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Z-45/22 Service Manual - Manuals

1. SLAVE SECONDARY PLATFORM PAR PRIMARY ROTATE d E Om L P Ls iz E za a EJ ow TH 173 L LH Hg 1 EXTENSION H lov U uy I 7 I IA I Ke H SSC lore REM Ze ag as L L FRONT R FRONT ey TURNTABLE ROTATE MOTOR MOTOR MASTER G IUN a x l RISER PRIMARY c Pra PR2 PLI Zas PL2 sS a s2 er R P1 P2__ EXTEN
2. SECONDARY BRAKE 2 SPEED MANIFOLD Se SLAVE 1 025 7 2 EA 1 PLATFORM PRIMARY I ROTATE AE I iP 3 eE Hmo w Ne Nr L gt lt E e HJ OPM TH L L L HT EXTENSION Ba SH if ray d P CS y A 2SPD BRAKE TO ya ny Katzen UN ky LE AS L fr ECK TURNTABLE ROTATE m MASTER O eelle el In a _ se alle _ en fe were erence BB m HEP de H el owe Y ak a MEDIUM gt gt o bony zai OR tH go go PRESS 2 Sat tt rej 4 ES FILTER 3 d 0 L L Gr r gt y METAR STADE Ea I Lo lor DAS IDAS DA dm mA GC l SELECT _ SR FH A dee AEE FUNCTION LST m pacca ul BDX yna PUMP TT g
3. SLAVE SECONDARY PLATFORM Ge PRIMARY ROTATE 4 d E Hi n a ail Aar i SE L L eet EXTENSION m r l I I M om Ie Mo 1 i uja lAa L4 gt lt Ga css Ly 7 NE TURNTABLE ROTATE 5 MASTER G melee ail e s e lie _ ZS plan sy WW FUNCTION sp 3 MEDIUM l Ra Lt FE Ze g w wsad LJ gt lt gt lt a A 116 lt gt PRESS Brot 4 E LL LE SEA I FILTER gt a LI EJ LI On A B RODE oe Top a M ADA MFD HDS HLDS DAS SHAXE EELNES el boo DRIVE PRESS En LH o 4 we 4 LL TRACTION l l ik H l 1 EIER HE i y I H L eed Ca na MANIFOLD l FUNCTION Tes 3 u DI ell A yK H XI Ae op mg M Sr PUMP the vd Ca Ed Te L HL HH 6 4 GPM J IT E L f enn LA ei zam PONEN Ne E IATA as La DRIVE PUMP X f Il sem TANK A A TANK ege a E ZE HE e RY HENE S rz e REG gt SIS Ee De A Sri RESERVOIR aux Pue TI a 2 sep MOTOR Lo spo moror Cz Ss EEE OSE ANI GWO O RZS ete EE EE al Ly II me A HO RAE El TT S IECH SIDEN Te 1 i zaj EAER EI I PSI sm 2 Lu i Men i i i GC I H l TANK e L RETURN Ch gkh SE I het 3 I ost pz 3 gt f eg s e STT i i L REAR R REAR Ju I I MOTOR MOTOR st sz STEERING l 2 8 CU IN ACCUMULATOR za ae PRE CHARGE W O OSCILLATING OPTION 1600 PSI f OSC
4. 12V With keyswitch on and both mushroom switches pulled out check voltage at blu wht wire at terminal 30 on CRG 12V With keyswitch on and both mushroom switches pulled out Crank engine and check voltage at terminal 87 on CHG 12V Continued on the next page N AAAA oV CHART 2A Repair open in red power wire circuit y Replace toggle switch Repair open in blu wht wire circuit from toggle switch to TP38 to TB38 Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 no good Check ground wire on Repair open in ground terminal 85 of CR6 wire Replace CR6 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 2A Hold start switch and oV Repair open in blu wht Continued from the check voltage at blu wht 36 wire ccd CR6 to Previous page wire on anti diesel valve anti diesel valve on engine carburetor o Hold start switch and oV Repair open in blu wht check voltage at blu wht 38 wire circuit from 38 wire on gasoline anti diesel valve to solenoid at gasoline gasoline solenoid tank Hold start switch does Reconnect the two engine fire wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for Go to chart 2B troubleshooti
5. 11 1 5 19 7 Engine Low Idle Inoperative Gasoline LPG Models 11111 111 5 22 8 Engine High Idle Inoperative Deutz Diesel Models 2 5 23 9 Engine Low Idle Inoperative Deutz Diesel Models 22 21 5 25 10 All Functions Inoperative Engine Starts and Runs e sss221421 5 26 11 All Lift and Steer Functions Inoperative Drive Functions Operational 5 27 12 Ground Controls Inoperative Platform Controls Operate Normally 5 28 13 Platform Controls Inoperative Ground Controls Operate Normally 5 29 14 Secondary Boom Up Function Inoperative oonnnnccinnnnnnnnnccnnnocnnnnncccnnanancnnnno 5 30 15 Secondary Boom Down Function Inoperative ee eseuaaae aaa aaaaazaaaai 5 32 16 Primary Boom Up Function Inoperative seeee aaa aaa oaza aaa aaa ainia 5 34 17 Primary Boom Down Function Inoperative seeeea aaa aaa aaa aaa anacaa 5 36 18 Primary Boom Extend Function Inoperative eeeeeeeaaea aaa aaa aaaaaanwea 5 38 19 Primary Boom Retract Function Inoperative ooonnnccnnnnnnncncncnnnncnnnncnncnnnnnnnnns 5 40 20 Turntable Rotate Function Inoperative ooonnnnnncccnnnnnnccccccnnnnnccnccananannnncccnnns 5 41 21 Turntable Rotate Left Function Inoperative o ooooccnnnnnnnccccnnnnnnccccccnnnnnncarcccnnnn 5 4
6. E ars ZA o es Leesch rd PRESS a l l l L 1 ak pre ea a e ee ES ES RESERVOIR AUX PUMP STEERING DWG HS2WD A lt a Z45 22 Hyd Index 45 22 HP 2WD HYDRAULIC SCHEMATIC SERIAL 4245 000989 TO Z45 002536
7. Interchange flow regulator valve item Y function operates Replace defective flow with a like valve regulator valve item X function inoperative Continued on the next page Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 14 i Hold toggle switch up function Check the resistance or GT Tom the and manually override Operates of the directional mn Replace the defective H page directional valve push valve coils VDS d valve coil s in paka 2 en of valve spool Note Overriding the valve will 4to5 ohms require two people If a helper is not available interchange the valve item R with a like valve item S Replace the valve function inoperative Interchange check valve function operates item M with a like valve item K Replace defective shuttle valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect boom from moving coupling on the function OR ronal cylinder manifold and hold the OR cylinder function switch counterbalance valve less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect consult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 31 Section 5 Troubleshooting Flow Charts Service
8. Bi 038 18 DEE ED z 3 a CERLE KEE EE H3 LZRLHM H 3 WFATA 980 H 3 TZFLHW 038 KEE EELER NEE EECH DEES e R 5 H3 94039 M18 Ha GUFAT8 H3 GY LHM ALTERNATOR 8 3 DIAS H 3 Guf038 ATB H 3 SZFA18 1HM HS 9zf034 LNM 2 F gt a gt z x e 22 a az z 38 m Re 2 328 8 8 2 8 BR ES E 38 3 85 5 2 52 5 CS gt ZS ZG 8 B hal e Z ay o 24 x gf 8 s ER H ZE 2 E E 5 E a Ha EN SD gt R R g 3 a 258 E 5 g z Da D y ER a 5 6 E 5 3 2 5 8 2 z E E z z 3 lt x A 3 A E g 6 a E 3 p h oh 5 3 a lt 5 2 A b al e E 5 S 2 KORE a a gt ul o al E 2 m E x S A 2 2 3 2 2 1 6 z R 3 2 S 5 A 5 5 S 3 5 Y 3 e gt a S 3 3 x S 2 NOTES gt DIODE WAS IN CIRCUIT FROM SERIAL 4245 001524 TO z45 002460 gt TR1 TRACTION DELAY RELAY WAS ELIMINATED SERIAL 4245 002538 BECAUSE OF DIVIDER COMBINER DRIVE TRACTION MANIFOLD WHICH ALSO p Z10 11A ELIMINATES THE TRACTION BY PASS SOLENOID VALVE DWG HES45D 1 J 745 22 2WD amp 4WD DEUTZ DIESEL ELECTRICAL SCHEMATIC cont d SERIAL 4245 001524 TO 5050 Z45 22 Diesel HP MP Index GRN 2 D m E D E BLU RED 3 D WHTA3 EH e e GRN D 3 R WHT 1 ZS RED 30 E H BLK I2 EH a S A a 2 pod dese d y DRIVE ENABLE BLU W
9. Genie Z 45 22 Part No 32960 Service Manual Second Edition 0000 22222222222222222222222222222 222L2 lt 7 Disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder ACAUTION 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 8 Remove the fasteners from the extension cylinder pivot pin then use a soft metal drift to remove the pin 9 Carefully pull out and properly support the extension cylinder from the platform end of the primary boom ACAUTION 3 5 Platform Leveling Master Cylinder Crushing hazard The cylinder will fall if it is not properly supported when it is pulled out of the extension tube To make installation the extension cylinder easier be sure that the cylinder rod is extended 3 to 4 feet 1 m 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 primary boom motion The master cylinder is located inside the upper mid pivot at the base of the primary boom How to Remove the Platform Section 7 Repair Procedures PRIMARY BOOM COMPONENTS Leveling Master Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop
10. 4WD Steering Axle Components 14 1 2 Disconnect the hydraulic hoses from the wheel motor and plug them Cap the wheel motor Yoke and Hub hydraulic fittings Bodily injury hazard Spraying How to Remove the Yoke and Hub ACAUTION hydraulic oil can penetrate and The yoke installation utilizes bushings and a thrust burn skin Loosen hydraulic washer that require periodic replacement connections very slowly to allow depending upon the application The yoke must be the oil pressure to dissipate l removed before the torque hub can be removed gradually Do not allow oil to squirt The wheel motor is an integral part of the torque or spray hub 3 Loosen the wheel lug nuts Do not remove 1 Remove the cotter pin then the clevis pin from them both the steering cylinder and the tie rod 4 Block the non steering wheels and then center weldment a lifting jack under the steering axle 5 Raise the machine 6 inches 15 cm and place blocks under the chassis 6 Remove the lug nuts then the tire and wheel assembly 7 Remove the pin retainer from the king pin Place a block between the oscillate cylinder lock out wedge and the chassis on the same side as the yoke torque hub being serviced axle pinretainer king pin yoke torque hub cotter and clevis pin steering cylinder tie rod Ja o Oo CO D block torque hub yoke axle lock outwedge chassis OD Oo CO D 7 54 Genie Z 45 22 Part No 32960 Service M
11. ACAUTION Crushing hazard If the jack is not centered the axle may tip when the pivot pin is removed 5 Remove the pin retainer from the axle pivot pin Use a soft metal drift to remove the axle pivot pin 6 Remove the oscillate cylinder Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures Steer and Oscillate Manifold 16 1 Steer and Oscillate Manifold Components Index Schematic No Description Item Function Torque 1 3 position 4 way DOT valve El Stechngi aca ee dE e 30 35 in lbs 3 4 Nm 2 Pilot operated unloader valve 1900 psi 131 bar 1 10 12 ft lbs 14 16 Nm Sensing valve 2 2221121112 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 2 position 4 way valve 10 12 ft lbs 14 16 Nm Check Valve az Ela 35 40 ft lbs 47 54 Nm Normally closed poppet valve o ao R O Part No 32960 Genie Z 45 22 7 57 Section 7 Repair Procedures Service Manual Second Edition STEER AND OSCILLATE MANIFOLD Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 16 2 Valve Adjustments How to Adjust the Sequencing Unloader Valve Bo
12. DWG 4ES45D 4 J Seil lt z ra oguz Z gt 0n lt O s IOR x T LO ES sl iea N LI Ly LES Y LID E ze IL l a EU gt E ISO lu TN es Z O LI eo T 0 GEN OPTION 45 GRN WHT 1 CN WT 4 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 SPARE 42 ORG RED 1 PULSE PICKUP OG BK ISM 41 ORG BLK 1 _OG BK EH LIMIT SWITCH 40 ORG 1 WI EH L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT BL BK_ D B 37 BLU BLK 1 BU BK EH STEER RIGHT BLU D B 36 BLU 1 BLU EH RPM BK RD S P BK RD R4 35 BLK RED 1 GLOW PLUG OPTION BK WT SP 34 BLK WHT _ BK WT EH START BLK SP BLK ISM 33 BLK 1 gt BLK R3 86 BRAKE WT RD_D B 52 _WHT RED 1 __WT RD EH E D C 31 WHT BLK 1 WT BK EH E D C 30 mt RED 30 E H 2WD 4WD 29 R W 1 Spot EH TILT ALARM 28 RED BLK 1 RD BK E H AUX PWR RED S P RED 1 5 M 27 RED 1 RED E H TEMP SENDER WT RD S P 26 WT RD E H OIL PRESSURE SENDER WI BK S P 25 WT BK E H WARNING SENDER WHT ISM he 24 gt WHT EH KEYSWITCH PWR WHT S P WHT 1 S M 23 WHT 2 RDZWTEH Y PWR TO PLAT BLK S P BLK R5 22 BLK 2 Q IGNITION
13. Gasoline LPG low idle adjustment a carburetor b adjustment screw R Turn the engine off and reconnect the blue black wire to the governor actuator al Start the engine from the ground controls Result Electronic governor low idle should be 1400 rpm o Move the engine idle control switch to high idle rabbit symbol from the ground controls O Result High idle should be 2150 rpm 7 Turn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from the electronic governor located on the engine side bulkhead then remove the back panel from the governor 9 Restart the engine turn the low or high speed set screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do not adjust any trimpot other than specified in this procedure Gasoline LPG idle adjustment a lowidle adjustment b highidle adjustment 10 Re assemble the governor and recheck low and high idle Gasoline LPG models Low idle carburetor 900 rpm Low idle electronic governor 1400 rpm High idle 2150 rpm Deutz Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures ee TABLE B PR
14. Motorcraft AWSF 52 Spark plug gap Coolant capacity Alternator output Fan belt deflection 0 042 0 046 inches 1 07 1 18mm 11 5 quarts 10 9 liters 35A 14 5V 2 to inch 9 to 12 mm Bolt torque specifications Item Size Torque Torque ft lbs Nm Auxiliary shaft gear bolt M 10 28 40 38 54 Auxiliary shaft thrust 6 9 8 12 plate bolt M 6 Belt tensioner timing 28 40 38 54 pivot bolt M 10 Belt tensioner timing 14 21 19 28 adjusting bolt M 8 Camshaft gear bolt M 12 50 71 68 96 Camshaft thrust plate bolt M 6 6 9 8 12 Carburetor to spacer stud M 8 7 5 15 10 20 Carburetor spacer to 10 14 14 19 manifold bolt M 8 Crankshaft damper bolt M 14 103 133 140 180 Service Manual Second Edition EH Cylinder head bolt M 12 torque in sequence first step 50 60 68 81 second step 80 90 108 122 Distributor clamp bolt M 10 14 21 19 28 Distributor vacuum tube 5 8 7 11 to manifold adaptor Exhaust manifold to cylinder head bolt or nut M 10 torque in sequence first step 14 19 19 26 second step 20 30 27 41 Flywheel to crankshaft bolt M 10 56 64 76 87 Fuel pump to cylinder block M 8 14 21 19 28 Intake manifold to cylinder 14 21 19 28 head bolt or nut M 8 Oil pressure sending 8 18 11 24 unit to block Oil pan drain plug to pan M 14 15 25 20 34 Oil pan to block M 6 10 13 5 14 18 Oi
15. 2 Move the primary boom switch to the down position hold for a moment and then release it Now move the secondary boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control then from the platform controls pull out the Emergency Stop button to the on position Result The flashing beacon should be on and flashing Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 4 Press down the foot switch Move the primary boom control handle to the down position hold for a moment and then release it Move the secondary boom control handle to the down position hold for a moment and then release it O Result The descent alarm should sound when each control handle is held down 6 Press down the foot switch Slowly move the drive control handle off center hold for a moment and then release it Slowly move the drive control handle off center in the opposite direction hold for a moment and then release it O Result The travel alarm should sound when the drive control handle is moved off center in either direction B 27 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil B 28 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require that this procedure b
16. Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLoseb 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 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 3 Disconnect the hydraulic hoses from the pumps and cap them Bodily injury hazard Spraying ACAUTION 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 Support the pump and remove the two drive pump mounting bolts Carefully remove the pump Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position 3 Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an
17. Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Frequent Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an N remove the machine from use repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no unacceptable R repaired Comments Checklist A Y NR B 20 Engine idle select Refer to Table A B 21 Fuel select gasoline B 22 Turntable rotation stop B 23 Drive enable system missing parts A 4 Engine oil A 5 Engine coolant A 6 Fuel leaks A 7 Hydraulic oil A 8 Hydraulic leaks A 9 Tire pressure A 10 Platform and ground controls A 11 Auxiliary power A 12 Tilt alarm A 13 Limit switches Perform every 100 hours A 14 Change engine oil and filter Gas LPG A 15 Change engine air filter A 1 Manuals A 2 Decals and placards A 3 Damage loose or ChecklistB YNR Refer to Table B B 1 Engine b
18. check resistance across Replace the coil the coil terminals 4 5 to 5 5 ohms Hold toggle switch and function Replace defective manually override operates proportional valve proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA function inoperative Interchange rotation function operates Replace defective flow regulator valve function flow regulator valve item X with a like valve item Y function inoperative 0 or infinite ohms Hold toggle switch to function Check the resistance left and manually operates of the directional override rotate left valve coils directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S Replace the defective valve coil s 4 to 5 ohms Replace the valve function inoperative Continued on the next page Part No 32960 Genie Z 45 22 5 41 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 20 Interchange check valve function item K with a like valve Operates item M Continued from the previous page Replace defective check valve Install a O to 3000 psi Check for mechanical pressu
19. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder 1 Remove the end cover from the turntable 2 Raise the secondary boom and place a 4x4x31 inch 78 cm block between the chassis counterweight and the upper mid pivot Carefully lower the secondary boom onto the block a Uppermid pivot b 4x4x31 inch block c counterweight Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 3 Extend the primary boom 6 inches 15 cm then raise the primary boom until it is level Part No 32960 Genie Z 45 22 7 19 Section 7 Repair Procedures Service Manual Second Edition PRIMARY BOOM COMPONENTS 4 Disconnect and plug the extension cylinder hydraulic hoses Cap the ports on the extension cylinder Bodily injury hazard Spraying ACAUTION 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 5 Fully lower the primary boom and support it with an overhead crane 6 Disconnect and plug the primary lift cylinder hydraulic hoses Cap the ports on the primary lift cylind
20. Part No 32960 Genie Z 45 22 7 29 Section 7 Repair Procedures Service Manual Second Edition FORD LSG 423 ENGINE 6 Manually pull the actuator arm through a full cycle to be sure that the linkage moves freely Be sure that the linkage activates the throttle shaft to approximately half throttle The linkage must be free of friction and obstruction Do not let it rub against the engine brackets or hoses If the throttle linkage is improperly ACAUTION adjusted and allowed to reach full throttle the engine will over rev and cause component damage 7 2 Choke Adjustments This engine is equipped with an electrically heated automatic choke The choke has a poppet valve to enhance cold starting ability on LPG fuel Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates Automatic Choke With Poppet Valve This choke functions in both gasoline and propane mode The choke butterfly may be adjusted to a fully closed rich position for colder climates and the poppet valve will provide a flow path during propane fueled operation 7 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 7 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LSG 423 2 3
21. Second Edition This page intentionally left blank iv Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z 45 22 Operating Instruction Manual will result in death or serious injury Many of the hazards identified in the operating instruction manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations H You have the appropriate tools lifting equipment and a suitable workshop Part No 32960 Genie Z 45 22 V Section 1 Safety Rules Service Manual Second Edition 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 number one priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Indicates the presence of A DANGER a hazard that will cause death or serious injury Indicates the presence of AWARNING a hazard that may cause death or ser
22. WHT 2 N N BLK 2 N Y o o GRN WHT 3 Do GRN BLK 3 N GRN 3 a ORG RED 3 or ORG BLK 3 gt ORG 3 W BLU RED 3 N BLU WHT 3 BLU BLK 3 o BLU 3 BLK RED 3 BLK WHT 3 BLK 3 TURN ROT F C WHT RED 3 WHT BLK 3 WHT 3 RED WHT 3 RED BLK 3 n ujajajo d w RED 3 910 HORSE POWER LIMITER GRD STUD Z45 22 Diesel HP MP Index p 21013 P2 NC NC STOP TS3 GLOW PLUG OPTION DP1 T54 HIGH R P M 000 000 LI LED TS2 START TS20 DO O O 070 GENERATOR D Wei E DRIVE ENABLE OPTION 158 000 000 DRIVE HIGH LOW Rt 1000 RZ TS1 O O O 0 O 0 AUX TS7 O O oo oo a z LI x Lu RETRACT O TSS PLATFORM ROTATE BP1 156 O 0 9 0 O 0 PLATFORM LEVEL CABLE CABLE CABLE 5 2 1 GRN 2 P3 HORN TILT ALARM DWG ES45D 3 J lt a Z45 22 Hyd Index 2 SPD MOTOR DRIVE
23. and check voltage at blk TR1 on traction bypass valve item Q oV Interchange bypass valve item Q with brake release valve item S low range inoperative Interchange motor shift valve item R with brake release valve item S low range inoperative Check drive mode bad toggle switch See Repair section ok Check drive resisters in platform control box See repair section bad Replace defective resister s low range operates low range operates Replace drive mode toggle switch Repair short in red wht wire circuit from drive mode switch through TP29 to TB29 Replace TR1 time delay relay Replace defective valve Replace defective valve Replace toggle switch Possible defective drive manifold or drive manifold component Please consult Genie Industries service department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 35 Traction Any type of traction H roblem consult Genie Function ndustries Service Inoperative Department Be sure all other functions operate normally Part No 32960 Genie Z 45 22 5 61 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 36 Mach me Wi ll M poom fully stowed Fry e replace pom H check TB40 for ift drive limit switch or Not Drive At continuity to ground boom extend limit Full Speed Switch
24. lockout module start lockout module good Replace the start lockout module OR consult Genie Industries Service Department Check ground to o good Repair open in ground terminal 85 on CR2 mg wire to CR2 good Continued on the next page Part No 32960 Genie Z 45 22 5 13 Section 5 Troubleshooting Flow Charts CHART 3 Crank engine and check py voltage at terminal 2 on start lockout module Continued from the previous page 6 to 7V While cranking engine for 15 seconds check yes continuity to ground on terminal 10 on start lockout module ls continuity maintained no Check voltage at 12V terminal 4 on start lockout module Replace start lockout module OR consult Genie Industries Service Department Service Manual Second Edition Crank engine and check oV voltage at org blk 41 wire on alternator 6to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module Disconnect wht blk 25 wire from oil pressure sender and check yes continuity to ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground wht blk 25 wire from sender to TB25 to start terminal 10 on lockout module Disconnect red wire from terminal 4 on start 12V lockout module and check voltage at terminal 4 Repair positive short in red wire cir
25. machine 33 Remove the fasteners from the underside of the rotate bearing then remove the rotate bearing Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures How to Install the Rotation Bearing and Worm Drive The rotation bearing is a structural component lt attaches the chassis to the turntable The turntable is bolted to the inner race with the worm gear housing sandwiched in between This housing has to be exactly positioned to provide the correct gear lash between the worm gear and the ring gear The outside bearing race is bolted to the chassis from the underside AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required If a repair requires that the turntable be removed from the chassis installing a new rotation bearing is recommended Consider the service life of the rotation bearing before installing a used bearing 1 Position the rotation bearing on the chassis 2 Locate the red mark on the outside bearing race Align the mark with the rotation stop block on the chassis TURNTABLE ROTATION COMPONENTS O mark outer bearing inner bearing dowel red mark rotation stop block p Oo CO D 2 Install the mounting fasteners from underneath
26. not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform level down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org blk wire on platform level down function directional valve Dor Remove both wires from infinite valve coil and check ohms resistance across the coil terminals 4 to 5 ohms Hold toggle switch and manually override the level down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item O with a like valve item N function inoperative Interchange check valve item L with like valve item K function inoperative 2400 Install a pressure gauge psi or at the quick disconnect more coupling on the function manifold and hold the function switch less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department function operates function Operates Repair open in org blk wire circuit from TB15 to directional valve Replace the coil Replace the platform level
27. then completely retract the primary boom 3 Hold the retract switch and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap item 28 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then reinstall the relief 6 Restart the engine Hold the retract switch and recheck the valve pressure Specifications Main relief valve pressure 2200 psi 152 bar How to Adjust the Primary or Secondary Boom Down Relief Valve 1 Connect a O 3000 psi 0 to 206 bar pressure gauge to the diagnostic nipple on the function manifold 2 Start the engine from the ground controls and then fully lower the boom to be adjusted 3 Hold the primary or secondary boom up down switch in the down position and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap item 17 for primary boom item 18 for secondary boom 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then reinstall the relief valve cap Tip over hazard Do not adjust the AWARNING relief valves higher than recommended They are set to prevent a tip over or damage to lift linkage 6 Restart the engine Hold the primary or secondary boom up down switch in the down valve cap position and reche
28. 10 12 ft lbs 14 16 Nm 7 64 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 4WD DRIVE MANIFOLD W 3 3 3 gt ES Sr FAR Rz RZ as z WA y a gt RE FS 222 K ESO 19 s ze y 7 M ee Wl Ch ae 2 Li P 8 7 Gs Part No 32960 Genie Z 45 22 7 65 Section 7 Repair Procedures Service Manual Second Edition 4WD DRIVE MANIFOLD Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 19 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connect a O to 600 psi 0 to 41 bar pressure gauge in between one of the medium pressure hydraulic hoses and the medium pressure hydraulic oil filter Bodily injury hazard Spraying ACAUTION 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 2 Start the engine from the platform controls 3 Drive the machine in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap 5 Adjust the internal hex socket Turn it clockwise
29. 5 8 18 905 8 18 Industrial 5 ft 9 5 8 in 176 8cm Lug nut torque 125 ft lbs 125 ft lbs S 169 5 Nm 169 5 Nm Height 6 ft 6 in 7ft4in 1 98m 2 23m Tire size 14 17 5NHS 9 14 5 LT Weight 13860 lbs 14410 lbs Tire ply rating 8 Tread 8 6287kg 6536kg Sidewall 6 Ground clearance 8 in 11 in Tire contact area 59 sq in 43 5 sq in 20 3cm 27 9cm 380sq cm 280sq cm Platform dimensions Overall tire diameter 35 8 inches 28 inches 91cm 71cm Length 6 ft 6 ft 182 8cm 182 8cm Tire pressure 2WD 40 psi 100 psi Width 30 in 30 in 2 76 bar 6 89 bar 76 2cm 76 2cm 4WD 28 psi Operational dimensions PEO Maximum platform height 45 ft 45 ft r la capacities 13 72m 13 72M Fuel tank 15 gallons 56 8 liters Maximum horizontal reach 23 ft 23 ft 7m 7M Propane tank 33 5 pounds 15 2kg Maximum up and over 21ft7in 21 ft 7 in clearance 6 58m 6 58m Hydraulic tank 25 gallons 95 liters Maximum turntable tailswing 1 inch none 2 54cm Hydraulic system 30 gallons 114 liters Wheelbase 6 ft3 in 6ft3in cluding tank 190 5cm 190 5cm Torque hubs 17 ounces 0 5 liters Minimum turning circle 14 ft 4 in 14 ft 9 in outside 4 37m 4 49M Continuous improvement of our products is a Genie Minimum turning circle 7 ft 6 ft8 in AE iz specifications are subject to change inside 2 13m 203m WEOE NECE Turntable rotation 359 359 Platform rotation 180 180 Part No 32960 Genie Z 45 22 Section 2 Specifications SPECIFICATIONS Performance Specifications Service Manual Seco
30. Check voltage at terminal 5 on electronic governor 12V Check voltage at electronic governor terminal 3 yellow wire 6 to 7V Turn machine off remove blu blk wire from terminal 4 on electronic governor and restart engine engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor engine goes to high idle Isolate the ground and platform rom switches check individually and replace defective switch Repair open in wht 21 wire circuit from CR2 to CR3 to CR4 Replace CR4 relay Repair open in blk red wire circuit from CR4 to electronic governor Repair open in yellow wire circuit from ignition coil to electronic governor Recheck throttle linkage see Repair section OR check and or replace governor actuator OR see Ford service manual for carburetor troubleshooting Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Deutz Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Check high idle Start engine switch rpm adjustment see select switch to high idle solenoid rabbit symbol and pulls in Maintenance section or check if ARA see Deutz workshop solenoid pulls in manual to
31. L eth L FRONT R FRONT o SWING GC MOTOR O MOTOR MASTER 3 2 1 CU IN 24 AN PLATFORM ROTATE a n LEVEL SWNG RISER PRIMARY i Pelee al Ma si ls aje Sach vm erect I I z a FUNCTION AN Ze Ch rd 3 rd MANIFOLD EE MEDIUM OR ALK 9 AE Ga gp ae I sa ear el I I I 2764 BR a SS I LI I I I I I EE 5 4 d ES I Il I I I I I I FILTER LI LI I t t i l AA I Eu der He SJ Hy rA H y H i I H I mau E BG SAKE ED oi EA DRIVE a 0 4 4 4 r 4 4 A I TRACTION ESA y ett ci eh e Ga 1 T MANIFOLD eos I ES I EH I at I A I Wes a EKA PUMP ug G EA MEA ME l D og m Mm a W Bet 4 I Es S Ee S Ly d lt E p T N EE kasel EEN n press L t DRIVE PUMP XX Kes com El pa t ma ER GEIER E Es a 2 l on I 2 ma A gt Tie 7 T lt gt ZS ts RESERVOIR AUX PUMP 2 SPD MOTOR A Z SPD MOTORS Ke Pa vm Je O STEER OSC MANIFOLD bo Ta Sep GEI ge i 80 I I Ly TANK a E Th RETURN elt ABT a EE oe e ji o w 34 CINE SEE L REAR R REAR Se II MOTOR MOTOR 2 8 CU IN ACCUMULATOR PRE CHARGE i 1600 PSI b 1 OSCILLATION STEERING LOCK OUT DWG HS4WD B p Z11 11 lt a Z45 22 Hyd Index 745 22 HP 4WD HYDRAULIC SCHEMATIC SERIAL Z45 000990 TO z45 002555
32. LR check in forward 35 40 ft lbs 47 54 Nm 13 Pilot to open check valve KB LF check in reverse s es 85 90 ft lbs 115 122 Nm 14 Pilot to open check valve WIRES LF check in forward 85 90 ft lbs 115 122 Nm 15 2 position 3 way valve Ozawa Energized in high range to pilot open check valves 9 10 13 8 14 to bypass flow regulators and allow full flow to front wheel motors 8 10 ft lbs 11 14 Nm 16 Shuttle valve 2 position 3 way T High pressure flow path for flow regulator bypass 10 13 ft lbs 14 18 Nm 17 Flow regulator valve Dia ist ati LR flow control in reverse 10 12 ft lbs 14 16 Nm 18 Flow regulator valve Basie LR flow control in forward 10 12 ft lbs 14 16 Nm 19 Flow regulator valve m EPEE RR flow control in reverse 10 12 ft lbs 14 16 Nm 20 Flow regulator valve acts RR flow control in forward 10 12 ft lbs 14 16 Nm 21 Flow regulator valve Aida is LF flow control in forward 10 12 ft lbs 14 16 Nm 22 Flow regulator valve Cuit LF flow control in reverse 10 12 ft lbs 14 16 Nm 23 Flow regulator valve Guin RF flow control in reverse 10 12 ft lbs 14 16 Nm 24 Flow regulator valve Esti RF flow control in forward
33. Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 7 5 RPM Adjustment See the scheduled maintenance procedure B 13 Check and Adjust the Engine RPM Genie Z 45 22 Part No 32960 Service Manual Second Edition FS 7 6 Flex Plate 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 Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner Disconnect and remove the muffler support bracket Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Remove the mounting fasteners from the regulator mounting bracket then pull the bracket up past the bell housing Secure the bracket before continuing Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts Carefully pull the pump away from the engine and secure it from moving Remove the flex plate mounting fasteners then remove the flex plate from the engine Section 7 Repair Procedures FORD LSG 423 ENGINE How to Install the Flex Plate 4 ACAUTION Install the flex plate onto the flywheel with the flat side of t
34. Manual Second Edition Chart 15 Secondary Boom Down Function Inoperative Be sure all other functions operate normally including boom up function If boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at blu blk wire on secondary boom function directional valve Hold toggle switch down and manually override the down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item R with a like valve item S function operates function inoperative Install a 0 to 3000 PSI pressure gauge at the 1800 quick disconnect psi coupling on the function manifold and hold the function switch less than 1800 psi Continued on the next page Repair open in blu blk wire circuit from TB11 to directional valve Check the resistance of the down directional valve coil 4 to 5 ohms Replace the valve Counting the turns adjust the boom down relief valve item F in all the way Then Operate the function down function operates Dor infinite
35. Part No 32960 Genie Z 45 22 7 1 Section 7 Repair Procedures Service Manual Second Edition Platform Controls 1 1 Joystick Controllers Maintinaing joystick controllers at the proper settings is essential to safe machine operaton Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion Platform control box a horsepower limiter board b quick disconnect terminal strip c drive proportional controller d secondary boom proportional controller e primary boom proportional controller f turntable rotate proportional controller Primary Boom Up Down Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 15 4V DC output Electrocution hazard Contact with AWARNING electircally charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position Do not start the engine Open the platform control box lid and locate the boom up down controller dual lo adjustable trimpot ramp rate adjustable trimpot terminal R activ
36. RETRACT AZ Da i PEB S E WNE J 8 MEDIUM l vi 9 yr gaj gt ge w OO RADA RZ lt gt PRESS ZEL RA 11 r nij HT Ji li i i FILTER ej L L LI za y l CH mas Ha CH CH Sie I X Dk X X I Sen ADA ANTAD y XE SUHE ANTAD ADA DRIVE PRESS th A Ee 1 bg 1 TRACTION X EH 8 OE ugitt T 7 T MANIFOLD I I la L ml i eh e EEN SE Y 4 Be di EH ie x o PUMP me IT ri S S Du d LH TE 6 4 GPM a O DEE qe owes Eb SE NAST EM PIZIE a GERE SE I B t t I DRIVE PUMP XX a ax L ROM ik TAN AE l Ji l l L ci L ER E EE I BIT h e The Se i Y 16 Sr RESERVOIR AUX PUMP LG SPD MOTOR 2 SPD MOTOR ae He aw f m STEER OSC MANIFOLD E Eh LI DAB l vi MOT I I I I L I I I i ki l TANK aes eE th RETURN eee ref gli T i i B Seu mj S SKO o L REAR R REAR MJ JI MOTOR MOTOR 2 8 CU IN ACCUMULATOR PRE CHARGE 1600 PSI f 1 OSCILLATION STEERING LOCK OUT p Zfied DWG 4HS4WD B lt a Z45 22 Hyd Index Z45 22 HP GP amp DIESEL 4WD HYDRAULIC SCHEMATIC SERIAL Z45 002539 AND ABOVE
37. Repair open in red wht wire circuit from toggle switch to TP29 Replace toggle switch Repair open in wht 21 wire circuit Repair open in ground wire Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts T Continued from the previous page CHART 33 Press down foot switch Repair open in blk TR1 and check voltage at blk wire circuit from time TR1 wire on traction delay relay to traction bypass solenoid valve bypass valve item Q Interchange traction bypass valve item Q with new solenoid valve and check high drive no high drive Replace traction bypass kati Replace traction ae Consult Genie and interchange new shuttle valve item Q Industries Service valve with motor stroke and check high drive Department valve item Q and check high drive Part No 32960 Genie Z 45 22 5 59 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 34 Low Range Drive Function Inoperative Be sure all other functions operate normally including drive high range two wheel symbol Turn key switch to 12V paren controls pull oth emergency stop buttons on switch drive mode to low range machine on incline symbol press down foot switch and check voltage at red wht wire on drive mode switch oV Press down foot switch and check voltage at TB29 Press down foot switch 12V
38. Switches 1 With the engine off and the machine in the stowed position visually inspect the oscillate lock out switch for the following Oscillating axle limit switch a limit switch b oscillate lock out wedge broken or missing rollers or arms missing fasteners loose wiring 2 Start the engine from the ground controls and raise the primary boom above the drive speed limit switch O Result The oscillation cylinder should extend the lock out wedges The boom should stop moving until the wedges are fully extended A 14 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 100 hour interval Perform this procedure after warming the engine to normal operating temperature ACAUTION Beware of hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the va
39. TRACTION MANIFOLD 2 SPD MOTORS BRAKE BRAKE 745 22 HP 2WD HYDRAULIC SCHEMATIC SERIAL Z45 000170 TO Z45 000987 L REAR MOTOR p Z11 08 R REAR 2 OTOR 8 CU IN SLAVE RISER PLATFORM Se PRIMARY ROTATE rq MH Of ae L gt lt E Ra gt ID o MEJ 1 E L4 SHATT EXTENSION O oo SH y I L gt lt i J 19 H4 SE A el L 8 SWING MASTER O birrat sins a enviar IL se e ler Bl cen aor gd FUNCTION MEDIUM AL ZC HO LE gt go yo MANIESED PRESS TES E Y FILTER e HEH zer SDS AIPTEK AXE MIER SHARE PRESS 4 Lt 0 4 EE r 4 p CER s le ell OE l IET FUNCTION L IA lg lej PUMP ee q pG o NI gt delt 6 4 GPM Go 4 4 pooh pe p
40. __ 0 gt __ _ gt TABLE OF CONTENTS Section Seven Repair Procedures Juttel ej A A ii 7 1 Platform Controls 1 1 Joystick Controllers eau aaa anawa aaa aaa aaa acna 7 2 1 2 Horsepower Limiter Board oooonnnicccinnnnnicccccnnnnonccnnnnnnnnnnnnnnnnnnn rn nnnnn cnn nn rc nnnnnnn 7 6 1 3 POOt Switch gees dere EENS 7 8 1 4 ROSISIO Sui id b AA 7 8 1 5 Toggle Gwitches AAA 7 9 Platform Components ST Platforma oni ath edi aver anda ails 7 10 2 2 Platform Leveling Slave Cylinder eos a aaa aacna 7 10 2 3 Plattorm Rotario daa 7 11 Primary Boom Components 3 1 Plastic Cable Track 7 13 S225 Primary BOOM ii al aa ied 7 13 3 3 Primary Boom Lift Cylinder aaa aaa aaa aaa aaa aaa eaaa aaa acnea 7 16 3 4 Extension Cylinder een aaa aaa nn nn carr 7 18 3 5 Platform Leveling Master Cylinder esse aaa aaa aaa aaa nana 7 19 Secondary Boom Components 4 1 Secondary Boom eeeeeee eee aaa aaa aaa c cananea cnn 7 21 4 2 Secondary Boom Lift Cylinders see e aaa aaa aaa aa aaa ananas acne 7 26 Turntable Covers 5 1 Turntable Covers vertida eii 7 27 Deutz Engine F3L 1011 6 1 RPM Adjustment ii a E E E EEE EEE 7 28 6 2 Flex Platona dt OWA O ete eee APA JP lada dad 7 28 Ford LSG 423 Engine 7 1 Governor Actuator conoccccccccncccnnoncnnnononcn nono cnn nan rca n narran 7 29 xii Genie Z 45 22 Part No 32960 Service Manual Second Edition DEEN Section Seven TABLE OF CONTENTS Repair Procedures contin
41. additional 15 seconds or until the pressure reaches 320 psi 22 bar HYDRAULIC PUMPS Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition Function Manifold 10 1 Function Manifold Components Index Schematic No Description Item 1 3 position 4 way DO1 valve A 2 Counterbalance valve Bom ties 3 Sandwich valve manifold a 4 3 position 4 way DO1 valve Olas 5 Counterbalance valve BB 6 Sandwich valve manifold AAA 7 3 position 4 way DO1 valve Putos 8 3 position 4 way D01 valve Oir 9 3 position 4 way DO1 valve Rosina 10 3 position 4 way DO1 valve litis 11 Counterbalance valve CC 12 Counterbalance valve us 13 Check valve AA Konania 14 CheckVaVE zi W W AL M 114421222 15 Flow regulator valve Masa 16 Relief valve 1200 psi 83 bar Diiira 17 Relief valve 1200 psi 83 bar SE 18 Relief valve 1200 psi 83 bar Extras 19 Proportional solenoid valve AA 20 Flow regulator valve SER 21 Normally closed poppet valve didas 22 Proportional solenoid valve Dios 23 Flow regulator valve Ni
42. att 24 Differential sensing valve AC naana 25 Flow regulator valve E EE 26 Flow regulator valve Wien 27 Diagnostic fitting oonnoconnnncninnaconnonannnnacnn narco 28 Relief valve 2200 psi 152 bar AR 29 Priority flow regulator valve A 30 Check valve coocooocconcccinccconccnancnancnonnnon RA 31 Check valve A H 32 Check valve coooooonoconcccnocccocccnnncnancnonnnos lacio Function Platform rotate Platform level up Platform level counterbalance valves Platform level 30 35 in lbs 3 4 Nm Turntable rotate right 35 40 ft lbs 47 54 Nm Turntable rotate counterbalance valves Turntable rotate 30 35 in lbs 3 4 Nm Secondary boom up down 30 35 in lbs 3 4 Nm Primary boom up down 30 35 in lbs 3 4 Nm Primary boom extend retract 30 35 in lbs 3 4 Nm Turntable rotate left 35 40 ft lbs 47 54 Nm Platform level down 35 40 ft lbs 47 54 Nm Turntable rotate differential sensing Primary and secondary boom differential sensing Primary boom secondary boom Primary boom extend Torque 30 35 in lbs 3 4 Nm 35 40 ft lbs 47 54 Nm 11 13 ft lbs 15 18 Nm 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 10 12 ft lbs 14 16 Nm Primary boom down Secondary boom down Primary boom secondary boom Turntable rotate Primary boom extend retract Plat
43. disconnect caps Carefully remove the jack stands lower the machine and remove the jack AWARNING Collision hazard Failure to re engage the torque hubs may result in death or serious injury and property damage Steer wheels 4WD models 7 Chock the drive wheels to prevent the machine from rolling 8 Position the lifting jack under the steering axle and center it between the steering wheels 9 Lift the wheels off the ground and then place jack stands under the chassis for support 10 Open the free wheel valve located on the drive pump by turning it counterclockwise two turns a drive pump b lift pump c free wheel valve Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES 11 Manually rotate each steer wheel O Result Each steer wheel should rotate with minimal effort 12 Close the free wheel valve clockwise Carefully remove the jack stands lower the machine and remove the jack AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an improperly greased gear will result in component damage 1 Raise the secondary boom and place a 4
44. end pivot pin and twist to remove the pin Remove each secondary lift cylinder from the machine a pivotpin b 10to12inch 30 cm rod Crushing hazard The secondary AWARNING lift cylinders will fall when the barrel end pivot pins are removed if they are not properly supported 37 Remove the lower cable tray from the number 3 arm 38 Pull all of the cables and hoses through the lower mid pivot and out of the turntable pivot Component damage hazard ACAUTION Cables and hoses can be irreparably damaged if they are kinked or pinched 39 Attach the strap from an overhead crane to the top tube of the lower mid pivot Then place a hydraulic jack between arm numbers 3 and 4 at the end nearest the lower mid pivot 40 Remove the pin retaining fastener from the lower mid pivot to number 3 arm pivot pin Use a soft metal drift to remove the pin 41 Carefully lower the lower mid pivot and compression link away from the machine to a resting position 42 Position the lifting strap from an overhead crane at the center of the number 3 arm Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 43 Remove the pin retaining fastener from the turntable pivot to number 3 arm pivot pin Use a slide hammer to remove the pin Crushing hazard If the overhead AWARNING crane is not properly attached the number 3 arm may become unbalanced and fall when it is disconnected from the turn
45. from the bottom of the tank 7 Use an appropriate lifting device to remove the tank from the machine Always use pipe thread sealant when re installing the drain plug Use only Dexron II equivalent hydraulic fluid Be sure to open the two hydraulic ACAUTION tank valves and prime the pump after installing the pump How to Prime the Pump 1 Gasoline LPG models Disconnect the ignition coil wire and isolate it from ground Diesel models Disconnect the wiring to the injection pump fuel on solenoid 2 Crank the engine with the starter motor for 15 seconds Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 2 AAA FUEL AND HYDRAULIC TANKS 11 2 Fuel Tank How to Remove the Fuel Tank Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Raise the secondary boom enough to access the back of the fuel tank 2 Turn the manual fuel shutoff valve to the closed position 3 Gasoline LPG models Disconnect the electrical collectors from the fuel shutoff solenoid Disconnect drain and plug the fuel hose Diesel models Disconnect drain and plug the supply and return fuel hoses Cap the fuel return fitting on
46. from the ground controls 5 Inspect the filter and related components to be sure that there are no leaks Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 7 Replace the Drive Loop Hydraulic Filter Replacing the drive loop hydraulic filter is essential to 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 filter be replaced more frequently Beware of hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Rotate the filter housing counterclockwise and remove the housing 2 Remove the filter element from the housing 3 Inspect the housing seal and replace it if necessary 4 Install the new filter part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 5 Start the engine from the ground controls 6 Inspect the filter assembly to ensure that there are no leaks C 8 Replace the Diesel Fuel Filter Deutz Diesel Models Replacing the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may
47. line repair rotation motor from the manifold and 2400 cap the port S1 Then with pressure gauge still attached operate the function Repair rotation motor less than 2400 psi Replace the directional valve OR the manifold has internal defects Consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts All Platform Leveling Functions Inoperative Be sure all other functions operate normally Be sure both automatic and manual platform leveling do not operate If automatic leveling operates but manual leveling does not troubleshoot Platform Leveling Up Function Inoperative Repair org red wire Hold ground control epa circuit from TB16 to flow function switch and check voltage at org red control valve wire on platform level flow control valve Dor infinite Remove both wires from oh 3 ohms valve coil and check resistance across coil terminals Replace the coil 4 to 8 ohms Remove both hydraulic Replace the hoses from the manifold counterbalance valves pons PL1 8 PL2 Plug items B amp C or valve the hoses and cap the block A manifold fittings Operate boom up function and check if platform levels Plumb a pressure gauge Check for mechanical into the master cylinder restrictions OR replace barrel end hydraulic the slave cylinder ho
48. marking two lines on the ground 20 feet 6m apart 2 Start the engine from the platform controls and then select high drive mode machine on flat ground 3 Move the engine speed control switch to high idle rabbit 8 foot switch and then fully lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a rear tire as a visual reference for use when crossing the start and finish lines 5 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 6 Continue at full speed and note the time when the machine reference point passes over the finish line Specifications stowed position high range Distance 20 feet 6 meters 4WD 2 85 seconds 0 25 seconds 2WD 2 75 seconds 0 25 seconds TABLE B PROCEDURES B 26 Test the Alarm Package optional equipment The alarm package includes travel alarm descent alarm flashing beacon Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion The alarm package components are installed on the right side on top of the turntable cover The alarm and beacons will operate with the engine running or not 1 Atthe ground controls pull out the Emergency Stop button to the on position and turn the key switch to ground control Result The flashing beacon should be on and flashing
49. ohms Replace the coil With boom fully lowered hold the function down switch Adjust the relief valve to read 1800 PSI and replace the cylinder counterbalance valve function inoperative Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valve is not allowing the cylinder to retract or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valve in this situation can be very dangerous Please consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts A O A Continued from the previous page CHART 15 Adjust the boom down With boom fully lower relief valve item F hold the function down in one turn clockwise switch Adjust the relief Then with pressure valve to read 1800 psi gauge still attached operate the function down less than 1800 psi Remove the boom down Repair the boom lift high pressure line from cylinder the manifold and cap the port Hold down function and recheck pressure less than 1800 psi Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 33 Section 5 Trouble
50. on the OR repair open in 2 speed solenoid blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Check if 2 speed ki Check linkage or solenoid moves in and replace solenoid out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms 5 24 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Low Idle Inoperative Deutz Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At platform controls start engine and switch rpm select switch to maintained low idle turtle symbol Check volts at blk red wire on rpm select switch Check voltage at the red wire on the 2 speed solenoid Check if 2 speed solenoid moves in and out freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department moves freely Chart 9 Isolate the platform and ground rpm switches check individually and replace defective switch Replace CR4 relay solenoid binds Check linkage or replace solenoid Part No 32960 Genie Z 45 22 5 25 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart
51. replace the cylinder counterbalance valve function inoperative Check for mechanical restrictions and or the cylinder has internal defects Please consult Genie Industries Service Department With boom fully extended hold the extend function switch Adjust the relief valve to read 1200 psi Repair the cylinder and or replace cylinder counterbalance valves Part No 32960 Genie Z 45 22 5 39 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 19 Primary Boom Retract Function Inoperative Be sure all other functions operate normally including boom extend function If primary boom retract function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If primary boom retract function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Repair open in blk wht wire circuit from TB8 to directional valve Hold ground control function switch and check volts at blk wht wire on extend retract function valve 0 or Hold toggle switch down ae Check the resistance infinite and manually override of the retract directional ohms Replace the coil the retract directional valve coil valve push in button on end of valve spool Note overriding the valve w
52. require that the filter be replaced more often ADANGER Engine fuels are combustible Replace the fuel filter 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 Turn the manual fuel shutoff valve located at the fuel tank to the cLoseb position 2 Remove the fuel filter with a filter wrench a fuel filter b oil filter 3 Apply a thin layer of oil or diesel fuel to the new fuel filter gasket Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Install the new filter part no 29560 and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 5 Turn the manual fuel shutoff valve located at the fuel tank to the open position 6 Start the engine from the ground controls then inspect the fuel filter for leaks If a fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operatethe machine Repair the leak immediately C 9 Replace the Gasoline Fuel Filter Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be
53. surface all hydraulic cylinders all hydraulic manifolds primary and secondary booms the underside of the chassis ground area under the machine Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 9 Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option AWARNING An over inflated tire can explode and may cause death or serious injury To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire Specifications 2WD Models 4WD Models Industrial tire 9 14 5LT 100 psi 6 89 bar Rough terrain tire 14 17 5NHS 14 17 5NHS 40 psi 2 76bar 28 psi 1 93 bar A 10 Test the Platform and Ground Controls Testing machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Start the engine from the ground controls and then operate each machine function through a full cycle Resu
54. temp High idle 2150 rpm A Brush length new 0 50 inches Low idle 1400 rpm 12 7mm Governor electronic Brush length wear limit 0 25 inches 6 35mm Compression pressure psi of lowest cylinder must be at least 75 of Brush spring tension 40 ounces highest cylinder Bolt torque through brush 55 75 inch pounds Valve clearances 98 134gm cm Intake 0 0010 0 0027 inches Brush mounting 15 20 foot pounds 0 025 0 068mm bolt torque 2 1 2 7kg m Exhaust 0 0015 0 0032 inches Maximum commutator 0 005 inches 0 038 0 081mm run out 0 127mm Lubrication System Battery Oil pressure operating 40 60 psi Type 12V Group 24 temp 2150 rpm 276 414 kPa Ampere hour 75A Oil capacity 5 quarts including filter 4 71 liters Cold Cranking Ampere 875A Oil viscosity requirements Reserve capacity 25A rate 125 minutes Below 60 F 15 5 sw 30 Fuel Pump 10 to 90 F 23 to 32 C 10W 30 Static pressure 5 0 7 0 psi above 10 F 23 C 10W 40 or 10W 50 Minimum volume flow 1 pint 473cc in 25 seconds above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Part No 32960 Genie Z 45 22 2 5 Section 2 Specifications FORD ENGINE LSG 423 SPECIFICATIONS Ignition System Ignition spark advance 10 BTDC Ignition coil primary resistance 1 13 1 25W 75 F Ignition coil secondary resistance 7700 9300W 75 F Spark plug type
55. the bolts that attach the torque hub to the chassis then remove the torque hub Crushing hazard The torque hub ACAUTION 7 a will fall if it is not properly supported when the mounting bolts are removed Specifications Lug nut torque 125 ft lbs 169 Nm Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition 2WD Drive Manifold 18 1 2WD Drive Manifold Components Index No 1 2 3 NO OO A 11 12 13 14 15 16 Schematic Description Item Check valve 02 2 0 21121122 Mu owoc 2 position 3 way valve ONA 2 position 3 way valve Nintento Orifice 0 036 in 0 914mm Punta odd Pilot to open check valve Bx detainee Pilot to open check valve Gundi Shuttle valve 3 position 3 way K Pilot to open check valve Dis netas to er Pilot to open check valve Dunia 2 position 3 way valve Dermatitis Shuttle valve 2 position 3 way Matta Do Flow regulator valve Acura Flow regulator valve Cunit Relief valve 320 psi 22 bar Laia Flow regulator valve Hita Flow regulator valve Foe za ait Plug Torque Specifications Description Hex Size Torque SAE No 2 Ma 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18
56. the chassis Use a torque wrench to tighten the fasteners in sequence to specifications Specifications torque First rotation 95 ft lbs 129 Nm Second rotation 190 ft lbs 258 Nm Part No 32960 Genie Z 45 22 7 49 Section 7 Repair Procedures Service Manual Second Edition TURNTABLE ROTATION COMPONENTS 4 Locate the 0 mark stamped in the outside bearing and the dowel on the inside bearing 5 Position the inside bearing dowel 90 degrees counterclockwise from the 0 mark on the outside bearing 6 Install a grease fitting on the inside bearing and apply grease until it comes out of the inner seal 7 Apply grease to 10 gear teeth on each side of the 0 mark on the outside bearing 8 Center the worm drive over the 0 mark on the outside bearing and install the two 5 16 inch fasteners Hand tighten the bolts 9 Push the worm drive towards the rotation bearing to be as close as possible 10 Position a dial indicator to measure the worm drive in relation to the ring gear Pull the worm drive away from the rotate bearing 0 035 inches 0 889mm 0 020 inches 0 508mm 11 Tighten the two 5 16 fasteners Observe the dial indicator to be sure that the worm drive does not move 12 Locate the 1 inch hex head on the end of the worm gear housing Turn the hex head to rotate the worm drive until it is positioned within the original reference marks on the chassis 13 Position the turnta
57. the fuel tank 4 Remove the tank anchor hook from the back of the tank 5 Remove the mounting fasteners from the bottom of the tank 6 Use an appropriate lifting device to remove the tank from the machine Clean the fuel tank and inspect for rust and corrosion before it is installed Part No 32960 Genie Z 45 22 7 45 Section 7 Repair Procedures Service Manual Second Edition Turntable Rotation Components 12 1 Rotation Hydraulic Motor The rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear may not be removed from the housing In order to remove the housing the turntable has to be removed How to Remove the Turntable Rotation Motor 1 Remove the hydraulic hoses attached to the turntable rotation motor and plug them Bodily injury hazard Sprayin ACAUTION oi R 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 2 Remove the turntable rotation motor mounting bolts then remove the motor Do not allow the turntable to rotate until the hydraulic motor is installed 12 2 Rotation Bearing and Worm Drive How to Remove the Rotation Bearing or Worm Drive The turntable and all components above it must be removed prior to removing the rotation bearing or worm drive This procedure requires specific AWARNING repair s
58. the lip of the seal may result 5 Be sure that the outer bearing is packed with grease and place it into the hub 6 Install the washer and slotted nut 7 Tighten the slotted nut to 35 foot pounds 47Nm 8 Loosen the slotted nut and then re tighten to 8 foot pounds 11Nm 9 Install a new cotter pin Bend the pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169Nm 13 2 Steering Cylinders How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires Bushings are used at both ends of each steering cylinder clevis 1 Disconnect the hydraulic hoses from the steering cylinder and plug them 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 ACAUTION 2 Remove the cotter pin then the clevis pin from each end of the steering cylinder 3 Remove the steering cylinder Always use a new cotter pin when re installing a clevis pin Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 13 3 Tie Rod How to Remove the Tie Rod Weldment 1 Remove the cotter pins then the clevi
59. to increase the pressure or counterclockwise to decrease the pressure Then reinstall the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Specifications Relief valve 320 psi 22 bar Genie Z 45 22 Part No 32960
60. to increase the rpm or functions should operate clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 Deutz Diesel models seconds Low idle 1300 rpm High idle 2300 rpm Part No 32960 Genie Z 45 22 4 17 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 14 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform personnel As a safety feature selecting and operating the ground controls can override the platform controls including the Emergency Stop button 1 Start the engine from the ground controls 2 Push down the Emergency Stop button to the off position O Result The engine should be off and no machine functions should operate Diesel models All functions should stop immediately The engine will shut off after 2 or 3 seconds 3 Start the engine from the platform controls 4 Push down the Emergency Stop button to the off position Result The engine should be off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key swit
61. troubleshoot fuel injection system solenoid does not pull in Check voltage at blk red gy wire on rpm select Check voltage on center terminal of rpm select switch switch Replace toggle switch Repair open in blk red wire circuit from toggle switch to TP35 to TB35 Check voltage at TB35 12 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 V Check voltage at terminal 30 on CR3 12V Check voltage to Repair open in wht 21 terminal 86 on CR3 wire circuit from terminal 87 CR2 to terminal 86 12V on CR3 Repair open in ground Check ground wire to wire to terminal 85 on CR3 terminal 85 on CR3 Check voltage to terminal 87 on CR3 Replace CR3 relay 12V Check voltage at initiate OV terminal 86 on CR4 Repair open in blk red wire circuit from CR3 to CR4 Continued on the next page Chart 8 Repair open in circuit supplying 12V to center terminal of switch Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 8 Repair ground wire to terminal 85 on CR4 Check ground wire to terminal 85 on CR4 Continued from the previous page Check voltage to Repair open in wht 21 terminal 30 on CR4 wire circuit from CR2 to CR3 to CR4 Check voltage at the Replace CR4 relay blk red wire
62. way to the down position Adjust the voltage to 4 05V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Engine should be at normal operating temperature Start the engine and move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol Raise the primary boom 1 inch 2 5cm above the drive limit switch 10 Start a timer and record how long it takes for the secondary boom to reach the full up position Adjust the max out trimpot to achieve a 23 to 27 second cycle time 11 Start a timer and record how long it takes for the secondary boom to lower into the full down position Adjust the dual range trimpot to achieve a 23 to 27 second cycle time Secondary boom up down specifications Threshold 2 50V DC Secondary boom up Max out 5 01V DC Cycle time 23 to 27 seconds Secondary boom down Dual Range 4 05V DC Cycle time 23 to 27 seconds Turntable Rotation Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 15 4V DC output Electrocution hazard Contact with AWARNING electircally charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accuratel
63. wheels and stops drive movement unless the drive enable override switch is used The drive limit switch is used to restrict drive speed when the boom is raised and signal the oscillate cylinder to extend the lock out wedges oscillating axle equipped machines Also on oscillating axle equipped machines there are two limit switches to stop the boom from being raised unless the lock out wedges are extended Improperly functioning limit switches will allow the boom to raise and or drive into an unsafe position Drive Limit Switch 1 With the engine off and the machine in the stowed position visually inspect the drive limit switch for the following broken or missing rollers or arms missing fasteners loose wiring Genie Z 45 22 Part No 32960 Service Manual Second Edition yA AAA AA Start the engine from the ground controls Raise the primary boom above the drive limit switch and turn the machine off Manually activate the drive limit switch a drive limit switch Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard Restart the engine and lower the boom into the fully stowed position Move the key switch to platform control and then start the engine from the platform controls Slowly move the drive control handle off center Result The machine should move at normal drive speeds Raise the primary boom above the
64. wire circuit from TB41 to H page switch press down foot horsepower limiter switch and check terminal 3 voltage at terminal 3 on horsepower limiter Check voltage at Repair open in org blk org blk wire on engine wire circuit from alternator alternator to TB41 Repair or replace alternator Press down foot switch and check voltage at terminal 10 on horsepower limiter Replace horsepower limiter board 9 to 12V Press down foot switch Repair open in red wire and check voltage at circuit from horse power terminal 6 on drive limiter board to drive controller control terminal 6 9 to 12V Continued on the next page 5 54 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 31 Disconnect drive pump Repair or replace drive ONE d BE the EDC wires press down controller p page foot switch hold drive controller in full forward position and check voltage across terminals 4 and 5 on drive controller Press down foot switch Repair open in either hold drive controller in wht or wht blk wire full forward position circuit from drive and check voltage controller to TP30 and across terminals TP31 respectively TP30 and TP31 Press down foot switch hold drive controller in TEE full forward position Repair open in either wht or wht blk wire and check voltage ircuit from TB30 and across terminals 7831 rom na an TB30 and TB3
65. 1 cda Y Press down foot switch Repair open in wht blk hold drive controller in wire circuit from TB31 to full forward position and EDC quick disconnect check voltage across OR repair open in wht the two wires at EDC wire circuit from TB30 to quick disconnect EDC quick disconnect Replace drive pump EDC OR consult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 55 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 32 Drive Disconnect the EDC voltage readings different aa or Vo the wire connector from the rive controller Forward Or drive pump start engine move the drive Reverse controller to full forward Function position and note the E voltage across terminals Inoperative TB30 and TB31 Reverse the volt meter leads and move the Be sure all other drive controller to full functions operate reverse position and normally including note the voltage drive in opposite direction of voltage readings the same SNE Adjust the drive pump Defective Sundstrand null neutral See no improvement drive pump contact Sundstrand Series 40 Sundstrand authorized Service Manual repair facility symptoms improve Check all drive speeds and monitor for recurring symptoms Possible contamination in hydraulic system 5 56 Genie Z 45 22 Part No 32960 Section 5 Troubleshooting Flow Charts Chart 33 Service Manual Second Edition Hig h Ran
66. 10 All Functions Inoperative Engine Starts and Runs ok Check pump suction line shutoff valves Valve handles should be parallel with hose Disconnect center coil wire from distributor cap and isolate from grounding Deutz models hold manual fuel shutoff lever counterclockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing spline drive at rear of main pump Engine to pump flex plate coupling Is defective See Repair section Check hydraulic fluid level spline does not turn Fill with Dexron II equivalent hydraulic fluid Open valves If engine has been run with valves closed it may have damaged one or both pumps Troubleshoot inoperative boom functions and inoperative drive functions separately 5 26 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Functions Operational Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the open position Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Install a O to 3000 PSI pressure gauge on the function manifold Start engine hold the boom retract function and check the hydraulic pressure less than 2400 psi 2400 psi or more Adjust t
67. 1523 TO z45 002154 GRN 2 BLU RED 3 DRIVE ENABLE BLU WHT 3 WHT BLK 1 WHT RED 1 BLU BLK 1 BLU 1 RED WHT 1 HIGH l LOW _ RED za I EXTEND soo RETRACT BLK WHT 3 EXTEND Boom RETRACT BLK RED 4 WHT RED 3 WHT BLK 3 WHT 3 RIGHT TURNTABLE ROTATE 3 D LEFT UP PRIMARY BOOM DOWN RED 3 RED BLK 3 RED WHT 3 BLU BLK 3 BLU 3 BLU UP BOOM SECONDARY DOWN BLU BLK RED WHT UB PLATFORM LEVEL DOWN ORG BLK 3 PLATFORM LEVEL ORG RED 3 LEFT PLATFORM ROTATE RIGHT GRN BLK 3 PLATFORM ROTATE WHT 13 EH GRN RED 3D E H BLK 12 EH WHT BLK 31 E H gt E DRIVE EDC WHT RED 32 E H BLU BLK 37 E H BLU 36 E H a a a p RED WHT 29 E H BLK TRI E H WHT 40 E H BLK WHT BLK WHT 4 WHT BLK WHT BLK 4 WHT RED 4 RED BLK RED BLK 4 RED WHT 4 BLU BLK 4 ORG BLK ORG BLK 4 ORG RED 4 GRN BLK GRN BLK 4 GROUND DRIVE ENABLE LIMIT SWITCH p Z9 20B DRIVE BRAKE VALVE STEER RIGHT STEER LEFT START STEER UNLOAD MOTOR STROKE TRACTION RELAY 10 SEC OFF DELAY TRACTION BY PASS BOOM UP LIMIT SWITCH BOOM EXTEND BOOM RETRACT TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL SECONDARY UP SECONDARY DOWN PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLAT
68. 2960 Genie Z 45 22 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition q __ _ ______ This page intentionally left blank 3 8 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Hl 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 frequently every 3 months annually and every 2 years as specified on the mainentance report Failure to properly complete each AWARNING inspection when required may result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating machine H Keep records on all inspections for three years H Unless otherwise specified perform each repair procedure with the machine in the following configuration machine parked on a flat level surface boom in stowed position turntable rotated with the boom between the non steering wheels key switch in the orF position with the key removed wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and st
69. 3 22 Turntable Rotate Right Function Inoperative ooccconnnnnncccnnnnnnncccccccnnnacancccnnns 5 44 23 All Platform Leveling Functions Inoperative ononcccnnnnnnnnccccnnnnnncccccccnnnnranccnnns 5 45 24 Platform Level Up Function Inoperative e eeeeeeea aaa aaa aaa aan aaanaaa 5 46 25 Platform Level Down Function Inoperative ssssee ee eaa aaa aaa eaanaaaae 5 47 x Genie Z 45 22 Part No 32960 Service Manual Second Edition DEEN TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 26 Platform Rotate Left Function Inoperative ooonnnnccicnnnnnnnncccnnnnnncccccnnnnnnccnccnns 5 48 27 Platform Rotate Right Function Inoperative oooononcccnnnnnnnncncnnnnccnnnccncnnnnnanannnos 5 49 28 Oscillate Function Inoperative eee aaa aaa aaa cnn aaa nana 5 50 29 Steer Left Function Inoperative esse e aaa aaa aaa aaa aaa cna 5 51 30 Steer Right Function Inoperative eeeesssee aaa asa cc cnnnnnnnnnnno 5 52 31 All Drive Functions Inoperative All Other Functions Operate Normally 5 53 32 Drive Forward Or Reverse Function Inoperative oooooncnnccnnnnncncnncccnnnncnnconnss 5 56 33 High Range Drive Function Inoperative oonnnicccnnnnnnnncccnnnnnncccccnnnnncenccnnns 5 57 34 Low Range Drive Function Inoperative eeeeeeeaa aaa aaa aaa aaa eaanaaaae 5 60 35 Traction Function Inoperative A 5 61 36 Machine Will Not Drive At Full Spee
70. 745 22 HP 4WD HYDRAULIC SCHEMATIC SERIAL Z45 O00001 TO z45 000981 SLAVE RISER e PLATFORM e PRIMARY ROTATE E r CH ome Oe z JL gt lt oh gt saa dal datt S L L 4 EXTENSION zai r4 Vv H Y KA zaje L gt 4 EE 19 H4 1 l AE E 085
71. A E O Lee AAN T lt A 5 a axle b pinretainer See 6 c kingpin d yoke e hub 7 f cotter and clevis pin g steering cylinder h tierod 2 Break loose the wheel lug nuts Do not remove them 3 Block the non steering wheels and place a lifting jack under the steering axle 4 Raise the machine and place blocks under the chassis 5 Remove the lug nuts then the tire and wheel assembly 6 Remove the pin retainer attached to the king pin Loosen the wheel lug nuts Do not remove them Place a lifting jack under the steering axle Raise the machine and place blocks under the chassis Remove the lug nuts then the tire and wheel assembly Remove the dust cap cotter pin and slotted nut Pull the hub from the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Part No 32960 Genie Z 45 22 7 51 Section 7 Repair Procedures Service Manual Second Edition 2WD STEERING AXLE COMPONENTS How to Install the Hub and Bearing 1 Be sure that the bearing is packed with grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal into the hub Rest the seal on the hub then press the seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle ACAUTION Component damage hazard Do not apply excessive force or damage to
72. C SERIAL 4245 001525 TO 002134 HCH RPU ENGINE SPEED BLK RED 1 use seeen ce and DWG ES45F 1 F BLK RED HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY RED WHT EH Joan do BLU BLK EH I Ize Z p BLK REDRA E H I e a ee o L 8 RED WHT 23 E H I ES Cea s l 15 c 4 88 BLU RED 1 BLU REDYR7 E H LPG SOLENOID BLU WHT 1 BLU WHTAR6 EH ANTIDIESEL VALVE BLU WHTYRG E H GASOLINE SOLENOID D FLASHING BEACONS BEN SES En RED ZWHT423 E H Wa FUEL RELAY WHTAR9 E H DSC VALVE BLK R9 EH OSCILLATE RELAY j ae 6 BLKYRIO En SECONDARY LIFT OSCILLATE LOCKOUT WHT RED PRIMARY LIFT WHT BLK D 53 S8 REJ EJ WNT RED 26 E H WATER TEMP SENDER WHT BLKA25 En OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE EEN 5 emm Se dE SYSTEM BLK R1 E H STARTER MOTOR aunar N a pue RED PRI RED 27 E H AUXILIARY AUXILIARY POWER RELAY AUXILIARY PUMP GRN WHT 1 GRN WHT 45 E H WHT 2 RED WHT 23 E H LEVEL SENSOR BLK RED 3 BLK RED SERVCE HORN RELAY ALK REDARB E H RED SERVICE HORN BRN BLK EH ORG BLK 1 1841 ORG BLK 41 EH a E 18 We E WHT 21 E H I lg RED EH pg wb l EK TEL a E koda Ve SE RED 20 E H Z9 20A D Z45 22 GP HP MP Index 745 22 HP 2WD amp 4WD FORD ELECTRICAL SCHEMATIC cont d SERIAL Z45 00
73. CR4 ISTART IGNITION RPM RPM C RELAY RELAY CUTOUT RELAY RELAY CRS CR6 CR7 CR8 HORN FUEL FUEL BALLAST RELAY CUTOUT CUTOUT BYPASS RELAY RELAY RELAY CRY CR10 CR11 Of oSCILLATE SCILLATE OSCILLATE RELAY LOCKOUT LOCKOUT RELAY RELAY O a pi UZ DWG 4ES45F 4 F 45002134 745 22 HP 2WD amp 4WD FORD PLATFORM CONTROL BOX LEGEND SERIAL Z45 001523 TO HORSE POWER LIMITER TILT ALARM 45 GRN WHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 SPARE 42 ORG RED 1 PULSE PICKUP _ 41 ORG BLK 1 LIMIT SWITCH _ 40 ORG 1 L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 SPARE 28 RED BLK 1 AUX PWR 27 RED 1 PWR TO F S 26 BLK F S PWR START 25 GREEN F S PWR GONT 24 WHT H P L PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 JIB VALVE 19 GRN WHT 3 PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 DRV ENA 12 BLU WHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOO
74. Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and ground personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the Genie 245 22 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for damage or illegibility Replace any illegible decal immediately Contact your Genie distributor or Genie Industries if replacement decals are needed A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including electrical components wiring and electrical cables hydraulic hoses fittings cylinders and manifolds fuel and hydraulic tanks drive and turntable rotation motors and gear boxes boom components and wear pads dents or damage to machine tires and wheels engine and rel
75. Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 32 49 6 68 8 1 4 inch 20 96 11 144 16 28 120 14 168 19 Sie inch 18 17 23 25 34 24 19 28 25 34 3 s inch 16 30 41 45 61 24 35 48 50 68 The inch 14 50 68 70 95 20 55 75 80 109 1 2 inch 13 75 102 110 149 20 90 122 120 163 8 16 inch 12 110 149 150 204 18 120 163 170 231 5 s inch 11 150 204 220 298 18 170 231 240 326 3 4 inch 10 260 353 380 515 16 300 407 420 570 T s inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specification for lubricated bolts is 25 less than dry torque specification for bolt size These bolt torque specifications are for general use only Specification may vary depending on application of bolt 2 4 Genie Z 45 22 Part No 32960 Service Manual Second Edition Ford Engine LSG 423 Displacement 140 cu in 2 3 liters Section 2 Specifications FORD ENGINE LSG 423 SPECIFICATIONS Starter motor Normal engine 110 rpm cranking speed Number of cylinders 4 Current draw normal load 150A Bore and stroke 3 780 x 3 126 inches 96 x 79 4mm Current draw maximum load 460A Horsepower 63 4000 rpm Current draw no load 70A Firing order 1 3 4 2 Maximum circuit 0 5V DC voltage drop normal
76. FORM ROTATE LEFT PLATFORM ROTATE RIGHT DWG 4ES45F 2 F lt a 745 22 GP HP MP Index Z45 22 HP 2WD amp 4WD FORD RELAY PANEL LEGEND SERIAL Z45 001523 TO 45 002134 O T09 NOLLINO O z O o C Je m EES O w ou TM Ec 410 Z A ID 0 HONHJAOD ATSV LIZI 7 9 9 9434 J VL IOA p 29 21 DWG 4E545F 5 F EJ Oo CS Ny Lo 5 CH a S Se CER x OOM m Gel CS 0 OO al Sy NR Na NZ A 5 lt Oa Seo Non al x El5 Al S SI o SIE lolo 2 CIS au 2 a css z o Lal 8 ela sz El 3 E selog Dza S 5 Z nn ei a Ss EISE WO Si gt 9 S EIS S alla Flad aS EES Esla 18 als S0 lt lt g e Co 5 REE aaRS SSS S14 a ANAE E D GEI sezes Su wl gt 3 i Blame oe a l SS gt 5 H ESS EIS Ska kale B zoja 9 g gE less mx mes E 110 Oo Ulea le Sojo S las zelas 2 5 22 0 EE E 58 eel El S S ek D x a i c ajaja ma JF fo Ed rr Ol aj ms Ju lnla m GEESS Bo ISIS ld PES S ZI Bl a Hf pulpa len aja lr Sad AA AAA AA EIE oo T E w o Oje o ola O es ie ele gt lt cz e o oj 0 OS amp ooo a gt z D 5 ooo 5 E H 2 3 a m o Oj looojg B o 0 8 kB o Oj OO0J a E o H
77. FP lovee continuity erat resistance rating printed on the resistor red to white no continuity infinite 2 black to white no continuity Do not use the colors of the connector as a guide for these tests Use the actual wire color to identify which contact to use for testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire connector combination listed below and check for continuity Test Desired result red to black no continuity infinite red to white no continuity black to white continuity zero Q 7 8 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures p AA PLATFORM CONTROLS 1 5 Test Desired result Toggle Switches Left Position Toggle switches used for single function switching terminal 1 to 2 3 4 5 amp 6 mo continuity infinite are single pole double throw SPDT switches RARE terminal 2 to 3 continuity zero Q Two function switching requires a double pole double throw DPDT switch terminal 2 to 4 5 amp 6 no continuity How to Test a Toggle Switch terminal 3 to 4 58 6 no continuity terminal 4 to 5 4 6 no continuity This procedure covers fundamental switch testing and does not specifically apply to all varieties of terminal 5 to 6 continuity toggle switches Center position There are no terminal 1 Turn the keyswitch to the off position and combinations that wi
78. Gasoline LPG Models Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve 2 Remove the hoses from the valve then remove the valve Install the new valve 4 Swing engine pivot plate back to its original position and replace the three retaining bolts a PCV valve b hose PCV valve to carburetor c hose PCV valve to crankcase C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LPG Models Distributor caps and rotors that are clean and free of damage wear and corrosion are essential to good engine performance and service life A dirty or worn cap and rotor may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap and rotor be replaced more frequently Perform this procedure with the engine off e OF Y Ges a _ pivot bolt plates 1 Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the distributor 2 Label and remove the coil and spark plug wires from the distributor cap Remove the cap and rotor from the distributor 4 Clean the cap and rotor using electrical contact cle
79. Genie Industries Technical Publications Genie 7 45 22 d Service Manual Second Edition First Printing Part No 32960 Introduction Service Manual Second Edition Genie Z 45 22 Important Read understand and obey the safety rules and operating instructions in the Genie Z 45 22 Operator s Manual before attempting any maintenance or repair procedure This service manual covers the Genie Z 45 22 2WD and 4WD models introduced in 1994 This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting 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 a Genie dealer service center Genie Industries 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 other manuals Please write to the technical publications team in care of Genie Ind
80. HT 3 ES a E E E E WHT BLK 1 RH WHT BLK 31 E H A e g DRIVE EDC D D e 3 E E WHT RED 1 JA WHT RED 32 E H De D D W R 5 A BLU BLK 1 3 BLU BLK437 E H BER BLU BLU 36 E H ei a os e R N i a i AI I s AE E se S yt on 2 8 RED WHT ES RED WHT 1 RED WHT 29 EH D A HIGH a A LOW RED Ges a tee 2 m S GREEN E we ET E OE 2 froo ni B RED BLK TR1 EH H E Re ORG 1 WHT440 E H GRN e f 6 e ER FRIEREEE lil wrta aGee Z ss EE E BLk 3 f I e L EXTEND I BOOM I Ty RETRACT BLK WHT 3 fait e B a BLK 4 l E sie it IRSCH 5 BLK WHT i T BOOM FE alt RETRACT eel BLK WHT 4 l fe 2 t 2 E l oA I t BLK RED 4 e SH WHT RED 3 1 I e I 4 A WHT BLK 3 WHT 3 WHT 1 me a e a E WHT 4 a E RIGHT WHT BLK 1 a j TURNTABLE ROTATE I al nil LEFT IZ WHT BLK 4 f a FEE h PA em BI 8 I I l Bi 5 4 WHT RED 4 f Ecg I I 8 n P I s I RED e 5 EA s een Ile el Due RED BLK I ja T PRIMARY BOOM N a H EET SA DOWN Ea RED BLK 4 Bes A A p A A el I LS z I 1 fe RED WHT 4 e I He RED 3 l e e RED BLK 3 1 m E l E E RED WHT 3 a I 5 I E I Es BLU BLK 3 1 I 5 BLU 3 BLK e o L t z Ek BLU BLU CRI BLU 4 Ire e EAS Yh BOOM SECONDARY 4 q Pow BLU BLK l BLU BLK 4 el ay 1 H g 3 l b se RED WHT Y I ES ORG 3 I Tup I 1 PLATFOR
81. ILLATION STEERING LOCK OUT DWG HS4WD B p Z11 09 lt a 745 22 Hyd 1 are 745 22 HP 2WD HYDRAULIC SCHEMA TIC SERIAL 42459002541 amp ABOVE BRAKE 2 SPEED MANIFOLD SLAVE SECONDARY 9 025 3 T I AJ SEEM a I iP PLATFORM PRIMARY Jh
82. M LEVEL I e DOWN ORG BLK 3 ORG l EN EN k E E x ORG 4 H FA 2 lo R ORG BLK l R PLATFORM LEVEL P WM DOWN ORG BLK 4 l y I I 2 l EE 2a I a 5 5 EJ t E ORG RED 4 1 2 De 5 ORG RED 3 e i E GRN 3 s I LEFT r PLATFORM ROTATE R p RIGHT GRN BLK 3 CON D z 4 p GRN 4 I E ped 2 Jr R GRN BLK PLATFORM ROTATE B e y RIGHT A ORN BLK 4 I De m i I U GROUND DRIVE ENABLE LIMIT SWITCH p Z10 11B DRIVE BRAKE VALVE STEER RIGHT STEER LEFT START STEER UNLOAD MOTOR STROKE TRACTION RELAY 10 SEC DFF DELAY TRACTION BY PASS bs BOOM UP LIMIT SWITCH BOOM EXTEND BOOM RETRACT TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL SECONDARY UP SECONDARY DOWN PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT DWG 4E545D 2 J 745 22 2WD amp 4WD DEUTZ DIESEL GROUND CONTROL BOX LEGEND SERIAL 4245001524 TO 5050
83. M Up 10 BLU 3 HORN 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 SWING F C 6 WHT RED 3 SWING RIGHT 5 WHT BLK 3 SWING LEFT 4 WHT 3 PRIMARY F C 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 112 314 5 6 7 8910 EN z te O a EP On CABLE CABLE CABLE 5 2 1 TILT ALARM li Z45 22 GP HP MP Index P2 ER O m m E TSZ O O O O EXTEND RETRACT BP1 TS4 LED DRIVE ENABLE TS8 TS6 O O O O O O PLATFORM LEVEL P3 NCINC STOP FUEL SELECT HIGH R P M IER START DRIVE HIGH LOW TSS PLATFORM ROTATE NO HORN DWG ES45F 3 F p Z9 23 lt a Z45 22 Diesel HP MP Index Z45 22 2WD amp 4WD DEUTZ DIESE ELECTRICAL SCHEMATIC SERIAL Z45 001524 TO 5050 NOTE CIRCUIT CONNECTION TO TP24 FOR UNITS WITHOUT GENERATOR OPTION al GRN yy GRN_TPZS Eu BLK gt P2 Dr Z6 BLK TPZI WHT NE TP24 Moa HOIH ABYTIKNTY DEE U33dS INNI 1 18 980 034 X18 1 W18 G3U 1HW A18 034 X18 1 IHW NYD ABYNIKNY e MEM T START RELAY Z TACHOMETER 3 START INPUT 4 AUX ON 5 GROUND 6 BATTERY Z KEY PWR OQ 8 KEY BYPASS 9 IGN FUEL ON Dap FAULT 15AMP A IGN START MODULE El 20 I
84. OCEDURES 2 Loosen the lock nut then turn the adjustment B 13 screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the lock nut and recheck the rpm Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control a solenoidboot 3 Operate each machine function from the b hob de adjustment nut ground controls clock nut d yoke Result The machine functions should not e lowidle adjustment screw operate f lock nut 3 Move the engine idle control switch to high idle EE rabbit symbol from the ground controls 5 Operate each machine function from the Result High idle should be 2300 rpm platica controls O Result The machine functions should not If high idle rpm is correct disregard operate adjustment step 4 6 Turn the key switch to the off position 4 Loosen the yoke lock nut then turn the y P adjustment nut and solenoid boot Result The engine should stop and no counterclockwise
85. PWR WHT S P WHT D B RO 21 WHT R2 WHT EH NS 12V BATT SUPPLY RED S P 20 RED En JIB VALVE 19 GRN WHT 3 PLAT ROT R GR BK_S P __ GR BK D B GRN BLK 3 GRN BLK d PLAT ROT L GRN S P GRN D B GRN 3 GRN 4 PLAT LEVEL F C OG RD S P 0G RD D B ORG RED 3 ORG RED 4 PLAT LEVEL DN 0G EK_S P _06 BK D B ORG BLK 3 ORG BLK 4 PLAT LEVEL UP ORG S P ORG D B ORG 3 ORG 4 DRV ENA LT 3 BLU RED 3 WHT IS En DRV ENA WHT I2 EH 2 BLU WHT 3 BLK 12 En SEC BOOM DN BU BK_S P BU BK D B 11 BLU BLK 3 BLU BLK 4 SEC BOOM UP BLU S P BLU D B 10 BLU 3 BLU RI0 y HORN BK RD R5 9 BLK RED 3 SS x u BOOM RETRACT BKZWT S P BK WT D B 8 BLK WHT 3 _ BLK WHT 4 7 gt El lt BOOM EXTEND BLK S P BLK D B 7 BLK 3 BLK 4 o 52 lo TURN ROT F C WT RD S P 6 WHT RED 3 W R 4 _ Sls MENE TURN ROT L WT BK_S P WT BK D B 5 WHT BLK 3 WHT eLK 4 ss 4 E TURN ROT R WHT S P WHT D B 4 WHT 3 WHT 4 3 Ax lz ESIE 3 PRI BOOM F C RD WT S P 3 RED WHT 3 RZW 4 IONES 53 8 PRI BOOM DOWN RD BK_S P RD BK_D B 2 RED BLK 3 RED BLK 4 za Be iw Se a PRI BOOM UP RED S P RED D B 1 RED 3 RED R11 Ela Sot aaee Z A B D Fale Sale zos ye is O 1 start RELAY B 0 z O l el O 2 TACHOMETER IGN START A loB n SIE ls CIP o e MODULE zl eH Clos gt le Z O 3 START INPUT MEEME AS e g9 alz gt l z EE zsiga alx O 4 Aux on sl se alo lt lt FIG IL La 2192 a a dake oo O e
86. RD CR3 35 BLK RED 1 34 BLK WHT 1 BLK_S P BLK 1 5 M 33 BLK 1 BLK CR7 WT RD D B 32 WHT RED 1 WT RD En 31 WHT BLK 1 WT BK E H RED 30 E H 30 WHT 1 29 R W 1 RD WT E H 28 RED BLK 1 RED S P RED 1 5 M 27 RED 1 RED EH WT RD S P 26 WT RD EH WT BK SP 25 WT BK EH WHT LSM Le 24 gt WHT S P WHT LSM 23 WHT 2 RD WT EH sj _ BLK S P BIK CR5 22 BLK 2 2 WHT S P WHT D B 21 WHT GR2 WHT EH NO RED S P RED EH GRN WHT 3GRN WHT 4 GR BK_S P GR BK D B GRN BLK 3 GRN BLK 4 GRN S P GRN D B CRN 3 GRN 4 loG rD S P losen D B ORE RED 3 ORG RED 4 loc ek Sp 0G BK D B ORG BLK 3 ORG BLK 4 ORG SP ORG D B ORG 3 ORG 4 BLU RED 3 WWTF13 E H WHT 12 E H BLU WHT 3 BLK12 E H BU BK_S P BU BK_D B 11 BLU BLK 3 BLU BLK 4 BLUS P BLU D B 10 BLU 5 __ BLU 4 Y BK RD CRS 9 BLK RED 3 gs IBK WT S P BK WT D B 8 BLK WHT 3 BLK WHT 4 MO BLK SP BLK D B 7 BLK 3 BLK 4 WT RD SP 6 WHT RED 3 W R 4 WT BK_S P WT BK D B 5 WHT BLK 3 WHT BLK 4 WHT S P WHT De 4 WHT 3 WHT 4 RD WT S P 3 RED WHT 3 SA RD BK S P RD BK D B 2 RED BLK 3 RED BLK 4 RED SP RED DB 1 RED 3 RED 4 A B E D O 1 START RELAY O 2 TACHOMETER IGN START Se O 3 START INPUT MODULE RAW O 4 Aux ON O 5 GROUND O 6 BATTERY O 7 KEY PWR O 8 KEY BYPASS O 9 IGN FUEL ON 10 ENG FAULT 4 2 8 8 IO O lo O o DIODE lo ol BLOCKS lo 9 e je IO O lo O CR1 CR2 CR3
87. RO O adi eel Ki ai owe A 7 53 4WD Steering Axle Components 141 Yok6 and HUD ia iia adidas 7 54 14 2 Steering Cylinders See 13 2 Steering Cylinders 2 2 2222212 21112 7 52 14 3 Tie Rod See 13 3 Tie POO rieren eare ievil i 7 53 Oscillating Axle Components 15 1 Oscillating Axle Lock out Cylinder oooooccconicccnnnnccccnncccnnnnaccnononnnnnnaccn nano anie 7 56 Steer and Oscillate Manifold 16 1 Steer and Oscillate Manifold Components oooconcccnnnncccnnnoccnnonaccnananccconnn nana 7 57 Le Eu CTT 7 58 Non steering Axle Components L t Drive Moto ii A Ai 7 59 17 2 Torque AUD at yi See A A A A a ele eons 7 59 2WD Drive Manifold 18 1 2WD Drive Manifold Components eee aaa aaa aaa aaa aaa anna 7 60 18 2 Valve Adjustments A 7 62 4WD Drive Manifold 19 1 4WD Drive Manifold Components eee aaa aaa aaa aaa aaa aaznaca 7 64 19 2 Valve Adjustments A 7 66 ivx Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 2 Specifications Specifications Machine Specifications Tires and wheels Rough terrain Industrial Stowed dimension 2WD AWD Wheel diameter 17 5inches 14 5 inches Length 17ft81 2in 17ft103 4in Wheel width 10 5 inches 7 inches 5 4m 5 45M Wheel lugs AWD 9 5 8 18 Width l l Wheel lugs 2WD Rough terrain 6ft81 4in 6ft45 8in Front 8 5 3 18 8 5 8 18 203 8cm 194 66m Gear 90
88. Remove and label the wear pads from the primary boom weldment and the extension 3 3 Service Manual Second Edition Primary Boom Lift Cylinder The lift cylinder raises and lowers the primary boom How to Remove the Primary Boom Lift Cylinder AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant tube component damage Dealer Pay careful attention to the service is strongly recommended location and amount of shims 1 Raise the secondary boom and place a 4x4x31 used with each wear pad inch 78cm block between the chassis counterweight and the upper mid pivot Carefully lower the secondary boom onto the block a Uppermid pivot b 4x4x31 inch block c counterweight AWARNING Crushing hazard Keep hands away from the block and all moving parts when lowering the secondary boom 7 16 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures esses SSS eee PRIMARY BOOM COMPONENTS 2 Raise the primary boom until the end of the 9 Carefully loosen the straps and allow the boom is 8 feet 2 5 m off the ground primary lift cylinder to slowly swing down Now attach the rod of the primary lift cylinder to an E Supports PALE Econ oye mena overhead crane or similar lifting device crane Do not lift the primary boom 10 Rem
89. TB35 oV Repair open in blk red wire circuit from TB35 to CR3 ov Repair open in wht 21 wire circuit from CR2 terminal 87 to terminal 86 on CR3 bad Repair open in ground wire to terminal 85 on CR3 DV Replace CR3 relay Repair open in blk red wire circuit from CR3 to CR4 bad Repair open in ground wire to terminal 85 on CR4 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 6 Check voltage on oV Repair open in wire Continued from the terminal 30 at CR4 circuit from CR3 previous page terminal 86 to terminal M 30 on CRA Check voltage at 12V Replace CR4 relay terminal 87a on CR4 o Check voltage at Repair short in blk red terminal 5 on wire circuit from CR4 to electronic governor terminal 5 on governor OR consult Genie Industries Service Department Check voltage at Repair open in red wht terminal 1 red wht wire wire circuit from TB23 to on electronic governor electronic governor Check voltage at Repair open in red wht terminal 1 red wht wire wire circuit from on governor actuator electronic governor to governor actuator Turn engine off then Repair open in blu blk turn machine on but do wire circuit from not start engine Check governor actuator to voltage at terminal 4 electronic governor OR on electronic g
90. Toggle Switches 8 3 Wago Components How to Remove a Wago Component Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry A small standard screw driver is provided and should be used when removing a Wago component This screwdriver is located in the instruction manual storage box in the platform 1 Label and then disconnect the wiring from the component to be removed 2 Locate the removal tab on the bottom or top side of the component 3 Use the provided screwdriver to gently pry up on the tab of the component and remove it GROUND CONTROLS 8 4 Resistors How to Test the Resistors Two resistors are used to maintain proper control of boom function speeds A 10 ohm resistor reduces voltage to all the boom function switches A 15 ohm resistor parallels the 10 ohm resistor to reduce the voltage to the turntable rotate switch Turn the key switch to the off position and remove the key Disconnect one of the resistor wires from the resistor or the opposite end terminal 2 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested 3 Compare the ohmmeter reading with the resistance rating printed on the resistor Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition GROUND CONTROLS 8 5 Power Relay Electrocution hazard Contact w
91. Turn machine off and Check engine oil level OR oil cooler fins for clogging OR check engine fan belts OR see Deutz service manual for troubleshooting an overheating engine continuity gt Replace temperature switch sender continuity gt Repair short in wht rd wire circuit from TB26 to temperature sender Dor infinite Replace the fuel isolate the fuel solenoid ohms solenoid Check the resistance of the solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel system Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 3 Hold start switch and Repair open in wht 21 check voltage at wht wire from CR2 to fuel 21 wire on terminal solenoid 87 of CR2 Continued from the previous page Check voltage at red Repair open in red wire wire on terminal 30 of circuit from battery to CR2 CB1 to CR1 to CR2 Hold start switch and Hold start switch and Repair open in blk wire check voltage at check voltage at 12V from terminal 86 on terminal 86 of CR2 terminal 9 on start CR2 to terminal 9 on lockout module start lockout module oV Check voltage at Repair open in power terminal 6 and 7 on supply wires to terminal start lockout module 6 and 7 on start lockout module 12V 12V Check ground wire Repair open in ground terminal 5 on start circuit to terminal 5 on
92. YAP ROTATE d 3 LI y Q L e I a Ge al oz Es apo dalda 2SPD BRAKE L L EXTENSION baste xia det E 3 ib E y LAN 1 see 17 gt I H4 WEJ Eech E L gt TURNTABLE ROTATE MASTER 3 PR lem pul _ _ La a EH alles _ pr feo ze RETRACT bar Ge 8 4 4 ESA 2 MEDIUM k UM H Ce na I PSI Roba Ei L J L 4 200 1200 m Ea 11 PRESS OPTIONAL l TAE ES tres a8 Mp I o Di pl FILTER MOTOR CEN RE a I fz O RS EE L L Fas a w ET w S E sech BE gon i I E Eeer SHAXE E K ADO pl o t Se sch H I kraj Ese Die CH H MES gt DIE I Fl FUNCTION press _ E i Bal mal 7 aa y OKO pun de DE ER cz sl 94 Me rz d I DRIVE eee EMS A PEM a E SE mest MANIFOLD gt DRIVE PUMP w lt Stee Me I bi 1 ze e 4 4 Tipe EES a gt CE I y a a te LIFT FUNCTION MANIFOLD A Psi Psi E i 4 I A lt gt NN I REAR 1 L_2 pe E AER AAA ASA AA A A RIGHT IP l TANK AUX PUMP l m5 H Vo Taye BOR SS SR Sn Sea rh I L4 I L I ae SS M I X J r r IE CCS i E od i 070 kom L d REAR i X i I I LE I r OE LERT rz za m ei ES I CI s si I SKETE I I a alle Exes E d Sei EI I f Sp si sz I l ACCUMULATOR STEERING PRE CHARGE 2E eas 1600 PSI E W O OSCILLATING OPTION OSCILLATION STEERING LOCK OUT p Z11 10 DWG HS2WD F lt a 745 22 Hyd Ind ER
93. a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction _ Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved 5 2 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure the emergency stop buttons are pulled up into the on position Be sure the circuit breaker s are not tripped Check battery voltage Ee than Check battery condition OR check alternator OR check battery cables OR replace the 12V or more battery Check voltage at center ON Trace circuit back terminal on start switch through the key switch emergency stop button and CB2 repair open Hold start switch and OV Replace start toggle check voltage at either switch side terminal on start switch D Hold start switch and oV check voltage at Repair blk wire circuit from start switch to f fF FT terminal TB33 TB33 D Hold start switch and OV Repair blk wire circuit check voltage at from TB33 to start terminal 3 on start lockout module terminal lockout module 3 Hold start switc
94. act with hot ACAUTION not crank the engine with the ACAUTION engine fluids or components may over temperature on cause severe burns The oil pressure switch is a normally closed switch Always use pipe thread sealant that opens at approximately 3 to 5 psi when installing a switch 0 21 to 0 34 bar If the oil pressure drops below the switch point the switch closes and shuts off Water temperature switch specifications the engine A low oil pressure indicator light at the ground controls should turn on when the switch Torque 8 18 ft lbs closes 11 24 Nm Component damage hazard Do ACAUTION not start or continue to run the ci SM engine with the low oil pressure Temperature switch point 230 F 112 light on C Oil pressure switch Torque 8 18 ft lbs 11 24 Nm Hex size 1 1 16 inch Oil pressure switch point 3 5 psi 0 21 0 34 bar a ol pressure switch b water temperature switch 7 32 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures FORD LSG 423 ENGINE 7 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING ao oo 1 Connect the leads from an ohmmeter or continuity tester to the common and normally open terminals Result There should be no continuity infinite Q 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity ze
95. and RE 3 O A EW oV limit switches OR one or Function measure the oscillate CR11 both oscillate limit Ge wedges See i switches is defective j aintenance Inoperative Procedures B 17 12V Check CR10 and CR11 green grounding wire wedges do not OR replace CR10 or extend 3 inches CR11 relay s or socket s Check voltage at blk Drive limit switch R9 on CR9 shorted repair or replace Check voltage at wht Replace CRO relay or R9 on oscillate valve relay socket OR repair short in wht R9 wire circuit from CR9 to oscillate valve Remove machine from service and please consult Genie Industries Service Department 5 50 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Steer Left Function Inoperative Be sure all other functions operate normally Start the engine from Repair or replace the the platform press steer microswitch in down foot switch hold controller handle the steer switch left and check voltage at terminal 8 on the drive controller blu wire Hold the steer switch Repair open in blu wire left and check voltage circuit from steer switch at TB36 to TP36 to TB36 Hold the steer switch Repair open in blu wire left and check voltage at circuit from TB36 to blu wire on steer valve steer valve Dor Remove both wires from infinite steer left coil and check ohms resistance across coil terminals Replace steer left valve c
96. aner or adamp cloth 5 Completely dry the cap and rotor Moisture in the distributor cap will cause the engine to run poorly 6 Inspect the cap and rotor for corrosion cracks and abrasion Replace the cap and rotor if they are damaged Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 7 Install the rotor and cap then re attach the coil and spark plug wires 8 Swing engine pivot plate back to its original position and replace the three retaining pins C 12 Replace the Spark Plugs Gasoline LPG Models Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine turned off 1 Label then disconnect the plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug a R DN Install the new plugs the reconnect the plug wires Be sure that each spark plug wire is attached to the correct spark plug Specifications Spark Plugs Motorcraft AWSF 42 Gap 0 032 0 036 inches 0 81 0 91mm Torque specs 5 10 foot pounds 6 8 13 6 Nm TABLE C PROCEDURES C 13 Check and Adjust the Air Propane Mixture Ma
97. anual Second Edition Section 7 Repair Procedures 9 Attach a strap from a lifting device to the yoke torque hub assembly and support it 10 Use a soft metal drift to drive the king pin down and out Crushing hazard The yoke torque AWARNING hub assembly will fall when the king pin is removed if it is not properly supported 11 Place the yoke torque hub assembly on a flat surface with the torque hub down Remove the bolts that secure the yoke to the torque hub Specifications Lug nut torque 125 ft lbs 169 Nm 14 2 Steering Cylinders How to Remove the Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure 13 2 How to Remove the Steering Cylinder 4WD STEERING AXLE COMPONENTS 14 3 Tie Rod How to Remove the Tie Rod Weldment This procedure is the same as the 2WD procedure See repair procedure 13 3 How to Remove the Tie Rod Weldment How to Perform the Tie Rod Toe in Adjustment This procedure is the same as the 2WD procedure See repair procedure 13 3 How to Perform the Tie Rod Toe in Adjustment Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition Oscillating Axle Components 15 1 Oscillating Axle Lock out Cylinder The oscillating axle lock out cylinder extends the lock out wedges between the chassis and the axle when the boom is raised above the drive limit switch When the lock out wedges are ful
98. ard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Assemble the engine and torque the pump mounting plate to 34 ft lbs 46 Nm Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 7 1 Governor Actuator How to Set Up the Governor Actuator and Linkage Adjustment of the governor actuator is only necessary when the governor actuator or the linkage has been replaced 1 Connect the linkage rod to the throttle plate shaft then tighten the lock nut 2 Fasten the lock nut and clevis yoke to the linkage rod Do not tighten the lock nut against the clevis yoke 3 Loosen the fastener on the actuator arm Rotate the actuator arm until it is at a 110 degree angle to the linkage rod Ford LSG 423 Engine 5 Governor Actuator and Linkage clevis yoke linkage rod carburetor throttle plate shaft governor actuator actuator shaft actuator arm zo Oo om Position the linkage rod so that the throttle is in the idle position Then adjust the clevis yoke on the linkage rod to obtain the proper length Install the yoke onto the actuator arm and tighten the lock nut With the throttle in the idle position and the actuator arm at a 110 degree angle to the linkage rotate the actuator shaft slightly counterclockwise to pre load the spring Tighten the fastener on the actuator arm without releasing the shaft
99. asoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and engine coolant level Be sure the gasoline shut off valve is in the on position Be sure that automatic choke is not sticking closed Perform following tests in gasoline mode only Hold start switch and less check battery voltage than while engine is 11V cranking Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery more than 11V Check if engine coolant continuity Check if radiator and or over temperature engine block feels excessively hot sending signal post has continuity to ground not hot Remove wht rd wire from temperature sending unit check continuity to ground no continuity Remove wht wire from TB26 and check continuity to ground no continuity no continuity Repair short in wht wire circuit from terminal 10 start lock out module to TB24 OR consult Genie Industries Service Department Remove 1 spark plug and ground spark plug body Crank engine and observe spark Go to Chart 2A page 5 8 See Ford service weak or no spark Disable starter by removing blk wire at the manual for starter solenoid hold troubleshooting ignition start switch and check system voltage at positive terminal on ignition coil less than 12V Continued on the next page cont
100. asoline LPG Models Maintaining PCV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the crankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses Shown with distributor cap removed a PCV valve b hose PCV valve to carburetor c hose PCV valve to crankcase JP i AG 3 Clean the hoses with a mild cleaning solvent 4 Dry both hoses and inspect them for cracks and damage Replace the hoses if they are damaged a pivotplate retaining bolts b engine pivot plate 4 40 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures lt P gt Z A A TABLE D PROCEDURES D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz number 0291 1942 Genie part number 29789 D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Operation Manual Deutz number 0297 4706 EN Genie part number 29790 D 9 Replace the Timing Belt Gasoline LPG Models Complete information to perform this procedure is available in the Fo
101. ated components limit switches alarms horns and beacon nuts bolts and other fasteners platform entry mid rail or gate cracks in welds or structural components compartment covers and latches Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 4 Check the Engine Oil Level Maintaining proper engine oil level is essential to good engine performance and service life Operating the machine at an improper oil level can damage engine components Check the oil level with the engine off 1 Check the oil level dipstick Add oil as needed O Result The oil level should be in the safe zone Ford Engine LSG 423 Oil capacity including filter 5 quarts 4 7 liters Ford Engine LSG 423 Oil viscosity requirements below 60F 15 5C 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Deutz Engine F3L 1011 Oil capacity including filter 8 5 quarts 8 liters Deutz Engine F3L 1011 Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades TABLE A PROCEDURES A 5 Check the Engine Coola
102. ates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot oO ro Oo D w Set the ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until you hear a click then turn the screw counterclockwise 5 turns Connect the red lead from a volt meter to the A terminal on the controller PC board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 2 50V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 2 Genie Z 45 22 Part No 32960 Service Manual Second Edition FS Set the max out Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 5 02V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the dual lo range Press down the foot switch then move the control handle all the way to the down position Adjust the voltage to Section 7 Repair Procedures PLATFORM CONTROLS Secondary Boom Up Down Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is abov
103. azard Spraying ACAUTION 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 9 Remove the pin retainer from the master cylinder barrel end pivot pin Use a soft metal drift and remove the pin Leave the master cylinder attached to the primary boom 10 Remove the retaining fastener from the primary boom pivot pin Do not remove the pin 11 Remove the hose clamp bolt on the primary boom next to the upper mid pivot 12 Support the lift cylinder with a lifting device 13 Remove the pin retainer from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin The lift cylinder will fall unless it is ACAUTION supported 14 Remove the hose and cable clamps from the underside of the primary boom 15 Use a slide hammer to remove the primary boom pivot pin then carefully lift the primary boom off the machine PRIMARY BOOM COMPONENTS How to Disassemble the Primary Boom Complete disassembly of the primary boom is only necessary if the outer or inner primary boom tube must be replaced The extension cylinder can be removed without completely disassembling the primary boom See 3 4 How to Remove the Extension Cylinder 1 Remove the primary boom See above How to Remove the Primary Boom 2 Remove the pin retainer from the slave cylinder rod end pivot pin Use a soft metal drift t
104. ble so that the flat side of the turntable is parallel with the worm drive gear 14 While lowering the turntable onto the chassis be sure that the milled area on the bottom surface of the turntable does not contact the top of the worm drive gear housing If it is remove the turntable and grind the worm drive gear housing until clearance is established 15 Install the turntable mounting fasteners Use a torque wrench to tighten the fasteners in sequence to specifications 20 9 1 S 6 68964 160 24 8 3 12 4 11 23 17 e 8 0909 E 21 o 10 19 Specifications torque First rotation 95 ft lbs 129 Nm Second rotation 190 ft lb 258 Nm After re assembly the turntable should swing smoothly without jerking or grinding Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 2WD Steering Axle Components 13 1 7 Place a second jack under the yoke hub ly Yoke and Hub SS 8 Use a soft metal drift to drive the king pin down How to Remove the Yoke Hub and out Assembly AWARNING Crushing hazard The yoke hub 1 Remove the cotter pin and the clevis pin from both the steering cylinder and tie rod weldment assembly will fall when the king pin is removed if it is not properly supported Always use a new cotter pin when re installing a clevis pin SR How to Remove the Hub and 3 Bearing HERE LS A lle Loi i e XQ A a O 4
105. c ol can penetrate and Secondary Boom Lift Cylinders uri skins Loosen hydraulic Ea aaa a connections very slowly to allow There are two boom lift cylinders incorporated in the oil pressure to dissipate the structure of the secondary boom assembly gradually Do not allow oil to squirt These cylinders operate in parallel and require or spray hydraulic pressure to extend and retract Each secondary boom lift cylinder is equipped with a 3 Remove the pin retainers from each secondary counterbalance valves to prevent movement in the lift cylinder rod end pivot pin event of a hydraulic line failure A 1200 psi 83 4 Place a rod through the rod end pivot pin and bar relief valve for the down function is located on twist to remove the pin the boom function manifold How to Remove the Secondary Lift Cylinders This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer a pivotpin service is strongly recommended b 10to12inch 30cm rod 1 Lower the secondary boom to full rest then 5 Loosen but do not remove the counterbalance raise the primary boom just above the drive valve to fully retract the cylinder WSW The counterbalance valve is pre set from the factory Do not L adjust this valve 6 Remove the pin retainer from the pivot pins at th
106. ce the Gasoline Fuel Filter jo C 10 Replace the PCV Valve A Y Gasoline LPG Models N O U C 11 Clear or Replace the Distributor Cap and A Rotor Gasoline LPG Models AN O ze C 12 Replace the Spark Plugs A Y Gasoline LPG Models AN o C 13 Check and Adjust the Air Propane Mixture a Gasoline LPG Models AN Xt A C 14 Check and Adjust the Ignition Timing Gasoling LPG Models AN Xt A C 15 Check the Engine Valve Clearances Deutz Diesel Models Part No 32960 Genie Z 45 22 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Warm Cold Dealer Table D Tools are New parts engine engine service required required required required suggested D 1 Test or Replace the Hydraulic Oil includes cleaning the suction strainers D 2 Change or Recondition the Engine Coolant A A ES including all coolant hoses and clamps ke 1N D 3 Change the Fuel Lines D 4 Check Engine Valve Clearance Gasoline LPG A Models D 5 Check Engine Cylinder Compression A Gasoline LPG Models D 6 Clean PCV Hoses and Fittings Gasoline LPG A Models D 7 Check the Fuel Injection Pumps and Injectors D Diesel Models D 8 Check the Toothed Belt Diesel Models D 9 Replace the Timing Belt Ford Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date
107. ch is switched to platform control B 15 Test the Ground Control Override 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 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 can not return the boom to the stowed position 1 Push in the platform Emergency Stop button to the off position 2 Start the engine from the ground controls 3 Operate each boom function through a partial cycle O Result All boom functions should operate B 16 Test the Oscillate Lock out Perform this test on oscillating axle equipped machines only Proper axle oscillate lock out when the boom is raised is essential to safe machine operation If the lock out wedges do not extend when the boom is raised the stability of the machine is compromised and it may tip over Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 1 From the ground controls raise the primary boom above the drive speed limit switch Oscillating axle limit switch a limit switch b oscillating lock out wedge Result The oscillate cylinder should extend the lock out wedges 3 inches 7 6cm past the chassis frame The boom sh
108. ches Every 100 hours perform the following two engine maintenance procedures A 14 Replace the Engine Oil and Filter U Gasoline LPG Models A A 15 Change the Engine Air Filter 3 2 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES W Cold Dealer Table B Tools are New parts eroine engine service required required required required suggested B 1 Check the Engine Belt s B 2 Check the Radiator U Gasoline LPG Models A se B 3 Check the Oil Cooler and Cooling Fins U Deutz Diesel Models A e B 4 Check the Exhaust System B 5 Check the Battery B 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect Electrical Wiring B 8 Inspect the Tires and Wheels U including lug nut torque A B 9 Confirm Proper Brake Configuration B 10 Check the Oil Level in the Torque Hubs B 11 Check and Adjust the Engine Idle Mixture s Gasoline LPG Models A Xt A B 12 Check and Adjust the Engine RPM B 13 Test the Key Switch B 14 Test the Emergency Stop Buttons B 15 Test the Ground Control Override Part No 32960 Genie Z 45 22 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES j Wi Cold Deal Table B continued Tools are New parts Baza engine a required required required required suggested B 16 Test the Oscillate Lock out U oscillati
109. ck the valve pressure Tip over hazard Do not adjust the AWARNING relief valves higher than Specifications recommended They are set to P prevent a tip over or damage to lift Relief valve pressure 1200 psi 83 bar linkage 7 42 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction Each proportional boom function uses a variable position proportional valve and a three position directional valve Example one position for boom up one position for neutral and one position for boom down The platform rotate and level functions use a three position valve and a two position poppet valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 10 1 Function Manifold Components in this section 1 Push the button on the end of the valve in Ya inch 6 mm 2 Move the ground control function switch for the function being overridden to operate function AWARNING Collision Hazard Impact with moving boom components may cause death or serious injury Use extreme caution when overriding a boom function and know the direction of intended travel FUNCTION MANIFOLD How to Check the Resistance of a Valve Coil 1 Turn the keyswitch to the off position and disconnect the wires from the valve coil to be tested 2 Connect the
110. cuit from TB27 Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Deutz service manual for troubleshooting low oil pressure Replace start lockout module OR consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure to check LPG fuel level Disconnect LPG supply line from LPG tank and bleed pressure from With keyswitch on and both mushroom switches pulled out check voltage at LPG side blu red wire of fuel select switch With keyswitch on and both mushroom switches pulled out check voltage at TB39 With keyswitch on and both mushroom switches pulled out check voltage at terminal 30 on CR7 Crank engine for 15 seconds and check voltage at terminal 86 on CR7 Check ground wire to terminal 85 on CR7 good Continued on the next page bad Replace fuel select switch Repair open in blu red wire circuit from fuel select switch to TP39 to TB39 Repair open in blu red wire circuit from TB39 to terminal 30 on CR7 Repair open in red blk wire circuit from vacuum swi
111. d ooonicccnnnncccnnccccnnncccccononannnnrccanannncnnna 5 62 37 Machine Drives At Full Speed With Platform Raised or Extended 5 63 38 Drive Enable System ls Malfunctioning ooccconnnnnnncccnnnnocccnnnccnnnnnccanann canon 5 64 39 Auxiliary Functions Inoperative oooonnnnncccnnnnncoccccnnnnnnccrcccnnnnnnrrrcc cnn rr 5 65 Section Six Schematics ite de 6 1 Electrical Symbol Legend sionista 6 2 Electrical Schematic Gasoline LPG Models ccceceeeeeeeeeeeseeeeeeeeaeeseeneeetenees 6 3 Ground Control Box Legend Gasoline LPG Models ccceeceeeeeteeteeereeeeenaeees 6 5 Relay Panel Legend Gasoline LPG Models u ooea aaa aaa aaa anna nica 6 6 Platform Control Box Legend Gasoline LPG Models sooouuuaaaaaaaassaaaa 6 7 Electrical Schematic Diesel Models ooocccocncccccncccononccccononnncnnnrnnnnnnc aaa aaa canon 6 8 Ground Control Box Legend Diesel Models ooocoonccccnnnnccconocccnnnncccnonannnnnnnnncnannncno 6 10 Platform Control Box Legend Diesel Models aaa aaaaaaaaaaaasscaaa 6 11 Hydraulic Symbols Legend cooooooccccccconococonoconananonononcnnnannnnoncnnnnnnnnnnncccnnnn nr nnnccnnnn E 6 12 2WD Hydraulic Schematic u seseeea aaa aaa aaa aaa aaa aaa anna 6 13 AWD Hydraulic Schematic eue ssseee aaa aaa aaa aaa aaa aaa wana aaa caca 6 14 Part No 32960 Genie Z 45 22 xi Service Manual Second Edition
112. d circuit to start lockout module Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 2 Hold start switch and Continued from the check voltage at wht on previous page terminal 87 of CR8 Repair open in brn R8 wire to ignition coil Check voltage at wht Repair open in wht wire wire on terminal 30 of circuit from terminal 87 CR8 on CR1 to terminal 30 on CR8 Hold start switch and Repair open in blk wire check voltage at i terminal 86 of CRS OO gl Check ground to Repair open in ground terminal 85 on CRG wire to CR8 If weak spark still exists contact Genie Industries Service Department Part No 32960 Genie Z 45 22 5 7 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2A Engine Cranks Over But Will Not Start Gasoline LPG Models or Engine Runs While Cranking Then Dies Continuation of good spark fault path Perform these tests in gasoline mode only Crank engine and check voltage at automatic choke 12V Check automatic choke for proper adjustment or internal damage good With keyswitch on and both mushroom switches pulled out check voltage at red wht 23 wire on vacuum oV bad oV switch 12V Remove the blk wire with diode from terminal TB33 D crank the engine over for 15 seconds a
113. dily injury hazard Spraying ACAUTION 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 1 Start the engine and raise the primary boom above the drive limit switch Do not lift the primary boom above the secondary boom a drive limit switch Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the diagnostic nipple on the function manifold Manually hold down the drive limit switch When the oscillate cylinder fully retracts the pressure will spike Note the maximum pressure reading Do not release the drive limit switch Release the drive limit switch When the oscillate cylinder fully extends the pressure will spike Note the maximum pressure reading Hold the unloader valve and remove the cap index 2 Adjust the internal hex socket by turning it clockwise to increase the pressure or counterclockwise to decrease the pressure Then reinstall the relief valve cap Manually hold down the drive limit switch and recheck the valve pressure Specifications Unloader valve 1900 psi 131 bar 7 58 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures Non steering Axle Components 17 1 Drive Motor Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer How to Remove a Drive Motor ACAUTION A drive m
114. dous conditions E Unless otherwise specified perform each procedure with the machine in the following confuguration machine parked on a flat level surface boom in the stowed position turntable rotated with the boom between the non steering wheels key switch in the off position with the key removed wheels chocked 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 Then to re assemble perform the disassembly steps in reverse order General Repair Procedure P Malfunction Determine discovered gt Ttoubleshoot cause NR DA problem o still exists a ps Retur to Inspect Perform j D repair service deet and test p Z solved Symbols Legend A RANGED Indicates the presence of a Edad bli hazard that will cause death or serious injury Indicates the presence of a AWARNING S hazard that may cause death or serious injury Indicates the presence of a ACAUTION hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information O Indicates that a specific result is expected after performing a series of steps
115. drive limit switch Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised All models 1 foot 0 3 meters per second Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES Drive Enable Limit Switch 4 With the engine off and the machine in the stowed position visually inspect the drive enable limit switch for the following broken or missing rollers or arms missing fasteners loose wiring Manually activate the drive enable limit switch a drive enable limit switch Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard Start the engine from the platform controls and then rotate the turntable to the left until the platform is positioned over the left non steer wheel Result The platform over steer wheels indicator light should be on Drive movement should stop until the drive enable override switch is activated Rotate the turntable to the right until the platform is positioned over the right non steer wheel Result The platform over steer wheels indicator light should be on Drive movement should stop until the drive enable override switch is activated Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES Oscillating Axle Limit
116. e Platform level down 15 seconds Multiple function 60 seconds stowed to full raised Multiple function 60 seconds full raised to stowed Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 2 Specifications Front drive motors 4WD models SPECIFICATIONS Steer oscillate manifold 2 1 cu in 34 4cc Displacement per revolution Rear drive motor Displacement per revolution High 2 8 cu in 45 9cc Low 0 15 cu in 2 5cc Function pump Sequencing valve 1800 psi pressure 123 bar Accumulator 1600 psi pre charge pressure 110 bar Auxillary pump Type fixed displacement gear pump Type fixed displacement gear pump Displacement 6 4 gpm 2150 rpm Displacement 0 85 gom 3 2 liters minute 0 4 liters second Auxillary pump 2030 psi relief pressure 138 bar Function circuit return 10 micron with line filter 25 psi 172kPa bypass Function manifold Function relief 2200 psi valve pressure 152 bar Secondary down relief 1200 psi valve pressure 83 bar Primary down relief 1200 psi valve pressure 83 bar Primary extend relief 1200 psi valve pressure 83 bar Steer oscillate 1 5 gom flow regulator 5 7 liters minute Part No 32960 Genie Z 45 22 2 3 Section 2 Specifications Service Manual Second Edition BOLT TORQUE SPECIFICATIONS Bolt Torque Specifications Torque
117. e 1000A Valve clearance cold Reserve capacity 25A rate 200 minutes intake 0 012in Fan belt deflection 3 8 to 1 2 inch 0 3mm 9 to 12 mm Exhaust 0 020in polt tightening specifications 0 5 mm torque torque Lubrication system Bolt description size grade ft lbs Nm Oil pressure 26 to 87 psi Camshaft thrust bearing bolt 15to 18 20 to 24 1 8to6 0bar M 8 x 35 8 8 Oil capacity 8 5 quarts Rocker arm bolts 15 to 18 20 to 24 including filter 8 liters M8 x 45 8 8 Oil viscosity requirements Rocker arm set screw nut 15 to 18 20 to 24 Temperature below 60 F 15 5 C synthetic _ 5Ww 30 Cylinder head cover 6to 7 8 to 10 Blower rotor nut 33 to 41 45 to 55 10 F to 90 F 23 C to 32 C 10W 40 3 x M 17 Valeo or M 18 Bosch T t b 4 F 34 C 15W 40 diwy woki ahaa Blower carrier bolts 15 to 18 20 to 24 Engine oil should have properties of API classification M 8 x 50 Torx 8 8 CC SE CD SE CC SF or CD SF grades 7 V belt pulley bolts 28 to 34 38 to 46 Injection system M 10 x 16 8 8 Injection pump make OMAP Part No 32960 Genie Z 45 22 2 7 Section 2 Specifications SPECIFICATIONS Bolt tightening specifications continued torque torque Bolt description size grade ft los Nm Idler pulley V belt pulley bolt 27 to 32 36 to 44 M 10 x 25 8 8 Idler pulley for toothed belt 30 to 36 41 to 49 M 10 x 50 8 8 Oil pump bolts 15 to 18 20 to 24 M 8 x 35 Torx Oil filter bracket bolt
118. e 12V DC and the alternator is operating properly with 12 5 to 15 4V DC output 4 33V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Electrocution hazard Contact with AWARNING electircally charged circuits may result in death or serious injury Remove all rings watches and 9 Start the engine and move the engine speed other jewelry control switch to foot switch activated high idle rabbit and foot switch symbol Raise the primary boom 1 inch 2 5 cm above the drive limit switch 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the keyswitch to platform control and pull the Emergency Stop button to the on position at both the ground and platform controls Do not start the engine Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the primary boom to reach the full up position 3 Adjust the max out trimpot to achieve a 25 to 29 second cycle time Open the platform control box lid and locate the secondary boom up down controller 11 Start a timer and record how long it takes for the primary boom to lower into the full down position Adjust the dual range trimpot to achieve a 33 to 37 second cycle time Primary boom up down specifications Threshold 2 50V DC 5 02V DC 25 to 29 seconds Primary boo
119. e barrel ends of each secondary lift cylinder l ANAS 7 Place a rod through each barrel end pivot pin and twist to remove the pins Remove the secondary lift cylinders from the machine Crushing hazard The secondary a ola AWARNING cylinders will fall when the 2 Disconnect and plug the hydraulic hose and barrel end pivot pins are removed steel lines for each secondary lift cylinder if they are not properly supported Prior to removing the secondary lift cylinder mark the location of the hydraulic fitting with a special internal orifice Be sure to install the fitting into the same location during re assembly 7 26 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support the open cover with an overhead crane or forklift Do not lift Crushing hazard Due to its heavy ACAUTION weight do not attempt to support the cover by hand 2 Remove the upper and lower retaining clips from the gas strut 3 Gently pry the strut pivot sockets off of the ball studs and remove the strut 4 Remove the fasteners from the cover hinge pins 5 Raise the cover slightly to relieve the pressure on the cover hinge pins 6 Remove the cover hinge pins 7 Carefully lift and remove the cover from the machine If a turntable cover must be AWARNING replaced be sure that all appro
120. e from the injection pump to the injectors Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Gasoline LPG models a b c d 3 Clean up any fuel that may have spilled during this procedure 4 Start the engine from the ground controls then inspect the fuel filter and hoses for leaks ADANGER If a fuel leak is discovered keep any additional personnel from entering the area and do not operatethe machine Repair fuel filter hose from the fuel filter to the carburetor hose from the fuel pump to the fuel filter hose from the fuel shutoff valve to the fuel pump the leak immediately TABLE D PROCEDURES D 4 Check the Engine Valve Clearance Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 Part No 32960 Genie Z 45 22 4 39 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES D 6 2 Disconnect the hoses from the PCV valve then Clean the PCV Hoses and disconnect the hoses from the engine Fittings G
121. e olima kak defective extend directional valve OPerateS coil i push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item S with a like valve item P 4 to 5 ohms Replace the valve function inoperative Continued on the next page Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Install a O to 3000 PSI pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch Continued from the previous page Adjust the boom extend relief valve item D in one turn clockwise Then with pressure gauge still attached operate the function Remove the extend function pressure line from the manifold and cap the port Then with pressure gauge still attached operate the function Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department less than 1200 psi less than 1200 psi less than 1200 psi CHART 18 Counting the turns function With boom fully adjust the boom extend operates extended hold the relief valve item D in extend function switch all the way Then Adjust the relief valve operate the extend to read 1200 PSI and function
122. e pad if it is less than 0 41 inches 1cm thick If the pad is more than 0 41 inches 1cm thick perform the following procedure 1 Raise the primary boom above the drive limit switch a drive limit switch Extend the primary boom 10 inches 25 4 cm Remove the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag Using a round punch align the holes in the shim to the wear pad and install the mounting fasteners Extend and retract through the entire range of motion to check for tight spots that could cause binding Always maintain squareness between the primary boom outer and inner tubes Part No 32960 Genie Z 45 22 7 13 Section 7 Repair Procedures Service Manual Second Edition PRIMARY BOOM COMPONENTS How to Remove the Primary Boom This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect and plug the hydraulic hoses at the slave cylinder and the platform rotator counterbalance valve Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipa
123. e performed every 500 hours Perform this procedure more often if dusty conditions exist Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Perform this procedure after warming the engine to normal operating temperature Beware of hot engine parts and ACAUTION oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover 2 Pull the end of the drain hose out from under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Install the plug into the drain hose 5 Use an oil wrench and remove the oil filter a engine oil level dipstick b oilfilter c fuel filter 6 Apply a thin layer of oil to the new filter gasket filter part no 29561 Then install the filter and tighten it securely by hand 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil fil
124. e traction manifold and plug them Pull these hoses up through the turntable and remove them from the machine b 10 Disconnect the in and return hydraulic hoses a bu from the steer oscillate manifold and plug them p Pull these hoses up through the turntable 11 Disconnect the hydraulic hoses from the turntable rotation motor and plug them Pull aL 10O 1A INEN oka these hoses up through the turntable b pivotpin E 12 Label and then disconnect all the wiring from rushing hazard The primary lift the traction manifold and the steer oscillate AWARNING cylinder will fall when the barrel manifold end pivot pin is removed if it is not ma o properly supported 13 Disconnect and remove the oscillating axle limit switches from the oscillation cylinder 6 Raise the secondary boom Remove the block from the turntable counterweight and lower the secondary boom to the stowed position 7 Close the two hydraulic tank valves located at the main pump Oscillating axle limit switch a limit switch open closed b oscillate lock out wedge Part No 32960 Genie Z 45 22 7 47 Section 7 Repair Procedures Service Manual Second Edition TURNTABLE ROTATION COMPONENTS 14 Disconnect and remove the drive enable limit switch a drive enable limit switch 15 Pull the wiring harness along with the limit switches up through the turntable 16 Remove the turntable end cover 17 Loosen the l
125. eaking exhaust system can cause component damage and unsafe operating conditions AWARNING Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine ACAUTION a components Contact with hot engine components may cause severe burns 1 Be sure that all nuts and bolts are tight 2 Inspect all welds for cracks 3 Inspect for exhaust leaks i e carbon buildup around seams and joints B 5 Check the Battery The factory ships each machine with a sealed battery checking the water level is not necessary If the battery is replaced with another type the battery acid level and specific gravity should be checked at this time Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and extremely hazardous conditions Batteries contain acid Avoid AWARNING spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear if batteries are to be opened 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold down and cable connections are tight Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 6 Check the Hydraulic Tank Filter Condition Indicator Maintaining t
126. ebris and foreign materials B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 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 Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns ACAUTION Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES Oil Cooler 1 Remove the cover from the side of the engine then remove the oil cooler top cover 2 Inspect the oil cooler for leaks and physical a oilcooler b cylinder head cooling fins c blowerfins 3 Clean the oil cooler of debris and foreign material Cooling and Blower Fins 4 Inspect the blower fins for physical damage 5 Clean the blower fins of debris and foreign material 6 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 7 Clean the cylinder head cooling passages of debris and foreign material B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Operating the machine with a damaged or l
127. ed rod Then pull the rod out the bottom of the platform rotator and remove the platform pivot weldment 5 Support the platform rotator but do not apply any lifting pressure 6 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin Use a soft metal drift to drive the pins out then remove the platform rotator Part No 32960 Genie Z 45 22 Section 7 Repair Procedures PLATFORM COMPONENTS How to Bleed the Platform Rotator 4 Comnect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any discharge 000 clear hose top bleed valve bottom bleed valve container Oo o w Open the top bleed valve but do not remove it 3 Start the engine from the ground controls Hold the platform rotate switch to the right for approximately 5 seconds then release it Repeat 3 times Crushing hazard Keep hands ACAUTION A A clear of the platform pivot weldment during rotation Hold the platform rotate switch to the left for approximately 5 seconds then release it Fully rotate the platform to the left and continue holding the platform rotate switch until air stops coming out of the bleed valve Immediately release the platform rotate switch and close the bleed valve Rotate the platform to the right until it is centered Connect the clear hose to the bottom bleed valve and open the valve Service Manua
128. elt s B 2 Engine radiator B 3 Oil cooler and fins Deutz B 4 Exhaust system B 5 Battery B 6 Hydraulic tank filter B 7 Electrical wiring B 8 Tires and wheels B 9 Brake configuration B 10 Drive torque hubs B 24 Drive brakes B 25 Drive speed B 26 Alarm package B 27 Oil analysis Perform every 500 hours B 28 Replace engine oil and filter Deutz Checklist C Refer to Table C C 1 Wear pads C 2 Turntable bolts C 3 Free wheel configuration C 4 Worm drive gear C 5 Drive torque hubs C 6 Hydraulic tank filter C 7 Drive loop hydraulic filter C 8 Fuel filter diesel C 9 Fuel filter gasoline C 10 PCV valve gasoline C 11 Distibutor cap gasoline C 12 Spark plugs C 13 Propane adjustments C 14 Ignition timing gasoline C 15 Valves Deutz ChecklistD Y N R Refer to Table D D 1 Hydraulic oil D 2 Engine coolant hoses and clamps B 11 Idle mixture gasoline D 3 Fuel lines and clamps B 12 Engine RPM B 13 Key switch B 14 Emergency Stop button B 15 Ground control override B 16 Oscillate lock out B 17 Platform leveling B 18 Service horn B 19 Foot switch D 4 Engine valve clearance gasoline D 5 Cylinder compression D 6 PCV hoses and fittings gasoline D 7 Fuel injection Deutz D 8 Toothed belt Deutz D 9 Timing belt Ford Part No 3
129. ep by step instructions Symbols Legend Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury ACAUTION Indicates the presence of a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 32960 Genie Z 45 22 4 1 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table A Procedures A 1 Inspect the Manuals Maintaining the Operator s and Safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the box provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the
130. er Bodily injury hazard Spraying ACAUTION 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 Support the barrel end of the primary lift cylinder with a strap 8 Remove the pin retainer from the primary lift cylinder barrel end pivot pin 9 Place a rod through the barrel end pivot pin and twist to remove the pin a pivotpin b 10to 12 inch 30cm rod 10 Carefully lower and rest the barrel end of the primary lift cylinder on the turntable counterweight 11 Disconnect and plug the platform leveling master cylinder hydraulic hoses Cap the fittings on the master cylinder Bodily injury hazard Spraying ACAUTION 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 12 Remove the retaining fastener from the platform leveling master cylinder rod end pivot pin then use a slide hammer to remove the pin 13 Attach a strap to the rod end of the platform leveling master cylinder 14 Remove the pin retainer from the platform leveling master cylinder barrel end pivot pin Then support the cylinder with the strap 15 Place a rod through the barrel end pivot pin and twist to remove the pin Crushing hazard The cylinder will ACAUTION fall if it is not supported when the piv
131. erious injury Remove all rings watches and otherjewelry Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position a manual fuel shutoff valve All models 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 13 Connect the wiring and start the engine from the ground controls Check the hydraulic tank for leaks Hydraulic system Hydraulic tank capacity 25 gallons 95 liters Hydraulic system 30 gallons capacity including tank 114 liters Hydraulic fluid Dexron Il equivalent D 2 Change or Recondition the Engine Coolant Gasoline LPG Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Beware of hot engine parts and coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Puton protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the co
132. extended Continue to hold the platform level switch for 10 seconds 3 Connect a clear hose to the bleed valve on the cylinder barrel Place the other end of the hose in a container to collect any discharge 4 Open the bleed valve but do not remove it 5 Hold the platform level switch to the right for 5 seconds then release it 6 Close the bleed valve then remove the hoses 7 Hold the platform level switch to the left until the slave cylinder is fully retracted 8 Connect the clear hose to the bleed valve on the slave cylinder block 9 Open the bleed valve and allow the slave cylinder to extend using gravity until the cylinder is fully extended Close the bleed valve PLATFORM COMPONENTS 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 180 degrees It is equipped with external counterbalance valves to hold platform in place and to provide pressure relief How to Remove the Platform Rotator 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect the hydraulic hoses from the platform rotator and cap them Bodily injury hazard Spraying ACAUTION hydraulic oil can perforate 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 6 mounting bolts from the platform pivot weldment 4 Remove the top nut from the thread
133. f a hydraulic line loss How to Remove the Extension Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the secondary boom and place a 4x4x31 inch 78 cm block between the chassis counterweight and the upper mid pivot Carefully lower the secondary boom onto the block a Uppermid pivot b 4x4x31 inch block c counterweight Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 2 extension boom end cap b extension boom c extension cylinder rod end weldment fasteners d primary boom Raise the primary boom until the extension boom end cap is 5 feet 1 5 m off the ground Extend the extension tube to the primary boom tube 17 inches 43 cm Then secure to prevent any additional movement Remove the extension boom end cap Remove the fasteners from the cylinder rod end weldment The bolts that secure the cylinder rod end weldment are installed with Loctite removable thread sealant It may be necessary to heat the bolts and the surrounding area to remove them Do not reuse the bolts If the function is operational extend the extension cylinder until the rod end weldment clears the end of the extension tube
134. 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 TABLE B PROCEDURES B 22 Test the Turntable Rotation Stop The turntable is capable of rotating the boom 359 degrees and is stopped midpoint between the steering wheels by the rotation stop Detecting a rotation stop malfunction is essential to safe operation and good machine performance If the turntable rotates past the rotation stop component damage may result 1 Start the engine from the platform controls 2 Rotate the turntable to the left as far as it will go Result Movement should stop when the boom reaches mid point between the steer tires 3 Rotate the turntable to the right full circle as far as it will go Result Movement should stop when the boom reaches mid point between the steer tires B 23 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the platform is over the non steering wheels drive movement is stopped and the indicator light turns on and the drive enable switch must be used to reactivate the drive function This should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperl
135. form level Turntable rotate Primary boom extend retract Platform level All functions Platform rotate jib boom Differential sensing circuit Testing System relief 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 10 12 ft lbs 14 16 Nm Steering Platform rotate right differential sensing Platform rotate left differential sensing 11 13 ft lbs 15 18 Nm Platform level differential sensing 11 13 ft lbs 15 18 Nm 11 13 ft lbs 15 18 Nm Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures FUNCTION MANIFOLD Part No 32960 Genie Z 45 22 7 41 Section 7 Repair Procedures Service Manual Second Edition FUNCTION MANIFOLD Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 J 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 10 2 Valve Adjustments Function Manifold How to Adjust the Main Relief Valve 1 Connect a 0 3000 psi 0 to 206 bar pressure gauge to the diagnostic nipple on the function manifold 2 Start the engine from the ground controls and
136. ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm Function Brake check Torque 25 30 ft lbs 34 41 Nm 8 10 ft lbs 11 14 Nm Brake release 2 Speed wheel motors energized in high range to destroke the rear motor swash plates 8 10 ft lbs 11 14 Nm Motor shift brake release circuit 85 90 ft lbs 115 122 Nm 85 90 ft lbs 115 122 Nm Right check in forward Right check in reverse Low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 85 90 ft lbs 115 122 Nm 85 90 ft lbs 115 122 Nm Left check in reverse Left check in forward Energized in high range to pilot open check valves 5 6 8 amp 9 to bypass flow regulators and allow full flow to front wheel motors 8 10 ft lbs 11 14 Nm High pressure flow path for flow regulator bypass Left flow control in forward 10 13 ft lbs 14 18 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm Left flow control in reverse Charge pressure Right flow control in reverse Right flow control in forward 7 60 Genie Z 45 22 Part No 32960 Section 7 Repair Procedures Service Manual Second Edition 2WD DRIVE MANIFOLD W o 00 Genie Z 45 22 Pa
137. ge Start engine from less Check voltage at Repair open in wht wire Drive platform controls switch than 8V terminal 1 on circuit from foot switch drive mode to high horsepower limiter to horsepower limiter i range and press down board board Fu nction on foot switch Be sure Inoperative engine rpm switch is on 12V high idle foot switch activated Check voltage at terminal 10 on horsepower limiter board Be sure all other functions operate normally including drive low range four wheel symbol Be sure all drive manifold solenoid valve grounding wires are free of corrosion and have full continuity to ground more than 8V Check voltage at red wire on center terminal of the drive speed select switch more than 8V Check voltage at red wire terminal 6 on drive controller more than 8V Continued on the next page Check voltage at terminal 3 on horsepower limiter board 6 to 7V oV Check voltage at TB41 BOM oV Check voltage at org blk 41 wire on engine alternator 6 to 7V Repair or replace alternator OR consult Genie Industries Service Department Repair open in red wire circuit from horsepower limiter board terminal 10 to center terminal on drive speed select switch Repair open in red wire circuit from drive speed select switch OR replace drive speed select switch Re adjust OR replace horsepower limiter board OR consult Genie Industries Se
138. h and Check repair open in check voltage at power supply wire to terminal 6 and 7 at terminal 6 and 7 on start lockout module start lockout module Hold start switch and Check ground wire to check voltage at terminal 5 on start terminal 1 on start lockout module lockout module Consult Genie Industries Service Department Continued on the next page Chart 1 bad Repair open in ground wire Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 1 Continued from the previous page Repair open in blk wire from terminal 1 on start lockout module to CR1 Hold start switch and check voltage at terminal 86 on CRI lia CR1 terminal 30 iV oV Check voltage at oV Repair red wire circuit terminal 30 on CR1 from battery to CB1 to oV Hold start switch and Check ground to bad dal open in ground check voltage at terminal 85 on CR1 to CR1 terminal 87 on CR1 good 12V Replace CR1 relay Check voltage at oV Repair open in blk wire initiate terminal starter circuit from CR1 to starter solenoid solenoid 12V Check repair or replace starter or starter solenoid Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start G
139. han 0 41 inches 1 cm thick If the pad is more than 0 41 inches 1 cm thick shim as necessary to obtain zero clearance and zero drag 4 Extend and retract through the entire range of motion to check for tight spots that could cause binding ro scraping Always maintain squareness between the primary boom outer and inner tubes C 2 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the 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 4x4x31 inch 78 cm block between the chassis counterweight and the upper mid pivot Carefully lower the secondary boom onto the block a upper mid pivot b 4x4x31 inch block c counterweight Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 2 Raise the primary boom until the end of the boom is approximately 7 feet 2 m off the ground 3 Be sure that each turntable bolt is torqued in sequence to 190 foot pounds 258 Newton meters 24 18 3 12 4 11 23 17 P 8 10900 5 21 o 10 19 Bolt torque sequence 4 Remove the support block and then lower the primary and secondary booms to the stowed position 5 Use a forklift to support the chassis counterweight directly below the turntable bearing Genie Z 45 22 Part No 32960 Se
140. harts Service Manual Second Edition Chart 18 Primary Boom Extend Function Inoperative Be sure all other functions operate normally If boom extend function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom extend function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at wht red wire on proportional valve Repair open in wht red wire circuit from TB6 to proportional valve 3 to 6V 0 or Remove both wires from Kinie valve coil and check ohms resistance across the Replace coil coil terminals 4 5 to 5 5 ohms function Replace the defective Hold toggle switch in Operates proportional valve extend position and manually override proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA function inoperative Interchange flow regulator valve item X with a like valve item Y function Replace defective flow operates regulator valve function inoperative Dor Hold toggle switch and Check the resistance of infinite d manually override function the directional valv
141. he function manifold relief valve item AB all the way in clockwise counting the number of turns Hold the boom retract switch and recheck the pressure less than 2400 psi Check the function pump see Repair section Replace the pump Chart 11 Troubleshoot each function individually or consult Genie Industries Service Department Hold the boom retract switch and readjust the relief pressure to 2400 psi Replace the relief valve OR manifold has internal defects consult Genie Industries Service Department Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 12 Ground Does the engine start Start the engine from Repair open in red wire from the ground the ground controls and circuit from key switch Controls controls check the voltage on to function switches i the center pole red Inoperative wire of the platform Platform level switch Controls Operate Troubleshoot the Normally functions individually Be sure all other Check voltage at red functions operate wire on ground controls Repair open in red wire normally including AE o GR fon emergency platform controls checked should stop button to the originate at the key switch emergency stop button Check voltage at red Check if key switch Replace key switch wire at ground controls internal cam is contact for ground contact on the key activating ground controls switch contac
142. he hydraulic reservoir 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 Start the engine from the platform controls 2 Switch the engine speed control to high idle rabbit symbol 3 Inspect the filter condition indicator a filter condition indicator b filter c hydraulic reservoir Result The filter should be operating in the green area lf the display shows red this indicates that the hydraulic filter is being bypassed and the filter should be replaced TABLE B PROCEDURES B 7 Inspect the Electrical Wiring 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 component damage Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires engine compartment relay panel engine wiring harness inside of the ground control box turntable manifold wiring 2 Start the engine from the ground contr
143. he key from the key switch and tag the machine to inform personnel of the condition 2 Disconnect and plug the lift steer pump hydraulic hoses Cap the fittings Bodily injury hazard Spraying ACAUTION 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 bolts Carefully remove the pump Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 9 2 Drive Hydraulic Pump The drive hydraulic pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC 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 Sundstrand Sauer service center How to Remove the Drive Hydraulic Pump Component damage hazard The ACAUTION 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 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 2 Close the two hydraulic tank valves located at the hydraulic tank open closed
144. he spline against the flywheel Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 32 inch 0 031 mm gap between the coupler and pump end plate 3 Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do not force the drive pump during re installation or the flex plate teeth may become damaged Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition gt gt gt AAA AAA FORD LSG 423 ENGINE 7 7 How to Remove the Water Water Temperature and Oil Temperature and Oil Pressure Pressure Switches Switches The water temperature switch is a normally open Perform this procedure with the engine off switch that closes at approximately 230 F 1 Remove the 3 bolts from the engine pivot plate 112 C When this switch closes the engine is Swing the engine pivot plate away from the shut off to prevent damage and will not restart until machine to access both switches the temperature drops below the switch point An over temperature indicator light at the ground and Disconnect the wiring from the desired switch platform controls should turn on when the switch 3 Remove the switch from the engine block and closes then install the new switch Do not over tighten Component damage hazard Do Burn hazard Cont
145. ifications and install the filler cap 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 11 Check the oil filter and the oil drain hose for leaks Part No 32960 Genie Z 45 22 4 9 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition A A TABLE A PROCEDURES A 15 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist 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 Remove the end cap from the air cleaner canister 2 Remove the mounting fastener from the air filter then remove the filter 3 Clean the inside of the canister and the gasket with a dry cloth 4 Insert the new filter and replace the mounting fastener 5 Replace the end cap on the canister Air filters Genie part numbers Ford LSG 423 Engine 27916 Deutz F3L 1011 29553 4 10 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 1 Check the Engine Belt s Maintaining the engine belt s is essential to good engine performance and service life The machine wil
146. ig end bolts 22 30 60 60 Flywheel bolts 22 30 60 30 Cylinder head step 1 22 30 studs step 2 59 80 step 3 118 160 120 NA Camshaft central bolt 22 30 150 NA Crankshaft central bolt 96 130 210 NA 2 8 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey Hl 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 damage M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating machine H Keep records on all inspections for three years MI Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following char
147. ill require two people If a helper is not available interchange the valve item S with a like valve item P 4 to 5 ohms Replace the valve function inoperative Check for mechanical restrictions keeping boom from retracting OR repair cylinder OR replace cylinder counterbalance valve Install a 0 to 3000 psi pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Function Inoperative Be sure all other functions operate normally If turntable rotate function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Chart 20 Repair open in wht red wire circuit from TB6 to Hold ground control function switch and check volts at wht red proportional valve wire on turntable rotate function proportional valve 4to 7V dor Remove both wires infinite from valve coil and ohms
148. ine speed control switch to foot switch activated high idle rabbit and foot switch symbol 7 6 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications Voltage setting 2WD model 8 0V DC Voltage setting 4WD model 9 0V DC 7 Move the engine speed control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0 03V DC voltage reading 9 Move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage setting 11 Be sure that the boom is in the fully stowed position then drive the boom and observe how the engine rpm reacts to drive control handle movement If the machine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C potentiometer will cause the engine to stall The C potentiometer adjustment is a compromise between engine stability and engine droop 12 Disconnect the volt meter PLATFORM CONTROLS 13 Raise the primary boom above the drive limit switch a drive limit swi
149. ing directional valve Replace defective check valve Interchange the level up 2400 and down psi or counterbalance valves More items B amp C function operates Replace defective counterbalance valve Chart 25 Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 26 Platform Hold ground control Repair apar in gh function switch and wire circuit from to Rotate Left check voltage at grn blk directional valve i wire on platform rotate Function left function directinal Inoperative valve Be sure all other functions operate normally If platform rotate left function operates normally from the ground controls but not from platform controls troubleshoot the platform control toogle switch See Repair section If platform rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Remove both wires from 0 or infinite ohms valve coil and check reisitance across coil terminals 4 to 5 ohms Hold toggle switch left function operates and manually override rotate left directional valve push in button on end of valve spool Note ove
150. intaining the proper air to fuel mixture during propane operation is essential to good engine performance Engine fuels are combustible A DANGER a 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 The engine rpm needs to be preset for gasoline fuel operation before adjusting the propane idle mixture The engine should be warmed to normal operatingtemperature before performing this procedure 1 Move the fuel select switch to propane fuel and start the engine from the ground controls 2 Loosen the high idle mixture adjustment lock nut low idle mixture adjustment screw high idle mixture adjustment screw propane regulator pressure adjustment Oo CO o Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition 3 Load the system by pressing the primary boom extension retract switch and then move the engine speed control switch to high idle rabbit symbol 4 Adjust the high idle adjustment nut to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the lock nut 6 Movethe engine speed control switch to low idle turtle symbol and adjust the low idle screw to obtain an air t
151. inuity circuit from TB26 to Chart 2 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual for troubleshooting an overheating engine _ Replace temperature continuity switch sender Repair short in wht wire temperature sender Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 2 Continued from the previous page Hold start switch and check voltage at wht 21 on terminal 87 of CR2 Check voltage at red wire on terminal 30 of CR2 Hold start switch and check voltage at terminal 86 of CR2 12V Check ground to no good terminal 85 on CR2 9 good Continued on the next page Repair open in wht 21 wire to ignition coil Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Hold start switch and check voltage at 12V terminal 9 on start lockout module oV Check voltage at terminal 6 on start lockout module 12V Check ground wire terminal 5 on start lockout module good Replace the start lockout module OR consult Genie Industries Service Department Repair open in ground wire to CR2 Repair open in blk wire from terminal 86 on CR2 to terminal 9 on start lockout module Repair open in power supply wires to terminal 6 on start lockout module Repair open in groun
152. ion down With boom fully lowered hold the function down switch Adjust the relief valve to read 1800 PSI and replace the cylinder counterbalance valve function inoperative Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valve is not allowing the cylinder to retract or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valve in this situation can be very dangerous Please consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts A O ZZL Continued from the previous page CHART 17 Adjust the boom down With boom fully lower relief valve item F hold the function down in one turn clockwise switch Adjust the relief Then with pressure valve to read 1800 psi gauge still attached operate the function down less than 1800 psi Remove the boom down Repair the boom lift high pressure line from cylinder the manifold and cap the port Hold down function and recheck pressure less than 1800 psi Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 37 Section 5 Troubleshooting Flow C
153. ious injury Indicates the presence of a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information other protective clothing if the situation G Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes e Be aware of potential crushing hazards sl Workplace Safety Be sure to keep sparks flames and W 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 U Be sure that all tools and working areas Be sure that your workshop or work area ET is properly ventilated and well lit 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 that fasteners intended for one gt time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time s Be sure to properly dispose of old oil or a other fluids Use an approved container w Please be enviro
154. itches is Repair limit switch i wiring OR replace boom intact ano SHOW NO lift drive limit switch OR sign of tampering replace boom extend drive limit switch Be sure orange wire cable1 is properly attached to horsepower limiter Part No 32960 Genie Z 45 22 5 63 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 38 Drive Enable Do not hold the drive Wil holding the drive H enable switch and enable switch allow System is check if machine will boom to drive in ioni drive in the stowed stowed position over Malfunctioning position with boom over non steer wheels non steer wheels Repair or replace drive enable limit switch Do not hold the drive enable switch and check if machine will drive in the stowed position with boom over the steer wheels Repair or replace drive enable limit switch Will holding the drive enable switch allow boom to drive in stowed position over steer wheels Repair or replace drive enable toggle switch Troubleshoot horsepower limit board drive controller or drive pump See chart 30 5 64 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the approproate position and the Emergnecy Stop buttons are pulled up to the on position Be sure engine is
155. ith AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry How to Test the Power Relay Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 13 to 170 no continuity infinite 2 large posts no continuity infinite Any small post to any large post 2 Connect 12V DC to one of the small posts and ground to the other small post then test the following terminal combination Test Desired result 2 large posts continuity zero Q ad a high amp power contact terminals large posts b solenoid activate coil terminals small posts Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 9 1 Lift Steer Pump How to Test the Lift Steer Pump 1 Disconnect and plug the high pressure hydraulic hose from the lift steer pump Bodily injury hazard Sprayin ACAUTION le ai a 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 2 Connect a O to 5000 psi 0 to 350 bar pressure gauge to the high pressure port 3 Gasoline LPG models Remove the high tension lead from the ce
156. ive Manifold 19 1 4WD Drive Manifold Components Index Schematic No Description Item Function Torque 1 Check valve 1 111111 WETO EE Brake check AA 25 30 ft lbs 34 41 Nm 2 2 position 3 way valve Sa hina Brake release 8 10 ft lbs 11 14 Nm 3 2 position 3 way valve ratio 2 speed wheel motors energized in high range to destroke the rear motor swash plates 8 10 ft lbs 11 14 Nm 4 Check valve 11 1 1 Keine RR check in forward 35 40 ft lbs 47 54 Nm 5 Orifice 0 025 in 0 635 mm X Motor shift brake release circuit 6 Check valve 1111111 Dadas RR check in reverse 35 40 ft lbs 47 54 Nm 7 Relief valve 320 psi 22 bar V Charge pressure 10 12 ft lbs 14 16 Nm 8 Shuttle valve 3 position 3 way U Low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 9 Pilot to open check valve On ete hits RF check in forward 85 90 ft lbs 115 122 Nm 10 Pilot to open check valve Puesta RF check in reverse 85 90 ft lbs 115 122 Nm 11 Check valve 1111111 Dia LR check in reverse 35 40 ft lbs 47 54 Nm 12 Check valve 111 11 cria
157. k ii open closed Componentdamage hazard The engine must not be started with the hydraulic tank shutoff 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 Table D Procedures 2 Remove the drain plug from the hydraulic tank 3 Completely drain the tank into a suitable container See capacity specifications listed below 4 Disconnect and cap the two suction hoses that are attached to the hydraulic tank shutoff valves 5 Remove the strainer assemblies from the tank 6 Carefully clean any foreign material from the strainers Clean the strainers from the inside out 7 Apply pipe thread sealant to the strainer mounting threads and then install them 8 Apply pipe thread sealant to the drain plug and then install it in the tank 9 Install the two suction hoses 10 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 11 Clean up any oil that may have spilled and open the hydraulic tank valves 12 Prime the pump by doing the following Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Remove the high tension lead from the center of the ignition coil AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or s
158. k engine for 15 seconds and check voltage at terminal 86 on CRG 12V Check ground wire to bad terminal 85 on CRG good Hold start switch and check voltage at blu wht wire on anti diesel valve on carburetor Continued on the next page Replace fuel select switch Repair open in blu wht wire circuit from fuel select switch to TP38 to TB38 Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 Repair open in red blk wire circuit from vacuum switch to CR6 Repair open in ground wire to terminal 85 on CRG Repair open in blu wht wire circuit from CR6 terminal 487 to anti diesel valve OR replace CRG Chart 5 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 5 Continued from the previous page Hold start switch and Repair open in blu wht check voltage at blu wht wire circuit from CR6 wire on gasoline to fuel solenoid solenoid at fuel tank Dor infinite ohms Check resistance of k Replace gasoline gasoline solenoid j solenoid 18 to 19 ohms Check ground wire to gas solenoid Repair ground wire infinite ohms Check resistance of anti diesel valve Replace anti diesel valve 24 to 25 ohms Reconnect starter check anti diesel and fuel valve for defects OR see Ford service manual for carburetor troubleshooti
159. kills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required Be sure that the chassis is level 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the primary boom See 3 2 How to Remove the Primary Boom Crushing hazard Do not remove AWARNING the 4x4x31 inch 78 cm support block installed during primary boom removal a Uppermid pivot b 4x4x31 inch block c counterweight Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures D TURNTABLE ROTATION COMPONENTS 3 Use an overhead crane to attach a lifting strap 8 Disconnect the three 3 4 inch hydraulic hoses to the rod end of the primary lift cylinder Then from the main pump and plug them raise the primary lift cylinder with the crane to EE IS Bodily injury hazard Spraying a vartigal position ACAUTION hydraulic oil can penetrate and 4 Remove the pin retainer from the pivot pin at burn skin Loosen hydraulic the barrel end of the primary lift cylinder connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Place a rod through the barrel end pivot pin and twist to remove the pin Remove the primary lift cylinder from the machine 9 Disconnect the same three 3 4 inch hydraulic 7 hoses from the driv
160. l Second Edition 9 Rotate the platform to the right and continue holding the platform rotate switch until air stops coming out of the bleed valve ACAUTION Crushing hazard Keep hands clear of the platform pivot weldment during rotation 10 Close the bleed valve and remove the hose 11 Turn off the engine and clean up any hydraulic oil that may have spilled 12 Restart the engine from the ground controls Then rotate the platform full left and right and inspect the bleed valves for leaks Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures Primary Boom Components 3 1 Plastic Cable Track The primary boom cable track guides cables and hoses running up the boom lt can be repaired link by link without removing the cables and hoses 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 Repair the Plastic Cable Track Component damage hazard The ACAUTION primary boom cable track can be damaged if it is twisted a linkseparation point b lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screw driver to pry the link to the side 3 2 Primary Boom How to Shim the Primary Boom Wear Pads Measure each wear pad Replace th
161. l configuration Refer to B 8 in this section Confirm Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark atest line on the ground for reference 2 Start the engine from the platform controls and then select high drive mode machine on flat ground Fully lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a rear 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 The brakes must be able to hold the machine on any slope it is able to climb Specifications high range paved surface 5 5 to 6 feet 1 67 to 1 82 m Stopping distance Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 25 Test Drive Speed Stowed Position 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 level and free of obstructions 1 Create start and finish lines by
162. l filter insert to block 20 35 27 47 Rocker arm cover to 5 8 7 11 cylinder head M 6 Spark plug to cylinder 5 10 7 14 head M 14 Temperature sending 8 18 11 24 unit to block M 14 Water jacket drain plug 23 28 31 38 to block Water pump to block bolt 14 21 19 28 Auxiliary shaft cover bolt M 6 6 9 8 12 Water outlet connection 14 21 19 28 bolt M 8 Cylinder front cover bolt M 6 6 9 8 12 Inner timing belt cover stud M 8 14 21 19 28 Outer timing belt cover bolt M 6 6 9 8 12 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 2 Specifications DEUTZ ENGINE F3L 1011 SPECIFICATIONS Deutz Engine F3L 1011 Injection pump pressure 4351 psi 300 bar Displacement 125 02 cu in P Injector opening pressure 3626 psi 2 049 liters AAA RS EA 250 bar Number of cylinders 3 s ne Fuel requirement diesel number 2 D Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Alternator output 55A 14V Horsepower 36 2300rpm Starter motor Firing order 1 2 3 Current draw no load 90A Compression ratio 18 5 1 Brush length new 0 7480 in ZETA zc ZE 19 mm Compression pressure 362 to 435 psi P R 25 to 30 w Brush length minimum 0 5 in Pressure psi of lowest cylinder must be at least 85 of 12 7 mm highest cylinder Battery Low idle 1300 rpm Type 12V Group 31 High idle 2300 rpm Quantity 1 Governor centrifugal mechanical Cold cranking amper
163. l not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns ACAUTION 1 Deutz Diesel models Remove front engine cover to access belt 2 All models Inspect the engine belt s for cracking glazing separation breaks 3 Check the engine belt s for proper tension A A ES ZO zx No f M Deutz Diesel engine Ford engine 3 8 inch to 1 2 inch 9 mm to 12 mm Belt deflection all models Table B Procedures B 2 Check the Radiator Gasoline LPG Models Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns ACAUTION 1 Inspect the radiator for leaks and physical damage 2 Clean the radiator fins of d
164. latform level through the entire range of primary 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 Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 1 Tilt the platform with the ground controls platform leveling switch until the platform is horizontal 2 Place blocks under the platform railing for support Then carefully rest the platform on the blocks 3 Disconnect the hydraulic hoses from the slave cylinder and connect them together with a straight line connector Bodily injury hazard Spraying ACAUTION 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 Remove the rod ends from both the barrel and rod end pins 5 Use a soft metal drift and drive the pins out Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures How to Bleed the Slave Cylinder ACAUTION Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the primary boom 6 inches 15cm above the primary boom rest 2 Move the manual platform level switch to the right until the slave cylinder is fully
165. lbs 169 5 Nm 169 5 Nm Wheel diameter 17 5 inches 14 5 inches Wheel width 10 5 inches 7 inches Wheel lugs 4WD 9 O 5 8 18 Wheel lugs 2WD Front 8 5 8 18 80 5 8 18 Rear 90 5 8 18 90 5 8 18 B 9 Confirm Proper Brake Configuration 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 the torque hub disconnect caps to be sure they are in the engaged position 2 On 4WD models be sure the free wheel valve on the drive pump is closed clockwise brake disengage position brake engage position a drive pump b liftpump c free wheelvalve 4 14 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 10 Check the Oil Level inthe Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause severe component damage 1 Drive the machine to rotate the hub until the side plugs are located one on top and the other at 90 degrees 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 plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug h
166. leads from an ohmmeter to the valve coil terminals Specifications En 8 Valve Resistance Proportional solenoid valve 50 3 pos 4 way directional valve 4 50 Normally closed 70 poppet valve a directional valves b proportional valves c function manifold Part No 32960 Genie Z 45 22 7 43 Section 7 Repair Procedures Service Manual Second Edition Fuel and Hydraulic Tanks 11 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation This tank has a 25 gallon 94 5 liters capacity and an oil level gauge with temperature indicator It utilizes internal suction strainers for the pump supply suction lines and has an external return line filter How to Remove the Hydraulic Tank The work area and surfaces ACAUTION 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 1 Raise the primary boom until it is horizontal to access the anchor hook 2 Close the two hydraulic tank valves located at the main pump open closed 3 Completely drain the oil from the tank by removing the drain plug located in the bottom front of tank Burn hazard Contact with hot oil A CAUTION may cause severe burns 4 Disconnect the hydraulic hoses from the tank 5 Remove the tank anchor hook from the back of the tank 6 Remove the mounting fasteners
167. ll disconnect all wiring from the toggle switch to produce continuity be tested infinite 2 Connect the leads of an ohmmeter to the Right Position switch terminals in the following combinations terminal i to 2 Continuity listed below to check for continuity terminal 1 to 3 4 5 amp 6 no continuity Left Center Right terminal 2 to 3 4 54 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity doubie trow H fama lazo cua SPDT Double pole double throw DPDT Part No 32960 Genie Z 45 22 7 9 Section 7 Repair Procedures Service Manual Second Edition Platform Components 2 1 Platform How to Remove the Platform 1 Remove the cable harness from the cable clamps located under the platform and disconnect the foot switch wiring plug 2 Remove the platform control box mounting bolts then lift it out and set it aside 3 Tilt the platform with the ground controls manual platform leveling switch until the platform lays horizontal a platform mounting bolts b block 4 Place blocks under the platform railing for support Then carefully rest the platform on the blocks 5 Remove the platform mounting bolts and remove the platform 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the p
168. low regulator valve item Y DV Repair open circuit in red wire from TB1 to boom function directional valve 0 or infinite ohms Replace coil with a like valve item X Continued on the next page NA function inoperative function operates Replace defective flow regulator valve Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 16 Hold toggle switch up function Check the resistance dor ine d CH the and manually override Operates of the directional Mn Replace the defective H page directional valve push valve coils Onms _ valve coil s in button 2 de of valve spool Note Geng the valve will 4 to 5 ohms require two people If a helper is not available interchange the valve item R with a like valve item S Replace the valve function inoperative Interchange check valve function operates item M with a like valve item K Replace defective shuttle valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect boom from moving coupling on the function OR ropali cylinder manifold and hold the OR cylinder function switch counterbalance valve less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect co
169. lt All machine functions should activate and operate smoothly TABLE A PROCEDURES 2 Push in the Emergency Stop button to the off position Result No function should operate the engine should stop Diesel models All functions should stop immediately The engine will shut off after 2 or 3 seconds 3 Start the engine from the platform controls and then operate each machine function through a full cycle O Result All machine functions should activate and operate smoothly 4 Push in the Emergency Stop button to the off position O Result No function should operate the engine should stop As a safety feature selecting and operating the ground controls can override the platform controls including the Emergency Stop button A 11 Test Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss Auxiliary power is designed for short term emergency use only and excessive use will result in battery drain and pump damage Oscillating axle equipped machines only From the stowed position auxiliary power can not raise the boom above the drive limit switch Auxiliary power can raise the boom if it is already raised above the drive limit switch 1 Turn the key switch to ground control and pull out the ground control Emergency Stop button
170. lve cover 4 8 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES 2 Pull the end of the oil drain hose out from 12 Swing the engine pivot plate back to its original under the engine position and replace the three retaining bolts 13 Check the engine oil level dipstick Add oil if needed Ford Engine LSG 423 5 quarts Oil capacity including filter 4 7 liters Ford Engine LSG 423 Oil viscosity requirements below 60F 15 5C 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 a _ pivot plate retaining bolts b engine pivot plate Use oils meeting API classification SF labeled SF CC c Oil drain hose or SF CD as they offer improved wear protection 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container 4 Install the plug into the drain hose Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter 6 Use an oil filter wrench and remove the filter 7 Apply a thin layer of oil to the new oil filter gasket filter part no 28656 Then install the filter and tighten it securely by hand 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fill the engine with new oil per spec
171. ly extended the oscillation lock out limit switches release and allow the primary boom to continue to raise above the drive limit switch How To Remove The Oscillating Axle Lock out Cylinder The oscillating axle lock out cylinder is held in place by the same pin that retains the axle Therefore the axle must be removed as part of this procedure This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure on a firm level surface 1 Disconnect and plug the oscillating axle lock out cylinder hydraulic hoses Disconnect and plug the steer and accumulator hoses from the steer oscillate manifold to provide clearance for pin removal 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 ACAUTION 2 Remove the oscillation lock out limit switches from the oscillating axle lock out cylinder Block the non steering wheels then center a jack under the oscillating axle and lift the machine 6 inches 15 cm 4 Support the raised machine with blocks then carefully lower the chassis onto the blocks Leave the jack under the axle to support it Do not lift
172. ly override operates directional valve rotate left directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S function inoperative Install a pressure gauge a d Interchange the ni Replace defective at the quick disconnect rotate left and right p counterbalance valve coupling on the function counterbalance valves manifold and hold the function switch item M and item N on turntable rotation motor function inoperative less than 2400 psi Check for mechanical restrictions keeping turntable from rotating left OR replace directional valve OR repair rotation motor Repair rotation motor Remove the rotate left function pressure line from the manifold and cap the port S2 Then with pressure gauge still attached operate the function less than 2400 psi Replace the directional valve OR the manifold has internal defects OR Consult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 43 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 22 Turntable Rotate Right Function Inoperative Be sure all other functions operate normally including turntable rotate right function If turntable rotate right function operates normally from the ground contr
173. m up Max out Cycle time 4 33V DC 33 to 37 seconds dual lo adjustable trimpot ramp rate adjustable trimpot terminal R activates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot Primary boom down Dual range Cycle time oO ro Oo D w Part No 32960 Genie Z 45 22 7 3 Section 7 Repair Procedures Service Manual Second Edition OOOO PLATFORM CONTROLS Set the ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until you hear a click then turn the screw counterclockwise 5 turns Connect the red lead from a volt meter to the A terminal on the controller PC board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 2 50V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the max out Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 5 01V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the dual range Press down the foot switch then move the control handle all the
174. manual for troubleshooting low oil pressure Replace start lockout module OR consult Genie Industries Service Department Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 3 Engine Cranks Over But Will Not Start Deutz Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the diesel shut off valve is in the on position Hold start switch and check battery voltage while engine is cranking less than 11V more than 11V Check if engine coolant over temperature sending signal post has continuity to ground no continuity Disable starter by removing blk wire at the starter solenoid hold start switch and check voltage at positive terminal on fuel solenoid Continued on the next page continuity Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if oil cooler hot and or engine block feels excessively hot not hot Remove wht rd wire from temperature sending unit check continuity to ground on wire no continuity y Remove wht rd wire from TB26 no continuity Repair short in wht wire circuit from start lock out module to TB24 OR consult Genie Industries Service Department
175. nal equipment ce eeeteeeeeeeettteeeeeeeeaes 4 23 B 27 Perform Hydraulic Oil Analysis 0 c ccccceseeeeeeeeeeeeeeeeeaaeeeeeaeeeeeeeeeeetaeeeees 4 24 B 28 Replace the Engine Oil and Filter Deutz Diesel Models 4 24 C 1 Check the Primary Boom Wear Pads ueeoe ua a aaa aaa aaa aaaaaaaenaa 4 26 C 2 Check the Turntable Rotation Bearing Bolts cccceseeeeeeeteeeeteeeeeeeees 4 26 C 3 Check the Free wheel Feature cccccceeeeeceececeeeeeeneeeeseseeeeseaaeeseceeeesaeees 4 27 C 4 Grease the Worm Drive Gear uuu aaa aaa aaa aaa aaa aaa aaa acna 4 28 C 5 Replace the Torque Hub Oil eeeeeeceeeeeeeeeeeeeeeaeeeeecaeeeeeeeeeeesaeeeseneeeeeeaeees 4 29 C 6 Replace the Hydraulic Tank Eiter 4 29 C 7 Replace the Drive Loop Hydraulic Eiter 4 30 C 8 Replace the Diesel Fuel Elter 4 30 C 9 Replace the Gasoline Fuel Elter 4 31 C 10 Replace the PCV Valve Gasoline LPG Models ccccssceceeeesssteeeeeens 4 32 C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LPG Models 4 32 C 12 Replace the Spark Plugs Gasoline LPG Models oooccnccconncccnnncccccnccncnanncoo 4 33 C 13 Check and Adjust the Air Propane Mixture Gasoline LPG Models 4 33 C 14 Check and Adjust the Ignition Timing Gasoline LPG Models 4 34 C 15 Check the Engine Valve Clearances Deutz Diesel Models 4 34 D 1 Te
176. nasa ae 4 3 A 7 Check the Hydraulic Oil Level 4 4 A 8 Check for Hydraulic Leaks 4 4 A 9 Check Tire Pressure mimar siete Aaa y 4 5 Part No 32960 Genie Z 45 22 vii Service Manual Second Edition gt qq q gt TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 10 Test the Platform and Ground Controls sesesas see e aaa aaa aaa aaaaanana ae 4 5 A 11 Test Auxiliary Power Operation sseeee aaa aaa aaa aaa conan aaa ena aiaa ae 4 5 A 12 Test the Tilt Level Sensor aaa aaa aaa aaa ananasa 4 6 A 13 Test the Limit Switches oooonncccinnnnncnnnnnnnnccccnnncccn cnn aaa aaa crac 4 6 A 14 Replace the Engine Oil and Filter Gasoline LPG Models 4 8 A 15 Change the Engine Air Eiter 4 10 B 1 Check the Engine Bettel 4 11 B 2 Check the Radiator Gasoline LPG Models A 4 11 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 11 BA Check the Exhaust System aaa e aaa aaa aaa aaa aaa aha 4 12 B 5 Check the Battery eee eee aaa aaa n cnn cnn 4 12 B 6 Check the Hydraulic Tank Filter Condition Indicator eeeeeeseeeeeee 4 13 B 7 Inspect the Electrical Wiring eee eee aaa aaa aaa aaa aaa aaa 4 13 B 8 Inspect the Tires and Wheels including lug nut torque 111 4 14 B 9 Confirm Proper Brake Configuration ooococinnncicinnncnnnnncccnnnncccnonnnnnanccanann
177. nd Edition Z A _ gt o2o2o2 gt gt mQ gt mQmQX AAA Hydraulic Specifications Drive speeds maximum 2WD 4wD Hydraulic fluid Dexron II equivalent Boom lowered high range 5 0 mph 4 8 mph 8 0km h 7 7km h Drive pump Boom lowered low range 1 1 mph 0 9 mph Type bi directional variable 1 8km h 1 4km h displacement piston pump or 5 feet or 4 feet in 3 sec in 3 sec Displacement 0 25 gpm Boom raised high range 0 68 mph 1km h 0 1 6 liters second or 1 foot per second Maximum drive 3800 psi pressure 262 bar Boom raised low range 0 68 mph 1km h or 1 foot persecond Charge pressure i Eskridge brake 360 psi 24 8 bar Gradeability stowed 30 40 Mico brake 290 psi 20 bar Boom function speeds maximum Medium pressure filter 3 micron from platform controls gt Medium pressure filter 50 psi Primary boom extend 29 seconds bypass pressure 345 kPa Primary boom retract 25 seconds Drive manifold Primary boom up 27 seconds Motor shift brake relief pressure Eskridge brake 320 psi 22 bar Primary boom down 35 seconds Mico brake 250 psi 17 2 bar Secondary boom up 25 seconds AWD front motor 3 0 gom Secondary boom down 25 s c nds flow regulators 11 4 liters minute o 4WD rear motor 4 5 gpm Ee 13 Seconds flow regulators 17 0 liters minute Platform rotate 180 15 seconds 2WD rear motor 7 0 gom Platform level up 25 seconds flow regulators 26 5 liters minut
178. nd check voltage at red blk wire on vacuum switch reconnect blk wire after test 12V With keyswitch on and both mushroom switches pulled out disconnect wires from vacuum switch and connect the wires together Check the voltage at terminal 86 on CR6 Continued on the next page oV oV Repair open in white 21 wire circuit from ignition module to automatic choke Adjust or replace automatic choke OR consult Genie Industries Service Department Repair open in red wht 23 wire circuit from TB23 to vacuum switch Turn machine off See bad Repair section for vacuum switch check Replace vacuum switch ok bad Replace vacuum line Check vacuum line for restrictions See Ford service manual to troubleshoot low manifold vacuum Repair open in red blk wire circuit from vacuum switch to CR6 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Continued from the Wi WT am previous page switches pulled out check voltage at center terminal on fuel select switch in platform control box With keyswitch on and both mushroom switches pulled out check voltage on gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal TB38
179. ng Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Gasoline LPG Models If high idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If high idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Be sure high idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Start engine and switch rpm select to high idle rabbit symbol for following checks Check voltage at blk red wire on rpm switch 12V Check voltage at TB35 12V Check voltage at terminal 30 on CR3 12V Check voltage at terminal 86 on CR3 12V Check ground wire to terminal 85 on CR3 good Check voltage to terminal 87 on CR3 12V Check voltage at terminal 86 blk red of CR4 12V Check ground wire to terminal 85 on CR4 good Continued on the next page Chart 6 oV Check voltage at center terminal on rpm select M mr Repair open in circuit supplying 12V to center terminal of switch switch 12V Replace rpm select toggle switch oV Repair open in blk red wire circuit from toggle switch to TP35 to
180. ng axle equipped models A B 17 Test Platform Self leveling B 18 Test the Service Horn B 19 Test the Foot Switch B 20 Test the Engine Idle Select B 21 Test Fuel Select Operation Gasoline LPG Models B 22 Test the Turntable Rotation Stop B 23 Test the Drive Enable System B 24 Test the Drive Brakes B 25 Test Drive Speed Stowed Position B 26 Test the Alarm Package optional equipment travel alarm descent alarm flashing beacon B 27 Perform Hydraulic Oil Analysis U 5 See D 1 Test or Replace the Hydraulic Oil A XR Every 500 hours perform the following engine maintenance procedure B 28 Replace the Engine Oil and filter Deutz Diesel Models 3 4 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES Table C Warm Cold Dealer Tools are New parts engine engine service required required required required suggested C 1 Check the Primary Boom Wear Pads ei C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Feature Lei CA Grease the Worm Drive Gear U A including turntable rotation bearing A O C 5 Replace the Torque Hub Oil O C 6 Replace the Hydraulic Tank Filter C 7 Replace the Drive Loop Hydraulic Filter C 8 Replace the Diesel Fuel Filter e C 9 Repla
181. ng fuel page 5 11 pump and or carburetor OR Consult Genie Industries Service Department 5 10 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Runs While Cranking Then Dies Crank engine and check gy voltage at terminal 2 on start lockout module 6 to 7V While cranking engine for 15 seconds check continuity to ground on yes terminal 10 start lockout module Is continuity maintained no Check voltage at terminal 4 on start 12V lockout module Replace start lockout module OR consult Genie Industries Service Department Crank engine and check voltage at org blk 41 wire On alternator 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module Disconnect wht 24 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground in wht 24 wire from sender to TB24 to start lockout module terminal 10 Disconnect red wire from terminal 4 on start lockout module and check voltage at terminal 4 Repair short to power in red wire circuit trom TB27 oV yes 12V Chart 2B Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Ford service
182. nmentally safe vi Genie Z 45 22 Part No 32960 Service Manual Second Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Information esi erri eia eee etree nana eee etree naan cnn aaa ii Safety Rules General Safety Rules oooococinnccccnnncccccnccccnnonnccnoncnnn crac nan rr iii Specifications Machine Specifications ze raramente 2 1 Performance Specifications oooooccncncnnnnccccnnnccnncnornnnnano cono aaa aaa aaa 2 2 Hydraulic Specifications eseeee eee aaa aaa aaa aaa aaa aaa aaa 2 2 Ford LSG 423 Engine Specifications eu sesee aaa aaa aaa aaa aaa aaa 2 5 Deutz F3L Engine Specifications 2 ee eee aaa aaa aaa aaa narran 2 7 Scheduled Maintenance Inspections lieler de 3 1 TASA te ba lada a aaa e EE 3 2 Table E 3 3 Tal ur talco CET 3 5 Fable Di AA AA add 3 6 Maintenance Inspection Report ccocoinnccccccnnnnnncncccnnnnnnneccnncnnnnnnnnc RERS BEEPER EENES EKE RES 3 7 Scheduled Maintenance Procedures dite Te de ITT 4 1 Axl Insbectthe Manuals anat 4 2 A 2 Inspect the Decals and Placards eeeeee aaa eee aaa aaa aaa aaa nc 4 2 A 3 Inspect for Damage Loose or Missing Parts A 4 2 A 4 Check the Engine Oil Level 4 3 A 5 Check the Engine Coolant Level Gasoline LPG Models 4 3 A 6 Check for Fuel Leaks eeuu eee aaa aaa aaa ana
183. nnnnnns 4 14 B 10 Check the Oil Level in the Torque Hubs ooooccccccoccnnnocccnnoncnccnnnnnnncnncnananannnnnna 4 15 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 15 B 12 Check and Adjust the Engine HPM 4 15 B 13 Test the Key Switch ccccceeeeeeeceeeeeeeeeeeseeaeeesaaeeeeeeeeeeseaaeeeseaaeeeseneeeeenaeees 4 17 B 14 Test the Emergency Stop Buttons oocooccconnncccconoccnnccnncnnonancnnnnn nn ncnnr cn nnnnn cnn 4 18 B 15 Test the Ground Control Override ee ea aaa aaa aaa aaa aaa anna ae 4 18 B 16 Test the Oscillate Lock out 4 18 B 17 Test Platform Self leveling oo e aaa aaa aaa aaa aaa 4 19 B 18 Test the Service Horn eeueea eee aaa aaa aaa aaa aaa a aaana ca 4 19 B 19 Test the Foot Switch 4 20 B 20 Test the Engine Idle Geet AAA 4 20 B 21 Test Fuel Select Operation Gasoline LPG Models 2111142111112 4 21 B 22 Test the Turntable Rotation Stop see eee eee aaa aaa aaa aaa aaa aaa nana 4 21 iix Genie Z 45 22 Part No 32960 Service Manual Second Edition DEEN Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 23 Test the Drive Enable System oooonnncnnnncnnnncccconccnnncnannnnnnnn ananasa 4 21 B 24 Lest the Drive Braks s simile aa RERS EEEE RERNA EEKi kE 4 22 B 25 Test Drive Speed Stowed Position ooooooconiccnnncccnnncccnnnnccccconnnnncnnrncnnnnn cnn 4 23 B 26 Test the Alarm Package optio
184. no continuity Be sure all other fincions opsie With boom fully stowed ful Orange wire shorted check horsepower continuity 9rouna repair normally limiter board terminal 6 orange wire circuit from TB40 to horsepower for continuity to ground limiter board Be sure the free wheel valve is closed on the drive pump Re adjust or replace horsepower limiter board See Repair no continuity section OR consult Genie Industries Service Department 5 62 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 37 Machine Raise boom off drive full Ki porywa o ee SE i limit switch turn continuity displacement controller rive pump Replace or Drives At Full machine off and check EDC wires drive eel at Steier j continuity between pump move drive undstrand repair Speed With ground and terminal 6 controller to full forward facility Platform on horsepower limiter position and check S board voltage between Raised or terminals 4 and 5 on drive controller Extended Remove machine from service immediately no continuity Replace horsepower limiter board Be sure boom lift i full 8 WEN RSE Check continuity imuity Repair open in org wire drive limit switch is between ground continuity circuit from TB40 to not being held down and TB40 horsepower limiter or up board terminal 6 no continuity Be sure wiring to limit sw
185. not running when using auxiliary power Note Operating auxiliary power with engine running should immediately kill the engine With engine not running pump lift switch cover hold runs auxiliary switch and listen for sound of auxiliary pump running pump does not run Hold the auxiliary power switch and check the voltage at terminal TB27 Hold the auxiliary power switch and check the voltage at initiate terminal red wire on PR1 motor start solenoid Hold the auxiliary power switch and check the voltage at positive power cable on auxiliary power unit Check auxiliary power unit grounding cable OR repair or replace electric motor Deadhead a pressure gauge into the pressure line of the auxiliary pump and hold the auxiliary power switch 2000 psi Reconnect pressure line and check battery condition There is possibly not enough battery capacity to operate both aux pump and function valves Replace defective auxiliary power toggle switch Repair open in red wire circuit from TB27 to PR1 Replace PR1 relay less than Hold auxiliary switch and adjust pump relief valve or replace pump Chart 39 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition EH This page intentionally left blank 5 66 Genie Z 45 22 Part No 32960 745 22 GP HP MP Index 745 22 HP 2WD 6 4WD FORD ELECTRICAL SCHEMATI
186. ns H Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact ADANGER with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 32960 Genie Z 45 22 5 1 Section 5 Troubleshooting Flow Charts Service Manual Second Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter onmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schemaiics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When
187. nsult Genie Industries Service Department Part No 32960 Genie Z 45 22 5 35 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 17 Primary Boom Down Function Inoperative Be sure all other functions operate normally including boom up function If boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom down function operates Hold ground control function switch and check volts at red blk wire on boom function directional valve Hold toggle switch down and manually override the down directional Valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item R with a like valve item S function operates function inoperative Install a 0 to 3000 PSI pressure gauge atthe 1800 quick disconnect psi coupling on the function manifold and hold the function switch less than 1800 psi Continued on the next page Repair open in red blk wire circuit from TB2 to directional valve Dor infinite ohms Replace the coil Check the resistance of the down directional valve coil 4 to 5 ohms Replace the valve Counting the turns adjust the boom down function relief valve item F in operates all the way Then operate the funct
188. nt Level Gasoline LPG Models Maintaining engine coolant at the proper level is essential to engine life Improper coolant level will affect the engines cooling capability and damage engine components Daily checks will allow the inspector to identify dramatic changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add water as needed Result The fluid level should be in the normal range A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Engine fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid propane gas LPG tank by turning it counterclockwise Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate propane leaks Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor gasoline tank shutoff valve solenoid shutoff valve hoses and fittings fuel pump and carburetor Deutz Diesel models fuel tank shutoff valve h
189. nter of the ignition coil Electrocution hazard Contact with AWARNING electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 4 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position 5 ACAUTION 6 Hydraulic Pumps Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position All models Observe the pressure gauge while cranking the engine Immediately stop cranking if the pressure reaches or exceeds 3000 psi 206 bar Component damage hazard Hydraulic pressure in excess of 3000 psi 206 bar will cause damage to the machine Result If the pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result If the pressure fails to reach 3000 psi 206 bar the pump is bad and will need to be serviced or replaced Gasoline LPG models Reconnect the high tension lead to the ignition coil Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition HYDRAULIC PUMPS How to Remove the Lift Steer Pump 1 Close the two hydraulic tank valves located at the hydraulic tank i open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur If the tank valves are closed remove t
190. ntrols troubleshoot the ground control toggle switch See Repair section Remove both wires from 0 or infinite ohms valve coil and check reisitance across coil terminals 4 to 5 ohms Hold toggle switch right function operates and manually override rotate left directional valve push in button on end of valve spool Note overriding valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative Install a pressure gauge 2400 psi or more at quick disconnect coupling on rotate function manifold and hold function switch 2400 psi Interchange check valve function operates item I with like valve item L function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department Replace the coil Replace platform rotate directional valve Check for mechanical restrictions OR hydraulic rotator or function manifold has internal defect Consult Genie Industries Service Department Replace defective check valve Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Chart 28 Service Manual Second Edition Osci late Raise the primary boom Open in red 23 wire until it is above the drive wedges BV supply to oscillate Lock out limit switch
191. o remove the pin 3 Remove the pin retainer from the slave cylinder barrel end pivot pin Use a soft metal drift to remove the pin then remove slave cylinder from the primary boom 4 Support the platform rotator with a lifting device 5 Remove the pin retainer from the platform rotator pivot pin Use a soft metal drift to remove the pin then remove the platform rotator from primary boom 6 Support the master cylinder with a lifting device 7 Remove the retaining fastener bolt from the master cylinder pivot pin Use a soft metal drift to remove the pin then remove the master cylinder from the primary boom 8 Remove the fasteners from the extension cylinder pivot pin Use a soft metal drift to remove the pin 9 Support and slide the extension boom out of the primary boom weldment Crushing hazard The extension ACAUTION tube will fall when it is removed from the primary boom if it is not properly supported Part No 32960 Genie Z 45 22 Section 7 Repair Procedures a IM PRIMARY BOOM COMPONENTS 10 Remove the extension boom end cap 11 Remove the fasteners from the extension cylinder rod end weldment then support and slide the extension cylinder out of the extension boom The bolts that secure the cylinder rod end weldment are installed with Loctite removable thread sealant It may be necessary to heat the bolts and the surrounding area to remove them Do not reuse the bolts 12
192. o secondary lift cylinder rod end pivot pins 10 Place a rod through each rod end pivot pin and twist to remove the pins 7 22 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 11 Lift the number 1 arm until the secondary lift cylinders can swing forward to rest on the lower mid pivot 12 Remove the block between the counterweight and the upper mid pivot 13 Lower the arms enough to relieve the pressure on the compression link upper pivat pin Specification to remove pressure on the compression link Industrial tires The upper mid pivot rest should be approximately 1 inch 2 5 cm above the rest block Rough terrain tires The upper mid pivot rest should be approximately 4 inches 10 cm above the rest block 14 Remove the pin retaining fastener from the compression link to number 1 arm pivot pin Use a soft metal drift to remove the pin 15 Lower the arms to full rest and re position the lifting strap to the center of the number 1 arm 16 Remove the pin retaining fastener from the lower mid pivot to number 1 arm pivot pin Use a soft metal drift to remove the pin 17 Remove the pin retaining fastener from the upper mid pivot to number 1 arm pivot pin Use a slide hammer to remove the pin Crushing hazard If the overhead AWARNING crane is not properly attached the number 1 arm may become unbalanced and fall when itis disconnected from the upper mid
193. o t LMP cl ES 2 6 4 GPM ioe Y Di L e z E zi a ee EEEE SE DRIVE PUMP XX Sta Ma mik NEJ t Tm 1 LI l 1 1 1 LA LLP EE SSC Soe SE 25 g 3 E I el I LIFT FUNCTION MANIFOLD D ds I I Q ae AE al ESEE REG TANK AUX PUMP i DRIVE i i MANIFOLD I I ZAB ni I STEER OSC MANIFOLD RA T o Ta l eb Af d ES I wae 4 ws Py gt aol Io T tt 7 I Lo I REAR 4 I I VU FRONT S R CH NITE OR mie k L Th E l fs a go Lm I m 2 1 CU IN z s a l 4 I t gt I HE IS Lip ENE l I I I SL JI I I REAR n h FRONT LEFT loi LAY LEFT 2 8 ACCUMULATOR CU IN PRE CHARGE i 1600 PSI b po L 1 e eg e ES REE naj STEERING I E DIVIDER 40d BY PASS DWG 4HS4WD F BZ JE Service Manual Second Edition Section 7 Repair Procedures Observe and Obey kl Repair procedures shall be completed by a person trained and qualified on the repair of this machine VJ Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction before operating the machine Before Repairs Start V Read understand and obey the safety rules and operating instructions in the Genie Z 45 22 Operator s Manual V Be sure that all necessary tools and parts are available and ready for use V Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazar
194. o fuel mixture ratio of 13 0 1 to 13 2 1 TABLE C PROCEDURES C 14 Check and Adjust the Ignition Timing Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Litre Industrial Engine Service Manual Ford number 194 216 Genie partnumber 29586 C 15 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz Number02611642 Genie partnumber 29789 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for 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 The machine uses Dexron II equivalent hydraulic oil 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 at the two year inspection quarterly testing B 27 thereafter should be completed Perform this procedure with the boom in the stowed position 1 Close the two hydraulic shutoff valves located at the hydraulic tan
195. oil 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department Chart 29 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 30 Steer Right Function Inoperative Be sure all other functions operate normally Start the engine from the platform press down foot switch hold the steer switch right and check voltage at terminal 7 on the drive controller blu blk wire Hold the steer switch right and check voltage at TB37 Hold the steer switch right and check voltage at blu blk wire on steer valve Remove both wires from steer right coil and check resistance across coil terminals Replace steer valve OR consult Genie Industries Service Department 4 to 8 ohms Repair or replace the steer microswitch in controller handle Repair open in blu blk wire circuit from steer switch to TP37 to TB37 Repair open in blu blk wire circuit from TB37 to steer valve Dor infinite ohms Replace steer right valve coil Genie Z 45 22 Part No 32960 Service Manual Second Edition All Drive Functions Inoperative All Other Functions Operate Normally Be sure the hydraulic suction line valve is in the open position Be sure machine not in the free wheel configuration Be sure the drive speed select switch is set to machine on level surface position maximum drive s
196. olant return tank 3 Remove the radiator cap from the radiator Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator petcock a pivot plate retaining bolts 5 Open the petcock on the radiator and allow all the coolant to drain into a container 6 After all the coolant has drained close the petcock Connect the coolant return hose to the radiator 7 Open the petcock on the engine block and allow the coolant to drain into a container After the fluid is drained close the petcock 8 Replace all coolant hoses and clamps 9 Pourthe proper coolant mixture anti freeze and water for your climate into the radiator until it is full TABLE D PROCEDURES 10 Disconnect hose A from hard line B and hold until coolant starts to pour out of the open hose Then immediately reconnect the hose a hoseA b hard line B 11 Fill the radiator and then fill the coolant recovery tank to the normaL range 12 Clean up any coolant spilled during this procedure 13 Start the engine from the ground controls run itfor 30 seconds and then turn it off 14 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed 15 Start the engine from the ground controls and run it until reaching normal operating tem
197. ole 4 Apply pipe thread sealant to the plug and then install it in the torque hub 5 Repeat this procedure for each torque hub Drive torque hub oil Capacity 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil APlservice classification GL5 TABLE B PROCEDURES B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Litre Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 B 12 Check and Adjust the Engine RPM 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 Gasoline LPG Models Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Disconnect the blue black wire from the governor actuator 2 Connect an rpm gauge to the engine then start the engine from the ground controls Result Carburetor low idle should be 900 rpm Skip to step 4 if the low idle rpm is correct Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 3 Turn the idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm
198. ols and then raise the secondary boom until the upper pivot is above the turntable covers 3 Inspect the upper pivot area for burnt chafed and pinched cables 4 Fully lower the boom into the stowed position and turn the engine off 5 Inspect the following areas for burnt chafed corroded pinched and loose wires cable track on the primary and secondary booms primary boom to platform cable harness inside of the platform control box Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 8 Inspectthe Tires and Wheels Maintaining the tires and wheels in good condition 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 An over inflated tire can explode and may cause death or serious injury 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 every lug nut for proper torque 4 Check the pressure in each air filled tire Tires and wheels Rough terrain Industrial Tire size 14 17 5NHS 9 14 5 LT Tire ply rating 8 Tread 8 Sidewall 6 Tire pressure 2WD 40 psi 100 psi 2 76 bar 6 89 bar 4WD 28 psi 1 93 bar Lug nut torque 125 ft lbs 125 ft
199. ols but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at wht wire on rotate function directional valve 12V Remove both wires from rotate right valve coil and check resistance across the coil terminals 4 to 5 ohms Hold toggle switch right and manually override rotate right directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S Repair open in wht wire circuit from TB4 to directional valve 0 or infinite ons Replace the valve coil sani Replace the rotate directional valve function inoperative 2400 Install a pressure gauge psi Interchange the me Replace defective at the quick disconnect rotate right and left p counterbalance valve coupling on the function counterbalance valves manifold and hold the item M and item N on function switch turntable rotation motor function inoperative less than 2400 psi P Check for mechanical restrictions keeping turntable from rotating right OR replace i directional valve OR Remove the rotate right A function pressure
200. on There are three settings Low idle turtle symbol allows the operator to control individual boom functions only Drive functions do not operate at low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Start the engine from the ground controls Then move the engine speed control switch to high idle rabbit symbol and hold in the on position Result The engine should change to high idle Release the engine speed control switch Result The engine should return to low idle Turn the key switch to platform controls NA At the platform controls move the engine speed control switch to high idle rabbit symbol Result The engine should change to high idle 6 Move the engine speed control switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol O Result The engine should not change to high idle 8 Pres
201. oses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 7 Check the Hydraulic Oil Level Maintaining hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the machine is in the fully stowed position then visually inspect the sight gauge located on the side of the hydraulic oil reservoir Result The hydraulic oil level should be within the top 2 inches 5cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron II equivalent Tank capacity 25 gallons 95 liters Hydraulic system 30 gallons including tank 114 liters A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas hydraulic tank filter fittings hoses and turntable surface engine compartment fittings hoses auxiliary power unit main pump and turntable
202. ot pin is removed a pivotpin b 10to12inch 30cm rod 16 Carefully lower the platform leveling master cylinder down and out of the upper mid pivot Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures Secondary Boom Components OOOO e ki 4 1 Secondary Boom How to Disassemble the Secondary Boom The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required AWARNING 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 T Xx Lei e o 5 IVE 7 LI ALI T Secondary Boom a b xT 7 TQ o upper secondary boom number 1 arm upper tension link number 2 arm lower tension link number 3 arm lower secondary boom number 4 arm secondary lift cylinder pinretainer compression link lower mid pivot drive limit switch primary boom rest turntable pivot upper mid pivot rest upper mid pivot Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition SECONDARY BOOM COMPONENTS 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the primar
203. otor can only be removed from the inside of the chassis Access on older machines is even more restricted The brake and motor must be removed together and then separated for repair The work area and surfaces ACAUTION 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 1 Disconnect the hydraulic hoses from the drive motor and plug them Bodily injury hazard Sprayin ACAUTION 200 Ao 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 2 Remove the drive motor mounting bolts 3 Slide the drive motor shaft out of the brake and then remove On older machines the drive motor and brake must be removed together 17 2 Torque Hub How to Remove a Drive Torque Hub The drive motor and brake must be removed in order to access the torque hub mounting bolts 1 Remove the drive motor and brake See 18 1 How to Remove a Drive Motor 2 Loosen the wheel lug nuts Do not remove them 3 Center a jack under the non steering axle Raise the machine and place blocks under the chassis to support it 4 Remove the wheel lug nuts then the tire and wheel assembly 5 Place a second jack under the torque hub for support 6 Remove the bolts that attach the brake to the hub 7 Remove
204. ould stop moving until the wedges are fully extended a oscillate lock out wedge 2 Lower the primary boom onto its resting pad Result The oscillate lock out wedges should fully retract When the primary and secondary booms are fully lowered into the stowed position and the engine is turned off the oscillate lock out wedges may partially extend This should not be mistaken for the full lock out position TABLE B PROCEDURES B 17 Test Platform Self leveling Precise 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 a hydraulic cylinder leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls then fully lower the boom into the stowed position 2 Adjust the platform to a level position using the manual platform leveling switch 3 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 18 Test the Service Horn A functional service horn is essential to safe machine operation The service horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning ho
205. ove the pin retainer from the remaining pivot pin then use a soft metal drift to remove the pin 4 Disconnect and plug the primary lift cylinder hydraulic hoses Bodily injury hazard Spraying ACAUTION 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 Crushing hazard The primary lift AWARNING cylinder will fall if it is not properly supported 5 Remove the pin retainer from the pivot pin at the barrel end of the primary lift cylinder 6 Use an overhead crane to lift the primary boom 1 inch 2 5 cm This will relieve pressure on the barrel end pivot pin 7 Support the primary lift cylinder with straps or ropes to restrict it from swinging freely 8 Place a rod through the barrel end pivot pin and twist to remove the pin a pivotpin b 10to12inch rod Crushing hazard When the ACAUTION barrel end pivot pin is removed the primary lift cylinder will swing down if it is not properly supported Part No 32960 Genie Z 45 22 7 17 Section 7 Repair Procedures Service Manual Second Edition PRIMARY BOOM COMPONENTS 3 4 Extension Cylinder The extension cylinder extends and retracts the primary boom steel extension tube It can only be removed from the platform end of the primary boom The extension cylinder is equipped with counterbalance valves to prevent movement in the event o
206. overnor check and or replace governor actuator o Continued on the next page 5 20 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 6 Turn machine off Dor remove both wires infinite from governor actuator ohms and check resistance across governor actuator terminals Continued from the previous page Replace governor actuator 2 to 3 ohms Reconnect governor Repair open in yellow wires and restart engine wire circuit from ignition and check voltage at coil to electronic electronic governor governor terminal 3 yellow wire See Maintenance section for governor adjustments OR replace electronic governor Part No 32960 Genie Z 45 22 5 21 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 7 Engine Low Idle Inoperative Gasoline LPG Models If low idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Start engine and switch rpm select to low idle turtle symbol Check voltage at terminal 30 blk red wire on CR3 Check voltage at oV terminal 30 on CR4 I 12V Check voltage at DN terminal 87A on CR4 12V
207. p 3 _ O0NO fe ooo s gt SOA x o za y ON0O 000 JG A m D 3 3 6 a A p a Bo p E R g kaj D ojoj E z 2 e 6 aye sie 5 x ojo a O CB2 CBI Oo O TS14 O O TSI3 TS12 fooo OO RPM PLAT ROTATE PLAT LEVEL TILT ALARM SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L P GAS STEER LEFT STEER RIGHT RPM GLOW PLUG START BRAKE E D C E D C 2WD 4WD SPARE AUX PWR TEMP SENDER OIL PRESSURE SENDER WARNING SENDER KEYSWITCH PWR PWR TO PLAT IGNITION PWR 12V BATT SUPPLY JIB VALVE PLAT ROT R PLAT ROT L PLAT LEVEL F C PLAT LEVEL DN PLAT LEVEL UP DRV ENA LT DRV ENA SEC BOOM DN SEC BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN ROT F C TURN ROT L TURN ROT R PRI BOOM F C PRI BOOM DOWN PRI BOOM UP r TRI N TRACTION DELAY TIMER ko 745 22 GP HP MP Index 45 GRN WHT 1 GN WT EH 44 GRN BLK 1 43 Sen 42 ORG RED 1 DG 8k 1 5 M 41 DRG BLK 0G BK_E H 40 ORG 1 WHT 40 En BU RD CR7 39 BLU RED 1 BU WT CRG 38 BLUZWHT 1 BL BK D B 37 BLU BLK 1 BU BK En BLU D B 36 BLU 1 _ BLU EH BK RD S P BK
208. peed Start engine from ground controls and standing clear of the tires momentarily move pump control override lever in each direction machine moves Move to platform isp down foot switch old drive enable switch to either side and try to drive machine drives no drive Disconnect drive pump electronic displacement controller EDC wires Check resistance across both wires on EDC side of quick disconnect Dor infinite 20 to 24 ohms Press down foot switch and check voltage at horsepower limiter board terminal 1 12V or more Continued on the next page machine does not move less than 12V Section 5 Troubleshooting Flow Charts Chart 31 Repair or replace the drive pump Place a jumper wire between TB30 and TB12 and test drive no drive Repair open in wht wire circuit from TP30 to TB30 without holding drive enable switch machine drives Replace drive enable limit switch OR repair open in wire circuits from terminal TB30 to limit switch and from limit switch to TB12 oime Replace EDC Correct insufficient voltage supply alternator or battery OR repair open in wht wire circuit supplying 12V to terminal 1 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 31 Switch rpm select Check voltage at TB41 Repair open in org blk PCE switch to rabbit with foot
209. perative Be sure all other functions operate normally If boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control Repair open in red wht function switch up and oV wire circuit with diode check volts at red wht from TB3 to proportional wire on boom function valve proportional valve suo Remove both wires from valve coil and check resistance across the coil terminals 0 or infinite ohms Replace coil 4 5 to 5 5 ohms Hold toggle switch up function operates and manually override proportional valve push in button on end of valve spool Note Overriding the valve will require two people Ifa helper is not available interchange the valve item AA with a like valve item Z Replace defective proportional valve function inoperative Hold ground control function switch up Check volts at blu wire on secondary boom function directional valve Repair open circuit in blu wire from TB10 to boom function directional valve Remove both wires from valve coil Check resistance across coil terminals 0 or infinite ohms Replace coil 4 to 5 ohms
210. perature 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine LSG 423 Coolant capacity 11 5 quarts 10 9 liters Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES D 3 Change the Fuel Lines Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel line may cause an unsafe operating condition Engine fuels are combustible A DANGER Replace the fuel lines 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 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under A DANGER z H pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them d a lA A AL A A uk J Ot a NG F O a Deutz Diesel models a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hos
211. pivot 18 Carefully remove the number 1 arm from the machine 19 Number each electrical cable and its entry location at the platform control box SECONDARY BOOM COMPONENTS 20 Open the platform control box and label each wire termination from the cables Disconnect all control cable wiring from the platform control box 21 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 22 Disconnect and plug the platform rotator hydraulic hoses at the union located near the upper mid pivot Remove the cable track assembly from the machine Bodily injury hazard Spraying ACAUTION 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 23 Remove the upper and lower cable trays from the number 2 arm Also remove the upper cable tray from the number 3 arm 24 Pull all of the cables and hoses down through the upper mid pivot Component damage hazard ACAUTION Cables and hoses can be irreparably damaged if they are kinked or pinched 25 Attach a lifting strap from an overhead crane to the upper mid pivot Then place a hydraulic jack between arm numbers 2 and 3 at the end nearest the upper mid pivot end of the arms 26 Adjust the hydraulic jack and overhead crane to relieve the pressure on the pivot pin connecting the number 2 arm to the upper mid pivot 27 Remove
212. priate safety and instructional decals are applied to the new cover Some adjustment may be necessary when a new cover is installed Turntable Covers Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition Deutz Engine F3L 1011 6 1 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM 6 2 Flex Plate The flex plate acts as a coupler between the engine and the pump lt is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 4 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts Carefully pull the pump away from the engine and secure it from moving Remove the flex plate mounting fasteners then remove the flex plate from the engine How to Install the Flex Plate 4 Install the flex plate onto the flywheel with the flat side of the spline against the flywheel Torque the flex plate mounting bolts to 34 ft lbs 46 Nm Install the coupler onto the pump shaft with the set screw toward the pump Leave a ie inch 4 7 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage haz
213. r Board The engine rpm must be correct before performing this procedure See Maintenance Procedure B 12 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the horsepower limiter board AWARNING Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry a horsepower limiter board Connect the black lead from a DC volt meter to the number 2 terminal and the red lead to the number 10 terminal 12V DC or greater ground engine rom sensor not used not used low drive speed limit switch not used not used not used output to drive controller lslelelelelelelele 0 6 8 9 GS by EZ Horsepower limiter board a A potentiometer maximum voltage output to the controller in the stowed position b B potentiometer maximum voltage output to the drive controller in the boom elevated position c C potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm Start the engine from the platform controls Move the eng
214. rd LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 Part No 32960 Genie Z 45 22 4 41 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition _ EET This page intentionally left blank 4 42 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey MI Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating the machine E Unless otherwise specified perform each repair procedure with the machine in the following configuration machine parked on a flat level surface boom in stowed position turntable rotated with the boom between the non steering wheels turntable secured with the turntable rotation lock pin key switch in the orF position with the key removed wheels chocked Before Troubleshooting H Read understand and obey the safety rules and operating instructions printed in the Genie Z 45 22 Operator s Manual H Be sure that all necessary tools and test equipment are available and ready for use H Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditio
215. re gauge at the restrictions keeping quick disconnect turntable from rotating coupling on the function OR check rotation motor manifold and hold the OR check rotation brake function switch OR check rotation torque hub function inoperative less than 2400 psi Repair rotation motor OR manifold has internal defect consult Genie Industries Service Department 5 42 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Left Function Inoperative Be sure all other functions operate normally including turntable rotate right function If turntable rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Chart 21 Hold ground control ov Repair open in wht blk function switch and wire circuit from TBS to check volts at wht blk directional valve wire on rotate function directional valve Dor Remove both wires from infinite rotate left valve coil and ohms check resistance across Replace the valve coll the coil terminals 4 to 5 ohms function Hold toggle switch left Replace the rotate and manual
216. replaced more frequently Engine fuels are combustible A DANGER ds Replace the fuel filter 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 TABLE C PROCEDURES 1 Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor la f OF a pivot plate bolts 2 Loosen the filter bracket mounting bolt Disconnect the fuel hoses from the filter then slide the filter out of the bracket 3 Install the new fuel filter in the bracket with the flow direction arrow on the filter pointing toward the carburetor Tighten the bracket mounting bolt then reconnect the fuel hoses to the filter 4 Clean up any fuel that may have spilled during the installation procedure 5 Swing the engine pivot plate back to its original position and replace the three retaining bolts 6 Start the machine from the ground controls then inspect the fuel filter and hoses for leaks ADANGER If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 10 Replace the PCV Valve
217. rn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position 2 Push down the service horn button at the platform controls Result The service horn should sound Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 19 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle mode if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Start the engine from the platform controls 2 Without pressing down the foot switch operate the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functions Result The machine functions should operate B 20 Test the Engine Speed Select A properly operating engine idle select switch is essential to good engine performance and safe machine operati
218. ro Q Component damage hazard Do ACAUTION not short vacuum switch terminals to ground Part No 32960 Genie Z 45 22 7 33 Section 7 Repair Procedures Service Manual Second Edition Ground Controls 8 1 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 to 86 represent the coil and should not be tested in any other combination terminal no 87A terminal no 85 terminal no 30 terminal no 86 terminal no 87 oO Oo CO o Test Desired result terminal 85 to 86 85 to 950 terminal 87 to 87a 8 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87a to 87 8 30 no continuity infinite Q terminal 87 to 30 continuity zero Q Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 8 2 Toggle Switches See 1 4
219. rouno R O 6 BATTERY a a ag pls o o n e Ellas ao ooo ala sw O 7 KEY Pw Slax AAA AA eee o o Te O a key ByPass M O 9 GN FUEL ON o ole o olg E O 10 ENG FAULT O o ole O ols lt a gt o olp 0 O 2 aR o 3 gi ooo Z o N o e je ooo D S D D e D DIODE x 000 3 DOG led 8 9 BLOCKS B O PRE E g 3 ooojg oooja g 9 a z D D CR1 CR2 CR3 CR4 3 GE START FUEL RPM RPM _ OONO E 000 Jr RELAY RELAY CUTOUT RELAY D Os Ok Ki a RELAY O NOO 000 JG zz S 3 A G a E l i II i II II a 5 E CG FEE si Z A CR5 e oS A ie Li HORN oro ln J gt RELAY sl a o ls lt Llz EE la D CH olo 2 g z ej E O ole Jo S E D za Pot l 2 E E SES o lt S CRY CRIO CR11 OE fe OSCILLATE OSCILLATE OSCILL TE gt RELAY LOCKOUT LOCKOUT vol RELAY RELAY al EL II Z45 22 Diesel HP MP Index PR1 O 745 22 2WD amp 4WD DEUTZ DIESE PLATFORM CONTROL BOX LEGEND SERIAL Z45 001524 TO 5050 45 GRN WHT 1 44 GRN BLK 1 43 GRN 1 42 ORG RED 1 41 ORG BLK 1 40 ORG 1 39 BLU RED 1 38 BLU WHT 1 37 BLU BLK 1 36 BLU 1 35 BLK RED 1 34 BLK WHT 1 33 BLK 1 32 WHT RED 1 31 WHT BLK 1 30 WHT 1 29 RED WHT 1 28 RED BLK 1 27 RED 1 26 BLK F S 25 GREEN F S 24 WHT H P L JN Wi
220. rriding valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative Install a pressure gauge at quick disconnect coupling on rotate function manifold and hold function switch 2400 psi or more 2400 psi Interchange check valve function operates item H with like valve item L function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department Replace the coil Replace platform rotate directional valve Check for mechanical restrictions OR hydraulic rotator or function manifold has internal defect Consult Genie Industries Service Department Replace defective check valve Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 27 Platform Hold ground control oh nm wire i function switch and circuit from to Rotate Rig ht check voltage at grn directional valve i wire on platform rotate Fu nction right function directional inoperative valve Be sure all other functions operate normally If platform rotate right function operates normally from the ground controls but not from platform controls troubleshoot the platform control toogle switch See Repair section If platform rotate right function operates normally from the platform controls but not from the ground co
221. rt No 32960 Section 7 Repair Procedures Service Manual Second Edition FAA 2WD DRIVE MANIFOLD 18 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge in between one of the medium pressure hydraulic hoses and the medium pressure hydraulic oil filter Bodily injury hazard Spraying ACAUTION 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 2 Start the engine from the platform controls 3 Drive the machine in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap index 14 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then reinstall the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Specifications Relief valve 320 psi 22 bar 7 62 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures A gt gt gt gt gt gt gt gt gt gt SS 2WD DRIVE MANIFOLD This page intentionally left blank Part No 32960 Genie Z 45 22 7 63 Section 7 Repair Procedures Service Manual Second Edition 4WD Dr
222. rvice Department Repair open in org blk wire circuit from TB41 to horsepower limiter board Repair open in org blk 41 wire circuit from alternator to TB41 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts CHART 33 Continued from the previous page Press down the foot switch and check voltage at terminal TB29 12V Press down foot switch and check voltage at red wht 29 wire on the motor stroke solenoid valve item N Press down foot switch and check voltage at red wht 29 wire on terminal 6 of time delay relay TR1 Press down foot switch and check voltage at blk FTR1 wire on terminal 1 of time delay relay 12V Continued on the next page Service Manual Second Edition Press down foot switch and check voltage at TP29 Press down foot switch and check voltage at red wht wire on drive mode select switch DV Press down foot switch and check voltage at wht wire supplying 12V to drive mode select switch DV Repair open in wht wire circuit supplying 12V to toggle switch deed open in red wht 29 wire circuit from TB29 to stroke solenoid valve Repair open in red wht 29 wire circuit from TB29 to time delay relay Check voltage at wht 21 wire on terminal 3 of time delay relay 12V Check ground wire to time delay relay good Replace time delay relay 12V bad Repair open in red wht wire circuit from TP29 to
223. rvice Manual Second Edition Section 4 Scheduled Maintenance Procedures 6 Loosen the counterwight positioning bolt then remove the 2 mounting bolts 7 Carefully lower and remove the counterweight 8 Be sure that each bearing mounting bolt is torqued in sequence to 190 foot pounds 258 Newton meters 10 1 15 13 7 O O e OO u 9 2 Bolt torque sequence 9 Reinstallthe counterweight C 3 Check the Free wheel Feature Proper use of the 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 result in death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Non steering wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 5000 lbs 2268 kg under the chassis between the rear drive wheels 3 Lift the wheels off the ground and then place jack stands under the chassis for support TABLE C PROCEDURES 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub disengage position mj e mj NY engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub
224. s 7 to8 9to 11 M 8 x 20 Torx 8 8 Oil intake housing bolts 15 to 18 20 to 24 M 8 x 75 Torx Fuel pump bolts 15to 18 20 to 24 Injection pump bolts 15 to 18 20 to 24 Injector cap nut 30 to 37 40 to 50 Injector fastening bolt 15 to 18 20 to 24 Injection line 10to12 13 5to 16 5 Air intake manifold bolts 15 to 18 20 to 24 M 8 x 30 8 8 Air intake manifold 3 hole 15 to 18 20 to 24 flange bolts M 8 x 35 Torx 8 8 Exhaust manifold bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Starter fastening bolts 28 to 34 38 to 46 M 10 x 28 8 8 Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Oil pan bolts 15 to 18 20 to 24 M 8 x 16 Torx 8 8 Oil drain bolts 37 to 44 50 to 60 Service Manual Second Edition P gt R L262 gt gt gt gt gt Q gt 2Z A torque torque ft lbs Nm Oil thermostat housing screw 37 to 44 50 to 60 plug M 38 x 1 5 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 M 6 x 35 Torx 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 M 6 x 80 Torx 8 8 Oil thermostat housing bolts 14 to 16 19 to 22 M 6 x 105 Torx 8 8 Valve plunger housing bolts 14 to 16 19 to 22 M 8 x 30 Torx 8 8 Alternator nuts M 5 3 4 Fuel bracket bolts M 8 x 20 8 8 15 20 Adapter housing bolts 70 to 77 95 to 105 M 12 x 35 10 9 or M 12 x 75 10 9 first step second step tightening tightening torque angles ft los Nm ist 2nd Main bearing bolts 37 50 60 45 B
225. s down the foot switch O Result The engine should change to high idle Gasoline LPG models Low idle 1400 rpm High idle 2150 rpm Deutz Diesel models Low idle 1300 rpm High idle 2300 rpm Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 21 Test Fuel Select Operation Gasoline LPG Models The ability to select and switch between gasoline and LP 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 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 propane gas fuel levels and warming the engine to normal operating temperature 1 Move the fuel select switch to gasoline and then move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the 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 4 Release the foot switch and stop the engine Move the fuel select switch to propane gas 6 Restart the engine and allow it to run at low idle 7 Press down the
226. s pins from the ends of the tie rod 2 Remove the tie rod weldment Always use a new cotter pin when re installing a clevis pin How to Perform the Tie Rod Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the fully stowed position 2WD STEERING AXLE COMPONENTS 5 Remove the cotter pin then remove the clevis pin from the adjustable end of the tie rod 6 Slide the tie rod off the yoke and adjust it by turning the end One half turn on the adjustable end equals a 3 16 inch 5 mm change in the front to rear measurement 7 Slide the tie rod onto the yoke Install the clevis pin then a new cotter pin 8 Tighten the jam nut against the tie rod 9 Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Specifications Tie rod adjustment 1 4 inch 0 635 mm toe in to 1 4 inch 0 635 mm toe out Measure 15 inches 38 cm up from the ground on the front and rear of each steer tire and make a reference mark at the center of the tire Measure the distance from the reference points on each tire Front to front and back to back Center a jack under the steering axle then raise the machine Loosen the jam nut on the adjustable end of the tie rod Part No 32960 Genie Z 45 22 7 53 Section 7 Repair Procedures Service Manual Second Edition
227. se using a tee fitting counterbalance valves Operate boom up function and read the pressure less than 2400 psi Deadhead the pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the boom one inch at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed 2500 psi Repair or replace the master cylinder 2400 psi or more Repair or replace the slave cylinder Chart 23 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 24 Platform Level Up Function Inoperative Be sure all other functions operate normally If platform level up function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform level up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org wire on platform level up function directional valve Dor Remove both wires from infinite valve coil and check ohms resistance across the coil terminals 4 to 5 ohms Hold toggle switch and manually override the level up directional valve push in button on end of valve spool Note overriding
228. shooting Flow Charts Service Manual Second Edition Chart 16 Primary Boom Up Function Inoperative Be sure all other functions operate normally If boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section proportional valve en Hold ground control Repair open in red wht function switch up and OY wire circuit with diode check volts at red wht from TB3 to proportional wire on boom function valve 0 or infinite ohms Remove both wires from valve coil and check resistance across the coil terminals 4 5 to 5 5 oh Hold toggle switch up and manually override proportional valve push in button on end of valve spool Note Overriding the valve will require two people If a helper is not available interchange the valve item AA with a like valve item Z ms Replace coil function operates Replace defective proportional valve function inoperative i Hold ground control function switch up Check volts at red wire on boom function directional valve 12V Remove both wires from valve coil Check resistance across coil terminals 4 to 5 ohms i Interchange f
229. stor Replace The Hydraulic OU 4 35 D 2 Change or Recondition the Engine Coolant eesssseeessseeerreessirerrreerreeesns 4 36 D 3 Change the Fuel Lines ooooccinccninnncccnnnccccnnaccconanoncnnononcnnnnnc cnn nn nn nan rca 4 38 D 4 Check Engine Valve Clearance Gasoline LPG Models 4 39 D 5 Check Engine Cylinder Compression Gasoline LPG Models 4 39 D 6 Clean PCV Hoses Tubes and Fittings Gasoline LPG Models 4 40 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 41 D 8 Check the Toothed Belt Deutz Diesel Models 1 4 22122 4 41 D 9 Replace The Timing Belt Gasoline LPG Models s nnnnssnnnnnnssnnnnnnnnnnnnnnene 4 41 Part No 32960 Genie Z 45 22 ix Service Manual Second Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts IMtOCUCTION Asaira haier ai idad 5 1 1 Engine Will Not Crank Over eee ee ass ae aaa aaa rana 5 3 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 5 5 3 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 12 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Model 5 15 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasolin6 EPG MOdEIS u easy nan Z EO a SE ad Pest 5 17 6 Engine High Idle Inoperative Gasoline LPG Models
230. t Replace key switch Repair open in red wire circuit from key switch to function switches 5 28 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 13 Platform Does engine start from yes Start engine from the ON Test and replace foot Controls the platform controls platform then press switch OR repair open down the foot switch in wht wire circuit from Inoperative au EES voltage at foot switch to TP24 Ground 12V Controls no Operate Repair open in wht wire circuit from TP24 to Normal ly function controllers y Be sure all Check voltage at TB22 EEN Check for open in red cables are in good wire circuit from key condition with no oe to TB22 OR kink bei 12V eplace the key switch INKS or abrasions platform contacts gt ov Check voltage at TP22 Repair open in blk 2 wire circuit from TB22 TP22 12V E Check voltage at blk OV Replace contact on wire on platform r emergency stop button emergency stop button 12V oV S 8 Check voltage at TP23 Repair open in blk wire circui from emergency 12V stop button to TP23 Repair open in blk wire circuit from TP23 to foot switch OR replace foot switch Part No 32960 Genie Z 45 22 5 29 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 14 Secondary Boom Up Function Ino
231. t screw clockwise to increase the voltage or counterclockwise to decrease the voltage PLATFORM CONTROLS 8 Set the dual lo range Turn the trimpot adjustment screw clockwise 15 turns or until you hear a click This is the only dual range adjustment for this controller Engine should be at normal operating temperature 9 Start the engine and move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol Rotate the turntable to the full right position 10 Start a timer and record how long it takes the turntable to rotate to the ful left position Adjust the max out trimpot to achieve a 71 to 75 second cycle time Turntable rotation specifications Threshold 3 35V DC 6 26V DC 71 to 75 seconds Turntable rotation Max out Cycle time Part No 32960 Genie Z 45 22 7 5 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 1 2 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output It reads engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to keep the engine from stalling Three adjustments are required for optimum performance How to Adjust the Horsepower Limite
232. t to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Reportto use for each inspection Store completed forms for three years Part No 32960 Genie Z 45 22 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Maintenance Tables Warm Cold Dealer Table A Tools are New parts engine engine service required required required required suggested A 1 Inspect the Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check Tire Pressure A 10 Test the Platform and Ground Controls A 11 Test Auxiliary Power Operation A 12 Test the Tilt Level Sensor A 13 Test the Limit Swit
233. table pivot 44 Carefully remove the number 3 arm from the machine 45 Position the strap from an overhead crane around the top tube of the lower mid pivot and then carefully lift the lower mid pivot until it is vertical 46 Remove the pin retaining fastener from the lower mid pivot to number 4 arm pivot pin Use a soft metal drift to remove the pin 47 Support the compression link by hand then carefully lift the lower mid pivot up and over the compression link and off of the machine SECONDARY BOOM COMPONENTS 48 Lower the compression link to a resting position Then attach the lifting strap from an overhead crane to the compression link and raise it to a vertical position 49 Remove the pin retaining fastener from the compression link to number 4 arm pivot pin Use a soft metal drift to remove the pin 50 Remove the compression link 51 Position the lifting strap from an overhead crane at the center of the number 4 arm 52 Remove the pin retaining fastener from the turntable pivot to number 4 arm pivot pin Use a slide hammer to remove the pin Crushing hazard If the overhead AWARNING crane is not properly attached the number 4 arm may become unbalanced and fall when it is disconnected from the turntable pivot 53 Carefully remove the number 4 arm Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition SSS SECONDARY BOOM COMPONENTS a ACAUTION pycraui
234. tch 14 Drive the boom for 20 feet 6 1 m and record the elapsed time Do this again in the opposite direction 15 Adjust the B potentiometer to obtain the correct elevated drive speed of 1 foot per second 30 5 cm per second 16 Close the platform control box lid and re install the fasteners Drive speed specifications Stowed position high range distance 20 ft 6 m 2WD 2 85 seconds 0 25 seconds 4WD 2 75 seconds 0 25 seconds Boom raised high range distance 20 ft 6 m 2WD and 4WD 1 foot per second 30 5 cm per second Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition OOOO PLATFORM CONTROLS 1 3 1 4 Foot Switch Resistors How to Test the Foot Switch Two resistors are used to maintain proper control of drive speeds Both resistors are located in the 1 Turn the keyswitch to the off position and platform control box disconnect the wiring quick disconnect plug from the platform toe board How to Test the Resistors 2 Do not press down the foot switch Connect the 4 Turn the keyswitch to the off position and set leads from an ohmmeter or continuity tester to the drive mode select switch to high range each wire connector combination listed below two wheel symbol and check for continuity 2 Connect the leads from an ohmmeter to each end of the resistor being tested Test Desired result lack sh 3 Compare the ohmmeter reading with the
235. tch to CR6 to CR7 Repair open in ground to terminal 85 on CR7 Chart 4 Part No 32960 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 4 Continued from the Hold start switch and Replace CR7 relay i check voltage at previous pagg terminal 87 on CR7 Hold start switch and Repair open in blu red check voltage at blu red wire circuit from CR7 wire on LPG solenoid terminal 87 to LPG solenoid Dor infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department 5 16 Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models Be sure fuel select switch is switched to gasoline Be sure to check gasoline fuel level Be sure that engine choke is operating properly With keyswitch on and both mushroom switches pulled out check voltage at gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both mushroom switches pulled out check voltage at TB38 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal 30 on CRG 12V Cran
236. te gradually Do not allow oil to squirt or spray 3 Remove the fasteners that secure the upper cable track tray to the primary boom 4 Loosen the fasteners that secure the lower cable track tray Tie the upper and lower cable tracks together with wire ties Remove the cable track assembly from the primary boom a woodblock b tie wrap c plastic cable track Component damage hazard The ACAUTION primary boom cable track can be damaged if it is twisted 5 Raise the secondary boom and place a 4x4x31 inch 78 cm block between the chassis counterweight and upper mid pivot Carefully lower the secondary boom onto the block a Uppermid pivot b 4x4x31 inch block c counterweight Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 6 Raise the end of the primary boom 8 feet 2 5 m off the ground then extend the primary boom 5 inches 12 5 cm 7 Attach an overhead crane to the primary boom Do not lift the primary boom AWARNING Crushing hazard If the overhead crane is not properly attached the primary boom may become unbalanced and fall when it is disconnected from the upper mid pivot Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 8 Disconnect and plug the extension cylinder and the platform leveling master cylinder hydraulic hoses Cap the extension cylinder fittings Bodily injury h
237. ter 8 Fill the engine with new oil per specifications and replace the oil filler cap 9 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off TABLE B PROCEDURES 10 Check the oil filter and oil pan for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F3L 1011 Oil capacity including filter 8 5 quarts 8 liters Deutz Engine F3L 1011 Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table C Procedures C 1 Check the Primary Boom Wear Pads Maintaining the primary boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom surfaces to provide alow friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Start the engine from the ground controls and raise the end of the primary boom to a comfortable working height chest high 2 Extend the extension boom 10 inches 25 cm 3 Measure each wear pad Replace the pad if it is less t
238. the valve will require two people If a helper is not available interchange the valve item O with a like valve item N function inoperative Interchange check valve item L with like valve item K function inoperative 2400 Install a pressure gauge psi or at the quick disconnect more coupling on the function manifold and hold the function switch less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department function operates function Operates Repair open in org wire circuit from TB14 to directional valve Replace the coil Replace the platform leveling directional valve Replace defective check valve Interchange the 2400 level up and down psror counterbalance valves more items B amp C function operates Replace defective counterbalance valve Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally If platform level down function operates normally from the ground controls but
239. the pin retaining fastener from the upper mid pivot to number 2 arm pivot pin Use a slide hammer to remove the pin Crushing hazard The upper AWARNING Ad chat will fall if it is not properly supported when the pivot pin is removed Part No 32960 Genie Z 45 22 Section 7 Repair Procedures Service Manual Second Edition SECONDARY BOOM COMPONENTS 28 Carefully lift and remove the upper mid pivot from the machine 29 Position the lifting strap from an overhead crane at the center of the number 2 arm 30 Remove the pin retaining fastener from the lower mid pivot to number 2 arm pivot pin Use a soft metal drift to remove the pin Crushing hazard If the overhead AWARNING crane is not properly attached the number 2 arm may become unbalanced and fall when it is disconnected from the mid pivot 31 Carefully remove the number 2 arm from the machine 32 Remove the two cable clamps from the inside of the lower mid pivot 33 Disconnect and remove the drive speed limit switch from the primary boom rest 34 Disconnect and plug the hydraulic hoses at the secondary lift cylinders Bodily injury hazard Spraying ACAUTION 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 35 Remove the pin retainers from each secondary lift cylinder barrel end pivot pin 36 Place a rod through each barrel
240. to the on position Part No 32960 Genie Z 45 22 4 5 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES 2 Simultaneously hold the auxiliary power switch on while activating the following functions through a partial cycle primary boom up down extend and retract secondary boom up down turntable rotate right left Result Each function should operate smoothly 3 Turn the key switch to platform control 4 Atthe platform controls pull out the Emergency Stop button to the on position press down the foot switch 5 Simultaneously hold the auxiliary power switch on while activating the following functions through a partial cycle primary boom up down extend and retract secondary boom up down turntable rotate right left steer left right A 12 Test the Tilt Level Sensor The tilt sensor sounds an alarm in the platform when the incline of the chassis exceeds 4 5 Select a level test area 1 Start the engine from the ground controls 2 Open the engine side cover and press down on one side of the tilt sensor Result After a 1 5 second delay the alarm in the platform should sound A 13 Test the Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive enable limit switch activates a signal light to inform the operator that the platform is past the non steer
241. ued 7 2 Choke Adjustment AE 7 30 73 TIMING el E ET 7 30 7 4 Carburetor Adjustment eee aaa cnn nan n cn rana 7 30 7 5 RPM AQjustment zaawan olineks WERE RIAA 7 30 T6 Hex WC 7 31 7 7 Water Temperature and Oil Pressure Switches ooonnnncinnnninninnononnconncnncnns 7 32 728 Vacuum Switeh ca a Seaia aa iaai 7 33 Ground Controls 8 1 Control Relays oia aa 7 34 8 2 Toggle Switches See 1 5 Toggle Switches oooooonccccnnoncccccoocccnnacccononannccnonnnnn 7 9 8 3 Wago Components eee ee eee aaa nc 7 35 A A dA ste ated sien N Ae ee Ee AGA Dee EE 7 35 8 5 Power Relay u aus oo dt a ta Aya dd 7 36 Hydraulic Pumps 9 1 EUSteerPUMpa sacz ada raid pa 7 37 9 2 Drive Hydraulic Pump scenes rinnen N EE R 7 38 Function Manifold 10 1 Function Manifold Components oooccconnccccnnncccnonacnccnonncnnnnn aaa aaa aaa 7 40 10 2 Valve Adjustments eorura cnn nano aaa aaa 7 42 Fuel and Hydraulic Tanks 111 Hydraulic RE 7 44 Tre TE ati di das 7 45 Turntable Rotation Components 12 1 Rotation Hydraulic Motor oooonincccccnnnnnccccccnnnnononccnncnnnonnnnn cnn nn rr narrar rra 7 46 12 2 Rotation Bearing and Worm Drive oooonnnnncccnnnnnnocccncnnnonnnnnnnnnnnnnnnn cnn nnn nana 7 46 2WD Steering Axle Components 1321 Yoke UD ii daa 7 51 13 2 Steering Cylinders eeeeseea aaa aaa aaa 7 52 Part No 32960 Genie Z 45 22 iivx Service Manual Second Edition A 2 4 TABLE OF CONTENTS Section Seven Repair Procedures continued 13 3 Te
242. ug nuts on both steer tires Do not remove them 18 Center a lifting jack under the steering axle Lift the machine until the tires are just off the ground 19 Support the chassis on blocks then remove both steer tires and wheel assemblies to improve access when removing the turntable 20 Prepare a forklift with a minimum rating of 18 000 pounds 8165 kg by spreading the forks to an inside width of 3 feet 0 9 m 21 Position the forklift at the counterweight end of the turntable Center the forks underneath the turntable and above the chassis Do not lift 22 Place a 5 inch 13cm tall block near the end of the forks for support a forks b block 23 Raise the forks up against the turntable Do not lift Be sure that the support block is still in its proper location 24 Place a safety strap around the upper mid pivot then secure the strap to the forklift carriage 25 Remove the turntable mounting bolts 26 Carefully lift the turntable off the chassis Set the turntable on blocks for support 27 Place reference marks on the chassis to note the position of the worm drive housing for proper re alignment during re installation 28 Remove the fasteners from the worm drive then remove the worm drive 29 Center the forklift forks under the chassis counterweight for support 30 Loosen the counterweight positioning bolt 31 Remove the fasteners from the counterweight 32 Carefully lower the counterweight from the
243. ustries PO Box 69 Redmond WA 98073 0069 USA If you have any questions call Genie Industries Genie North America Telephone 206 881 1800 Toll Free in U S A 800 536 1800 Toll Free in Canada 800 426 8089 Fax 206 883 3475 Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 Genie Industries Copyright O 1994 by Genie Industries Second Edition First Printing August 1994 Genie0 is a registered trademark of Genie Industries Registered 2009987 These machines comply with ANSI SIA 92 5 1992 Printed on recycled paper Patents Pending Printed in U S A ii Genie Z 45 22 Part No 32960 Service Manual Second Edition Important Verify Correct Manual Do not read any further until you have verified that this is the correct manual for this machine Contact Genie Industries if you have any questions This manual covers the Genie Z 45 22 2WD and AWD models produced from May 1994 starting with serial number Z 45 001523 TW m Ka The serial number plate is cja located under the engine side turntable cover It is secured to the bulkhead near the hydraulic pump Use the Genie Z 45 22 Service Manual First Edition part number 29487 to service machines not covered in this second edition Do not use this manual with the Genie Z 45 22 DC Bi fuel Tri fuel Diesel and Gas LPG models Compare turntable cover size and shape Part No 32960 Genie Z 45 22 iii Service Manual
244. vals may cause the machine to perform poorly and continued use may cause component damage 1 Select the torque 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 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs and then install the plugs 5 Repeat steps 1 through 4 for all the other drive torque hubs Specifications Capacity 17 fluid ounces 0 5 liters Type SAE 90 multipurpose hypoid gear oil API classification GL5 TABLE C PROCEDURES C 6 Replace the Hydraulic Tank Filter Replacement of the hydraulic tank filter 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 filter be replaced more frequently Beware of hot oil Contact with hot ACAUTION oil may cause severe burns Perform this procedure with the engine off 1 Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter part no 20293 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Start the engine
245. x4x31 78 cm block between the chassis counter weight and the upper mid pivot Carefully lower the secondary boom onto the block a Uppermid pivot b 4x4x31 inch block c counterweight Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 2 Raise the primary boom uniil the end of the boom is approximately 7 feet 2 m off the ground Then shut off the engine 3 Locate the grease fitting on the inside of the bearing in the middle of the turntable 4 Pump grease into the rotation bearing until you see it coming out of the bearing seal gap Repeat this step with the platform in the following locations platform over the drive wheels platform over the left side platform over the drive wheels platform over the right side Crushing hazard Turn the key AWARNING switch to the off position and remove the key while pumping grease 5 Locate the grease fitting on the worm drive housing a greasefitting b grease overflow 6 Pump grease into the gear until you see it coming out of the side of the gear housing Specification Multipurpose grease Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly inter
246. y adjust the controller 2 Turn the key switch to platform control and pull the Emergency Stop button to the on position at both the ground and platform controls Do not start the engine Genie Z 45 22 Part No 32960 Service Manual Second Edition Section 7 Repair Procedures 3 Open the platform control box lid and locate the turntable rotate controller dual lo adjustable trimpot ramp rate adjustable trimpot terminal R activates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot 70 O Oo o 4 Set the ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until you hear a click then turn the screw counterclockwise 5 turns 5 Connect the red lead from a volt meter to the A terminal on the controller PC board Connect the black lead to ground 6 Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 3 35V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Set the max out Press down the foot switch then move the control handle all the way to the full right or full left position Adjust the voltage to 6 26V DC Turn the max out trimpot adjustmen
247. y boom See 3 2 How to Remove the Primary Boom Crushing hazard Do not remove AWARNING the 4x4x31 inch 78 cm support block installed during primary boom removal a Uppermid pivot b 4x4x31 inch block c counterweight 3 Use an overhead crane to attach a lifting strap to the rod end of the primary lift cylinder Then raise the primary lift cylinder with the crane to a vertical position 4 Remove the pin retainer from the pivot pin at the barrel end of the primary lift cylinder 5 Place a rod through the barrel end pivot pin and twist to remove the pin Remove the primary lift cylinder from the machine Crushing hazard The primary lift AWARNING ARR cylinder will fall if it is not properly supported when the barrel end pivot pin is removed a pivotpin b 10to12inch 30 cm rod Remove the turntable end cover Be sure that the upper mid pivot rest is in the industrial tire position Machines equipped with Rough terrain tires Move the upper mid pivot rest up into the industrial tire position on the mid pivot Industrial tires No modification is necessary upper mid pivot mounting position holes for rough terrain tire models upper mid pivot rest d mounting position holes for industrial tire models ow o 8 Attach the lifting strap from an overhead crane to the number 1 arm at the end nearest the upper mid pivot and lift to support Remove the pin retainers from the tw
248. y functioning drive enable system may allow the boom to be moved into an unsafe position 1 Start the engine from the platform controls 2 Rotate the turntable to the right until the platform is positioned over the right non steer wheel Result Platform over non steer wheel indicator light should turn on Part No 32960 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 3 Slowly move drive control handle off center Always use the color coded ACAUTION Y direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel O Result Drive function should not operate 4 Hold drive enable toggle switch to either side and slowly move the drive control handle off center O Result Drive function should operate 5 Rotate the turntable to the left until platform is positioned over the left non steer tire Result Platform over steer wheel indicator light should come on 6 Repeat steps 3 and 4 B 24 Test the Drive Brakes Proper brake action is essential to safe machine operation The Brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when not fully operational Be sure that the machine is not in free wheel or partial free whee

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