Z-45/22 Service Manual - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data/Service/Z... · Part No. 32960 Genie Z-45/22 Service Manual - Second Edition Important Verify

TechnicalPublications

Second Edition, First PrintingPart No. 32960

®

ServiceManual

Z-45 22

Genie Z-45/22 Part No. 32960

Service Manual - Second Edition

ii

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-45/22Operator's Manual before attempting anymaintenance or repair procedure.

This service manual covers the Genie Z-45/222WD and 4WD models introduced in 1994.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at a Genie dealer service center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aGenie policy. Therefore product specifications aresubject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 69, Redmond WA98073-0069 USA.

If you have any questions, call Genie Industries.

®

®

Genie North AmericaTelephone (206) 881-1800Toll Free in U.S.A. 800 536-1800Toll Free in Canada 800 426-8089Fax (206) 883-3475

Genie EuropeTelephone (44) 0636-813943Fax (44) 0636-815270

Introduction

Copyright © 1994 by Genie Industries

Second Edition: First Printing, August 1994

Genie® is a registered trademarkof Genie Industries Registered 2009987

These machines comply withANSI/SIA 92.5-1992

Printed on recycled paper

Patents Pending

Printed in U.S.A.

Part No. 32960 Genie Z-45/22


Important

Verify Correct Manual

Do not read any further until youhave verified that this is thecorrect manual for this machine.Contact Genie Industries if youhave any questions.

iii

This manual covers the GenieZ-45/22 2WD and 4WD models produced fromMay 1994, starting with serial numberZ-45-001523.

The serial number plate islocated under the engineside turntable cover. It issecured to the bulkheadnear the hydraulic pump.

Use the Genie Z-45/22 Service Manual, FirstEdition, part number 29487, to service machinesnot covered in this second edition.

Do not use thismanual with theGenie Z-45/22 DC,Bi-fuel, Tri-fuel, Dieseland Gas/LPG models.Compare turntablecover size and shape.



This page intentionally left blank.

iv



v

Safety Rules

Section 1 - Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-45/22 OperatingInstruction Manual will result in death or seriousinjury.

Many of the hazards identified in the operatinginstruction manual are also safety hazards whenmaintenance and repair procedures areperformed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.



SAFETY RULES

vi

Section 1 - Safety Rules

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure that your workshop or work areais properly ventilated and well lit.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your number one priority.

Read each procedure thoroughly. Thismanual and the decals, on the machine,use signal words to identify the following:

Indicates the presence ofa hazard that will causedeath or serious injury.

Indicates the presence ofa hazard that may causedeath or serious injury.

Indicates the presence ofa hazard that will or maycause serious injury ordamage to the machine.

Indicates specialoperation or maintenanceinformation.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components, and lifting or

placing loads. Always wear approved steel-toedshoes.



Table of Contents

vii

Introduction

Important Information ..................................................................................................... ii

Section One Safety Rules

General Safety Rules .................................................................................................... iii

Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications ........................................................................................... 2 - 2

Ford LSG 423 Engine Specifications ........................................................................ 2 - 5

Deutz F3L Engine Specifications .............................................................................. 2 - 7

Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C ..................................................................................................................... 3 - 5

Table D ..................................................................................................................... 3 - 6

Maintenance Inspection Report ................................................................................ 3 - 7

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

A-1 Inspect the Manuals ........................................................................................ 4 - 2

A-2 Inspect the Decals and Placards .................................................................... 4 - 2

A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2

A-4 Check the Engine Oil Level ............................................................................. 4 - 3

A-5 Check the Engine Coolant Level - Gasoline/LPG Models ............................... 4 - 3

A-6 Check for Fuel Leaks ...................................................................................... 4 - 3

A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 4

A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4

A-9 Check Tire Pressure ....................................................................................... 4 - 5



Section Four Scheduled Maintenance Procedures, continued

A-10 Test the Platform and Ground Controls .......................................................... 4 - 5

A-11 Test Auxiliary Power Operation ...................................................................... 4 - 5

A-12 Test the Tilt Level Sensor ............................................................................... 4 - 6

A-13 Test the Limit Switches ................................................................................... 4 - 6

A-14 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................. 4 - 8

A-15 Change the Engine Air Filter ......................................................................... 4 - 10

B-1 Check the Engine Belt(s) .............................................................................. 4 - 11

B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 11

B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 11

B-4 Check the Exhaust System ........................................................................... 4 - 12

B-5 Check the Battery ......................................................................................... 4 - 12

B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 13

B-7 Inspect the Electrical Wiring .......................................................................... 4 - 13

B-8 Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 14

B-9 Confirm Proper Brake Configuration ............................................................. 4 - 14

B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 15

B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 15

B-12 Check and Adjust the Engine RPM............................................................... 4 - 15

B-13 Test the Key Switch ...................................................................................... 4 - 17

B-14 Test the Emergency Stop Buttons ................................................................ 4 - 18

B-15 Test the Ground Control Override ................................................................. 4 - 18

B-16 Test the Oscillate Lock-out ........................................................................... 4 - 18

B-17 Test Platform Self-leveling ............................................................................ 4 - 19

B-18 Test the Service Horn ................................................................................... 4 - 19

B-19 Test the Foot Switch ..................................................................................... 4 - 20

B-20 Test the Engine Idle Select ........................................................................... 4 - 20

B-21 Test Fuel Select Operation - Gasoline/LPG Models ..................................... 4 - 21

B-22 Test the Turntable Rotation Stop .................................................................. 4 - 21

TABLE OF CONTENTS

iix



Section Four Scheduled Maintenance Procedures, continued

B-23 Test the Drive Enable System ...................................................................... 4 - 21

B-24 Test the Drive Brakes ................................................................................... 4 - 22

B-25 Test Drive Speed - Stowed Position ............................................................. 4 - 23

B-26 Test the Alarm Package (optional equipment) .............................................. 4 - 23

B-27 Perform Hydraulic Oil Analysis ..................................................................... 4 - 24

B-28 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 24

C-1 Check the Primary Boom Wear Pads ........................................................... 4 - 26

C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 26

C-3 Check the Free-wheel Feature ..................................................................... 4 - 27

C-4 Grease the Worm Drive Gear ....................................................................... 4 - 28

C-5 Replace the Torque Hub Oil ......................................................................... 4 - 29

C-6 Replace the Hydraulic Tank Filter ................................................................. 4 - 29

C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 30

C-8 Replace the Diesel Fuel Filter ....................................................................... 4 - 30

C-9 Replace the Gasoline Fuel Filter ................................................................... 4 - 31

C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 32

C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models ..... 4 - 32

C-12 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 33

C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models ............. 4 - 33

C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models ...................... 4 - 34

C-15 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 34

D-1 Test or Replace The Hydraulic Oil ................................................................ 4 - 35

D-2 Change or Recondition the Engine Coolant .................................................. 4 - 36

D-3 Change the Fuel Lines .................................................................................. 4 - 38

D-4 Check Engine Valve Clearance - Gasoline/LPG Models .............................. 4 - 39

D-5 Check Engine Cylinder Compression - Gasoline/LPG Models ..................... 4 - 39

D-6 Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models ................... 4 - 40

D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 41

D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 41

D-9 Replace The Timing Belt - Gasoline/LPG Models ......................................... 4 - 41

TABLE OF CONTENTS

ix



Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1

1 Engine Will Not Crank Over ............................................................................ 5 - 3

2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5

3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12

4 Engine Will Not Start On LPG, But Will Start On Gasoline- Gasoline/LPG Models ................................................................................. 5 - 15

5 Engine Will Not Start On Gasoline, But Will Start On LPG- Gasoline/LPG Models ................................................................................. 5 - 17

6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19

7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 22

8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 23

9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 25

10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 26

11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 27

12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 28

13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 29

14 Secondary Boom Up Function Inoperative ................................................... 5 - 30

15 Secondary Boom Down Function Inoperative ............................................... 5 - 32

16 Primary Boom Up Function Inoperative ........................................................ 5 - 34

17 Primary Boom Down Function Inoperative ................................................... 5 - 36

18 Primary Boom Extend Function Inoperative ................................................. 5 - 38

19 Primary Boom Retract Function Inoperative ................................................. 5 - 40

20 Turntable Rotate Function Inoperative .......................................................... 5 - 41

21 Turntable Rotate Left Function Inoperative ................................................... 5 - 43

22 Turntable Rotate Right Function Inoperative ................................................ 5 - 44

23 All Platform Leveling Functions Inoperative .................................................. 5 - 45

24 Platform Level Up Function Inoperative ........................................................ 5 - 46

25 Platform Level Down Function Inoperative ................................................... 5 - 47

TABLE OF CONTENTS

x



Section Five Troubleshooting Flow Charts, continued

26 Platform Rotate Left Function Inoperative .................................................... 5 - 48

27 Platform Rotate Right Function Inoperative .................................................. 5 - 49

28 Oscillate Function Inoperative ....................................................................... 5 - 50

29 Steer Left Function Inoperative ..................................................................... 5 - 51

30 Steer Right Function Inoperative .................................................................. 5 - 52

31 All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 53

32 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 56

33 High Range Drive Function Inoperative ........................................................ 5 - 57

34 Low Range Drive Function Inoperative ......................................................... 5 - 60

35 Traction Function Inoperative ....................................................................... 5 - 61

36 Machine Will Not Drive At Full Speed ........................................................... 5 - 62

37 Machine Drives At Full Speed With Platform Raised or Extended ................ 5 - 63

38 Drive Enable System Is Malfunctioning ........................................................ 5 - 64

39 Auxiliary Functions Inoperative ..................................................................... 5 - 65

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Symbol Legend ......................................................................................... 6 - 2

Electrical Schematic - Gasoline/LPG Models ........................................................... 6 - 3

Ground Control Box Legend - Gasoline/LPG Models ............................................... 6 - 5

Relay Panel Legend - Gasoline/LPG Models ........................................................... 6 - 6

Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 7

Electrical Schematic - Diesel Models ....................................................................... 6 - 8

Ground Control Box Legend - Diesel Models ......................................................... 6 - 10

Platform Control Box Legend - Diesel Models ........................................................ 6 - 11

Hydraulic Symbols Legend ..................................................................................... 6 - 12

2WD Hydraulic Schematic ...................................................................................... 6 - 13

4WD Hydraulic Schematic ...................................................................................... 6 - 14

TABLE OF CONTENTS

xi



Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Platform Controls

1-1 Joystick Controllers ......................................................................................... 7 - 2

1-2 Horsepower Limiter Board .............................................................................. 7 - 6

1-3 Foot Switch ..................................................................................................... 7 - 8

1-4 Resistors ......................................................................................................... 7 - 8

1-5 Toggle Switches ............................................................................................. 7 - 9

Platform Components

2-1 Platform ........................................................................................................ 7 - 10

2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 10

2-3 Platform Rotator ............................................................................................ 7 - 11

Primary Boom Components

3-1 Plastic Cable Track ....................................................................................... 7 - 13

3-2 Primary Boom ............................................................................................... 7 - 13

3-3 Primary Boom Lift Cylinder ........................................................................... 7 - 16

3-4 Extension Cylinder ........................................................................................ 7 - 18

3-5 Platform Leveling Master Cylinder ................................................................ 7 - 19

Secondary Boom Components

4-1 Secondary Boom .......................................................................................... 7 - 21

4-2 Secondary Boom Lift Cylinders ..................................................................... 7 - 26

Turntable Covers

5-1 Turntable Covers .......................................................................................... 7 - 27

Deutz Engine F3L 1011

6-1 RPM Adjustment ........................................................................................... 7 - 28

6-2 Flex Plate ...................................................................................................... 7 - 28

Ford LSG 423 Engine

7-1 Governor Actuator ........................................................................................ 7 - 29

TABLE OF CONTENTS

xii



TABLE OF CONTENTS

iivx

Section Seven Repair Procedures, continued

7-2 Choke Adjustments ....................................................................................... 7 - 30

7-3 Timing Adjustment ........................................................................................ 7 - 30

7-4 Carburetor Adjustment .................................................................................. 7 - 30

7-5 RPM Adjustment ........................................................................................... 7 - 30

7-6 Flex Plate ...................................................................................................... 7 - 31

7-7 Water Temperature and Oil Pressure Switches ............................................ 7 - 32

7-8 Vacuum Switch ............................................................................................. 7 - 33

Ground Controls

8-1 Control Relays .............................................................................................. 7 - 34

8-2 Toggle Switches, See 1-5, Toggle Switches ................................................... 7 - 9

8-3 Wago® Components...................................................................................... 7 - 35

8-4 Resistors ....................................................................................................... 7 - 35

8-5 Power Relay ................................................................................................. 7 - 36

Hydraulic Pumps

9-1 Lift/Steer Pump ............................................................................................. 7 - 37

9-2 Drive Hydraulic Pump ................................................................................... 7 - 38

Function Manifold

10-1 Function Manifold Components .................................................................... 7 - 40

10-2 Valve Adjustments ........................................................................................ 7 - 42

Fuel and Hydraulic Tanks

11-1 Hydraulic Tank .............................................................................................. 7 - 44

11-2 Fuel Tank ...................................................................................................... 7 - 45

Turntable Rotation Components

12-1 Rotation Hydraulic Motor .............................................................................. 7 - 46

12-2 Rotation Bearing and Worm Drive ................................................................ 7 - 46

2WD Steering Axle Components

13-1 Yoke and Hub ............................................................................................... 7 - 51

13-2 Steering Cylinders ........................................................................................ 7 - 52



Section Seven Repair Procedures, continued

13-3 Tie Rod ......................................................................................................... 7 - 53


14-1 Yoke and Hub ............................................................................................... 7 - 54

14-2 Steering Cylinders, See 13-2, Steering Cylinders ......................................... 7 - 52

14-3 Tie Rod, See 13-3, Tie Rod .......................................................................... 7 - 53

Oscillating Axle Components

15-1 Oscillating Axle Lock-out Cylinder ................................................................ 7 - 56

Steer and Oscillate Manifold

16-1 Steer and Oscillate Manifold Components .................................................... 7 - 57


Non-steering Axle Components

17-1 Drive Motor ................................................................................................... 7 - 59

17-2 Torque Hub ................................................................................................... 7 - 59

2WD Drive Manifold

18-1 2WD Drive Manifold Components ................................................................. 7 - 60


4WD Drive Manifold

19-1 4WD Drive Manifold Components ................................................................. 7 - 64


TABLE OF CONTENTS

ivx

Part No. 32960 Genie Z-45/22 2 - 1

Section 2 - SpecificationsService Manual - Second Edition

Tires and wheels Rough terrain Industrial

Wheel diameter 17.5 inches 14.5 inches

Wheel width 10.5 inches 7 inches

Wheel lugs - 4WD 9 @ 5/8-18

Wheel lugs - 2WDFront 8 @ 5/8 -18 8 @ 5/8 -18Rear 9 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque 125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Tire size 14-17.5NHS 9-14.5 LT

Tire ply rating 8 Tread 8Sidewall 6

Tire contact area 59 sq in 43.5 sq in380sq cm 280sq cm

Overall tire diameter 35.8 inches 28 inches91cm 71cm

Tire pressure 2WD 40 psi 100 psi

2.76 bar 6.89 bar4WD 28 psi

1.93 bar

Fluid capacities

Fuel tank 15 gallons 56.8 liters

Propane tank 33.5 pounds 15.2kg

Hydraulic tank 25 gallons 95 liters

Hydraulic system 30 gallons 114 liters(including tank)

Torque hubs 17 ounces 0.5 liters

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

Stowed dimension 2WD 4WD

Length 17 ft 8 1/2 in 17 ft 10 3/4 in5.4m 5.45m

WidthRough terrain 6 ft 8 1/4 in 6 ft 4 5/8 in

203.8cm 194.6cmIndustrial 5 ft 9 5/8 in

176.8cm

Height 6 ft 6 in 7 ft 4 in1.98m 2.23m

Weight 13860 lbs 14410 lbs6287kg 6536kg

Ground clearance 8 in 11 in20.3cm 27.9cm

Platform dimensions

Length 6 ft 6 ft182.8cm 182.8cm

Width 30 in 30 in76.2cm 76.2cm

Operational dimensions

Maximum platform height 45 ft 45 ft13.72m 13.72m

Maximum horizontal reach 23 ft 23 ft7m 7m

Maximum up-and-over 21 ft 7 in 21 ft 7 inclearance 6.58m 6.58m

Maximum turntable tailswing 1 inch none2.54cm

Wheelbase 6 ft 3 in 6 ft 3 in190.5cm 190.5cm

Minimum turning circle, 14 ft 4 in 14 ft 9 inoutside 4.37m 4.49m

Minimum turning circle, 7 ft 6 ft 8 ininside 2.13m 2.03m

Turntable rotation 359° 359°

Platform rotation 180° 180°

Specifications

Machine Specifications

2 - 2 Genie Z-45/22 Part No. 32960

Section 2 - Specifications Service Manual - Second Edition

Hydraulic fluid Dexron II equivalent

Drive pump

Type bi-directional variabledisplacement piston pump

Displacement 0 - 25 gpm0 - 1.6 liters/second

Maximum drive 3800 psipressure 262 bar

Charge pressureEskridge brake 360 psi 24.8 barMico brake 290 psi 20 bar

Medium pressure filter 3 micron

Medium pressure filter 50 psi bypass pressure 345 kPa

Drive manifold

Motor shift/brake relief pressureEskridge brake 320 psi 22 barMico brake 250 psi 17.2 bar

4WD front motor 3.0 gpmflow regulators 11.4 liters/minute

4WD rear motor 4.5 gpmflow regulators 17.0 liters/minute

2WD rear motor 7.0 gpmflow regulators 26.5 liters/minute

Drive speeds, maximum 2WD 4WD

Boom lowered, high range 5.0 mph 4.8 mph8.0km/h 7.7km/h

Boom lowered, low range 1.1 mph 0.9 mph1.8km/h 1.4km/hor 5 feet or 4 feetin 3 sec. in 3 sec.

Boom raised, high range 0.68 mph / 1km/hor 1 foot per second

Boom raised, low range 0.68 mph / 1km/hor 1 foot per second

Gradeability (stowed) 30% 40%

Boom function speeds, maximumfrom platform controls

Primary boom extend 29 seconds

Primary boom retract 25 seconds

Primary boom up 27 seconds

Primary boom down 35 seconds

Secondary boom up 25 seconds

Secondary boom down 25 seconds

Turntable rotate (359°) 73 seconds

Platform rotate (180°) 15 seconds

Platform level up 25 seconds

Platform level down 15 seconds

Multiple function 60 secondsstowed to full raised

Multiple function 60 secondsfull raised to stowed

SPECIFICATIONS

Performance Specifications Hydraulic Specifications

Part No. 32960 Genie Z-45/22 2 - 3


Front drive motors - 4WD models

Displacement per revolution 2.1 cu in34.4cc

Rear drive motor

Displacement per revolution High - 2.8 cu in / 45.9ccLow - 0.15 cu in / 2.5cc

Function pump

Type fixed displacement gear pump

Displacement 6.4 gpm @ 2150 rpm0.4 liters/second

Function circuit return 10 micron with line filter 25 psi / 172kPa bypass

Function manifold

Function relief 2200 psivalve pressure 152 bar

Secondary down relief 1200 psivalve pressure 83 bar

Primary down relief 1200 psivalve pressure 83 bar

Primary extend relief 1200 psivalve pressure 83 bar

Steer/oscillate 1.5 gpmflow regulator 5.7 liters/minute

SPECIFICATIONS

Steer/oscillate manifold

Sequencing valve 1800 psipressure 123 bar

Accumulator 1600 psipre-charge pressure 110 bar

Auxillary pump

Type fixed displacement gear pump

Displacement 0.85 gpm3.2 liters/minute

Auxillary pump 2030 psirelief pressure 138 bar

2 - 4 Genie Z-45/22 Part No. 32960


BOLT TORQUE SPECIFICATIONS

24

32

20

28

18

24

16

24

14

20

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

43

49

96

120

17

19

30

35

50

55

75

90

110

120

150

170

260

300

430

470

640

700

5

6

11

14

23

28

41

48

68

75

102

122

149

163

204

231

353

407

583

637

868

949

60

68

144

168

25

25

45

50

70

80

110

120

150

170

220

240

380

420

600

660

900

1000

7

8

16

19

34

34

61

68

95

109

149

163

204

231

298

326

515

570

814

895

1221

1356

Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts

Bolt Torque Specifications

13

20

12

18

11

18

10

16

9

14

8

12

Torque specification for lubricated bolts is 25% less than dry torque specification for bolt size.

No. 10

1/4 inch

5/16 inch

3/8 inch

7/16 inch

1/2 inch

9/16 inch

5/8 inch

3/4 inch

7/8 inch

1 inch

These bolt torque specifications are for general use only. Specification may vary depending on applicationof bolt.

Part No. 32960 Genie Z-45/22 2 - 5


Starter motor

Normal engine 110 rpmcranking speed

Current draw, normal load 150A

Current draw, maximum load 460A

Current draw, no load 70A

Maximum circuit 0.5V DC voltage drop (normal temp)

Brush length, new 0.50 inches12.7mm

Brush length, wear limit 0.25 inches6.35mm

Brush spring tension 40 ounces

Bolt torque through brush 55 - 75 inch-pounds98 - 134gm-cm

Brush mounting 15 - 20 foot-poundsbolt torque 2.1 - 2.7kg-m

Maximum commutator 0.005 inchesrun out 0.127mm

Battery

Type 12V, Group 24

Ampere hour 75A

Cold Cranking Ampere 875A

Reserve capacity @ 25A rate 125 minutes

Fuel Pump

Static pressure 5.0 - 7.0 psi

Minimum volume flow 1 pint / 473cc in 25 seconds

Displacement 140 cu in / 2.3 liters

Number of cylinders 4

Bore and stroke 3.780 x 3.126 inches96 x 79.4mm

Horsepower 63 @4000 rpm

Firing order 1 - 3 - 4 - 2

High idle 2150 rpm

Low idle 1400 rpm

Governor electronic

Compression pressure psi of lowest cylindermust be at least 75% of

highest cylinder

Valve clearances

Intake 0.0010 - 0.0027 inches0.025 - 0.068mm

Exhaust 0.0015 - 0.0032 inches0.038 - 0.081mm

Lubrication System

Oil pressure (operating 40-60 psitemp. @ 2150 rpm) 276-414 kPa

Oil capacity 5 quarts(including filter) 4.71 liters

Oil viscosity requirements

Below 60°F / 15.5°C 5W - 30

-10 to 90°F / -23 to 32°C 10W - 30

above -10°F / -23°C 10W - 40 or 10W - 50

above 25°F / -4°C 20W - 40 or 20W - 50

Use oils meeting API classification SF (labeled SF/CCor SF/CD) as they offer improved wear protection.

FORD ENGINE LSG-423 SPECIFICATIONS

Ford Engine LSG-423

2 - 6 Genie Z-45/22 Part No. 32960


Cylinder head bolt / M-12torque in sequence:first step 50-60 68-81second step 80-90 108-122

Distributor clamp bolt / M-10 14-21 19-28

Distributor vacuum tube 5-8 7-11to manifold adaptor

Exhaust manifold to cylinder head bolt or nut / M-10torque in sequence:first step 14-19 19-26second step 20-30 27-41

Flywheel to crankshaft bolt / M-10 56-64 76-87

Fuel pump to cylinder block / M-8 14-21 19-28

Intake manifold to cylinder 14-21 19-28head bolt or nut / M-8

Oil pressure sending 8-18 11-24unit to block

Oil pan drain plug to pan / M-14 15-25 20-34

Oil pan to block / M-6 10-13.5 14-18

Oil filter insert to block 20-35 27-47

Rocker arm cover to 5-8 7-11cylinder head / M-6

Spark plug to cylinder 5-10 7-14head / M-14

Temperature sending 8-18 11-24unit to block / M-14

Water jacket drain plug 23-28 31-38to block

Water pump to block bolt 14-21 19-28

Auxiliary shaft cover bolt / M-6 6-9 8-12

Water outlet connection 14-21 19-28bolt / M-8

Cylinder front cover bolt / M-6 6-9 8-12

Inner timing belt cover stud / M-8 14-21 19-28

Outer timing belt cover bolt / M-6 6-9 8-12

Ignition System

Ignition spark advance 10° BTDC

Ignition coil 1.13 - 1.25W (75°F)primary resistance

Ignition coil 7700 - 9300W (75°F)secondary resistance

Spark plug type Motorcraft AWSF-52

Spark plug gap 0.042 - 0.046 inches1.07 - 1.18mm

Coolant capacity 11.5 quarts10.9 liters

Alternator output 35A, 14.5V

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Bolt torque specificationsItem / Size Torque Torque

(ft-lbs) (Nm)

Auxiliary shaft gear bolt / M-10 28-40 38-54

Auxiliary shaft thrust 6-9 8-12plate bolt / M-6

Belt tensioner (timing) 28-40 38-54pivot bolt / M-10

Belt tensioner (timing) 14-21 19-28adjusting 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 14-19manifold bolt / M-8

Crankshaft damper bolt / M-14 103-133 140-180

FORD ENGINE LSG-423 SPECIFICATIONS

Part No. 32960 Genie Z-45/22 2 - 7


DEUTZ ENGINE F3L 1011 SPECIFICATIONS


Displacement 125.02 cu in2.049 liters

Number of cylinders 3

Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower 36 @ 2300 rpm

Firing order 1 - 2 - 3

Compression ratio 18.5:1

Compression pressure 362 to 435 psi25 to 30 bar

Pressure (psi) of lowest cylinder must be at least 85% ofhighest cylinder

Low idle 1300 rpm

High idle 2300 rpm

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6.0 bar

Oil capacity 8.5 quarts(including filter) 8 liters

Oil viscosity requirements

Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades.

Injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement diesel number 2-D

Alternator output 55A, 14V

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm

Battery

Type 12V, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Bolt tightening specificationstorque torque

Bolt description (size, grade) ft-lbs Nm

Camshaft/thrust bearing bolt 15 to 18 20 to 24(M-8 x 35, 8.8)

Rocker arm bolts 15 to 18 20 to 24(M-8 x 45, 8.8)

Rocker arm set screw nut 15 to 18 20 to 24

Cylinder head cover 6 to 7 8 to 10

Blower rotor nut 33 to 41 45 to 55(M-17 Valeo or M-18 Bosch)

Blower carrier bolts 15 to 18 20 to 24(M-8 x 50 Torx, 8.8)

V-belt pulley bolts 28 to 34 38 to 46(M-10 x 16, 8.8)

2 - 8 Genie Z-45/22 Part No. 32960


SPECIFICATIONS

torque torqueft-lbs Nm

Oil thermostat housing screw 37 to 44 50 to 60plug (M-38 x 1.5)

Oil thermostat housing bolts 5.5 to 7 7.5 to 9(M-6 x 35 Torx, 8.8)

Oil thermostat housing bolts 5.5 to 7 7.5 to 9(M-6 x 80 Torx, 8.8)

Oil thermostat housing bolts 14 to 16 19 to 22(M-6 x 105 Torx, 8.8)

Valve plunger housing bolts 14 to 16 19 to 22(M-8 x 30 Torx, 8.8)

Alternator nuts (M-5) 3 4

Fuel bracket bolts (M-8 x 20, 8.8) 15 20

Adapter housing bolts 70 to 77 95 to 105(M-12 x 35, 10.9 or M-12 x 75, 10.9)

first step second steptightening tightening

torque angles

ft-lbs Nm 1st 2nd

Main bearing bolts 37 50 60° 45°

Big end bolts 22 30 60° 60°

Flywheel bolts 22 30 60° 30°

Cylinder head step 1 22 30studs step 2 59 80

step 3 118 160 120° NA

Camshaft/central bolt 22 30 150° NA

Crankshaft/central bolt 96 130 210° NA

Bolt tightening specifications, continuedtorque torque

Bolt description (size, grade) ft-lbs Nm

Idler pulley/V-belt pulley bolt 27 to 32 36 to 44(M-10 x 25, 8.8)

Idler pulley for toothed belt 30 to 36 41 to 49(M-10 x 50, 8.8)

Oil pump bolts 15 to 18 20 to 24(M-8 x 35 Torx)

Oil filter bracket bolts 7 to 8 9 to 11(M-8 x 20 Torx, 8.8)

Oil intake housing bolts 15 to 18 20 to 24(M-8 x 75 Torx)

Fuel pump bolts 15 to 18 20 to 24

Injection pump bolts 15 to 18 20 to 24

Injector cap nut 30 to 37 40 to 50

Injector fastening bolt 15 to 18 20 to 24

Injection line 10 to 12 13.5 to 16.5

Air intake manifold bolts 15 to 18 20 to 24(M-8 x 30, 8.8)

Air intake manifold, 3-hole 15 to 18 20 to 24flange bolts (M-8 x 35 Torx, 8.8)

Exhaust manifold bolts 27 to 32 36 to 44(M-10 x 30 Torx, 10.9)

Starter fastening bolts 28 to 34 38 to 46(M-10 x 28, 8.8)

Starter carrier bolts 50 to 60 68 to 82(M-12 x 28, 8.8)

Oil pan bolts 15 to 18 20 to 24(M-8 x 16 Torx, 8.8)

Oil drain bolts 37 to 44 50 to 60

Part No. 32960 Genie Z-45/22 3 - 1

Section 3 - Scheduled Maintenance InspectionsService Manual - Second Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Scheduled Maintenance Inspections

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every2 years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

About This SectionThe Schedule

There are four types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, annual, two year. To account forrepeated procedures, the Maintenance Tables andthe Maintenance Inspection Report have beendivided into four subsections—A, B, C, D. Use thefollowing chart to determine which group(s) ofprocedures are required to perform a scheduledinspection.

Inspection Table or Checklist

Daily A

Quarterly A + B

Annual A + B + C

Two year A + B + C + D

Maintenance Tables

The maintenance tables contained in this sectionprovide summary information on the specificphysical requirements for each inspection.

Complete step-by-step instructions for eachscheduled maintenance procedure are provided insection 4, Scheduled Maintenance Procedures.

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance InspectionReport to use for each inspection. Storecompleted forms for three years.

3 - 2 Genie Z-45/22 Part No. 32960

Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Table A

A-1 Inspect the Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Engine Oil Level

A-5 Check the Engine Coolant Level

A-6 Check for Fuel Leaks

A-7 Check the Hydraulic Oil Level

A-8 Check for Hydraulic Leaks

A-9 Check Tire Pressure

A-10 Test the Platform and Ground Controls

A-11 Test Auxiliary Power Operation

A-12 Test the Tilt Level Sensor

A-13 Test the Limit Switches

Every 100 hours, perform the following two enginemaintenance procedures.

A-14 Replace the Engine Oil and Filter- Gasoline/LPG Models

A-15 Change the Engine Air Filter

Maintenance Tables

Part No. 32960 Genie Z-45/22 3 - 3


Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Table B

B-1 Check the Engine Belt(s)

B-2 Check the Radiator- Gasoline/LPG Models

B-3 Check the Oil Cooler and Cooling Fins- Deutz Diesel Models

B-4 Check the Exhaust System

B-5 Check the Battery

B-6 Check the Hydraulic Tank Filter ConditionIndicator

B-7 Inspect Electrical Wiring

B-8 Inspect the Tires and Wheelsincluding lug nut torque

B-9 Confirm Proper Brake Configuration

B-10 Check the Oil Level in the Torque Hubs

B-11 Check and Adjust the Engine Idle Mixture- Gasoline/LPG Models

B-12 Check and Adjust the Engine RPM

B-13 Test the Key Switch

B-14 Test the Emergency Stop Buttons

B-15 Test the Ground Control Override

MAINTENANCE TABLES

3 - 4 Genie Z-45/22 Part No. 32960


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suggested

Table B, continued

B-16 Test the Oscillate Lock-outoscillating axle equipped models

B-17 Test Platform Self-leveling

B-18 Test the Service Horn

B-19 Test the Foot Switch

B-20 Test the Engine Idle Select

B-21 Test Fuel Select Operation - Gasoline/LPGModels

B-22 Test the Turntable Rotation Stop

B-23 Test the Drive Enable System

B-24 Test the Drive Brakes

B-25 Test Drive Speed - Stowed Position

B-26 Test the Alarm Package (optional equipment)travel alarm, descent alarm, flashing beacon

B-27 Perform Hydraulic Oil AnalysisSee D-1, Test or Replace the Hydraulic Oil

Every 500 hours, perform the following enginemaintenance procedure.

B-28 Replace the Engine Oil and filter -Deutz Diesel Models

MAINTENANCE TABLES

Part No. 32960 Genie Z-45/22 3 - 5


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required

Coldengine

required

Dealerservice

suggested

MAINTENANCE TABLES

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 Gearincluding turntable rotation bearing

C-5 Replace the Torque Hub Oil

C-6 Replace the Hydraulic Tank Filter

C-7 Replace the Drive Loop Hydraulic Filter

C-8 Replace the Diesel Fuel Filter

C-9 Replace the Gasoline Fuel Filter

C-10 Replace the PCV Valve - Gasoline/LPG Models

C-11 Clear or Replace the Distributor Cap andRotor - Gasoline/LPG Models

C-12 Replace the Spark Plugs - Gasoline/LPG Models

C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models

C-14 Check and Adjust the Ignition Timing - Gasoling/LPG Models

C-15 Check the Engine Valve Clearances - Deutz Diesel Models

3 - 6 Genie Z-45/22 Part No. 32960


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required

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MAINTENANCE TABLES

Table D

D-1 Test or Replace the Hydraulic Oilincludes cleaning the suction strainers

D-2 Change or Recondition the Engine Coolantincluding all coolant hoses and clamps

D-3 Change the Fuel Lines

D-4 Check Engine Valve Clearance - Gasoline/LPGModels

D-5 Check Engine Cylinder Compression -Gasoline/LPG Models

D-6 Clean PCV Hoses and Fittings - Gasoline/LPGModels

D-7 Check the Fuel Injection Pumps and Injectors- Diesel Models

D-8 Check the Toothed Belt - Diesel Models

D-9 Replace the Timing Belt - Ford

Part No. 32960 Genie Z-45/22 3 - 7


Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Maintenance Inspection Report

Instructions· Make copies of this page to use for

each inspection.

· Select the appropriate checklist(s) forthe 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 boxafter each inspection procedure iscompleted.

· Use the maintenance tables in thissection and the step-by-stepprocedures in section 4 to learn how toperform these inspections.

· If any inspection receives an “N”,remove the machine from use , repairand re-inspect it. After repair, place acheck in the “R” box.

LegendY = yes, acceptableN = no, unacceptable

R = repaired

Comments

B-20 Engine idle select

B-21 Fuel select-gasoline

B-22 Turntable rotation stop

B-23 Drive enable system

B-24 Drive brakes

B-25 Drive speed

B-26 Alarm package

B-27 Oil analysis

Perform every 500 hours:

B-28 Replace engine oiland filter - Deutz

Checklist C Y N R

Refer to Table C

C-1 Wear pads

C-2 Turntable bolts

C-3 Free-wheel configuration

C-4 Worm drive gear

C-5 Drive torque hubs

C-6 Hydraulic tank filter

C-7 Drive loop hydraulic filter

C-8 Fuel filter-diesel

C-9 Fuel filter-gasoline

C-10 PCV valve-gasoline

C-11 Distibutor cap-gasoline

C-12 Spark plugs

C-13 Propane adjustments

C-14 Ignition timing-gasoline

C-15 Valves - Deutz

Checklist D Y N R

Refer to Table D

D-1 Hydraulic oil

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 andfittings-gasoline

D-7 Fuel injection - Deutz

D-8 Toothed belt - Deutz

D-9 Timing belt-Ford

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist A Y N R

Refer to Table A

A-1 Manuals

A-2 Decals and placards

A-3 Damage, loose ormissing 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 andground controls

A-11 Auxiliary power

A-12 Tilt alarm

A-13 Limit switches

Perform every 100 hours:

A-14 Change engine oiland filter - Gas/LPG

A-15 Change engine air filter

Checklist B Y N R

Refer to Table B

B-1 Engine belt(s)

B-2 Engine radiator

B-3 Oil cooler and fins-Deutz

B-4 Exhaust system

B-5 Battery

B-6 Hydraulic tank filter

B-7 Electrical wiring

B-8 Tires and wheels

B-9 Brake configuration

B-10 Drive torque hubs

B-11 Idle mixture-gasoline

B-12 Engine RPM

B-13 Key switch

B-14 Emergency Stop button

B-15 Ground control override

B-16 Oscillate lock-out

B-17 Platform leveling

B-18 Service horn

B-19 Foot switch

3 - 8 Genie Z-45/22 Part No. 32960


Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested


Part No. 32960 Genie Z-45/22 4 - 1

Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, frequently (every 3 months),annually and every 2 years as specified on themainentance report.

Failure to properly complete eachinspection when required mayresult in death, serious injury orsubstantial machine damage.


Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· machine parked on a flat, level surface

· boom in stowed position

· turntable rotated with the boom between the non-steering wheels

· key switch in the OFF position with the key removed

· wheels chocked

Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend

Indicates the presence of ahazard that will cause death orserious injury.

Indicates the presence of ahazard that may cause death orserious injury.

Indicates the presence of ahazard that will or may causeserious injury or damage to themachine.

Indicates special operation ormaintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

4 - 2 Genie Z-45/22 Part No. 32960

Service Manual - Second EditionSection 4 - Scheduled Maintenance Procedures

A-1Inspect the Manuals

Maintaining the Operator's and Safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the box providedin the platform. An illegible or missing manual willnot provide safety and operational informationnecessary for a safe operating condition.

1 Check to be sure that the storage container ispresent and in good condition.

2 Check to make sure that the operator's,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your Genie distributor orGenie Industries if replacementmanuals are needed.

2 Inspect all decals for damage or illegibility.Replace any illegible decal immediately.

Contact your Genie distributor orGenie Industries if replacementdecals are needed.

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and ground personnel to the manypossible hazards associated with using thismachine. They also provide users with operationand maintenance information. An illegible decalwill fail to alert personnel of a procedure or hazardand could result in unsafe operating conditions.

1 Refer to the Decals section in the Genie Z45/22Operator's Manual and use the decal list andillustrations to determine that all decals andplacards are in place.

A-3Inspect for Damage, Loose orMissing Parts

Daily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including:

· electrical components, wiring and electricalcables

· hydraulic hoses, fittings, cylinders andmanifolds

· fuel and hydraulic tanks

· drive and turntable rotation motors and gearboxes

· boom components and wear pads

· dents or damage to machine

· tires and wheels

· engine and related components

· limit switches, alarms, horns and beacon

· nuts, bolts and other fasteners

· platform entry mid-rail or gate

· cracks in welds or structural components

· compartment covers and latches

Table A Procedures

Part No. 32960 Genie Z-45/22 4 - 3


A-4Check the Engine Oil Level

Maintaining proper engine oil level is essential togood engine performance and service life.Operating the machine at an improper oil level candamage engine components.

Check the oil level with the engineoff.

1 Check the oil level dipstick. Add oil as needed.

Result: The oil level should be in the "safe"zone.

Ford Engine LSG-423 5 quartsOil capacity (including filter) 4.7 liters

Ford Engine LSG-423 Oil viscosity requirements

below 60F / 15.5C 5W-30

-10 to 90F / -23 to 32C 10W-30

above -10F / -23C 10W-40 or 10W-50

above 25F / -4C 20W-40 or 20W-50


Deutz Engine F3L 1011 8.5 quartsOil capacity (including filter) 8 liters

Deutz Engine F3L 1011 Oil viscosity requirements

below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40


TABLE A PROCEDURES

A-5Check the Engine Coolant Level- Gasoline/LPG Models

Maintaining engine coolant at the proper level isessential to engine life. Improper coolant level willaffect the engines cooling capability and damageengine components. Daily checks will allow theinspector to identify dramatic changes in coolantlevel that might indicate cooling system problems.

1 Check the fluid level in the coolant recoverytank. Add water as needed.

Result: The fluid level should be in the normalrange.

A-6Check for Fuel LeaksFailure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Engine fuels are combustible.Inspect the machine in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

1 Open the shutoff valve on the liquid propanegas (LPG) tank by turning it counterclockwise.

4 - 4 Genie Z-45/22 Part No. 32960


TABLE A PROCEDURES

2 Perform a visual inspection around thefollowing areas. An LPG detector may benecessary to locate propane leaks.

Gasoline/LPG models:

· LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator, and carburetor

· gasoline tank, shutoff valve, solenoid shutoffvalve, hoses and fittings, fuel pump andcarburetor

Deutz Diesel models:

· fuel tank, shutoff valve, hoses and fittings, fuelpump, fuel filter, fuel injection pumps and fuelinjectors

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repair theleak immediately.

A-7Check the Hydraulic Oil Level

Maintaining hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes inoil level that might indicate the presence ofhydraulic system problems.

1 Be sure that the machine is in the fully stowedposition, then visually inspect the sight gaugelocated on the side of the hydraulic oilreservoir.

Result: The hydraulic oil level should be withinthe top 2 inches (5cm) of the sight gauge.

Hydraulic oil specifications

Hydraulic oil type Dexron II equivalent

Tank capacity 25 gallons95 liters

Hydraulic system 30 gallons(including tank) 114 liters

A-8Check for Hydraulic Leaks

Detecting hydraulic fluid leaks is essential tooperational safety and good machineperformance. Undiscovered leaks can develop intohazardous situations, impair machine functionsand damage machine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· hydraulic tank—filter, fittings, hoses andturntable surface

· engine compartment—fittings, hoses, auxiliarypower unit, main pump and turntable surface

· all hydraulic cylinders

· all hydraulic manifolds

· primary and secondary booms

· the underside of the chassis

· ground area under the machine

Part No. 32960 Genie Z-45/22 4 - 5


TABLE A PROCEDURES

A-9

Check the Tire PressureThis procedure does not need tobe performed on machinesequipped with the foam-filled tireoption.

An over-inflated tire can explodeand may cause death or seriousinjury.

To safeguard maximum stability, achieve optimummachine handling and minimize tire wear, it isessential to maintain proper pressure in all air-filled tires.

1 Check each tire with an air pressure gauge andadd air as needed.

Tire Specifications 2WD Models 4WD Models

Industrial tire 9-14.5LT100 psi / 6.89 bar

Rough terrain tire 14-17.5NHS 14-17.5NHS40 psi / 2.76 bar 28 psi / 1.93 bar

A-10Test the Platform andGround Controls

Testing machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions and shut off the engine. Eachfunction should activate, operate smoothly and befree of hesitation, jerking and unusual noise.

1 Start the engine from the ground controls, andthen operate each machine function through afull cycle.

Result: All machine functions should activateand operate smoothly.

2 Push in the Emergency Stop button to the offposition.

Result: No function should operate, the engineshould stop.

Diesel models: All functionsshould stop immediately. Theengine will shut off after 2 or 3seconds.

3 Start the engine from the platform controls, andthen operate each machine function through afull cycle.

Result: All machine functions should activateand operate smoothly.

4 Push in the Emergency Stop button to the offposition.

Result: No function should operate, the engineshould stop.

As a safety feature, selecting andoperating the ground controls canoverride the platform controls,including the Emergency Stopbutton.

A-11Test Auxiliary Power Operation

Detection of auxiliary power system malfunctionsis essential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. Auxiliary power is designed for shortterm emergency use only, and excessive use willresult in battery drain and pump damage.

Oscillating axle equippedmachines only: From the stowedposition, auxiliary power can notraise the boom above the drivelimit switch. Auxiliary power canraise the boom if it is alreadyraised above the drive limit switch.

1 Turn the key switch to ground control and pullout the ground control Emergency Stop buttonto the on position.

4 - 6 Genie Z-45/22 Part No. 32960


TABLE A PROCEDURES

2 Simultaneously hold theauxiliary power switch onwhile activating thefollowing functions througha partial cycle:

· primary boom up/down

· extend and retract

· secondary boom up/down

· turntable rotate right/left

Result: Each function should operate smoothly.

3 Turn the key switch to platform control.

4 At the platform controls, pull out the EmergencyStop button to the on position, press down thefoot switch.

5 Simultaneously holdthe auxiliary powerswitch on whileactivating the followingfunctions through apartial cycle:

· primary boomup/down

· extend and retract

· secondary boom up/down

· turntable rotate right/left

· steer left/right

A-12Test the Tilt Level Sensor

The tilt sensor sounds an alarm in the platformwhen the incline of the chassis exceeds 4.5°.

Select a level test area.

1 Start the engine from the ground controls.

2 Open the engine side cover and press down onone side of the tilt sensor.

Result: After a 1.5 second delay, the alarm inthe platform should sound.

A-13Test the Limit Switches

Detecting limit switch malfunctions is essential tosafe machine operation. The drive enable limitswitch activates a signal light to inform theoperator that the platform is past the non-steerwheels, and stops drive movement unless thedrive enable override switch is used. The drivelimit switch is used to restrict drive speed when theboom is raised and signal the oscillate cylinder toextend the lock-out wedges (oscillating axleequipped machines). Also, on oscillating axleequipped machines, there are two limit switches tostop the boom from being raised unless the lockout wedges are extended. Improperly functioninglimit switches will allow the boom to raise and/ordrive into an unsafe position.

Drive Limit Switch

1 With the engine off and the machine in thestowed position, visually inspect the drive limitswitch for the following:

· broken or missing rollers or arms

· missing fasteners

· loose wiring

Part No. 32960 Genie Z-45/22 4 - 7


TABLE A PROCEDURES


3 Raise the primary boom above the drive limitswitch and turn the machine off.

4 Manually activate the drive limit switch.

a drive limit switch

Result: The drive limit switch arm should movefreely and spring return to center. A distinctclick should be felt and heard.

5 Restart the engine and lower the boom into thefully stowed position.

6 Move the key switch to platform control, andthen start the engine from the platform controls.

7 Slowly move the drive control handle off center.

Result: The machine should move at normaldrive speeds.

8 Raise the primary boom above the drive limitswitch.

9 Slowly move the drive control handle off center.

Result: The machine should move at a reduceddrive speed.

Drive speed, maximum, raised

All models 1 foot/ 0.3 metersper second

a

Drive Enable Limit Switch

1 With the engine off and the machine in thestowed position, visually inspect the driveenable limit switch for the following:



· loose wiring

2 Manually activate the drive enable limit switch.

a drive enable limit switch

Result: The drive enable limit switch rollershould move freely and spring return to center.A distinct click should be felt and heard.

3 Start the engine from the platform controls andthen rotate the turntable to the left until theplatform is positioned over the left non-steerwheel.

Result: The platform over steer wheelsindicator light should be on. Drive movementshould stop until the drive enable overrideswitch is activated.

4 Rotate the turntable to the right until theplatform is positioned over the right non-steerwheel.

Result: The platform over steer wheelsindicator light should be on. Drive movementshould stop until the drive enable overrideswitch is activated.

a

4 - 8 Genie Z-45/22 Part No. 32960


TABLE A PROCEDURES

Oscillating Axle Limit Switches

1 With the engine off and the machine in thestowed position, visually inspect the oscillatelock-out switch for the following:

Oscillating axle limit switcha limit switchb oscillate lock out wedge



· loose wiring

2 Start the engine from the ground controls andraise the primary boom above the drive speedlimit switch.

Result: The oscillation cylinder should extendthe lock-out wedges. The boom should stopmoving until the wedges are fully extended.

b

a

A-14Replace the Engine Oil and Filter- Gasoline/LPG Models

Ford engine specifications requirethat this procedure be performedevery 100 hours. Perform thisprocedure more often if dustyconditions exist or the machine issubjected to extended low idleoperation.

Periodic replacement of the engine oil and filteris essential to good engine performance.Operating the machine with an improper oil levelor neglecting periodic oil and filter changes candamage engine components. A daily check ofelapsed machine hours against the hours notedon the oil filter will allow the inspector to anticipateand perform oil and filter changes at the 100 hourinterval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Beware of hot engine parts andoil. Contact with hot engine oiland/or engine parts may causesevere burns.

1 Remove the oil filler cap located on thevalve cover.

Part No. 32960 Genie Z-45/22 4 - 9


TABLE A PROCEDURES

2 Pull the end of the oil drain hose out fromunder the engine.

a pivot plate retaining boltsb engine pivot platec oil drain hose

3 Remove the plug from the end of the drainhose and allow all of the oil from the engineto drain into a suitable container.

4 Install the plug into the drain hose.

5 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the oil filter.

6 Use an oil filter wrench and remove the filter.

7 Apply a thin layer of oil to the new oil filtergasket (filter part no. 28656). Then install thefilter and tighten it securely by hand.

8 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

9 Fill the engine with new oil per specificationsand install the filler cap.

10 Start the engine from the ground controls.Allow the engine to run for 30 seconds, thenturn the engine off.

11 Check the oil filter and the oil drain hosefor leaks.

12 Swing the engine pivot plate back to its originalposition and replace the three retaining bolts.

13 Check the engine oil level dipstick. Add oilif needed.

Ford Engine LSG-423 5 quartsOil capacity (including filter) 4.7 liters

Ford Engine LSG-423 Oil viscosity requirements

below 60F / 15.5C 5W-30

-10 to 90F / -23 to 32C 10W-30

above -10F / -23C 10W-40 or 10W-50

above 25F / -4C 20W-40 or 20W-50


c a aba

4 - 10 Genie Z-45/22 Part No. 32960


TABLE A PROCEDURES

A-15

Replace the Engine Air FilterEngine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditionsexist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and componentdamage.

Perform this procedure with theengine off.

1 Remove the end cap from the air cleanercanister.

2 Remove the mounting fastener from the airfilter, then remove the filter.

3 Clean the inside of the canister and the gasketwith a dry cloth.

4 Insert the new filter and replace the mountingfastener.

5 Replace the end cap on the canister.

Air filters - Genie part numbersFord LSG-423 Engine 27916Deutz F3L 1011 29553

Part No. 32960 Genie Z-45/22 4 - 11


Table B Procedures

B-1Check the Engine Belt(s)Maintaining the engine belt(s) is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Do not inspect while the engineis running. Remove the key tosecure from operation.

Beware of hot enginecomponents. Contact with hotengine components may causesevere burns.

1 Deutz Diesel models: Remove front enginecover to access belt.

2 All models: Inspect the engine belt(s) for:

· cracking

· glazing

· separation

· breaks

3 Check the engine belt(s) for proper tension.

Belt deflection - all models 3/8 inch to 1/2 inch9 mm to 12 mm

Ford engine Deutz Diesel engine

B-2Check the Radiator- Gasoline/LPG ModelsMaintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.

Do not inspect while the engine isrunning. Remove the key tosecure from operation.


1 Inspect the radiator for leaks and physicaldamage.

2 Clean the radiator fins of debris and foreignmaterials.

B-3

Check the Oil Cooler and CoolingFins - Deutz Diesel ModelsMaintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Do not inspect while the engineis running. Remove the key tosecure from operation.


4 - 12 Genie Z-45/22 Part No. 32960


Oil Cooler

1 Remove the cover from the side of the engine,then remove the oil cooler top cover.

2 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc blower fins

3 Clean the oil cooler of debris and foreignmaterial.

Cooling and Blower Fins

4 Inspect the blower fins for physical damage.

5 Clean the blower fins of debris and foreignmaterial.

6 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

7 Clean the cylinder head cooling passages ofdebris and foreign material.

B-4Check the Exhaust System

Maintaining the exhaust system is essential togood engine performance and service life.Operating the machine with a damaged or leakingexhaust system can cause component damageand unsafe operating conditions.

TABLE B PROCEDURES

Do not inspect while the engine isrunning. Remove the key tosecure from operation.


1 Be sure that all nuts and bolts are tight.

2 Inspect all welds for cracks.

3 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

B-5Check the Battery

The factory ships each machinewith a sealed battery; checkingthe water level is not necessary. Ifthe battery is replaced withanother type, the battery acidlevel and specific gravity shouldbe checked at this time.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and extremely hazardous conditions.

Batteries contain acid. Avoidspilling or contacting battery acid.Neutralize battery acid spills withbaking soda and water.

1 Put on protective clothing and eye wear ifbatteries are to be opened.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold down and cableconnections are tight.

a b c

Part No. 32960 Genie Z-45/22 4 - 13


TABLE B PROCEDURES

B-6Check the Hydraulic Tank FilterCondition IndicatorMaintaining the hydraulic reservoir filter in goodcondition is essential to good system performanceand safe machine operation. The filter conditionindicator will show when the hydraulic flow isbypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Start the engine from the platform controls.

2 Switch the engine speed control to high idle(rabbit symbol).

3 Inspect the filter condition indicator.

a filter condition indicatorb filterc hydraulic reservoir

Result: The filter should be operating in thegreen area. If the display shows red, thisindicates that the hydraulic filter is beingbypassed and the filter should be replaced.

a

b

c

B-7Inspect the Electrical Wiring

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits may result indeath or serious injury. Removeall rings, watches and otherjewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· engine compartment relay panel

· engine wiring harness

· inside of the ground control box

· turntable manifold wiring

2 Start the engine from the ground controls, andthen raise the secondary boom until the upperpivot is above the turntable covers.

3 Inspect the upper pivot area for burnt, chafedand pinched cables.

4 Fully lower the boom into the stowed positionand turn the engine off.

5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· cable track on the primary and secondarybooms

· primary boom to platform cable harness

· inside of the platform control box

4 - 14 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

B-8Inspect the Tires and Wheels

Maintaining the tires and wheels in good conditionis essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

An over-inflated tire canexplode and may cause deathor serious injury.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check every lug nut for proper torque.

4 Check the pressure in each air-filled tire.

Tires and wheels Rough terrain Industrial

Tire size 14-17.5NHS 9-14.5 LT

Tire ply rating 8 Tread 8Sidewall 6

Tire pressure 2WD 40 psi 100 psi

2.76 bar 6.89 bar4WD 28 psi

1.93 bar

Lug nut torque 125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Wheel diameter 17.5 inches 14.5 inches

Wheel width 10.5 inches 7 inches

Wheel lugs - 4WD 9 @ 5/8-18

Wheel lugs - 2WDFront 8 @ 5/8 -18 8 @ 5/8 -18Rear 9 @ 5/8 -18 9 @ 5/8 -18

b

c

a

B-9Confirm ProperBrake Configuration

Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically released,spring applied individual wheel brakes can appearto operate normally when they are actually notfully operational.

1 Check the torque hub disconnect caps to besure they are in the engaged position.

2 On 4WD models, be sure the free-wheel valveon the drive pump is closed (clockwise).

a drive pumpb lift pumpc free-wheel valve

brake disengage position

brake engage position

Part No. 32960 Genie Z-45/22 4 - 15


TABLE B PROCEDURES

B-10Check the Oil Levelin the Torque Hubs

Failure to maintain proper torque hub oil levelsmay cause the machine to perform poorly andcontinued use may cause severe componentdamage.

1 Drive the machine to rotate the hub until theside plugs are located one on top and the otherat 90 degrees.

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Apply pipe thread sealant to the plug, and theninstall it in the torque hub.

5 Repeat this procedure for each torque hub.

Drive torque hub oil

Capacity 17 fluid ounces0.51 liters

Type: SAE 90 multipurpose hypoid gear oil - APIserviceclassification GL5

B-11Check and Adjust the Engine IdleMixture - Gasoline/LPG Models

Complete information to perform this procedure isavailable in the Ford LSG-423 2.3 Litre IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

B-12

Check and Adjust theEngine RPMMaintaining the engine rpm at the proper settingfor both low and high idle is essential to goodengine performance and service life. The machinewill not operate properly if the rpm is incorrect andcontinued use may cause component damage.

Gasoline/LPG Models

Perform this procedure in gasolinemode with the engine at normaloperating temperature.

1 Disconnect the blue/black wire from thegovernor actuator.

2 Connect an rpm gauge to the engine, then startthe engine from the ground controls.

Result: Carburetor low idle should be 900 rpm.

Skip to step 4 if the low idle rpm is correct.

4 - 16 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

3 Turn the idle adjustment screw on thecarburetor clockwise to increase rpm orcounterclockwise to decrease rpm.

Gasoline/LPG low idle adjustmenta carburetorb adjustment screw

4 Turn the engine off and reconnect theblue/black wire to the governor actuator.


Result: Electronic governor low idle shouldbe 1400 rpm.

6 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.

Result: High idle should be 2150 rpm.

7 Turn the engine off.

If low and high idle rpm’s are correct,disregard adjustment steps 8 and 9.

8 Remove the mounting fasteners from theelectronic governor located on the engineside bulkhead, then remove the back panelfrom the governor.

9 Restart the engine, turn the low or high speedset screw clockwise to increase the rpm orcounterclockwise to decrease the rpm.

Do not adjust any trimpot other than specified inthis procedure.

Gasoline/LPG idle adjustmenta low idle adjustmentb high idle adjustment

10 Re-assemble the governor and recheck lowand high idle.

Gasoline/LPG models

Low idle - carburetor 900 rpm

Low idle - electronic governor 1400 rpm

High idle 2150 rpm

Deutz Diesel models

1 Connect an rpm gauge to the engine, and thenstart the engine from the ground controls.

Result: Low idle should be 1300 rpm.

Skip to step 3 if the low idle rpm is correct.

b

a

b

a

Part No. 32960 Genie Z-45/22 4 - 17


TABLE B PROCEDURES

2 Loosen the lock nut, then turn the adjustmentscrew clockwise to increase the rpm orcounterclockwise to decrease the rpm. Tightenthe lock nut and recheck the rpm.

a solenoid bootb high idle adjustment nutc lock nutd yokee low idle adjustment screwf lock nut

3 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.

Result: High idle should be 2300 rpm.

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut, then turn theadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Deutz Diesel models

Low idle 1300 rpm

High idle 2300 rpm

f

e

c dba

B-13Test the Key Switch

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch toplatform control.

3 Operate each machine function from theground controls.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Operate each machine function from theplatform controls.


6 Turn the key switch to the off position.

Result: The engine should stop and nofunctions should operate.

Deutz Diesel models: All functionsshould stop immediately. Theengine will shut off after 2 to 3seconds.

4 - 18 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

B-14Test the Emergency Stop ButtonsProperly functioning Emergency Stop buttons areessential for safe machine operation. Animproperly operating Emergency Stop button willfail to shut off power and stop all machinefunctions resulting in a hazardous situation forground and platform personnel.

As a safety feature, selecting andoperating the ground controls canoverride the platform controls,including the Emergency Stopbutton.


2 Push down the Emergency Stop button to theoff position.

Result: The engine should be off and nomachine functions should operate.

Diesel models: All functionsshould stop immediately. Theengine will shut off after 2 or 3seconds.


4 Push down the Emergency Stop button to theoff position.

Result: The engine should be off and nomachine functions should operate.

The ground Emergency Stopbutton will stop all machineoperation, even if the key switch isswitched to platform control.

B-15Test the Ground Control OverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the on oroff position. This function is particularly useful ifthe operator at the platform controls can not returnthe boom to the stowed position.

1 Push in the platform Emergency Stop button tothe off position.


3 Operate each boom function through a partialcycle.

Result: All boom functions should operate.

B-16Test the Oscillate Lock-out

Perform this test on oscillatingaxle equipped machines only.

Proper axle oscillate lock-out when the boom israised is essential to safe machine operation. Ifthe lock-out wedges do not extend when the boomis raised, the stability of the machine iscompromised and it may tip over.

Part No. 32960 Genie Z-45/22 4 - 19


TABLE B PROCEDURES

1 From the ground controls, raise the primaryboom above the drive speed limit switch.

Oscillating axle limit switcha limit switchb oscillating lock out wedge

Result: The oscillate cylinder should extend thelock-out wedges 3 inches (7.6cm) past thechassis frame. The boom should stop movinguntil the wedges are fully extended.

a oscillate lock out wedge

2 Lower the primary boom onto its resting pad.

Result: The oscillate lock-out wedges shouldfully retract.

When the primary and secondarybooms are fully lowered into thestowed position and the engine isturned off, the oscillate lock-outwedges may partially extend. Thisshould not be mistaken for the fulllock-out position.

b

a

3 inches

a

B-17Test Platform Self-leveling

Precise automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. The platformis maintained at level by a hydraulic cylinder(leveling slave cylinder) which is controlled by themaster cylinder located at the base of the primaryboom. A platform self-leveling failure creates anunsafe working condition for platform and groundpersonnel.

1 Start the engine from the ground controls, thenfully lower the boom into the stowed position.

2 Adjust the platform to a level position using themanual platform leveling switch.

3 Raise and lower the primary boom through afull cycle.

Result: The platform should remain level at alltimes to within ±5 degrees.

B-18Test the Service Horn

A functional service horn is essential to safemachine operation. The service horn is activatedat the platform controls and sounds at the groundas a warning to ground personnel. An improperlyfunctioning horn will prevent the operator fromalerting ground personnel of hazards or unsafeconditions.

1 Turn the key switch to platform control and pullout the Emergency Stop button to the onposition.

2 Push down the service horn button at theplatform controls.

Result: The service horn should sound.

4 - 20 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

B-19Test the Foot Switch

A properly functioning foot switch is essential tosafe machine operation. Machine functions shouldactivate and operate smoothly as long as the footswitch is pressed down, and promptly stop whenthe foot switch is released. The foot switch willalso shift the engine into high idle mode if the idleselect is switched to the rabbit and foot switchsymbol. An improperly functioning foot switch cancause an unsafe working condition and endangerplatform and ground personnel.

The engine should not start if thefoot switch is pressed down.


2 Without pressing down the foot switch, operatethe machine functions.


3 Press down the foot switch and operate themachine functions.

Result: The machine functions should operate.

B-20Test the Engine Speed Select

A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions only. Drivefunctions do not operate at low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle and is usually selected onlywhen the generator option is being used.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Pull out the Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Start the engine from the ground controls. Thenmove the engine speed control switch to highidle (rabbit symbol) and hold in the on position.

Result: The engine should change to high idle.

3 Release the engine speed control switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 At the platform controls, move the enginespeed control switch to high idle (rabbitsymbol).


6 Move the engine speed control switch to lowidle (turtle symbol).

Result: The engine should change to low idle.

7 Move the engine speed control switch to footswitch activated high idle (rabbit and footswitch symbol).

Result: The engine should not change to highidle.

8 Press down the foot switch.


Gasoline/LPG models

Low idle 1400 rpm

High idle 2150 rpm

Deutz Diesel models

Low idle 1300 rpm

High idle 2300 rpm

Part No. 32960 Genie Z-45/22 4 - 21


TABLE B PROCEDURES

B-21Test Fuel Select Operation -Gasoline/LPG ModelsThe ability to select and switch between gasolineand LP fuels as needed is essential to safemachine operation. A fuel selection can be madewhen the engine is running or not. Switchingmalfunctions and/or the failure of the engine to runproperly in both fuel modes and through all idlespeeds can indicate fuel system problems thatcould develop into a hazardous situation.

Perform this test after checkingthe gasoline and propane gas fuellevels, and warming the engine tonormal operating temperature.

1 Move the fuel select switch to gasoline andthen move the engine speed control switch tofoot switch activated high idle (rabbit and footswitch symbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

4 Release the foot switch and stop the engine.

5 Move the fuel select switch to propane gas.

6 Restart the engine and allow it to run at lowidle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continue torun on the selected fuel if the fuelsource is switched while theengine is running.

B-22Test the Turntable Rotation StopThe turntable is capable of rotating the boom 359degrees and is stopped midpoint between thesteering wheels by the rotation stop. Detecting arotation stop malfunction is essential to safeoperation and good machine performance. If theturntable rotates past the rotation stop, componentdamage may result.


2 Rotate the turntable to the left as far as it willgo.

Result: Movement should stop when the boomreaches mid-point between the steer tires.

3 Rotate the turntable to the right full circle as faras it will go.

Result: Movement should stop when the boomreaches mid-point between the steer tires.

B-23Test the Drive Enable SystemProper drive enable system operation is essentialto safe machine operation. When the platform isover the non-steering wheels, drive movement isstopped and the indicator light turns on and thedrive enable switch must be used to reactivate thedrive function. This should inform the operator thatthe machine will move in the opposite directionthat the drive and steer controls are moved. Animproperly functioning drive enable system mayallow the boom to be moved into an unsafeposition.


2 Rotate the turntable to the right until theplatform is positioned over the right non-steerwheel.

Result: Platform over non-steer wheel indicatorlight should turn on.

4 - 22 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

3 Slowly move drive control handle off center.

Always use the color codeddirection arrows on the platformcontrol panel and the drivechassis to identify which directionthe machine will travel.

Result: Drive function should not operate.

4 Hold drive enable toggle switch to either sideand slowly move the drive control handle offcenter.

Result: Drive function should operate.

5 Rotate the turntable to the left until platform ispositioned over the left non-steer tire.

Result: Platform over steer wheel indicator lightshould come on.

6 Repeat steps 3 and 4.

B-24

Test the Drive BrakesProper brake action is essential to safe machineoperation. The Brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear tooperate normally when not fully operational.

Be sure that the machine is not infree-wheel or partial free-wheelconfiguration. Refer to B-8 in thissection, Confirm Proper BrakeConfiguration.

Select a test area that is firm,level and free of obstructions.

1 Mark a test line on the ground for reference.

2 Start the engine from the platform controls, andthen select high drive mode (machine on flatground).

3 Fully lower the boom into the stowed position.

4 Choose a point on the machine; i.e., contactpatch of a rear tire, as a visual reference foruse when crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drivejoystick when your reference point on themachine crosses the test line.

6 Measure the distance between the test line andyour machine reference point.

The brakes must be able to holdthe machine on any slope it isable to climb.

Specifications: high range, paved surface

Stopping distance, 5.5 to 6 feet1.67 to 1.82 m

Part No. 32960 Genie Z-45/22 4 - 23


TABLE B PROCEDURES

B-25

Test Drive Speed - StowedPositionProper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.

Select a test area that is firm,level and free of obstructions.

1 Create start and finish lines by marking twolines on the ground 20 feet (6m) apart.

2 Start the engine from the platform controls, andthen select high drive mode (machine on flatground).

3 Move the engine speed control switch to highidle (rabbit & foot switch), and then fully lowerthe boom into the stowed position.

4 Choose a point on the machine; i.e., contactpatch of a rear tire, as a visual reference foruse when crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point passes over thefinish line.

Specifications: stowed position, high range

Distance: 20 feet / 6 meters

4WD 2.85 seconds (±0.25 seconds)

2WD 2.75 seconds (±0.25 seconds)

B-26

Test the Alarm Package(optional equipment)The alarm package includes:

· travel alarm

· descent alarm

· flashing beacon

Alarms and beacons are installed to alertoperators and ground personnel of machineproximity and motion. The alarm packagecomponents are installed on the right side, on topof the turntable cover.

The alarm and beacons willoperate with the enginerunning or not.

1 At the ground controls pull out the EmergencyStop button to the on position and turn the keyswitch to ground control.

Result: The flashing beacon should be on andflashing.

2 Move the primary boom switch to the downposition, hold for a moment and then release it.Now move the secondary boom switch to thedown position, hold for a moment and thenrelease it.

Result: The descent alarm should sound wheneach switch is held down.

3 Turn the key switch to platform control, thenfrom the platform controls, pull out theEmergency Stop button to the on position.

Result: The flashing beacon should be on andflashing.

4 - 24 Genie Z-45/22 Part No. 32960


TABLE B PROCEDURES

4 Press down the foot switch. Move the primaryboom control handle to the down position, holdfor a moment and then release it. Move thesecondary boom control handle to the downposition, hold for a moment and then release it.

Result: The descent alarm should sound wheneach control handle is held down.

6 Press down the foot switch. Slowly move thedrive control handle off center, hold for amoment and then release it. Slowly move thedrive control handle off center in the oppositedirection, hold for a moment and thenrelease it.

Result: The travel alarm should sound whenthe drive control handle is moved off center ineither direction.

B-27

Perform Hydraulic Oil AnalysisSee D-1, Test or Replace the Hydraulic Oil.

B-28

Replace the Engine Oil andFilter - Deutz Diesel Models

Engine specifications requirethat this procedure be performedevery 500 hours. Perform thisprocedure more often if dustyconditions exist.

Periodic replacement of the engine oil andfilter is essential to good engine performance.Operating the machine with an improper oil levelor neglecting periodic oil and filter changes candamage engine components. A frequent checkof elapsed machine hours against the hoursnoted on the oil filter will allow the inspector toanticipate and perform oil and filter changes atthe 500 hour interval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Beware of hot engine parts andoil. Contact with hot engine oiland/or engine parts may causesevere burns.

1 Remove the oil filler cap located on thevalve cover.

2 Pull the end of the drain hose out from underthe engine.

3 Remove the plug from the end of the drainhose and allow all of the oil from the engine todrain into a suitable container.

Part No. 32960 Genie Z-45/22 4 - 25


TABLE B PROCEDURES

4 Install the plug into the drain hose.

5 Use an oil wrench and remove the oil filter.

a engine oil level dipstickb oil filterc fuel filter

6 Apply a thin layer of oil to the new filter gasket(filter part no. 29561). Then install the filter andtighten it securely by hand.

7 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

8 Fill the engine with new oil per specificationsand replace the oil filler cap.

9 Start the engine from the ground controls.Allow the engine to run for 30 seconds thenturn the engine off.

10 Check the oil filter and oil pan for leaks.

11 Check the engine oil level dipstick. Add oil ifneeded.

Deutz Engine F3L 1011 8.5 quartsOil capacity (including filter) 8 liters

Deutz Engine F3L 1011 Oil viscosity requirements

Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40


a

bc

4 - 26 Genie Z-45/22 Part No. 32960


C-1Check the Primary BoomWear PadsMaintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom surfaces to providea low friction, replaceable wear pad betweenmoving parts. Improperly shimmed wear pads orcontinued use of worn out wear pads may result incomponent damage and unsafe operatingconditions.

1 Start the engine from the ground controls andraise the end of the primary boom to acomfortable working height (chest high).

2 Extend the extension boom 10 inches (25 cm).

3 Measure each wear pad. Replace the pad if it isless than 0.41 inches (1 cm) thick. If the pad ismore than 0.41 inches (1 cm) thick, shim asnecessary to obtain zero clearance and zerodrag.

4 Extend and retract through the entire range ofmotion to check for tight spots that could causebinding ro scraping.

Always maintain squarenessbetween the primary boom outerand inner tubes.

C-2Check the Turntable RotationBearing Bolts

Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place a 4x4x31inch (78 cm) block between the chassiscounterweight and the upper mid-pivot. Carefullylower the secondary boom onto the block.

b

Table C Procedures

a

c

a upper mid-pivotb 4x4x31 inch blockc counterweight

Crushing hazard. Keep handsaway from the block and allmoving parts when lowering thesecondary boom.

2 Raise the primary boom until the end of theboom is approximately 7 feet (2 m) off theground.

3 Be sure that each turntable bolt is torqued insequence to 190 foot-pounds (258 Newtonmeters).

Bolt torque sequence

4 Remove the support block and then lower theprimary and secondary booms to the stowedposition.

5 Use a forklift to support the chassiscounterweight, directly below the turntablebearing.

16

1

3

7

10

12

13

14

22

18

4

195

15

23

221

8

11

17

24

620 9

Part No. 32960 Genie Z-45/22 4 - 27


4 Disengage the torque hubs by turning over thetorque hub disconnect caps on each non-steering wheel hub.

5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotatewith minimum effort.

6 Re-engage the torque hubs by turning over thehub disconnect caps. Carefully remove the jackstands, lower the machine and remove the jack.

Collision hazard. Failure to re-engage the torque hubs may resultin death or serious injury andproperty damage.

Steer wheels: 4WD models

7 Chock the drive wheels to prevent the machinefrom rolling.

8 Position the lifting jack under the steering axleand center it between the steering wheels.

9 Lift the wheels off the ground and then placejack stands under the chassis for support.

10 Open the free wheel valve, located on the drivepump, by turning it counterclockwise two turns.

a drive pumpb lift pumpc free-wheel valve

disengage position

engage position

TABLE C PROCEDURES

a

c

b

6 Loosen the counterwight positioning bolt, thenremove the 2 mounting bolts.

7 Carefully lower and remove the counterweight.

8 Be sure that each bearing mounting bolt istorqued in sequence to 190 foot-pounds(258 Newton meters).

Bolt torque sequence

9 Reinstall the counterweight.

C-3Check the Free-wheel Feature

Proper use of the free-wheel configuration isessential to safe machine operation. The free-wheelconfiguration is used primarily for towing. Amachine configured to free-wheel without operatorknowledge may result in death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

Non-steering wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(5000 lbs / 2268 kg) under the chassis betweenthe rear drive wheels.

3 Lift the wheels off the ground and then placejack stands under the chassis for support.

2

5

6

12

13

14

18

11

8

16

17

7

151

43

9

10

4 - 28 Genie Z-45/22 Part No. 32960


TABLE C PROCEDURES

b

a

c

a

b

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimal effort.

12 Close the free wheel valve (clockwise).Carefully remove the jack stands, lower themachine and remove the jack.

Collision hazard. Failure tore-engage the torque hubs maycause death or serious injury andproperty damage.

C-4Grease the Turntable RotationBearing and Worm Drive Gear

Yearly application of lubrication to the turntablebearing and worm drive gear is essential to goodmachine performance and service life. Continueduse of an improperly greased gear will result incomponent damage.

1 Raise the secondary boom and place a 4x4x31(78 cm) block between the chassis counter-weight and the upper mid-pivot. Carefully lowerthe secondary boom onto the block.



2 Raise the primary boom until the end of theboom is approximately 7 feet (2 m) off theground. Then shut off the engine.

3 Locate the grease fitting on the inside of thebearing in the middle of the turntable.

4 Pump grease into the rotation bearing until yousee it coming out of the bearing seal gap.Repeat this step with the platform in thefollowing 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 keyswitch to the off position andremove the key while pumpinggrease.

5 Locate the grease fitting on the worm drivehousing.

a grease fittingb grease overflow

6 Pump grease into the gear until you see itcoming out of the side of the gear housing.

Specification

Multipurpose grease

Part No. 32960 Genie Z-45/22 4 - 29


C-6Replace theHydraulic Tank Filter

Replacement of the hydraulic tank filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore frequently.

Beware of hot oil. Contact with hotoil may cause severe burns.


1 Remove the filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter (part no. 20293) andtighten it securely by hand. Clean up any oilthat may have spilled during the installationprocedure.


5 Inspect the filter and related components to besure that there are no leaks.

TABLE C PROCEDURES

C-5Replace the Torque Hub Oil

Replacing the torque hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

1 Select the torque hub to be serviced. Thendrive the machine until one of the two plugs isat the lowest point.

2 Remove both plugs and drain the oil.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs, andthen install the plugs.

5 Repeat steps 1 through 4 for all the other drivetorque hubs.

Specifications

Capacity 17 fluid ounces0.5 liters

Type SAE 90 multipurposehypoid gear oil.

API classification GL5

4 - 30 Genie Z-45/22 Part No. 32960


TABLE C PROCEDURES

C-7Replace theDrive Loop Hydraulic Filter

Replacing the drive loop hydraulic filter is essentialto good machine performance and service life. Adirty or clogged filter may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the filter be replaced morefrequently.

Beware of hot oil. Contact with hotoil may cause severe burns.


1 Rotate the filter housing counterclockwise andremove the housing.

2 Remove the filter element from the housing.

3 Inspect the housing seal and replace it ifnecessary.

4 Install the new filter (part no. 20880) and handtighten the housing onto the filter head. Cleanup any oil that may have spilled during theinstallation procedure.


6 Inspect the filter assembly to ensure that thereare no leaks.

C-8

Replace the Diesel FuelFilter - Deutz Diesel ModelsReplacing the diesel fuel filter is essential to goodengine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Engine fuels are combustible.Replace the fuel filter in an open,well-ventilated area away fromheaters, sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.


1 Turn the manual fuel shutoff valve, located atthe fuel tank, to the CLOSED position.

2 Remove the fuel filter with a filter wrench.

a fuel filterb oil filter

3 Apply a thin layer of oil or diesel fuel to the newfuel filter gasket.

Part No. 32960 Genie Z-45/22 4 - 31


TABLE C PROCEDURES

4 Install the new filter (part no. 29560) and tightenit securely by hand. Clean up anydiesel fuel that might have spilled during theprocedure.

5 Turn the manual fuel shutoff valve, located atthe fuel tank, to the OPEN position.

6 Start the engine from the ground controls, theninspect the fuel filter for leaks.

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repairthe leak immediately.

C-9Replace the Gasoline Fuel Filter

Replacing the gasoline fuel filter is essential togood engine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more frequently.

Engine fuels are combustible.Replace the fuel filter in an open,well-ventilated area away fromheaters, sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.


1 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the fuel filter, located nearthe carburetor.

a pivot plate bolts

2 Loosen the filter bracket mounting bolt.Disconnect the fuel hoses from the filter, thenslide the filter out of the bracket.

3 Install the new fuel filter in the bracket with theflow direction arrow, on the filter, pointing towardthe carburetor. Tighten the bracket mountingbolt, then reconnect the fuel hoses to the filter.

4 Clean up any fuel that may have spilled duringthe installation procedure.

5 Swing the engine pivot plate back to its originalposition and replace the three retaining bolts.

6 Start the machine from the ground controls, theninspect the fuel filter and hoses for leaks.

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repair theleak immediately.

a

a

a

4 - 32 Genie Z-45/22 Part No. 32960


TABLE C PROCEDURES

c

ba a

a

a

C-10Replace the PCV Valve -Gasoline/LPG Models

Yearly replacement of the PCV valve is essential togood engine performance. A malfunctioning valvecan impair crankcase ventilation and may causeengine damage.


1 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the PCV valve.

2 Remove the hoses from the valve, then removethe valve.

3 Install the new valve.

4 Swing engine pivot plate back to its originalposition and replace the three retaining bolts.

a PCV valveb hose, PCV valve to carburetorc hose, PCV valve to crankcase

C-11Clean or Replace the DistributorCap and Rotor - Gasoline/LPGModelsDistributor caps and rotors that are clean and freeof damage, wear and corrosion are essential togood engine performance and service life. A dirty orworn cap and rotor may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the cap and rotor be replaced morefrequently.


a pivot bolt plates

1 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the distributor.

2 Label and remove the coil and spark plug wiresfrom the distributor cap.

3 Remove the cap and rotor from the distributor.

4 Clean the cap and rotor using electrical contactcleaner or a damp cloth.

5 Completely dry the cap and rotor.

Moisture in the distributor cap willcause the engine to run poorly.

6 Inspect the cap and rotor for corrosion, cracksand abrasion. Replace the cap and rotor if theyare damaged.

Part No. 32960 Genie Z-45/22 4 - 33


TABLE C PROCEDURES

a b c d

7 Install the rotor and cap, then re-attach the coiland spark plug wires.

8 Swing engine pivot plate back to its originalposition and replace the three retaining pins.

C-12Replace the Spark Plugs -Gasoline/LPG Models

Periodic replacement of the spark plugs is essentialto good engine performance and service life. Worn,loose or corroded spark plugs will cause the engineto perform poorly and may result in componentdamage.

Perform this procedure with theengine turned off.

1 Label, then disconnect the plug wires from thespark plugs by grasping the molded boot. Donot pull on the plug wire.

2 Blow out any debris around spark plugs.

3 Remove all the spark plugs from the engine.

4 Adjust the gap on each new spark plug.

5 Install the new plugs, the reconnect the plugwires. Be sure that each spark plug wire isattached to the correct spark plug.

Specifications

Spark Plugs (Motorcraft) AWSF-42

Gap 0.032 - 0.036 inches0.81 - 0.91mm

Torque specs 5 - 10 foot-pounds6.8 - 13.6 Nm

C-13Check and Adjust theAir/Propane Mixture

Maintaining the proper air-to-fuel mixture duringpropane operation is essential to good engineperformance.

Engine fuels are combustible.Perform this procedure in an open,well-ventilated area away fromheaters, sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easyreach..

The engine rpm needs to be presetfor gasoline fuel operation beforeadjusting the propane idle mixture.

The engine should be warmed tonormal operating temperaturebefore performing this procedure.

1 Move the fuel select switch to propane fuel andstart the engine from the ground controls.

2 Loosen the high idle mixture adjustment locknut.

a low idle mixture adjustment screwb high idle mixture adjustment screwc propane regulatord pressure adjustment

4 - 34 Genie Z-45/22 Part No. 32960


3 Load the system by pressing the primary boomextension retract switch, and then move theengine speed control switch to high idle (rabbitsymbol).

4 Adjust the high idle adjustment nut to obtain anair-to-fuel mixture ratio of 13.0:1 to 13.2:1, usingan exhaust gas analyzer.

If an exhaust gas analyzer is notavailable, adjust to obtain peak oroptimum rpm.

5 Hold the adjustment screw and tighten the locknut.

6 Move the engine speed control switch to low idle(turtle symbol) and adjust the low idle screw toobtain an air-to-fuel mixture ratio of 13.0:1 to13.2:1.

C-14

Check and Adjust the IgnitionTiming - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LSG-423 2.3 Litre IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

C-15

Check the Engine ValveClearances - Deutz DieselModelsComplete information to perform this procedureis available in the Deutz FL 1011 Workshop Manual(Deutz Number 02611642). Genie part number29789.

TABLE C PROCEDURES

Part No. 32960 Genie Z-45/22 4 - 35


2 Remove the drain plug from the hydraulic tank.

3 Completely drain the tank into a suitablecontainer. See capacity specifications listedbelow.

4 Disconnect and cap the two suction hosesthat are attached to the hydraulic tankshutoff valves.

5 Remove the strainer assemblies from the tank.

6 Carefully clean any foreign material fromthe strainers. Clean the strainers from the insideout.

7 Apply pipe thread sealant to the strainermounting threads, and then install them.

8 Apply pipe thread sealant to the drain plug,and then install it in the tank.

9 Install the two suction hoses.

10 Fill the tank with hydraulic oil until the level iswithin the top 2 inches (5 cm) of the sightgauge. Do not overfill.

11 Clean up any oil that may have spilled and openthe hydraulic tank valves.

12 Prime the pump by doing the following:

Connect a 0 to 600 psi (0 to 41 bar) pressuregauge to the test port on the drive pump.

Gasoline/LPG models:

Remove the high tension lead from the center ofthe ignition coil.

Electrocution hazard. Contact withelectrically charged circuits maycause death or serious injury.Remove all rings, watches andother jewelry.

D-1Test or Replace the Hydraulic OilReplacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more often.

The machine uses Dexron IIequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oilis not replaced at the two yearinspection, quarterly testing(B-27) thereafter should becompleted.

Perform this procedure with theboom in the stowed position.

1 Close the two hydraulic shutoff valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started with thehydraulic tank shutoff valves in theCLOSED position or componentdamage will occur.If the tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

Table D Procedures

open closed

4 - 36 Genie Z-45/22 Part No. 32960


D-2Change or Recondition theEngine Coolant- Gasoline/LPG ModelsReplacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.

Beware of hot engine parts andcoolant. Contact with hot engineparts and/or coolant will causesevere burns.

Perform this procedure with theengine off and cooled.

1 Put on protective clothing and eye wear.

2 Disconnect the coolant return hose at theradiator and drain the coolant return tank.

3 Remove the radiator cap from the radiator.

Deutz Diesel models:

Hold the manual fuel shutoff valvecounterclockwise to the CLOSED position.

a manual fuel shutoff valve

All models:

Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 320 psi (22 bar).

13 Connect the wiring and start the engine fromthe ground controls. Check the hydraulic tankfor leaks.

Hydraulic system

Hydraulic tank capacity 25 gallons95 liters

Hydraulic system 30 gallonscapacity (including tank) 114 liters

Hydraulic fluid Dexron ll equivalent

TABLE D PROCEDURES

a

Part No. 32960 Genie Z-45/22 4 - 37


TABLE D PROCEDURES

4 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the radiator petcock.

a pivot plate retaining bolts

5 Open the petcock on the radiator and allowall the coolant to drain into a container.

6 After all the coolant has drained, close thepetcock. Connect the coolant return hose tothe radiator.

7 Open the petcock on the engine block and allowthe coolant to drain into a container.After the fluid is drained, close the petcock.

8 Replace all coolant hoses and clamps.

9 Pour the proper coolant mixture (anti-freeze andwater) for your climate into the radiator until it isfull.

10 Disconnect hose A from hard line B and holduntil coolant starts to pour out of the open hose.Then immediately reconnect the hose.

a hose Ab hard line B

11 Fill the radiator and then fill the coolant recoverytank to the NORMAL range.

12 Clean up any coolant spilled during thisprocedure.

13 Start the engine from the ground controls,run it for 30 seconds, and then turn it off.

14 Inspect for leaks and then check the fluidlevel in the coolant recovery tank. Addwater if needed.

15 Start the engine from the ground controlsand run it until reaching normal operatingtemperature.

16 Allow engine to cool and check the fluid level inthe coolant recovery tank. Add water if needed.

Ford Engine LSG-423 11.5 quartsCoolant capacity 10.9 liters

a b

a

a

a

4 - 38 Genie Z-45/22 Part No. 32960


Deutz Diesel modelsa hose from the injector to

the fuel tankb hoses connecting injectorsc hose from the fuel shutoff valve

to the fuel pumpd hose from the fuel pump to

the fuel filtere hose from the fuel filter to the

injection pumpf hose from the injection pump

to the injectors

TABLE D PROCEDURES

D-3Change the Fuel LinesMaintaining the fuel lines in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel line may cause an unsafe operatingcondition.

Engine fuels are combustible.Replace the fuel lines in an open,well-ventilated area away fromheaters, sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.


1 Close the manual fuel shutoff valve, locatednext to the fuel tank.

2 Remove and replace the fuel line hoses andclamps according to the following illustrations:

Fuel may be expelled underpressure. Wrap a cloth around fuelhoses to absorb leaking fuel beforedisconnecting them.

b b b b b b

e d cf

ba

Part No. 32960 Genie Z-45/22 4 - 39


Gasoline/LPG modelsa fuel filterb hose from the fuel filter to

the carburetorc hose from the fuel pump

to the fuel filterd hose from the fuel shutoff

valve to the fuel pump

3 Clean up any fuel that may have spilled duringthis procedure.

4 Start the engine from the ground controls, theninspect the fuel filter and hoses for leaks.

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repairthe leak immediately.

TABLE D PROCEDURES

D-4Check the Engine ValveClearance - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LSG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

D-5Check the Engine CylinderCompression- Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LSG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

d

c

a b

4 - 40 Genie Z-45/22 Part No. 32960


TABLE D PROCEDURES

2 Disconnect the hoses from the PCV valve, thendisconnect the hoses from the engine.

Shown with distributor cap removeda PCV valveb hose, PCV valve to carburetorc hose, PCV valve to crankcase

3 Clean the hoses with a mild cleaning solvent.

4 Dry both hoses and inspect them for cracksand damage. Replace the hoses if they aredamaged.

D-6Clean the PCV Hoses andFittings - Gasoline/LPG ModelsMaintaining PCV hoses is essential to good engineperformance. Improperly functioning PCV hoseswill fail to ventilate the crankcase and continueduse of neglected hoses could result in componentdamage.


1 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access the PCV hoses.

a pivot plate retaining boltsb engine pivot plate

ba

ba

c

a

Part No. 32960 Genie Z-45/22 4 - 41


D-7Check the Fuel Injection Pumpsand Injectors- Deutz Diesel ModelsComplete information to perform this procedure isavailable in the Deutz FL 1011 Workshop Manual(Deutz number: 0291 1942). Genie part number29789.

D-8Check the Toothed Belt- Deutz Diesel ModelsComplete information to perform this procedure isavailable in the Deutz FL 1011 Operation Manual(Deutz number: 0297 4706 EN). Genie partnumber 29790.

D-9Replace the Timing Belt- Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LSG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

TABLE D PROCEDURES

4 - 42 Genie Z-45/22 Part No. 32960



Part No. 32960 Genie Z-45/22 5 - 1

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-45/22 Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitsmay result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.


Repair any machine damage or malfunctionbefore operating the machine.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· machine parked on a flat level surface

· boom in stowed position

· turntable rotated with the boom between the non-steering wheels

· turntable secured with the turntable rotation lock pin

· key switch in the OFF position with the key removed

· wheels chocked

5 - 2 Genie Z-45/22 Part No. 32960

Service Manual - Second EditionSection 5 - Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function willnot operate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Part No. 32960 Genie Z-45/22 5 - 3


Engine Will NotCrank OverBe sure the key switchis in the appropriateposition.

Be sure the emergencystop buttons are pulledup into the on position.

Be sure the circuitbreaker(s) are nottripped.

Chart 1

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5 - 4 Genie Z-45/22 Part No. 32960


CHART 1

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Part No. 32960 Genie Z-45/22 5 - 5


Chart 2

Engine CranksOver But WillNot Start -Gasoline/LPGModelsBe sure to check theengine oil level and fillas needed.

Be sure to check fuellevels and enginecoolant level.

Be sure the gasolineshut-off valve is in theon position.

Be sure that automaticchoke is not stickingclosed.

Perform following testsin gasoline mode only.

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5 - 6 Genie Z-45/22 Part No. 32960


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Part No. 32960 Genie Z-45/22 5 - 7


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5 - 8 Genie Z-45/22 Part No. 32960


Chart 2A

Engine CranksOver But WillNot Start -Gasoline/LPGModels

or

Engine RunsWhile CrankingThen DiesContinuation of “goodspark” fault path.

Perform these tests ingasoline mode only.

1 )%#

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Part No. 32960 Genie Z-45/22 5 - 9


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5 - 10 Genie Z-45/22 Part No. 32960


CHART 2A

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Part No. 32960 Genie Z-45/22 5 - 11


Chart 2B

Engine RunsWhile CrankingThen Dies

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5 - 12 Genie Z-45/22 Part No. 32960


Engine CranksOver But WillNot Start -Deutz DieselModelsBe sure to check theengine oil level and fillas needed.

Be sure to checkfuel level.

Be sure the dieselshut-off valve is inthe on position.

Chart 3

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Part No. 32960 Genie Z-45/22 5 - 13


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5 - 14 Genie Z-45/22 Part No. 32960


CHART 3

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Part No. 32960 Genie Z-45/22 5 - 15


Engine Will NotStart On LPG,But Will StartOn Gasoline -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto LPG.

Be sure to checkLPG fuel level.

Chart 4

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5 - 16 Genie Z-45/22 Part No. 32960


CHART 4

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Part No. 32960 Genie Z-45/22 5 - 17


Chart 5

Engine WillNot Start OnGasoline,But Will StartOn LPG -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto gasoline.

Be sure to checkgasoline fuel level.

Be sure that enginechoke is operatingproperly.

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5 - 18 Genie Z-45/22 Part No. 32960


CHART 5

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Part No. 32960 Genie Z-45/22 5 - 19


Chart 6

EngineHigh IdleInoperative -Gasoline/LPGModelsIf high idle operateson LPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If high idle operateson gasoline but noton LPG, see Repairsection for LPGregulator adjustments.

Be sure throttlelinkage from governorto carburetor is notbinding, see Repairsection.

Be sure high idle canbe achieved bygrasping the governoractuator arm andmomentarily pulling tothrottle the carburetor.

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5 - 20 Genie Z-45/22 Part No. 32960


CHART 6

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Part No. 32960 Genie Z-45/22 5 - 21


CHART 6

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5 - 22 Genie Z-45/22 Part No. 32960


Engine Low IdleInoperative -Gasoline/LPGModelsIf low idle operateson LPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If low idle operateson gasoline but noton LPG, see Repairsection for LPGregulator adjustments.

Be sure throttlelinkage from governorto carburetor is notbinding, see Repairsection.

Chart 7

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Part No. 32960 Genie Z-45/22 5 - 23


Chart 8

EngineHigh IdleInoperative -Deutz DieselModelsBe sure mechanicallinkage is not bindingor defective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

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5 - 24 Genie Z-45/22 Part No. 32960


CHART 8

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Part No. 32960 Genie Z-45/22 5 - 25


Chart 9

EngineLow IdleInoperative -Deutz DieselModelsCheck ifmechanical linkagefrom 2-speedsolenoid to fuelinjection system isbinding or defective.

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5 - 26 Genie Z-45/22 Part No. 32960


Chart 10

All FunctionsInoperative,Engine Startsand Runs

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Part No. 32960 Genie Z-45/22 5 - 27


Chart 11

All Lift andSteer FunctionsInoperative,Drive FunctionsOperationalBe sure the hydraulicsuction line shutoffvalve for the lift/steerpump is in the openposition.

Be sure all groundingwires for the hydraulicmanifold valves are freeof corrosion and havefull continuity to ground.

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5 - 28 Genie Z-45/22 Part No. 32960


Chart 12

GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingplatform controls.

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Part No. 32960 Genie Z-45/22 5 - 29


Chart 13

PlatformControlsInoperative,GroundControlsOperateNormallyBe sure allcables are in goodcondition with nokinks or abrasions.

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5 - 30 Genie Z-45/22 Part No. 32960


Chart 14

SecondaryBoom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

If boom up functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller.See Repair section.

If boom up functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 31


CHART 14

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5 - 32 Genie Z-45/22 Part No. 32960


SecondaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally includingboom up function.

If boom down functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller.See Repair section.

If boom down functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

Chart 15

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Part No. 32960 Genie Z-45/22 5 - 33


CHART 15

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5 - 34 Genie Z-45/22 Part No. 32960


PrimaryBoom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

If boom up functionoperates normallyfrom the groundcontrols butnot from theplatform controls,troubleshoot theplatform controller.See Repair section.

If boom up functionoperates normallyfrom the platformcontrols butnot from the groundcontrols,troubleshoot theground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 35


CHART 16

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5 - 36 Genie Z-45/22 Part No. 32960


PrimaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally includingboom up function.

If boom downfunction operatesnormally from theground controls butnot from theplatform controls,troubleshoot theplatform controller.See Repair section.

If boom downfunction operates

Chart 17

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Part No. 32960 Genie Z-45/22 5 - 37


CHART 17

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5 - 38 Genie Z-45/22 Part No. 32960


Chart 18

Primary BoomExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

If boom extend functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller.See Repair section.

If boom extend functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 39


CHART 18

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5 - 40 Genie Z-45/22 Part No. 32960


Chart 19

Primary BoomRetractFunctionInoperativeBe sure all otherfunctions operatenormally includingboom extend function.

If primary boom retractfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If primary boom retractfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 41


Chart 20

TurntableRotate FunctionInoperativeBe sure all otherfunctions operatenormally.

If turntable rotatefunction operatesnormally from theground controls butnot from the platformcontrols, troubleshootthe platform controller.See Repair section.

If turntable rotatefunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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5 - 42 Genie Z-45/22 Part No. 32960


CHART 20

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Part No. 32960 Genie Z-45/22 5 - 43


Chart 21

TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally includingturntable rotate rightfunction.

If turntable rotate leftfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If turntable rotate leftfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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5 - 44 Genie Z-45/22 Part No. 32960


Chart 22

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally includingturntable rotate rightfunction.

If turntable rotate rightfunction operatesnormally from theground controls butnot from the platformcontrols, troubleshootthe platform controller.See Repair section.

If turntable rotate rightfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 45


Chart 23

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure both automaticand manual platformleveling do not operate.

If automatic levelingoperates but manualleveling does not,troubleshoot PlatformLeveling Up FunctionInoperative.

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5 - 46 Genie Z-45/22 Part No. 32960


Chart 24

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level upfunction operatesnormally from theground controls butnot from the platformcontrols, troubleshootthe platform controltoggle switch. SeeRepair section.

If platform level upfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Part No. 32960 Genie Z-45/22 5 - 47


Chart 25

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level downfunction operatesnormally from theground controls butnot from the platformcontrols, troubleshootthe platform controltoggle switch. SeeRepair section.

If platform level downfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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5 - 48 Genie Z-45/22 Part No. 32960


Chart 26

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PlatformRotate LeftFunctionInoperative

Be sure all otherfunctions operatenormally.

If platform rotate leftfunction operatesnormally from theground controls butnot from platformcontrols,troubleshoot theplatform controltoogle switch. SeeRepair section.

If platform rotate leftfunction operatesnormally from theplatform controlsbut not from theground controls,troubleshoot theground controltoggle switch. SeeRepair section.

Part No. 32960 Genie Z-45/22 5 - 49


Chart 27

PlatformRotate RightFunctionInoperative


If platform rotateright functionoperates normallyfrom the groundcontrols but notfrom platformcontrols,troubleshoot theplatform controltoogle switch. SeeRepair section.

If platform rotateright functionoperates normallyfrom the platformcontrols but notfrom the groundcontrols,troubleshoot theground controltoggle switch. SeeRepair section.

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5 - 50 Genie Z-45/22 Part No. 32960


OscillateLock-outFunctionInoperative

Chart 28

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Part No. 32960 Genie Z-45/22 5 - 51


Chart 29

Steer LeftFunctionInoperative


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5 - 52 Genie Z-45/22 Part No. 32960


Chart 30

Steer RightFunctionInoperative


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Part No. 32960 Genie Z-45/22 5 - 53


Chart 31

All DriveFunctionsInoperative,All OtherFunctionsOperateNormally

Be sure thehydraulic suctionline valve is in theopen position.

Be sure machinenot in the freewheel configuration.

Be sure the drivespeed select switchis set to machine onlevel surfaceposition (maximumdrive speed).

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5 - 54 Genie Z-45/22 Part No. 32960


CHART 31

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Part No. 32960 Genie Z-45/22 5 - 55


CHART 31

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5 - 56 Genie Z-45/22 Part No. 32960


Chart 32

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DriveForward OrReverseFunctionInoperative

Be sure all otherfunctions operatenormally includingdrive in oppositedirection ofmalfunction.

Part No. 32960 Genie Z-45/22 5 - 57


High RangeDriveFunctionInoperative

Be sure all otherfunctions operatenormally includingdrive low range(four wheelsymbol).

Be sure all drivemanifold solenoidvalve groundingwires are free ofcorrosion and havefull continuity toground.

Chart 33

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5 - 58 Genie Z-45/22 Part No. 32960


CHART 33

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Part No. 32960 Genie Z-45/22 5 - 59


CHART 33

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5 - 60 Genie Z-45/22 Part No. 32960


Chart 34

Low RangeDriveFunctionInoperative

Be sure all otherfunctions operatenormally includingdrive high range(two wheel symbol).

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Part No. 32960 Genie Z-45/22 5 - 61


Chart 35

TractionFunctionInoperative


5 - 62 Genie Z-45/22 Part No. 32960


Chart 36

Machine WillNot Drive AtFull Speed


Be sure the free-wheel valve isclosed on the drivepump.

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Part No. 32960 Genie Z-45/22 5 - 63


Chart 37

MachineDrives At FullSpeed WithPlatformRaised orExtended

Remove machinefrom serviceimmediately.

Be sure boom liftdrive limit switch isnot being held downor up.

Be sure wiring tolimit switches isintact and show nosign of tampering.

Be sure orange wire(cable1) is properlyattached tohorsepower limiter.

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5 - 64 Genie Z-45/22 Part No. 32960


Chart 38

Drive EnableSystem isMalfunctioning

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Part No. 32960 Genie Z-45/22 5 - 65


Chart 39

AuxiliaryFunctionsInoperative


Be sure key switchis in theapproproateposition and theEmergnecy Stopbuttons are pulledup to the onposition.

Be sure engine isnot running whenusing auxiliarypower.

Note: Operatingauxiliary power withengine runningshould immediatelykill the engine.

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5 - 66 Genie Z-45/22 Part No. 32960



Part No. 32960 Genie Z-45/22 7 - 1

Service Manual - Second Edition Section 7 - Repair Procedures

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair ofthis machine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start

Read, understand and obey the safety rulesand operating instructions in theGenie Z-45/22 Operator's Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhere tothe instructions.. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified. perform eachprocedure with the machine in the followingconfuguration:

· machine parked on a flat, level surface

· boom in the stowed position

· turntable rotated with the boom between thenon-steering wheels

· key switch in the off position with the keyremoved

· wheels chocked

Malfunctiondiscovered Troubleshoot Determine

cause

Performrepair

Return toservice

problemsolved

problemstill exists

Inspectand test

About This Section

Most of the procedures in this section should onlybe performed by a trained service professional in asuitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then to re-assemble, perform the disassembly steps inreverse order.

General Repair Procedure

Symbols Legend

Indicates the presence of ahazard that will cause death orserious injury.

Indicates the presence of ahazard that may cause death orserious injury.

Indicates the presence of ahazard that will or may causeserious injury or damage to themachine.

Indicates special operation ormaintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

7 - 2 Genie Z-45/22 Part No. 32960

Service Manual - Second EditionSection 7 - Repair Procedures

1-1Joystick Controllers

Maintinaing joystick controllers at the propersettings is essential to safe machine operaton.Every joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

Platform control boxa horsepower limiter boardb quick disconnect terminal stripc drive proportional controllerd secondary boom proportional

controllere primary boom proportional

controllerf turntable rotate proportional controller

Primary Boom Up/DownController Adjustments

Do not adjust the joystickcontrollers unless the staticbattery voltage is above 12V DCand the alternator is operatingproperly with 12.5 to 15.4V DCoutput.

Electrocution hazard. Contact withelectircally charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

Platform Controls

1 Check the battery condition with a volt meter.The reading should be 12V DC or more toaccurately adjust the controller.

2 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition. Do not start the engine.

3 Open the platform control box lid and locate theboom up/down controller.

a dual (lo) adjustable trimpotb ramp rate adjustable trimpotc terminal "R" - activates max-out ranged terminal unusede terminal "X" auxiliaryf terminal "-" - groundg terminal "+" - battery, positiveh terminal "A" - proportional outputi threshold adjustable trimpotj max-out adjustable trimpot

4 Set the ramp rate: Turn the trimpot adjustmentscrew clockwise 15 turns or until you hear aclick, then turn the screw counterclockwise 5turns.

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 centeruntil the moment a voltage reading appears.Adjust the voltage to 2.50V DC. Turn thethreshold trimpot adjustment screw clockwiseto increase the voltage or counterclockwise todecrease the voltage.

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Part No. 32960 Genie Z-45/22 7 - 3


PLATFORM CONTROLS

7 Set the max-out: Press down the foot switch,then move the control handle all the way to theup position. Adjust the voltage to 5.02V DC.Turn the max-out trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

8 Set the dual (lo) range: Press down the footswitch, then move the control handle all theway to the down position. Adjust the voltage to4.33V DC. Turn the dual range trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

9 Start the engine and move the engine speedcontrol switch to foot switch activated high idle(rabbit and foot switch symbol). Raise theprimary boom 1 inch (2.5 cm) above the drivelimit switch.

Engine should be at normaloperating temperature.

10 Start a timer and record how long it takes forthe primary boom to reach the full up position.Adjust the max-out trimpot to achieve a 25 to29 second cycle time.

11 Start a timer and record how long it takes forthe primary boom to lower into the full downposition. Adjust the dual range trimpot toachieve a 33 to 37 second cycle time.

Primary boom up/down specifications

Threshold 2.50V DC

Primary boom up - Max-out 5.02V DCCycle time 25 to 29 seconds

Primary boom down - Dual range 4.33V DCCycle time 33 to 37 seconds

Secondary Boom Up/DownController Adjustments




2 Turn the keyswitch to platform control and pullthe Emergency Stop button to the on positionat both the ground and platform controls. Donot start the engine.

3 Open the platform control box lid and locate thesecondary boom up/down controller.

a b c d e f g h i j


7 - 4 Genie Z-45/22 Part No. 32960


PLATFORM CONTROLS

4 Set the ramp rate: Turn the trimpot adjustmentscrew clockwise 15 turns or until you hear aclick, then turn the screw counterclockwise5 turns.


6 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 2.50V DC. Turn thethreshold trimpot adjustment screw clockwiseto increase the voltage or counterclockwise todecrease the voltage.

7 Set the max-out: Press down the foot switch,then move the control handle all the way to theup position. Adjust the voltage to 5.01V DC.Turn the max-out trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

8 Set the dual range: Press down the foot switch,then move the control handle all the way to thedown position. Adjust the voltage to 4.05V DC.Turn the dual range trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.


9 Start the engine and move the engine speedcontrol switch to foot switch activated high idle(rabbit and foot switch symbol). Raise theprimary boom 1 inch (2.5cm) above the drivelimit switch.

10 Start a timer and record how long it takes forthe secondary boom to reach the full upposition. Adjust the max-out trimpot to achievea 23 to 27 second cycle time.

11 Start a timer and record how long it takes forthe secondary boom to lower into the full downposition. Adjust the dual range trimpot toachieve a 23 to 27 second cycle time.

Secondary boom up/down specifications

Threshold 2.50V DC

Secondary boom up - Max-out 5.01V DCCycle time 23 to 27 seconds

Secondary boom down - Dual Range 4.05V DCCycle time 23 to 27 seconds

Turntable Rotation ControllerAdjustments




2 Turn the key switch to platform control and pullthe Emergency Stop button to the on positionat both the ground and platform controls. Donot start the engine.

Part No. 32960 Genie Z-45/22 7 - 5


PLATFORM CONTROLS

3 Open the platform control box lid and locate theturntable rotate controller.

4 Set the ramp rate: Turn the trimpot adjustmentscrew clockwise 15 turns or until you hear aclick, then turn the screw counterclockwise5 turns.


6 Set the threshold: Press down the foot switchthen slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 3.35V DC. Turn thethreshold trimpot adjustment screw clockwiseto increase the voltage or counterclockwise todecrease the voltage.

7 Set the max-out: Press down the foot switchthen move the control handle all the way to thefull right or full left position. Adjust the voltageto 6.26V DC. Turn the max-out trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

8 Set the dual (lo) range: Turn the trimpotadjustment screw clockwise 15 turns or untilyou hear a click. This is the only dual rangeadjustment for this controller.


9 Start the engine and move the engine speedcontrol switch to foot switch activated high idle(rabbit and foot switch symbol). Rotate theturntable to the full right position.

10 Start a timer and record how long it takes theturntable to rotate to the full left position. Adjustthe max-out trimpot to achieve a71 to 75 second cycle time.

Turntable rotation specifications

Threshold 3.35V DC

Turntable rotation - Max-out 6.26V DCCycle time 71 to 75 seconds

a b c d e f g h i j


7 - 6 Genie Z-45/22 Part No. 32960


PLATFORM CONTROLS

1-2Horsepower Limiter Board

The horsepower limiter board is responsible forgoverning drive pump output. It reads engine rpmfrom the alternator. The horsepower limiter boardsenses drops in rpm normally due to increaseddrive resistance (rough terrain or incline) anddecreases voltage to the drive controller which inturn decreases voltage to the drive pump therebyreducing pump output to keep the engine fromstalling. Three adjustments are required foroptimum performance.

How to Adjust the HorsepowerLimiter Board

The engine rpm must becorrect before performing thisprocedure. See MaintenanceProcedure B-12, Check andAdjust the Engine RPM.

Do not adjust the horsepowerlimiter board unless the staticbattery voltage is above 12V DCand the alternator is operatingproperly with 12.5 to 14.5V DCoutput.

Gasoline/LPG models: Performthis procedure in gasoline mode.

1 Remove the fasteners from the platform controlbox lid.

2 Open the control box lid and locate thehorsepower limiter board.


a horsepower limiter board

3 Connect the black lead(-) from a DC volt meterto the number 2 terminal, and the red lead(+) tothe number 10 terminal.



b

a

c

12V DC or greatergroundengine rpm sensornot usednot usedlow drive speed limit switchnot usednot usednot usedoutput to drive controller

Horsepower limiter boarda "A" potentiometer-maximum voltage

output to the controller in the stowedposition

b "B" potentiometer-maximum voltageoutput to the drive controller in theboom elevated position

c "C" potentiometer-reaction rate orhow fast the voltage output reacts tothe change in engine rpm

a

Part No. 32960 Genie Z-45/22 7 - 7


PLATFORM CONTROLS

6 Press down the foot switch and adjust the "A"potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

"A" potentiometer specifications

Voltage setting - 2WD model 8.0V DC

Voltage setting - 4WD model 9.0V DC

7 Move the engine speed control switch to lowidle (turtle symbol).

8 Press down the foot switch and then adjust the"C" potentiometer to obtain a 0.01V DC to0.03V DC voltage reading.


10 Press down the foot switch and re-adjust the"A" potentiometer to the previous voltagesetting.

11 Be sure that the boom is in the fully stowedposition, then drive the boom and observe howthe engine rpm reacts to drive control handlemovement. If the machine surges or hunts,adjust the "C" potentiometer counterclockwiseuntil surging is minimized.

Under an extreme load, anexcessive counterclockwiseadjustment to the "C"potentiometer will cause theengine to stall. The "C"potentiometer adjustment is acompromise between enginestability and engine droop.

12 Disconnect the volt meter.



14 Drive the boom for 20 feet (6.1 m) and recordthe elapsed time. Do this again in the oppositedirection.

15 Adjust the "B" potentiometer to obtain thecorrect elevated drive speed of 1 foot persecond (30.5 cm per second).

16 Close the platform control box lid and re-installthe fasteners.

Drive speed specifications

Stowed position, high range, distance: 20 ft / 6 m2WD 2.85 seconds (±0.25 seconds)4WD 2.75 seconds (±0.25 seconds)

Boom raised, high range, distance: 20 ft / 6 m2WD and 4WD 1 foot per second

30.5 cm per second

a

7 - 8 Genie Z-45/22 Part No. 32960


PLATFORM CONTROLS

Desired result

continuity (zero Ω)

no continuity (infinite Ω)

no continuity

1-3Foot Switch

How to Test the Foot Switch1 Turn the keyswitch to the off position and

disconnect the wiring quick disconnect plugfrom the platform toe board.

2 Do not press down the foot switch. Connect theleads from an ohmmeter or continuity tester toeach wire connector combination listed belowand check for continuity.

Test

red to black

red to white

black to white

Do not use the colors of theconnector as a guide for thesetests. Use the actual wire color toidentify which contact to use fortesting.

3 Press down the foot switch. Connect the leadsfrom an ohmmeter or continuity tester to eachwire connector combination listed below andcheck for continuity.

Test

red to black

red to white

black to white

1-4Resistors

Two resistors are used to maintain proper controlof drive speeds. Both resistors are located in theplatform control box.

How to Test the Resistors1 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 eachend of the resistor being tested.

3 Compare the ohmmeter reading with theresistance rating printed on the resistor.

Desired result


no continuity


Part No. 32960 Genie Z-45/22 7 - 9


PLATFORM CONTROLS

1-5Toggle Switches

Toggle switches used for single function switchingare single pole double throw (SPDT) switches.Two function switching requires a double poledouble throw (DPDT) switch.

How to Test a Toggle SwitchThis procedure covers fundamental switch testingand does not specifically apply to all varieties oftoggle switches.

1 Turn the keyswitch to the off position anddisconnect all wiring from the toggle switch tobe tested.

2 Connect the leads of an ohmmeter to theswitch terminals in the following combinationslisted below to check for continuity.



no continuity

no continuity

no continuity

continuity

There are no terminalcombinations that willproduce continuity(infinite Ω)

continuity

no continuity

no continuity

no continuity

continuity

no continuity

no continuity

Right

Single pole,double throw(SPDT)

Double pole, double throw(DPDT)

1

2

3

4 5 6

1 2 3

1

2

3 1

2

3

1 2 3 1 2 3

1 2 3 1 2 3 1 2 3

4 5 6 4 5 6

CenterLeft

Test Desired result

Left Position

terminal 1 to 2, 3, 4, 5, & 6

terminal 2 to 3

terminal 2 to 4, 5 & 6


terminal 4 to 5 & 6

terminal 5 to 6

Center position

Right Position

terminal 1 to 2

terminal 1 to 3, 4, 5 & 6

terminal 2 to 3, 4, 5 & 6


terminal 4 to 5

terminal 4 to 6

terminal 5 to 6

7 - 10 Genie Z-45/22 Part No. 32960


2-1Platform

How to Remove the Platform1 Remove the cable harness from the cable

clamps located under the platform anddisconnect the foot switch wiring plug.

2 Remove the platform control box mountingbolts, then lift it out and set it aside.

3 Tilt the platform with the ground controlsmanual platform leveling switch until theplatform lays horizontal.

a platform mounting boltsb block

4 Place blocks under the platform railing forsupport. Then carefully rest the platform on theblocks.

5 Remove the platform mounting bolts andremove the platform.

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through the entirerange of primary boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the SlaveCylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is no airin the closed loop.

1 Tilt the platform with the ground controlsplatform leveling switch until the platform ishorizontal.

2 Place blocks under the platform railing forsupport. Then carefully rest the platform on theblocks.

3 Disconnect the hydraulic hoses from the slavecylinder and connect them together with astraight line connector.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

4 Remove the rod ends from both the barrel androd end pins.

5 Use a soft metal drift and drive the pins out.

a

a

bb

Platform Components

Part No. 32960 Genie Z-45/22 7 - 11


How to Bleed the Slave CylinderDo not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 Raise the primary boom 6 inches (15cm) abovethe primary boom rest.

2 Move the manual platform level switch to theright until the slave cylinder is fully extended.Continue to hold the platform level switch for10 seconds.

3 Connect a clear hose to the bleed valve on thecylinder barrel. Place the other end of the hosein 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 5seconds, then release it.

6 Close the bleed valve, then remove the hoses.

7 Hold the platform level switch to the left untilthe slave cylinder is fully retracted.

8 Connect the clear hose to the bleed valve onthe slave cylinder block.

9 Open the bleed valve and allow the slavecylinder to extend using gravity, until thecylinder is fully extended. Close the bleedvalve.

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform180 degrees. It is equipped with externalcounterbalance valves to hold platform in placeand to provide pressure relief.

How to Remove the PlatformRotator1 Remove the platform. See 2-1, How to Remove

the Platform.

2 Disconnect the hydraulic hoses from theplatform rotator and cap them.

Bodily injury hazard. Sprayinghydraulic oil can perforate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

3 Remove the 6 mounting bolts from the platformpivot weldment.

4 Remove the top nut from the threaded rod.Then pull the rod out the bottom of the platformrotator and remove the platform pivotweldment.

5 Support the platform rotator, but do not applyany lifting pressure.

6 Remove the pin retainer from the slave cylinderrod-end pivot pin and the rotator pivot pin.

7 Use a soft metal drift to drive the pins out, thenremove the platform rotator.

PLATFORM COMPONENTS

7 - 12 Genie Z-45/22 Part No. 32960


How to Bleed the Platform Rotator1 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a containerto collect any discharge.

a clear hoseb top bleed valvec bottom bleed valved container

2 Open the top bleed valve, but do not remove it.


4 Hold the platform rotate switch to the right forapproximately 5 seconds, then release it.Repeat 3 times.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

5 Hold the platform rotate switch to the left forapproximately 5 seconds, then release it.

6 Fully rotate the platform to the left and continueholding the platform rotate switch until air stopscoming out of the bleed valve. Immediatelyrelease the platform rotate switch and close thebleed valve.

7 Rotate the platform to the right until it iscentered.

8 Connect the clear hose to the bottom bleedvalve and open the valve.

PLATFORM COMPONENTS

9 Rotate the platform to the right and continueholding the platform rotate switch until air stopscoming out of the bleed valve.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

10 Close the bleed valve and remove the hose.

11 Turn off the engine and clean up any hydraulicoil that may have spilled.

12 Restart the engine from the ground controls.Then rotate the platform full left and right andinspect the bleed valves for leaks.

b

c

d

a

Part No. 32960 Genie Z-45/22 7 - 13


3-1Plastic Cable Track

The primary boom cable track guides cables andhoses running up the boom. It can be repaired linkby link without removing the cables and hoses thatrun through it. Removing the entire primary boomcable track is only necessary when performingmajor repairs that involve removing the primaryboom.

How to Repair the Plastic CableTrack

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 Repeat step 1 for each link.

3 To remove a single link, open the lower clip andthen use a screw driver to pry the link to theside.

3-2Primary Boom

How to Shim the Primary BoomWear Pads

Measure each wear pad. Replacethe pad if it is less than0.41 inches (1cm) thick. If the padis more than 0.41 inches (1cm)thick, perform the followingprocedure.



2 Extend the primary boom 10 inches(25.4 cm).

3 Remove the wear pad mounting fasteners.

4 Install the new shims under the wear pad toobtain zero clearance and zero drag.

5 Using a round punch, align the holes in theshim to the wear pad and install the mountingfasteners.

6 Extend and retract through the entire range ofmotion to check for tight spots that could causebinding.

Always maintain squarenessbetween the primary boom outerand inner tubes.

aa

b

Primary Boom Components

7 - 14 Genie Z-45/22 Part No. 32960


How to Remove the PrimaryBoom

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

1 Remove the platform. See 2-1, How to Removethe Platform.

2 Disconnect and plug the hydraulic hoses at theslave cylinder and the platform rotatorcounterbalance valve.


3 Remove the fasteners that secure the uppercable track tray to the primary boom.

4 Loosen the fasteners that secure the lowercable track tray. Tie the upper and lower cabletracks together with wire ties. Remove thecable track assembly from the primary boom.

a wood blockb tie-wrapc plastic cable track

PRIMARY BOOM COMPONENTS

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

5 Raise the secondary boom and place a4x4x31 inch (78 cm) block between the chassiscounterweight and upper mid-pivot. Carefullylower the secondary boom onto the block.



6 Raise the end of the primary boom 8 feet (2.5m) off the ground, then extend the primaryboom 5 inches (12.5 cm).

7 Attach an overhead crane to the primary boom.Do not lift the primary boom.

Crushing hazard. If the overheadcrane is not properly attached, theprimary boom may becomeunbalanced and fall when it isdisconnected from the uppermid-pivot.

b

a

c

a

b c b

a

Part No. 32960 Genie Z-45/22 7 - 15


8 Disconnect and plug the extension cylinder andthe platform leveling master cylinder hydraulichoses. Cap the extension cylinder fittings.


9 Remove the pin retainer from the mastercylinder barrel-end pivot pin. Use a soft metaldrift and remove the pin.

Leave the master cylinderattached to the primary boom.

10 Remove the retaining fastener from the primaryboom pivot pin. Do not remove the pin.

11 Remove the hose clamp bolt on the primaryboom, next to the upper mid-pivot.

12 Support the lift cylinder with a lifting device.

13 Remove the pin retainer from the lift cylinderrod-end pivot pin. Use a soft metal drift toremove the pin.

The lift cylinder will fall unless it issupported.

14 Remove the hose and cable clamps from theunderside of the primary boom.

15 Use a slide hammer to remove the primaryboom pivot pin, then carefully lift the primaryboom off the machine.

How to Disassemble thePrimary Boom

Complete disassembly of theprimary boom is only necessary ifthe outer or inner primary boomtube must be replaced. Theextension cylinder can beremoved without completelydisassembling the primary boom.See 3-4, How to Remove theExtension Cylinder.

1 Remove the primary boom. See above, How toRemove the Primary Boom.

2 Remove the pin retainer from the slave cylinderrod-end pivot pin. Use a soft metal drift toremove the pin.

3 Remove the pin retainer from the slave cylinderbarrel-end pivot pin. Use a soft metal drift toremove the pin, then remove slave cylinderfrom the primary boom.

4 Support the platform rotator with a liftingdevice.

5 Remove the pin retainer from the platformrotator pivot pin. Use a soft metal drift toremove the pin, then remove the platformrotator from primary boom.

6 Support the master cylinder with a liftingdevice.

7 Remove the retaining fastener bolt from themaster cylinder pivot pin. Use a soft metal driftto remove the pin, then remove the mastercylinder from the primary boom.

8 Remove the fasteners from the extensioncylinder pivot pin. Use a soft metal drift toremove the pin.

9 Support and slide the extension boom out ofthe primary boom weldment.

Crushing hazard. The extensiontube will fall when it is removedfrom the primary boom if it is notproperly supported.


7 - 16 Genie Z-45/22 Part No. 32960


10 Remove the extension boom end cap.

11 Remove the fasteners from the extensioncylinder rod-end weldment, then support andslide the extension cylinder out of the extensionboom.

The bolts that secure the cylinderrod-end weldment are installedwith Loctite® removable threadsealant. It may be necessary toheat the bolts and the surroundingarea to remove them. Do notreuse the bolts.

12 Remove and label the wear pads from theprimary boom weldment and the extensiontube.

Pay careful attention to thelocation and amount of shimsused with each wear pad.


3-3Primary Boom Lift Cylinder

The lift cylinder raises and lowers the primaryboom.

How to Remove the PrimaryBoom Lift Cylinder


1 Raise the secondary boom and place a 4x4x31inch (78cm) block between the chassiscounterweight and the upper mid-pivot.Carefully lower the secondary boom onto theblock.



b

a

c

Part No. 32960 Genie Z-45/22 7 - 17



9 Carefully loosen the straps and allow theprimary lift cylinder to slowly swing down. Nowattach the rod of the primary lift cylinder to anoverhead crane or similar lifting device.

10 Remove the pin retainer from the remainingpivot pin, then use a soft metal drift to removethe pin.

Crushing hazard. The primary liftcylinder will fall if it is not properlysupported.

2 Raise the primary boom until the end of theboom is 8 feet (2.5 m) off the ground.

3 Support the primary boom with an overheadcrane. Do not lift the primary boom.

4 Disconnect and plug the primary lift cylinderhydraulic hoses.


5 Remove the pin retainer from the pivot pin atthe barrel-end of the primary lift cylinder.

6 Use an overhead crane to lift the primary boom1 inch (2.5 cm). This will relieve pressure onthe barrel-end pivot pin.

7 Support the primary lift cylinder with straps orropes to restrict it from swinging freely.

8 Place a rod through the barrel-end pivot pinand twist to remove the pin.

a pivot pinb 10 to 12 inch rod

Crushing hazard. When thebarrel-end pivot pin is removed,the primary lift cylinder will swingdown if it is not properlysupported.

a

b

7 - 18 Genie Z-45/22 Part No. 32960



3-4Extension Cylinder

The extension cylinder extends and retracts theprimary boom steel extension tube. It can only beremoved from the platform end of the primaryboom. The extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line loss.

How to Remove theExtension Cylinder


1 Raise the secondary boom and place a 4x4x31inch (78 cm) block between the chassiscounterweight and the upper mid-pivot.Carefully lower the secondary boom onto theblock.



b

a

c

a extension boom end capb extension boomc extension cylinder rod-end weldment

fastenersd primary boom

2 Raise the primary boom until the extensionboom end cap is 5 feet (1.5 m) off the ground.

3 Extend the extension tube to the primary boomtube 17 inches (43 cm). Then secure toprevent any additional movement

4 Remove the extension boom end cap.

5 Remove the fasteners from the cylinder rod-end weldment.

The bolts that secure the cylinderrod-end weldment are installedwith Loctite® removable threadsealant. It may be necessary toheat the bolts and the surroundingarea to remove them. Do notreuse the bolts.

6 If the function is operational, extend theextension cylinder until the rod-end weldmentclears the end of the extension tube.

a

b

c

d

Part No. 32960 Genie Z-45/22 7 - 19



7 Disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


8 Remove the fasteners from the extensioncylinder pivot pin, then use a soft metal drift toremove the pin.

9 Carefully pull out and properly support theextension cylinder from the platform end of theprimary boom.

Crushing hazard. The cylinder willfall if it is not properly supportedwhen it is pulled out of theextension tube.

To make installation the extensioncylinder easier, be sure that thecylinder rod is extended 3 to 4feet (1 m).

3-5Platform Leveling Master Cylinder

The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulicloop that keeps the platform level through theentire range of primary boom motion. The mastercylinder is located inside the upper mid-pivot at thebase of the primary boom.

How to Remove the Platform

Leveling Master CylinderThis procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Before cylinder removal isconsidered, bleed the cylinder tobe sure that there is no air in theclosed loop. See 2-2, How toBleed the Slave Cylinder.

1 Remove the end cover from the turntable.

2 Raise the secondary boom and place a 4x4x31inch (78 cm) block between the chassiscounterweight and the upper mid-pivot.Carefully lower the secondary boom onto theblock.


3 Extend the primary boom 6 inches (15 cm),then raise the primary boom until it is level.


b

a

c

7 - 20 Genie Z-45/22 Part No. 32960



4 Disconnect and plug the extension cylinderhydraulic hoses. Cap the ports on theextension cylinder.


5 Fully lower the primary boom and support itwith an overhead crane.

6 Disconnect and plug the primary lift cylinderhydraulic hoses. Cap the ports on the primarylift cylinder.


7 Support the barrel-end of the primary liftcylinder with a strap.

8 Remove the pin retainer from the primary liftcylinder barrel-end pivot pin.


a pivot pinb 10 to 12 inch (30cm) rod

10 Carefully lower and rest the barrel-end of theprimary lift cylinder on the turntablecounterweight.

11 Disconnect and plug the platform levelingmaster cylinder hydraulic hoses. Cap thefittings on the master cylinder.


12 Remove the retaining fastener from theplatform leveling master cylinder rod-end pivotpin, then use a slide hammer to remove thepin.

13 Attach a strap to the rod-end of the platformleveling master cylinder.

14 Remove the pin retainer from the platformleveling master cylinder barrel-end pivot pin.Then support the cylinder with the strap.


Crushing hazard. The cylinder willfall if it is not supported when thepivot pin is removed.


16 Carefully lower the platform leveling mastercylinder down and out of the upper mid-pivot.

ab

a

b

Part No. 32960 Genie Z-45/22 7 - 21


m

a b c d

f

e

h

g

j

i

k

l

4-1Secondary Boom

How to Disassemble theSecondary Boom

The procedures in this sectionrequire specific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools may result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.

Secondary Booma upper secondary boom

(number 1 arm)b upper tension link

(number 2 arm)c lower tension link

(number 3 arm)d lower secondary boom

(number 4 arm)e secondary lift cylinderf pin retainerg compression linkh lower mid-pivoti drive limit switchj primary boom restk turntable pivotl upper mid-pivot restm upper mid-pivot

f e

Secondary Boom Components

7 - 22 Genie Z-45/22 Part No. 32960


6 Remove the turntable end cover.

7 Be sure that the upper mid-pivot rest is in theindustrial tire position.

Machines equipped with:

Rough terrain tires. Move the upper mid-pivotrest up into the industrial tire position on themid-pivot.

Industrial tires. No modification is necessary.

a upper mid-pivotb mounting position holes for

rough-terrain tire modelsc upper mid-pivot restd mounting position holes for

industrial tire models

8 Attach the lifting strap from an overhead craneto the number 1 arm at the end nearest theupper mid-pivot and lift to support.

9 Remove the pin retainers from the twosecondary lift cylinder rod-end pivot pins.

10 Place a rod through each rod-end pivot pin andtwist to remove the pins.

SECONDARY BOOM COMPONENTS


2 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

Crushing hazard. Do not removethe 4x4x31 inch (78 cm) supportblock installed during primaryboom removal.


3 Use an overhead crane to attach a lifting strapto the rod-end of the primary lift cylinder. Thenraise the primary lift cylinder with the crane, toa vertical position.


5 Place a rod through the barrel-end pivot pinand twist to remove the pin. Remove theprimary lift cylinder from the machine.

Crushing hazard. The primary liftcylinder will fall if it is not properlysupported when the barrel-endpivot pin is removed.

ab

a pivot pinb 10 to 12 inch (30 cm) rod

b

a

c

a

c

b

d

Part No. 32960 Genie Z-45/22 7 - 23


11 Lift the number 1 arm until the secondary liftcylinders can swing forward to rest on thelower mid-pivot.

12 Remove the block between the counterweightand the upper mid-pivot.

13 Lower the arms enough to relieve the pressureon the compression link upper pivot pin.

Specification: to remove pressure on thecompression link

Industrial tires The upper mid-pivot rest shouldbe approximately 1 inch (2.5 cm)

above the rest block.

Rough terrain tires The upper mid-pivot rest shouldbe approximately 4 inches

(10 cm) above the rest block.

14 Remove the pin retaining fastener from thecompression 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 thelifting strap to the center of the number 1 arm.

16 Remove the pin retaining fastener from thelower mid-pivot to number 1 arm pivot pin. Usea soft metal drift to remove the pin.

17 Remove the pin retaining fastener from theupper mid-pivot to number 1 arm pivot pin. Usea slide hammer to remove the pin.

Crushing hazard. If the overheadcrane is not properly attached, thenumber 1 arm may becomeunbalanced and fall when it isdisconnected from the uppermid-pivot.

18 Carefully remove the number 1 arm from themachine.

19 Number each electrical cable and its entrylocation at the platform control box.

20 Open the platform control box and label eachwire termination from the cables. Disconnect allcontrol cable wiring from the platform controlbox.

21 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

22 Disconnect and plug the platform rotatorhydraulic hoses at the union, located near theupper mid-pivot. Remove the cable trackassembly from the machine.


23 Remove the upper and lower cable trays fromthe number 2 arm. Also remove the uppercable tray from the number 3 arm.

24 Pull all of the cables and hoses down throughthe upper mid-pivot.

Component damage hazard.Cables and hoses can beirreparably damaged if they arekinked or pinched.

25 Attach a lifting strap from an overhead crane tothe upper mid-pivot. Then place a hydraulicjack between arm numbers 2 and 3 at the endnearest the upper mid-pivot end of the arms.

26 Adjust the hydraulic jack and overhead crane torelieve the pressure on the pivot pin connectingthe number 2 arm to the upper mid-pivot.

27 Remove the pin retaining fastener from theupper mid-pivot to number 2 arm pivot pin. Usea slide hammer to remove the pin.

Crushing hazard. The uppermid-pivot will fall if it is notproperly supported when the pivotpin is removed.


7 - 24 Genie Z-45/22 Part No. 32960


28 Carefully lift and remove the upper mid-pivotfrom the machine.

29 Position the lifting strap from an overheadcrane at the center of the number 2 arm.


Crushing hazard. If the overheadcrane is not properly attached, thenumber 2 arm may becomeunbalanced and fall when it isdisconnected from the mid-pivot.


32 Remove the two cable clamps from the insideof the lower mid-pivot.

33 Disconnect and remove the drive speed limitswitch from the primary boom rest.

34 Disconnect and plug the hydraulic hoses at thesecondary lift cylinders.


35 Remove the pin retainers from each secondarylift cylinder barrel-end pivot pin.

36 Place a rod through each barrel-end pivot pinand twist to remove the pin. Remove eachsecondary lift cylinder from the machine.

a pivot pinb 10 to 12 inch (30 cm) rod

Crushing hazard. The secondarylift cylinders will fall when thebarrel-end pivot pins are removedif they are not properly supported.

37 Remove the lower cable tray from thenumber 3 arm.

38 Pull all of the cables and hoses through thelower mid-pivot and out of the turntable pivot.

Component damage hazard.Cables and hoses can beirreparably damaged if they arekinked or pinched.

39 Attach the strap from an overhead crane to thetop tube of the lower mid-pivot. Then place ahydraulic jack between arm numbers 3 and 4 atthe end nearest the lower mid-pivot.


41 Carefully lower the lower mid-pivot andcompression link away from the machine to aresting position.



a

b

Part No. 32960 Genie Z-45/22 7 - 25


43 Remove the pin retaining fastener from theturntable pivot to number 3 arm pivot pin. Usea slide hammer to remove the pin.

Crushing hazard. If the overheadcrane is not properly attached, thenumber 3 arm may becomeunbalanced and fall when it isdisconnected from the turntablepivot.


45 Position the strap from an overhead cranearound the top tube of the lower mid-pivot andthen carefully lift the lower mid-pivot until it isvertical.


47 Support the compression link by hand, thencarefully lift the lower mid-pivot up and over thecompression link and off of the machine.


48 Lower the compression link to a restingposition. Then attach the lifting strap from anoverhead crane to the compression link andraise it to a vertical position.

49 Remove the pin retaining fastener from thecompression link to number 4 arm pivot pin.Use a soft metal drift to remove the pin

50 Remove the compression link.


52 Remove the pin retaining fastener from theturntable pivot to number 4 arm pivot pin. Usea slide hammer to remove the pin.

Crushing hazard. If the overheadcrane is not properly attached, thenumber 4 arm may becomeunbalanced and fall when it isdisconnected from the turntablepivot.

53 Carefully remove the number 4 arm.

7 - 26 Genie Z-45/22 Part No. 32960




3 Remove the pin retainers from each secondarylift cylinder rod-end pivot pin.

4 Place a rod through the rod-end pivot pin andtwist to remove the pin.


5 Loosen, but do not remove, the counterbalancevalve to fully retract the cylinder.

The counterbalance valve ispre-set from the factory. Do notadjust this valve.

6 Remove the pin retainer from the pivot pins atthe barrel-ends of each secondary lift cylinder.

7 Place a rod through each barrel-end pivot pinand twist to remove the pins. Remove thesecondary lift cylinders from the machine.

Crushing hazard. The secondarylift cylinders will fall when thebarrel-end pivot pins are removedif they are not properly supported.

Prior to removing the secondarylift cylinder, mark the location ofthe hydraulic fitting with a specialinternal orifice. Be sure to installthe fitting into the same locationduring re-assembly.

a

b

4-2Secondary Boom Lift Cylinders

There are two boom lift cylinders incorporated inthe structure of the secondary boom assembly.These cylinders operate in parallel and requirehydraulic pressure to extend and retract. Eachsecondary boom lift cylinder is equipped with acounterbalance valves to prevent movement in theevent of a hydraulic line failure. A 1200 psi (83bar) relief valve for the down function is located onthe boom function manifold.

How to Remove the SecondaryLift Cylinders


1 Lower the secondary boom to full rest, thenraise the primary boom just above the drivelimit switch.


2 Disconnect and plug the hydraulic hose andsteel lines for each secondary lift cylinder.

a

Part No. 32960 Genie Z-45/22 7 - 27


5-1Turntable Covers

How to Remove a Turntable Cover1 Raise the turntable cover. Support the open

cover with an overhead crane or forklift.Do not lift.

Crushing hazard. Due to its heavyweight, do not attempt to supportthe cover by hand.

2 Remove the upper and lower retaining clipsfrom the gas strut.

3 Gently pry the strut pivot sockets off of the ballstuds and remove the strut.

4 Remove the fasteners from the cover hingepins.

5 Raise the cover slightly to relieve the pressureon the cover hinge pins.

6 Remove the cover hinge pins.

7 Carefully lift and remove the cover from themachine.

If a turntable cover must bereplaced, be sure that allappropriate safety andinstructional decals are applied tothe new cover.

Some adjustment may benecessary when a new cover isinstalled.

Turntable Covers

7 - 28 Genie Z-45/22 Part No. 32960


6-1RPM AdjustmentRefer to Maintenance Procedures, B-12,Check and Adjust the Engine RPM.

6-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

displacement controller (EDC), located onthe drive pump.

2 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

3 Carefully pull the pump away from the engineand secure it from moving.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the engine.

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

flat side of the spline against the flywheel.Torque the flex plate mounting bolts to34 ft-lbs (46 Nm).

2 Install the coupler onto the pump shaft with theset screw toward the pump. Leave a 3/16 inch(4.7 mm) gap between the coupler and pumpend plate.


3 Apply Loctite® removable thread sealant to thecoupler set screw. Torque the set screw to45 ft-lbs (61 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

4 Assemble the engine and torque the pumpmounting plate to 34 ft-lbs (46 Nm).

Part No. 32960 Genie Z-45/22 7 - 29


e

b c

f

g

7-1Governor Actuator

How to Set Up the GovernorActuator and Linkage

Adjustment of the governoractuator is only necessary whenthe governor actuator or thelinkage has been replaced.

1 Connect the linkage rod to the throttle plateshaft, then tighten the lock nut.

2 Fasten the lock nut and clevis yoke to thelinkage rod. Do not tighten the lock nut againstthe clevis yoke.

3 Loosen the fastener on the actuator arm.Rotate the actuator arm until it is at a 110degree angle to the linkage rod.

Governor Actuator and Linkagea clevis yokeb linkage rodc carburetord throttle plate shafte governor actuatorf actuator shaftg actuator arm

4 Position the linkage rod so that the throttle is inthe idle position. Then adjust the clevis yoke onthe linkage rod to obtain the proper length.Install the yoke onto the actuator arm andtighten the lock nut.

5 With the throttle in the idle position and theactuator arm at a 110 degree angle to thelinkage, rotate the actuator shaft slightlycounterclockwise to pre-load the spring.Tighten the fastener on the actuator armwithout releasing the shaft.

d

110°

a

Ford LSG 423 Engine

7 - 30 Genie Z-45/22 Part No. 32960


6 Manually pull the actuator arm through a fullcycle to be sure that the linkage moves freely.Be sure that the linkage activates the throttleshaft to approximately half throttle.

The linkage must be free offriction and obstruction. Do not letit rub against the engine, bracketsor hoses.

If the throttle linkage is improperlyadjusted and allowed to reach fullthrottle, the engine will over-revand cause component damage.

FORD LSG 423 ENGINE

7-2Choke Adjustments

This engine is equipped with an electrically heatedautomatic choke. The choke has a poppet valve toenhance cold starting ability on LPG fuel.

Choke adjustments are affectedby climate. Richer adjustment willbe necessary in colder climates,leaner adjustment in warmerclimates.

Automatic Choke With PoppetValveThis choke functions in both gasoline and propanemode. The choke butterfly may be adjusted to afully closed (rich) position for colder climates andthe poppet valve will provide a flow path duringpropane fueled operation.

rich lean

7-3Timing Adjustment

Complete information to perform this procedure isavailable in the Ford LSG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

7-4Carburetor Adjustment

Complete information to perform this procedure isavailable in the Ford LSG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: 194-216).Genie part number 29586.

7-5RPM Adjustment

See the scheduled maintenance procedure B-13,Check and Adjust the Engine RPM.

Part No. 32960 Genie Z-45/22 7 - 31


FORD LSG 423 ENGINE

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

flat side of the spline against the flywheel.Torque the flex plate mounting bolts to 34 ft-lbs(46 Nm).

2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/32 inch(0.031 mm) gap between the coupler andpump end plate.

3 Apply removable Loctite® thread sealant to thecoupler set screw. Torque the set screw to45 ft-lbs (61 Nm).

Component damage hazard. Donot force the drive pump duringre-installation or the flex plateteeth may become damaged.

7-6Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drive thepump.

Flex Plate Removal1 Disconnect and remove the hose between the

carburetor venturi and the air cleaner.

2 Disconnect and remove the muffler supportbracket.

3 Disconnect the linkage from the governor, thenremove the governor linkage from thecarburetor. Do not alter the length of thelinkage.

4 Disconnect the wiring plug at the electronicdisplacement controller (EDC), located on thedrive pump.

5 Remove the mounting fasteners from theregulator mounting bracket, then pull thebracket up past the bell housing. Secure thebracket before continuing.

6 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

7 Carefully pull the pump away from the engineand secure it from moving.

8 Remove the flex plate mounting fasteners, thenremove the flex plate from the engine.

7 - 32 Genie Z-45/22 Part No. 32960


FORD LSG 423 ENGINE

7-7Water Temperature and OilPressure Switches

The water temperature switch is a normally openswitch that closes at approximately 230° F(112° C). When this switch closes, the engine isshut off to prevent damage and will not restart untilthe temperature drops below the switch point. Anover-temperature indicator light at the ground andplatform controls should turn on when the switchcloses.

Component damage hazard. Donot crank the engine with theover-temperature on.

The oil pressure switch is a normally closed switchthat opens at approximately 3 to 5 psi(0.21 to 0.34 bar). If the oil pressure drops belowthe switch point, the switch closes and shuts offthe engine. A low oil pressure indicator light at theground controls should turn on when the switchcloses.

Component damage hazard. Donot start or continue to run theengine with the low oil pressurelight on.

How to Remove the WaterTemperature and Oil PressureSwitchesPerform this procedure with the engine off.

1 Remove the 3 bolts from the engine pivot plate.Swing the engine pivot plate away from themachine to access both switches.

2 Disconnect the wiring from the desired switch.

3 Remove the switch from the engine block, andthen install the new switch. Do not over tighten.

Burn hazard. Contact with hotengine fluids or components maycause severe burns

Always use pipe thread sealantwhen installing a switch.

Water temperature switch specifications

Torque 8-18 ft-lbs11-24 Nm

Hex size 13/16 inch

Temperature switch point 230° F (112°C)

Oil pressure switch

Torque 8-18 ft-lbs11-24 Nm

Hex size 1-1/16 inch

Oil pressure switch point 3-5 psi0.21-0.34 bar

a oil pressure switchb water temperature switch

b

a

Part No. 32960 Genie Z-45/22 7 - 33


FORD LSG 423 ENGINE

7-8Vacuum Switch

How to Test the Vacuum Switch

a ohmmeterb common terminal (SOL.)c vacuum switchd normally open terminal (ING.)

1 Connect the leads from an ohmmeter orcontinuity tester to the common and normallyopen terminals.

Result: There should be no continuity(infinite Ω).

2 Apply mild suction to the vacuum port.

Result: The switch should close and show fullcontinuity (zero Ω).

Component damage hazard. Donot short vacuum switch terminalsto ground.

a b

d c

7 - 34 Genie Z-45/22 Part No. 32960


Ground Controls

8-1Control Relays

Relays used for single function switching aresingle pole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay

Electrocution hazard. Contact withelectrically charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

1 Label and then disconnect all the wiring fromthe relay to be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 to 86represent the coil and should not be tested inany other combination.

a terminal no. 87Ab terminal no. 85c terminal no. 30d terminal no. 86e terminal no. 87

d

e

c

a

b

Test Desired result

terminal 85 to 86 85 to 95Ω

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87a to 87 & 30 no continuity(infinite Ω)

terminal 87 to 30 continuity(zero Ω)

Part No. 32960 Genie Z-45/22 7 - 35


GROUND CONTROLS

8-2Toggle Switches

See 1-4, Toggle Switches.

8-4Resistors

How to Test the ResistorsTwo resistors are used to maintain proper controlof boom function speeds. A 10 ohm resistorreduces voltage to all the boom function switches.A 15 ohm resistor parallels the 10 ohm resistor toreduce the voltage to the turntable rotate switch.

Turn the key switch to the offposition and remove the key.

1 Disconnect one of the resistor wires from theresistor or the opposite end terminal.

2 Connect the leads from an ohmmeter to eachend or wiring of the resistor being tested.

3 Compare the ohmmeter reading with theresistance rating printed on the resistor.

8-3Wago® Components

How to Remove a Wago®

ComponentElectrocution hazard. Contact withhot or live circuits may result indeath or serious injury. Removeall rings, watches and otherjewelry.

A small standard screw driver isprovided and should be usedwhen removing a Wago®

component. This screwdriver islocated in the instruction manualstorage box in the platform.

1 Label and then disconnect the wiring from thecomponent to be removed.

2 Locate the removal tab on the bottom or topside of the component.

3 Use the provided screwdriver to gently pry upon the tab of the component and remove it.

7 - 36 Genie Z-45/22 Part No. 32960


GROUND CONTROLS

a high amp power contact terminals(large posts)

b solenoid activate coil terminals(small posts)

a b

8-5Power Relay


How to Test the Power RelayElectrocution hazard. Disconnectthe ground cable from the batterybefore performing this procedure.

1 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.

Test Desired result

2 small posts 13 to 17Ω

2 large posts no continuity(infinite Ω)

Any small post to no continuityany large post (infinite Ω)

2 Connect 12V DC to one of the small posts andground to the other small post, then test thefollowing terminal combination.

Test Desired result

2 large posts continuity(zero Ω)

Part No. 32960 Genie Z-45/22 7 - 37


9-1Lift/Steer Pump

How to Test the Lift/Steer Pump1 Disconnect and plug the high pressure

hydraulic hose from the lift/steer pump.


2 Connect a 0 to 5000 psi (0 to 350 bar) pressuregauge to the high pressure port.

3 Gasoline/LPG models: Remove the hightension lead from the center of the ignition coil.

Electrocution hazard. Contact withelectrically charged circuits maycause death or serious injury.Remove all rings, watches andother jewelry.

4 Turn the key switch to ground control andpull out the Emergency Stop button to theON position.

5 Deutz Diesel models: Hold the manualfuel shutoff valve counterclockwise to theCLOSED position.

All models: Observe the pressure gaugewhile cranking the engine. Immediately stopcranking if the pressure reaches or exceeds3000 psi (206 bar).

Component damage hazard.Hydraulic pressure in excess of3000 psi (206 bar) will causedamage to the machine.

Result: If the pressure gauge reads3000 psi (206 bar), immediately stopcranking the engine. The pump is good.

Result: If the pressure fails to reach 3000 psi(206 bar), the pump is bad and will need to beserviced or replaced.

6 Gasoline/LPG models: Reconnect the hightension lead to the ignition coil.

Hydraulic Pumps

7 - 38 Genie Z-45/22 Part No. 32960


HYDRAULIC PUMPS

How to Remove theLift/Steer Pump1 Close the two hydraulic tank valves located at

the hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valvesin the CLOSED position orcomponent damage will occur.If the tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

2 Disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

9-2Drive Hydraulic Pump

The drive hydraulic pump is a bi-directionalvariable displacement piston pump. The pumpoutput is controlled by the electronic displacementcontroller (EDC), located on the pump. The onlyadjustment that can be made to the pump is theneutral or null adjustment. Any internal service tothe pump should only be performed at anauthorized Sundstrand-Sauer service center.

How to Remove the DriveHydraulic Pump

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulicsystem and cause severecomponent damage. Dealerservice is recommended.

1 Disconnect the electrical connection at theelectronic displacement controller (EDC)located on the drive pump.

2 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valvesin the CLOSED position orcomponent damage will occur. Ifthe tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

open closed

open closed

Part No. 32960 Genie Z-45/22 7 - 39


3 Disconnect the hydraulic hoses from the pumpsand cap them.


4 Support the pump and remove the twodrive pump mounting bolts. Carefullyremove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

How to Prime the Pump1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port on the drive pump.

2 Gasoline/LPG models: Remove the hightension lead from the center of the ignition coil.

Electrocution hazard.Contact with electrically chargedcircuits may cause death orserious injury. Remove all rings,watches and other jewelry.

Deutz Diesel models: Hold the manual fuelshutoff valve counterclockwise to the CLOSED

position.

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 320 psi (22 bar).

HYDRAULIC PUMPS

7 - 40 Genie Z-45/22 Part No. 32960


Function Manifold

10-1Function Manifold Components

Index Schematic

No. Description Item Function Torque

1 3 position 4 way D01 valve ............... N ........... Platform rotate ..................................30-35 in-lbs / 3-4 Nm

2 Counterbalance valve ........................ B ........... Platform level up ...............................35-40 ft-lbs / 47-54 Nm

3 Sandwich valve manifold ................... A ........... Platform level counterbalance valves

4 3 position 4 way D01 valve ............... O ........... Platform level ....................................30-35 in-lbs / 3-4 Nm

5 Counterbalance valve ........................ BB ......... Turntable rotate right ........................35-40 ft-lbs / 47-54 Nm

6 Sandwich valve manifold ................... AAA ...... Turntable rotate counterbalance valves

7 3 position 4 way D01 valve ............... P ........... Turntable rotate ................................30-35 in-lbs / 3-4 Nm

8 3 position 4 way D01 valve ............... Q ........... Secondary boom up/down ................30-35 in-lbs / 3-4 Nm

9 3 position 4 way D01 valve ............... R ........... Primary boom up/down.....................30-35 in-lbs / 3-4 Nm

10 3 position 4 way D01 valve ............... S ........... Primary boom extend/retract ............30-35 in-lbs / 3-4 Nm

11 Counterbalance valve ........................ CC ........ Turntable rotate left ..........................35-40 ft-lbs / 47-54 Nm

12 Counterbalance valve ........................ C ........... Platform level down ..........................35-40 ft-lbs / 47-54 Nm

13 Check valve ....................................... K ........... Turntable rotate -differential sensing ............................11-13 ft-lbs / 15-18 Nm

14 Check valve ....................................... M .......... Primary and secondary boom -differential sensing ............................11-13 ft-lbs / 15-18 Nm

15 Flow regulator valve .......................... Y ........... Primary boom/secondary boom .......10-12 ft-lbs / 14-16 Nm

16 Relief valve, 1200 psi (83 bar) .......... D ........... Primary boom extend .......................25-30 ft-lbs / 34-41 Nm

17 Relief valve, 1200 psi (83 bar) .......... F ........... Primary boom down ..........................25-30 ft-lbs / 34-41 Nm

18 Relief valve, 1200 psi (83 bar) .......... E ........... Secondary boom down .....................25-30 ft-lbs / 34-41 Nm

19 Proportional solenoid valve ............... AA ......... Primary boom/secondary boom .......10-12 ft-lbs / 14-16 Nm

20 Flow regulator valve .......................... X ........... Turntable rotate/Primary boom extend/retract ............10-12 ft-lbs / 14-16 Nm

21 Normally closed poppet valve ........... J ............ Platform level ....................................25-30 ft-lbs / 34-41 Nm

22 Proportional solenoid valve ............... Z ........... Turntable rotate/Primary boom extend/retract ............10-12 ft-lbs / 14-16 Nm

23 Flow regulator valve .......................... V ........... Platform level ....................................10-12 ft-lbs / 14-16 Nm

24 Differential sensing valve .................. AC ........ All functions .......................................10-12 ft-lbs / 14-16 Nm

25 Flow regulator valve .......................... U ........... Platform rotate/jib boom ...................10-12 ft-lbs / 14-16 Nm

26 Flow regulator valve .......................... W .......... Differential sensing circuit .................10-12 ft-lbs / 14-16 Nm

27 Diagnostic fitting ............................................... Testing

28 Relief valve, 2200 psi (152 bar) ........ AB ......... System relief .....................................35-40 ft-lbs / 47-54 Nm

29 Priority flow regulator valve ............... T ........... Steering .............................................10-12 ft-lbs / 14-16 Nm

30 Check valve ....................................... I ............ Platform rotate right -differential sensing ............................11-13 ft-lbs / 15-18 Nm

31 Check valve ....................................... H ........... Platform rotate left -differential sensing ............................11-13 ft-lbs / 15-18 Nm

32 Check valve ....................................... L ........... Platform level - differential sensing ..11-13 ft-lbs / 15-18 Nm

Part No. 32960 Genie Z-45/22 7 - 41


73 4 5

FUNCTION MANIFOLD

6

11

12

13

14

15

16

18

17

19

20

21

25 24 2326

27

28

29

31

30

32

1 8

22

2 109

7 - 42 Genie Z-45/22 Part No. 32960


FUNCTION MANIFOLD

6 Restart the engine. Hold the retract switch andrecheck the valve pressure.

Specifications

Main relief valve pressure 2200 psi / 152 bar

How to Adjust the Primary orSecondary Boom Down ReliefValve1 Connect a 0 - 3000 psi (0 to 206 bar) pressure

gauge to the diagnostic nipple on the functionmanifold.

2 Start the engine from the ground controls andthen fully lower the boom to be adjusted.

3 Hold the primary or secondary boom up/downswitch in the down position and observe thepressure reading on the pressure gauge.

4 Turn the engine off. Hold the relief valve andremove the cap (item 17 for primary boom,item 18 for secondary boom).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then reinstall the reliefvalve cap.

Tip-over hazard. Do not adjust therelief valves higher thanrecommended. They are set toprevent a tip-over or damage to liftlinkage.

6 Restart the engine. Hold the primary orsecondary boom up/down switch in the downposition and recheck the valve pressure.

Specifications

Relief valve pressure 1200 psi / 83 bar

10-2Valve Adjustments - FunctionManifold

How to Adjust the Main ReliefValve1 Connect a 0 - 3000 psi (0 to 206 bar) pressure

gauge to the diagnostic nipple on the functionmanifold.

2 Start the engine from the ground controls andthen completely retract the primary boom.

3 Hold the retract switch and observe thepressure reading on the pressure gauge.

4 Turn the engine off. Hold the relief valve andremove the cap (item 28).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then reinstall the reliefvalve cap.

Tip-over hazard. Do not adjust therelief valves higher thanrecommended. They are set toprevent a tip-over or damage to liftlinkage.

Plug Torque Specifications

Description Hex Size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

Part No. 32960 Genie Z-45/22 7 - 43


FUNCTION MANIFOLD

How to Override a ValveA hydraulic valve may need to be manuallyoverridden to troubleshoot a malfunction. Eachproportional boom function uses a variableposition proportional valve and a three positiondirectional valve. Example: one position for boomup, one position for neutral and one position forboom down. The platform rotate and levelfunctions use a three position valve and a twoposition poppet valve. The three position valvesand the proportional valves can be manuallyoverridden. To identify the manifold valves see10-1 Function Manifold Components in thissection.

1 Push the button on the end of the valve in¼ inch (6 mm).

2 Move the ground control function switch for thefunction being overridden to operate function.

Collision Hazard. Impact withmoving boom components maycause death or serious injury. Useextreme caution when overriding aboom function and know thedirection of intended travel.

a directional valvesb proportional valvesc function manifold

b

a

c

How to Check the Resistance of aValve Coil1 Turn the keyswitch to the off position and

disconnect the wires from the valve coil to betested.

2 Connect the leads from an ohmmeter to thevalve coil terminals.

Specifications

Valve Resistance

Proportional solenoid valve 5Ω

3 pos 4 way directional valve 4.5Ω

Normally closed 7Ωpoppet valve

7 - 44 Genie Z-45/22 Part No. 32960


11-1Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. This tank has a 25 gallon (94.5 liters)capacity and an oil level gauge with temperatureindicator. It utilizes internal suction strainers forthe pump supply suction lines and has an externalreturn line filter.

How to Remove the HydraulicTank

The work area and surfaceswhere this procedure will beperformed must be clean and freeof debris that could get into thehydraulic system and causesevere component damage.

1 Raise the primary boom until it is horizontal toaccess the anchor hook.

2 Close the two hydraulic tank valves located atthe main pump.

3 Completely drain the oil from the tank byremoving the drain plug located in the bottomfront of tank.

Burn hazard. Contact with hot oilmay cause severe burns.

4 Disconnect the hydraulic hoses from the tank.

5 Remove the tank anchor hook from the back ofthe tank.

open closed

6 Remove the mounting fasteners from thebottom of the tank.

7 Use an appropriate lifting device to remove thetank from the machine.

Always use pipe thread sealantwhen re-installing the drain plug.

Use only Dexron II equivalenthydraulic fluid.

Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

How to Prime the Pump1 Gasoline/LPG models: Disconnect the ignition

coil wire and isolate it from ground.

Diesel models: Disconnect the wiring to theinjection pump fuel-on solenoid

2 Crank the engine with the starter motor for 15seconds.

Fuel and Hydraulic Tanks

Part No. 32960 Genie Z-45/22 7 - 45


FUEL AND HYDRAULIC TANKS

11-2Fuel Tank

How to Remove the Fuel TankEngine fuels are combustible.Remove the fuel tank in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

1 Raise the secondary boom enough to accessthe back of the fuel tank.

2 Turn the manual fuel shutoff valve to the closedposition.

3 Gasoline/LPG models: Disconnect theelectrical collectors from the fuel shutoffsolenoid. Disconnect, drain and plug the fuelhose.

Diesel models: Disconnect, drain and plug thesupply and return fuel hoses. Cap the fuelreturn fitting on the fuel tank.

4 Remove the tank anchor hook from the back ofthe tank.

5 Remove the mounting fasteners from thebottom of the tank.

6 Use an appropriate lifting device to remove thetank from the machine.

Clean the fuel tank and inspect forrust and corrosion before it isinstalled.

7 - 46 Genie Z-45/22 Part No. 32960


12-1Rotation Hydraulic Motor

The rotation hydraulic motor is the onlyserviceable component of the turntable rotationassembly. The worm gear may not be removedfrom the housing. In order to remove the housing,the turntable has to be removed.

How to Remove the TurntableRotation Motor1 Remove the hydraulic hoses attached to the

turntable rotation motor and plug them.


2 Remove the turntable rotation motor mountingbolts, then remove the motor.

Do not allow the turntable torotate until the hydraulic motor isinstalled.

12-2Rotation Bearing and Worm Drive

How to Remove the RotationBearing or Worm DriveThe turntable and all components above it must beremoved prior to removing the rotation bearing orworm drive.

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is required.

Be sure that the chassis is level.


2 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

Crushing hazard. Do not removethe 4x4x31 inch (78 cm) supportblock installed during primaryboom removal.


Turntable Rotation Components

b

a

c

Part No. 32960 Genie Z-45/22 7 - 47


TURNTABLE ROTATION COMPONENTS

3 Use an overhead crane to attach a lifting strapto the rod-end of the primary lift cylinder. Thenraise the primary lift cylinder with the crane, toa vertical position.


5 Place a rod through the barrel-end pivot pinand twist to remove the pin. Remove theprimary lift cylinder from the machine.

a 10 to 12 inch (30 cm) rodb pivot pin

a

b

Crushing hazard. The primary liftcylinder will fall when the barrel-end pivot pin is removed if it is notproperly supported.

6 Raise the secondary boom. Remove the blockfrom the turntable counterweight and lower thesecondary boom to the stowed position.

7 Close the two hydraulic tank valves located atthe main pump.

open closed

8 Disconnect the three 3/4 inch hydraulic hosesfrom the main pump and plug them.


9 Disconnect the same three 3/4 inch hydraulichoses from the drive traction manifold and plugthem. Pull these hoses up through the turntableand remove them from the machine.

10 Disconnect the “in” and “return” hydraulic hosesfrom the steer/oscillate manifold and plug them.Pull these hoses up through the turntable.

11 Disconnect the hydraulic hoses from theturntable rotation motor and plug them. Pullthese hoses up through the turntable.

12 Label and then disconnect all the wiring fromthe traction manifold and the steer/oscillatemanifold.

13 Disconnect and remove the oscillating axle limitswitches from the oscillation cylinder.

Oscillating axle limit switcha limit switchb oscillate lock-out wedge

b

a

7 - 48 Genie Z-45/22 Part No. 32960



14 Disconnect and remove the drive enable limitswitch.

a drive enable limit switch

15 Pull the wiring harness along with the limitswitches up through the turntable.

16 Remove the turntable end cover.

17 Loosen the lug nuts on both steer tires. Do notremove them.

18 Center a lifting jack under the steering axle. Liftthe machine until the tires are just off theground.

19 Support the chassis on blocks, then removeboth steer tires and wheel assemblies toimprove access when removing the turntable.

20 Prepare a forklift with a minimum rating of18,000 pounds (8165 kg) by spreading theforks to an inside width of 3 feet (0.9 m).

21 Position the forklift at the counterweight end ofthe turntable. Center the forks underneath theturntable and above the chassis. Do not lift.

22 Place a 5 inch (13cm) tall block near the end ofthe forks for support.

a forksb block

23 Raise the forks up against the turntable. Do notlift. Be sure that the support block is still in itsproper location.

24 Place a safety strap around the upper mid-pivot, then secure the strap to the forkliftcarriage.

25 Remove the turntable mounting bolts.

26 Carefully lift the turntable off the chassis. Setthe turntable on blocks for support.

27 Place reference marks on the chassis to notethe position of the worm drive housing forproper 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 chassiscounterweight for support.

30 Loosen the counterweight positioning bolt.

31 Remove the fasteners from the counterweight.

32 Carefully lower the counterweight from themachine.

33 Remove the fasteners from the underside ofthe rotate bearing, then remove the rotatebearing.

a b

a

a

Part No. 32960 Genie Z-45/22 7 - 49



How to Install the RotationBearing and Worm DriveThe rotation bearing is a structural component. Itattaches the chassis to the turntable. Theturntable is bolted to the inner race, with the wormgear housing sandwiched in-between. Thishousing has to be exactly positioned to provide thecorrect gear lash between the worm gear and thering gear. The outside bearing race is bolted to thechassis from the underside.

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is required.

If a repair requires that theturntable be removed from thechassis, installing a new rotationbearing is recommended.Consider the service life of therotation bearing before installing aused bearing.

1 Position the rotation bearing on the chassis.

2 Locate the “red” mark on the outside bearingrace. Align the mark with the rotation stopblock on the chassis.

e

f

d

c a

b

2

5

6

12

13

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18

11

8

16

17

7

151

43

9

10

a "O" markb outer bearingc inner bearingd dowele red markf rotation stop block

3 Install the mounting fasteners from underneaththe chassis. Use a torque wrench to tighten thefasteners in sequence to specifications.

Specifications - torque

First rotation 95 ft-lbs 129 Nm

Second rotation 190 ft-lbs 258 Nm

7 - 50 Genie Z-45/22 Part No. 32960



4 Locate the “0” mark stamped in the outsidebearing and the dowel on the inside bearing.

5 Position the inside bearing dowel 90 degreescounterclockwise from the “0” mark on theoutside bearing.

6 Install a grease fitting on the inside bearing andapply grease until it comes out of the innerseal.

7 Apply grease to 10 gear teeth on each side ofthe “0” mark on the outside bearing.

8 Center the worm drive over the “0” mark on theoutside bearing and install the two 5/16 inchfasteners. Hand tighten the bolts.

9 Push the worm drive towards the rotationbearing to be as close as possible.

10 Position a dial indicator to measure the wormdrive in relation to the ring gear. Pull the wormdrive away from the rotate bearing 0.035inches (0.889mm) ±0.020 inches (0.508mm).

11 Tighten the two 5/16 fasteners. Observe thedial indicator to be sure that the worm drivedoes not move.

12 Locate the 1 inch hex head on the end of theworm gear housing. Turn the hex head torotate the worm drive until it is positioned withinthe original reference marks on the chassis.

13 Position the turntable so that the flat side of theturntable is parallel with the worm drive gear.

14 While lowering the turntable onto the chassis,be sure that the milled area on the bottomsurface of the turntable does not contact thetop of the worm drive gear housing. If it is,remove the turntable and grind the worm drivegear housing until clearance is established.

15 Install the turntable mounting fasteners. Use atorque wrench to tighten the fasteners insequence to specifications.

Specifications - torque

First rotation 95 ft-lbs 129 Nm

Second rotation 190 ft-lb 258 Nm

After re-assembly, the turntableshould swing smoothly withoutjerking or grinding.

16

1

3

7

10

12

13

14

22

18

4

195

15

23

221

8

11

17

24

620 9

Part No. 32960 Genie Z-45/22 7 - 51


13-1Yoke and Hub

How to Remove the Yoke/HubAssembly1 Remove the cotter pin, and the clevis pin from

both the steering cylinder and tie rod weldment.

a axleb pin retainerc king pind yokee hubf cotter and clevis ping steering cylinderh tie rod

2 Break loose the wheel lug nuts. Do not removethem.

3 Block the non-steering wheels and place alifting jack under the steering axle.

4 Raise the machine and place blocks under thechassis.

5 Remove the lug nuts, then the tire and wheelassembly.

6 Remove the pin retainer attached to the kingpin.

7 Place a second jack under the yoke/hubassembly.

8 Use a soft metal drift to drive the king pin downand out.

Crushing hazard. The yoke/hubassembly will fall when the kingpin is removed if it is not properlysupported.

Always use a new cotter pin whenre-installing a clevis pin.

How to Remove the Hub andBearing1 Loosen the wheel lug nuts. Do not remove

them.

2 Place a lifting jack under the steering axle.

3 Raise the machine and place blocks under thechassis.


5 Remove the dust cap, cotter pin and slottednut.

6 Pull the hub from the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

a

b

d

c

e

g

h

f

f


7 - 52 Genie Z-45/22 Part No. 32960


2WD STEERING AXLE COMPONENTS

How to Install the Hub andBearing1 Be sure that the bearing is packed with grease.

2 Place the large inner bearing into the rear ofthe hub.

3 Press the bearing seal into the hub. Rest theseal on the hub, then press the seal evenly intothe hub until it is flush.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayresult.

5 Be sure that the outer bearing is packed withgrease, 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 to8 foot-pounds (11Nm).

9 Install a new cotter pin. Bend the pin to lock itin.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to125 foot-pounds (169Nm).

13-2Steering Cylinders

How to Remove a SteeringCylinderThere are two identical steering cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod maintains equal movement of the tires.Bushings are used at both ends of each steeringcylinder clevis.

1 Disconnect the hydraulic hoses from thesteering cylinder and plug them.


2 Remove the cotter pin, then the clevis pin fromeach end of the steering cylinder.

3 Remove the steering cylinder.


Part No. 32960 Genie Z-45/22 7 - 53


13-3Tie Rod

How to Remove the Tie RodWeldment1 Remove the cotter pins, then the clevis pins

from the ends of the tie rod.

2 Remove the tie rod weldment.


How to Perform theTie Rod Toe-in Adjustment

Perform this procedure on afirm level surface. Block thenon-steering tires and be surethat the machine is in the fullystowed position.

1 Measure 15 inches (38 cm) up from the groundon the front and rear of each steer tire andmake a reference mark at the center of the tire.

2 Measure the distance from the reference pointson each tire: Front to front and back to back.

3 Center a jack under the steering axle, thenraise the machine.

4 Loosen the jam nut on the adjustable end of thetie rod.


5 Remove the cotter pin, then remove the clevispin from the adjustable end of the tie rod.

6 Slide the tie rod off the yoke and adjust it byturning the end.

One half turn on the adjustableend equals a 3/16 inch (5 mm)change in the front to rearmeasurement.

7 Slide the tie rod onto the yoke. Install the clevispin, then a new cotter pin.

8 Tighten the jam nut against the tie rod.

9 Lower the machine and recheck the frontand back measurements (step 2). If furtheradjustment is needed, repeat steps 3through 8.

Specifications

Tie rod adjustment 1/4 inch (0.635 mm) toe-into 1/4 inch (0.635 mm) toe-out

7 - 54 Genie Z-45/22 Part No. 32960


14-1Yoke and Hub

How to Remove the Yoke and HubThe yoke installation utilizes bushings and a thrustwasher that require periodic replacementdepending upon the application. The yoke must beremoved before the torque hub can be removed.The wheel motor is an integral part of the torquehub.

1 Remove the cotter pin, then the clevis pin fromboth the steering cylinder and the tie rodweldment.

g

h

f

a axleb pin retainerc king pind yokee torque hubf cotter and clevis ping steering cylinderh tie rod

2 Disconnect the hydraulic hoses from the wheelmotor and plug them. Cap the wheel motorhydraulic fittings.


3 Loosen the wheel lug nuts. Do not removethem.

4 Block the non-steering wheels, and then centera lifting jack under the steering axle.

5 Raise the machine 6 inches (15 cm) and placeblocks under the chassis.


7 Remove the pin retainer from the king pin.

8 Place a block between the oscillate cylinderlock-out wedge and the chassis on the sameside as the yoke/torque hub being serviced.

a blockb torque hubc yoked axlee lock-out wedgef chassis

ef d

a

c b


a

b

d

c

e

Part No. 32960 Genie Z-45/22 7 - 55



14-3Tie Rod

How to Remove the Tie RodWeldmentThis procedure is the same as the 2WDprocedure. See repair procedure 13-3, How toRemove the Tie Rod Weldment.

How to Perform the Tie RodToe-in AdjustmentThis procedure is the same as the 2WDprocedure. See repair procedure 13-3, How toPerform the Tie Rod Toe-in Adjustment.

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 downand out.

Crushing hazard. The yoke/torquehub assembly will fall when theking pin is removed if it is notproperly supported.

11 Place the yoke/torque hub assembly on a flatsurface with the torque hub down. Remove thebolts that secure the yoke to the torque hub.

Specifications

Lug nut torque 125 ft-lbs 169Nm

14-2Steering Cylinders

How to Remove the SteeringCylinderThis procedure is the same as the 2WDprocedure. See repair procedure 13-2, How toRemove the Steering Cylinder.

7 - 56 Genie Z-45/22 Part No. 32960


15-1Oscillating Axle Lock-out Cylinder

The oscillating axle lock-out cylinder extends thelock-out wedges between the chassis and the axlewhen the boom is raised above the drive limitswitch. When the lock-out wedges are fullyextended, the oscillation lock-out limit switchesrelease and allow the primary boom to continue toraise above the drive limit switch.

How To Remove The OscillatingAxle Lock-out CylinderThe oscillating axle lock-out cylinder is held inplace by the same pin that retains the axle.Therefore, the axle must be removed as part ofthis procedure.


Perform this procedure on a firmlevel surface.

1 Disconnect and plug the oscillating axle lock-out cylinder hydraulic hoses. Disconnect andplug the steer and accumulator hoses from thesteer-oscillate manifold to provide clearance forpin removal.


2 Remove the oscillation lock-out limit switchesfrom the oscillating axle lock-out cylinder.

3 Block the non-steering wheels, then center ajack under the oscillating axle and lift themachine 6 inches (15 cm).

4 Support the raised machine with blocks, thencarefully lower the chassis onto the blocks.Leave the jack under the axle to support it. Donot lift.

Crushing hazard. If the jack is notcentered, the axle may tip whenthe pivot pin is removed.

5 Remove the pin retainer from the axle pivot pin.Use a soft metal drift to remove the axle pivotpin.

6 Remove the oscillate cylinder.

Oscillating Axle Components

Part No. 32960 Genie Z-45/22 7 - 57


16-1Steer and Oscillate Manifold Components

Index SchematicNo. Description Item Function Torque

1 3 position 4 way DO1 valve .............. F ........... Steering .............................................30-35 in-lbs / 3-4 Nm

2 Pilot operated unloader valve,1900 psi / (131 bar) ........................... C ........... Sequencing .......................................10-12 ft-lbs / 14-16 Nm

3 Sensing valve .................................... B ........... 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 ....................... D ........... Oscillate ............................................10-12 ft-lbs / 14-16 Nm

6 Check valve ....................................... E ........... Oscillate check ..................................35-40 ft-lbs / 47-54 Nm

Steer and Oscillate Manifold

1

2

3

4

5

6

7 - 58 Genie Z-45/22 Part No. 32960


STEER AND OSCILLATE MANIFOLD

16-2Valve Adjustments

How to Adjust the SequencingUnloader Valve


1 Start the engine and raise the primary boomabove the drive limit switch. Do not lift theprimary boom above the secondary boom.


a

2 Connect a 0 to 3000 psi (0 to 206 bar) pressuregauge to the diagnostic nipple on the functionmanifold.

3 Manually hold down the drive limit switch.When the oscillate cylinder fully retracts, thepressure will spike. Note the maximumpressure reading. Do not release the drive limitswitch.

4 Release the drive limit switch. When theoscillate cylinder fully extends, the pressure willspike. Note the maximum pressure reading.

5 Hold the unloader valve and remove the cap(index 2).

6 Adjust the internal hex socket by turning itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Then reinstall the relief valve cap.

7 Manually hold down the drive limit switch andrecheck the valve pressure.

Specifications

Unloader valve 1900 psi131 bar




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

Part No. 32960 Genie Z-45/22 7 - 59


17-1Drive Motor

Repairs to the motor should onlybe performed by an authorizedSundstrand-Sauer dealer.

How to Remove a Drive MotorA drive motor can only be removed from the insideof the chassis. Access on older machines is evenmore restricted. The brake and motor must beremoved together and then separated for repair.

The work area and surfaceswhere this procedure will beperformed must be clean and freeof debris that could get into thehydraulic system and causesevere component damage.Dealer service is recommended.

1 Disconnect the hydraulic hoses from the drivemotor and plug them.


2 Remove the drive motor mounting bolts.

3 Slide the drive motor shaft out of the brake andthen remove.

On older machines, the drivemotor and brake must beremoved together.

Non-steering Axle Components

17-2Torque Hub

How to Remove a Drive TorqueHubThe drive motor and brake must be removed inorder 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 removethem.

3 Center a jack under the non-steering axle.Raise the machine and place blocks under thechassis to support it.

4 Remove the wheel lug nuts, then the tire andwheel assembly.

5 Place a second jack under the torque hub forsupport.

6 Remove the bolts that attach the brake to thehub.

7 Remove the bolts that attach the torque hub tothe chassis, then remove the torque hub.

Crushing hazard. The torque hubwill fall if it is not properlysupported when the mountingbolts are removed.

Specifications

Lug nut torque 125 ft-lbs 169 Nm

7 - 60 Genie Z-45/22 Part No. 32960


18-12WD Drive Manifold Components


1 Check valve ................................. M .................... Brake check .......................... 25-30 ft-lbs / 34-41 Nm

2 2 position 3 way valve ................. O .................... Brake release ........................ 8-10 ft-lbs / 11-14 Nm

3 2 position 3 way valve ................. N ..................... 2-Speed wheel motors,(energized in high range todestroke the rear motorswash plates ......................... 8-10 ft-lbs / 11-14 Nm

4 Orifice 0.036 in (0.914mm) ......... P ..................... Motor shift / brake release circuit

5 Pilot to open check valve ............ E ..................... Right check in forward .......... 85-90 ft-lbs / 115-122 Nm

6 Pilot to open check valve ............ G .................... Right check in reverse .......... 85-90 ft-lbs / 115-122 Nm

7 Shuttle valve 3 position 3 way .... K ..................... Low pressure flow path forbrake release and 2-speedmotor shift ............................. 15-18 ft-lbs / 20-24 Nm

8 Pilot to open check valve ............ D ..................... Left check in reverse ............. 85-90 ft-lbs / 115-122 Nm

9 Pilot to open check valve ............ B ..................... Left check in forward ............. 85-90 ft-lbs / 115-122 Nm

10 2 position 3 way valve ................. J ..................... Energized in high range topilot open check valves5,6, 8 & 9 to bypass flowregulators and allow fullflow to front wheel motors ..... 8-10 ft-lbs / 11-14 Nm

11 Shuttle valve 2 position 3 way ..... I ..................... High pressure flow path forflow regulator bypass ............ 10-13 ft-lbs / 14-18 Nm

12 Flow regulator valve .................... A ..................... Left flow control in forward .... 10-12 ft-lbs / 14-16 Nm

13 Flow regulator valve .................... C ..................... Left flow control in reverse .... 10-12 ft-lbs / 14-16 Nm

14 Relief valve, 320 psi (22 bar) ...... L ..................... Charge pressure ................... 10-12 ft-lbs / 14-16 Nm

15 Flow regulator valve .................... H ..................... Right flow control in reverse . 10-12 ft-lbs / 14-16 Nm

16 Flow regulator valve .................... F ..................... Right flow control in forward . 10-12 ft-lbs / 14-16 Nm

2WD Drive Manifold




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

Part No. 32960 Genie Z-45/22 7 - 61


1

2WD DRIVE MANIFOLD

2 3 5 6 94 1087

11

14

13

12

16

15

7 - 62 Genie Z-45/22 Part No. 32960


2WD DRIVE MANIFOLD


How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge in between one of the medium pressurehydraulic hoses and the medium pressurehydraulic oil filter.



3 Drive the machine in either direction andobserve the pressure reading on the pressuregauge.

4 Turn the engine off. Hold the relief valve andremove the cap (index 14).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then reinstall the valvecap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove the pressuregauge.

Specifications

Relief valve 320 psi / 22 bar

Part No. 32960 Genie Z-45/22 7 - 63


2WD DRIVE MANIFOLD


7 - 64 Genie Z-45/22 Part No. 32960


19-14WD Drive Manifold Components


1 Check valve ........................... W ................... Brake check ............................... 25-30 ft-lbs / 34-41 Nm

2 2 position 3 way valve ........... S .................... Brake release ............................. 8-10 ft-lbs / 11-14 Nm

3 2 position 3 way valve ........... R .................... 2-speed wheel motors(energized in high range todestroke the rear motorswash plates) ............................. 8-10 ft-lbs / 11-14 Nm

4 Check valve ........................... K .................... RR check in forward................... 35-40 ft-lbs / 47-54 Nm

5 Orifice 0.025 in (0.635 mm) ... X .................... Motor shift / brake release circuit

6 Check valve ........................... L .................... RR check in reverse ................... 35-40 ft-lbs / 47-54 Nm

7 Relief valve, 320 psi (22 bar) . V .................... Charge pressure ........................ 10-12 ft-lbs / 14-16 Nm

8 Shuttle valve 3-position 3 way U.................... Low pressure flow path forbrake release and2 speed motor shift .................... 15-18 ft-lbs / 20-24 Nm

9 Pilot to open check valve ....... O ................... RF check in forward ................... 85-90 ft-lbs / 115-122 Nm

10 Pilot to open check valve ....... P .................... RF check in reverse ................... 85-90 ft-lbs / 115-122 Nm

11 Check valve ........................... J .................... LR check in reverse ................... 35-40 ft-lbs / 47-54 Nm

12 Check valve ........................... I ..................... LR check in forward ................... 35-40 ft-lbs / 47-54 Nm

13 Pilot to open check valve ....... N .................... LF check in reverse .................... 85-90 ft-lbs / 115-122 Nm

14 Pilot to open check valve ....... M ................... LF check in forward ................... 85-90 ft-lbs / 115-122 Nm

15 2 position 3 way valve ........... Q ................... Energized in high range topilot open check valves9, 10, 13 & 14 to bypass flowregulators and allow fullflow to front wheel motors .......... 8-10 ft-lbs / 11-14 Nm

16 Shuttle valve 2 position 3 way T .................... High pressure flow path forflow regulator bypass ................. 10-13 ft-lbs / 14-18 Nm

17 Flow regulator valve ............... D .................... LR flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

18 Flow regulator valve ............... B .................... LR flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

19 Flow regulator valve ............... H .................... RR flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

20 Flow regulator valve ............... F .................... RR flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

21 Flow regulator valve ............... A .................... LF flow control in forward ........... 10-12 ft-lbs / 14-16 Nm

22 Flow regulator valve ............... C .................... LF flow control in reverse ........... 10-12 ft-lbs / 14-16 Nm

23 Flow regulator valve ............... G ................... RF flow control in reverse .......... 10-12 ft-lbs / 14-16 Nm

24 Flow regulator valve ............... E .................... RF flow control in forward .......... 10-12 ft-lbs / 14-16 Nm

4WD Drive Manifold

Part No. 32960 Genie Z-45/22 7 - 65


4WD DRIVE MANIFOLD

1 3 42 5 76 8 9 10 11 12 13 14

15

1618 17

19

20

24

23

22

21

7 - 66 Genie Z-45/22 Part No. 32960


4WD DRIVE MANIFOLD


How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge in between one of the medium pressurehydraulic hoses and the medium pressurehydraulic oil filter.



3 Drive the machine in either direction andobserve the pressure reading on the pressuregauge.

4 Turn the engine off. Hold the relief valve andremove the cap.

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then reinstall the valvecap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove the pressuregauge.

Specifications

Relief valve 320 psi / 22 bar




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

Documents

Z-45/22 Service Manual - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data/Service/Z... · Part No. 32960 Genie Z-45/22 Service Manual - Second Edition Important Verify