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Z-45/22 Service Manual - Manuals

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4. SLAVE RISER X PLATFORM PRIMARY ROTATE I 1 T ore U Mo SE 4 SL oie e i Kale IE4 9 MES y Lo Lo ui EXTENSION LL LL 1 omi Din 1 A SEZ ack oO C CG Wb A GRE 085 M n L Y EN L F
5. E SECONDARY BRAKE 2 SPEED MANIFOLD j SLAVE 2 025 7 y S PLATFORM PRIMARY O ROTATE B BI NE y NE Lee IG eso r 15 wt Kis im L4 L FH EXTENSION 0 y NN V O rm IJ MG o t 2SPD BRAKE W gt lt LH Q9 rM 4 Ka po teg T L 4 t ES TURNTABLE ROTATE 1 i MASTER 3 FR1 PRZ PL1 PL2 s1 52 R1 RZ pls EXTEN RETRACT Z500 T if 1500 BB R cC 1200 4 s Q Q Q Q le OTe PS MEDIUM PR Ae CIE A j m _ 1200 1200 _ 290 i PRESS OPTIONAL UT sert VEI La RS AE ege le PS SE SS NZ FILTER MOTOR GEN AAA E e CH LA Set G CO On LJ LJ d a Q CDA eu S UTR i 4 a i 0 4 ALTA ADA T 3500 D 4 M 1
6. SLAVE SECONDARY 9 025 T X CL pre PLATFORM PRIMARY NI NE ROTATE t 1 3 yw die pA o M DI om IP Wm 2SPD BRAKE L E q EXTENSION gt A A e V uo ut lt A om IE AS S m i TURNTABLE ROTATE y MASTER G PR1 PRZ PL1 PL2 St 2 R1 RZ P1 P2 EXTEN RETRACT 2500 y E 1500 Si PSI PSI 4200 A A Q O O J PSI eS ES PS MEO OPTIONAL uc de De C HER ES IZ PSI lt gt PRESS Ll M ma A CG E GE LA a z PO O LJ LJ E i Q WIHHIX SIDAD Etat SE CH FA AA SHAE Se AID 3500 een SE 4 MO 1 Weed w EE al EGEN L 15 P AAN TZ HR SELECT ew EE GE gt F CTION PRESS crm e A 4
7. HIGH RPM ENGINE SPEED LO E N 5E a E BLK RED 1 M o i ENGINE RPM e SN p HICH BLK RED E BLK 430 9 D RPM COIL BLK RED TN B u b 1 AUXILARY S 2 PUMP x gm E a 1 RED BLK _ F BLK 20 BLK e AUX COIL AUXILARY a IR YPME RED BLK 2 BLK CH up UX DISABLE COIL N E E X BLK D AN RESTART COIL x ENGINE UI Oe TU amp 1 START BLK ENGINE m ke START 1 o LK 45 NE z 1 BLK 1 BLK 55 LG START COIL C5 TELS NE o o WHT S WHT p l N 5 o ANTI RESTART COIL D E A ENGINE D I CHOKE E 1 ORG RED O WHT Le ENGINE S Kee 5 SHORE SS ORG RED 1 la R a po o BLK E um p m IK 42 X BLK WHT 1 E BLK 429 ah e GG CHOKE RELAY O Ss D m j 5 BLU RED 1 BLK 354 E o s L P SOLENOID We FUEL 1 Ny GAS BLU WHT 1 m BLK 33 e ANTI DIESEL Ny LO ke He A NE S BE n beni al JJ CAS SOLENOID RED BLK 1 m E 2 HOUR METER
8. SLAVE SECONDARY x X PLATFORM 3 PRIMARY ROTATE 1 d Lk im GE nc E FA 9 M IE o 0 JD LZ E LA La N EXTENSION ho V o o A NE Li om El 085 LI BEN 4 L FRONT R FRONT TURNTABLE ROTATE gt MOTOR OTOR MASTER m Q 2 1 CU IN C3 7 N RISER PRIMARY PR1 PRZ PL1 PL2 1 SZ RI R2 P1 P2 EXTEN RETRACT i FUNCTION A B i tog 2 EDIUM va He eI ee ea gm ec ON end r 290 qJ N DPE gt lt 4 gt lt NE NT LE t GER SCH mr L 2 N N E gt gt EN ae gt oh SE Ge SAKS aire SEXS ag a ax Cx Sr DRIVE og is Ti PRESS CG ee 1 1 1 TRACTION O y c molt DUZF4 DEH Q MANIFOLD R 1 Scam DI x 2 RE d 1 UNCTION SEH EH zi OOO PuMP SE O CH 6 6 4 GPM t QM EE ER i 4 X PRESS p DRIVE PUMP X bs e w TANK e e de e e d A TANK dy M ENI Ci SEC REG gt s Ps gt P y d 1 ur NM ux I n IN 7 o p D Bs P RESERVOIR AUX PUMP 2 SPD MOTOR
9. SLAVE SECONDARY x X PLATFORM PRIMARY ROTATE J 1 AN 7 E t FAEH 9r El LE 7 L 1 L EXTENSION L L 1 WER Q WOO e 9r IE FR L ass t e 4 LM L Les TURNTABLE ROTATE MASTER 3 RISER PRIMARY PR1 PR2 PL1 PL2 si 2 R1 RZ Pi P2 EXTEN RETRACT L 4 4 FUNCTION RR GG 82 MEDIUM TALE Mol eme oe Lg com IS NONSE aepo oe S LZ FS LS PRESS A A ST i U T FILTER 1 LT LT gt EH ORO A B s Fx d gt at E SMED el sees snis 2 DRIVE 1 3500 9 E PRESS L L 8 4 4 pum A TRACTION zi a 1 X s Sel UL wrr eg Ge E MESA CR li dt FUNCTION E us 3 aru Df GES AA A Sy Jw ap 4 j I EN PUMP ra TT Ee E V a4 exu A Ke gt 6 4 GPM LI di Spe MEAE X PRESS V DRIVE PUMP acc D 1 GPM NZ TANK 4 gt d X TANK GA pa VEN fe Pa SEC REG 25 L NES LI a Oe ET I7TXl T T I Ce NM a7 e n pal 4 RESERVOIR AUX PUMP r2 SPD MOTOR 2 SPD MOTOR BRAKE BRAKE b STEER OSC MANIFOLD TANK zozs RSW PSI t Mol
10. SLAVE x RISER X PLATFORM PRIMARY ROTATE 1 i E ue BB FEB p dic S 1 TC r i O MIE O 0 JP LZ _ 3 E LA Rp EXTENSION 4 e KE ao t A me M II E Ke Be ESEE 085 T EN SWING E MASTER 3 PLATFORM ROTATE PLATFORM LEVEL SWING RISER PRIMARY PR1 PRZ PL1 PL2 S1 52 R1 RZ P1 PZ EXTEN RETRACT d FUNCTION WEEN EDIUM AE aile deo Lo go mu MEARUM Za EE e da Ra Az r EJ EA FILTER US LT A R ME l EA 15 GPM TY xe A AR A A NE A SH X H AR at DRIVE 3500 PRESS e SES f Q 4 4 4 5 TRACTION rae e imi molt uod T ATE MEJ ATE Ip X X X 00 OLA PUMP Te 1 Q O Mr KH O Kz o KH ZE d WER 6 4 GPM Ti A e X PRESS Ner DRIVE PUMP HC ji A 4 mka X TANK EM FA Ek NI 54 ER SEC REG 25 Ey I o Ps Ps SZ o gt ch Se ei x Ben A RESERVOIR AUX PUMP r2 SPD MOTOR 2 SPD MOTOR BRAKE BRAKE TANK 7 Y 2 035 IER N Y SI SZ a N O L REAR R REAR M 4 MOTOR MOTOR 2 8 CU IN STEERING p Z11 08 DWG HS2WD 745 22 Hyd Index 745 22 HP 2WD HYDRAULIC SCHEMA TIC SERIAL ZzZ45 000989 IO Z45 0025 56
11. 4 14 B 9 Check the Oil Level in the Torque Hubs ii 4 14 B 10 Check the Engine Choke Gasoline LPG Models 4 15 B 11 Check the Glow Plugs Diesel Models eeeesssssssss 4 15 B 12 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 16 B 13 Check and Adjust the Engine RPM 4 16 B 14 Test the Key EE 4 17 B 15 Test the Emergency Stop Buttons ee 4 18 B 16 Test the Ground Control Override i 4 18 B 17 Test the Oscillate Lock out 4 18 B 18 Test Platform Self leveling sese 4 19 B 19 T stthe Serviee HO NEE 4 19 5 20 Testo FOOL SWIC i oo buta edu caet buts si a UE A 4 19 B 21 Test the Engine Speed Geert 4 20 B 22 Test Fuel Select Operation Gasoline LPG Models 4 20 B 23 Test the Turntable Rotation StoD a 4 21 Vi Genie Z 45 22 Part No 29487 Service Manual First Edition ANN Section Four Part No 29487 TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 24 B 25 B 26 B 27 cj CZ C 3 C 4 C 5 C 6 CF C 8 C 9 C 10 C 11 612 C 13 C 14 D 1 D 2 D 3 D 4 D 5 D 6 D 7 D 8 D 9 Test the Drive Enable System 4 21 Test Ine DINE BI
12. Charge pressure 10 12 ft Ibs 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 OR A RF check in forward 85 90 ft lbs 115 122 Nm 10 Pilot to open check valve Ped RF check in reverse 85 90 ft lbs 115 122 Nm 11 Check valve UR LR check in reverse 35 40 ft lbs 47 54 Nm 12 Check valve Se LR check in forward 35 40 ft lbs 47 54 Nm 13 Pilot to open check valve K LF check in reverse 85 90 ft lbs 115 122 Nm 14 Pilot to open check valve VE LF check in forward 85 90 ft lbs 115 122 Nm 15 2 position 3 way valve Gnesnensis inn Energized in high range to pilot open check valves 9 10 13 amp 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 Doop LR flow control in reverse 10 12 ft lbs 14 16 Nm 18 Flow regulator valve EE LR flow control in forward 10 12 ft lbs 14 16 Nm 19 Flow regula
13. NE H UT i o Ny D RED WHT E RED WHT 1 BLK 436 e e FUEL CON ae NA N Nr A O EN 2ED W WHT BLK 3 REDNWH I d RED S 2 E e Ke x m N RT ca Game WHT 8 As gt X E Z n T A A WTS1 MO RED ZN WHT BLK K fo BLK 423 et ER e e o WATER TEMP A E SWITCH N NY yee d RED A WHT pou BU X Se 5s gt i OIL PRESSURE l SWITCH a d et X D a OPST N C e S if X x GRN S RESTART RELAY 3 SEC OFF DELAY re w CN OF E WHT 51 f O P COIL WHT BLK lt Az gt a mM LO a c T sgk BLK 2 5 Gees o s HORN COIL a LO ce X BLK 454 o HORN oO DC BLK 455 e o OSC VALVE LO neg S RED EE BLK BLK 456 D e e e E OSCILATE LOCKOUT COIL ON r P og a E eer BLK 457 SE S 2 No SC LIFT LOCKOUT Se EE st D BLU RED 2 P BLK 24 pe eo e e 5 LEVEL SENSOR RED 2 S LEE GE Geer 8 AUXILARY PUMP RED 1 o SZJ Oo E E ai RED OC ENGINE CHOKE N LO n gt O X X 5 w amp U Jaula Po ul a ad lt lt LJ a 15 CRN 4 z s c w Da amp JE BLK SR BLK M e C lt x in IS 1 WHT O C3 F ES a A ls i E LJ o ortzrox sy N hj LE EM d 5 tn SOLO ER ee G E gt cL oc Ti S o gt IGNITION y 9 BROWN a NSG 5 2 a J 5 p _ SYSTEM C a LM ka 4 TT C WH I ce i SSC RED 425 a EJ e M 2 STARTER MOTOR
14. 12V Replace TR2 time delay relay 5 10 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Choke Inoperative Gasoline LPG Models Be sure machine is equipped with manual choke Be sure choke solenoid to carburetor linkage is in place and properly attached Be sure choke solenoid plunger can be manually pushed into the solenoid and the linkage in turn rotates the choke plate linkage Be sure fuel select switch is in the gasoline position Part No 29487 Check voltage at OV common terminal of PR4 12V Hold choke switch and check voltage at red wire normally open terminal of PR4 Check voltage on center OV terminal of choke switch 12V Hold choke switch and check voltage at org red wire on toggle switch 12V Hold choke switch and check voltage at red wire on center terminal of fuel select switch Hold choke switch and check voltage at blk wht wire on fuel select 12V Continued on the next page Genie Z 45 22 o 5 a Chart 4 Repair open in black cable supplying 12V to Hold choke switch and check voltage at red wire Repair open in red wire circuit from PR4 on choke solenoid to choke solenoid 12V Repair open in green Check solenoid ground SPRA grounding wire circuit good Replace solenoid Note Resistance across solenoid terminals should be approximately
15. 4 37 Check the Engine Nozzle Injection Pressure Diesel Models 4 38 Check Injection Timing Diesel Models ui 4 38 Replace The Timing Belt Fond 4 38 Genie Z 45 22 vii Service Manual First Edition Aaa TABLE OF CONTENTS Section Five Troubleshooting Flow Charts Io A OO AGE 5 1 1 Engine Will Not Crank Over ii dO aa EE ALECA 5 3 2 Engine Cranks But Will Not Start Gasoline LPG Models 5 4 3 Engine Cranks But Will Not Start Diesel Models 5 9 4 Engine Choke Inoperative Gasoline LPG Models 5 11 5 Engine Glow Plugs Inoperative Diesel Models See B 11 Check The Glow Plugs 4 15 6 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline EPO Models reote il 5 13 7 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPO Models cse eom RD ac 5 14 8 Engine High Idle Inoperative Gasoline LPG Models 5 15 9 Engine Low Idle Inoperative Gasoline LPG Models 5 17 10 Engine High Idle Inoperative Diesel Models 5 18 11 Engine Low Idle Inoperative Diesel Models 5 19 12 All Functions Inoperative Engine Starts and Hung 5 20 13 Al Lift and Steer Functions Inoperative Drive Functions Operational 5 21 14 Ground Controls Inoperative
16. BP1 100 OHM 250 On o BRZ y SPARE GRN BLK 1 GLOWPLUG ORG RED 1 SPARE BLU RED 1 SPARE BLU WHT 1 STEER RIGHT BLU BLK 1 STEER LEFT BLU 1 R P M BLK RED 1 SPARE BLK WHT 1 START BLK 1 BRAKE WHT RED 1 E D C WHT BLK 1 E D C WHT 1 VAC POWER RED WHT 1 SPARE RED BLK 1 12V SUPPLY RED 1 DRIVE EN LT BLK RED 2 DRIVE ENABLE BLK WHT 2 HORN BLK 2 SPARE WHT RED 2 WTR TEMP LT WHT BLK 2 OIL PRESS LT WHT 2 4WD RED WHT AUXILIARY RED BLK 2 12V SUPPLY RED 2 ALARM 12V GROUND GREEN PWR TO F S BLK F S PWR START GREEN F S PWR CONT WHT H P L 2 4WD RED H P L PLAT ROTATE GRN WHT 3 PLAT ROT R GRN BLK 3 PLAT ROT L GRN 3 PLAT LEVEL ORG RED 3 PLAT LVL DN ORG BLK 3 PLAT LVL UP ORG 3 SEC BOOM F C BLU WHT 3 SEC BOOM DN BLU BLK 3 SEC BOOM UP 10 BLU 3 EXT RET F C 9 BLK RED 3 RETRACI 8 BLK WHT 3 EXTEND 7 BLK 3 SWING F C 6 WHT RED 3 SWING RICHT 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 11215 41516 8 910 HORSEPOWER LIMITER B 2 A me BP3 P4 NO 155 OOO OOO
17. QS Turntable rotate 30 35 in lbs 3 4 Nm 3 position 4 way valve SM Secondary up down 30 35 in lbs 3 4 Nm 3 position 4 way valve ER Primary up down 30 35 in lbs 3 4 Nm Counterbalance valve AN ien Turntable rotate left 10 12 ft lbs 15 18Nm Check valVe ici dia SE Secondary flow regulator 11 13 ft lbs 15 18 Nm Check valve nasisisi AD ius Primary flow regulator 11 13 ft lbs 15 18 Nm Check EE AB Extend Retract flow regulator 11 13 ft Ibs 15 18 Nm 3 position 4 way valve e RHET Extend Retract 30 35 in lbs 3 4 Nm Flow regulator valve AAA Extend Retract La 10 12 ft lbs 14 16 Nm Flow regulator valve M di PHP ERA 10 12 ft lbs 14 16 Nm Relief valve 1200 psi 83 bar RRE Primary down 25 30 ft lbs 34 41 Nm Flow regulator valve KE Secondary scite een 10 12 ft lbs 14 16 Nm Relief valve 1200 psi 83 bar R Secondary down 25 30 ft lbs 34 41 Nm Flow regulator valve Ossa IM Mr E 10 12 ft lbs 14 16 Nm Proportional s
18. U 1 PSI ECE LEE 15 AN L rw IL e SE ECT eu XU 06 med dr FUNCTION press S SD goce F Pe epee po PA A A 6 4 GPM Ce Eje q E DRIVE PUMP XX NO a Ml le 2560 TANK PSI 25 SEC REG 3 3 ZS LIFT FUNCTION MANIFOLD PSI PSI d JANK AUX PUMP DRIVE MANIFOLD STEER OSC MANIFOLD E 4 zso im ME e ee 9 ME t MOTT REAR x i FRONT gt 1 T II T r 4 RIGHT A EDT du LL vr SEH OET MS M6 2 1 CU IN ES Ka o WH It o gt HE EC Y 1 u AXi Th M3 Ereti t y M4 amp 070 L a eos2 ere REAR er X pee Ee FRONT EF 9 6 070 Co EFT 2 8 i mio iw ACCUMULATO CU IN PRE CHARGE i E 1600 PSI boj a OSCILLA TION STEERING 1 SPEED EJ DIVIDER LOCK OUT o BY PASS DWG HS4WD F ELSE Service Manual First Edition Section 7 Repair Procedures Observe and Obey WI 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 M Repair any machine damage or malfunction before operating the machine Before Repairs Start WI Read understand and obey the safety rules and operating instructions printed in the Genie Z 45 22 Operating Instruction Manual M Be sure that all necessary tools and parts are avallable and ready for use M Read each procedu
19. SE AMOO AG Pl e O O 5 mo OI OJO O 2a O OT Te EG Ola VIO us Ojo asa AL ls SEE SPR hee 2 A dud ues 12 D y MIOOO Oor gt ei ES oOQO lt sal A A alo Ee EN O O Bice o O 00 O O as ce O O Im Or Oa hog 900 DRIVE ENABLE POGO U O O H Dus DRIVE ENABLE LIGHT AUX OIL 0 6 7 HIGH RPM x ENGINE SPEED WwW 09 ES N a BLK RED 1 e ei vo ENGINE RPM N nad IGI m TAREN BLK RED BLK 430 e e RPM COIL e e N I e BLK DI EN NE 2 H e AUX DISABLE COIL AUXILARY e SE t N Oe c y PUMP RED BLK PF BLK 20 o BLK Dr e ee AUX COIL AUXILARY o a t PUMP RED BLK 2 ES N oc gt 2 BLK 2H 7 ENGINE o s ANTI RESTART COIL T dl START Dd S BLK ENGINE START a 1 STA BLK 1 LK g
20. a plvotplate bolts b oildrain hose Genie Z 45 22 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a container capable of holding 3 gallons 4 Re install the plug into the drain hose 5 Use an oil filter wrench and remove the filter Ford models Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter 6 Apply a thin layer of oil to the new oil filter gasket Then install the filter and tighten it securely by hand 7 Fil the engine with new oil per specifications and replace the filler cap 8 Start the engine from the ground controls Allow the engine to run for 30 seconds and then turn the engine off 9 Check the oil filter and the oil drain hose for leaks 10 Use an indelible ink marker to write the date and number of hours from the hour meter on the oil filter Ford Models Swing the engine pivoy plate back to its original position and replace the three retaining bolts 11 Check the engine oil level dipstick Add oil if needed Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Proced ures Specifications Ford Engine LSG 423 Lubrication System Oil capacity 5 quarts 4 7 liters Oil viscosity requirements 5W 30 10W 30 10W 40 or 10W 50 below 60F 15 5C 10 to 90F 23 to 32C above 10F 23C above 25F 4C 20W 40 or 20W 50 Kubota Engin
21. SPRA 5 Pilot to open check valve Seer eee E 6 Pilot to open check valve 7 Shuttle valve 3 position 3 way K 8 Pilot to open check valve Dp M EN 9 Pilot to open check valve ie 10 2 position 3 way valve R 11 Shuttle valve 2 position 3 way A 12 Flow regulator valve D 13 Flow regulator valve quM 14 Relief valve 320 psi 22 bar EA 15 Flow regulator valve lis 16 Flow regulator valve SNE Plug Torque Specifications Description Torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft Ibs 102 Nm 62 Genie Z 45 22 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
22. open closed Part No 29487 Genie Z 45 22 HYDRAULIC PUMPS 3 Disconnect the hydraulic hoses from the pump and cap them Bodily injury hazard Spraying 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 4 Support the pump and remove the two pump mounting bolts Carefully remove the pump Be sure to open the two hydraulic 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 Section 7 Repair Procedures Service Manual First Edition Function Manifold 11 1 Function Manifold Components Index No 1 CO N O OF Bb N 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Schematic Description Item Function Torque Counterbalance valve Ledo Platform leveling cylinder extend 10 12 ft lbs 15 18Nm 3 position 4 way DO1 valve DAA Platform level 30 35 in lbs 3 4 Nm Counterbalance valve pe Turntable rotate right 10 12 ft lbs 15 18Nm 3 position 4 way valve
23. Repair open in blk 34 check voltage at blk 34 wire circuit from TB34 to wire on LPG solenoid 12V Check green grounding wire circuit for LPG solenoid Move start switch on a off repeatedly Listen to and feel LPG solenoid for click LPG solenoid Repair green grounding wire circuit nd no click Replace LPG solenoid solenoid clicks Reconnect LPG tank and see Maintenance section for LPG adjustments Genie Z 45 22 9 13 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 7 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 Disconnect and isolate black positive cable from starter motor hold start switch and check voltage at gasoline side blu wht wire of fuel select switch 12V Hold start switch and 0V check voltage at TB33 12V Hold start switch and check voltage at blk 33 wire on anti diesel valve on carburetor Hold start switch and check voltage at blk 33 wire on anti gasoline solenoid at fuel tank 12V Check green grounding wire circuit for gasoline solenoid Move start switch on and off repeatedly Listen to and feel gasoline solenoid for click solenoid clicks Reconnect black cable to starter chec
24. HIG 153 OOO T GLOWPLUG START TS7 O O O O GD L1 cane WATER 158 POO TS6 QOO QUO HIGH LOW PLATFORM PLATFORM TS9 AUX DRIVE ENABLE HORN BR M Dz OIL 0 LEVEL RIVE LIGHT DRIVE ENABLE JE Service Manual First Edition Section 6 Troubleshooting Flow Charts f Pressure gauge Filter Fixed displacement pump 2 Bi directional variable displacement pump i Bi directional motor T 2 speed bi directional motor EI Pump prime mover engine or motor Cylinder WWA Accumulator NO 0 035 Orifice with size E Variable orifice Or Shut off valve ns Check valve DE Relief valve L Priority flow divider Solenoid operated dump valve Hydraulic Symbol Legend Differential sensing valve B Solenoid operated proportional valve Flow regulator valve Solenoid operated 2 pos 3 Way directional valve de Solenoid operated 2 pos 4 way directional valve eene Solenoid operated 3 pos 4 way directional valve DO1 d 2 pos 3 way shuttle valve ats 3 pos 4 way directional valve E Sequencing valve Counterbalance valve Part No 29487 Genie Z 45 22 6 3 745 22 Hyd Index 5 22 HP 2WD HYDRAULIC SCHEMA TIC SERIAL wo DOLO TO ZA UEC
25. 15 5C 10 to 90F 23 to 32C above 10F 23C above 25F 4C 20w 40 or 20W 50 Kubota Engine V1702 B Lubrication System Oil capacity 9 5 quarts 9 liters Oil viscosity requirements 10W 30 Engine oil should be MIL L 2104C or have the properties of Al classification CC CD CE grades A 5 Check the Engine Coolant Level 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 Part No 29487 TABLE A PROCEDURES 1 Check the fluid level in the coolant recovery tank Add water as needed O 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 A DANGER fea 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 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
26. BLK 59 ENABLE D RS L N Pl R a z e gt gt l d He DRIVE ENABLE BLK WHT 2 gt BLU WHT 8 WHT BI m i p WHT BLK 1 e BLK 427 E D C e e BLK f BLU BLK 1 a BLK 432 M E STEER RIGHT je Z BLU 1 BU ROA E STEER LEFT gt d y BLK EE EE 3 S E xx Q a D m Th ae v STEER UNLOAD 8 A N E en bd 1 RED WHT 2 Fa A p RED WHT DER MOTOR STROKE HIGH e N h 3 gt lo 3 EON RED O Se x 3 x Si GRN GW gt a TRACTION RELAY uj 3 SEC OFF DELAY uo BLK 7000 SE WHT R6 BLK 41 Leak l TRACTION BY PASS RED Oo x p vi RE A m j n 2 SRS E BK 5 e HI T Sen DRIVE LIMIT SWITCH o S ina ei uum atl ESZX m Goo K E LE N S A d a 2 SS BLU WHT 3 E BLU BLK 3 BLU 3 7 BLK BLU o uec BLU CR EI E e e SECONDARY UP ELIT Te UP BOOM SECONDARY 2 BLK z d A DOWN Y S Ss rj m 9 9 o BEBO e E85 S NM y SECONDARY DOWN RZ p o A E D BLU WHT BLU WHT Ste Imi SECONDARY FLOW CON BLK RED 3 00 A SS BLK WHT 3 BLK 3 gt s PLK m BLK BLK d e Le EXTEND e EXTEND KA 4 A m Dr P a RETRACI TY EE gt D LUNE RETRACT S E 1 BLK RED BLK RED 9 E e vi EXT amp RET 0c O Oo LJ d p D S WH7 RED 3 s D WHT 3 WHT BLK 3 25 lt O WHI BIK WHT BLK 3 d i e DEE SWING RIGHT RIGHT swine H g IK
27. F 112 C When this switch closes the engine is shut off to prevent damage and will not restart until the temperature drops below the switch point An over temperature indicator light at the ground and platform controls should turn on when the switch closes Component damage hazard Do not crank the engine with the over temperature on The oil pressure switch is a normally closed switch that opens at approximately 3 to 5 psi 0 21 to 0 34 bar If the oil pressure drops below the switch point the switch closes and shuts off the engine A low oil pressure indicator light at the ground and platform controls should turn on when the switch closes Component damage hazard Do not start or continue to run the engine with the low oil pressure light on ll f DUA ASPARK testad tough a oil pressure switch b water temperature switch Part No 29487 Genie Z 45 22 FORD LSG 423 ENGINE How to Remove the Water Temperature and Oil Pressure Switches 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 both switches 2 Disconnect the wiring from the desired switch 3 Remove the switch from the engine block and then install the new switch Do not over tighten Burn hazard Contact with hot engine fluids or components may cause severe burns Always use pipe thread sealant when installing a
28. First Edition TABLE D PROCEDURES D 2 Change or Recondition the Engine Coolant 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 1 Put on protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the coolant return tank 3 Remove the radiator cap from the radiator Ford models Remove the 3 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator petcock 4 Open the petcock on the radiator and allow coolant to drain into a container a a a pivotplate bolt 5 After all the coolant has drained close the petcock Reconnect the coolant return hose to the radiator 6 Open the petcock on the engine block and allow the coolant to drain into a container After the fluid is drained close the petcock Genie Z 45 22 7 Replace all coolant hoses and clamps 8 Pour the proper coolant mixture anti freeze amp water for your climate into the radiator until it is full 9 Disconnect hose a from hard line b and hold until coolant starts to pour out of the open hose Then immediately
29. Liocurnieci 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 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 2 Remove the oscillation lock out limit switches 7 58 Genie Z 45 22 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 15cm 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 Crushing hazard If the jack is not centered the axle may tip when the pivot pin is removed Remove the pin retainer from the axle pivot pin Use a soft metal drift to remove the axle pivot pin Remove the oscillate cylinder Part No 29487 Service Manual First Edition Section 7 Repair Procedures Steer and Oscillate Manifold 17 1 Steer and Oscillate Manifold Components Index Schematic No Description Item Function Torque 1 3 position 4 way DO1 valve NSE SIEGNINO P 30 35 in lbs 3 4 Nm 2 Pilot operated unloader valve 1900 psi 131 bar PM Sequencing 10 12 ft lbs 14
30. Part No 29487 Genie Z 45 22 4 37 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES D 7 Check the Engine Nozzle Injection Pressure Diesel Models Complete information to perform this procedure is available in the Kubota V1702 B Diesel Engine Workshop Manual Kubota code number 97897 00691 Genie part number 29587 D 8 Check Injection Timing Diesel Models Complete information to perform this procedure is available in the Kubota V1702 B Diesel Engine Workshop Manual Kubota code number 97897 00691 Genie part number 29587 D 9 Replace the Timing Belt Ford 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 4 38 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Aaa Part No 29487 Genie Z 45 22 4 39 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Ea 4 40 Genie Z 45 22 Part No 29487 Service Manual First 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 button is pulled up into the on position Be sure the circuit breaker is not tripped Part No 29487 Check battery voltage 12V or more Check voltage at
31. 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 replaced more frequently Engine fuels are combustible A DANGER Replace the fuel filter in an open well ventilated area away from heater sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Fuel filter water seperator a ventplug b filter bowl c drainplug d seperatorhead e headbolt 1 Loosen the vent plug located on the fuel filter water separator head 2 Place a container under the bowl and then loosen the drain plug located at the bottom of the bowl Completely drain the bowl 3 Loosen the head bolt then rotate the bowl counterclockwise and remove it Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 4 Remove the filter element from the bowl 5 Apply a thin layer of oil onto the bowl gasket and then install the new filter element 6 Tighten the drain plug and fill the bowl with clean diesel fuel 7 Install the bowl onto the filter head and then tighten the head bolt to 65 inch pounds 7Nm 8 Tighten the vent plug 9 Clean up any diesel that may have spilled during the installation procedure 10 Start the engine from the ground controls then inspect the
32. i Adjust the voltage to 2 50V DC Turn the Turntable Rotation Controller threshold trimpot adjustment screw clockwise Adjustments to increase the voliage or counterclockwise to decrease the voltage 1 Check the battery condition with a volt meter The reading should be 12V DC or more to 7 Set the max out Press down the foot switch accurately adjust the controller then move the control handle all the way to the up position Adjust the voltage to 5 01V DC 2 Turn the key switch to platform control and pull Turn the max out trimpot adjustment screw the Emergency Stop button to the on position clockwise to increase the voltage or at both the ground and platform controls Do counterclockwise to decrease the voltage not start the engine 8 Set the dual range Press down the foot switch 3 Open the platform control box lid and locate the then move the control handle all the way to the secondary boom up down controller down position Adjust the voltage to 4 05V DC Turn the dual range trimpot adjustment screw C b d KE g W p D clockwise to increase the voltage or counterclockwise to decrease the voltage Engine should be at normal Sin re operating temperature M EE M 9 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 f
33. yOHO HOLIMS WNNOVA MS LINT ANG MS JIBVN3 ANG 411 318VN3 ANG 3SJnd 11V 1dH LS L H OOO gt e C o OQ OO Ee N Q ON 7 ON de lt E OJO U VM o m N BEN i313 OA SCH m 779 5 N R AJ 1 D x lt m esos n ES BO N B wz e L a gt gt lt Pal Se Ze Se T gt A OGG is SME E O O UJ iD VE e a gt i T AJ O Ox JO O U O A JE ER E 2 0 Ola O OJJ rn U R e OOO OOO Em Tr gt UU gt al POCO lO 1000 ees d Z 0 vol Y A O m E p Sel Sare o lo e CAI O ans 6 5 SPA AUX DISABLE ee AE GOVERNOR TON ON fa SOS Ee PR RPM SZ PAS oN A KU KU PR 2 OIL PRESS SE w PR3 AUX 0R Dp O IO P R 4 CHOKE VOLTAGE REG 2d Na O SM MES PR5 P STARI COIL WER LIMITER PO HORSE SPARE 48 GRN BLK 1 CHOKE 47 ORG RED 1 L P 46 BLU RED 1 CAS 45 BLU WHT 1 STEER RIGHT 44 BLU BLK 1 STEER LEFT 45 BLU 1 R P M 42 BLK RED 1 CHOKE 41 BLK WHT 1 START 40 BLK 1 BRAKE 59 WH
34. 2 A 2 Inspect the Decals and Placards ui 4 2 A 3 Inspect for Damage Loose or Missing Parts ua 4 2 A 4 Check the Engine Oil Level E 4 3 A 5 Check the Engine Coolant Level 4 3 A 6 Check ftor ENEE 4 3 A 7 Check the Hydraulic Oil Level 4 4 A 8 CHECK Tor huet 4 4 A9 Check Tire Pressure NS ia 4 4 Genie 45 22 V Service Manual First Edition CC TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 10 Test the Platform and Ground Controls iii 4 5 A 11 Test Auxiliary Power Operation sese 4 5 A 12 Test the Tilt Level Sensor 0 4 6 A 13 Test the Limit Switches ooo aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa nennen nnns 4 6 A 14 Replace the Engine Oil and Filter 4 8 A 715 Change the Engine Air Fite rss rra 4 9 A 16 Drain the Fuel Filter Water Separator Diesel Models 4 10 B 1 Check the Engine Fan Belts ii 4 11 p 2 Gheckthe Le e 4 11 Bo Check the Exhaust SVs le RR PH OE Hb Eve E EUER i eee 4 11 B 4 Gheck Ihe Batley EE 4 12 B 5 Check the Hydraulic Reservoir Filter Condition Indicator 4 12 E 6 Inspect Elected VVIDIEIQ RNN 4 13 B 7 Inspect the Tires and Wheels sin a 4 13 B 8 Confirm Proper Brake Configuration
35. 33 to 37 second cycle time Specifications Primary Boom Up Down Function Threshold 2 50V DC 5 02V DC 25 29 seconds Primary boom up Max out time 4 33V DC 33 37 seconds Primary boom down Dual range time Part No 29487 The reading should be 12V DC or more to accurately 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 3 Open the platform control box lid and locate the primary extend retract controller Ry dze MAA FF dual lo adjustable trimpot ramp rate adjustable trimpot terminal R activates max out range terminalunused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot TO 00009 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 Genie Z 45 22 7 3 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 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 t
36. 4WD 2 75 seconds 0 25 seconds Boom raised high range distance 20 ft 6m 2WD and 4WD 1 foot per second 30 5cm per second 1 3 Foot Switch How to Test the Foot Switch 1 Turn the keyswitch to the off position and disconnect the wiring quick disconnect plug from the platform toe board 2 Do not 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 continuity zero Q 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 onmmeter 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 1 4 Resistors Two resistors are used to maintain proper control of drive speeds Both resistors are located in the platform control box How to Test the Resistors 1 Turn the keyswitch to the off position and set the drive mode select switch to high range two wheel symbol 2 Connect the leads from an ohmmeter to each end of the resistor being tested 3 Compare the ohmmeter reading with the resistance rating prin
37. 895 2 4 Genie Z 45 22 Part No 29487 Service Manual First Edition AAA AAA AAA Ford Engine LSG 423 Displacement Number of cylinders Bore and stroke Horsepower Firing order High engine speed Low engine speed Governing Compression pressure Valve clearances Intake Exhaust Lubrication System Oil pressure operating temp 2150 rpm Oil capacity including filter Oil viscosity requirements Below 60 F 15 5 10 to 90 F 23 to 32 C above 10 F 23 C above 25 F 4 0 Use oils meeting API classification SF labeled SF CC 140 cu in 2 3 liters 4 3 780 x 3 126 inches 96 x 79 4mm 63 4000 rpm ER dz 2150 rpm 1200 rpm Precision electronic psi of lowest cylinder must be at least 75 of highest cylinder 0 0010 0 0027 inches 0 025 0 068mm 0 0015 0 0032 inches 0 038 0 081mm 40 60 psi 275 8 413 7kPa 5 quarts 4 71 liters 5W 30 10W 30 10W 40 or 10W 50 20W 40 or 20W 50 or SF CD as they offer improved wear protection Part No 29487 Starter motor Normal engine cranking speed Current draw normal load Current draw maximum load Current draw no load Maximum circuit voltage drop normal temp Brush length new Brush length wear limit Brush spring tension Bolt torque through brush Brush mounting bolt torque Maximum commutator runout Battery Type Ampere hour Cold Cranking Ampere Section 2 Spe
38. A Procedures A 1 Inspect the Operating Instruction and Safety Manuals Maintaining the Operating Instruction 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 make sure that the Operating Instruction and Safety manuals are present in the storage box in the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition 3 Always return the manuals to the storage box after use Contact your Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the 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 Operating Instructions and use the decal list and illustrations to determine that all decals and placards are in place 4 2 Genie Z 45 22 2 Inspect all decals for damage or illeg
39. Down 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 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 14 for primary boom item 16 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 position and recheck the valve pressure Specifications Relief valve pressure 1200 psi 83 bar Part No 29487 Service Manual First 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 po
40. E PUMP NET z O E X O z X 2 PSI DRIVE SC LIZ ai z MANIFOLD DRIVE PUMP XX PE X os TANK r 4 zoo 25 re SEC REG 5 gt gt ZW EL LIFT FUNCTION MANIFOLD PSI PSI Q E m LI REAR RIGHT Hal l TANK AUX PUMP M5 l T IMP C X pa EE M3 E Lal PSI PS 070 H _ 250 A D Mo 1 REAR 4 A ded LEFT ka i ES y A TANK T RETURN Mi r lth a S Ba AK Eds DS2 Es o WY H 1 IW IN gt S1 S2 i ACCUMULATOR PEERING PRE CHARGE RE eS W O OSCILLATING OPTION OSCILLATION STEERING LOCK OUT p Z11 10 DWG HS2WD Z45 22 Hyd Index 745 S 97 EE ZO HYDRAULIC SCHEMA TIC SERIAL 4445000001 TO Z45 000981
41. Edition TABLE OF CONTENTS Section Seven Repair ProcedureS continued 722 Choke GEIER ee 7 31 729 Jure AUS Mea ri i w CG 7 32 7 4 Carburetor Adjustment AE 7 32 7 5 RPM Adjustment A 7 32 ELP OS UTD 7 32 7 7 Water Temperature and Oil Pressure Switches ee aaaaaaaccc 7 33 edd m m 7 34 Ground Controls 9 1 Oontol RAYS uscito ENEE 7 35 8 2 Toggle Switches See 1 5 Toggle Zwiiches esses 7 9 8 9 Wago Components surco 7 36 EE e TEE 7 37 Relay Panel 9 CONTO Ra Sn in E 7 38 932 ENEE Relay ennenen i 7 39 Hydraulic Pumps TO T MUS RUN O ONE 7 40 10 2 Ee PUN Dana A ada 7 41 Function Manifold 11 1 Function Manifold Components 7 42 wie Valve AUS ne EE 7 44 Fuel and Hydraulic Tanks 12 1 TydraulcHeselVOIl a ee 7 46 22 FUEL dada 7 47 Turntable Rotation Components 13 1 Rotation YOUIIGIMOIO ERR 7 48 13 2 Rotation Bearing and Worm Drive ui 7 48 2WD Steering Axle Components JS ele Tele RU cl i i i a 7 53 E E Le ue E 7 54 Part No 29487 Genie Z 45 22 X Service Manual First Edition TABLE OF CONTENTS Section Seven XII Repair Procedures coniinued 14S ME RO a A 7 55 4WD Steering Axle Components E SEOKO and UD aa 7 56 15 2 Steering Cylinders See 14 2 Steering Cylinders 7 57 1563 Me Rod See 14 3 HeRod add 7 55 Oscillating Axle Components 16 1
42. 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 C with a like valve item B function operates Repair open in blu wht wire circuit from TB11 to directional valve Check the resistance of the down directional valve coil 4to5 ohms 0 or infinite ohms Replace the coil function does not operate Install a pressure gauge at the quick disconnect coupling on the function manifold and hold the function down switch 1200 PSI less than 1200 PSI Adjust the secondary down relief valve item U in one turn clockwise Then with pressure gauge still attached hold the function down Counting the turns adjust the secondary down relief valve item U in all the way Then operate the function function With secondary boom fully lowered hold the function down switch Adjust the relief valve to read 1200 PSI and replace the 1200 PSI or more less than 1200 PSI Continued on the next page Genie Z 45 22 function inoperalive Chart 17 Replace the valve Check for mechanical restrictions and or a condition exists in which the cylinder s counterbalance valves are not allowing the cylinders to retract or the cylinders have internal defects Disconnecting hydraulic lines or adjusting
43. Interchange motor shift valve item R with brake release valve item S low range inoperative Check drive mode toggle switch See Repair section Check drive resisters in platform control box See repair section Possible defective drive manifold or drive manifold component Please consult Genie Industries service low range operates low range operates Chart 36 Replace drive mode toggle switch Repair short in red wht wire circuit from drive mode switch through TP27 to TB21 Replace TR3 time delay relay Replace defective valve Replace defective valve Replace toggle switch Replace defective resister s Genie Z 45 22 9 03 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 37 Machine Will Not Drive At Full Speed Be sure all other functions operate normally With boom fully stowed full continuity check TB37 for continuity to ground no continuity With boom fully stowed check horsepower limiter board terminal 6 for continuity to ground full continuity no continuity Re adjust horsepower limiter board See Repair section Genie Z 45 22 Repair or replace drive limit switch Orange wire shorted to ground repair orange wire circuit from TB37 to horsepower limiter Part No 29487 Service Manual First Edition Section 6 Troubleshooting Flow Charts Observe and Obey WI
44. Le e UP LA x PLATFORM LEVEL Bl BLK DOWN ORG BLK pu ORG BLK rj o elle X m 1 ORG RED ORG WH I elle M i m a GRN BLK 3 RIGHT PLATFORM ROTATE aci GRN LO a SS GRN WHT 3 e 1 GRN BLK e CRN BLK D elle N RIGHT PLATFORM ROTATE BLK d o e LEFT GRN d ES R Ls GRN TE m i fo 1 GRN WHT GRN WHT D co m TRAVEL HORN BRAKE RELEASE PLATFORM GROUND DRIVE ENABLE EDC STEER RIGHT STEER LEFT STEER UNLOAD MOTOR STROKE TRACTION RELAY 3 SEC OFF DELAY TRACTION BY PASS DRIVE LIMIT SWITCH SECONDARY UP SECONDARY DOWN SECONDARY FLOW CON EXTEND RETRACT EXT amp RET FLOW CON ROTATE RIGHT ROTATE LEFT ROTATE FLOW CON PRIMARY UP PRIMARY DOWN PRIMARY FLOW CON LEVEL UP LEVEL DOWN LEVEL SOLENOID ROTATE RIGHT ROTATE LEFT ROTATE SOLENOID ES45F4 1 SB OO O O AX Vs O DU OO Gi Nt La ES SS DQ O EOB SIE Z CA P O OO Ex R O E E OO x TA AJ Cn O 05 OO E EC 38 oo OO NE bu GE QMS p I O UY gt Q3M C Q3M X18 GER 18 034 x18 34 z X18 X 18 038 1HM G3ME LIHM Q3N 1HM G
45. Li a g Eom EE A OT A KADR 5 ES Se M LL e ES CN Y CN gt C I a uj LI CC LL gt m LL LJ L lr sw CN gt LI Lt Ee O LO LL S16 1919 O HOUR METER Ra x BS c iy STOP KEY AUX lt NO ON ooolQ Y GOTI P1 KS1 HPL ALT PULSE DRV ENABLE LT DRV ENABLE SW DRV LIMIT SW RELAY TRI CLOWPLUG STEER RICHT STEER LEFT HIGH RPM CLOWPLUG DRIVE BRAKE DRIVE EDC DRIVE EDC BAT TILT SENSOR WATER TEMP LT OIL PRES LT DRV LOW RANGE AUXILIARY 12V TO PLAT PLAT PLAT PLAT PLAT PLAT PLAT ROTATE ROTATE L ROTATE R LEVEL LEVEL DN LEVEL UP SECONDARY F C SECONDARY DN SECONDARY UP EXT RET F C RETRACT EXTEND SWING F C SWING RIGHT SWING LEFT PRIMARY F C PRIMARY DOWN PRIMARY UP Oe D 0 o EE EE o0 o o z e 40 ORG BLK 1 BLK 39 BLK RED 2 BLK 38 WHT 1 BLK 3 7 1ORG 1 BLK R W gt H RED 36 R W 1 BLK ORG RED BLK 35 ORG RED 1 54 BLU RED 1 BLK 33 BLU WHT 1 BLK BLK 32 BLU BLK 1 BLK BLK 31 BLUE 1 BLK BLK RED 30 BLK RED 1 BLK BLK 29 BLK WHT 1 BLK BLK 28 WHT RED 1 BLK 2
46. OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Geinie Industries service 5 34 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boom Retract Function Inoperative Be sure all other functions operate normally including primary 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 Part No 29487 Chart 21 Hold ground control function switch and check volts at blk wht Repair open in blk wht wire circuit from TB8 to directional valve wire on extend retract function valve 12V Hold toggle switch down and manually override the retract 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 A with a like valve item B 4to5 ohms Replace the valve function operates Check the resistance of the down directional valve coil 0 or infinite ohms Replace the defective valve coil fu
47. Oscillating Axle Lock out Cylinder ii 7 58 Steer and Oscillate Manifold 17 1 Steer and Oscillate Manifold Components 7 59 172 Male AdJUS TM Sai 7 60 Non steering Axle Components 18 1 Drive Motor 7 61 102 NO 7 61 2WD Drive Manifold 19 1 2WD Drive Manifold Components lt 7 62 19 2 Valve Adjustments A 7 64 4WD Drive Manifold 20 1 4WD Drive Manifold Components 7 66 20 2 Valve ACIUSIMEIMNS EE 7 68 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 2 Specifications Machine Specifications Stowed dimension Length Width Rough terrain Industrial Height Weight Ground clearance Platform dimensions Length Width Operational dimensions Maximum plaform height Maximum platform reach Maximum up and over clearance Maximum turret tailswing Wheelbase Minimum turning radius outside Minimum turning radiius inside Turret rotation Platform rotation Part No 29487 2WD 4WD 17 ft 8 ein 17 ft 10 3 4 in 5 4m 5 45m 6 ft 8 4 in 6 ft 4 s in 203 8cm 194 6cm 5 ft 9 s in 176 8cm 6 ft 6 in 7ft4in 1 98m 2 23m 13860 Ibs 14410 Ibs 6287kg 6536kg 8 in 11 in 20 3cm 2 9cm 6 ft 6 ft 182 8cm 182 8cm 30 in 30
48. PSI gauge still attached operate the function less than 2000 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 Repair open in grn blk wire circuit from TB17 to directional valve 0 or infinite ohms function operates Interchange the platform rotate left and right counterbalance valves in the manifold installed on 2000 the primary boom PSI extension located under the platform function Replace defective counterbalance valve Repair the hydraulic rotator OR replace the rotator counterbalance valves and or manifold Genie Z 45 22 Replace the coil Replace the platform rotate directional Valve Check for mechanical restrictions keeping platform from rotating OR repair hydraulic rotator OR replace directional valve Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 30 Oscillate Raise the primary boom Mes Open in wht wire 12V until it is above the drive supply to oscillate Lock out limit switch and measure 7 Check voltage at bik 57 OV limit switches OR one Function the oscillate lock out Ire wire on CRT or both oscillate limit wedges See switches is defective Inoperative Maintenance Procedures 12V wedges do not Check CR7 green extend 3
49. Part No 29487 Genie Z 45 22 PLATFORM CONTROLS 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 13 Raise the primary boom above the drive limit switch a drive limit switch 14 Drive the boom for 20 feet 6 1m and record the elapsed time Do this again in the opposite direction Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 15 Adjust the B potentiometer to obtain the correct elevated drive speed of 1 foot per second 30 5cm per second 16 Close the platform control box lid and re install the fasteners Specifications Stowed position high range distance 20 ft 6m 2WD 2 85 seconds 0 25 seconds
50. Platform Controls Operate Normally 5 22 15 Platform Controls Inoperative Ground Controls Operate Normally 5 23 16 Secondary Boom Up Function Inoperative 5 24 17 Secondary Boom Down Function Inoperative 5 27 18 Primary Boom Up Function Inoperative iii 5 29 19 Primary Boom Down Function Inoperative ieee 5 31 20 Primary Boom Extend Function Inoperative uint 5 33 21 Primary Boom Retract Function Inoperative iii 5 39 22 Turntable Rotate Function Inoperative 5 36 23 Turntable Rotate Left Function Inoperative 5 38 24 Turntable Rotate Right Function Inoperative 5 39 25 All Platform Leveling Functions Inoperative iinet 5 40 26 Platform Level Up Function Inoperative 5 41 27 Platform Level Down Function Inoperative 5 42 Viii Genie Z 45 22 Part No 29487 Service Manual First Edition Section Five Section Six Part No 29487 TABLE OF CONTENTS Troubleshooting Flow Charts continued 28 Pl
51. Tools are required ma Table A A 1 Inspect the Operating Instruction and Safety 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 Switches Every 100 hours check for and or perform as necessary the engine maintenance procedures listed below A 14 Replace the Engine Oil and Filter A 15 Change the Engine Air Filter A 16 Drain the Fuel Filter Water Separator Diesel Models Genie Z 45 22 Part No 29487 Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES 2 o S 5 2 o Oe Go mo 50 ot o c a gL PA O D 5 5 J 3 8 88 8 38 g Table B a 2 O g gt 2 lt 2 2g B 1 Check the Engine Fan Belts B 2 Check the Radiator ES PA ra B 3 Check the Exhaust System B 4 Check the Battery B 5 Check the Hydraulic Reservoir Filter Condition Indicator B 6 Inspect Electrical Wiring B 7 Inspect the Tires and Wheels including lug nut torque B 8 Confirm Proper Brake Configuration ES Pa Es B 9 Check the Oil Level in the Torque Hubs B 10 Check the Engine Choke Gasoli
52. W LO ce N m m x LIO im s lt GRN RED YEL WHT o 28 oc ORG BLU ES o E ORG BLK 1 m BLK 40 g lt lls c 3j m E E lt Q 2 m dt E sl d G x DC oa O aji J L LO x ia Illu 6 3 ORG BLK 1 WHT BLK E WHT RED 1 e BLK 428 o o GRN GRN e GRN 1 amp 2 a m o gt E s BLK RED 2 B BLK 9 OS Ni E GRN WHT 1 BLK 438 T BLK 59 e e 00 o to D gt pe B S m Ho z N D a N N p Pz ro a amp DRIVE ENABLE BLK WHT 2 gt BLK WHT sacl m 2 a
53. adjustment is needed repeat steps 3 Perform this procedure on a through 8 firm level surface Block the non steering tires and be sure that the machine is in the fully Tie rod adjustment 1 4 inch 0 635mm toe in to stowed position 1 4 inch 0 635mm toe out Specifications 1 Measure 15 inches 38cm up from the ground on the front and rear of each steer tire and make a reference mark at the center of the tire 2 Measure the distance from the reference points on each tire Front to front and back to back 3 Center a jack under the steering axle then raise the machine 4 Loosen the jam nut on the adjustable end of the tie rod Part No 29487 Genie Z 45 22 7 55 Section 7 Repair Procedures Service Manual First Edition 4WD Steering Axle Components 15 1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that require periodic replacement depending upon the application The yoke must be removed before the torque hub can be removed The wheel motor is an integral part of the torque hub 1 Remove the cotter pin then the clevis pin from both the steering cylinder and the tie rod weldment CD K E axle pin retainer king pin yoke torque hub cotter and clevis pin steering cylinder tie rod TO O OO O 0 4 Disconnect the hydraulic hoses from the wheel motor and plug them Cap the wheel motor hydraulic fittings Bodily in
54. and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls and then select high drive mode 2 wheel symbol 3 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 meters Stopping distance normal operating temp Genie Z 45 22 B 26 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 marking two lines on the ground 20 feet 6m apart 2 Start the engine from the platform controls and then select high drive mode 2 wheel symbol 3 Move the engine speed control switch to high idle rab
55. and lower retaining clips from the gas strut Gently pry the strut pivot sockets off of the ball studs and remove the strut Remove the fasteners from the cover hinge pins Raise the cover slightly to relieve the pressure on the cover hinge pins Remove the cover hinge pins Carefully lift and remove the cover from the machine If a turntable cover must be replaced be sure that all INE appropriate safety and instructional decals are applied to the new cover Some adjustment may be necessary when a new cover is installed Part No 29487 Genie Z 45 22 Section 7 Repair Procedures Turntable Covers Section 7 Repair Procedures Service Manual First Edition Kubota V1702 B Engine 6 1 Timing Adjustment Complete information to perform this procedure is available in the Kubota V1702 B Diesel Engine Workshop Manual Kubota code number 97897 00691 Genie part number 29587 6 2 Glow Plugs How to Check the Glow Plugs See the scheduled maintenance procedure B 11 Check The Glow Plugs Diesel Models 6 3 RPM Adjustment See the scheduled maintenance procedure B 13 Check and Adjust the Engine RPM 6 4 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 How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the
56. as specified on the maintenance inspection report Failure to properly complete each inspection when required may result in death serious injury or substantial machine damage Vl Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine II Keep records on all inspections for three years Part No 29487 About This Section There are two components to this section maintenance tables and an inspection reporting form Maintenance Tables The maintenance tables provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure is provided in section 4 Scheduled Maintenance Details Maintenance Inspection Report The maintenance inspeciion report contains checklists for each type of scheduled inspection Daily inspection Use checklist A Frequent inspection every 150 hours or three months Use checklists A and B Annual inspection Use checklists A B and C Two year inspection Use checklists A B C and D Make copies of this form to use for each inspection Store completed forms for three years Genie Z 45 22 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Dealer Service recommended Warm engine Cold engine required required New parts required
57. 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 to the on position 2 Simultaneously hold the auxiliary power switch on while activating the following functions through a partial cycle primary boom up down extend and retract elevate 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 and repeat step 2 Genie Z 45 22 4 5 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 12 Test the Tilt Level Sensor The tilt sensor sounds an alarm in the platform when the incline of the chassis exceeds 3 Select a level test area 1 Start the engine from the platform controls 2 Open the engine side cover and press down on one side of the tilt sensor O Result After a 1 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 over the steering wheels and
58. check for tight spots that could cause binding Always maintain squareness between the primary boom outer and inner tubes Part No 29487 Genie Z 45 22 7 13 Section 7 Repair Procedures Service Manual First 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 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 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 wood block b tie wrap c plastic cable track Genie Z 45 22 Component damage hazard The primary boom cable track can be damaged if it is twisted 5 Raise the secondary boom and place a 4x4x31 inch 78cm block between the chassis cou
59. check valves 5 6 8 4 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 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 forward Left flow control in reverse Charge pressure Right flow control in reverse Right flow control in forward Part No 29487 Section 7 Repair Procedures Service Manual First Edition 2WD DRIVE MANIFOLD 63 Genie Z 45 22 Part No 29487 Section 7 Repair Procedures SR _ _ gt lt a _x0EDEOQGRDAA AB 2WD DRIVE MANIFOLD 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 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 Start the engine from the platform controls Drive the machine in either direction and observe the pressure reading on the pressure gauge Turn the engine off Hold the relief valve and remove the cap index 14 Adjust the internal hex socket Turn it clockwi
60. continued use of worn out wear pads may result in component damage and unsafe operating conditions 4 Start the engine from the ground controls then raise the end of the primary boom to a comfortable working height chest high Extend the extension boom 10 inches 25cm Measure each wear pad Replace the pad if it is less than 0 41 inches 1cm thick If the pad is more than 0 41 inches 1cm thick shim as necessary to obtain zero clearance and zero drag 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 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 4 24 Raise the secondary boom and place a 4x4x31 inch 78cm block between the chassis counterweight and the upper mid pivot Carefully lower the secondary boom onto the block Genie Z 45 22 a Uuppermid 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 Raise the primary boom until the end of the boom is approximately 7 feet 2m off the ground Be sure that each turntable bolt is torqued to 190 foot pounds 258 Newton me
61. e LEFT WHT WHT gt e DEER SWING LEFT Z E A 3 Er le 15 Ge WHT R rj 5 aea E e ARES E SWING FLOW CON e i gt ala I Bg _BLK 4 S 2 O June Se E RED Ra RED CR7 E 8 e o db PRIMARY UP UP PRIMARY BOOM BLK z S lt 4 v M A a DOWN RED BLK Es mu RED BLK e PRIMARY DOWN ro je 1 z en E RED WHT RED WHT a PRIMARY FLOW CON RED 3 A RED BLK 3 a 2 EN RED WHT 3 a Q SS ORGC 3 e UP PLATFORM LEVEL DOWN ORG BLK 3 A A a SS m ORG RED 3 BLK 4 ORG deg ORG 3 A LEVEL UP UP PLATFORM LEVEL BLK EET ORC BLK E ORG BLK e LEVEL DOWN 5 y z m Ex m 1 ORG RED ORG WHT A RUM LEVEL SOLENOID LO TY in a g GRN BLK 3 RIGHT PLATFORM ROTATE LEFT GRN 3 LO d GRN WHT 3 A BLK 4 00 GRN BLK Lp GRN BLK 3 3 E e e ROTATE RICHT T ent PLATFORM ROTATE Ng BLK m B lt 1 LEFT GRN 2 GRN M ROTATE LEFT B en ES 1 GRN WHT GRNAWHE TATE e DEE ROTATE SOLENOID fo O Ro gt Om gt Oo ag9 Oob O0 nm pero A OO e O Dc sa m A O gt E f mre OOO1O61OOO Ss m O00 000 E a an Lu D es CX XR SCO ace pr CY XOM umi uo gt 29 00 eeler 3 o er onu O O olo ololooo 5 LLI gt SH PS sl O
62. 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 B 23 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 Swing 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 Swing 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 24 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the platform is over the steering wheels drive movement is Part No 29487 Genie Z 45 22 TABLE B PROCEDURES 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 improperly functioning drive enable system may a
63. ground Replace the pump Part No 29487 Genie Z 45 22 5 21 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 14 Ground Controls Inoperative Platform Controls Operate Normally Be sure all other functions operate normally including platform controls Does the engine start yes from the ground no Check voltage at red wire on ground controls contact of the key switch OV the red wire checked should originate at the emergency stop button 12V Check voltage at red wht 36 wire at ground controls contact on the key switch 12V Repair open in red wire circuit from key switch to function switches Start the engine from the ground controls and check the voltage on the center pole red wire of the platform level switch 12V Troubleshoot the functions individually Repair open in red wire circuit from emergency stop button to the key switch Check if key switch internal cam is activating ground contact Replace key switch Genie Z 45 22 Repair open in red wire circuit from key switch to function VV Replace key switch contact for ground controls Part No 29487 Service Manual First Edition Platform Controls Inoperative Ground Controls Operate Normally Be sure all cables are in good condition with no kinks or abrasions Part No 29487 Does engine start from Y S the platform
64. ground controls troubleshoot the ground control toggle switch See Repair section Note Oscillating axle equipped models from the stowed position the 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 With engine running and boom in fully stowed position hold the primary raises and stops but will not LUIITUIIUC up function and check if the boom will raise up to the drive limit switch no movement Hold ground control function switch and check volts at blu wht wire on secondary function proportional Repair open in blu wht wire circuit from TB12 to proportional valve 3 to 6V Remove both wires from valve coil and check resistance across the coil terminals 0 or infinite ohms 4 5 to 5 5 ohms 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 I with a like valve item H function operates function inoperative Interchange secondary function flow regulator valve item N with a like valve item M function operates function inoperative Continued on the next page Genie Z 45 22 See Oscillate Lock out Function Is Malfunctioning troubleshooting Replace coil Replace the propo
65. high idle 8 Press down the foot switch Result The engine should change to high idle Specifications High idle 2150 rpm Low idle 1200 rpm B 22 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 5 Move the fuel select switch to propane gas Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 6 Restart the engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle O Result The
66. in 76 2cm 76 2cm 45 ft 45 ft 13 72m 13 72m 23 ft 23 ft 7m 7m 21 ft 7 in 21 ft 7 in 6 58m 6 58m 1 inch none 2 54cm 6 ft 3 in 6 ft 3 in 190 5cm 190 5cm 14 ft 4 in 14 ft 9 in 4 3 m 4 49m 7 ft 6 ft 8 in 2 13m 2 03m 359 359 180 180 Specifications Tires and wheels Wheel diameter Wheel width Wheel lugs 4WD Wheel lugs 2WD Front Rear Lug nut torque Tire size Tire ply rating Tire contact area Overall tire diameter Tire pressure 2WD 4WD Fluid capacities Fuel tank Propane tank Hydraulic tank Hydraulic system including tank Torque hubs Rough terrain Industrial 17 5 inches 10 5 inches 9 5 8 18 8 5 8 18 9 5 8 18 125 ft lbs 169 5 Nm 14 17 5NHS 8 59 sq in 380sq cm 35 8 inches 91cm 71cm 40 psi 2 6 bar 28 psi 1 93 bar 15 gallons 56 8 liters 33 5 pounds 15 2kg 25 gallons 95 liters 30 gallons 114 liters 17 ounces 14 5 inches 7 inches 8 5 8 18 9 5 8 18 125 ft lbs 169 5 Nm 9 14 5 LT Tread 8 Sidewall 6 43 5 sq in 280sq cm 28 inches 100 psi 6 89 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Z 45 22 Section 2 Specifications Service Manual First Edition SPECIFICATIONS Performance Specifications Drive speeds maximum Boom lowered high range Boom lowered low range Boom raised high range Boom raised
67. is switched to platform control B 16 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 4 18 Genie Z 45 22 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 Result All boom functions should operate B 17 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 1 From the ground controls raise the primary boom above the drive speed limit switch Oscillating axle limit switch a limitswitch 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 should stop moving until the wedges are fully extended Part No 29487 Service Manu
68. life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Connect an rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1200 rpm Skip to step 3 if the low idle rpm is correct 2 Turn the idle adjustment screw clockwise to increase rom or counterclockwise to decrease rom Kubota low idle adjustment a adjustment screw Genie Z 45 22 Ford low idle adjustment a adjustment screw 3 Move the engine speed control switch to high idle rabbit symbol from the ground controls O Result High idle should be 2150 rpm Adjust high idle rpm if necessary by following the appropriate steps for the engine model Ford engines 4 through 7 4 Turn the engine off 5 Remove the mounting fasteners from the electronic governor located on the relay panel and then remove the back panel from the JOVO AWARNING Electrocution Hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 6 Restart the engine turn the speed set screw clockwise to increase rpm or counterclockwise to de a CA AL Lem Les Lem Les Le mumiumimmium um ee e ee Ford high idle adjustment a highidle adjustment Part No 29487 Service Manual First Edition Section 4 Sch
69. plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug OT R C N 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 5 10 foot pounds 6 8 13 6 Nm Torque specs Part No 29487 Genie Z 45 22 TABLE C PROCEDURES C 13 Check and Adjust the Air Propane Mixture Maintaining the proper air to fuel mixture during propane operation is essential to good engine performance Engine fuels are combustible A DANGER al 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 operating temperature 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 Q Section 4 Scheduled Maintenance Procedures Service Manual First Edition LZ ee TABLE C PROCEDURES 3 Load the system by pressing the primary boom C 14 e
70. reconnect the hose zdj AAR li UL a hose b hard line 10 Re fill the radiator and then fill the coolant recovery tank 11 Clean up any coolant spilled during this procedure 12 Start the engine from the ground controls run it for 30 seconds and then turn it off 13 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water needed Specifications Ford Engine LSG 423 coolant capacity 11 5 quarts 10 9 liters Kubota Engine V1702 B coolant capacity 7 25 quarts 6 9 liters Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance 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 result in an unsafe operating condition poor engine performance and component damage A DANGER Engine fuels are combustible 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 Raise the primary boom until the end of the boom is approximately eight feet off the ground 2 Close the manual fuel shut off valve located next to the fuel tank 3 Remove and replace the fuel line hoses according to the following illustrations Fu
71. solenoid pulls in pulls in Contnued on the next page light on does no pull in Check battery condition OR check alternator OR check battery cables OR replace the battery Check if radiator and or engine block feels excessively hot not hot Remove blk 423 wire from temperature hot light goes out light stays on Remove blk 23 wire from TB23 light goes out light stays on Remove wht blk wire from over temperature light goes out light stays on Replace defective Over temperature light 1 Be sure solenoid has a good ground blk wire then hold start switch and check voltage at the wht wire on the fuel 12V Check resistance of fuel solenoid pull in coil wht wire OV 0 or infinite ohms Replace fuel solenoid Genie Z 45 22 Chart 3 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Kubota service manual for troubleshooting an LIVE Replace Temperature sending unit Repair short in blk 23 wire circuit from TB23 to temperature sending unit Repair short in wht blk with diode wire circuit from over temperature light to Repair open in wht wire circuit from starter to fuel Check linkage for mechanical Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 3 Continued from the Hold then release the solenoi
72. standing drive pump Functions clear of the tires Inoperative momentarily move pump control override lever in All Other each direction Functions machine moves Operate SEN ace a jumper wire Normally Ee n des machine between TB38 and TB26 Machine Repair open in wht ee drives and test drive without drives wire circuit from TP37 Be sure the hydraulic drive enable switch to te to TB38 suction line valve is in EE deii RARE SWITCH the open position weie no arive Be sure machine is not in the free wheel Replace drive enable configuration limit switch OR repair open in blk 38 or blk 59 wires from terminals TB38 and TB26 to limit Disconnect drive pump electronic displacement controller EDC wires 0 or infinite ohms and check resistance across both wires on EDC side of quick di CCI Replace EDC 20 to 24 ohms Correct insufficient voltage supply OR repair open in wht wire circuit supplying 12V to terminal 1 Press down foot switch less than 12V and check voltage at horsepower limiter board terminal 1 12V or more Switch rom select switch to rabbit with foot switch Repair open in org blk wire circuit from TB40 OV 6 to 7V mi press down foot switch Check voltage at TB40 to horsepower limiter and check voltage at terminal 3 terminal 3 on oV horsepower limiter Check voltage at blk 40 6 t0 7V Repair open in blk 40 6 to 7V wire on engine wire cir
73. the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries service With secondary boom fully lower hold the function down switch Adjust the relief valve to read 1200 PSI Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 17 Continued from the previous page 1200 PSI Interchange secondary relief valve item U with like valve item T Hold secondary down function and recheck pressure less than 1200 PSI If secondary boom is in stowed position remove and plug the secondary down high pressure line 1200 PSI from the cylinder on the fuel tank side of the machine Hold secondary down function and recheck pressure less than 1200 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 Genie Z 45 22 Replace defective valve Repair both secondary function cylinders Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boom Up Function Inoperative Be sure all other functions operate normally If primary boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If primary boom up function ope
74. 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 2 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 machine 33 Remove the fasteners from the underside of the rotate bearing then remove the rotate bearing Part No 29487 Service Manual First 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 AWARNI
75. 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 Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS the primary boom weldment Crushing hazard The extension tube will fall when it is removed from the primary boom if it is not properly supported 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 lt may be necessary to heat the bolts and the surrounding area to remove them Do not reuse the bolts 11 Remove and label the wear pads from the primary boom weldment and the extension tube Pay careful attention to the location and amount of shims used with each wear pad Genie Z 45 22 3 3 Primary Boom Lift Cylinder The lift cylinder raises and lowers the primary boom How to Remove the Primary Boom Lift Cylinder This procedure requires specific PULL 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 rec
76. to the top bleed valve Place the other end of the hose in a container to collect any discharge SU R Y TR Induit TU a clear hose b top bleed valve C bottom bleed valve d container 2 Open the top bleed valve but do not remove it 3 Start the engine from the ground controls 4 Hold the platform rotate switch to the right for approximately 5 seconds then release it Repeat 3 times Crushing hazard Keep hands clear of the platform pivot weldment during rotation 5 Hold the platform rotate switch to the left for approximately 5 seconds then release it 6 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 7 Rotate the platform to the right until it is centered 8 Connect the clear hose to the bottom bleed valve and open the valve 9 Rotate the platform to the right and continue 7 12 Genie Z 45 22 holding the platform rotate switch until air stops coming out of the bleed valve 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 Part No 2948
77. voltage to 6 26V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 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 6 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 7 Start a timer and record how long it takes the turntable to rotate to the full left position Adjust the max out trimpot to achieve a 71 to 75 second cycle time Specifications Turntable Rotation function Threshold 3 35V DC 6 26V DC 71 75 seconds Turntable rotation Max out time 7 6 Genie Z 45 22 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 rom 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 Limiter Board a horsepower limiter board 1 Remove the fasteners from the platfor
78. 0 3 ohms Repair open in circuit supplying 12V to choke switch Replace toggle switch Repair open in red wire circuit from choke switch to fuel select switch Replace fuel select VV Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 4 Continued from the Hold choke switch and OV Repair open in blk wht previous page check voltage at TB29 wire circuit from fuel select switch to TB29 12V Hold choke switch and Repair open in blk 29 check voltage at initiate wire circuit from TB29 to terminal of PR4 PR4 12V Check green grounding Dot wire circuit for PR4 Repair open in green grounding wire circuit Replace PR4 id A 5 12 Genie Z 45 22 Part No 29487 Service Manual First 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 Part No 29487 Chart 6 Disconnect LPG supply line from LPG tank and bleed pressure from line Disconnect and isolate black positive cable from starter motor hold start switch and check voltage at LPG side blu red Replace fuel select VV wire of fuel select switch 12V Hold start switch and check voltage at TB34 12V Hold start switch and OV Repair open in blu red wire circuit from fuel select switch to TB34
79. 0 35 in lbs 3 4 Nm Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures FUNCTION MANIFOLD Part No 29487 Genie Z 45 22 7 43 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD Plug Torque Specifications Description Torque SAE No 2 4 2 ft lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 11 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 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 26 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 Genie Z 45 22 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
80. 1 Close the two hydraulic tank valves located at the main pump open closed 2 Disconnect the hydraulic hoses from the pump and cap them Bodily injury hazard Spraying 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 pump mounting bolts Carefully remove the pump Component damage hazard Be sure to open the two hydraulic tank valves after re installing the pump Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 10 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 The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service IS recommended 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the main pump 2 Close the two hydraulic tank valves located at the main pump
81. 14 2 How to Remove the Steering Cylinder Part No 29487 Genie Z 45 22 4WD STEERING AXLE COMPONENTS 15 3 Tie Rod How to Remove the Tie Rod Weldment This procedure is the same as the 2WD procedure See repair procedure 14 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 14 3 How to Pertorm the Tie Rod Toe in Adjustment Section 7 Repair Procedures Service Manual First Edition Oscillating Axle Components 16 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 fully 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 repair skills lifting equipment and WP VIG 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
82. 16 Nm 3 Sensing valve esses E eres Differential sensing 10 12 ft lbs 14 16 Nm 4 Normally closed poppet valve A Steering dump 25 30 ft lbs 34 41 Nm 5 2 position 4 way valve BR A 10 12 ft lbs 14 16 Nm 6 Check valve es Oscillate check 35 40 ft lbs 47 54 Nm Part No 29487 Genie Z 45 22 7 59 Section 7 Repair Procedures Service Manual First Edition Z STEER AND OSCILLATE MANIFOLD Plug Torque Specifications 2 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the diagnostic nipple on the function Description Torque manifold SAE No 2 50 in los 6 Nm 3 Manually hold down the drive limit switch E When the oscillate cylinder fully retracts the SAE No 4 13 ft lbs 18 Nm pressure will spike Note the maximum SAE No 6 joie 252 NIE pressure reading Do not release the drive limit A switch lcd 50 ft lbs 68 Nm 4 Release the drive limit switch When the SAE No 10 55 ft lbs 75 Nm oscillate cylinder fully extends the pressure will spike Note the maximum pressure reading SAE No 12 75 ft lbs 102 Nm 5 Hold the unloader valve and remove the cap index 2 6 Adjust the internal hex socket by turning it 17 2 clockwise to increase the pressure or counterclockwise to decrease the pressur
83. 182 3 80 5 83 5 Full open 203 95 C Starter motor Current draw no load 90A Brush length new 0 7480 in 19mm Brush length minimum 0 5 in 12 7mm Battery Type 12V Group 24 Ampere hour 75A Cold cranking ampere 875A Section 2 Specifications Service Manual First Edition SPECIFICATIONS Bolt torque specifications continued Size Standard M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 Size Grade 7 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 Size Grade 9 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 ft lbs 5 7 13 15 29 33 46 53 79 92 123 141 180 210 246 289 7 8 17 20 35 41 57 66 91 108 145 166 203 235 2 1 318 9 10 22 25 45 52 76 86 123 144 192 224 253 296 362 419 Nm 8 9 18 20 39 45 63 72 108 125 167 191 245 284 334 392 10 11 24 27 48 56 78 90 124 147 196 225 275 318 368 431 12 14 30 34 61 70 103 117 168 196 260 304 343 402 490 568 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey WI 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
84. 2 SPD MOTOR BRAKE BRAKE 7 STEER OSC MANIFOLD TANK le 025 mW M TI BO L 4 TANK Lo RETURN SE Kr CH OS7 pe 54 y 7 S osz BS R 1 IN oe AXE EE L REAR R REAR MOTOR OTOR s1 sz 2 8 CU IN ACCUMULATOR PRE CHARGE 1600 PSI i OSCILLA TION STEERING LOCK OUT NEUE DWG HS4WD 745 22 Hyd Index Z45722 HP GP d DIESEL AWD HYDRAULIC SCHEMATIC SERIAL Z45 002539 AND ABOV
85. 22 Secondary Boom a b J Q gt O upper secondary boom number 1 arm uppertension link number 2 arm lower tension link number 3 arm lower secondary boom number 4 arm secondary lift cylinder pin retainer compression link lower mid pivot drive limit switch primary boom rest turntable pivot upper mid pivot rest upper mid pivot Section 7 Repair Procedures Service Manual First Edition SECONDARY BOOM COMPONENTS 1 Remove the platform See 2 1 How to Remove the Platform Crushing hazard Do not remove AWARNING the 4x4x31 inch 78cm support block installed during primary boom removal SE 2 Remove the primary boom See 3 2 How to CS i Remove the Primary Boom Se a a YNA A Ae MA a pivotpin b 10to12inch 30cm rod 6 Remove the turntable end cover 7 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 a uppermid pivot mid pivot b 4x4x31 inch block c counterweight Industrial tires No modification is necessary 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 throu
86. 29487 Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES oO 8 E o S D oO oO E e GB 55 HU ot o c a gL les 38 32 33 8 3 3 S 8 Table C continued ae 62 z8 29 Pe CONTINU El ma C 7 Replace the Drive Loop Hydraulic Filter gt C 8 Replace the Diesel Fuel Filter EEEHEHEEH 4 44 4444 C 9 Replace the Gasoline Fuel Filter C 10 Replace the PCV Valve Gasoline LPG Models C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LPG Models C 12 Replace the Spark Plugs Gasoline LPG Models gt ZER C 13 Check and Adjust the Air Propane Mixture Gasoline LPG Models ZE Ep C 14 Check and Adjust the Ignition Timing Gasoline LPG Models Table D D 1 Change the Hydraulic Oil includes cleaning the suction strainers D 2 Change or Recondition the Engine Coolant including all coolant hoses and clamps D 3 Change the Fuel Lines 2 O ZER ERE o D 4 Check Engine Valve Clearance Gasoline LPG Models ES D 5 Check Engine Cylinder Compression Gasoline LPG Models Es D 6 Clean PCV Hoses and Fittings Gasoline LPG Models D 7 Check the Engine Nozzle Injection Pressure Diesel Models E PS j LA VA V PA VA VA UA D 8 Check Injection Timing Diesel Models D 9 Replace the Timing Belt Ford ZER E E Part No 29487 Genie Z 45 22 3 5 Section 3 Scheduled Main
87. 34 LHM C IHM X18 THM X18 1HM X18 1HM S X18 X18 LHM Q3M L1HM Q3H 1HM 9 G3M 1HM A 1d cAI Z X18 EN IHM x18 E 1LHM 18 8 X18 LHM 18 034 418 C 0I4 XA18 6 0394 18 34018 30718 OL X18 3n18 x18 n18 x18 018 LL X18 x18 n18 1HM nd8 e 1HW n18 el 1HW N1a 990 58O CI X18 340 118 930 H19 940 pl X18 119 2930 034 940 E a34 940 Gi d34 940 N39 NM9 9I X18 MA X 18 N39 A18 N19 ZI X18 M19 NY9 LHM NID E LHM NMO9 81 1HM ND 1 034 0 61 gay X18 2 418 03Y oz 418 033 X18 2 LHM 038 LZ A19IZ 1HM DF ZZ He Mie JH 418 2 48 M cz e IS He SM A18 034 N18 bz RER SZ aad A18 Z 1HM A1d 9z 65 18 A19 1 418 1HM zz 418 1 034 1HM Sz X18 X18 L LHM X18 6z X18 1039 4718 o q a 1 x18 L 3018 1 X18 X18 118 7018 ze X18 X18 L LHM D 18 ec X18 L G34 0 8 bo L 034 980 c d34 940 MI I M S gt l oe dy he M A wid 1 990 7 wid L LHM ge X18 2039 4189 6c X18 L X 18 980 Ob Aj MEC S 22 42 Sr gs dn ANVWINd NMOG VAINJd DY AMVMIJd 1337 ONIMS LHOIN ONIMS 94 9NIMS dN IX 19VML3M 04 134 1X3 dn AMVONO23S NG ANVONO23S 94 AMYUNOO3S dn 13A31 Lui MO 13A31 1v1d TJA31 Leid M J1VION 1vid 1 31V1ON Vd 31V1OY 1vid TV d OL Ael ABVIUXNY J NYY MOT ANG 11 S3Md IO 11 dW3L N3LVM MOSN3S LTIL Leg 903 IMYA 203 JAING ya JANG 3MOHO 3NION3 Nay H9IH 1331 Y3318 LHOIN M33LS INMOSVI 9471
88. 5 crank the engine over and check voltage at blk 50 wire on vacuum switch 12V Disconnect wires from vacuum switch and connect the wires together Check the voltage at terminal 5 on CR4 12V Disconnect and isolate blk positive cable from starter Hold start switch and check voltage at terminal 9 on CHA 12V Hold start switch and check voltage at terminal 5 on CR5 12V Continued on the next page Repair open in blk 36 wire circuit from TB36 to vacuum switch Turn machine off and bad see Repair section for vacuum switch check OK Check vacuum line for bad restrictions OK See Ford service manual to troubleshoot low manifold vacuum Repair open in blk 50 wire circuit from vacuum switch to CR4 Repair open in wht 52 wire circuit that connects CR1 CR2 CR3 CR4 and CR5 Check CR4 grounding wire circuit OR replace CR4 relay OR replace relay socket Genie Z 45 22 Chart 2A Check all diodes at TB36 for open OR repair open in red blk wire circuit from key switch to TB36 Replace vacuum switch Replace vacuum line Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2A Continued from the previous page Hold start switch and check voltage at center terminal on fuel select switch 12V Hold start switch and check voltage on gasoline side blk wht wire of fuel select Hold start switch and check vo
89. 5 foot pounds 129 Newton meters Second rotation 190 foot pounds 258 Newton meters After re assembly the turntable should swing smoothly without jerking or grinding Part No 29487 Service Manual First Edition Section 7 Repair Procedures 14 1 2WD Steering Axle Components Yoke and Hub How to Remove the Yoke Hub Assembly 1 Remove the cotter pin and the clevis pin from both the steering cylinder and tie rod weldment Place a second jack under the yoke hub assembly Use a soft metal drift to drive the king pin down and out Crushing hazard The yoke hub AWARNING ZEIT ee 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 How to Remove the Hub and Se CN i UEN Bearing Di a 1 Loosen the wheel lug nuts Do not remove v i AN 2 Place a lifting jack under the steering axle o m A Raise the machine and place blocks under the za chassis A ka e S 4 Remove the lug nuts then the tire and wheel IU assembly 5 Remove the dust cap cotter pin and slotted a axle nut ee 6 Pull the hub from the spindle The washer and d Sien Outer bearing should fall loose from the hub e hub 7 Place the hub on a flat surface and gently pry f cotter and clevis pin the bearing seal out of the hub Remove the g steering cylinder rear bearing h tierod 2 Break loose the wheel lug nu
90. 7 Service Manual First 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 primary boom cable track can be damaged if it is twisted a linkseparation point b lowerclip 1 Use a slotted screwdriver to Dry down on the lower clip 2 Repeat step 2 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 the 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 2 Extend the primary boom 10 inches 25 4cm Remove the wear pad mounting fasteners 4 Install the new shims under the wear pad to obtain zero clearance and zero drag 5 Using a round punch align the holes in the shim to the wear pad and install the mounting fasteners 6 Extend and retract through the entire range of motion to
91. 7 WHT BLK 1 BLK BLK 59 26 BLK WHT 2 BLK RED 23 RED 24 BLU RED 2 BLK W BK gt H BLK rH 23 W BK 2 BLK WHT PH BLK gt 22 WHT 2 BLK 21 RED WHT 2 BLK RED BLK 20 RED BLK 2 BLK RED 19 RED 2 RED GRN WHT 18 GRN WHT 3 GRN WH T GRN BLK BLK 17 CRN BLK 3 CRN BLK GRN BLK 16 GRN 3 GRN ORG RED 15 ORG RED 3 ORG RED ORC BLK BLK 14 ORG BLK 5 ORG BLK ORG BLK 15 ORG 3 ORG BLU WHT 12 BLU WHT 3 BLU WHT BLU BLK BLK 11 BLU BLK 3 BLU BLK BLUE BLK 10 BLUE 3 BLUE BLK RED 9 BLK RED 3 BLK RED BLK WHT BLK 8 BLK WHI 3 BLK WHT BLK BLK 7 BLK 3 BLK WHT RED 6 WHT RED 3 WHT RED WH T BLK BLK 5 WHT BLK 3 WHT BLK WHT BLK 4 WHT 3 WHT RED WHT 3 RED WHT 3 RED WHT RED BLK BLK 2 RED BLK 3 RED BLK RED BLK 1 RED 3 RED lt L m O a pe pes gt OO lt 2 cde Ga ES GQ OO OO gS LO O A roo ae LO O ad nad 00 oO BIE RZ O GE OO US ZE ka xloo Im Z O La a O S 21000 GO D pal O ele OO YN xd O zl m NN C3 e C3 OSCILLA TE OIL PRESSURE ANTI RESTART CABLE 3 6 10 EE HIRG RPM Nen a Vas wu 3 C gt R 3 ES O V J E PR4 GLOWPLUG CN m Le NN P2 STOP NCINC DPT
92. Box 69 Redmond WA 98073 0069 USA If you have any questions call Genie Industries li Genie Z 45 22 Genie U S A and Canada Telephone 206 881 1800 Toll Free 800 536 1800 Fax 206 883 3475 Telex 152351 Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 Genie Industries Copyright O 1992 by Genie Industries First Edition October 1992 Genie is a registered trademark of Genie Industries Registered 2009987 Ga Printed on recycled paper Printed in U S A Part No 29487 Service Manual First 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 applicable governmental regulations II You have the appropriate tools lifting equipment and a suitable workshop Part No 29487 Genie Z 45 22 lii Section 1 Safety Rules Service Manual First Edition SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety haz
93. E WHT BLK 1 Si BLK 427 BLK 3 3 s S BLU BLK 1 a BLK 432 5 SE BLU 1 B BLK 31 pa 5 E m dil Sa al JL E SE E ES Te ME X N RED WHT RED WHT 2 BLK 21 vis HIGH SE e LOW RED 5555 y A Y 4 A x a GRN m I BLK 160 np En v Ome WHT R6 W 6 Bei RED Oo a N ES S no ORG 1 AN WA GRN ISS mix COOEO N a BLU WHT 3 D BLU BLK 3 BLU 3 S BLK 4 BLU ID BLU SRF BLU af H TS Eels Je UP goow SECONDARY BLK M To pow BLU BLK m Qt BLU BLK D D ice e o E ES o E i fn gl i 1 BLU WHT BLU WHT E 0 ei Le A b BLK RED 3 cO BLK WH7 3 BLK 3 BLK P eg BLK p BLK i EXTEND i d m BLK a e RETRACT md vies ha z BLK WHT BLK WHT 3 oo p p V 1 BLK RED BLK RED e M ac E p WHT RED 3 E A SS WHT 3 WHT BLK 3 BLK 4 LO WHT WHT 2 WHT BLK WHT BLK D RIGHT re ROTATE m _BLK 4 A ped WHT ES WHT N te e zT Te A z S 150 WHT Se n y WHT RED 4 WHT RED D Wei SKA B L A BLK E ER NN cad RED CR7 RED SE e Sg elle m PRIMARY BOOM BLK HENTIE y SE Ge NEA yny LO z a e ei Le 10 ne e jaa x RED WHT RED WHT 0 Ez id RED 3 lt RED BLK 3 o E s RED WHT 3 a D ORG j UP PLATFORM LEVEL UO ORG BLK 3 R ES ORG RED 3 e gt 4 ORG ke ORG rj ei
94. Edition Section 7 Repair Procedures E FUEL AND HYDRAULIC TANKS 12 2 Fuel Tank How to Remove the Fuel Tank Engine fuels are combustible A DANGER 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 A DANGER transferring fuel connect a grounding wire between the machine and pump or container mb Raise the elevate assembly 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 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 29487 Genie Z 45 22 7 47 Section 7 Repair Procedures Service Manual First Edition Turntable Rotation Components 13 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
95. FUEL VALVE PULL 1 dl le 5 WwW RED 25 a O e e e uy a E STARTER MOTOR N BLK WHT gt WH I DE INS u gt WH T RED gt SR 33 WHT BLK 309 gt LJ T BLK gt WHT GRN C o ORG BLK 1 mp BLK 440 p e KN C3 LO m ac T hd nini BLK TRAVEL HORN FLOW CON ES45D4 1 D 00 4 gt cs WHT RED 1 BLK 28 Y lt BRAKE RELEASE GRN GRN e CRN 1 amp 2 PLATFORM GROUND N 55 M Ke a E 8 e 2 ai JY BLK RED 2 BLK 39 ES LO SZ A x GR DESSEN SC Eu DRIVE WHT 1 BLK 38 W
96. Fan belts B 2 Engine radiator lt z JJ B 3 Exhaust system B 4 Battery B 5 Hydraulic reservoir filter B 6 Electrical wiring B 7 Tires and wheels B 8 Brake configuration B 9 Drive torque hubs B 10 Engine choke gasoline B 11 Glow plugs diesel B 12ldle mixture gasoline B 13 Engine RPM B 14 Key switch B 15 Emergency Stop button B 16 Ground control override B 17 Oscillate lock out Genie Z 45 22 B 18 Platform leveling B 19 Service horn B 20 Foot switch B 21 Engine speed select B 22 Fuelselect gasoline B 23 Turntable rotation stop B 24 Drive enable system B 25 Drive brakes B 26 Drive speed B 27 Alarm package Checklist C Refer to Table C C 1 Wear pads C 2 Turntable bolts C 3 Free wheel configuration lt N J C 4 Worm drive gear C 5 Drive torque hubs C 6 Hydraulic reservoir 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 Checklist D Refer to Table D D 1 Hydraulic oil lt J D 2 Engine coolant hoses and clamps D 3 Fuel lines and clamps D 4 Engine valve clearance gasoline D 5 Cylinder compression D 6 PCV hoses and fittings gasoline D 7 Engine injection nozzle diesel D 8 Injection timing diesel D 9 Timing belt Ford Part No 29487 Service Manual First Edition Section 4 Scheduled Mai
97. Genie Industries Technical Publications Genie Z 45 22 O O A Service First Edition Part No 29487 Introduction Service Manual First Edition Genie Z 45 22 Important Read understand and obey the safety rules and operating instructions in the Genie Z 45 22 Operating Instruction Manual before attempting any maintenance or repair procedure This service manual covers the Genie Z 45 22 2WD and 4WD models introduced in 1991 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 Industries PO
98. NG 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 Part No 29487 Genie Z 45 22 TURNTABLE ROTATION COMPONENTS O mark outer bearing inner bearing dowel red mark rotation stop block OD OO O 0 3 Install the mounting fasteners from underneath the chassis Use a torque wrench to tighten the fasteners in sequence to specifications Specifications torque First rotation 95 foot pounds 129 Newton meters Second rotation 190 foot pounds 258 Newton meters 51 Section 7 Repair Procedures Service Manual First 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 i
99. RONT R FRONT SWING er MOTOR OTOR MASTER 1 Si 2 1 CU IN N Sa es Se PLATFORM ROTATE PLATFORM LEVEL SWING RISER PRIMARY PRI PRZ PL1 PL2 51 52 Ri RZ pi P2 EXTEN RETRACT i FUNCTION A B Caro B MEDIUM oM doe oMi Le coge MANIFOLD 2 ES Es PRESS O DEE E d p ut FILTER LS LET WH 3 Tol EX 3 0 gt gt gt Ee X x Hi c YC ji O l Es 1 5 GPM M Zb A E X Mt X DRE AT Ab dl AN DRIVE 3500 gt PRESS gt 1 O 1 Si 1 4 A een TRACTION La O Holt si li d NE repr lie dE MANIFOLD Tel FUNCTION e osa IE BEBE Ic WEN S OX PUMP ESCH EH A dml 6 MERA MIA gt O gt gt 6 4 GPM L TM 7 4 e 4 ec Y DRIVE PUMP XX Los X PRESS WZ TANK L L X TANK I ES Y a A i SR SEC REG 25 AD NZ TS eg T 2 D ZS RESERVOIR AUX PUMP 2 SPD MOTOR 2 SPD MOTOR BRAKE BRAKE 7 AN STEER OSC MANIFOLD 9 025 A A ee t dO f lal Bg TANK L aT RETURN DZ FC os SA ap ZE m E T7 xm d L REAR R REAR MOTOR OTOR s1 sz 2 8 CU IN ACCUMULATOR PRE CHARGE 1 1600 PSI i OSCILLATION STEERING LOCK OUT VALE NJ U DWG HS4W 745 22 Hyd Index 245 22 HP 4WD HYDRAULIC SCHEMATIC SERIAL 4245 000990 TO Z45 002535
100. T RED 1 EDC 38 WHT BLK 1 EDC 37 WHT 1 VAC POWER 46 RED WHT 1 12V F SEL 35 JRED BLK 1 12V SUPPLY 34 RED 1 DRIVE EN LT 33 BLK RED 2 DRIVE ENABLE 32 BLK WHT 2 HORN 31 BLK 2 SPARE 30 WHT RED 2 WTR TEMP LT 29 WHT BLK 2 OIL PRESS LT 26 WHT 2 4WD 27 IRED WHT 2 AUXILIARY 26 RED BLK 2 12v SUPPLY 25 RED 2 ALARM 24 12V GROUND 23 GREEN PWR TO F S 22 BLK ES PWR START 21 GREEN F S PWR CONT 20 WHT H P L 2 4WD 19 RED H P L PLAT ROTATE 18 GRN WHT 3 PLAT ROT R 17 GRN BLK 3 PLAT ROT L 16 GRN 3 PLAT LEVEL 15 ORG RED 3 PLAT LVL DN 14 ORG BLK 3 PLAT LVL UP 15 ORG 3 SEC BOOM F C 12 BLU WHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 EXTARE UP 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 SWING F C 6 WHI 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 2131415161 181910 100 0HM ON ABLE 2 gt 50 OHM STOP RZ NCINC DP1 0O m LO lt A CN A X TR m al IX I X laut X v b Oya IX y Pa v zZ ax KR
101. Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine II Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating the machine Before Troubleshooting WI Read understand and obey the safety rules and operating instructions printed in the Genie Z 45 22 Operating Instruction Manual M Be sure that all necessary tools and test equipment are available and ready for use Part No 29487 Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with AWARNING bot Or live circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to s Perform service problem repair solved Genie Z 45 22 6 1 Section 6 Troubleshooting Flow Charts Service Manual First Edition Electrical Symbol Legend 1518 9480 Wire color with cable numb
102. Valve clearance cold Lubrication System Oil pressure Oil capacity including filter Oil viscocity requirements Engine oil should be MIL L 2104C or have properties of 105 7 cu in 1 732 liters 4 3 23 x 3 23 inches 82 x 82mm 36 2800 rpm 1 3 4 2 22 1 427 469 psi 29 4 32 3 bar 2150 rom 1200 rom centrifugal ball API classification CC CD CE grades Injection System Injection pump Injection pump pressure Injection timing Fuel requirement Coolant capacity Alternator output Part No 29487 mechanical Reserve capacity 25A rate 125 minutes 0 0071 0 0087 inches Glow plug resistance 1 50 0 18 0 22mm Fan belt tension 0 275 0 354 in 7 9mm Bolt torque specifications 42 7 64 psi T 294 2 441 3kPa SR e EE ft lbs Nm 9 5 quarts 9 liters Cylinder head bolt 65 68 88 93 10W 30 Fuel injector nozzle holder 22 36 29 49 to cylinder head Fuel injector retaining nut 43 58 59 78 to nozzle holder body Flywheel to crankshaft bolt 72 79 98 108 Bosch K Type Oil pressure sending 8 18 11 24 unit to block 1991 psi 1437 bar Oil pan drain plug to pan 15 25 20 34 25 BTDC ES A A 3 022 Rocker arm cover to 5 7 7 9 Diesel number 2 D cylinder head 7 25 quarts 6 9 liters Rocker arm mounting nuts 17 24 24 27 35A 14V Temperature sending 8 18 11 24 unit to block Genie Z 45 22 2 7 Section 2 Specifications SPECIFICATIONS Thermostat Beginning opening 176 9
103. akeS EE 4 22 Test Drive Speed Stowed Position ies 4 22 Test the Alarm Package optional equipment 4 23 Check the Primary Boom Wear Pads ii 4 24 Check the Turntable Rotation Bearing Bolts 4 24 Check the Free wheel Feature ne 4 25 Grease the Worm Drive Gear 4 26 Replace the Torque Hub Oil tte 4 27 Replace the Hydraulic Reservoir Elter 4 27 Replace the Drive Loop Hydraulic Eiter 4 28 Replace the Diesel Fuel Elter 4 28 Replace the Gasoline Fuel Elter 4 29 Replace the PCV Valve Gasoline LPG Models sss 4 30 Clean or Replace the Distributor Cap and Rotor Gasoline LPG Models 4 30 Replace the Spark Plugs Gasoline LPG Models 4 31 Check and Adjust the Air Propane Mixture Gasoline LPG Models 4 31 Check and Adjust the Ignition Timing Gasoline LPG Models 4 32 Change he Hydraulic e NEE 4 33 Change or Recondition the Engine Coolant aaa aaaaaaasecaac 4 34 Change the FUELENES ouis Moo t aee ie aiu 4 35 Check Engine Valve Clearance Gasoline LPG Models 4 36 Check Engine Cylinder Compression Gasoline LPG Models 4 36 Clean PCV Hoses Tubes and Fittings Gasoline LPG Models
104. al First Edition Section 4 Scheduled Maintenance Procedures JAN 3 inches N_ZN a oscillate lock out wedge 2 Lower the primary boom onto its resting pad O 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 B 18 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 O Result The platform should remain level at all times to within 5 degrees Part No 29487 Genie Z 45 22 TABLE B PROCEDURES B 19 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 grou
105. al First Edition Section 5 Troubleshooting Flow Charts Chart 11 Engine Low At platform controls Isolate the platform and start engine and switch 12V ground rpm switches Idle Inoperative rpm select switch to check individually and Diesel Models maintained low idle turtle symbol Check Check if mechanical volts at blk red wire on linkage from 2 speed rpm select switch solenoid to fuel injection pump is binding or defective replace defective switch Check voltage at the red wire on the 2 speed solenoid Replace PR2 relay solenoid binds Check if 2 speed solenoid moves in and Check linkage or replace solenoid V moves freely Check adjustment of linkage and fuel injection pump low idle see Maintenance section See Kubota workshop manual to troubleshoot fuel injection pump Part No 29487 Genie Z 45 22 5 19 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 12 All Functions Inoperative TT Engine Starts Check pump suction line and Runs shutoff valves Valve handles should be parallel with hose open Disconnect center coil Check hydraulic fluid OW Fill with Dexron Il equivalent hydraulic Open valves H engine closed has been run with valves closed it may have damaged one or both pumps wire from distributor cap and isolate from grounding Remove function pump from drive pump but leave all hos
106. anel Legend Diesel Models 6 11 Platform Control Box Legend Diesel Models na 6 12 Hydraulic Symbols Legend E 6 13 2WD HydraulioSchetfialG se occccant enun ueu sede E duR Ee Rae gets RU ne codo oet as 6 14 AWD Hydraulic Schematic A 6 15 Genie Z 45 22 ix Service Manual First Edition EEN TABLE OF CONTENTS Section Seven Repair Procedures A TE 7 1 Platform Controls Tal sJoysuck ee gell 7 2 1 2 Horsepower Limiter Board 7 6 to ee e BEE 7 8 ROSISIOLS YY 7 8 To TOGOIESWICENES str EET 7 9 Platform Components 2 O AZ A deut 7 10 2 2 Platform Leveling Slave Cylinder SS NR 7 10 2 0 cien eiie Seta al 7 11 Primary Boom Components Sicht Plastic Gable Track EE 7 13 32 Gell BOOM A NN NN i N 7 13 3 3 Primary Boom Lift Cylinder A 7 16 3 4 Extension Cylinder ea aaa aaa aaa aaa aaaaaa enne 7 18 3 5 Platform Leveling Master Cylinder ii 7 19 Secondary Boom Components 4 6609HGdaIVBOO KKT N V VO 7 21 4 2 Secondary Boom Lift Cylinders 7 26 Turntable Covers 5 1 Veiner 7 27 Kubota V1702 B Engine 6 1 Timing Adjustment A 7 28 SC MEE Cle M PICS secre i ZO EW 7 28 69 ARMA US imei eher EE 7 28 A E o ECO A 7 28 6 5 Water Temperature and Oil Pressure Switches ea 7 28 Ford LSG 423 Engine FV GOVEMO lie EU t RETE 7 30 X Genie 45 22 Part No 29487 Service Manual First
107. 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 4x4x31 78cm 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 Genie Z 45 22 2 Raise the primary boom until the end of the boom is approximately 7 feet 2m 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 S o to a Ja Ze 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 Part N
108. ards 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 serious 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 sl Be aware of potential crushing hazards zl iv Genie 45 22 Workplace Safety Be sure to keep sparks flames and Ae lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working areas Be sure that your workshop or work area nu D TE is well ventilated and safely and w S SS adequately illuminated Be sure any forklift overhead crane or other lifting
109. at whtred wire on turntable rotate function proportional Repair open in wht red wire circuit from TB6 to proportional valve 4 to 7V Hemove both wires from valve coil and check resistance across the 0 or infinite ohms Replace coll coil terminals 4 5 to 5 5 ohms Hold toggle switch up function and manually override operates Replace the proportional proportional valve push valve in button on end of valve spool function inoperative function operates Replace defective flow regulator valve Interchange primary function flow regulator valve item O with a like valve item M function inoperative 4 t0 5 ohms Replace the valve 0 or infinite ohms function operates Check the resistance of the directional valve Hold toggle switch to left and manually override rotate left directional valve push in button on end of valve spool Replace the defective function inoperative valve coil s Continued on the next page Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 22 Continued from the Install a pressure gauge 2000 Interchange sandwich function Check for mechanical previous page at the quick disconnect PSI block including inoperatve restrictions keeping coupling on the function counterbalance valves turntable from rotating manifold and hold the OR repair rotation function switch with leveli
110. ate 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 fall if it is not supported when the pivot pin is removed a pivotpin b 10to12 inch 30cm rod 16 Carefully lower the platform leveling master cylinder down and out of the upper mid pivot Part No 29487 Service Manual First Edition Section 7 Repair Procedures Secondary Boom Components 4 1 Secondary Boom How to Disassemble the Secondary Boom The procedures in this section AWARNING 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 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 Part No 29487 Genie Z 45
111. ate back to its original position and replace the three retaining bolts Start the machine from the ground controls then inspect the fuel filter and hoses for leaks A DANGER If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Genie Z 45 22 4 29 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 10 Replace the PCV Valve 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 3 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 Genie Z 45 22 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 Ext
112. atform Rotate Left Function Inoperative iii 5 43 29 Platform Rotate Right Function Inoperative iii 5 44 30 Oscillate Lock out Function Inoperative 5 45 31 Steer Left Function Inoperative 5 46 32 Steer Right Function Inoperative ecne 5 47 33 All Drive Functions Inoperative All Other Functions Operate Normally 5 48 34 Drive Forward Or Reverse Function Inoperative 5 50 35 High Range Drive Function Inoperative 5 91 36 Low Range Drive Function Inoperative eee eeeaae aaa aaa aaa aaa caaaenccc 5 53 37 Machine Will Not Drive At Full Speed uuu 5 54 38 Machine Drives At Full Speed With Platform Elevated atn 5 55 39 Drive Enable System Is Malfunctioning iii 5 56 40 Auxiliary Functions Inoperative iii 5 57 Schematics e PES 6 1 Eleethncal Symbol Legend nii EE 6 2 Electrical Schematic Gasoline LPG Models tennant 6 3 Ground Control Box Legend Gasoline LPG Models i 6 5 Relay Panel Legend Gasoline LPG Models ii 6 6 Platform Control Box Legend Gasoline LPG Models 6 7 Electrical Schematic Diesel Models srnu 6 8 Ground Control Box Legend Diesel Models uti 6 10 Relay P
113. ating axle limit switch a limitswitch 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 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 Genie Z 45 22 4 7 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 14 Replace the Engine Oil and Filter 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 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 valve cover 2 Pull the end of the oil drain hose out from under the engine
114. bit amp 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 seeends 2WD TDS SOC ONES 0 25 seconds Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 27 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 otop button to the on position and turn the key switch to ground control O Result The flashing beacon should be on and flashing 2 Move the primary boom switch to the down position hold for a moment and then rel
115. bowl Allow the water to drain into a container until fuel starts to come out Immediately tighten the drain plug hours along with an oil and 3 Tighten the vent plug and clean up any spills or wet conditions may necessitate performing this procedure more often Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor eng component damage Perform this procedure with the engi ine performance and wet surfaces If the fuel bowl is completely drained you must prime the fuel filter water separator before starting the engine Refer to C 8 In this section Replace The Diesel Fuel Filter for instructions on how to prime the fuel filter water separator 4 Start the engine from the ground controls and ne off check the fuel filter water separator for leaks Engine fuels are explosive A DANGER 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 Fuel filter water seperator a OQO O head bolt filter bowl drain plug vent plug separator head Genie Z 45 22 Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 1 Check the Engine Fan Belts Maintaining the engine fan belts is essential to good engine performance and service life The
116. ce steer valve Replace steer left valve coil Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Right Function Inoperative Be sure all other functions operate normally Machines not equipped with oscillating axle disregard the steer unloader valve troubleshooting Part No 29487 Chart 32 Repair or replace the steer microswitch in Start the engine from the platform press down foot switch hold the steer switch right and controller handle check volt age at terminal 7 on the drive controller blu blk wire 12V Hold the steer switch left Repair open in blu wire and check voltage at circuit from TP44 to TB32 330 Hold the steer switch right and check voltage at blk 32 wire on steer Repair open in blk 32 wire circuit from TB32 to steer valve 12V Remove both wires from steer right coil and check resistance across coil terminals 0 or infinite ohms Replace steer right valve coil 4 to 8 ohms Reconnect coil wires hold steer switch and Test and replace diode or repair open in jumper wire circuit from steer right coil to steer unload check voltage at steer unload valve Genie Z 45 22 12V Replace steer valve Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 33 All Drive Start engine from ground Machine does not move Repair or replace the controls and
117. center terminal on start switch 12V Hold start switch and check voltage at either side terminal on start switch 12V Hold start switch and check voltage at terminal 1 on CR1 12V Check voltage at terminal 9 on CR1 12V Check voltage at blk 53 on PR5 12V Check voltage at output cable terminal on PR5 12V Check voltage at positive cable terminal on starter motor 12V Check starter ground cable OR repair or replace starter Kubota Models Check black jumper wire connecting positive cable terminal and starter bendix terminal Genie Z 45 22 OV OV OV Chart 1 less than 12V Check battery condition OR check alternator OR check fro short circuits Trace circuit back through the key switch OR check battery cables OR replace the battery and emergency stop button repair open Replace start toggle switch Repair blk wire circuit from start switch to CR1 Replace CR1 relay or relay socket Repair open in blk 53 wire circuit from CR1 to PR5 Check PR5 grounding wire OR replace PR5 relay Replace cable from PR5 to starter Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 2 Engine Cranks Over But Will Not Start Gasoline 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 i
118. check and or consult Geinie Industries service department Genie Z 45 22 0 or infinite ohms Chart 24 Repair open in wht blk wire circuit from TB5 to directional valve Replace the valve operates Replace the rotate directional valve Interchange the rotate right and left function operates Replace defective counterbalance valve function inoperative counterbalance valves in the sandwich block Check for mechanical restrictions keeping turntable from rotating right OR replace directional valve OR repair rotation motor Check for mechanical restrictions keeping turntable from rotating right OR repair rotation motor Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 25 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 Remove both hydraulic Replace the hoses from the manifold counterbalance valves in ports PL1 amp PL2 Plug the sandwich block the hoses and cap the items Z amp AZ manifold fittings Operate primary boom up function and check if platform levels no Plumb a pressure gauge into the barrel end hydraulic hose using a tee fitting Operate primary boom up function and read the C
119. cifications SPECIFICATIONS 110 rpm 150A 460A 70A 0 5V DC 0 50 inches 12 7mm 0 25 inches 6 35mm 40 ounces 55 75 inch pounds 98 134gm cm 15 20 foot pounds 2 1 2 7kg m 0 005 inches 0 127mm 12V Group 24 75A 875A Reserve capacity 25A rate 125 minutes Fuel Pump Static pressure Minimum volume flow Genie Z 45 22 5 0 7 0 psi 1 pint 473cc in 25 seconds Section 2 Specifications SPECIFICATIONS Ignition System Ignition spark advance 10 BTDC Ignition coil primary resistance Ignition coil secondary resistance 1 13 1 250 75 7700 93002 75 F Gap 0 042 0 046 inches 1 07 1 18mm Coolant capacity 11 5 quarts 10 9 liters Alternator output 35A 14 5V Fan belt tension new 120 150 foot pounds used 90 120 foot pounds 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 Genie Z 45 22 Service Manual First Edition AAA A AA AN Cylinder head bolt M 12 torque in sequ
120. continuity no continuity no continuity continuity no continuity no continuity Section 7 Repair Procedures Service Manual First 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 AN a platform mounting bolts b block gt 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 Genie Z 45 22 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 platform 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 h
121. controls no Check voltage at TB19 0V 12V Check voltage at TP34 OV and TP25 12V Check voltage at blk wire OV on platform emergency stop button 12V Check voltage at TP22 OV 12V Repair open in blk wire circuit from TP22 to foot switch OR replace foot switch Genie Z 45 22 Section 5 Troubleshooting Flow Charts Chart 15 Start engine from the platform then press down the foot switch and Repair open in wht wire circuit from foot switch to TP20 OR check voltage at TP20 test and replace foot Repair open in wht wire circuit from TP20 to function controllers Check for open in red wire circuit from key switch to TB19 OR replace the key switch Repair open in red 1 and red 2 wire circuit from TB19 to TP34 and TP25 respectively Replace contact on emergency stop button Repair open in blk wire circuit from emergency stop button to TP22 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 16 Secondary Boom Up Function Inoperative Perform this test only if the boom is in the fully lowered position Be sure all other functions operate normally If secondary boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If secondary boom up function operates normally from the platform controls but not from the
122. cuit from ternatC alternator to TB40 OV Repair or replace alternator Continued on the next page 5 48 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 33 Replace horsepower limiter board Continued from the Press down foot switch previous page and check voltage at terminal 10 on horsepower limiter 9 to 12V Press down foot switch Repair open in red wire and check voltage at red circuit from horsepower wire on center terminal limiter through TP15 to of drive mode select drive mode switch Switch drive mode to high range two wheels Repair open in red wire press down foot switch circuit from drive mode and check voltage at switch to drive controller terminal 6 on drive 9 to 12V Disconnect drive pump EDC wires press down foot switch hold drive controller in full forward position and check voltage across terminals 4 and 5 on drive Repair open in either wht or wht blk wire circuit Replace drive controller 4 to 5V Press down foot switch hold drive controller in full forward position and check voltage across terminals TP37 and from drive controller to TP38 and TP38 4 to 5V Press down foot switch hold drive controller in full forward position and check voltage across terminals TB26 and Repair open in wht blk wire circuit from TP38 to TB27 Repair open in either blk 27 or blk 26 circuits Pr
123. d releases aier g seconds Recheck fuel level previous page start switch and observe check that fuel shut off is the fuel solenoid open and check that fuel filter is free of water and solenoid releases italy Remove black jumper wire from the starter 12V Replace the fuel motor solenoid hold the solenoid hold coil start switch and check resistance red wire to voltage at red wire blk wire should be hold coil on the fuel o Bleed fuel injectors OR refer to Kubota service manual to troubleshoot fuel injection pump Hold start switch and check voltage at blk wire with diode on initiate terminal of PRI Check diode for open and replace OR repair open in blk wire circuit from PRS to PRI 12V Repair open in red wire supplying 12V to PR1 common terminal OR Hold start switch and check voltage at red wire check PR1 ground OR on output terminal of PRE replace PR1 relay 12V Reconnect starter and 9R Check oil pressure hold engine cranking for SYS ON sending unit and replace 15 seconds Check that OR see Kubota service oil pressure light goes manual for Jut troubleshooting low oil light goes out Remove the wht 451 wire from CR4 terminal 5 hold start switch and check voltage at terminal 5 on CR4 Repair open in wht 51 wire circuit from CR4 terminal 5 to PR1 Repair open in wht 51 Replace CR4 relay or relay socket wire circuit from CR4 terminal 5 to PR1
124. drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine 7 28 Genie Z 45 22 How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 4 inch 0 635mm gap between the coupler and pump end plate 3 Apply removable Loctite removable thread sealant to the coupler set screw Torque the set screw to 36 ft lbs 49 Nm Component damage hazard Do not force the drive pump during re installation or the flex plate teeth may become damaged 6 5 Water Temperature and Oil Pressure Switches The water temperature switch is a normally open switch that closes at approximately 225 F 107 C When this switch closes the engine is shut off to prevent damage and will not restart until the temperature drops below the switch point An over temperature indicator light at the ground at platform controls should turn on when the switch closes Component damage hazard Do not crank the engine with the over temperature light on The oil pressure switch is a normally closed switch that opens at approximately 7 1 psi 0 5 bar If the oil
125. e Valve Adjustments Then reinstall the relief valve cap 7 Manually hold down the drive limit switch and recheck the valve pressure How to Adjust the Sequencing Unloader Valve Bodily injury hazard Spraying Specifications hydraulic oil can perforate and Unloader valve 1900 psi burn skin Loosen hydraulic 131 bar 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 7 60 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures Non steering Axle Components 18 1 Drive Motor Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer How to Remove a Drive Motor A drive motor 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 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 Spraying hydraulic oil can perforate and burn skin Loosen hydraulic connections very slowly to allow the oil
126. e Manual First Edition Section 5 Troubleshooting Flow Charts Continued from the previous page Part No 29487 Hold start switch and check voltage at positive side of ignition coil 12V Hold start switch and check voltage at wht terminal of ignition module 12V Hold start switch and check voltage at blk wire with diode on initiate terminal of PRI 12V Check voltage at red wire on common terminal of PR1 12V Hold start switch and check voltage at red wire on output terminal of 12V Reconnect starter and light hold engine cranking for Stays on 15 seconds Check that oil pressure light goes light goes out Continued on the next page Genie Z 45 22 CHART 2 Repair open in brown wire circuit from PR5 to ignition coil Repair open in wht wire circuit from PRS to ignition module Check diode for open and replace OR repair open in blk wire circuit from PR5 to PR1 Repair open in red wire circuit from circuit breaker through TB20 to Check PR1 grounding wire circuit OR replace PR1 relay Check oil pressure sending unit and replace OR see Ford service manual for troubleshooting low oil Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2 Continued from the previous page Disconnect and isolate positive cable from starter remove blk 22 wire from oil pressure sending unit and disconnect wht 451 wire from ini
127. e V1702 B Lubrication System Oil capacity 9 5 quarts 9 liters Oil viscosity 10W 30 requirements Engine oil should be MIL L 2104C or have the properties of Al classification CC CD CE grades Part No 29487 TABLE A PROCEDU A 15 Change the Engine Air Filter RES 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 Kubota models Remove the air cleaner canister mounting straps then the end cap 2 Remove the mounting fastener from the air filter and then remove the air filter 3 Insert the new air filter and replace the mounting fasteners 4 Replace the end cap on the canister Genie Z 45 22 Section 4 Scheduled Maintenance Procedures EI TABLE A PROCEDURES A 16 Drain the Fuel Separator Diesel Models Engine specifications require that this procedure be performed every 100 filter change Poor fuel quality or very Service Manual First Edition 1 Loosen the vent plug located on the fuel filter Filter Water water separator head 2 Loosen the drain plug located at the bottom of the
128. e at initiate Repair open in blk 30 terminal blk 30 wire PR2 12V of wire circuit from TB30 to PR2 Check PR2 green bad Repair open in green grounding wire grounding wire OK Check voltage at Repair open in wht wire terminal 1 wht wire on circuit from PR1 to governor actuator 12V Turn off engine disconnect blk wire fro governor actuator m terminal 44 on electronic governor and disconnect no wht wire from governor continuity actuator Restart engine Replace PR2 switch to high idle and check continuity between loose blk wire and blk wire terminal o governor actuator f full continuity Continued on the next page Genie Z 45 22 OF US Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 8 Continued from the previous page Check resistance across governor actuator terminals 2 to 3 ohms Check voltage at OV terminal 1 on electronic V 12V Check electronic governor green grounding wire terminal Check voltage at OV governor terminal 3 V VV VV 6 to 7V Reconnect all wires and see Maintenance section for governor adjustments OR replace electronic governor Genie Z 45 22 0 or infinite ohms Replace governor actuator Repair open in wht wire circuit from PR1 to electronic governor Repair open in green wire grounding circuit Repair open in yellow wire ci
129. e 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 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 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 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 2WD STEERING AXLE COMPONENTS 14 3 5 Remove the cotter pin then remove the clevis Tie Rod pin from the adjustable end of the tie rod SE 6 Slide the tie rod off the yoke and adjust it by How to Remove the Tie Rod ENING ECS Weldment One half turn on the adjustable end equals a 3 16 inch 5mm 1 Remove the cotter pins then the clevis pins change in the front to rear from the ends of the tie rod measurement 2 Remove the tie rod weldment 7 Slide the tie rod onto the yoke Install the clevis in then a new cotter pin Always use a new cotter pin when P H re installing a clevis pin 8 Tighten the jam nut against the tie rod How to Perform the 9 Lower the machine and recheck the front and back measurements step 2 If further Tie Rod Toe in Adjustment
130. e 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 Hemove the Platform 2 Disconnect the hydraulic hoses from the platform rotator and cap them Bodily injury hazard Spraying 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 threaded 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 7 Use a soft metal drift to drive the pins out then remove the platform rotator Part No 29487 Genie Z 45 22 7 11 Section 7 Repair Procedures Service Manual First Edition PLATFORM COMPONENTS How to Bleed the Platform Rotator 1 Connect a clear hose
131. ease it Now move the secondary boom switch to the down position hold for a moment and then release it O Result The descent alarm should sound when each switch is held down TABLE B PROCEDURES 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 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 Hesult The descent alarm should sound when each control handle is held down 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 Hesult The travel alarm should sound when the drive control handle is moved off center in either direction Part No 29487 Genie Z 45 22 4 23 Section 4 Scheduled Maintenance Procedures Service Manual First 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 a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or
132. econdary boom 7 18 Genie Z 45 22 a 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 5m off the ground Extend the extension tube to the primary boom tube 17 inches 43cm 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 Loctitee 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 Disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Part No 29487 Service Manual First Edition Section 7 Repair Procedures Bodily injury hazard Spraying 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 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 Crushing hazard The cylinder will fall if it is not
133. eduled Maintenance Procedures 7 Re assemble the governor and recheck high idle rom Kubota engines 8 through 11 8 Turn the engine off 9 Loosen the lock nut on the Trombetta solenoid and then pull the rubber boot off the solenoid Kubota high idle adjustment a rubberboot b adjustmentnut c locknut d yoke 10 Screw the adjustment nut into the yoke to increase the rpm Back the adjustment nut out of the yoke to decrease rpm Be sure that the stop screw on the governor throttle lever does not limit solenoid travel The solenoid must fully retract when energized to prevent solenoid damage 11 Reconnect the rubber boot to the solenoid Then tighten the lock nut and recheck the rpm Specifications Ford and Kubota Engines Low idle 1200 rpm High idle 2150 rpm Part No 29487 TABLE B PROCEDURES B 14 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 Genie Z 45 22 Pull out the Emergency Stop button to the on position at both the ground and platform controls Turn the key switch to ground control start the engine and then turn the key switch to platform control Operate each machine f
134. edures Service Manual First Edition Hydraulic Pumps 10 1 Lift Steer Pump How to Test the Lift Steer Pump 1 Gasoline LPG models Remove the coil wire from the distributor cap Diesel models Disconnect the 3 wires from the fuel on solenoid at the fuel injector pump Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 2 Disconnect the high pressure hydraulic hose from the pump and cap it Burn hazard Contact with hot oil may cause severe burns 3 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 4 Turn the key switch to ground control and pull the Emergency Stop button to the on position 5 Observe the pressure gauge while cranking the engine Immediately stop cranking if the pressure reaches or exceeds 3000 psi 206 bar Hydraulic pressure in excess of 3000 psi 206 bar will cause severe component damage Result If the pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result If pressure fails to reach 3000 psi 206 bar the pump is bad and will need to be replaced 6 Remove the pressure gauge and reconnect the hydraulic hose 7 Gasoline LPG models Reconnect the coil wire to the distributor cap Diesel models Reconnect the wiring to the fuel on solenoid How to Remove the Lift Steer Pump
135. el may be expelled under A DANGER pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Plug all open fuel lines Part No 29487 Genie Z 45 22 a OD OO O TABLE D PROCEDURES o W Diesel models hose from the injector to the fuel tank hoses connecting injectors hose from the injection pump to the injectors hose from the fuel shutoff valve to the fuel pump hose from the fuel filter water separator to the injection pump hose from the fuel pump to the fuel water separator Once air has been introduced into the diesel fuel injection system the injectors must be bled before the engine is restarted Refer to the Kubota V1702 B Diesel Engine Workshop Manual Kubota code number 97897 00691 for information on how to bleed the fuel system Genie part number 29587 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES D 4 Check Engine Valve Clearance 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 D 5 Check Engine Cylinder Compression 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 Gasoline LPG models a fuel filter b ho
136. em Pull these hoses up through the turntable 11 Disconnect the hydraulic hoses from the turntable rotation motor and plug them Pull these hoses up through the turntable 12 Label and then disconnect all the wiring from the traction manifold and the steer oscillate manifold 13 Disconnect and remove the oscillating axle limit switches from the oscillation cylinder Oscillating axle limit switch a limitswitch b oscillate lock out wedge Part No 29487 Genie Z 45 22 Section 7 Repair Procedures Service Manual First 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 lug 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 8165kg by spreading the forks to an inside width of 3 feet 0 9m 21 Position the forklift at the counterweight end of the turntable Center the forks underneath the turntable and above the chassis Do not lift Genie Z 45 22 22 Place a 5 inch 13cm tall block near the end of
137. em T in all the way Then operate the function function With primary boom fully lowered hold the function down switch Adjust the relief valve to read 1200 PSI and replace the 1200 PSI or more less than 1200 PSI Continued on the next page Genie Z 45 22 function inoperative Chart 19 Replace the valve 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 With primary boom fully lower hold the function down switch Adjust the relief valve to read 1200 PSI Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 19 Continued from the previous page 1200 PSI Interchange primary relief valve item T with like valve item U Hold primary down function and recheck pressure less than 1200 PSI Remove the primary down high pressure line from the manifold and cap the port P2 Hold primary down function and recheck pressure 1200 PSI less than 1200 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 Ind
138. ence first step 50 60 second step 80 90 Distributor clamp bolt M 10 14 21 Distributor vacuum tube 5 8 to manifold adaptor 68 81 108 122 19 28 Yd Exhaust manifold to cylinder head bolt or nut M 10 torque in sequence first step second step 14 19 20 30 Flywheel to crankshaft bolt M 10 56 64 Fuel pump to cylinder block M 8 14 21 Intake manifold to cylinder 14 21 head bolt or nut M 8 Oil pressure sending 8 18 unit to block Oil pan drain plug to pan M 14 15 25 Oil pan to block M 6 10 13 5 Oil filter insert to block 20 35 Rocker arm cover to 5 8 cylinder head M 6 Spark plug to cylinder 5 10 head M 14 Temperature sending 8 18 unit to block M 14 Water jacket drain plug 23 28 to block Water pump to block bolt 14 21 Auxiliary shaft cover bolt M 6 6 9 Water outlet connection 14 21 bolt M 8 Cylinder front cover bolt M 6 6 9 Inner timing belt cover stud M 8 14 21 Outer timing belt cover bolt M 6 6 9 19 26 2 41 76 87 19 28 19 28 11 24 20 34 14 18 01 547 Sat 7 14 11 24 31 38 19 28 8 12 19 28 8 12 19 28 8 12 Part No 29487 Service Manual First Edition AAA AAA AAA Kubota Engine V1702 B Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure High engine speed Low engine speed Governing
139. ener from the turntable pivot to number 4 arm pivot pin Use a slide hammer to remove the pin AWARNING Crushing hazard If the overhead 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 Section 7 Repair Procedures Service Manual First Edition SECONDARY BOOM COMPONENTS 4 2 Secondary Boom Lift Cylinders There are two boom lift cylinders incorporated in the structure of the secondary boom assembly These cylinders operate in parallel and require hydraulic pressure to extend and retract Each secondary boom Iift cylinder is equipped with a counterbalance valves to prevent movement in the event of a hydraulic line failure A 1200 psi 83 bar relief valve for the down function is located on 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 service is strongly recommended 1 Lower the secondary boom to full rest then raise the primary boom just above the drive limit switch L W IL a drive limit switch 2 Disconnect and plug the hydraulic hose and steel lines for each secondary lift cylinder D Bodily injury haza
140. er TB20 Terminal Quick disconnect terminal BLK 21 TB21 T circuits connect at terminal T circuits connect Connection no terminal Circuits crossing no connection Battery 15AMP Les Circuit breaker Solenoid or relay coll TILT ALARM Horn n oF Light Resistor Tilt Sensor li Spark plug Glow plug Ground supression circuit LS4 NC lli Limit switch Limit switch normally open held closed As NC Limit switch normally closed held open DCH Vacuum Switch ON LSdO Oil pressure switch normally closed Genie Z 45 22 4 Water temperature switch normally closed ON ISIM FS1 BLK RED Foot switch PLAT Ksi GRND Key switch HORN DP Horn button normally open P1 a Emergency Stop button normally closed O D R Relay contact normally open Relay panel contactor PRS T Starter motor relay Time delay relay 2 TRI Time delay relay Toggle switch SPDI TS6 q Toggle switch DPDT 1331 l LHOIY BP2 Single axis proportional controller Dual axis proportional controller Part No 29487
141. ernor 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 70 degree angle to the linkage rod 7 30 Genie Z 45 22 Governor Actuator and Linkage clevis yoke linkage rod carburetor throttle plate shaft governor actuator actuator shaft actuator arm O ro ana O 0 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 70 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 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 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 obs
142. es connected Hold start switch and crank engine over while observing spline drive at rear of spline Engine to pump flex plate coupling is defective See Repair spline Troubleshoot inoperative turns boom functions and inoperative drive functions separately does not turn Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 13 All Lift and Start engine hold the Troubleshoot each Steer platform rotate function 2000 PSI or more function individually or and check the hydraulic consult Genie Industries Functions pressure at the quick service department disconnect fitting on the Inoperative turntable function Drive manifold Functions less than 2000 PSI Operational Adjust the function manifold relief valve Hold the platform rotate item AF all the way in 2000 PSI or more switch and readjust the Be sure the hydraulic suction line shutoff i lockwi ting th valve for the lift steer 0 wee CA NE relief pressure to 2200 p number of turns Hold PSI pump ts In the open the platform rotate position switch and recheck the Be sure all grounding less than 2000 PSI Replace the relief valve wires for the hydraulic OK OR manifold has internal manifold valves are Check the function defects consult Genie free of corrosion and pump see Repair Industries service atoi have full continuity to department a
143. ess down foot switch from TB27 and TB26 to hold drive controller in EDC full forward position 4 to 5V Replace drive pump check voltage across two wires at EDC quick disconnect DC Part No 29487 Genie Z 45 22 5 49 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 34 Drive Forward Disconnect the EDC wire Voltage readings are different Repair or replace the connector from the drive drive controller Or Reverse pump start engine Function move the drive controller to full forward position and note the voltage Inoperative across terminals TB27 Be sure all other and TB26 Reverse the functions operate iv includi volt meter leads and REN LA Ing move the drive controller drive in opposite to full reverse position direction of and note the voltage malfunction voltage readings are the same Defective Sundstrand drive pump contact Adjust the drive pump null neutral See Sundstrand Series 40 no improvement Sundstrand authorized repair facility symptoms improve Check all drive speeds and monitor for recurring symptoms Possible contamination in hydraulic system 5 50 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts High Range Drive Function Inoperative Be sure all other functions operate normally including drive low range four wheel symbol Be sure all drive ma
144. fe Operating the machine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Do not inspect while the engine is AWARNING running Remove the key to secure from operation Beware of hot engine 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 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 4 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 B 5 Check the Hydraulic Reservoir Fi
145. fittings solenoid shutoff valve LPG regulator and carburetor gasoline tank shutoff valve solenoid shutoff valve hoses and fittings fuel pump and carburetor Diesel models diesel tank shutoff valve solenoid shutoff valve hoses and fittings fuel pump fuel filter water separator fuel injection pump fuel injectors If a fuel leak is discovered kee A DANGER P any additional personnel from entering the area and do not operate the machine Repair the leak immediately Genie Z 45 22 4 3 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES 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 O Result The hydraulic oil level should be within the top 2 inches bcm of the sight gauge Specifications Hydraulic oil type Dexron Il equivalent Reservoir capacity 25 gallons 95 liters Do not overfill A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develo
146. fuel filter water separator and hoses for leaks If a fuel leak is discovered kee A DANGER P any additional personnel from entering the area and do not operate the 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 replaced more frequently Engine fuels are combustible A DANGER s 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 Part No 29487 TABLE C PROCEDURES 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 a plvotplate bolts Loosen the filter bracket mounting bolt Disconnect the fuel hoses from the filter then slide the filter out of the bracket 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 Clean up any fuel that may have spilled during the installation procedure Swing the engine pivot pl
147. ggle switch left and manually override function rotate left directional operates valve push in button on end of valve spool Note overriding the valve will require two function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the rotate left function pressure line from the manifold and cap the port S2 Then with pressure gauge still 2000 attached operate the PSI function less than 2000 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 Geinie Industries service department Genie Z 45 22 0 or infinite ohms Repair open in wht wire circuit from TB4 to directional valve Replace the valve Replace the rotate directional valve Interchange the rotate left and right function operales Replace defective counterbalance valve function inoperative counterbalance valves in the sandwich block Check for mechanical restrictions keeping turntable from rotating left OR replace directional valve OR repair rotation motor Check for mechanical restrictions keeping turntable from rotating left OR repair rotation Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Righ
148. gh the barrel end pivot pin and twist to remove the pin Remove the l a uppermid pivot primary lift cylinder from the machine b mounting position holes for Crushing hazard The primary lift EEN AWARNING P c upper mid pivot rest cylinder will fall if it is not properly d Een pivot pin is removed 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 9 Remove the pin retainers from the two 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 29487 Service Manual First 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 pivot pin Specification to remove pressure on the compression link Industrial tires The upper mid pivot rest should be approximately 1 inch 2 5cm above the rest block The upper mid pivot rest should be approximately 4 inches 10cm above the rest block Rough terrain tires 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 stra
149. he platform rotate directional Valve Replace the coil Check for mechanical restrictions keeping platform from rotating OR repair hydraulic rotator OR replace directional valve Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 29 Platform Rotate Right Function Inoperative Be sure all other functions operate normally If platform rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform 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 grn blk wire on platform rotate right function directional 12V Remove both wires from valve coil and check resistance across the coil terminals 4 to 5 ohms Hold toggle switch right and manually override the rotate right directional valve push in button on end of valve spool OR interchange valve item E with a like function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the rotate right function pressure line from the manifold and cap the port PR2 2000 Then with pressure
150. he primary boom 6 inches 15cm then raise the primary boom until it is level 4 Disconnect and plug the extension cylinder hydraulic hoses Cap the ports on the extension cylinder Bodily injury hazard Spraying 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 Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS 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 cylinder Bodily injury hazard Spraying 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 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 7 Le RJ h LS ON a pivotpin b 10to12 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 Genie Z 45 22 Bodily injury hazard Spraying hydraulic oil can perfor
151. heck for mechanical 2000 PSI restrictions OR replace the slave cylinder counterbalance valves less than 2000 PSI Deadhead the pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one 2000 PSI or more Repair or replace the slave cylinder inch at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed less than 2000 PSI Repair or replace the master cylinder Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts 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 Part No 29487 Hold ground control function switch and check volts at org wire on platform level up function directional 12V Remove both wires from valve coil and check resistance across the coil terminals 4 to 5 ohms Hold toggle switch right and manually override the level up directional valve push in button on end of valve spool OR inter change the valve item D
152. hoses down through the upper mid pivot Component damage hazard 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 2 Remove 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 mid pivot will fall if it is not properly supported when the pivot pin is removed Section 7 Repair Procedures Service Manual First 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 AWARNING Crushing hazard If the overhead 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
153. i p z NE BUR 4 A START COIL A C3 CN D z War NM WIT Sp ANTI RESTART COIL GE P as o o WHT i uet m au ENGINE CN GLOWPLUG y ORG RED a ENGINE Y l B X d E p E ES ORG RED 1 BLK 429 a 2 El E gt gt e e le CHOKE RELAY m E m Dr aS OUR METER o z J H yA IER sT A Q L ES AC E EE El Cn m o n6 a RED WHT m RED WHT 1 BLK 436 zm Ny 8 EE Ne A B REDNWHT RED YT WHT BLK gt A to E a m 2 pz S UA WHT or gt x A D R m A a A WTS1 N O WHT BLK E BLK 423 gt WATER TEMP w SWITCH N WHT m BLK 22 eq gt gt e GEZ OIL PRESSURE a SWITCH de A OPS1 N C SS zal a Cr o i GRN a o o o DU RESTART RELAY Lu Lu Lu fe A A s z T 3 SEC OFF DELAY WH I LO N BLK fe GRN ENGINE OFF RELAY D N 2 5 o m gt s 3 SEC OFF DELAY O o 4 e v o w WHT e WHT me e e O P COIL a 5 B EL Dr SP s os BLK 2 SH E e HORN COII S ies LK 54 e o HORN fe o BLK 455 w oe VE OSC VALVE O d RED a gt BLK BLK 456 e os e mm A OSCILATE LOCKOUT COIL E z E MN BLK 457 s pov T f OSC LIFT LOCKOUT lt LJ ka o o Fo lt N BLU RED 2 BLK 24 if e e RED 2 S EA aan gt I LEVEL SENSOR RED 1 4 D E S T A Eel d a Tr AUXILARY PUMP E e Me a E a A J E ep e e UU Ds 00 us o GLOW PLUCS q T E i el Q m amp l1 A FUEL VALVE HOLD e e OR
154. ibility 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 tanks drive and swing motors and gear boxes boom components and wear pads tires and wheels engine and related components limit switches alarms horns and beacon nuts bolts and other fasteners cracks in welds or structural components Part No 29487 Service Manual First 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 Specifications Ford Engine LSG 423 Lubrication System Oil capacity 5 quarts 4 7 liters Oil viscosity requirements 5W 30 10W 30 10W 40 or 10W 50 below 60F
155. ifications Capacity 17 fluid ounces 0 5 tor Type SAE 90 multipurpose hypoid gear oil API lassification GL5 Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 10 Check the Engine Choke Gasoline LPG Models Automatic Choke The machine IS equipped with an automatic choke if a choke switch can t be found near the start switch The automatic choke does not need to be inspected or adjusted unless the following conditions exist The machine does not start easily in cold temperatures The engine does not run smoothly after a cold start See 7 4 Choke Adjustments Manual Choke A properly functioning choke is essential to good engine performance An improperly functioning choke will result in difficulty with engine starting 1 Check the choke linkage connections linkage carburetor linkage lock nuts choke solenoid Q OO 2 Turn the key switch to ground control and then pull out the ground control Emergency Stop button to the on position 3 While operating the choke switch inspect the choke solenoid O Result The choke solenoid should be fully retracted when the choke switch is activated Part No 29487 Genie Z 45 22 TABLE B PROCEDURES 4 Turn the key switch to platform control 5 Pull out the platform control Emergency Stop button to the on position and then operate the choke switch and listen for choke solenoid operation B 11 Chec
156. inches grounding wire OR replace CR7 relay or socket Drive limit switch shorted repair or Check voltage at blk 55 12V Replace CR6 relay or On oscillate valve relay socket Check voltage at blk 56 12V on CR6 Remove machine from service and please consult Genie Industries service department Part No 29487 Genie Z 45 22 5 45 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 31 Steer Left Function Inoperative Be sure all other functions operate normally Machines not equipped with oscillating axle disregard the steer unloader valve troubleshooting Repair or replace the steer microswitch in Start the engine from the platform press down foot switch hold the steer switch left and check volt age at terminal 8 on the drive controller handle Hold the steer switch left Repair open in blu wire and check voltage at circuit from TP43 to TB31 Hold the steer switch left and check voltage at blk 31 wire on steer valve Repair open in blk 31 wire circuit from TB31 to steer valve 12V Remove both wires from steer left coil and check resistance across coil terminals 0 or infinite ohms 4 to 8 ohms Reconnect coil wires hold steer switch and Test and replace diode or repair open in jumper wire circuit from steer left coil to steer unload check voltage at steer unload valve Genie Z 45 22 12V Repla
157. jury hazard Spraying 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 Loosen the wheel lug nuts Do not remove them Block the non steering wheels and then center a lifting jack under the steering axle Raise the machine 6 inches 15cm and place blocks under the chassis Remove the lug nuts then the tire and wheel assembly 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 block torque hub yoke axle lock out wedge chassis OO OD OD 7 56 Genie Z 45 22 Part No 29487 Service Manual First 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 125 foot pounds 169 Newton meters Lug nut torque 15 2 Steering Cylinders How to Remove the Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure
158. k anti diesel for defects OR see Ford service manual for carburetor troubleshooting Genie Z 45 22 no click Replace fuel select VV Repair open in blu wht wire circuit from fuel select switch to TB33 Repair open in blk 33 wire circuit from TB33 to anti diesel valve Repair open in blk 33 wire circuit from anti diesel valve to fuel Repair green grounding wire circuit Replace gasoline solenoid Part No 29487 Service Manual First 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 Part No 29487 Start engine and switch rpm select to high idle rabbit symbol Check voltage at blk red wire rpm switch OV Check voltage at TB30 Chart 8 Check voltage at center Repair open in circuit terminal on rpm select supplying 12V to switch center terminal of on 12V Replace rpm select toggle switch Repair open in blk red wire circuit from toggle switch to TB30 Check voltag
159. k the Glow Plugs Diesel Models Maintaining the glow plugs in good condition is essential to good engine performance and service life Improperly functioning glow plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine turned off 1 Connect an ohmmeter between the far left glow plug and machine ground O Result The resistance should be approximately 0 40 2 If the ohm reading is different than 0 40 remove each wire from the four individual glow plugs Then one glow plug at a time check the resistance between the glow plug and machine ground O Result The resistance should be approximately 1 69 for each individual glow plug 3 Turn the machine on but do not start the engine 4 Connect a volt meter to the number four glow plug and machine ground 5 Hold the glow plug switch in the on position O Result The volt meter should read 12 volts Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 12 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 13 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
160. l no 86 terminal no 87 OD OO O o Genie Z 45 22 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 amp 30 no continuity infinite Q terminal 87 to 30 continuity zero Q Part No 29487 Service Manual First Edition Section 7 Repair Procedures RELAY PANEL 9 2 Power Relay Electrocution hazard Contact with 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 D Ge m D am a high amp power contact terminals large posts 1 Connect the leads from an ohmmeter to each A terminal combination and check for continuity small posts Test Desired result 2 small posts 13 to 170 2 large posts no continuity infinite 2 Any small post to no continuity any large post infinite 2 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 Part No 29487 Genie Z 45 22 7 20 Section 7 Repair Proc
161. llow the boom to be moved into an unsafe position 1 Start the engine from the platform controls 2 Swing the turntable to the right until the platform is positioned over the right steer wheel Result Platform over steer wheel indicator light should turn on 3 Slowly move drive control handle off center Always use the color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Result Drive function should not operate 4 Hold drive enable toggle switch to either side and slowly move the drive control handle off center Result Drive function should operate 5 Swing the turntable to the left until platform is positioned over the left steer tire Result Platform over steer wheel indicator light should come on 6 Repeat steps 3 and 4 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 25 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 wheel configuration Refer to B 8 in this section Confirm Proper Brake Configuration Select a test area that is firm level
162. low range Gradeability stowed 2WD 5 0 mph 8 0km h 1 1 mph 1 8km h or 5 feet In 3 sec 4WD 4 8 mph 7 7km h 0 9 mph 1 4km h or 4 feet In 3 sec 0 68 mph 1km h or 1 foot per second 0 4 mph 0 65km h or 0 59 feet per second 30 Boom function speeds maximum from platform controls Boom extend Boom retract Primary boom lift Primary boom lower Secondary boom lift Secondary boom lower Turntable rotate 359 Platform rotate 180 Platform level up Platform level down Multiple function stowed to full raised Multiple function full lowered to stowed 29 seconds 25 seconds 2 seconds 35 seconds 25 seconds 25 seconds 73 seconds 15 seconds 25 seconds 15 seconds 60 seconds 60 seconds 40 Hydraulic Specifications Hydraulic fluid Drive pump Type Displacement Maximum drive pressure Charge pressure Medium pressure filter Medium pressure filter bypass pressure Drive manifold Motor shift brake relief pressure 4WD front motor flow regulators 4WD rear motor flow regulators Genie Z 45 22 Dexron Il equivalent bi directional variable displacement piston pump 0 25 gpm O 1 6 liters second 3500 psi 241 3 bar 360 psi 24 8 bar 3 micron 50 psi 345kPa 350 psi 24 1 bar 3 0 gpm 11 4 liters minute 4 5 Opm 17 0 liters minute Part No 29487 Service Manual First Edition AAA AAA Front drive motors 4WD models Displacement
163. ltage at terminal TB33 12V Hold start switch and check voltage at blk 433 wire on anti diesel valve on engine carburetor 12V Hold start switch and check voltage at blk 433 wire on gasoline solenoid at gasoline tank 12V Reconnect blk positive cable to starter blk wire to CR2 the two wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for troubleshooting fuel Repair open in red blk wire circuit from CR4 to fuel select toggle switch Replace toggle switch Repair open in blk wht wire circuit from toggle switch to TB33 Repair open in blk 33 wire circuit from TB33 to anti diesel valve Repair open in blk 33 wire circuit from anti diesel valve to gasoline Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Diesel 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 diesel shut off valve is in the on position Be sure engine glow plugs operate normally see Maintenance section Part No 29487 Hold start switch and check battery voltage while engine is cranking less than 11V more than 11V Check if engine coolant over temperature light is on light not on Hold start switch and check if fuel
164. ltage 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 02V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Part No 29487 Service Manual First Edition EI 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 4 33V DC Turn the dual range trimpot Section 7 Repair Procedures PLATFORM CONTROLS Primary Boom Extend Retract Controller Adjustments 1 Check the battery condition with a volt meter adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 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 Engine should be at normal operating temperature 8 Start a timer and record how long it takes for the primary boom to reach the full up position Adjust the max out trimpot to achieve a 25 to 29 second cycle time 9 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
165. lter Condition Indicator Maintaining the 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 filtercondition indicator b filter c hydraulic reservoir Result The filter should be operating in the green area If the display shows red this indicates that the hydraulic filter is being bypassed and the filter should be replaced Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 6 Inspect 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 AWARNING Electrocution hazard Contact with 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 har
166. lve and check Industries service valve with motor stroke high drive department valve item R and check high drive Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 35 Continued from the Press down foot switch 12V Repair open in red wht previous page and check voltage at wire circuit from TP27 to TP27 TB21 Press down foot switch and check voltage at red wht wire on drive mode select switch Repair open in red wht wire circuit from toggle switch to TP27 Press down foot switch and check voltage at wht wire supplying 12V to drive mode select Replace toggle switch Repair open in wht wire circuit supplying 12V to toggle switch 5 52 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Low Range Drive Function Inoperative Be sure all other functions operate normally including drive high range two wheel symbol Part No 29487 Turn key switch to platform controls pull both emergency stop buttons on switch drive mode to low range four wheel symbol press down foot switch and check voltage at red wht wire on drive mode Press down foot switch and check voltage at TB21 Press down foot switch and check voltage at blk 41 on traction bypass valve item Q Interchange bypass valve item Q with brake release valve item S low range inoperative
167. m Down Function Inoperative Be sure all other functions operate normally including primary up function If primary boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If primary boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Part No 29487 Hold ground control function switch and check volts at red blk wire on primary function directional valve 12V 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 B with a like valve item C function operates function inoperative Install a pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch 1200 PSI less than 1200 PSI Adjust the primary down relief valve item T in one turn clockwise Then with pressure gauge still attached operate the function Repair open in red blk wire circuit from TB2 to directional valve Check the resistance of the down directional valve coil 4to5 ohms 0 or infinite ohms Replace the coil Counting the turns adjust the primary down relief valve it
168. m control box lid 2 Open the control box lid and locate the horsepower limiter board Part No 29487 Service Manual First Edition Section 7 Repair Procedures L 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 1 016 8 9 S v t c Horsepower limiter board a X 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 Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 3 Connect the black lead from a DC volt meter to the number 2 terminal and the red lead to the number 10 terminal 4 Start the engine from the platform controls Move the engine speed control switch to foot switch activated high idle rabbit and foot switch symbol 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage Specifications A Pot Setting 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
169. machine will not operate properly with a loose or defective belt and continued use may cause component damage Do not inspect while the engine is AWARNING running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns 1 Inspect the engine fan belts for cracking glazing separation breaks 2 Check the engine fan belts for proper tension Specifications 3 8 inch 1 2 inch 0 9cm 1 2cm Belt Deflection B 2 Check the Radiator 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 Part No 29487 Genie Z 45 22 Table B Procedures check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems Do not inspect while the engine is AWARNING running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns 1 Inspect the radiator for leaks and physical damage 2 Clean the radiator fins of debris and foreign materials B 3 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service li
170. motion a horsepowerlimiter b quick disconnect terminal strip C drive proportional controller d primary boom proportional controller e turntablerotate proportional controller f extend retractproportional controller 9 secondary boom proportional controller Primary Boom Up Down Controller Adjustments 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 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 Open the platform control box lid and locate the primary up down controller Genie Z 45 22 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 DO TD OO 0 0 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 vo
171. n 7 Repair Procedures 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 Na NES a NIN a 10to12 inch 30cm rod b plvotpin Crushing hazard The primary lift AWARNING cylinder will fall when the barrel end pivot pin is removed if it is not properly supported 6 Raise the elevate assembly Remove the block from the turntable counterweight and lower the elevate assembly to the fully stowed position 7 Close the two hydraulic tank valves located at the main pump open closed TURNTABLE ROTATION COMPONENTS 8 Disconnect the three 3 4 inch hydraulic hoses from the main pump and plug them Bodily injury hazard Spraying 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 9 Disconnect the same three 3 4 inch hydraulic hoses from the drive traction manifold and plug them Pull these hoses up through the turntable and remove them from the machine 10 Disconnect the in and return hydraulic hoses from the steer oscillate manifold and plug th
172. n at the barrel end of the primary lift cylinder 6 Use an overhead crane to lift the primary boom 1 inch 2 5cm 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 Part No 29487 Genie Z 45 22 7 17 Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS 3 4 Extension Cylinder The extension cylinder extends and retracts the primary boom steel extension tube lt 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 of 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 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 Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the s
173. n overhead crane at the center of the number 3 arm Part No 29487 Service Manual First 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 Me crane is not properly attached the number 3 arm may become unbalanced and fall when it is disconnected from the turntable 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 Part No 29487 Genie Z 45 22 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 fast
174. n the on position Perform these tests in gasoline mode Hold start switch and less check battery voltage than while engine is cranking H Check battery condition OR check alternator OR check battery cables OR replace the battery more than 11V Check if engine coolant over temperature light is Check if radiator and or engine block feels excessively hot light on on light not on not hot Remove blk 23 wire from temperature light stays on Remove blk 23 wire from TB23 light stays on light stays on Replace defective Over temperature light Go to Chart 2A page 5 7 good spark Remove 1 spark plug and ground spark plug body Crank engine and observe spark weak or no spark Disconnect and isolate black battery cable from the starter hold start switch and check voltage at terminal H on PR5 brown wire OV Replace PRS 12V Continued on the next page Genie Z 45 22 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual for troubleshooting an LIVE d U enuine light Replace temperature goes out sending unit hot Repair short in blk 23 light wire circuit from TB23 goes OUI to temperature sending unit light Repair short in wht blk goes Out with diode wire circuit from over temperature light to Part No 29487 Servic
175. nction inoperative Check for mechanical restrictions OR a condition exists in which the cylinder counterbalance valve is not allowing the cylinder to retract or the cylinder has internal defects Please consult Genie OUSTITE ervice department Repair the extend retract function cylinder Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the primary 2000 retract high pressure line poi from the manifold and cap the port RETRACT Hold primary retract function and recheck less than 1200 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 Genie Z 45 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 22 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 Hold ground control function switch and check volts
176. nd as a warning to ground personnel An improperly functioning horn 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 O Result The service horn should sound B 20 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 O Result The machine functions should operate 4 19 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 21 Test the Engine Speed Select A properly operating engine rpm select switch iS essential to good engine pe
177. ndary Boom Up Down Controller Adjustments 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 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 Open the platform control box lid and locate the secondary boom up down controller dual lo adjustable trimpot ramp rate adjustable trimpot terminal R activates max out range terminalunused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot TO TD OO 0 0 7 4 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 0 ZA PLATFORM CONTROLS 4 Set the ramp rate Turn the trimpot adjustment Specifications Secondary Boom Up Down screw clockwise 15 turns or until you hear a Function click then turn the screw counterclockwise 5 turns Threshold 2 94V DC 5 Connect the red lead from a volt meter to Secondary boom up 7 00V DC the A terminal on the controller PC board Max out time 29 33 seconds Connect the black lead to ground Seconda boom dowmes 700V DG 6 Setthe threshold Press down the foot switch Dual Range time 22 26 seconds then slowly move the control handle off center until the moment a voltage reading appears
178. ndle off center Result The machine should move at a reduced drive speed Specifications Elevated position 2WD and 4WD second Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Drive Enable Limit Switch 1 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 2 Manually activate the drive enable limit switch a drive enable limit switch O Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard 3 Start the engine from the platform controls and then swing the turntable to the left until the platform is positioned over the left steer wheel O Result The platform over steer wheels indicator light should be on Drive movement should stop until the drive enable override switch is activated 4 Swing the turntable to the right until the platform is positioned over the right steer wheel O 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 29487 TABLE A PROCEDURES Oscillating Axle Limit Switches 1 With the engine off and the machine in the stowed position visually inspect the oscillate lock out switch for the following Oscill
179. ne LPG Models B 11 Check the Glow Plugs Diesel Models B 12 Check and Adjust the Engine Idle Mixture Gasoline LPG Models B 13 Check and Adjust the Engine RPM ES E LJ 3 PS ES E B 14 Test the Key Switch B 15 Test the Emergency Stop Buttons B 16 Test the Ground Control Override B 17 Test the Oscillate Lock out oscillating axle equipped models Part No 29487 Genie Z 45 22 3 3 Section 3 Scheduled Maintenance Inspections Service Manual First Edition gt gt gt III MAINTENANCE TABLES oO 8 gt 9 5 E x GE O 8 8 oe Cold engine required Warm engine required New parts required Tools are required Table B continued B 18 Test Platform Self leveling B 19 Test the Service Horn B 20 Test the Foot Switch B 21 Test the Engine Speed Select B 22 Test Fuel Select Operation Gasoline LPG Models B 23 Test the Turntable Rotation Stop B 24 Test the Drive Enable System B 25 Test the Drive Brakes ES Es B 26 Test Drive Speed Stowed Position B 27 Test the Alarm Package optional equipment travel alarm descent alarm flashing beacon Table C C 1 Check the Primary Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Feature C 4 Grease the Worm Drive Gear including turntable rotation bearing C 5 Replace the Torque Hub Oil bd ERES Ea EA Pa PA PA PA C 6 Replace the Hydraulic Reservoir Filter 3 4 Genie Z 45 22 Part No
180. ness inside of the ground control box turntable manifold wiring 2 Start the engine from the ground controls 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 29487 Genie Z 45 22 TABLE B PROCEDURES B 7 Inspect the 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 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 Specifications Tires and Wheels Rough terrain Industrial Wheel lugs 4WD 9 5 8 18 Wheel lugs 2WD front 8 5 8 18 rear 8 5 8 18 Lug nut torque 9 5 8 18 9 5 8 18 EFC Le Aine Hes Tire size 169 5 Nm Tire ply rating 14 17 5NHS 9 14 5 LT Tire pressure 2WD Tread 8 Tread 8 Ti
181. ng sandwich block motor OR replace directional valve less than 2000 PSI function less than 2000 PSI Remove the left function pressure line from the manifold and cap the port S2 Then with 2000 pressure gauge still PSI Repair or replace the attached operate the rotation motor Replace defective sandwich block with counterbalance valves less than 2000 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 Geinie Industries service department Part No 29487 Genie Z 45 22 5 37 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 23 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 Hold ground control OV function switch and check volts at wht wire on rotate function Remove both wires from rotate left valve coil and check resistance across the coil terminals 4 to 5 ohms Hold to
182. nifold solenoid valve grounding wires are free of corrosion and have full continuity to ground Part No 29487 Chart 35 Continued on the next page Start engine from platform controls switch drive mode to high and press down the foot switch Check the voltage at terminal TB21 12V Press down foot switch wait 3 seconds and check voltage at blk 21 wire on the motor stroke solenoid valve item N Repair open in blk 21 wire circuit from TP21 to stroke solenoid valve 12V Press down foot switch wait 3 seconds and check voltage at blk 21 wire on terminal 6 of time delay relay Repair open in blk 21 wire circuit from TP21 to time delay relay 12V Press down foot switch wait 3 seconds and check voltage at blk 41 wire on terminal 3 of time delay relay 12V 12V Replace time delay erav Check voltage at wht wire on terminal 1 of time delay relay Repair open in wht wire circuit from supplying 12V to time UGIadV V Press down foot switch wait 3 seconds and check voltage at blk 41 wire on traction bypass solenoid valve item Q Repair open in blk 41 wire circuit from time delay relay to traction bypass valve 12V Interchange traction bypass valve item Q with new solenoid valve and check high drive no high drive Replace traction bypass no hiah no hah i and interchange new hs Replace traction bypass ee Consult Genie shuttle va
183. nsult Genie Industries service department Repair open in org blk wire circuit from TB14 to directional valve 0 or infinite ohms function operates 2000 PSI Interchange the level up and down counterbalance valves in the sandwich block function Replace defective counterbalance valve Repair the master and or slave cylinder OR replace the slave cylinder counterbalance Genie Z 45 22 Replace the coil Replace the platform leveling directional valve Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valves are not allowing the cylinder to retract or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries service Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Rotate Left Function Inoperative Be sure all other functions operate normally If platform rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle 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 Part No 29487 Hold gr
184. ntenance Procedures Scheduled Maintenance Procedures Observe and Obey WI 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 I Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine II Keep records on all inspections for three years Part No 29487 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 Indicates the presence of a A DANGER hazard that will cause death or serious injury Indicates the presence of a AWARNING hazard that may cause death or serious 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 O Indicates that a specific result is expected after performing a series of steps Genie Z 45 22 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table
185. nterweight and 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 6 Raise the end of the primary boom 8 feet 2 5m off the ground then extend the primary boom 5 inches 12 5cm 7 Attach an overhead crane to the primary boom Do not lift the primary boom Crushing hazard If the overhead AWARNING crane is not properly attached the primary boom may become unbalanced and fall when it is disconnected from the upper mid pivot Part No 29487 Service Manual First 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 hazard Spraying 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 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 lif
186. nual First Edition Chart 10 Engine High Start engine switch rpm Idle Inoperative Diesel Models check if 2 speed solenoid pulls in Check high idle select switch to high idle solenoid pulls in adjustment see rabbit symbol and Maintenance section Or see Kubota workshop manual to troubleshoot fuel injector pump Be sure mechanical linkage from 2 speed solenoid does not pull in to fuel injector pump is not binding or defective Check voltage at blk red 0V Check voltage on center Repair open in circuit wire on rpm select terminal of rom select supplying 12V to center itch switch terminal of switch e Z D 12V Be sure PR2 relay and 2 speed solenoid grounding wires are Replace toggle switch free of corrosion and have full continuity to ground Repair open in blk red wire circuit from toggle switch to TB30 Check voltage at TB30 lt Check voltage at initiate terminal blk 30 wire on PR2 Repair open in blk 30 wire circuit from TB30 to PR2 Replace PR2 relay or repair open in red wire circuit from PR2 to 2 speed solenoid Check voltage at the red wire on the 2 speed solenoid 12V solenoid binds Check linkage or replace solenoid Check if 2 speed solenoid moves in and UU ZE V moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 5 18 Genie Z 45 22 Part No 29487 Service Manu
187. nually override extend directional valve push in button on end of valve spool Continued on the next page function 4 to 5 operates Check the resistance of ohms the directional valve coil 0 or infinite ohms function inoperative Replace the defective valve coil Genie Z 45 22 Chart 20 Replace the coil Replace the proportional valve Replace defective flow regulator valve Replace the valve al I W CO Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 20 Continued from the Install a pressure gauge 2000 previous page at the quick disconnect PSI coupling on the function If primary is extended function one inch or more operates Replace defectve interchange the counterbalance valve accessible counterbalance valve with like valve from a secondary lift cylinders Re test function If valve is inaccessible continue manifold and hold the function switch less than 2000 PSI Check for mechanical restrictions OR the cylinder has internal defects OR replace counterbalance valve Please consult Genie Industries service department Remove the extend function pressure line 2000 from the manifold and PSI cap the port EXTEN Repair the cylinder and or replace cylinder counterbalance valves Then with pressure gauge still attached operate the function up less than 2000 PSI Internal defect in manifold
188. o 29487 Service Manual First 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 intervals 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 Then re 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 Part No 29487 Genie Z 45 22 TABLE C PROCEDURES C 6 Replace the Hydraulic Reservoir Filter Replacement of the hydraulic reservoir 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 oil may cause severe burns Perform this procedure with the engine off 1 Remove the filte
189. o 2 94V 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 extend position Adjust the voltage to 7 00V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the dual lo range Press down the foot switch then move the control handle all the way to the retract position Adjust the voltage to 7 00V 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 9 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 until it is level Fully retract the primary boom 10 Start a timer and record how long it takes for the primary boom to reach full extension Adjust the max out trimpot to achieve a 29 to 33 second cycle time 11 Start a timer and record how long it takes for the primary boom to fully retract Adjust the dual range trimpot to achieve a 22 to 26 second cycle time Specifications Primary Boom Extend Retract Function Threshold 2 50V DC Primary boom extend 5 01V DC Max out time 23 27 seconds Primary boom retract 4 05V DC Dual Range time 23 27 seconds Seco
190. oil may cause severe burns CO Completely drain the reservoir into a container See capacity specifications listed below 4 Disconnect and cap the two 1 inch 2 5cm suction hoses that are attached to the reservoir 5 Hemove the strainer assemblies from the reservoir O Carefully clean any foreign material from the strainers Part No 29487 Genie Z 45 22 Table D Procedures 7 Apply pipe thread sealant to the strainer mounting threads and then re install them 8 Apply pipe thread sealant to the drain plug and then re install it in the reservoir 9 Re install the two suction hoses 10 Fill the reservoir with hydraulic oil until the level is within the top 2 inches 5cm of the sight gauge Do not overfil 11 Clean up any oil that may have spilled and re open the hydraulic tank valves 12 Prime the pump by doing the following 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 All models Crank the engine with the starter motor for 15 seconds 13 Reconnect the wiring and start the engine from the ground controls Check the hydraulic reservoir for leaks Specifications Hydraulic tank capacity 25 gallons 95 liters Hydraulic system 30 gallons capacity including tank 114 liters Hydraulic fluid Dexron Il equivalent Section 4 Scheduled Maintenance Procedures Service Manual
191. olenoid valve C Extend Retract ii ci 10 12 ft lbs 14 16 Nm Proportional solenoid valve Heus 10 12 ft lbs 14 16 Nm Proportional solenoid valve o Seconda Y e dak ieu 10 12 ft lbs 14 16 Nm Proportional solenoid valve osa e A cb Mort es 10 12 ft lbs 14 16 Nm Differential sensing valve S ANIUNEUO S iaa 10 12 ft lbs 14 16 Nm Orifice 0 030 in 0 76mm AG Platform rotate Normally closed poppet valve RETE Platform level 25 30 ft lbs 34 41 Nm Normally closed poppet valve OMA Platform rotate aia aii 25 30 ft lbs 34 41 Nm Relief valve 2200 psi 152 bar Ara THEIN cross 35 40 ft lbs 47 54 Nm Priority flow regulator valve NE el D 10 12 ft lbs 14 16 Nm CHECK Valsa AC nts Platform rotate flow regulator 11 13 ft lbs 15 18 Nm Orifice 0 015 in 0 38mm WO Differential sensing Check valve 21 AD cus Platform level flow regulator 11 13 ft lbs 15 18 Nm Check valve NEE Swing flow regulator 11 13 ft lbs 15 18 Nm Counterbalance valve A s Platform leveling cylinder retract 10 12 ft lbs 15 18 Nm 3 position 4 way valve Eod Platform rotar iio iii 3
192. ommended 1 Raise the secondary boom and place a 4x4x31 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 Part No 29487 Service Manual First Edition Section 7 Repair Procedures PRIMARY BOOM COMPONENTS Crushing hazard Keep hands Crushing hazard When the AWARNING away from the block and all barrel end pivot pin is removed moving parts when lowering the the primary lift cylinder will swing secondary boom down if it is not properly 2 Raise the primary boom until the end of the supponga boom is 8 feet 2 5m off the ground 9 Carefully loosen the straps and allow the primary lift cylinder to slowly swing down Now attach the rod of the primary lift cylinder to an overhead crane or similar lifting device 3 Support the primary boom with an overhead crane Do not lift the primary boom 4 Disconnect and plug the primary lift cylinder hydraulic hoses 10 Remove the pin retainer from the remaining pivot pin then use a soft metal drift to remove Bodily injury hazard Spraying the pin hydraulic oil can perforate and l Crushing hazard The primary lift EE ALL d cylinder will fall if it is not properly connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray supported 5 Remove the pin retainer from the pivot pi
193. onent and remove it Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 02 OJ 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 1 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 29487 Genie Z 45 22 7 37 Section 7 Repair Procedures Service Manual First Edition Relay Panel 9 1 Control Relays How to Test a Single Pole Double Throw Relay Electrocution hazard Contact with AWARNING hot or live 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 ES a terminal no 87A terminal no 85 terminal no 30 termina
194. or the secondary boom to reach the full up position Adjust the max out trimpot to achieve a 23 to 27 second cycle time 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 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 TO TD Q oO 0 0 e Part No 29487 Genie Z 45 22 7 5 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 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
195. 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 that fasteners intended for one A time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be mindful of the environment e Part No 29487 Service Manual First Edition Introduction Section One Section TWO Section Three Section Four Part No 29487 Table of Contents IMPportant NIOTMALO ita add li Safety Rules General Safety RUl6S sodio ue due asuntos inv estis Bi edu End esatta do Read Uu Aor id iii Specifications Machine SpecilicalOn Stade 2 1 Performance Specifications 2 2 ryvdraule SBECICANONS a Ed GK OC a O iii 2 2 Ford LSG 423 Engine Specifications 2 5 Kubota V1702 B Engine Specifications 2 7 Scheduled Maintenance Inspections A A ei 3 1 Ee EE 3 2 TAB o e e 3 3 Ee talar AOI 3 4 A A E a 3 5 Maintenance Inspection Report EE 3 6 Scheduled Maintenance Procedures a IA 4 1 A 1 Inspect the Operating Instruction and Safety Manuals 4
196. 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 Spraying 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 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 Genie Z 45 22 13 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 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 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 AWARNING Crushing hazard Do not remove the 4x4x31 inch 78cm support block installed during primary boom removal a upper mid pivot b 4x4x31 inch block c counterweight Part No 29487 Service Manual First Edition Sectio
197. orizontal 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 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 4 Remove the rod ends from both the barrel and rod end pins 5 Use a soft metal drift and drive the pins out Part No 29487 Service Manual First Edition Section 7 Repair Procedures How to Bleed the Slave Cylinder 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 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 th
198. ound control function switch and check volts at grn wire on platform rotate left function directional 12V Remove both wires from valve coil and check resistance across the coil terminals 4 to 5 ohms Hold toggle switch left and manually override the rotate left directional valve push in button on end of valve spool OR interchange valve item E with a like valve item function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the rotate left function pressure line from the manifold and cap the port PR1 Then with pressure 2000 gauge still attached PSI operate the function left less than 2000 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 Repair open in grn wire circuit from TB16 to directional valve 0 or infinite ohms function operates Interchange the platform rotate left and right counterbalance valves in the manifold installed on 2000 the primary boom PSI extension located under the platform function Replace defective counterbalance valve Repair the hydraulic rotator OR replace the rotator counterbalance valves and or manifold Genie Z 45 22 Chart 28 Replace t
199. out Function Is Malfunctioning troubleshooting flow Replace coil Replace the proportional valve Replace defective flow regulator valve Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 18 Continued from the previous page Hold toggle switch up and manually override directional valve push in function 4 to 5 operates Check the resistance of ohms the directional valve oits button on end of valve 0 or infinite ohms spool Replace the defective function inoperative valve coil s Install a pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch 2000 PSI less than 2000 PSI Remove the up function pressure line from the manifold and cap the port P1 Then with pressure gauge still attached operate the 2000 PSI less than 2000 PSI One of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Geinie Industries service department Genie Z 45 22 Replace the valve Check for mechanical restrictions keeping primary boom from moving Interchange the primary lift cylinder counter balance valve with a like valve from one of the secondary cylinders function inoperative Repair the cylinder Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boo
200. p 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 reservoir fittings hoses and turntable surface engine compartment fittings hoses auxiliary power unit main pump and turntable surface Genie Z 45 22 all cylinders all valve manifolds elevate and primary booms the underside of the chassis ground area under the machine A 9 Check Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option 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 Specifications 2WD model 9 14 5LT 100 psi 6 89 bar industrial tire 14 17 5NHS 40 psi 2 76 bar rough terrain tire 4WD model rough terrain tire 14 17 5NHS 28 psi 1 93 bar Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 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
201. p 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 it is disconnected from the upper mid 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 Part No 29487 Genie Z 45 22 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 cables 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 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 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
202. per revolution 2 1 cu in 34 4cc Rear drive motor Displacement per revolution High 2 8 cu in 45 9cc Function pump Type Displacement Function circuit return line filter Function manifold Function relief valve pressure Secondary down relief valve pressure Primary down relief valve pressure Steer oscillate flow regulator Part No 29487 Low 0 15 cu in 2 5cc fixed displacement gear pump 6 4 gom O 2150 rpm 0 4 liters second 10 micron with 25psi 172kPa bypass 2200psi 138 bar 1200 psi 83 bar 1200 psi 83 bar 1 5 gom 5 7 liters minute Steer oscillate manifold Sequencing valve pressure Accumulator pre charge pressure Auxillary pump Type Displacement Auxillary pump relief pressure Genie Z 45 22 Section 2 Specifications SPECIFICATIONS 1800 psi 1600 psi fixed displacement gear pump 0 85 gpm 3 2 liters minute 2030 psi 138 bar Section 2 Specifications Service Manual First Edition SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts E SAE Grade 8 Bolts Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters pe e s mu e w w e s pe pm s a s Torque specification for lubricated bolts is 2596 less than dry torque specification for bolt size A al CO 00 7 k 660
203. port bracket 3 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 How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 4 inch 0 635mm gap between the coupler and pump end plate Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 36 ft lbs 49 Nm Component damage hazard Do not force the drive pump during re installation or the flex plate teeth may become damaged Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 7 7 Water Temperature and Oil Pressure Switches The water temperature switch is a normally open switch that closes at approximately 230
204. ppet valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 11 1 Function Manifold Components in this section 1 Push the button on the end of the valve in 14 inch 6mm 2 Move the ground control function switch for the function being overridden to operate function Collision Hazard Impact with AWARNING moving boom components may cause death or serious injury Use extreme caution when overriding a boom function and know the direction of intended travel a den y fmm S i Bate leier A j ier dk CZ a directional valves b proportional valves C function manifold Part No 29487 Genie Z 45 22 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 leads from an ohmmeter to the valve coil terminals Specifications Valve Resistance Proportional solenoid valve 50 3 pos 4 way directional valve 4 50 Normally closed 7 poppet valve Section 7 Repair Procedures Service Manual First Edition Fuel and Hydraulic Tanks 12 1 Hydraulic Reservoir The primary functions of the hydraulic reservoir are to cool clean and deaerate the hydraulic fluid during operation This reservoir has a 25 gallon 94 5 liters capacity and an oil level gauge with temperature indicator It u
205. pressure drops below the switch point the switch closes and shuts off the engine A low oil pressure indicator light at the ground and platform controls should turn on when the switch closes Component damage hazard Do not start or continue to run the engine with the low oil pressure light on Part No 29487 Service Manual First Edition Section 7 Repair Procedures a watertemperature switch b oil pressure switch How to Remove the Water Temperature and Oil Pressure Switches KUBOTA V1702 B ENGINE 2 Disconnect the wiring from the desired switch 3 Remove the switch from the engine block and then install the new switch Do not over tighten Burn hazard Contact with hot engine fluids or components may cause severe burns Always use pipe thread sealant when installing a switch Specifications Water temperature switch Torque 8 18 foot pounds 11 24 Newton meters Hex size 13 16 inch Temperature switch point 225 F 107 C 2 Oil pressure switch Torque 8 18 foot pounds 11 24 Newton meters Hex size 1 1 16 inch Oil pressure switch point 7 1 psi 0 5 bar Perform this procedure with the engine off 1 Remove the 3 bolts from the engine pivot plate owing the engine pivot plate away from the machine to access both switches a __ pivot plate bolts Part No 29487 Genie Z 45 22 7 29 Section 7 Repair Procedures Service Manual First Edition Ford LSG 423 Engine 7 1 Gov
206. 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 Part No 29487 Genie Z 45 22 18 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 the bolts that attach the torque hub to the chassis then remove the torque hub Crushing hazard The torque hub will fall if it is not properly supported when the mounting bolts are removed Specifications 125 foot pounds 169 Newton meters Lug nut torque Section 7 Repair Procedures Service Manual First Edition 2WD Drive Manifold 19 1 2WD Drive Manifold Components Index Schematic No Description Item 1 Check valve ti ME 2 2 position 3 way valve O SE 3 2 position 3 way valve Naso utis 4 Orifice 0 036 in 0 914mm
207. 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 1m 3 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of 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 Leveling Master Cylinder This procedure requires specific repair skills lifting equipment and ANDINA 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 Before cylinder removal is Part No 29487 Genie Z 45 22 PRIMARY BOOM COMPONENTS 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 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 Crushing hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom 3 Extend t
208. r that was disconne U LU less than 2000 PSI Continued on the next page Part No 29487 Genie Z 45 22 5 25 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 16 Continued from the previous page Re install all hydraulic lines in the original configuration then remove and cap the function up pressure line port R1 on the manifold OR cap the hose at the point the hose connects to the engine side cylinder on the Hold One of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Geinie Industries service department Genie Z 45 22 Repair both secondary function cylinders Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Secondary Boom Down Function Inoperative Be sure all other functions operate normally including secondary up function If secondary boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If secondary boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Part No 29487 Hold ground control function switch and check volts at blu blk wire on secondary function directional 12V
209. r with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Start the engine from the ground controls Inspect the filter and related components to be sure that there are no leaks Section 4 Scheduled Maintenance Procedures Service Manual First 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 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 Genie Z 45 22 C 8 Replace the Diesel Fuel Filter Replacing the diesel fuel filter is essential to good
210. rates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Note Oscillating axle equipped models from the stowed position the 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 Part No 29487 With engine running and boom in fully stowed position hold the primary raises and stops but will not LUIIUIIUC up function and check if the boom will raise up to the drive limit switch no movement Hold ground control function switch and check volts at red wht wire on primary function proportional valve Repair open in red wht wire circuit from TB3 to proportional valve 3 to 6V Remove both wires from valve coil and check resistance across the coil terminals 0 or infinite ohms 4 5 to 5 5 ohms 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 H with a like valve item I function operates function inoperative Interchange primary function flow regulator valve item M with a like valve item L function operates function inoperative Continued on the next page Genie Z 45 22 Chart 18 See Oscillate Lock
211. raying 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 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 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 29487
212. rcuit from ignition module to electronic Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts 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 Part No 29487 Start engine and switch rom select to low idle 12V turtle symbol Check voltage at blk red wire on rpm switch OV Check voltage at blk 30 12V wire on PR2 OV Remove both blk wires from PR2 and check continuity across open terminals full continuity Replace PR2 relay continuity Isolate ground and platform rpm switches check individually and replace defective switch Remove blk red wire with diode from PR2 initiate terminal and check voltage at blk 30 wire on PR2 OV Check voltage at blk red 0V wire on PRS 12V Blk red wire has short OR if engine will not cranking PR5 is Iere Ve Recheck throttle linkage see Repair section OR see Ford service manual for carburetor troubleshooting Genie Z 45 22 Chart 9 12V Repair short in blk 30 wire Repair short in blk red wire circuit Section 5 Troubleshooting Flow Charts Service Ma
213. rd Spraying 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 Remove the pin retainers from each secondary lift cylinder rod end pivot pin Place a rod through the rod end pivot pin and twist to remove the pin a pivotpin b 10to12inch 30cm rod Loosen but do not remove the counterbalance valve to fully retract the cylinder The counterbalance valve is pre set from the factory Do not adjust this valve Remove the pin retainer from the pivot pins at the barrel ends of each secondary lift cylinder 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 AWARNING lift cylinders will fall when the Genie Z 45 22 barrel end pivot pins are removed 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 Part No 29487 Service Manual First Edition 5 1 Turntable Covers How to Remove a Turntable Cover Raise the turntable cover Support the open cover with an overhead crane Or forklift Do not lift Crushing hazard Due to its heavy weight do not attempt to support the cover by hand Remove the upper
214. re pressure 4WD Sidewall 6 40 psi 100 psi 2 76 bar6 89 bar 28 psi 1 93 bar 4 13 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 8 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 brake disengage position b TB brake engage position 2 On4WD models be sure the free wheel valve on the drive pump is closed clockwise a drivepump b liftpump c free wheelvalve Genie Z 45 22 B 9 Check the Oil Level in the 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 hole then re install the plugs into the hub 4 Repeat this procedure for each torque hub Spec
215. re thoroughly Attempting shortcuts may produce hazardous conditions Part No 29487 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional ina 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 Process Malfunction gt Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Symbols Legend Indicates the presence of a A DANGER hazard that will cause death or serious injury Indicates the presence of a INPUTS hazard that may cause death or serious 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 O Indicates that a specific result is expected after performing a series of steps Genie Z 45 22 7 1 Section 7 Repair Procedures Service Manual First Edition Platform Controls 1 1 Joystick Controllers Maintaining each joystick controller at the proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of
216. relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 13 and 14 represent the coil and should not be tested in any other combination r r Le le a d Ir D d c a E p te za Y m Ufec EK ES Coli m ad mam terminal no 5 terminal no 1 relay terminal no 13 terminal no 9 terminal no 12 terminal no 14 terminal no 4 terminal no 8 TO TD Q o 0 0 Part No 29487 Ground Controls Test terminal 13 to 14 terminal 8 to 5 4 1 12 8 9 terminal 5 to 8 4 1 12 8 9 terminal 4 to 8 5 1 4 9 terminal 1 to 8 5 4 amp 12 terminal 4 to 12 terminal 1 to 9 Desired result 160 to 1700 no continuity infinite 2 no continuity no continuity no continuity continuity zero Q continuity 4 Connect 12V DC to terminal 14 and a ground wire to terminal 13 then test the following terminal combinations Test terminal 8 to 1 5 9 amp 4 terminal 5 to 1 4 8 amp 12 terminal 4 to 1 5 9 8 amp 12 terminal 1 to 5 9 4 8 amp 12 terminal 8 to 12 terminal 5 to 9 Genie Z 45 22 Desired result no continuity infinite 2 no continuity no continuity no continuity continuity zero Q continuity Section 7 Repair Procedures SR _ _ gt ZA GROUND CONTROLS How to Test a Single Pole Double Throw Relay This procedure covers fundamental relay testing and does not
217. remely dirty conditions may require that the cap and rotor be replaced more frequently Perform this procedure with the engine off a pivotbolt 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 cleaner or a damp 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 Part No 29487 Service Manual First 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
218. rformance and safe machine operation There are three rpm settings The foot switch activated high idle rabbit and foot switch symbols should be sued for normal machine operation This selection activates high idle only when the foot switch is pressed down Low idle turtle symbol mode allows the operator to control individual boom functions only High idle rabbit symbol mode allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and usually selected only when the generator option is being used 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 o A w 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 Genie Z 45 22 Result The engine should not change to
219. rtional valve Replace defective flow regulator valve Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 16 Continued from the Hold toggle switch up function Check the resistance of 4105 previous page and manually override operates both directional valve ohms directional valve push in coils button on end of valve spool Note overriding 0 or infinite ohms the valve will require two people If a helper is not available interchange the valve item C with a like valve item B Replace the defective valve coil s function inoperative Install a pressure gauge at the quick disconnect coupling on the function Check for mechanical restriction keeping 2000 PSI secondary from moving manifold and hold the function switch less than 2000 PSI Remove and cap the up function steel pressure line attached to the 2000 PSI cylinder on the fuel tank Repair the cylinder side Then with pressure that was gauge still attached i operate the function up less than 2000 PSI Reconnect the cylinder Then disconnect up function high pressure hose and the fitting from the engine side cylinder and install into the other cylinder in place of plugged port Remove and cap the up function steel pressure line attached to the cylinder on the engine side Then with pressure gauge still attached 2000 PSI Repair the cylinde
220. se to increase the pressure or counterclockwise to decrease the pressure Then reinstall the valve cap Restart the engine Drive the machine in either direction and recheck the valve pressure Turn the engine off then remove the pressure gauge Specifications Relief valve 320 psi 22 bar Genie Z 45 22 Service Manual First Edition Part No 29487 Service Manual First Edition Section 7 Repair Procedures DEE 2WD DRIVE MANIFOLD This page intentionally left blank Part No 29487 Genie Z 45 22 7 65 Section 7 Repair Procedures Service Manual First Edition 4WD Drive Manifold 20 1 4WD Drive Manifold Components Index Schematic No Description Item Function Torque 1 Check valve We Brake check 25 30 ft lbs 34 41 Nm 2 2 position 3 way valve EE Brake release 8 10 ft Ibs 11 14 Nm 3 2 position 3 way valve RU UN ME 2 speed wheel motors energized in high range to destroke the rear motor swash plates 8 10 ft Ibs 11 14 Nm 4 Check valve ANA RR check in forward 35 40 ft lbs 47 54 Nm 5 Orifice 0 025 in 0 635mm X Motor shift brake release circuit 6 Check valve Bee RR check in reverse 35 40 ft Ibs 47 54 Nm 7 Relief valve 320 psi 22 bar V
221. se from the fuel filter to the carburetor c hose from the fuel pump to the fuel filter d X hose from the fuel shutoff valve to the fuel pump 4 Clean up any fuel that may have spilled during the installation procedure 5 Start the machine from the ground controls then inspect the fuel filter and hoses for leaks If a fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operate the machine Repair the leak immediately 4 36 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE D PROCEDURES D 6 a el Clean PCV Hoses and Fittings Gasoline 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 Gasoline LPG models machine to access the PCV hoses shown with distributor cap removed PCV valve a b hose PCV valve to carburetor C hose PCV valve to crankcase 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 plvotplate bolt 2 Disconnect the 2 hoses from the PCV valve then disconnect the 2 hoses from the engine
222. 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 O Result All machine functions should activate and operate smoothly 2 Push in the Emergency Stop button to the off position O 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 Part No 29487 TABLE A PROCEDURES 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
223. specifically apply to all varieties of relays 1 Test Desired result terminal 13 to 14 190 to 2000 terminal 5 to 1 4 9 no continuity infinite 2 terminal 1 to 9 continuity zero Q Turn the keyswitch to the off position and remove the key Label and then disconnect all the wiring from the relay to be tested Connect the leads from an onmmeter or continuity tester to each terminal combination and check for continuity Terminals 13 to 14 represent the coil and should not be tested in any other combination 4 Connect 12V DC to terminal 14 and a ground Test Desired result terminal 1 to 5 amp 9 no continuity infinite 2 terminal 5 to 9 continuity zero Q 7 36 wire to terminal 13 then test the following terminal combinations Service Manual First Edition 8 2 Toggle Switches See 1 4 Toggle Switches 8 3 Wago Components How to Remove a Wago Component AWARNING Electrocution hazard Contact with 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 comp
224. 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 Genie Z 45 22 broken or missing rollers or arms missing fasteners loose wiring 2 Start the engine from the ground controls 3 Raise the primary boom above the drive limit switch and turn the machine off 4 Manually activate the drive limit switch L ILL a drive limit switch O Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 5 Restart the engine and lower the boom into the fully stowed position 6 Move the key switch to platform control and then start the engine from the platform controls 7 Slowly move the drive control handle off center O Result The machine should move at normal drive speeds 8 Raise the primary boom above the drive limit switch 9 Slowly move the drive control ha
225. switch Specifications Water temperature switch Torque 8 18 foot pounds 11 24 Newton meters Hex size 13 16 inch Temperature switch point 230 F 112 C Oil pressure switch Torque 8 18 foot pounds 11 24 Newton meters Hex size 1 1 16 inch Oil pressure switch point 3 5 psi 0 21 0 34 bar Section 7 Repair Procedures Service Manual First Edition Z FORD LSG 423 ENGINE 7 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING Q OO OD 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 zero 2 Component damage hazard Do not short vacuum switch terminals to ground 7 34 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 7 Repair Procedures 8 1 Control Relays Relays used for single function switching are single pole double throw SPDT switches Two function switching requires a double pole double throw DPDT relay How to Test a Double Pole Double Throw Relay This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays 1 Turn the keyswitch to the off position and remove the key 2 Label and then disconnect all the wiring from the
226. switch from the primary boom rest 34 Disconnect and plug the hydraulic hoses at the secondary lift cylinders Bodily injury hazard Spraying 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 35 Remove the pin retainers from each secondary lift cylinder barrel end pivot pin 36 Place a rod through each barrel end pivot pin and twist to remove the pin Remove each secondary lift cylinder from the machine Genie Z 45 22 a pivotpin b 10to12 inch 30cm rod Crushing hazard The secondary PNP ULL 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 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 a
227. t lal RE TANK wt Fh RETURN XEHE VEL er os ba AE gll ps P d B P RY 052 Hz 2 w IN L NL RKA T i L REAR R REAR MOTOR GK i a STEERING ACCUMULA TOR PRE CHARGE W O OSCILLATING OPTION 1600 PSI i OSCILLATION STEERING LOCK 0UT DWG ZHS4WD B De EE 745 22 Hyd I A Z45 22 HP 2WD HYDRAULIC SCHEMATIC SERIAL 4 45 002541 amp ABOVE BRAKE 2 SPEED MANIFOLD
228. t Function Inoperative Be sure all other functions operate normally including turntable rotate left function If turntable rotate right function operates normally from the ground controls 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 Part No 29487 Hold ground control function switch and check volts at wht blk 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 function valve push in button on end of valve spool Note overriding the valve will require two DCUDIC function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the rotate right function pressure line from the manifold and cap the port S1 Then with pressure gauge still 2000 attached operate the PSI function less than 2000 PSI Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Re
229. t caps on each rear wheel hub brake disengage position b TN TB NSE brake engage position 5 Manually rotate each rear wheel Result Each rear wheel should rotate with minimum effort 6 Re engage the brakes by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack Collision hazard Failure to re AWARNING engage the brakes 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 front 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 liftpump c free wheelvalve Part No 29487 Genie Z 45 22 Section 4 Scheduled Maintenance Procedures Service Manual First 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 Collision hazard Failure to close AWARNING the free wheel valve may result in death or serious injury and property damage C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly
230. t comes out of the inner seal 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 turntable 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 Genie Z 45 22 15 Install the turntable mounting fasteners Use a torque wrench to tighten the fasteners in sequence to specifications 20 9 1 99 6 0909 16 H 24 KE 12 3 11 7 23 14 9009 2 21 2 10 Specifications torque First rotation 9
231. ted on the resistor 7 8 Genie 45 22 Part No 29487 Service Manual First Edition 1 5 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Two function switching requires a double pole double throw DPDT switch How to Testa Toggle Switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the keyswitch to the off position and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an onmmeter to the switch terminals in the following combinations listed below to check for continuity Right Left Center Single pole double throw SPDT Double pole double throw DPDT Part No 29487 Section 7 Repair Procedures 02 OJ Test Left Position terminal 1 to 2 3 4 5 amp 6 terminal 2 to 3 terminal 2 to 4 5 amp 6 terminal 3 to 4 5 amp 6 terminal 4 to 5 amp 6 terminal 5 to 6 Center position Right Position terminal 1 to 2 terminal 1 to 3 4 5 amp 6 terminal 2 to 3 4 5 amp 6 terminal 3 to 4 5 amp 6 terminal 4 to 5 terminal 4 to 6 terminal 5 to 6 Genie Z 45 22 PLATFORM CONTROLS Desired result no continuity infinite 2 continuity zero Q no continuity no continuity no continuity continuity There are no terminal combinations that will produce continuity infinite 2 continuity no
232. tenance Inspections Service Manual First Edition Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspectortitle 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 fany 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 ChecklistA Refer to Table A A 1 Operation and Safety manuals lt z H A 2 Decals and placards A 3 Damage loose or 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 A 15 Change engine air filter A 16 Drain fuel filter water separator diesel Checklist B Refer to Table B B 1
233. ter the engine reaches normal operating temperature select propane mode A flow path past the choke butterfly is required if the engine is to be cold started in the propane mode A 1 4 inch 6mm flow path is recommended Adjust the choke only when the engine and choke are cold 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 Section 7 Repair Procedures Service Manual First Edition FORD LSG 423 ENGINE 7 3 Timing Adjustment 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 7 4 Carburetor Adjustment 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 7 5 RPM Adjustment See the scheduled maintenance procedure B 13 Check and Adjust the Engine RPM 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 2 Disconnect and remove the muffler sup
234. ters 20 AG 13 9905 i 16 2 O 18 12 3 a 11 17 e 36 e 14 9009 gt 21 o 10 Bolt torque sequence Remove the support block and then lower the primary and secondary booms to the fully stowed position 5 Use a forklift to support the chassis counterweight directly below the turntable bearing Loosen the counterwight positioning bolt then remove the 2 mounting bolts Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 7 Carefully lower and remove the counterweight 8 Be sure that each bearing mounting bolt is torqued to 190 foot pounds 258 Newton meters Bolttorque sequence 9 Reinstall the 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 Collision hazard Select a work AWARNING site that is firm and level Rear drive wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 5000 Ibs 2268kg 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 rear brakes by turning over the torque hub disconnec
235. tiate terminal of PR1 if equipped with time delay relay disconnect wht 451 wire from TR2 terminal 1 Hold start switch and check voltage at terminal Without replacing any wires hold start switch and check voltage at terminal 9 on CR3 Remove blk wire from CR3 terminal 13 and hold start switch Check voltage at terminal 1 on CR3 12V Reconnect all wiring and check all wires connected to terminals TB22 and TB23 for short to ground and repair as aly 12V Reconnect blk 22 wire to oil pressure sending unit wht 51 wire to PR1 initiate terminal and wht 51 to TR2 terminal 1 Hold start switch and check voltage at red wire On ignition module Reconnect blk cable to starter and see Ford service manual for ignition system roubleshootina Repair open in wht 52 wire circuit that connects CR1 CR2 CR3 CR4 and CR6 Check CR3 grounding wire circuit OR replace CR3 relay OR replace relay socket Genie Z 45 22 Repair open in red wire circuit from PR1 to ignition module Reconnect cable to Starter Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Gasoline LPG Models Continuation of good spark fault path from previous flow chart Part No 29487 Check voltage at TB36 0V 12V Check voltage at blk 36 ov on vacuum switch 12V Disconnect blk wire from CR2 terminal
236. tilizes internal suction strainers for the pump supply suction lines and has an external return line filter How to Remove the Hydraulic Reservoir The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage 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 reservoir by removing the drain plug located in the bottom front of reservoir Burn hazard Contact with hot oil may cause severe burns 4 Disconnect the hydraulic hoses from the reservoir 5 Remove the reservoir anchor hook from the back of the reservoir Remove the mounting fasteners from the bottom of the reservoir Use an appropriate lifting device to remove the reservoir 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 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 7 46 Genie Z 45 22 Part No 29487 Service Manual First
237. ting 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 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 Part No 29487 Genie Z 45 22 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 to 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
238. tor valve ie RR flow control in reverse 10 12 ft lbs 14 16 Nm 20 Flow regulator valve tandas RR flow control in forward 10 12 ft lbs 14 16 Nm 21 Flow regulator valve e EE LF flow control in forward 10 12 ft lbs 14 16 Nm 22 Flow regulator valve STY LF flow control in reverse 10 12 ft lbs 14 16 Nm 23 Flow regulator valve E E RF flow control in reverse 10 12 ft lbs 14 16 Nm 24 Flow regulator valve Sa RF flow control in forward 10 12 ft lbs 14 16 Nm 7 66 Genie Z 45 22 Part No 29487 Section 7 Repair Procedures 4WD DRIVE MANIFOLD BEAR Xf SN N ra ON S A First Edition N Service Manual 6 Genie Z 45 22 Part No 29487 Section 7 Repair Procedures Service Manual First Edition 4WD DRIVE MANIFOLD Plug Torque Specifications Description Torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm 20 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 Sp
239. truction Do not let it rub against the engine brackets or hoses If the throttle linkage is improperly 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 one of three different choke configurations Early models were equipped with manual chokes They were replaced with electrically heated automatic chokes These chokes were improved with the addition of a poppet valve to enhance cold starting ability on propane fuel The machine is equipped with an automatic choke if there is not a choke switch on the control panel Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates Manual Choke The manual choke is solenoid operated and is only operational in the gasoline mode This choke will not operate in propane mode Component damage hazard During adjustments do not allow the choke butterfly to stop the solenoid from fully retracting The plunger must be able to bottom out inside the solenoid housing Part No 29487 Genie Z 45 22 FORD LSG 423 ENGINE Automatic Choke Without Poppet Valve This choke functions in both gasoline and propane mode Adjusting the choke to a rich mixture for cold climates will hamper engine performance when starting a cold engine on propane fuel To avoid this problem start the engine in gasoline mode Af
240. ts Service Manual First Edition Chart 27 Platform Level Down Function Inoperative Be sure all other functions operate normally If platform level down 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 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 org blk wire on platform level down function directional 12V Remove both wires from valve coil and check 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 OR interchange valve item D with a like valve item function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the level down function pressure line from the manifold and 2000 cap the port PL2 Then with pressure gauge still PSI attached operate the function down less than 2000 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 co
241. ts 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 Part No 29487 Genie Z 45 22 7 58 Section 7 Repair Procedures Service Manual First 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 Component damage hazard Do not apply excessive force or damage to 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 Genie Z 45 22 14 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 opposit
242. unction from the ground controls Hesult The machine functions should not operate Turn the key switch to ground control Operate each machine function from the platform controls Hesult The machine functions should not operate Turn the key switch to the off position Result The engine should stop and no functions should operate Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 15 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 Push down the Emergency Stop button to the off position O 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 switch
243. ustries service Genie Z 45 22 Replace defective valve Repair the primary function cylinder Part No 29487 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boom Extend Function Inoperative Be sure all other functions operate normally If primary boom extend function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If primary boom extend function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Part No 29487 Hold ground control function switch and check volts at blk red wire on extend retract proportional valve 3 to 6V Remove both wires from valve coil and check resistance across the coil terminals 4 to 5 ohms 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 G with a like valve item H Repair open in blk red wire circuit from TB9 to proportional valve 0 or infinite ohms function operates function inoperative Interchange extend retract flow regulator valve item L with a like valve V D function 0perates function inoperative Hold toggle switch up and ma
244. with a like valve function inoperative Install a pressure gauge 2000 at the quick disconnect PSI coupling on the function manifold and hold the function switch less than 2000 PSI Remove the level up function pressure line from the manifold and cap the port PL1 Then 2000 with pressure gauge still PSI attached operate the function up less than 2000 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 Repair open in org wire circuit from TB13 to directional valve 0 or infinite ohms function operates 2000 PSI Interchange the level up and down counterbalance valves in the sandwich block function Replace defective counterbalance valve Repair the master and or slave cylinder OR replace the slave cylinder counterbalance Genie Z 45 22 Chart 26 Replace the coil Replace the platform leveling directional valve Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valves are not allowing the cylinder to extend or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries service Section 5 Troubleshooting Flow Char
245. xtension retract switch and then move the engine speed control switch to high idle rabbit Check and Adjust the Ignition symbol Timing Gasoline LPG Models 4 Adjust the high idle adjustment nut to obtain an Complete information to perform this procedure is air to fuel mixture ratio of 13 0 1 to 13 2 1 available in the Ford LSG 423 2 3 Litre Industrial using an exhaust gas analyzer Engine Service Manual Ford number 194 216 If an exhaust gas analyzer is not Genie part number 29586 available adjust to obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the lock nut 6 Move the engine speed control switch to low idle turtle symbol and adjust the low idle screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 4 32 Genie Z 45 22 Part No 29487 Service Manual First Edition Section 4 Scheduled Maintenance Procedures D 1 Change the Hydraulic Oil Replacement 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 frequently Perform this procedure with the machine in the fully stowed position 1 Close the two hydraulic tank valves located at the main pump open closed 2 Remove the drain plug from the hydraulic reservoir Beware of hot oil Contact with hot

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