161517B Positive Air Shutdown
Contents
1. o ND MAIN GROUND GND 000000000 3NISN3 G 0 gt G O O O O G O O G G O O G O G U ooo o 000000500 1WId OL 90 Act ooo VOL 189 o o 00Qq000000000 oo S318VO 81 61 O O OO qu DO 0 0 au rela 1831 49 M810 WH ISM 9 CE SEE U34 CR1 CR2 CR4 CR5 Salo Va Agro 0 819 S318VO 81 61 Hg GND XALO V PZS1 H9 1S31 Mat PartNo 161517 Z yZS1 Ge lV8vELd V 8LO Heal MAO WdHLYO A 8LO 172. Genio PartNo 161517 Z 45 25 Z 45 25J 9 Section 1 Parts Information May 2013 oc O E oEs isa This page intentionally left blank Genie 10 Z 45 25 Z 45 25J PartNo 161517 May 2013 Section 2 Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Hl Immediately tag and remove from service a damaged or malfunctioning machine EI Repair any machine damage or malfunction before operating machine H Keep records on all inspections for three years H Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the non steering 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 PartNo 161517 Genie Z 45 25 Z 45 25J 11 About This Section This section contains de
3. lithium based or equivalent a May 2013 Illustration 1 solenoid shutdown valve assembly lever shaft air intake tube b c d Illustration 2 Genie 14 Z 45 25 e Z 45 25J PartNo 161517 May 2013 Section 3 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Hl Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting H Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine H Be sure that all necessary tools and test equipment are available and ready for use PartNo 161517 Genie Z 45 25 Z 45 25J 15 Schematics About This Section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry General Repair Process Malfunction Identify Jou Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Section 3 Schematics May 2013 System Wiring Diagram TROMBETTA Ce B PULL COI
4. PRESS FAULT 12 24 Volt IGNITON START MODULE P N 56057 SNOILONNA D C TERMINAL BASE TB o PRIMARY BOOM UP o PRIMARY BOOM DOWN o TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT SECONDARY BOOM UP SECONDARY BOOM DOWN Do Op OS O O x PLATFORM LEVEL UP o E PLATFORM LEVEL DOWN 15 o E PLAT ROTATE LEFT JIB UP 17 0000000000 o E PLAT ROTATE RIGHT JIB DOWN 18 WH CR17 12 VOLT BATTERY POWER 20 T WH CR17 12 VOLT IGN POWER 21 WH FUSE 12 VOLT IGN POWER 21 12 VOLT IGN POWER 21 12 VOLT TO PLATFORM 22 12 VOLT TO PLATFORM 23 KEYSWITCH POWER 23 pa CBi POWER 24 ps OIL PRESSURE ANDTEMP SW 25 27 AUXILIARY PUMP 27 ps MOTOR STROKE 29 30 DRIVE FORWARD 30 GI DRIVE REVERSE 31 B2 33 START ENGINE BRAKE 32 33 B4 GLOW PLUG OR LP 35 HIGH RPM 35 DI ALTERNATOR PULSE PICKUP 41 45 GENERATOR OPT 45 1129 ALARMS OPT 129 134 KS POWER 134 1134A_KS POWER 134A GND MAIN GROUND GND Oo G O O oo oo oo o OG O o O O O OQ Oo O GND MAIN GROUND GND 00o00000000o0ooooooooooooCc
5. Procedures Maintenance Inspection Report AA 10 A 3 1 Test the Automatic Engine Overspeed Control System 11 A 9 1 Lubricate the Lever Shaft U 12 Section 3 Schematics IMTPOCUCHON p 13 System Wiring Diagram ENNEN 14 Ground Control Box Wiring Diagram a 15 Genie PartNo 161517 Z 45 25 Z 45 25J 5 May 2013 Section 1 Parts Information Engine Components NN A e BCS e a d lA ZA ey NAA VES Z M AN o gt o 29 WEA EAD CAR WZ d Fess N AS WC 2 7 A IN 6 eT IDR y e y NOTA Vz fe 24 f A AM d As Z LAL tt lt N Z In e Genie Z 45 25 Z 45 25J PartNo 161517 May 2013 Section 1 Parts Information R ENGINE COMPONENTS ltem PartNo Description Qty 1 101957 Solenoid A2V AT 1 2 6357 Hex Nut 1 4 20 GR iii A EAA A ATA AEA 2 3 6638 Flat Washer AAA 2 4 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 r 2 5 21130 Clevis Yoke 1 4 228 n AE decet enero eden rogare eoe sopore co editae ea ties 1 6 21496 Nut 1 4528 GR Lido E REN RT OPE bacc 1 7 6888 Screw HHC 1 4 20 x 1 inch GpRp conan no nono non nn nnnn nan cna snas ninans 1 8 6091 Nylock Nut 1 4 290 1 9 61211 Circuit breaker 15 Amp sss 1 10 75041 Screw Philips La T EE 2 11 6146 flat Washer 310 iita dere bee e eet nd ce y Ea 4 12 6178 Nylock
6. Genie A TEREX BRAND Parts and Service Supplement Positive Air Shutdown Valve Serial Number Range 2 45 25 from Z452513A 47001 2 45 25J Part No 161517 Rev B May 2013 May 2013 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 Manualbefore attempting any maintenance or repair procedure This manual provides detailed parts and service information 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 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 specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genielift com e mail awp techpub terex com Genie This Parts and Service Manual Supplement provides service parts information and electrical schematics for t
7. L a HOLD R20BAT RD 12 CR6 87 A HOLD COIL 30 87 Cc GROUND T A J57 E 86 85 a eg erent 1 N A CBB U18 415A CONTROL MODULE T MENT ja M ME 7 J196 7 WH J57 B ULL COIL J196 11 WH CR6 86 HOLD COIL RELAY SE J196 1 BR GND M J196 2 RD P134BAT TS74 2 12V J196 10 OR BK C41RPM TB41 RPM SIGNAL See 4 38 3I GEN B 20 8 8 m 8 PE OPFPOFPOFOTO O 12V DC 1874 EN TEST SWITCH lt L a aa e a ao Q tc oc O es a m m 3 2 e Genie 16 Z 45 25 e Z 45 25J PartNo 161517 May 2013 Section 3 Schematics TROMBETTA o e cH EH 7 e o 2 SIS N lee e z 2 8 8 o 3 z E I gt KE r z 6 m z lt BATTERY Llc Zz m K el m CONTROL s MODULE U18 is S E 8 S S 2 g 5E E 5 B s 3 Zz a E i g Ground Control Box Wiring Diagram g TS74 TEST SWITCH INO 3unss3ud TIO o dN3L H31VM HOLVOIQNI AH311v8 0000000000 Zoo aro 0000000 13471092 Genie Industries TO REMOVE Push gently gt and ift START RELAY START INPUT GROUND BATTERY 1 2 3 4 U1 ISM 7 8 10 9 H TACHOMETER AUX PWR UNIT TO KEY SW DIESEL ONLY JUMP TO 7 GAS ONLY IGN OR FUELON 0 TEMP OR
8. duled machine maintenance inspections as outlined in the Service Manual Hour meter Machine owner Checklist A Rev A YNR A 3 1 Lubricate lever shaft Perform every 100 hours A 9 1 Lubricate lever shaft Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Store completed forms for three years If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Genie 12 Z 45 25 Z 45 25J PartNo 161517 May 2013 Section 2 Maintenance Procedures Maintenance Procedures A 3 1 Test the Automatic Engine Overspeed Control System Genie specifications requires that this procedure be performed daily or every 8 hours whichever comes first Regular testing the automatic engine overspeed control system is essential to safe machine operation Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition Component damage may result Note Perform this procedure with the machine on a firm level surface 1 Pull out the red Emergency Stop Button to the on position at both the ground and platform controls 2 Turn the key switch
9. he recently released Positive Air Shutdown System which are not included in your parts or service manuals Please add this parts information and electrical schematics to the parts and service manuals for your machine Copyright 2011 Terex Corporation 161517 Rev B May 2013 First Edition Second Printing Genie and Z are registered trademarks of Terex South Dakota Inc in the USA and many other countries es Printed on recycled paper Printed in U S A 2 Z 45 25 Z 45 25J PartNo 161517 May 2013 Revision History Revision Date Section Procedure Schematic Page Description A ia Nena OOO 5 2013 mita 6 Pg 7 Chassis PRRPQS e B Pg 9 Kubota Engine_Section 2_Specifications Electronic Version A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_ Section 4_Repair Procedure Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 35 6 56 6 104 Section 6 Schematic Page Genie PartNo 161517 Z 45 25 Z 45 25J 3 May 2013 e gt gt gt gt lt gt m AA This page intentionally left blank Genie 4 Z 45 25 Z 45 25J PartNo 161517 May 2013 Introduction Table of Contents Introduction ImportantlInformation z ainn nd dd 2 Section 1 Service Parts Engine Componerts nennen enne nennen nennen nnns nennen nns 4 Chassis Components orient nara 6 Section 2 Maintenance
10. nut LA errato a ad 3 13 49826 Screw Phillips 10 32 X625 ENEE 1 14 61225 Relay 12 VDO 70 Amp itae IER lr alti teet 1 15 128079 Gasket Deutz Adapter AA 1 16 25368 Nut Nylock M8 x 1 25 _ a 3 17 33277 Washer Flat M8 tacon conte eere be e eb td 3 18 49386 Screw HAC M8 X40 EE 3 19 128065 Valve Positive Air Shutdown with Deutz Adapter 1 Genie PartNo 161517 Z 45 25 Z 45 25J 7 May 2013 Section 1 Parts Information Chassis Components Ground Control Box N oco Y 000 PartNo 161517 Z 45 25 Z 45 25J May 2013 Section 1 Parts Information CHASSIS COMPONENTS Item PartNo Description Qty 219681 Wire Harness Positive Air Shutdown 1 52607 BIER EE 1 2 128200 Toggle Switch SPDT 3 position momentary Test includes Mounting fasteners cnn naar cnn nan cn naar anar nann na nnne 1 27246 Toggle Switch Botes ed eet eda pe e Did reed 128578 Screw PHPH 6 32 X 025 N U P a nennen enne a dui iu ka sad 3 6091 Nvlock Nuts 1 420 iu 2 4 6638 Flat Washer 1 4 eh seg ut t S EENS 4 5 6884 Screw HHC 1 4 20 x 2 5 inches Gpp nana no canon a aa 2 6 128067 Positive Air Shutdown Controller a a 1 128068 Positive Air Shutdown System Software 110984 Control Module 128069 Control Module Label
11. tailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend A 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage 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 2 Maintenance Procedures May 2013 Maintenance Inspection Report Model Referto the Genie Z 45 25 and Z 45 25J Service Manual for scheduled machine maintenance procedures Serial number The following scheduled maintenance procedures will need to be Date performed in addition to regularly sche
12. to ground control Start the engine from the ground controls and allow it to idle 3 Locate the test toggle switch on the side of the ground control box Move and hold the toggle switch to the Test position 4 Activate high idle rabbit symbol O Result The engine should shut off Wi Result The engine does not shut off Consult the Genie Service Department PartNo 161517 Genie Z 45 25 e Z 45 25J 13 5 Wait approximately 5 to 10 seconds for the solenoid valve to reset 6 Start the engine from the ground controls Result The engine should start and operate normally w Result The engine does not start Consult the Genie Service Department Section 2 Maintenance Procedures MAINTENANCE PROCEDURES A 9 1 Lubricate the Lever Shaft Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Perform this procedure more often if dusty conditions exist Lubrication to the lever shaft is essential to safe machine operation Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition Component damage may result 1 Locate the lever shaft on the shutdown valve assembly 2 Applya liberal coating of grease to the shaft end surfaces on both sides of the valve Refer to Illustrations 1 and 2 Grease Specification Chevron Ultra duty grease EP NLGI 2
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