is important to allow the starter motor to cool for 30 seconds between each 15 second i
297. inal Strip Wiring Diagram Z 45 25 Deutz F3L 2011 Models GROUND BK ALARM August 2006 BK ALARM BK BRN GND GR BK H6 RD TS52 RD TS51 BK C7B 1 8 Ground Control Box Terminal Strip Wiring Diagram Z 45 25 Section 6 Schematics Deutz F3L 2011 Models 5 t do Nua o 65025 SSES SECHM 1SFHM fr 4951 5 619 HAVE 2 89 SE SSOH vSrau wave Weg 61 50 2 E V2E QH HM WHV V QH HM 85 95 e MEO OZ DD ICD x DI MCCC EIC sen
298. ine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 OR the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 OR the Perkins 400 Series Operation Manual Perkins part number 14435 Ford LRG 425 EFI Operator Handbook REVD To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Deutz FL 2011 Operation Manual Genie part number 84794 Perkins 400 Series Operation Manual Genie part number 94890 Genie TEREX COMPANY 3 8 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 4 Check the High Pressure Hydraulic Filter Condition Indicator Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the high pressure hydrauli
299. injectors faulty or stuck closed OR fuel quality is pressure OR clean or replace the fuel poor OR fuel pressure is too low injectors MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or 1 42 Adaptive rich fault Low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair limit Gasoline injectors are stuck closed OR there is electro fuel injectors magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace 1 43 Adaptive learn high LPG open or shorted OR sensor is faulty OR there are sensor OR repair any vacuum and exhaust vacuum leaks or exhaust leaks OR fuel quality is leaks OR replace fuel OR test and repair the poor OR fuel system components may be faulty fuel system components Engine wire harness may have an intermittent Repair short in engine wire harness OR test 144 Adaptive learn low LPG short to 5V DC or 12V DC OR fuel system 9 components may be faulty and repair the fuel system components 1 61 System voltage low Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair 9 battery supply wiring to is open shorted battery supply wiring to ECM 1 62 System voltage high Alternator is overcharging the battery when Repair or replace the alternator engine RPM is
300. ion Result The engine should change to high idle Release the function enable toggle switch Result The engine should return to low idle gt o 0 Turn the key switch to platform controls Genie TEREX COMPANY 2 45 25 Z 45 25J REVC Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle Press down the foot switch Result The engine should change to high idle Move the engine idle control switch to foot switch activated low idle turtle symbol Result The engine should change to low idle Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC B 14 Test the Fuel Select Operation Ford Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Atthe platform controls move the fuel
301. ions from the ground controls Result All ground control functions should not operate 11 Activate the auxiliary power toggle switch If the platform overload system is notoperating properly Refer to Repair Procedure 2 3 How to Calibrate the Platform Overload System if equipped 17 Using a suitable lifting device remove the The engine will turn off when the remaining test weights from the platform auxiliary power is activated 12 Using auxiliary power test all machine functions from the ground controls O Result All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from the platform O Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound There may be an 2 second delay before the overload indicator lights and alarm turn off 14 Start the engine and test all machine functions from the ground controls O Result All ground control functions should operate normally Genie TEREX COMPANY Part No 107846 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES 4 Replace the Fuel Filter Water Separator Perkins Models Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Regular replacement of the fuel filter water separator is
302. is a poor system ground connection OR throttle position sensor 2 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 534 TPS2 signal voltage low The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 2 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 535 TPS1 higher than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors 536 TPS1 lower than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors 537 Throttle unable to open Governor actuato
303. ise the primary boom slightly with the overhead crane to relieve the pressure on the primary boom lift cylinder rod end pivot pin 18 Use a soft metal drift to remove the primary boom lift cylinder rod end pivot pin Crushing hazard The primary AWARNING boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 19 Lower the rod end of the primary boom lift cylinder approximately 12 inches 30 cm 20 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder 21 Raise the rod end of the primary boom lift cylinder back into position and install the rod end pivot pin Install the pin retaining fasteners 22 Attach a strap from an overhead crane to the cable track 23 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 24 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom TEREX Z 45 25 Z 45 25J REV 25 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched CAUTION How to Repair the Primary Boom Cable Track Component damage hazard CAUTION
304. ition until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING Cushing hazard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks Z 45 25 Z 45 25J 4 9 Section 4 Repair Procedures August 2006 PLATFORM COMPONENTS 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromise
305. iz 8 Bi L SL Le gage viii ab Lund o EE 3 g e RD RD RD TEREX COMPANY PartNo 107846 Z 45 25 Z 45 25J 6 40 August 2006 Section 6 Schematics n rr Ground Control Box Switch Panel Wiring Diagram Z 45 25J CE Models Deutz F3L 2011 Models August 2006 Section 6 Schematics T_T Platform Control Box Wiring Diagram Z 45 25J Deutz F3L 201 1 Models August 2006 Platform Control Box Wiring Diagram Z 45 25J Section 6 Schematics Deutz F3L 2011 Models PLATFORM CONTROL HARNESS TO SWITCH PANEL 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR DESCRIPTION TILT ALARM CONTROL BOARD OUTPUT CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM H1 cg C1P C4P 48 CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 Part No 107846
306. joystick Self clearing transient Power up controller with problem corrected Power up controller with problem corrected Not calibrated Just calibrated Value at 5V Value too high Value too low Value at OV Not calibrated Normal function except threshold for one or both directions is zero Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Joystick speed and direction frozen at zero and neutral Calibrate valve thresholds Self clearing Power up controller with problem corrected Calibrate joystick Just calibrated Initiate 1 second beep of alarm Self clearing transient Boom 2 directional valves Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Genie Part No 107846 TEREX COMPANY Power up controller with problem corrected 25 Continued on next page Z 45 25 Z 45 25J 5 3 Section 5 Fault Codes FAULT CODES August 2006 REVA Error Source Error Type ID Name D Nrs Condition Solution 33 Boom 2 flow Limited speed and control valve direction frozen at ower up e Kache ie dE zero and neutral controller with Alarm sounds problem corrected indicating fault Normal function except threshold for Calibrate valve 17 Not calibrated one or both directions thresholds is zer
307. kins Models Engine specifications require that this procedure be performed every 600 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 14435 Perkins 400 Series Operation Manual Genie part number 94890 To access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD CHECKLIST C PROCEDURES 7 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance
308. l Strip Wiring Diagram 2 45 25 6 41 A Platform Control Box Switch Panel Wiring Diagram Z 45 25J 6 42 Perkins 404 22 models C Electrical Schematic 2 45 25 certis ri arc v refor Exe He ara hi bea 6 44 A Ground Control Box Terminal Strip Wiring Diagram Z 45 25 6 48 B Ground Control Box Switch Panel Wiring Diagram Z 45 25 6 49 A Platform Control Box Terminal Strip Wiring Diagram Z 45 25 6 52 A Platform Control Box Switch Panel Wiring Diagram 2 45 25 6 53 C Electrical Schematic 7 45 25 6 56 B Ground Control Box Terminal Strip Wiring Diagram 2 45 25 6 60 B Ground Control Box Switch Panel Wiring Diagram 2 45 25 6 61 A Platform Control Box Terminal Strip Wiring Diagram Z 45 25J 6 63 A Platform Control Box Switch Panel Wiring Diagram 2 45 25 6 65 Hydraulic Schematics D Hydraulic Schematic 2WD Models before serial number 27001 6 67 B Hydraulic Schematic 2WD Models after serial number 27000 6 69 C Hydraulic Schematic 4WD Models before serial number 27001 6 71 B Hydraulic Schematic 4WD Models after serial number 27000
309. lashing the code the yellow LED will be on solid Determine the error type The yellow LED indidates the error type and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second When the yellow LED is flashing the code the red LED will be on solid Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected 5 2 Z 45 25 Z 45 25J PartNo 107846 August 2006 Section 5 Fault Codes REVA FAULT CODES Error Source Error Type ID Name Boom 1 Joystick primary boom up down Boom 1 directional valves Boom 1 flow control valve Boom 2 Joystick secondary boom up down or primary boom extend retract Name Value at 5V Value too high Value too low Value at OV Condition Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Solution Power up controller with problem corrected Not calibrated Just calibrated Value too high Value too low Joystick speed and direction frozen at zero and neutral Initiate 1 second beep of alarm Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Calibrate
310. ll out the hydraulic hoses Part No 107846 August 2006 Section 4 Repair Procedures REV B 6 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 disconnect the hydraulic hoses from the platform leveling slave cylinder at the union and connect them together using a connector Connect the hoses from the cylinder together using a connector AWARNING SC injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PRIMARY BOOM COMPONENTS 9 Tag disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder Cap the fittings on the unions AWARNING
311. lockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle 7 Swing the engine back to its original position and close the engine pivot plate latch 8 Install the engine pivot plate safety pin Perkins models This procedure will require two people 1 Openthe engine side turntable cover 2 Remove safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Connect a tachometer to the engine Start the engine from the ground controls Refer to Section 2 Specifications Skip to step 6 if the low idle rpm is correct CHECKLIST B PROCEDURES 5 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm d ni To a solenoid boot b high idle adjustment nut yoke d low idle lock nut and adjustment screw 6 Move the function enable toggle switch to the high idle rabbit symbol position Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 7 Genie Part No 107846 T
312. lus T46 hydraulic oil when oil temperatures consistently exceed 205 96 Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Part No 107846 A TEREX CON Z 45 25 Z 45 25J MEANY SPECIFICATIONS Drive pump Type bi directional variable displacement piston pump Flow rate 2500 rpm 32 gpm 121 L min Drive pressure maximum 3500 psi 241 bar Charge pump Type gear Displacement 0 84 cu in 13 76 cc Flow rate 2500 rpm 9 1 gpm 34 4 L min Charge pressure 2500 rpm 315 psi 21 7 bar Function pump Type gear Displacement 0 67 cu in 11 cc Flow rate 2500 rpm 7 25 gpm 27 4 L min Auxiliary pump Type gear fixed displacement Displacement per revolution 0 067 cu in 1 1 Auxiliary pump relief pressure 3200 psi 220 6 bar Continuous improvement of our products is Genie policy Product specifications are subject to change without notice Section 2 Specifications January 2011 SPECIFICATIONS REV H Function manifold Hydraulic filters System relief valve pressure 3200 psi High pressure filter Beta 3 gt 200 220 6 bar High pressure filter 100 psi Secondary boom down 2100 psi bypass pressure 6 89 bar relief valve pressure 145 bar Medium pressure filter Beta 3 gt 200 Platform level
313. may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine 2 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC 3 Thoroughly clean the outside surfaces of the fuel filter assembly 4 Place a suitable container under the fuel filter element 5 Disconnect and plug the fuel line from the fuel pump to the fuel filter element a fuelline b filter head fuelfilter element 6 Remove the fuel filter element with a filter wrench 7 Apply a thin layer of fuel to the new fuel filter element O ring 8 Install the new fuel filter element and tighten it securely by hand Clean up any fuel that may have spilled during the installation procedure 9 Use a permanent ink marker to write the date and number of hours from the hour meter on t
314. move the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box 54 Remove the number 3 arm from the machine AWARNING Crushing hazard The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 55 Remove the upper and lower hose and cable covers from the number 3 arm 56 Remove the secondary boom drive speed limit Switch mounting fasteners from the number 4 arm at the mid pivot end Do not disconnect the wiring Part No 107846 Z 45 25 Z 45 25J SECONDARY BOOM COMPONENTS 57 Remove the pin retaining fasteners from the number 4 arm at the turntable riser Do not remove the pin 58 Attach a lifting strap from the overhead crane to the center point of the number 4 arm Do not lift it 59 Use a slide hammer to remove the number 4 arm from the turntable riser through the ground controls side bulkhead 60 Remove the number 4 arm from the machine Crushing hazard The number 4 AWARNING arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 4 31 Section 4 Repair Procedures August 2006 SECONDARY BOOM COMPONENTS 5 2 Secondary Boom Lift Cylinders There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly These cylinders operate in parallel and require hydraulic pressure
315. n 12 14 ft Ibs 16 19 Nm 31 Solenoid valve 2 position 3 way CC Primary boom retract 20 ft lbs 27 Nm 32 Shuttle valve Blues Platform level circuit 12 14 ft lbs 16 19 Nm 33 Check valve dual pilot operated 135 psi 9 3 Dar dtes BJ uos Platform level circuit 20 ft lbs 27 Nm Genie TEREX COMPANY Z 45 25 Z 45 25J Part No 107846 MANIFOLDS Section 4 Repair Procedures June 2012 REVE BO BA BB BS 17 16 15 14 G Na Im 2 5 0 9277 DER o z 51 a enie Z 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012 MANIFOLDS 8 4 Valve Adjustments Function Manifold after serial number 27000 How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge to the 1 port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the high rpm position and activate and hold the primary boom retract switch with the boom fully retracted 4 ObDservethe pressure reading on the pressure gauge Refer to Section 2 Specifica
316. n 6 Schematics 0 5 2 Lu Nua Nua tr zou x EE i 1561 AST6LO 2 80 E 2 Lu Wuvivoa 61 62 8 92 9 lt o i 21 o a z gt n 2 89 GH HM 8 t gt SCHU 258 I orc Q 1 gt I g E 42 m U 5 f 3 E 5 5 5 28 on 3 T gt 515 1 lt gt 9 a Zu 3 Pa SC EE RETE BOGS SEES 228d 6 99 gt i amp uou tou Srog D 1 orca 6 862 z Sr d qu 1 90 i 2 E o 90 Pew i 9 9 11 92 1 1801 92 1 gt PW da e T dd i z c gi 55 2 E 2 mM Er ZEIEN 8690 ad E e g 25 4 auzainaera 66 90 alg 5 bd t p g d Fog g bod o z g E Io x el 2 9 5 Gi 3 5 x iz q 6 E 8 H 2125 2 2 ME T 9 gt 3 5 5 50 8 B 55 z MP c amp D oe amp 23 55 71488 88 88 556 BE 1 2 2 gt
317. n the locked position m AWARNING Crushing hazard The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 4 72 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures REVC 10 1 Hub and Bearings 2WD Models How to Remove the Hub and Bearings 2WD Models 1 Loosenthe wheel lug nuts Do not remove them 2 Blockthe non steer wheels and place a lifting jack of ample capacity under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the chassis for support Crushing hazard The machine ACAUTION may fall if not properly supported 4 Remove the lug nuts Remove the tire and wheel assembly 5 Remove the dust cap cotter pin and castle nut Always use a new cotter pin when installing a castle nut 6 Pullthe hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub 8 Remove the rear bearing Part No 107846 Z 45 25 Z 45 25J Axle Components How to Install the Hub and Bearings 2WD Models When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing s
318. nbalanced and fall if not properly supported when removed from the machine 11 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 12 Remove the suction strainers from the tank and clean them using a mild solvent 13 Rinse out the inside of the tank using a mild solvent 14 Install the suction strainers using a thread sealant on the threads 15 Install the drain plug using a thread sealant on the threads CHECKLIST E PROCEDURES 16 Install the hydraulic return filter housing onto the hydraulic tank 17 Install the hydraulic tank onto the machine 18 Install the two suction hoses to the suction strainers 19 Install the supply hose for the auxiliary power unit and the return filter hose 20 Models with hydraulic tank shut off valves Open the two hydraulic tank valves at the hydraulic tank 21 Fill the tank with the proper hydraulic oil for your machine until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill Refer to Section 2 Specifications 22 Clean up any oil that may have spilled 23 Prime the pump Refer to Repair Procedure 7 2 How to Prime the Pump Always use pipe thread sealant when installing the suction hose fittings and the drain plug Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST E P
319. nd or connections for sensors open or 1 22 Closed loop multiplier low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair gasoline injectors are stuck open OR there is electro fuel injectors magnetic interference from a faulty crankshaft and or camshaft position sensor Heated oxygen sensor wiring and or connections Repair wiring and or connections OR replace Closed loop multiplier low open or shorted OR sensor is faulty OR fuel 124 LPG ni OR fuel sensor OR replace fuel OR test and repair the quality is poor system components may fuel system components be faulty Repair exhaust leaks OR there is an 1 33 Gasoline cat monitor There are exhaust leaks OR ihecatalyst system emissions compliance issue Contact Ford efficiency is below the acceptable level Power Products for assistance Repair exhaust leaks OR there is an There are exhaust leaks OR the catalyst system MS 1 34 SSES efficiency is below the acceptable level slices Miu Ua Ford 135 NG cat monitor lo Ne N El nl issue Corel Ford efficiency is below the acceptable level Power Products for Heated oxygen sensor wiring and or connections Repair heated oxygen sensor wiring and or Adaptive lean fault High open or shorted OR sensor is faulty OR there are connections OR replace sensor OR repair 141 li i 9 vacuum or exhaust leaks OR one more fuel vacuum and exhaust leaks OR test the fuel imit Gasoline
320. ners intended for one time use i e pins self locking nuts are not reused These components may fail if they are used a second time June 2012 Introduction Section 1 Section 2 Rev H Table of Contents Important INFOMATION tac ee nee ii Number aea Ene ij Serial Number Legend iii Safety Rules General Safety Rulas uiui Specifications Machine Specifications terit e rese ei ak 2 1 Performance Specifications u sen 2 2 Hydraulic ene 2 3 Manifold Component Specifications 2 2 5 Ford LRG 425 EFI Engine Specifications 2 6 Ford DSG 423 EFI Engine Specifications 2 7 Deutz F3L 2011 02011 03 Engine Specifications 2 8 Perkins 404 22 Engine Specifications 2 10 Machine Torque 2 12 Hydraulic Hose and Fitting Torque Specifications 2 13 SAE and Metric Fastener Torque Chart 2 14 Genie Part No 107846 A TEREX COMPANY Z 45 25 Z 45 25J vii June 2012 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction 3 1 Pre Delivery Prep aration u 3 3 Maint
321. nitiate 1 second beep of alarm Self clearing transient Steer directional valves Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Genie Part No 107846 TEREX COMPANY Z 45 25 Z 45 25J Power up controller with problem corrected Section 5 Fault Codes August 2006 FAULT CODES Ford LRG 425 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Perform this procedure with the key switch in the off position 1 Locate the run test toggle switch on the side of the ground control box 2 Pullout the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position Result The c
322. ns 4 33 6 3 I educ 4 33 6 4 Engine Fault Codes Ford Models 4 37 B Hydraulic Pumps 7 1 nnnn enne 4 38 T2 Diva PUMP EE 4 39 A TEREX COMPANY Part No 107846 Z 45 25 Z 45 25J xi June 2012 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued E Manifolds 8 1 Function Manifold Components before serial number 27001 8 2 Valve Adjustments Function Manifold before serial number 27001 8 8 Function Manifold Components after serial number 27000 8 4 Valve Adjustments Function Manifold after serial number 27000 8 5 Jib Boom Platform Rotate Manifold Components before serial number 27001 8 6 Jib Boom Platform Rotate Manifold Components after serial number 27000 8 7 Turntable Rotation Manifold Components before serial number 27001 8 8 Turntable Rotation Manifold Components after serial number 27000 8 9 Directional Valve Manifold Components 8 10 Traction Manifold Components 2WD before serial number 27001
323. nterval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system 20 Swing the engine back to its original position and close the engine pivot plate latch 21 Install the engine pivot plate safety pin Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES 5 Replace the Engine Air Filter Element Deutz and Perkins Models Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap Remove and discard the filter element 4 Clean the inside of the canister and the end with a damp cloth 5 Install the new filter element 6 Install the air filter canister end cap and secure the end cap latches Be sure the discharge valve is pointing down when the cap is instaled REVD C 6 Perform Engine Maintenance Per
324. ntrolled 1600 rpm 27 Hz High function idle computer controlled 2500 rpm 42 Hz Compression ratio 9 7 1 Compression pressure approx Pressure psi or bar of lowest cylinder must be at least 75 of highest cylinder Lubrication system Oil pressure 29 to 39 psi at operating temperature 2500 rpm 2 to 2 7 bar Oil capacity 4 quarts including filter 3 8 liters Cil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 107846 A TEREX COMPANY Z 45 25 e Z 45 25J SPECIFICATIONS Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FEC 0 044 to 0 045 inches 1 125 to 1 135 mm Spark plug gap Engine coolant Capacity 10 quarts 9 5 liters Cylinder head temperature sending unit Fault code set temperature 280 F 138 Engine shut down temperature 300 F 149 C Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140
325. o 18 Just calibrated Self clearing transient 41 Turntable rotate 11 Value at 5V Limited speed and joystick 12 Value too high direction frozen at Power up 15 Value too low zero and neutral controller with 16 Value at OV Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate joystick zero and neutral Initiate 1 Self clearing EE of alarm transient 42 Turntable rotate Limited speed and directional valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault 43 Turntable rotate Limited speed and flow control valve 12 Value too high direction frozen at Power up zero and neutral controller with 15 Value too low Alarm sounds problem corrected indicating fault Normal function Calibrate valve Tu a except threshold for thresholds one or both directions Self clearing 18 Just calibrated TE transient 9 44 Drive enable Enable override Power up override switches 21 Fault direction is frozen at controller with neutral problem corrected Genie 5 4 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 5 Fault Codes S n1 REVA FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 51 Drive joystick 11 Value at 5V Limit
326. o d m 8 EL a BK era CA46HRNBK RD C3B 9 CA6HRN BK RD L HORN RELAY ag 2 T d C7P 2 P23BAT WH C7B 2 ER 5 a 1 E 1 C7P 1 P22BATBK C7B 1 P22HRN BK e PAGHEN BK RD C6 9 A HORN 3 Es o 5 e 5 2 lt 7 5 c e T 5 E a C107AF WH amp 5 BIFA n 4 5 4 BAT RD G C41RPM C2B 3 a 5 g 5 KH S LL LL INS c p 1 E t m bal a 1 N ASC zc 1 E Zi EE e 4 2 8 P20BATRD__ F C74 41 lt 2 3 T N Part 107846 A TEREX COMPANY Z 45 25 Z 45 25J G in the stowed position and the keyswitch off Section 6 Schematics August 2006 Electrical Schematic Z 45 25 Ford LRG 425 EFI Models before serial number 30142 REV C C28TTA RD BK P26ESTP P26ESTP BK C28TTA RD BK
327. odels Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Componentdamage hazard The CAUTION engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications 3 50 2 45 25 2 45 25 Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD 5 Tag disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank The hoses can be accessed through the access hole under the turntable 6 Disconnect and plug the return filter hydraulic hose at the return filter Cap the fitting on the filter housing 7 Removethe ground controls side turntable cover 8 Support the hydraulic tank with an appropriate lifting device 9 Remove the hydraulic tank mounting fasteners 10 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic tank could become u
328. of the hydraulic tank Remove the cap from the filter housing Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing 4 Remove filter element from the filter housing REVD 5 Install the new filter element into the filter housing Push the filter element down to be sure the O ring on the element is fully seated into the housing 7 Rotate the filter element clockwise to lock it in place 8 Install the filter housing cap 9 Useapermanent ink marker to write the date and number of hours from the hour meter on the oil filter housing Medium and high pressure filters The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit 10 Open the engine side turntable cover and locate the medium and high pressure filters The medium pressure filter is mounted near the pump The high pressure filter with filter condition indicator is mounted to the bulkhead 11 Place a suitable container under each filter 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings 13 Remove the filter elements from the housings 14 Inspect the housing seals and replace them if necessary Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures
329. on 6 Schematics Hydraulic Schematic 4WD Models after serial number 27000 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
330. ons can result in engine component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 sure that battery hold downs and cable connections are tight Genie TEREX COMPANY REVC Be sure that the battery separator wire connections are tight if equipped Fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more b
331. or each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service R repaired Checklist B Rev C Checklist A Rev D YNR 1 Pre operation inspection A 2 Functions tests A 3 Engine maintenance 4 Filter condition indicator 5 axle Perform after 40 hours B 1 Battery B 2 Electrical wiring B 3 Exhaust system B 4 Inspect air filter B 5 Oil cooler and fins Deutz models B 6 Tires and wheels A 6 30 day service Perform every 100 hours B 7 Brake configuration B 8 Drive hub oil level A 7 Engine maintenance Ford models B 9 Engine RPM All models A 8 Fuel filter separator Diesel models Rotation bearing Perform every 200 hours A 10 Engine maintenance Ford models
332. or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause componentdamage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Openthe engine side turntable cover 2 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine 3 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Hydraulic manifold wiring Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST B PROCEDURES 5 Openthe ground controls side turntable cover 6 Inspectthe following areas for burnt chafed corroded and loose wires Ground control box wire harnesses Inside of the ground control box Hydraulic manifold wiring 7 Inspect for a liberal coating of dielectric grease at following location All wire harnesses connectors to the ground control box 8 Startthe engine from the ground controls and raise the secondary boom above the turntable covers
333. osity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 6 A TEREX COM Z 45 25 Z 45 25J PANY REV H Electronic fuel pump Fuel pressure static 63 psi 4 3 bar Fuel flow rate 0 58 gpm 2 2 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FM Spark plug gap Engine coolant 0 042 to 0 046 inches 1 07 to 1 17 mm Capacity 11 5 quarts 10 9 liters Coolant temperature switch Temperature switch point 230 F 110 C Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Alternator Output 95A 14 5V DC Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25A rate 200 minutes Part No 107846 January 2011 Section 2 Specifications REVH Ford DSG 423 EFI Engine Displacement 140 4 cu in 2 3 liters Number of cylinders 4 Bore amp stroke 3 44 x 3 7 inches 87 5 x 94 mm Horsepower 59 Q 2500 rpm 44 kW 2500 rpm Firing order 1 3 4 2 Low function idle computer co
334. ot pin Do not remove the pins 1 Attach a strap from an overhead crane to the lug on the rod end of one of the secondary boom lift cylinders for support Do not apply any lifting pressure 12 Use a soft metal drift to drive the barrel end pivot pin half way out Lower the barrel end of the secondary boom lift cylinder and let it hang down 13 Use a soft metal drift to drive the rod end pivot pin half way out 14 Remove the secondary boom lift cylinder from the machine 15 Repeat steps 11 through 14 for the other secondary boom lift cylinder AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Component damage hazard When removing a secondary boom lift cylinder from the machine be careful not to damage the counterbalance valve at the barrel end of the cylinder CAUTION 16 Attach a lifting strap from an overhead crane to the upper pivot for support Do not lift it TEREX Z 45 25 Z 45 25J 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid point between the upper pivot and mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid pivot and the upper pivot Do not remove the pins 19 Use a soft metal drift to drive both pins out 20 Remove the number 1 arm from the machine AWARNING
335. pecifications 1 Raisethe secondary boom until both the rod end and barrel end pivot pins on the master cylinder are accessible 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach overhead crane or similar lifting device to the master cylinder TEREX Z 45 25 Z 45 25J 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 5 Placearod through the barrel end pivot pin and twist to remove the pin 6 Remove the pin retaining fastener from the rod end pivot pin 7 Placearod through the rod end pivot pin and twist to remove the pin 8 Remove the master cylinder from the machine Crushing hazard The master AWARNING cylinder could become unbalanced and fall if not properly attached to the overhead crane Part No 107846 August 2006 Section 4 Repair Procedures This page intentionally left blank PartNo 107846 Z 45 25 Z 45 25J 4 25 Section 4 Repair Procedures August 2006 Secondary Boom Components REV B Secondary Boom components a uppe
336. per engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 access the engine 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 2 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine Genie TEREX COMPANY 3 54 2 45 25 2 45 25 Part No 107846 August 2006 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine Be sure that all necessary tools and parts available and ready for use Read each procedure completely and
337. pivot pin Carefully remove the primary boom lift overhead crane or similar lifting device cylinder from the machine 6 Tag disconnect and plug the primary boom lift AWARNING Crushing hazard The lift cylinder cylinder hydraulic hoses Cap the fittings on the could become unbalanced and fall cylinder if not properly supported and DEE secured to the lifting device AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Cushing hazard The primary boom will fall if not properly supported when the primary boom rod end pivot pin is removed 8 Place a support block across both turntable covers under the primary boom lift cylinder 9 Lower the rod end of the lift cylinder onto the block Protect the cylinder rod from damage Crushing hazard The primary AWARNING boom lift cylinder could fall if not properly supported TEREX COMPANY 4 22 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures Es _ zz z k z REVB PRIMARY BOOM COMPONENTS 4 4 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the Primary Boom Ex
338. position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 107846 TEREX COMPANY Z 45 25 Z 45 25J 5 1 Fault Codes Before Troubleshooting H Read understand and obey the safety rules and operating instructions printed in the Genie Z 45 25 and Genie Z 45 25J Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate fault code thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard Whentesting or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures
339. primary boom cable track can be damaged if it is twisted A 7 link repair section of cable track is available through the Genie Industries Service Parts Department a link separation point b lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 Toremove a single link open the lower clip and then use a screw driver to pry the link to the side 3 Repeat steps 1 and 2 for each link Part No 107846 August 2006 Section 4 Repair Procedures REV B 4 2 Primary Boom How to Remove the Primary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform 2 Z 45 25 Remove the platform rotator and platform mounting weldment Z 45 25J Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the cable track See 4 1 How to Remove the Cable Track Part No 107846 Z 45 25 Z 45 25J PR
340. promise the stability of the machine resulting in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Tolevel the drive chassis start the engine and loosen the lock nuts on both sides of the urethane cushions 7 Pushupor pull down on the threaded rod until the machine is completely level TEREX Z 45 25 Z 45 25J 8 Verify that ground and drive chassis completely level 9 Tighten the nuts on both sides of the urethane cushions until they are snug Tighten the locknuts 10 Check to be sure the drive chassis is completely level 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level repeat steps 6 through 10 OR consult Genie Industries Service Department Part No 107846 June 2012 Section 4 Repair Procedures lt REVE MANIFOLDS This page intentionally left blank PartNo 107846 Z 45 25 Z 45 25J 4 59 Section 4 Repair Proc
341. r is stuck closed OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 538 Throttle unable to close Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 545 Governor interlock failure Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty Repair wiring and or connections in engine harness OR replace the ECM Max governor speed override 551 ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 552 Fuel rev limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 553 Spark rev limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks betw
342. r lights are off at the platform and ground controls and the alarm does not sound Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing atthe platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 The platform will need to be moved up and down and allowed to settle between each adjustment There may be a 2 second delay before the platform overload indicator lights and alarm responds TEREX COMPA 4 10 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures REVC 7 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 8 Result The overload indicator lights are flashing atthe platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Add an additional 10 Ib 4 5 kg test weight to the platform O Result The overload indicator light is flashing at both the ground and platform controls and the alarm is sounding
343. r s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop A TEREX COMPANY Part No 107846 Z 45 25 Z 45 25J Section 1 Safety Rules June 2012 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death TJ Used to indicate the presence of 7 an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation wh
344. r secondary boom number 1 arm b upper tension link number 2 arm lower tension link number 3 arm mid pivot compression link secondary boom lift cylinder 2 lower secondary boom number 4 arm turntable pivot i boom rest j upper pivot ro TEREX COMPANY 4 26 Z 45 25 Z 45 25J Part No 107846 August 2006 Section 4 Repair Procedures REV B 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING Dodly injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform 2 Z 45 25J Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the primary boom See 3 2 How to the Primary Boom 4 Removethe master cylinder See 4 5 How to Remove the Master Cylinder Part No 107846 Z
345. r serial number 27000 continued Index Schematic No Description Item Function Torque 21 Check valve 5 psi 0 3 bar BD Differential sensing circuit platform rotate right and Jib DOOM Be EE 25 ft lbs 34 Nm 22 Flow regulator valve 0 1 0 38 L min BX Primary boom load sense circuit 20 ft lbs 27 Nm 23 Counterbalance valve 3000 psi 207 CD s Primary boom down circuit 30 35 ft lbs 45 50 Nm 24 Pressure compensator valve D I Deh 5 5 Dar ann Turntable rotate circuit 0 0 eee eeeeeee 25 ft lbs 34 Nm 25 Shuttle valve CE uu Differential sensing circuit primary boom up down 12 14 ft Ibs 16 19 Nm 26 Flow regulator valve 0 4 1 5 L min BE Jib boom and platform le 20 ft lbs 27 Nm 27 Needle valve Platform level flow control 20 ft lbs 27 Nm 28 Relief valve 2500 psi 172 bar Platform level circuit 20 ft lbs 27 Nm 29 Check valve 5psi 0 3 bar Differential sensing circuit platform level 12 14 ft Ibs 16 19 Nm 30 Check valve 5psi 0 3 bar Blau Differential sensing circuit platform level dow
346. re up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb O Result The non steer tires should stay in firm contact with the ground If the chassis does not remain level during test refer to Repair Procedure 8 9 How to Set Up the Directional Valve Linkage Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES A 6 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage whichever comes first After this interval refer to the maintenance checklist for continued scheduled maintenance 1 Performthefollowing maintenance procedures A 9 Greasethe Turntable Rotation Bearing and Rotate Gear A 10 Perform Engine Maintenance Ford Models B 6 Inspectthe Tires Wheels and Lug Nut Torque B8 Check the Oil Level in the Drive Hubs C1 Perform Engine Maintenance Deutz Models e 0 2 Checkthe Turnable Rotation Bearing Bolts e 0 6 Replace the Hydraulic Filters Genie 7 45 25 Z 45 25J 0 7 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 100 ho
347. relief valve pressure 2500 psi 172 Medium pressure filter 50 psi bypass pressure 3 4 bar Steer flow regulator 1 5 gpm 5 7 L min Hydraulic return filter 10 micron with 25 psi 1 7 bar bypass Boom extend flow regulator 2 gpm 7 6 L min Jib boom platform rotate flow regulator 0 4 gpm 1 5 L min Drive manifold Hot oil relief pressure 250 psi 17 2 bar Steer end drive motors AWD models Displacement 1 53 cu in per revolution 25 cc Non steer end drive motors Displacement per revolution variable 0 12 to 2 14 cu in 4WD 2 speed motor before serial number 23812 1 97 to 35 cc Displacement per revolution variable 0 01 to 1 83 cu in 4WD 2 speed motor after serial number 23811 1 61 to 30 cc Displacement per revolution variable 1 37 to 2 14 cu in 2WD before serial number 24690 22 5 to 35 cc Displacement per revolution variable 0 99 to 1 83 cu in 2WD after serial number 24689 16 2 to 30 cc Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 4 A TEREX COM Z 45 25 Z 45 25J Part No 107846 January 2011 Section 2 Specifications zu REVH SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 36 in Ibs 4 Nm SAE No 4 10 ft Ibs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm
348. rom heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Be sure to only use operated pump suitable for use with gasoline and diesel fuel 46 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled 47 Remove the fuel tank mounting fasteners Carefully remove the fuel tank from the machine Component damage hazard The CAUTION fuel tank is plastic and may become damaged if allowed to fall Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine Part No 107846 August 2006 Section 4 Repair Procedures REV B 48 Remove the retaining fastener from the ground control box and function manifold pivot plate 49 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin 50 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support Do not lift it 51 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser 52 Remove the pin retaining fasteners from the number 3 arm at the turntable riser Do not remove the pin 53 Use a slide hammer to re
349. roportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Start the engine from the platform controls Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC B 17 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm
350. rushing hazard The upper pivot could become unbalanced and fall when removed from the machine if not properly attached to the overheadcrane 28 Attach the lifting strap from an overhead crane to the number 2 arm at the upper pivot end 29 Raise the number 2 arm slightly and remove the 4x4x 11 inch 10 x 10 x 28 cm block 30 Lower the number 2 arm onto the boom rest pad Part No 107846 Z 45 25 Z 45 25J SECONDARY BOOM COMPONENTS 31 Insert a 4 x 4 x 81 2 inch 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid pivot end 32 Attach a lifting strap from the overhead crane to the mid pivot for support Do not lift it 33 Remove the pin retaining fasteners from the number 2 3 and 4 arm pivot pins at the mid pivot Do not remove the pins 34 Use a soft metal drift to drive each pin out Then remove the mid pivot from the secondary boom assembly Crushing hazard The mid pivot AWARNING could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane 35 Attach the lifting strap from an overhead crane to the center point of the number 2 arm for support Do not lift it 36 Remove the pin retaining fasteners from both compression link pivot pins Do not remove the pins 37 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm 38 Support the compression link with an appropriate lif
351. ry 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Genie A TEREX COMPANY 3 2 Z 45 25 Z 45 25J Part No 107846 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH
352. s 1HSIH 31VLOH JIAYLNYNL 2951 9 NAHM 8 80 7 Hu 988 E gt 98 9 282 D JOHINOONOLONndWOOS AHVWIHd 20 88 1951 HWGH V2 5 98 9 z 9 9 g D Lui j HIWGH ger 229 HERR 2 WOO8 AHYWNIHd 2 1961 JP a 8 dN WOOg Au O 1951 09 Qu 98 2280 v g 91 36 8 1VNIWH3 L a Part No 107846 Z 45 25 Z 45 25J G 6 19 August 2006 Section 6 Schematics R E V B Ground Control Box Switch Panel Wiring Diagram Z 45 25J H LABEL DESCRIPTION nn RD GREK LEE EE CIRCUIT BREAKER ENGINE 15 38 See 839 CB2 CIRCUIT BREAKER CONTROLS 15A 35 RD RD RD a E g CR1 IGNITION START RELAY 59 BETA Je 2 i E cR2 INGITION POWER RELAY ib PER a CR4 HIGH IDLE RELAY RD 2 c S Li 2 lt c 5 HORN RELAY RD 855 5 5 5 8 5 o E E RD c A 8 51 KEY SWITCH 55 Eum BRS 12 CHECK ENGINE LED 222 1 RED EMERGENCY STOP BUTTON GR BK GR BK R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS g
353. s can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 7 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test on the ground for reference 2 Giant the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb REVC B 16 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire p
354. sconnect the wire connectors from the circuit board 6 Remove the ALC 500 circuit board mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box Genie an PLATFORMCONTROLS 1 2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control If a joystick is disconnected or replaced it must be calibrated before that particular machine function willoperate The joystick must be calibrated before the threshold max out or ramp rate can be set Perform this procedure with the engine off 1 Openthe platform control box 2 Pulloutthe red Emergency Stop button to the on position at both the ground and platform controls 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnectthe wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for a moment then move the joystick full stroke in the opposite direction Hold for 5 seconds and return the joystick to the neutral position O Result The alarm should sound indicating successful joystick calibration 8 Repeatthis procedure for each joystick controlled machine function inclu
355. ses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Remove the Cable Track Z 45 25 When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 2 Disconnect the cables from the platform control box 3 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 4 Raisethe primary boom to a horizontal position Genie an Primary Boom Components 5 Tag disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder Cap the fittings on the unions AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING Bodily injury
356. sor OR replace sensor oo o w 245 Camshaft sensor noise Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty e sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 253 Knock sensor open Knock sensor wiring and or connections open or shorted OR sensor is faulty Repair wiring and or connections to knock sensor OR replace knock sensor 254 Excessive knock signal Knock sensor wiring and or connections open or shorted OR there is excessive engine vibration OR sensor is faulty Check for excessive engine vibration OR repair wiring and or connections to knock sensor OR replace knock sensor njector driver 1 open 311 Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 312 njector driver 1 shorted Wiring and or connections to fuel injector 1 shorted OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 313 njector driver 2 open Open wiring and or connections to fuel injector 2 OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fue
357. ssure setting Directional valve mechanically activated 50 50 Flow divider combiner valve with pressure balancing orifice and flow percentages Pilot operated 3 position 3 way shuttle valve Differential sensing valve Solenoid operated proportional valve Part No 107846 E Priority flow regulator valve tN Solenoid operated 2 position 3 way directional valve 3000 psi 206 8 bar MI Deo Counterbalance valve with pressure and pilot ratio gt 2 position 2 way Solenoid valve Z bai Directional valve pilot operated 2 position 2 way lt gt 2 position 3 way shuttle valve Brake Shut off valve A TEREX COMPANY Z 45 25 Z 45 25J Section 6 Schematics August 2006 Ford Engine Relay Layout REVA Ford LRG 425 before serial number 30142 Power Relay F5 15A F4 15A 20 F2 5A F1 30A Starter Relay Fuel Pump Relay Starter Empty F1 10A F2
358. st 2006 Section 3 Scheduled Maintenance Procedures REVC CHECKLIST B PROCEDURES B 11 B 12 Check the Oscillate Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this test only on models equipped with an oscillating axle Proper axle oscillation is essential to safe machine operation If the oscillate directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover and the axle covers from the non steer end of the drive chassis 2 Locate the oscillate directional valve inside of the non steer axle and inspect the linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for plat
359. stick controller c secondary boom up down joystick controller d primary boom up down and turntable rotate left right joystick controller A TEREX 4 2 Z 45 25 Z 45 25J REV B 1 1 ALC 500 Circuit Board AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated See 1 2 How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted to the inside of the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 107846 August 2006 Section 4 Repair Procedures REV B 4 Attach a grounded wrist strap to the ground screw inside the platform control box Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5 Carefully di
360. stick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 6 times Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode 8 Startthe engine from the platform controls and press down the foot switch 9 Starta timer and simultaneously move the joystick in either direction full stroke Note how long it takes the function to reach maximum speed This is the ramp rate Part No 107846 PLATFORM CONTROLS 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease 11 While the joystick is activated set the ramp r
361. sting Shuttle valve position way Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor SHINE certes 15 18 ft lbs 20 24 Nm 7 Relief valve 250 psi 17 2 bar AD Charge pressure circuit 10 12 ft Ibs 14 16 Nm 8 Solenoid valve 2 position way AG 2 speed motor shift 10 12 ft Ibs 14 16 Nm 9 Orifice 0 030 inch 0 76 mm Brake and 2 speed motor shift circuit 10 Solenoid valve 2 position 3 way AF BAKING ec echoes 10 12 ft Ibs 14 16 Nm 11 Check 2 speed motor shift circuit 10 12 ft Ibs 14 16 Nm 12 Orifice 0 025 inch 0 64 MM Up 2 speed motor shift circuit 13 Flow divider combiner valve Controls flow to flow divider Combiner valves 1 and 17 25 30 ft Ibs 34 41 Nm 14 Check Steer end drive motor circuit 10 12 ft Ibs 14 16 Nm 15 Orifice 0 052 in 1 32 MM Drive circuit 16 Check Steer end drive motor circuit 10 12 ft lbs 14 16 Nm 17 Flow divider combiner valve W Controls flow to steer end drive motors in forward and
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363. t tools and accessories from the platform Failure to remove all weight tools and accessories from the platform will result in an inaccurate test Genie Part No 107846 TEREX COMPANY 2 45 25 Z 45 25J Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST C PROCEDURES REVD 4 Using a suitable lifting device place a test 6 Using a suitable lifting device place an weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Illustration 1 additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should b
364. t z 5 2 2 9 Q 5 5 RD RD R14 UP DOWN SPEED RESISTER 7 5 OHMS 5258 GR GR 5 lt PERS 7551 AUXILIARY TOGGLE SWITCH A 5 Le OOS 7552 ENGINE START TOGGLE SWITCH CAN 7553 FUELSELECT TOGGLE SWITCH 57 zz M 5 1554 FUNCTION ENABLE TOGGLE SWITCH I 258 8 o goat 7557 PLATFORM ROTATE TOGGLE SWITCH gui um TS58 JIB BOOM UP DOWN TOGGLE SWITCH 5 5 5 5 3 5 5 5 8 lt Y I I U lt A lt n TS59 PLATFORM LEVEL TOGGLE SWITCH N lt lt g zi E n SS 2 8 8 2288 3 2 55 5825 5 7560 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH RD RD BK 22A TS62 TURNTABLE ROTATE TOGGLE SWITCH s y a a a TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 8 8 E s a lt 5 7564 RUN TEST TOGGLE SWITCH 2 2 2 5 Bt SS m mcm P BOX 5 a 5 E ET 950 D g NOTE DASHED LINES INDICATE OPTION WIRES 55 Zo WH 23 z AE 888 7 885 kam bd G BOX x 4528 RD 88 c 8 ay RD RD RD cc 3 M 5 c c 5 a cu g 3 5 8 5 G ux 55 E 5 5 8 GER Eu 82 E G S 525 5 c a PER 558 zac 83 lt ek 566 e m c zzo c Sou RD RD 2 DE Qt t alle a I 4 S a z lt c o x 2 RD 39 a e Ql H Ze m RD
365. t your local EDI distributor Refer to the engine operator s handbook on your machine for EDI distributor locations REVC Deutz models This procedure will require two people 1 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweight end of the machine 2 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 3 Connect a tachometer to the engine and then start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 5 if the low idle rpm is correct 4 Loosen the low idle lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the rpm a solenoid boot b high idle adjustment nut yoke lock nut d yoke e low idle adjustment screw f low idle lock nut Genie TEREX COMPANY 2 45 25 Z 45 25J Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVC 5 Move the function enable rpm select toggle switch to the high idle rabbit symbol position at the ground controls and check the rpm Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 6 6 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterc
366. tension cylinder barrel end pivot pin at the pivot end of the primary boom Use a soft metal drift to remove the pin 4 Remove and label the location of the wear pads from the platform end of the primary boom Pay careful attention to the location and amount of shims used with each wear pad 5 Supportand slide the extension tube and extension cylinder assembly out of the boom tube AWARNING Cushing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing Part No 107846 August 2006 Section 4 Repair Procedures REV B 6 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube Use a soft metal drift to remove the pin 7 Supportand slide the extension cylinder out of the base end of the extension tube Place the extension cylinder on blocks for support Crushing hazard The extension AWARNING cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing Genie bt PRIMARY BOOM COMPONENTS 4 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift
367. tension fittings on the cylinder Cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary 5 Atthe platform end of the boom remove the Boom Extension Cylinder external snap rings from the extension cylinder rod end pivot pin Use a soft metal drift to AWARNING Bodily injury hazard This remove the pin procedure 6 Removethe barrel end pivot pin retaining skills lifting equipment and a fasteners suitable workshop Attempting this procedure without these skills and 7 rod through the barrel end pivot and tools could result in death or twist to remove the pin serious injury and significant component damage Dealer service is strongly recommended 8 Support and slide the extension cylinder out of the upper pivot AWARNING Crushing hazard The extension cylinder could fall when removed from the extension boom if not When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections propenysuppane must be
368. ternal communication fault detection The MegayJector detects an internal communications failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at and all connections and repair as necessary OR Megavector has an internal fault Contact Ford Power Products for assistance 411 Coil driver 1 open Open wiring and or connections to ignition coil 1 OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 412 Coil driver 1 shorted Wiring and or connections to ignition coil 1 shorted OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 413 Coil driver 2 open Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 414 Coil driver 2 shorted Wiring and or connections to ignition coil 2 shorted OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 2 OR replace ignition coil 2 Part No 107846 Continued on next page 28 A TEREX COMPANY Z 45 25 Z 45 25J 5 9 Section 5 Fault Codes August 2006 FAULT CODES REV B Code Problem Cause Solution If this fault appears on your machine contact 51 1 FPPThigh voltage
369. the fuel filter water separator Section 3 Scheduled Maintenance Procedures August 2006 CHECKLIST A PROCEDURES 10 Clean up any fuel that may have spilled 11 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnelfrom entering the area and do not operate the machine Repair the leak immediately 12 Swing the engine back to its original position and close the engine pivot plate latch 13 Install the engine pivot plate safety pin Deutz models 1 Puton protective clothing and eye wear 2 Remove the safety pin from the engine pivot plate latch The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Locate the fuel filter water separator next to the oil filter Genie TEREX COMPANY 3 12 2 45 25 Z 45 25J 0 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Do not completely drain the filter a fuel filter water separator b drain valve Clean up any fuel that may have spilled Start the engine from the ground controls and check the fuel filter w
370. ting device Section 4 Repair Procedures August 2006 SECONDARY BOOM COMPONENTS 39 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm Remove the compression link from the machine AWARNING Crushing hazard The number 2 arm could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane Crushing hazard The compression ACAUTION link may fall if not properly supported when removed from the secondary boom assembly 40 Remove the number 2 arm from the machine Crushing hazard The number 2 AWARNING arm could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane 41 Remove the upper and lower hose and cable covers from the number 3 arm 42 Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched TEREX Z 45 25 Z 45 25J 43 Open the ground controls side turntable cover 44 Remove the fuel tank filler cap 45 Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away f
371. tion 4 Repair Procedures August 2006 Hydraulic Pumps 7 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Component damage hazard CAUTION engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed TEREX Z 45 25 Z 45 25J 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting
372. tions 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item BA 6 Adjust the internal hex socket it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeatsteps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge 4 52 A TEREX CON Z 45 25 Z 45 25J REV E How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the 1 port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the high rpm position and activate and hold the secondary boom down switch with the secondary boom fully lowered 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turnthe engine off Use a wrench to hold the relief valve and remove the cap item BV 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeatsteps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge Part No 107846 June 201
373. tm OJO VISIT Ix O Oa lt ulm Qu ke LO LO 10 1010 LO LO CO GIO QS Sq x A 00 wo 5 5 E EEIEIEE EEIEIE LABEL 6 61 A TEREX COMPANY Z 45 25 Z 45 25J G Part No 107846 August 2006 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram Z 45 25J Perkins 404 22 Models Section 6 Schematics August 2006 pra m o ccs Platform Control Box Wiring Diagram Z 45 25J Perkins 404 22 Models REVA August 2006 Platform Control Box Wiring Diagram Z 45 25J Section 6 Schematics Perkins 404 22 Models PLATFORM CONTROL HARNESS TO SWITCH PANEL RD P2 RD H1 Ci9JSV WH JIB C32BRK WH RD C1P 6 CE OPTION ONLY Ka Wa Ki C40LSS OR C2P 2 P24FS WH C9P 2 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH C4P 7 C18JD GR BK C4P 6 C17JU GR 5 i C14PLU OR 2 1 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR CONTROL BOARD O
374. to extend and retract Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove a Secondary Boom Lift Cylinder AWARNING Body injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Lower the secondary boom to the stowed position 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod end pivot pin REV B 3 Tag disconnect and plug the hydraulic hoses on the secondary boom lift cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin and barrel end pivot pin Do not remove the pins Attach a strap from an overhead crane to the lug on the rod end of the secondary
375. torqued to specification CAUTION Component damage hazard Be during installation Refer to careful not to damage the Section 2 Hydraulic Hose and counterbalance valves on the Fitting Torque Specifications primary boom extension cylinder 1 Raise the primary boom to a horizontal position when the primary boom 2 Extendthe primary boom until the primary boom extension cylinder rod end pivot pin is CAUTION accessible in the primary boom extension tube Component damage hazard Hoses and cables can be damaged if the primary boom extension cylinder is 3 Remove the hose and cable guard from the dragged across them Aper pues Note the length of the cylinder after removal The cylinder must be at the same length for installation PartNo 107846 Z 45 25 Z 45 25J 4 23 Section 4 Repair Procedures August 2006 PRIMARY BOOM COMPONENTS 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base of the primary boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque S
376. trainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced atthe two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Heplace the Hydraulic Oil Part No 107846 Genie 2 45 25 2 45 25 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the cap from the fu
377. ts refer to the Engine Operator Handbook on your machine Oil temperature switch Temperature switch point 300 F 149 C Oil pressure switch Oil pressure switch point 7 psi Deutz F3L 2011 Engine 0 5 bar Oil pressure switch point 22 psi Deutz D2011L03i Engine 1 5 bar Part No 107846 January 2011 Section 2 Specifications REVH SPECIFICATIONS Fuel injection system Injection pump make Bosch Injection pump pressure maximum 15000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Starter motor Current draw no load 90A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25 rate 200 minutes Alternator output 60A Q 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 107846 Z 45 25 e Z 45 25J 2 9 Section 2 Specifications January 201 1 SPECIFICATIONS Perkins 404 22 Engine Displacement 134 cu in 2 2 liters Number of cylinders 4 Bore and stroke 3 31 x 3 94 inches 84 x 100 mm Horsepower 51 2500 rpm 38 kW 2500 rpm Firing order 1 3 4 2 Low idle 1300 rpm 22 Hz Hi
378. ully lowered 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AC 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeatsteps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge Part No 107846 June 2012 Section 4 Repair Procedures lt REVE MANIFOLDS This page intentionally left blank PartNo 107846 Z 45 25 Z 45 25J 4 47 Section 4 Repair Procedures EE MANIFOLDS 8 3 June 2012 REVE Function Manifold Components after serial number 27000 The function manifold is located next to the hydraulic tank underneath the ground controls side cover Index No 1 2 10 11 12 13 14 15 16 17 18 19 20 Schematic Description Item Function Solenoid valve 3 position 4 way BM Platform level up down Solenoid valve 3 position 4 way CG uus Platform rotate left right and jib boom up down Flow regulator valve 2 GPM 7 6 BZ ius Boom extend r
379. ures June 2012 MANIFOLDS REV E Genie 2 45 25 Z 45 25J Part No 107846 Section 4 Repair Procedures June 2012 EE MANIFOLDS REVE 8 11 Traction Manifold Components 2WD after serial number 27000 The traction manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way AF Braking nee 10 12 ft Ibs 14 16 Nm 2 Relief valve 250 psi 17 2 bar AD Charge pressure circuit 10 12 ft Ibs 14 16 Nm Flow divider combiner valve Usu Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 4 Orifice 0 070 in 1 78 mm AL Drive circuit 5 Check Drive GIICUlt 2 2 25 30 ft lbs 34 41 Nm 6 Check AA Drive circuit sssrinin aas 25 30 ft Ibs 34 41 Nm 7 Shuttle valve position way Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift oci rane ten 15 18 ft Ibs 20 24 Nm 8 Di gnostie BEE Testing 9 Orifice 0 030 in 0 76 mm AE Brake circuit 10 Solenoid valve 2 position 3 way AG 2 speed motor shift
380. urs Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDIpart number 1060020 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Part No 107846 August 2006 Section 3 Scheduled Maintenance Procedures REVD A 8 Inspect the Fuel Filter Water Separator Diesel Models Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks
381. ust 2006 EE Platform Control Box Wiring Diagram Z 45 25 Deutz F3L 201 1 Models PLATFORM CONTROL HARNESS TO SWITCH PANEL August 2006 DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM 7 J2 CR27 CR30 1518 Part No 107846 Z 45 25 Z 45 25J G Platform Control Box Wiring Diagram Z 45 25 Section 6 Schematics Deutz F3L 2011 Models RD P2 RD H1 z er 5 E E QA a gt E E ie 5 Aue C32BRK WH RD og E C32BRK WH RD 42 19 gt es tat bert os 1 gt i a gt i EE E ec e C40LSS OR J2 4 es et es P24FS C9P 2 E
382. xtend 20 ft lbs 27 Nm 6 Solenoid valve 3 position 4 way Fun Platform rotate left right and jib boom up down 2 45 25 25 ft lbs 34 Nm Solenoid valve 2 position 3 way E E Primary boom 20 ft lbs 27 Nm Solenoid valve 3 position 4 way El ue Platform level up down 25 ft lbs 34 Nm Check valve dual pilot operated erem Platform level circuit 20 ft lbs 27 Nm 10 Check valve Differential sensing circuit platform rotate right and jib boom up Z 45 25J 12 14 ft Ibs 16 19 Nm 11 Check Differential sensing circuit platform rotate left and jib boom down 2 45 25 12 14 ft Ibs 16 19 12 Differential sensing valve Eus Meters flow to functions 25 ft lbs 34 Nm 13 Check M Differential sensing circuit secondary boom down 12 14 ft Ibs 16 19 Nm 14 Check Differential sensing circuit secondary boom 12 14 ft Ibs 16 19 Nm 15 Priority flow regulator valve 1 5 5 7 L min
383. y alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures August 2006 Platform Controls The platform control box contains one printed circuit board The ALC 500 circuit board inside the platform control box controls all proportional machine functions from the platform The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls If a joystick error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 2 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion 29 8 b ALC 500 circuit board drive steer joy

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