Positive Air Shutdown Valve Supplement to 13A
Contents
1. 4567 TROMBETTA Genie Industries UN 4 TOREMOVE 1 STARTRELAY C32 bed di S 2 Pushgently gt 2 TACHOMETER 1345678 12 6 3 andiit 3 START INPUT vom ola 4 AUX PWR UNIT ols 5 GROUND AA S S 2 O6 6 BATTERY ANA A 8 o lg 7 7 TO KEY SW DIESEL ONLY g o 8 JUMP TO 7 GAS ONLY g 8 A m9 918 9999999 o IGNORFUELON IS O ho 10TEMP OR PRESS FAULT i N S 12 24 Volt IGNITON START MODULE EN D C TERMINAL BASE TB B A S 8 3 O O PRIMARY BOOM UP io o 2 O O 2 PRIMARY BOOM DOWN 210 o OA il 2 O O 3 PRIMBOOMFUNCCONTROL 3 O O g 9 S 9 o om Zoo ei 3 O O 5 TURNIABLEROTATERIGHT 5 0 O A BATTERY ee 5 O O 6 TURNTABLE ROTFUNCCTRL 6 0 O O 7 PRIMARY BOOM EXTEND Too 2 O O 8 PRIMARY BOOMRETRACT 8 0 O o ES O O 10 SECONDARY BOOM UP ijo o o d 9 O O M SECONDARYBOOMDOWN 1i O O CB 2 O 12 SECBOOM FUNC CTRL i20 O Bed O O i4 PLATFORM LEVEL UP ijo o CR6 SOLENOID RELAY BREAKER CONTROL MODULE O O 15 PLATFORM LEVEL DOWN Bjo o 30 Q O O IT PLATROTATELEFTUIBUP_77 0 O 85 D Q O O 18 PLAT ROTATE RIGHT JIB DOWN 18 O O o o O O 20 X12 VOLT POWER 20 O O 90299229 5 a 1523925 9 O O BLIGNITION POWER ajo o 9 O O 22 412 VOLTTO PLATFORM 22 0 O m 2 o O O 23 KEYSWITCH POWER 23 O0 O O S d E 9 O O 24 CBi POWER Bo o o o IS 9 o SE a a3 5 2 IS S Eo gl 3 m 2 O O 25 O2. January 2013 Ex EE EE EE EE EE t Section 1 es Parts Information REV B ENGINE COMPONENTS tem PartNo Description Qty 1 101957 Solenoid 12V DEERE li SE vo de x bie e AT REIS ER ER ee bua AENEA Ge dd Cu 1 2 6357 Hex Nut 1 4 20 GR 2 esse see ee ee ee eed E ee ee EE Ee ee ee ee ee E anna nana 2 3 6638 Flat Washer 1 4 inch 5 icc i reel ende GE GO EO 2 4 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 Nt 2 5 21130 Clevis Yoke 4228 a adas 1 6 21496 Nuts 1 4228 GR 25 sg OE EE RE RE ud sa EE 1 7 6888 Screw HHC 1 4 20 x 1 inch GpRp teatrais 1 8 6091 NAAA 1 9 128079 Gasket Deutz Adapter ereta narra nn nn ee ee eke de ee ee ee 1 10 128065 Valve Positive Air Shutdown with Deutz Adapter ppp 1 Genie PartNo 128269 Z 45 25 0 Z 45 25J 5 January 2013 Section 1 es Parts Information REV B Chassis Components e 2 P NX REED RRS RE EEH Ce EE Ground Control Box Part No 128269 Z 45 25 Z 45 25J January 2013 Section 1 es Parts Information REV B ltem PartNo Description 128064 Wire Harness Positive Air Shutdown 1 61211 Circuit Breaker TA neue Roda eri a e adia Ari donas tunada 2 75044 Screw PHPM 10 32 x 1 inch Nt 3 6178 Nylock Nut 10 32 id nec ee ate itta el 4 128067 Positive Air Shutdown Controller ps 128068 Positive Air Shutdown System Software 110984 Control Module 128069 C
3. January 2013 Section 2 Maintenance Procedures Maintenance Procedures REV B A 3 1 Test the Automatic Engine Overspeed Control System Genie specifications requires that this procedure be performed daily or every 8 hours whichever comes first Regular testing the automatic engine overspeed control system is essential to safe machine operation Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition Component damage may result Note Perform this procedure with the machine on a firm level surface 1 Pull out the red Emergency Stop Button to the on position at both the ground and platform controls 2 Turn the key switch to ground control Start the engine from the ground controls and allow it to idle 3 Locate the test toggle switch on the side of the ground control box Move and hold the toggle switch to the TEST position 4 Activate high idle rabbit symbol Result The engine should shut off Wi Result The engine does not shut off Consult the Genie Service Department A TEREX COME Z 45 25 e Z 45 25J 11 Part No 128269 5 Wait approximately 5 to 10 seconds for the solenoid valve to reset 6 Startthe engine from the ground controls O Result The engine should start and operate normally w Result The engine does not start Consult the Genie Service Department Section 2 M
4. Genie A TEREX BRAND Parts and Service Supplement Positive Air Shutdown Valve Serial Number Range Z 45 25 before Z452513A A7001 Z 45 25 Part No 128269 Rev B January 2013 Introduction January 2013 Important Read understand and obey the safety rules and operating instructions in the Genie Z 45 25 and Genie Z 45 25J Operator s Manualbefore attempting any maintenance or repair procedure This manual provides detailed parts and service information for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us PO Box 97030 Redmond WA 98073 9730 USA www genielift com e mail awp techpub O terex com Genie ke This Parts and Service Manual Supplement provides s
5. IL PRESSURE SWITCH 25 O O E gt w w D m CH BB 8 mg 2 oR BS AIS Tebi O O 26 OILTEMPERATURESWITCH 26 0 O SES EE 8 pR sREE RONTEST SWITCH O O 27 AUXILIARY PUMP 27 0 O O O 82 BRAKE 320 O O O 33 START ENGINE Bjo o O O 84 GLOW PLUG so o O O 85 HIGH RPM 350 O 38 SPARE 38 TEST GR 8 opt 9 9 39 SPARE 39 C41 OR BK 9034 2 is d O O W ALTERNATOR PULSE PICKUP oi cf o P134 RD A amp O O 42 SPARE 4210 O 2 O O 44 JIBDOWNDESCENTALARM 44 O O o 9 8 O O 134 KSPOWER 134 o 5 q E o 184A KS POWER iBA lO o D o D El D C B A ES CR1 CR2 CR4 CR23 IGNITION POWER HIGH RPM DRIVE LIGHT START RELAY SOLENOID OPTION RELAY o RELAY RELAY amp Ze i W fat GROUND BOLT jj CR5 CR32 CR33 CR37 HORN PRIMARY TURNTABLE SECONDARY RELAY BOOM ROTATE BOOM RELAY RELAY RELAY enie A TEREX COMPANY Part No 128269 Z 45 25 e Z 45 25J 15
6. aintenance Procedures January 2013 MAINTENANCE PROCEDURES REV B A 9 1 Lubricate the Lever Shaft Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Perform this procedure more often if dusty conditions exist Lubrication to the lever shaft is essential to safe machine operation Continued use of an improperly lubricated lever shaft could result in a positive air shutdown control system malfunction during an engine overspeed condition Component damage may result 1 Locate the lever shaft on the shutdown valve assembly 2 Applya liberal coating of grease to the shaft end surfaces on both sides of the valve Refer to Illustrations 1 and 2 Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Illustration 1 a b c d solenoid shutdown valve assembly lever shaft air intake tube Illustration 2 Genie ke 12 Z 45 25 Z 45 25J Part No 128269 January 2013 Section 3 Schematics REV B Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine E Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting H Read understand and obey the safety rules and operating instruction
7. ervice parts information and electrical schematics for the recently released Positive Air Shutdown System which are not included in your parts or service manuals Please add this parts information and electrical schematics to the parts and service manuals for your machine Copyright O 2011 Terex Corporation 128269 Rev B January 2013 First Edition Second Printing Genie and Z are registered trademarks of Terex South Dakota Inc in the USA and many other countries es Printed on recycled paper Printed in U S A 2 Z 45 25 Z 45 25J Part No 128269 January 2013 Introduction Table of Contents Introduction Important Information isi Ee cee ds Se EE ESE d tke EE DEE GE ee cleric behead 2 Section 1 Rev Service Parts B EngineComponents Nt 4 B Chassis Component iii rt eer apti re n D ER Ke EE ee Re DE Ee re EK Oe ee es 6 Section 2 Rev Section 3 Rev Maintenance Procedures Maintenance Inspection Report eee 10 A 3 1 Test the Automatic Engine Overspeed Control System pp 11 A 9 1 Lubricate the Lever Shaft A 12 Schematics dese ie p 13 System Wiring Diagram Nt 14 Ground Control Box Wiring Diagram errantes 15 Genie Part No 128269 Z 45 25 e Z 45 25J 3 January 2013 Section 1 es Parts Information REV B Engine Components W A 0 o t ASX NE l V ES y N QNI Z 45 25 Z 45 25J G Part No 128269
8. move from service a damaged or malfunctioning machine EI Repair any machine damage or malfunction before operating machine H Keep records on all inspections for three years H Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 128269 A TEREX CON Z 45 25 e Z 45 25J 9 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend A Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous sit
9. ontrol Module Label 5 6091 Nylock Nut 4 20 tender e ance SE a Gee 6 6638 Flat Washer 1 4 inch Re nnn 7 6884 Screw HHC 1 4 20 x 2 5 inches G 8 49826 Screw PHPM 10 32 x 0 625 inch GP 9 61225 Relay KEE 10 8915 Screw HHC 1 4 20 x 1 25 inches GR 5 RN 11 56912 Spring Clip 1 420 os EE ME iet i N N 12 128031P Control Module Mounting Bracket A 13 128200 Toggle Switch SPDT 3 position momentary Test includes Mounting fasteners iese ke AR Re Re ee 27246 Toggle Switch BOO esse ee ee AA ee RA aaie ee ee ee ee 128578 Screw PHPH 6 32 x O2p ee ee ee ee ee ee ee arer ee ee 14 52607 Decal fI Genie Part No 128269 Z 45 25 Z 45 25J CHASSIS COMPONENTS Qty Section 1 Parts Information January 2013 ESG RR YRI amp YIJ RP PF ER This page intentionally left blank A TEREX COMPANY 8 Z 45 25 e Z 45 25J Part No 128269 January 2013 Section 2 Maintenance Procedures Scheduled Maintenance Procedures REV B Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage Hl Immediately tag and re
10. s in the appropriate operator s manual on your machine H Be sure that all necessary tools and test equipment are available and ready for use PartNo 128269 A TEREX CO Z 45 25 e Z 45 25J 13 MPANY Schematics About This Section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry General Repair Process Malfunction Identify Jou Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved Section 3 e Schematics January 2013 System Wiring Diagram REV B SOLENOID RELAY LC E TROMBETTA PULL COIL GROUND HOLD COIL C1 P7 PULL RELAY GND C1 P12 PULL RELAY CPL ael ous C1 P2 7 442 C1 10 JL RPM SIGNAL C1 P9 TEST SWITCH orei gt od ud Sas 7 g o O o UJ O x Q JD O Les za Cn O XJ m 14 Z 45 25 Z 45 25J PartNo 128269 January 2013 Section 3 e Schematics Ground Control Box Wiring Diagram REV B
11. uation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps MPANY Section 2 Maintenance Procedures January 2013 Maintenance Inspection Report REV B Model Refer to the Genie Z 45 25 and Z 45 25J Service Manual for scheduled machine maintenance procedures Serial number The following scheduled maintenance procedures will need to be Date performed in addition to regularly scheduled machine maintenance inspections as outlined in the Service Manual Hour meter Machine owner Checklist A Rev A Y NR A 3 1 Lubricate lever shaft Perform every 100 hours A 9 1 Lubricate lever shaft Inspected by print Inspector signature Inspector title Inspector company Instructions e Make copies of this report to use for each inspection Store completed forms for three years e If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments A TEREX COMPANY 10 Z 45 25 e Z 45 25J PartNo 128269
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