Genie Z-45/25 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z-45/25

from Z452513A-47001 to

Z452516N-57199

This manual includes:

Repair

procedures

Fault Codes

Electrical and

Hydraulic Schematics

Z-45/25J

from Z452514B-3301 to

Z452516M-6699

IC Power

from Z452513D-101 to

Z452516D-

939

from Z4525D-940

from Z4525M-6700

For detailed maintenance

procedures, refer to

the

appropriate Maintenance

Manual for your machine.

from Z4525N-57200

Part No. 1268548

Rev A1

September 2016

Service and Repair Manual September 2016

Introduction

ii Z-45/25 • Z-45/25J Part No. 1268548

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1268548 Rev A, September 2015

First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“Z” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual

Introduction

Part No. 1268548 Z-45/25 • Z-45/25J iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2015

Initial Release

A1 9/2016 Introduction Serial Number Legend

Reference Examples: Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual September 2016

Introduction

iv Z-45/25 • Z-45/25J Part No. 1268548

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label (located under cover)

September 2016 Service and Repair Manual

Safety Rules

Part No. 1268548 Z-45/25 • Z-45/25J v

Section 1 Safet y Rul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance 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, lifting

equipment and a suitable workshop.

Service and Repair Manual September 2016

Safety Rules

vi Z-45/25 • Z-45/25J Part No. 1268548

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could res

ult in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to

wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are

in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

September 2016

Table of Contents

Part No. 1268548 Z-45/25 • Z-45/25J vii

Introduction Introduction...........................................................................................................ii

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

Find a Manual for this Model..................................................................................ii

Serial Number Legend ..........................................................................................iv

Section 1 Safety Rules..........................................................................................................v

General Safety Rules .............................................................................................v

Section 2Specifications.......................................................................................................1

Machine Specifications...........................................................................................1

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

Hydraulic Specification...........................................................................................3

Hydraulic Component Specifications......................................................................5

Ford MSG-425 EFI Engine Specifications .............................................................7

Deutz D2011 L03i Engine Specifications...............................................................9

Deutz D 2.9 L4 Engine Specifications..................................................................11

Perkins 404D-22 Engine Specifications...............................................................13

Perkins 404F-22 Engine Specifications ...............................................................15

Machine Torque Specifications............................................................................16

Hydraulic Hose and Fitting Torque Specifications ...............................................17

Torque Procedure ................................................................................................18

SAE and Metric Fasteners Torque Charts ...........................................................20

September 2016

Table of Contents

viii Z-45/25 • Z-45/25J Part No. 1268548

Section 3 Repair Procedures..............................................................................................21

Introduction...........................................................................................................21

Platform Controls ...............................................................................................23

1-1 ALC-500 Circuit Board ...................................................................................23

1-2 Joysticks.........................................................................................................24

How to Adjust the Joystick Max-out Setting....................................................25

How to Adjust the Joystick Ramp Rate Setting...............................................26

How to Adjust the Joystick Threshold Setting.................................................27

Platform Components........................................................................................29

2-1 Platform Leveling Slave Cylinder ...................................................................29

How to Bleed the Slave Cylinder.....................................................................30

2-2 Platform Rotator .............................................................................................31

2-3 Platform Overload System .............................................................................32

Jib Boom Components ......................................................................................34

3-1 Jib Boom.........................................................................................................34

3-2 Jib Boom Lift Cylinder ....................................................................................35

Primary Boom Components..............................................................................37

4-1 Cable Track....................................................................................................37

How to Remove the Cable Track, Z-45/25......................................................37

How to Remove the Cable Track, Z-45/25J....................................................39

How to Repair the Primary Boom Cable Track...............................................41

4-2 Primary Boom.................................................................................................41

How to Disassemble the Primary Boom..........................................................43

4-3 Primary Boom Lift Cylinder.............................................................................44

4-4 Primary Boom Extension Cylinder .................................................................45

4-5 Platform Leveling Master Cylinder .................................................................46

September 2016

Table of Contents

Part No. 1268548 Z-45/25 • Z-45/25J ix

Secondary Boom Components.........................................................................47

5-1 Secondary Boom............................................................................................48

5-2 Secondary Boom Lift Cylinders......................................................................53

Engines................................................................................................................55

6-1 RPM Adjustment - Deutz D2011L03i Models ................................................55

6-2 RPM Adjustment - Perkins 404D-22 Models .................................................55

6-3 Flex Plate .......................................................................................................55

How to Install the Flex Plate............................................................................57

How to install the Pump and Bell Housing Assembly .....................................58

6-4 Ford MSG-425 Engine Fault Codes...............................................................59

6-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.............59

Hydraulic Pumps................................................................................................60

7-1 Lift/Steer Pump ..............................................................................................60

7-2 Drive Pump.....................................................................................................61

How to Prime the Pump ..................................................................................62

Manifolds.............................................................................................................64

8-1 Function Manifold Components .....................................................................64

8-2 Valve Adjustments - Function Manifold..........................................................68

How to Adjust the System Relief Valve...........................................................68

How to Adjust the Secondary Boom Down Relief Valve.................................69

8-3 Jib Boom / Platform Rotate Manifold Components........................................70

8-4 Turntable Rotation Manifold Components .....................................................71

8-5 Directional Valve Manifold Components........................................................72

How to Set Up the Directional Valve Linkage.................................................73

8-6 Traction Manifold Components, 2WD............................................................74

8-7 Valve Adjustments, 2WD Traction Manifold...................................................76

8-8 Traction Manifold Components, 4WD............................................................77

8-9 Valve Adjustments, 4WD Traction Manifold...................................................79

8-10 Hydraulic Generator Manifold Components, 2.2kW ....................................80

8-11 Valve Coils ...................................................................................................81

How to Test a Coil Diode ................................................................................81

September 2016

Table of Contents

x Z-45/25 • Z-45/25J Part No. 1268548

Turntable Rotation Components.......................................................................83

9-1 Turntable Rotation Assembly.........................................................................83

Axle Components...............................................................................................85

10-1 Hub and Bearings, 2WD Models..................................................................85

How to Remove the Hub and Bearings...........................................................85

How to Install the Hub and Bearings...............................................................85

10-2 Oscillating Axle Cylinders.............................................................................86

Section 4 Fault Codes.........................................................................................................87

Introduction...........................................................................................................87

Control System Fault Codes .............................................................................88

How to Retrieve Control System Fault Codes.................................................88

Control System Fault Codes ...........................................................................89

Fault Code Display - Deutz and Perkins Models.............................................93

How to Retrieve Active Engine Fault Codes

Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................93

Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and

Perkins 404F-22 Models..........................................................................94

Soft Key Functions and Icons -

Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................95

Main Menu Structure - Deutz D 2.9 L4 Models...............................................96

Main Menu Structure - Perkins 404F-22 Models.............................................97

Deutz D 2.9 L4 Engine Fault Codes ..................................................................98

Perkins 404F-22 Engine Fault Codes .............................................................109

Ford MSG-425 Engine Fault Codes ................................................................111

How to Retrieve Ford MSG-425 Engine Fault Codes...................................111

Ford MSG-425 Engine Fault Codes..............................................................112

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