Z-45/22 Service Manual - Manuals - Geniemanuals.gogenielift.com/Parts And Service...

TechnicalPublications

First Edition

Part No. 29487

®

ServiceManual

Z-45 22

Genie Z-45/22 Part No. 29487

Service Manual - First Edition

ii

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-45/22Operating Instruction Manual before attemptingany maintenance or repair procedure.

This service manual covers the Genie Z-45/222WD and 4WD models introduced in 1991.

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 U.S.A. and CanadaTelephone (206) 881-1800Toll Free 800 536-1800Fax (206) 883-3475Telex 152351

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

Introduction

Copyright © 1992 by Genie Industries

First Edition, October 1992

Genie® is a registered trademarkof Genie Industries

Registered 2009987

Printed on recycled paper

Printed in U.S.A.

Part No. 29487 Genie Z-45/22


iii

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- applicable governmental regulations

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



SAFETY RULES

iv

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 well ventilated and safely andadequately illuminated.

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 mindful of the environment.

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

v

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

Kubota V1702-B Engine Specifications .................................................................... 2 - 7

Section Three Scheduled Maintenance Inspections

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

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

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

Table C ..................................................................................................................... 3 - 4

Table D ..................................................................................................................... 3 - 5

Maintenance Inspection Report ................................................................................ 3 - 6

Section Four Scheduled Maintenance Procedures

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

A-1 Inspect the Operating Instruction and Safety 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 ..................................................................... 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 - 4



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 ................................................................... 4 - 8

A-15 Change the Engine Air Filter ........................................................................... 4 - 9

A-16 Drain the Fuel Filter/Water Separator - Diesel Models ................................. 4 - 10

B-1 Check the Engine Fan Belts ......................................................................... 4 - 11

B-2 Check the Radiator ....................................................................................... 4 - 11

B-3 Check the Exhaust System .......................................................................... 4 - 11

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

B-5 Check the Hydraulic Reservoir Filter Condition Indicator .............................. 4 - 12

B-6 Inspect Electrical Wiring ............................................................................... 4 - 13

B-7 Inspect the Tires and Wheels ....................................................................... 4 - 13

B-8 Confirm Proper Brake Configuration ............................................................. 4 - 14

B-9 Check the Oil Level in the Torque Hubs ....................................................... 4 - 14

B-10 Check the Engine Choke - Gasoline/LPG Models ........................................ 4 - 15

B-11 Check the Glow Plugs - Diesel Models ......................................................... 4 - 15

B-12 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 16

B-13 Check and Adjust the Engine RPM............................................................... 4 - 16

B-14 Test the Key Switch ...................................................................................... 4 - 17

B-15 Test the Emergency Stop Buttons ................................................................ 4 - 18

B-16 Test the Ground Control Override ................................................................ 4 - 18

B-17 Test the Oscillate Lock-out ........................................................................... 4 - 18

B-18 Test Platform Self-leveling ............................................................................ 4 - 19

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

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

B-21 Test the Engine Speed Select ...................................................................... 4 - 20

B-22 Test Fuel Select Operation - Gasoline/LPG Models ..................................... 4 - 20

B-23 Test the Turntable Rotation Stop .................................................................. 4 - 21

TABLE OF CONTENTS

vi



Section Four Scheduled Maintenance Procedures, continued

B-24 Test the Drive Enable System ...................................................................... 4 - 21

B-25 Test the Drive Brakes ................................................................................... 4 - 22

B-26 Test Drive Speed - Stowed Position ............................................................. 4 - 22

B-27 Test the Alarm Package (optional equipment) .............................................. 4 - 23

C-1 Check the Primary Boom Wear Pads ........................................................... 4 - 24

C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 24

C-3 Check the Free-wheel Feature ..................................................................... 4 - 25

C-4 Grease the Worm Drive Gear ....................................................................... 4 - 26

C-5 Replace the Torque Hub Oil ......................................................................... 4 - 27

C-6 Replace the Hydraulic Reservoir Filter ......................................................... 4 - 27

C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 28

C-8 Replace the Diesel Fuel Filter ....................................................................... 4 - 28

C-9 Replace the Gasoline Fuel Filter ................................................................... 4 - 29

C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 30

C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models ..... 4 - 30

C-12 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 31

C-13 Check and Adjust the Air/Propane Mixture - Gasoline/LPG Models ............. 4 - 31

C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 32

D-1 Change The Hydraulic Oil ............................................................................. 4 - 33

D-2 Change or Recondition the Engine Coolant .................................................. 4 - 34

D-3 Change the Fuel Lines .................................................................................. 4 - 35

D-4 Check Engine Valve Clearance - Gasoline/LPG Models .............................. 4 - 36

D-5 Check Engine Cylinder Compression - Gasoline/LPG Models ..................... 4 - 36

D-6 Clean PCV Hoses, Tubes, and Fittings - Gasoline/LPG Models .................. 4 - 37

D-7 Check the Engine Nozzle Injection Pressure - Diesel Models ...................... 4 - 38

D-8 Check Injection Timing - Diesel Models ........................................................ 4 - 38

D-9 Replace The Timing Belt - Ford .................................................................... 4 - 38

TABLE OF CONTENTS

vii



Section Five Troubleshooting Flow Charts

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

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

2 Engine Cranks But Will Not Start - Gasoline/LPG Models .............................. 5 - 4

3 Engine Cranks But Will Not Start - Diesel Models .......................................... 5 - 9

4 Engine Choke Inoperative - Gasoline/LPG Models ....................................... 5 - 11

5 Engine Glow Plugs Inoperative - Diesel ModelsSee B-11, Check The Glow Plugs ................................................................ 4 - 15

6 Engine Will Not Start On LPG, But Will Start On Gasoline- Gasoline/LPG Models ................................................................................. 5 - 13

7 Engine Will Not Start On Gasoline, But Will Start On LPG- Gasoline/LPG Models ................................................................................. 5 - 14

8 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 15

9 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 17

10 Engine High Idle Inoperative - Diesel Models ............................................... 5 - 18

11 Engine Low Idle Inoperative - Diesel Models ................................................ 5 - 19

12 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 20

13 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 21

14 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 22

15 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 23

16 Secondary Boom Up Function Inoperative ................................................... 5 - 24

17 Secondary Boom Down Function Inoperative ............................................... 5 - 27

18 Primary Boom Up Function Inoperative ........................................................ 5 - 29

19 Primary Boom Down Function Inoperative ................................................... 5 - 31

20 Primary Boom Extend Function Inoperative ................................................. 5 - 33

21 Primary Boom Retract Function Inoperative ................................................. 5 - 35

22 Turntable Rotate Function Inoperative .......................................................... 5 - 36

23 Turntable Rotate Left Function Inoperative................................................... 5 - 38

24 Turntable Rotate Right Function Inoperative ................................................ 5 - 39

25 All Platform Leveling Functions Inoperative .................................................. 5 - 40

26 Platform Level Up Function Inoperative ........................................................ 5 - 41

27 Platform Level Down Function Inoperative ................................................... 5 - 42

TABLE OF CONTENTS

viii



Section Five Troubleshooting Flow Charts, continued

28 Platform Rotate Left Function Inoperative .................................................... 5 - 43

29 Platform Rotate Right Function Inoperative .................................................. 5 - 44

30 Oscillate Lock-out Function Inoperative ........................................................ 5 - 45

31 Steer Left Function Inoperative ..................................................................... 5 - 46

32 Steer Right Function Inoperative .................................................................. 5 - 47

33 All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 48

34 Drive Forward Or Reverse Function Inoperative .......................................... 5 - 50

35 High Range Drive Function Inoperative ........................................................ 5 - 51

36 Low Range Drive Function Inoperative ......................................................... 5 - 53

37 Machine Will Not Drive At Full Speed ........................................................... 5 - 54

38 Machine Drives At Full Speed With Platform Elevated ................................. 5 - 55

39 Drive Enable System Is Malfunctioning ........................................................ 5 - 56

40 Auxiliary Functions Inoperative ..................................................................... 5 - 57

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

Relay Panel Legend - Diesel Models ........................................................................ 6-11

Platform Control Box Legend - Diesel Models .......................................................... 6-12

Hydraulic Symbols Legend ....................................................................................... 6-13

2WD Hydraulic Schematic ........................................................................................ 6-14

4WD Hydraulic Schematic ........................................................................................ 6-15

TABLE OF CONTENTS

ix



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

Kubota V1702-B Engine

6-1 Timing Adjustment ........................................................................................ 7 - 28

6-2 Glow Plugs.................................................................................................... 7 - 28

6-3 RPM Adjustment ........................................................................................... 7 - 28

6-4 Flex Plate ...................................................................................................... 7 - 28

6-5 Water Temperature and Oil Pressure Switches............................................ 7 - 28

Ford LSG 423 Engine

7-1 Governor Actuator ........................................................................................ 7 - 30

TABLE OF CONTENTS

x



TABLE OF CONTENTS

xi

Section Seven Repair Procedures, continued

7-2 Choke Adjustments ....................................................................................... 7 - 31

7-3 Timing Adjustment ........................................................................................ 7 - 32

7-4 Carburetor Adjustment .................................................................................. 7 - 32

7-5 RPM Adjustment ........................................................................................... 7 - 32

7-6 Flex Plate ...................................................................................................... 7 - 32

7-7 Water Temperature and Oil Pressure Switches............................................ 7 - 33

7-8 Vacuum Switch ............................................................................................. 7 - 34

Ground Controls

8-1 Control Relays .............................................................................................. 7 - 35

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

8-3 Wago® Components ..................................................................................... 7 - 36

8-4 Resistors ....................................................................................................... 7 - 37

Relay Panel

9-1 Control Relays .............................................................................................. 7 - 38

9-2 Power Relay ................................................................................................. 7 - 39

Hydraulic Pumps

10-1 Lift/Steer Pump ............................................................................................. 7 - 40

10-2 Drive Hydraulic Pump ................................................................................... 7 - 41

Function Manifold

11-1 Function Manifold Components .................................................................... 7 - 42

11-2 Valve Adjustments ........................................................................................ 7 - 44

Fuel and Hydraulic Tanks

12-1 Hydraulic Reservoir ...................................................................................... 7 - 46

12-2 Fuel Tank ...................................................................................................... 7 - 47

Turntable Rotation Components

13-1 Rotation Hydraulic Motor .............................................................................. 7 - 48

13-2 Rotation Bearing and Worm Drive ................................................................ 7 - 48

2WD Steering Axle Components

14-1 Yoke and Hub ............................................................................................... 7 - 53

14-2 Steering Cylinders ........................................................................................ 7 - 54



Section Seven Repair Procedures, continued

14-3 Tie Rod ......................................................................................................... 7 - 55


15-1 Yoke and Hub ............................................................................................... 7 - 56

15-2 Steering Cylinders, See 14-2, Steering Cylinders ......................................... 7 - 57

15-3 Tie Rod, See 14-3, Tie Rod .......................................................................... 7 - 55

Oscillating Axle Components

16-1 Oscillating Axle Lock-out Cylinder ................................................................ 7 - 58

Steer and Oscillate Manifold

17-1 Steer and Oscillate Manifold Components .................................................... 7 - 59


Non-steering Axle Components

18-1 Drive Motor ................................................................................................... 7 - 61

18-2 Torque Hub ................................................................................................... 7 - 61

2WD Drive Manifold

19-1 2WD Drive Manifold Components ................................................................. 7 - 62


4WD Drive Manifold

20-1 4WD Drive Manifold Components ................................................................. 7 - 66


TABLE OF CONTENTS

xii

Part No. 29487 Genie Z-45/22 2 - 1

Section 2 - SpecificationsService Manual - First Edition

59 sq in 43.5 sq in380sq cm 280sq cm

35.8 inches 28 inches91cm 71cm

17.5 inches 14.5 inches

10.5 inches 7 inches

9 @ 5/8-18

8 @ 5/8-18 8 @ 5/8-189 @ 5/8-18 9 @ 5/8-18

125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Specifications

Machine Specifications

14-17.5NHS 9-14.5 LT

8 Tread 8Sidewall 6

15 gallons56.8 liters

33.5 pounds15.2kg

25 gallons95 liters

30 gallons114 liters

17 ounces0.5 liters

Fluid capacities

Fuel tank

Propane tank

Hydraulic tank

Hydraulic system(including tank)

Torque hubs

Continuous improvement of our products is aGenie policy. Product specifications are subject tochange without notice.

40 psi 100 psi2.76 bar 6.89 bar

28 psi1.93 bar

Tires and wheels Rough terrain Industrial

Wheel diameter

Wheel width

Wheel lugs - 4WD

Wheel lugs - 2WDFrontRear

Lug nut torque

Tire size

Tire ply rating

Tire contact area

Overall tire diameter

Tire pressure - 2WD

4WD

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

6 ft 8 1/4 in 6 ft 4 5/8 in203.8cm 194.6cm

5 ft 9 5/8 in176.8cm

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

13860 lbs 14410 lbs6287kg 6536kg

8 in 11 in20.3cm 27.9cm

6 ft 6 ft182.8cm 182.8cm

30 in 30 in76.2cm 76.2cm

45 ft 45 ft13.72m 13.72m

23 ft 23 ft7m 7m

21 ft 7 in 21 ft 7 in6.58m 6.58m

1 inch none2.54cm

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

14 ft 4 in 14 ft 9 in4.37m 4.49m

7 ft 6 ft 8 in2.13m 2.03m

359° 359°

180° 180°

Stowed dimension 2WD 4WD

Length

WidthRough terrain

Industrial

Height

Weight

Ground clearance

Platform dimensions

Length

Width

Operational dimensions

Maximum plaform height

Maximum platform reach

Maximum up-and-overclearance

Maximum turret tailswing

Wheelbase

Minimum turning radius,outside

Minimum turning radiius,inside

Turret rotation

Platform rotation

2 - 2 Genie Z-45/22 Part No. 29487

Section 2 - Specifications Service Manual - First Edition

5.0 mph 4.8 mph8.0km/h 7.7km/h

1.1 mph 0.9 mph1.8km/h 1.4km/hor 5 feet or 4 feetin 3 sec. in 3 sec.

0.68 mph / 1km/hor 1 foot per second

0.4 mph / 0.65km/hor 0.59 feet per second

30% 40%

29 seconds

25 seconds

27 seconds

35 seconds

25 seconds

25 seconds

73 seconds

15 seconds

25 seconds

15 seconds

60 seconds

60 seconds

Dexron II equivalent

bi-directional variabledisplacement pistonpump

0 - 25 gpm0 - 1.6 liters/second

3500 psi241.3 bar

360 psi / 24.8 bar

3 micron

50 psi / 345kPa

350 psi24.1 bar

3.0 gpm11.4 liters/minute


SPECIFICATIONS

Performance Specifications

Drive speeds, maximum 2WD 4WD

Boom lowered, high range

Boom lowered, low range

Boom raised, high range

Boom raised, low range

Gradeability (stowed)

Boom function speeds maximumfrom platform controls

Boom extend

Boom retract

Primary boom lift

Primary boom lower

Secondary boom lift

Secondary boom lower

Turntable rotate (359°)

Platform rotate (180°)

Platform level up

Platform level down

Multiple functionstowed to full raised

Multiple functionfull lowered to stowed

Hydraulic Specifications

Hydraulic fluid

Drive pump

Type

Displacement

Maximum drivepressure

Charge pressure

Medium pressure filter

Medium pressure filterbypass pressure

Drive manifold

Motor shift/brakerelief pressure

4WD front motorflow regulators

4WD rear motorflow regulators

Part No. 29487 Genie Z-45/22 2 - 3


2.1 cu in / 34.4cc

High - 2.8 cu in / 45.9ccLow - 0.15 cu in / 2.5cc

2200psi138 bar

1200 psi83 bar

1200 psi83 bar


fixed displacement gearpump

6.4 gpm @ 2150 rpm0.4 liters/second

10 micron with 25psi /172kPa bypass

1800 psi

1600 psi

fixed displacement gearpump


2030 psi138 bar

SPECIFICATIONS

Front drive motors - 4WD models

Displacement per revolution

Rear drive motor

Displacement per revolution

Function pump

Type

Displacement

Function circuit returnline filter

Function manifold

Function reliefvalve pressure

Secondary down reliefvalve pressure

Primary down reliefvalve pressure

Steer/oscillateflow regulator

Steer/oscillate manifold

Sequencing valvepressure

Accumulatorpre-charge pressure

Auxillary pump

Type

Displacement

Auxillary pumprelief pressure

2 - 4 Genie Z-45/22 Part No. 29487


SPECIFICATIONS

13

20

12

18

11

18

10

16

9

14

8

12

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

10

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

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

Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts

Bolt Torque Specifications

Part No. 29487 Genie Z-45/22 2 - 5


12V, Group 24

75A

110 rpm

150A

460A

70A

0.5V DC

0.50 inches / 12.7mm

0.25 inches / 6.35mm

40 ounces

55 - 75 inch-pounds98 - 134gm-cm

15 - 20 foot-pounds2.1 - 2.7kg-m

0.005 inches / 0.127mm

SPECIFICATIONS

5.0 - 7.0 psi

1 pint / 473cc in 25seconds

875A

125 minutes

5W - 30

10W - 30

10W - 40 or 10W - 50

20W - 40 or 20W - 50

40 - 60 psi275.8 - 413.7kPa

5 quarts / 4.71 liters

0.0010 - 0.0027 inches0.025 - 0.068mm

0.0015 - 0.0032 inches0.038 - 0.081mm

140 cu in / 2.3 liters

4

3.780 x 3.126 inches96 x 79.4mm

63 @4000 rpm

1 - 3 - 4 - 2

2150 rpm

1200 rpm

Precision electronic

psi of lowest cylindermust be at least 75% ofhighest cylinder

Ford Engine LSG-423

Displacement

Number of cylinders

Bore and stroke

Horsepower

Firing order

High engine speed

Low engine speed

Governing

Compression pressure

Valve clearances

Intake

Exhaust

Lubrication System

Oil pressure (operatingtemp. @ 2150 rpm)

Oil capacity(including filter)

Oil viscosity requirements

Below 60°F / 15.5°C

-10 to 90°F / -23 to 32°C

above -10°F / -23°C

above 25°F / -4°C

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

Starter motor

Normal enginecranking speed

Current draw, normal load

Current draw, maximum load

Current draw, no load

Maximum circuitvoltage drop (normal temp)

Brush length, new

Brush length, wear limit

Brush spring tension

Bolt torque through brush

Brush mountingbolt torque

Maximum commutatorrunout

Battery

Type

Ampere hour

Cold Cranking Ampere

Reserve capacity @ 25A rate

Fuel Pump

Static pressure

Minimum volume flow

2 - 6 Genie Z-45/22 Part No. 29487


10° BTDC

1.13 - 1.25Ω (75°F)

7700 - 9300Ω (75°F)

Motorcraft AWSF-52

0.042 - 0.046 inches1.07 - 1.18mm

120 - 150 foot-pounds

90 - 120 foot-pounds

11.5 quarts/10.9 liters

35A, 14.5V

28 - 40 38 - 54

6 - 9 8 - 12

28 - 40 38 - 54

14 - 21 19 - 28

50 - 71 68 - 96

6 - 9 8 - 12

7.5 - 15 10 - 20

10 - 14 14 - 19

103 - 133 140 - 180

50 - 60 68 - 8180 - 90 108 - 122

14 - 21 19 - 28

5 - 8 7 - 11

14 - 19 19 - 2620 - 30 27 - 41

56 - 64 76 - 87

14 - 21 19 - 28

14 - 21 19 - 28

8 - 18 11 - 24

15 - 25 20 - 34

10 - 13.5 14 - 18

20 - 35 27 - 47

5 - 8 7 - 11

5 - 10 7 - 14

8 - 18 11 - 24

23 - 28 31 - 38

14 - 21 19 - 28

6 - 9 8 - 12

14 - 21 19 - 28

6 - 9 8 - 12

14 - 21 19 - 28

6 - 9 8 - 12

Cylinder head bolt / M-12torque in sequence:first stepsecond step

Distributor clamp bolt / M-10

Distributor vacuum tubeto manifold adaptor

Exhaust manifold to cylinder head bolt or nut / M-10torque in sequence:first stepsecond step

Flywheel to crankshaft bolt / M-10

Fuel pump to cylinder block / M-8

Intake manifold to cylinderhead bolt or nut / M-8

Oil pressure sendingunit to block

Oil pan drain plug to pan / M-14

Oil pan to block / M-6

Oil filter insert to block

Rocker arm cover tocylinder head / M-6

Spark plug to cylinderhead / M-14

Temperature sendingunit to block / M-14

Water jacket drain plugto block

Water pump to block bolt

Auxiliary shaft cover bolt / M-6

Water outlet connectionbolt / M-8

Cylinder front cover bolt / M-6

Inner timing belt cover stud / M-8

Outer timing belt cover bolt / M-6

SPECIFICATIONS

Ignition System

Ignition spark advance

Ignition coilprimary resistance

Ignition coilsecondary resistance

Type

Gap

Coolant capacity

Alternator output

Fan belt tension

new

used

Bolt torque specifications

Item / Size Torque Torque

(ft-lbs) (Nm)

Auxiliary shaft gear bolt / M-10

Auxiliary shaft thrustplate bolt / M-6

Belt tensioner (timing)pivot bolt / M-10

Belt tensioner (timing)adjusting bolt / M-8

Camshaft gear bolt / M-12

Camshaft thrust plate bolt / M-6

Carburetor to spacer stud / M-8

Carburetor spacer tomanifold bolt / M-8

Crankshaft damper bolt / M-14

Part No. 29487 Genie Z-45/22 2 - 7


Bosch K Type

1991 psi / 1437 bar

25° BTDC

Diesel number 2-D

7.25 quarts / 6.9 liters

35A, 14V

176.9 - 182.3°F80.5 - 83.5°C

203°F / 95°C

90A

0.7480 in. / 19mm

0.5 in. / 12.7mm

65 - 68 88 - 93

22 - 36 29 - 49

43 - 58 59 - 78

72 - 79 98 - 108

8 - 18 11 - 24

15 - 25 20 - 34

5 - 7 7 - 9

17 - 24 24 - 27

8 - 18 11 - 24

12V, Group 24

75A

875A

125 minutes

1.5Ω

0.275-0.354 in / 7 - 9mm

105.7 cu in / 1.732 liters

4

3.23 x 3.23 inches82 x 82mm

36 @2800 rpm

1 - 3 - 4 - 2

22:1

427 - 469 psi29.4 - 32.3 bar

2150 rpm

1200 rpm

centrifugal ballmechanical

0.0071 - 0.0087 inches0.18 - 0.22mm

42.7 - 64 psi294.2 - 441.3kPa

9.5 quarts / 9 liters

10W - 30

SPECIFICATIONS

Kubota Engine V1702-B

Starter motor

Current draw, no load

Brush length, new

Brush length, minimum

Battery

Type

Ampere hour

Cold cranking ampere

Reserve capacity @ 25A rate

Glow plug resistance

Fan belt tension

Bolt torque specifications

Item Torque Torque

(ft-lbs) (Nm)

Cylinder head bolt

Fuel injector nozzle holderto cylinder head

Fuel injector retaining nutto nozzle holder body

Flywheel to crankshaft bolt

Oil pressure sendingunit to block

Oil pan drain plug to pan

Rocker arm cover tocylinder head

Rocker arm mounting nuts

Temperature sendingunit to block

Thermostat

Beginning opening

Full-open

Displacement

Number of cylinders

Bore and stroke

Horsepower

Firing order

Compression ratio

Compression pressure

High engine speed

Low engine speed

Governing

Valve clearance, cold

Lubrication System

Oil pressure

Oil capacityincluding filter

Oil viscocityrequirements

Engine oil should be MIL-L-2104C or have properties ofAPI classification CC/CD/CE grades.

Injection System

Injection pump

Injection pump pressure

Injection timing

Fuel requirement

Coolant capacity

Alternator output

2 - 8 Genie Z-45/22 Part No. 29487


5 - 7 8 - 9

13 - 15 18 - 20

29 - 33 39 - 45

46 - 53 63 - 72

79 - 92 108 - 125

123 - 141 167 - 191

180 - 210 245 - 284

246 - 289 334 - 392

7 - 8 10 - 11

17 - 20 24 - 27

35 - 41 48 - 56

57 - 66 78 - 90

91 - 108 124 - 147

145 - 166 196 - 225

203 - 235 275 - 318

271 - 318 368 - 431

9 - 10 12 - 14

22 - 25 30 - 34

45 - 52 61 - 70

76 - 86 103 - 117

123 - 144 168 - 196

192 - 224 260 - 304

253 - 296 343 - 402

362 - 419 490 - 568

SPECIFICATIONS

Bolt torque specifications - continued

Size - Standard ft-lbs Nm

M-6

M-8

M-10

M-12

M-14

M-16

M-18

M-20

Size - Grade 7

M-6

M-8

M-10

M-12

M-14

M-16

M-18

M-20

Size - Grade 9

M-6

M-8

M-10

M-12

M-14

M-16

M-18

M-20

Part No. 29487 Genie Z-45/22 3 - 1

Section 3 - Scheduled Maintenance InspectionsService Manual - First Edition

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Scheduled Maintenance Inspections

About This SectionThere are two components to this section,maintenance tables and an inspection reportingform.

Maintenance Tables

The maintenance tables provide summaryinformation on the specific physical requirementsfor each inspection.

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

Maintenance Inspection Report

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

· Daily inspectionUse checklist A

· Frequent inspection (every 150 hoursor three months)Use checklists A and B

· Annual inspectionUse checklists A, B and C

· Two year inspectionUse checklists A, B, C and D

Make copies of this form to use for eachinspection. Store completed forms for three years.

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 themaintenance inspection report.

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

3 - 2 Genie Z-45/22 Part No. 29487

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

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Maintenance Tables

A-1 Inspect the Operating Instruction and Safety Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Engine Oil Level

A-5 Check the Engine Coolant Level

A-6 Check for Fuel Leaks

A-7 Check the Hydraulic Oil Level

A-8 Check for Hydraulic Leaks

A-9 Check Tire Pressure

A-10 Test the Platform and Ground Controls

A-11 Test Auxiliary Power Operation

A-12 Test the Tilt Level Sensor

A-13 Test the Limit Switches

Every 100 hours, check for and/or perform as necessary theengine maintenance procedures listed below.

A-14 Replace the Engine Oil and Filter

A-15 Change the Engine Air Filter

A-16 Drain the Fuel Filter/Water Separator - Diesel Models

Table A

Part No. 29487 Genie Z-45/22 3 - 3


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MAINTENANCE TABLES

B-1 Check the Engine Fan Belts

B-2 Check the Radiator

B-3 Check the Exhaust System

B-4 Check the Battery

B-5 Check the Hydraulic Reservoir Filter Condition Indicator

B-6 Inspect Electrical Wiring

B-7 Inspect the Tires and Wheelsincluding lug nut torque

B-8 Confirm Proper Brake Configuration

B-9 Check the Oil Level in the Torque Hubs

B-10 Check the Engine Choke - Gasoline/LPG Models

B-11 Check the Glow Plugs - Diesel Models

B-12 Check and Adjust the Engine Idle Mixture- Gasoline/LPG Models

B-13 Check and Adjust the Engine RPM

B-14 Test the Key Switch

B-15 Test the Emergency Stop Buttons

B-16 Test the Ground Control Override

B-17 Test the Oscillate Lock-outoscillating axle equipped models

Table B

3 - 4 Genie Z-45/22 Part No. 29487


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MAINTENANCE TABLES

Table B, continued

B-18 Test Platform Self-leveling

B-19 Test the Service Horn

B-20 Test the Foot Switch

B-21 Test the Engine Speed Select

B-22 Test Fuel Select Operation - Gasoline/LPG Models

B-23 Test the Turntable Rotation Stop

B-24 Test the Drive Enable System

B-25 Test the Drive Brakes

B-26 Test Drive Speed - Stowed Position

B-27 Test the Alarm Package (optional equipment)travel alarm, descent alarm, flashing beacon

Table C

C-1 Check the Primary Boom Wear Pads

C-2 Check the Turntable Rotation Bearing Bolts

C-3 Check the Free-wheel Feature

C-4 Grease the Worm Drive Gearincluding turntable rotation bearing

C-5 Replace the Torque Hub Oil

C-6 Replace the Hydraulic Reservoir Filter

Part No. 29487 Genie Z-45/22 3 - 5


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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 Clean or Replace the Distributor Cap and Rotor - 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 - Gasoline/LPG Models

Table C, continued

MAINTENANCE TABLES

Table D

D-1 Change 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/LPG Models

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

D-6 Clean PCV Hoses and Fittings - Gasoline/LPG Models

D-7 Check the Engine Nozzle Injection Pressure - Diesel Models

D-8 Check Injection Timing - Diesel Models

D-9 Replace the Timing Belt - Ford

3 - 6 Genie Z-45/22 Part No. 29487


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Refer to Table A

A-1 Operation andSafety 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

A-15 Change engine air filter

A-16 Drain fuel filter/waterseparator-diesel

Checklist B Y N R

Refer to Table B

B-1 Fan belts

B-2 Engine radiator

B-3 Exhaust system

B-4 Battery

B-5 Hydraulic reservoir filter

B-6 Electrical wiring

B-7 Tires and wheels

B-8 Brake configuration

B-9 Drive torque hubs

B-10 Engine choke-gasoline

B-11 Glow plugs-diesel

B-12 Idle mixture-gasoline

B-13 Engine RPM

B-14 Key switch

B-15 Emergency Stop button

B-16 Ground control override

B-17 Oscillate lock-out

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

Maintenance Inspection Report

B-18 Platform leveling

B-19 Service horn

B-20 Foot switch

B-21 Engine speed select

B-22 Fuel select-gasoline

B-23 Turntable rotation stop

B-24 Drive enable system

B-25 Drive brakes

B-26 Drive speed

B-27 Alarm package

Checklist C 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 reservoir filter

C-7 Drive loop hydraulic filter

C-8 Fuel filter-diesel

C-9 Fuel filter-gasoline

C-10 PCV valve-gasoline

C-11 Distibutor cap-gasoline

C-12 Spark plugs

C-13 Propane adjustments

C-14 Ignition timing-gasoline

Checklist D 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 Engine injection nozzle-diesel

D-8 Injection timing-diesel

D-9 Timing belt-Ford

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Part No. 29487 Genie Z-45/22 4 - 1

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

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.

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.

4 - 2 Genie Z-45/22 Part No. 29487

Service Manual - First EditionSection 4 - Scheduled Maintenance Procedures

A-1Inspect the Operating Instructionand Safety Manuals

Maintaining the Operating Instruction and Safetymanuals in good condition is essential to safemachine operation. Manuals are included witheach machine and should be stored in the boxprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to make sure that the OperatingInstruction and Safety manuals are present inthe storage box in the platform.

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

3 Always return the manuals to the storage boxafter 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 OperatingInstructions 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 tanks

· drive and swing motors and gear boxes

· boom components and wear pads

· tires and wheels

· engine and related components

· limit switches, alarms, horns and beacon

· nuts, bolts and other fasteners

· cracks in welds or structural components

Table A Procedures

Part No. 29487 Genie Z-45/22 4 - 3


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.

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

Diesel models:

· diesel tank, shutoff valve, solenoid shutoffvalve, hoses and fittings, fuel pump, fuel filter/water separator, fuel injection pump, fuelinjectors

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

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

Result: The fluid level should be in the normalrange.


5W-30

10W-30

10W-40 or 10W-50

20w-40 or 20W-50


10W-30

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.

Specifications

Ford Engine LSG 423 Lubrication System

Oil capacity


below 60F / 15.5C

-10 to 90F / -23 to 32C

above -10F / -23C

above 25F / -4C

Kubota Engine V1702-B Lubrication System

Oil capacity

Oil viscosityrequirements

Engine oil should be MIL-L-2104C or have theproperties of AI classification CC/CD/CE grades.

A-5Check the Engine Coolant Level

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.

TABLE A PROCEDURES

4 - 4 Genie Z-45/22 Part No. 29487


· all cylinders

· all valve manifolds

· elevate and primary booms

· the underside of the chassis

· ground area under the machine


25 gallons / 95 litersDo not overfill

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 reservoir—fittings, hoses andturntable surface

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

9-14.5LT100 psi / 6.89 bar

14-17.5NHS40 psi / 2.76 bar

14-17.5NHS28 psi / 1.93 bar

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.

Specifications

Hydraulic oil type

Reservoir capacity

A-9Check Tire Pressure

This procedure does not need tobe performed on machinesequipped with the foam-filled tireoption.

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.

Specifications

2WD model

industrial tire

rough terrain tire

4WD model

rough terrain tire

TABLE A PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 5


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.

2 Simultaneously hold the auxiliary power switchon while activating the following functionsthrough a partial cycle:

· primary boom up/down

· extend and retract

· elevate up/down

· turntable rotate right/left

Result: Each function should operate smoothly.

3 Turn the key switch to platform control.

4 At the platform controls, pull out theEmergency Stop button to the on position,press down the foot switch and repeat step 2.

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.

TABLE A PROCEDURES

4 - 6 Genie Z-45/22 Part No. 29487


1 foot / 0.3 meter persecond

· broken or missing rollers or arms

· missing fasteners

· loose wiring

2 Start the engine from the ground controls.

3 Raise the primary boom above the drive 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 platformcontrols.

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.

Specifications

Elevated position

2WD and 4WD

A-12Test the Tilt Level Sensor

The tilt sensor sounds an alarm in the platformwhen the incline of the chassis exceeds 3°.

Select a level test area.

1 Start the engine fromthe platform controls.

2 Open the engine sidecover and pressdown on one side ofthe tilt sensor.

Result: After a 1second delay, thealarm in the platformshould sound. a

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 over the steeringwheels, and stops drive movement unless thedrive enable override switch is used. The drivelimit switch is used to restrict drive speed whenthe boom is raised and signal the oscillate cylinderto extend 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:

TABLE A PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 7


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 swing the turntable to the left until theplatform is positioned over the left steer wheel.

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

4 Swing the turntable to the right until theplatform is positioned over the right steerwheel.

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

a

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 boom above the drive speed limitswitch.

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

b

a

TABLE A PROCEDURES

4 - 8 Genie Z-45/22 Part No. 29487


a pivot plate boltsb oil drain hose

A-14Replace the Engine Oil and Filter

Engine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditionsexist or the machine is subjectedto extended low idle operation.

Periodic replacement of the engine oil and filter isessential to good engine performance. Operatingthe machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily check ofelapsed machine hours against the hours noted onthe 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 the valvecover.

2 Pull the end of the oil 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 container capable of holding 3gallons.

4 Re-install the plug into the drain hose.

5 Use an oil filter wrench and remove the filter.

Ford models: Remove the 3 bolts from theengine pivot plate. Swing the engine pivot plateaway from the machine to access the oil filter.

6 Apply a thin layer of oil to the new oil filtergasket. Then install the filter and tighten itsecurely by hand.

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

8 Start the engine from the ground controls.Allow the engine to run for 30 seconds andthen turn the engine off.

9 Check the oil filter and the oil drain hose forleaks.

10 Use an indelible ink marker to write the dateand number of hours from the hour meter onthe oil filter.

Ford Models: Swing the engine pivoy plateback to its original position and replace thethree retaining bolts.

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

a b a a

TABLE A PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 9



5W-30

10W-30

10W-40 or 10W-50

20W-40 or 20W-50


10W-30

Specifications

Ford Engine LSG 423 Lubrication System

Oil capacity


below 60F / 15.5C

-10 to 90F / -23 to 32C

above -10F / -23C

above 25F / -4C

Kubota Engine V1702-B Lubrication System

Oil capacity

Oil viscosityrequirements

Engine oil should be MIL-L-2104C or have theproperties of AI classification CC/CD/CE grades.

A-15Change the Engine Air Filter

Engine 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 component damage.

Perform this procedure with theengine off.

1 Remove the end cap from the air cleanercanister.

Kubota models: Remove the aircleaner canister mounting strapsthen the end cap.

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

3 Insert the new air filter and replace themounting fasteners.

4 Replace the end cap on the canister.

TABLE A PROCEDURES

4 - 10 Genie Z-45/22 Part No. 29487


A-16Drain the Fuel Filter/ WaterSeparator - Diesel Models

Engine specifications require thatthis procedure be performed every100 hours, along with an oil andfilter change. Poor fuel quality orvery wet conditions maynecessitate performing thisprocedure more often.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedurecan lead to poor engine performance andcomponent damage.


Engine fuels are explosive.Perform this procedure in anopen, well-ventilated area awayfrom heaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

1 Loosen the vent plug located on the fuel filter/water separator head.

2 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into acontainer until fuel starts to come out.Immediately tighten the drain plug.

3 Tighten the vent plug and clean up any spills orwet surfaces.

If the fuel bowl is completelydrained, you must prime the fuelfilter/water separator beforestarting the engine. Refer to C-8in this section, Replace TheDiesel Fuel Filter, for instructionson how to prime the fuel filter/water separator.

4 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

Fuel filter/water seperator

a head boltb filter bowlc drain plugd vent pluge separator head

a

e

d

b

c

TABLE A PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 11


3/8 inch - 1/2 inch0.9cm - 1.2cm

B-1Check the Engine Fan Belts

Maintaining the engine fan belts is essential togood engine performance and service life. Themachine will not operate properly with a loose ordefective belt and continued use may causecomponent damage.

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

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

1 Inspect the enginefan belts for:

· cracking

· glazing

· separation

· breaks

2 Check the engine fan belts for proper tension.

Specifications

Belt Deflection

Table B Procedures

check allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.



1 Inspect the radiator for leaks and physicaldamage.

2 Clean the radiator fins of debris and foreignmaterials.

B-2Check the Radiator

Maintaining 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 frequent

B-3Check 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.



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.

4 - 12 Genie Z-45/22 Part No. 29487


B-4Check 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-5Check the Hydraulic ReservoirFilter Condition Indicator

Maintaining 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.

b

c

TABLE B PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 13


B-7Inspect 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.

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.

9 @ 5/8-18

8 @ 5/8-188 @ 5/8-18

9 @ 5/8-189 @ 5/8-18125 ft-lbs125 ft-lbs169.5 Nm169.5 Nm

14-17.5NHS9 - 14.5 LT

Tread 8Tread 8

Sidewall 6

40 psi100 psi2.76 bar6.89 bar

28 psi1.93 bar

Specifications:

Tires and Wheels Rough terrain Industrial

Wheel lugs - 4WD

Wheel lugs - 2WDfrontrear

Lug nut torque

Tire size

Tire ply rating

Tire pressure - 2WD

Tire pressure - 4WD

B-6Inspect 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

TABLE B PROCEDURES

4 - 14 Genie Z-45/22 Part No. 29487


17 fluid ounces / 0.5liters

SAE 90 multipurposehypoid gear oil - APIservice classification GL5

B-8Confirm 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

B-9Check 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, then re-install the plugs into thehub.

4 Repeat this procedure for each torque hub.

Specifications

Capacity

Type

b

c

a

TABLE B PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 15


B-10Check the Engine Choke -Gasoline/LPG Models

Automatic Choke

The machine is equipped with anautomatic choke if a choke switchcan't be found near the startswitch. The automatic choke doesnot need to be inspected oradjusted unless the followingconditions exist:

· The machine does not starteasily in cold temperatures.

· The engine does not runsmoothly after a cold start.See 7-4, Choke Adjustments.

Manual Choke

A properly functioning choke is essential to goodengine performance. An improperly functioningchoke will result in difficulty with engine starting.

1 Check the choke linkage connections.

a linkageb carburetorc linkage lock nutsd choke solenoid

2 Turn the key switch to ground control and thenpull out the ground control Emergency Stopbutton to the on position.

3 While operating the choke switch, inspect thechoke solenoid.

Result: The choke solenoid should be fullyretracted when the choke switch is activated.

4 Turn the key switch to platform control.

5 Pull out the platform control Emergency Stopbutton to the on position and then operate thechoke switch and listen for choke solenoidoperation.

a

d c

b

B-11Check the Glow Plugs - Diesel Models

Maintaining the glow plugs in good condition isessential to good engine performance and servicelife. Improperly functioning glow plugs will causethe engine to perform poorly and may result incomponent damage.

Perform this procedure with theengine turned off.

1 Connect an ohmmeter between the far leftglow plug and machine ground.

Result: The resistance should be approximately0.4Ω.

2 If the ohm reading is different than 0.4Ω,remove each wire from the four individual glowplugs. Then, one glow plug at a time, check theresistance between the glow plug and machineground.

Result: The resistance should be approximately1.6Ω for each individual glow plug.

3 Turn the machine on, but do not start theengine.

4 Connect a volt meter to the number four glowplug and machine ground.

5 Hold the glow plug switch in the on position.

Result: The volt meter should read 12 volts.

TABLE B PROCEDURES

4 - 16 Genie Z-45/22 Part No. 29487


B-13Check and Adjustthe Engine RPM

Maintaining 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.

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

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

Result: Low idle should be 1200 rpm.

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

2 Turn the idle adjustment screw clockwise toincrease rpm or counterclockwise to decreaserpm.

B-12Check 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.

a

Ford low idle adjustment

a adjustment screw

Ford high idle adjustment

a

3 Move the engine speed control switch to highidle (rabbit symbol) from the ground controls.

Result: High idle should be 2150 rpm.

Adjust high idle rpm, if necessary, byfollowing the appropriate steps for the enginemodel:

Ford engines: 4 through 7

4 Turn the engine off.

5 Remove the mounting fasteners from theelectronic governor located on the relay panel,and then remove the back panel from thegovernor.

Electrocution Hazard. Contactwith hot or live circuits may resultin death or serious injury. Removeall rings, watches and otherjewelry.

6 Restart the engine, turn the speed set screwclockwise to increase rpm or counterclockwiseto decrease rpm.

a high idle adjustment

a

Kubota low idle adjustmenta adjustment screw

TABLE B PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 17


B-14Test 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.

7 Re-assemble the governor and recheck highidle rpm.

Kubota engines: 8 through 11

8 Turn the engine off.

9 Loosen the lock nut on the Trombetta solenoid,and then pull the rubber boot off the solenoid.

Kubota high idle adjustment

a b c

d

1200 rpm

2150 rpm

a rubber bootb adjustment nutc lock nutd yoke

10 Screw the adjustment nut into the yoke toincrease the rpm. Back the adjustment nut outof the yoke to decrease rpm.

Be sure that the stop screw on thegovernor throttle lever does notlimit solenoid travel. The solenoidmust fully retract when energizedto prevent solenoid damage.

11 Reconnect the rubber boot to the solenoid.Then tighten the lock nut and recheck the rpm.

Specifications

Ford and Kubota Engines

Low idle

High idle

TABLE B PROCEDURES

4 - 18 Genie Z-45/22 Part No. 29487


B-15Test the Emergency Stop Buttons

Properly 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.

ground 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 Ground Control Override

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from the

B-17Test 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.

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.

b

a

TABLE B PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 19


B-19Test 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.

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-18Test 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-20Test 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.

3 inches

a

TABLE B PROCEDURES

4 - 20 Genie Z-45/22 Part No. 29487


B-21Test the Engine Speed Select

A properly operating engine rpm select switch isessential to good engine performance and safemachine operation. There are three rpm settings:

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

Low idle (turtle symbol) mode allows the operatorto control individual boom functions only.

High idle (rabbit symbol) mode allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains a consistenthigh idle and usually selected only when thegenerator option is being used.

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).

2150 rpm

1200 rpm

Result: The engine should not change to highidle.

8 Press down the foot switch.


Specifications

High idle

Low idle

B-22Test Fuel Select Operation -Gasoline/LPG Models

The 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.

TABLE B PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 21


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-23Test the Turntable Rotation Stop

The 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 Swing the turntable to the left as far as it willgo.

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

3 Swing 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-24Test the Drive Enable System

Proper drive enable system operation is essentialto safe machine operation. When the platform isover the steering wheels, drive movement is

stopped 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 Swing the turntable to the right until theplatform is positioned over the right steerwheel.

Result: Platform over steer wheel indicator lightshould turn on.

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 Swing the turntable to the left until platform ispositioned over the left steer tire.

Result: Platform over steer wheel indicator lightshould come on.

6 Repeat steps 3 and 4.

TABLE B PROCEDURES

4 - 22 Genie Z-45/22 Part No. 29487


2.85 seconds (±0.25seconds)

2.75 seconds (±0.25seconds)

5.5 to 6 feet /1.67 to 1.82 meters

TABLE B PROCEDURES

B-25Test the Drive Brakes

Proper 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 (2 wheel symbol).

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,normal operating temp.

B-26Test Drive Speed - StowedPosition

Proper 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 (2 wheel symbol).

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

2WD

Part No. 29487 Genie Z-45/22 4 - 23


TABLE B PROCEDURES

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 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-27Test 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.

4 - 24 Genie Z-45/22 Part No. 29487


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 (2m) off theground.

3 Be sure that each turntable bolt is torqued to190 foot-pounds (258 Newton meters).

Bolt torque sequence

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

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

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

C-1Check the Primary BoomWear Pads

Maintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom surfaces toprovide a low friction, replaceable wear padbetween moving parts. Improperly shimmed wearpads or continued use of worn out wear pads mayresult in component damage and unsafe operatingconditions.

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

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

3 Measure each wear pad. Replace the pad if it isless than 0.41 inches (1cm) thick. If the pad ismore than 0.41 inches (1cm) 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.

Always maintain squarenessbetween the primary boom outerand inner tubes.

b

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 (78cm) block between the chassiscounterweight and the upper mid-pivot.Carefully lower the secondary boom onto theblock.

Table C Procedures

a

c

16

1

3

7

10

12

13

14

22

18

4

195

15

23

221

8

11

17

24

620 9

Part No. 29487 Genie Z-45/22 4 - 25


TABLE C PROCEDURES

7 Carefully lower and remove the counterweight.

8 Be sure that each bearing mounting bolt. istorqued to 190 foot-pounds (258 Newtonmeters).

Bolt torque sequence

9 Reinstall the counterweight.

2

5

6

12

13

14

18

11

8

16

17

7

151

43

9

10

C-3Check the Free-wheel Feature

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

Collision hazard. Select a worksite that is firm and level.

Rear drive wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

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

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

brake disengage position

brake engage position

a

4 Disengage the rear brakes by turning over thetorque hub disconnect caps on each rear wheelhub.

5 Manually rotate each rear wheel.

Result: Each rear wheel should rotate withminimum effort.

6 Re-engage the brakes by turning over the hubdisconnect caps. Carefully remove the jackstands, lower the machine and remove thejack.

Collision hazard. Failure to re-engage the brakes may result indeath 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 front axle andcenter 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

c

b

4 - 26 Genie Z-45/22 Part No. 29487


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 to closethe free-wheel valve may result indeath or serious injury andproperty damage.

TABLE C PROCEDURES

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

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(78cm) block between the chassis counter-weight and the upper mid-pivot. Carefully lowerthe secondary boom onto the block.



b

a

c

a

b

Part No. 29487 Genie Z-45/22 4 - 27


17 fluid ounces0.5 liters

SAE 90 multipurposehypoid gear oil. APIclassification GL5

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.Then re-install the plugs.

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

Specifications

Capacity

Type

C-6Replace theHydraulic Reservoir Filter

Replacement of the hydraulic reservoir 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 and tighten it securely byhand. Clean up any oil that may have spilledduring the installation procedure.


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

4 - 28 Genie Z-45/22 Part No. 29487


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.



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 and hand tighten thehousing onto the filter head. Clean up any oilthat may have spilled during the installationprocedure.


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

C-8Replace the Diesel Fuel Filter

Replacing 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 frequently.

Engine fuels are combustible.Replace the fuel filter in an open,well-ventilated area away fromheater, sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


c

b

e

da

Fuel filter/water seperatora vent plugb filter bowlc drain plugd seperator heade head bolt

1 Loosen the vent plug located on the fuel filter/water separator head.

2 Place a container under the bowl and thenloosen the drain plug located at the bottom ofthe bowl. Completely drain the bowl.

3 Loosen the head bolt then rotate the bowlcounterclockwise and remove it.

Part No. 29487 Genie Z-45/22 4 - 29


TABLE C PROCEDURES

4 Remove the filter element from the bowl.

5 Apply a thin layer of oil onto the bowl gasketand then install the new filter element.

6 Tighten the drain plug and fill the bowl withclean diesel fuel.

7 Install the bowl onto the filter head, and thentighten the head bolt to 65 inch-pounds (7Nm).

8 Tighten the vent plug.

9 Clean up any diesel that may have spilledduring the installation procedure.

10 Start the engine from the ground controls, theninspect the fuel filter water separator and hosesfor leaks.


C-9Replace the Gasoline Fuel Filter

Replacing the gasoline fuel filter is essential togood engine performance and service life. A dirtyor clogged 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 andlighted tobacco. Always have anapproved fire extinguisher withineasy 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, pointingtoward the carburetor. Tighten the bracketmounting bolt, then reconnect the fuel hoses tothe 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,then inspect the fuel filter and hoses for leaks.


a

a

a

4 - 30 Genie Z-45/22 Part No. 29487


TABLE C PROCEDURES

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

Yearly replacement of the PCV valve is essentialto good engine performance. A malfunctioningvalve can impair crankcase ventilation and maycause engine 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

ba

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 dirtyor worn 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 replacedmore frequently.


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.

a

a

a

Part No. 29487 Genie Z-45/22 4 - 31


TABLE C PROCEDURES

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 isessential to good engine performance and servicelife. Worn, loose or corroded spark plugs willcause the engine to perform poorly and may resultin component damage.

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)

Gap

Torque specs

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 anopen, well-ventilated area awayfrom heaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach..

The engine rpm needs to bepreset for gasoline fuel operationbefore adjusting the propane idlemixture.

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

a b c d

AWSF-42

0.032 - 0.036 inches0.81 - 0.91mm

5 - 10 foot-pounds6.8 - 13.6 Nm

4 - 32 Genie Z-45/22 Part No. 29487


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,using an 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 lowidle (turtle symbol) and adjust the low idlescrew to obtain an air-to-fuel mixture ratio of13.0:1 to 13.2:1.

C-14Check and Adjust the IgnitionTiming - Gasoline/LPG Models


TABLE C PROCEDURES

Part No. 29487 Genie Z-45/22 4 - 33


25 gallons95 liters

30 gallons114 liters


D-1Change the Hydraulic Oil

Replacement of the hydraulic oil is essential forgood machine performance and service life. Dirtyoil and suction strainers may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed morefrequently.

Perform this procedure with themachine in the fully stowedposition.

1 Close the two hydraulic tank valves located atthe main pump.

2 Remove the drain plug from the hydraulicreservoir.


3 Completely drain the reservoir into a container.See capacity specifications listed below.

4 Disconnect and cap the two 1 inch (2.5cm)suction hoses that are attached to thereservoir.

5 Remove the strainer assemblies from thereservoir.

6 Carefully clean any foreign material from thestrainers.

open closed

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

8 Apply pipe thread sealant to the drain plug, andthen re-install it in the reservoir.

9 Re-install the two suction hoses.

10 Fill the reservoir with hydraulic oil until the levelis within the top 2 inches (5cm) of the sightgauge. Do not overfill.

11 Clean up any oil that may have spilled and re-open the hydraulic tank valves.

12 Prime the pump by doing the following:

Gasoline/LPG models:

Disconnect the ignition coil wire and isolate itfrom ground.

Diesel models:

Disconnect the wiring to the injection pumpfuel-on solenoid

All models:

Crank the engine with the starter motor for 15seconds.

13 Reconnect the wiring and start the engine fromthe ground controls. Check the hydraulicreservoir for leaks.

Specifications

Hydraulic tank capacity

Hydraulic systemcapacity (including tank)

Hydraulic fluid

Table D Procedures

4 - 34 Genie Z-45/22 Part No. 29487




TABLE D PROCEDURES

D-2Change or Recondition theEngine Coolant

Replacing 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.

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.

Ford models: Remove the 3 bolts from theengine pivot plate. Swing the engine pivot plateaway from the machine to access the radiatorpetcock.

4 Open the petcock on the radiator and allowcoolant to drain into a container.

a pivot plate bolt

5 After all the coolant has drained, close thepetcock. Reconnect the coolant return hose tothe radiator.

6 Open the petcock on the engine block andallow the coolant to drain into a container. Afterthe fluid is drained, close the petcock.

a

a

a

7 Replace all coolant hoses and clamps.

8 Pour the proper coolant mixture (anti-freeze &water) for your climate into the radiator until itis full.

9 Disconnect hose a from hard line b and holduntil coolant starts to pour out of the openhose. Then immediately reconnect the hose.

a hoseb hard line

10 Re-fill the radiator and then fill the coolantrecovery tank.

11 Clean up any coolant spilled during thisprocedure.

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

13 Inspect for leaks and then check the fluid levelin the coolant recovery tank. Add water ifneeded.

Specifications

Ford Engine LSG 423

coolant capacity

Kubota Engine V1702-B

coolant capacity

a b

Part No. 29487 Genie Z-45/22 4 - 35


TABLE D PROCEDURES

Diesel modelsa hose from the injector to the fuel tankb hoses connecting injectorsc hose from the injection pump to the injectorsd hose from the fuel shutoff valve to the fuel pumpe hose from the fuel filter/water separator

to the injection pumpf hose from the fuel pump to the fuel/water

separator

Once air has been introduced intothe diesel fuel injection system,the injectors must be bled beforethe engine is restarted. Refer tothe Kubota V1702-B DieselEngine Workshop Manual (Kubotacode number: 97897-00691) forinformation on how to bleed thefuel system. Genie part number29587.

D-3Change the Fuel Lines

Maintaining the fuel lines in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel line may result in an unsafe operatingcondition, poor engine performance andcomponent damage.

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


1 Raise the primary boom, until the end of theboom is approximately eight feet off theground.

2 Close the manual fuel shut off valve, locatednext to the fuel tank.

3 Remove and replace the fuel line hosesaccording to the following illustrations:

Fuel may be expelled underpressure. Wrap a cloth aroundfuel hoses to absorb leaking fuelbefore disconnecting them. Plugall open fuel lines.

b ba

ef d c

b

4 - 36 Genie Z-45/22 Part No. 29487


TABLE D PROCEDURES

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

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

5 Start the machine from the ground controls,then inspect the fuel filter and hoses for leaks.


d

c

a b

D-5Check Engine CylinderCompression - Gasoline/LPGModels


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


Part No. 29487 Genie Z-45/22 4 - 37


TABLE D PROCEDURES

Gasoline/LPG models(shown with distributor cap removed)a 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.

c

baD-6Clean PCV Hoses and Fittings -Gasoline/LPG Models

Maintaining 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 frommachine to access the PCV hoses.

a pivot plate bolt

2 Disconnect the 2 hoses from the PCV valve,then disconnect the 2 hoses from the engine.

a

a

a

4 - 38 Genie Z-45/22 Part No. 29487


TABLE D PROCEDURES

D-7Check the Engine Nozzle InjectionPressure - Diesel Models

Complete information to perform this procedure isavailable in the Kubota V1702-B Diesel EngineWorkshop Manual (Kubota code number: 97897-00691). Genie part number 29587.

D-8Check Injection Timing- Diesel Models

Complete information to perform this procedure isavailable in the Kubota V1702-B Diesel EngineWorkshop Manual (Kubota code number: 97897-00691). Genie part number 29587.

D-9Replace the Timing Belt - Ford


Part No. 29487 Genie Z-45/22 4 - 39


4 - 40 Genie Z-45/22 Part No. 29487


Part No. 29487 Genie Z-45/22 5 - 3

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Engine Will NotCrank Over

Be sure the key switchis in the appropriateposition.

Be sure theemergency stop buttonis pulled up into the onposition.

Be sure the circuitbreaker is not tripped.

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5 - 4 Genie Z-45/22 Part No. 29487

Service Manual - First EditionSection 5 - Troubleshooting Flow Charts

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.

Perform these tests ingasoline mode.

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Engine CranksOver But WillNot Start -Gasoline/LPGModelsContinuation of“good spark” fault pathfrom previous flowchart.

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Engine CranksOver But WillNot Start -Diesel ModelsBe sure to check theengine oil level and fillas needed.

Be sure to check fuellevels and enginecoolant level.

Be sure the dieselshut-off valve is in theon position. Be sureengine glow plugsoperate normally, seeMaintenance section.

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Engine ChokeInoperative -Gasoline/LPGModelsBe sure machine isequipped with manualchoke.

Be sure chokesolenoid to carburetorlinkage is in place andproperly attached.

Be sure chokesolenoid plunger canbe manually pushedinto the solenoid andthe linkage in turnrotates the choke platelinkage.

Be sure fuel selectswitch is in thegasoline position.

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Engine Will NotStart On LPG,But Will StartOn Gasoline -Gasoline/LPGModelsBe sure fuel selectswitch is switched toLPG.

Be sure to check LPGfuel level.

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Engine Will NotStart onGasoline, ButWill Start onLPG- Gasoline/LPGModelsBe sure fuel selectswitch is switched togasoline.

Be sure to checkgasoline fuel level.

Be sure that enginechoke is operatingproperly.

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Engine HighIdle Inoperative- Gasoline/LPGModelsIf high idle operates onLPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If high idle operates ongasoline but not onLPG, see Repairsection for LPGregulator adjustments.

Be sure throttle linkagefrom governor tocarburetor is notbinding, see Repairsection.

Be sure high idle canbe achieved bygrasping the governoractuator arm andmomentarily pulling tothrottle the carburetor.

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Engine LowIdle Inoperative- Gasoline/LPGModelsIf low idle operates onLPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If low idle operates ongasoline but not onLPG, see Repairsection for LPGregulator adjustments.

Be sure throttle linkagefrom governor tocarburetor is notbinding, see Repairsection.

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Engine HighIdle Inoperative- Diesel ModelsBe sure mechanicallinkage from 2-speedto fuel injector pump isnot binding ordefective.

Be sure PR2 relay and2-speed solenoidgrounding wires arefree of corrosion andhave full continuity toground.

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5 - 20 Genie Z-45/22 Part No. 29487


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All FunctionsInoperative,Engine Startsand Runs

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All Lift andSteerFunctionsInoperative,DriveFunctionsOperationalBe sure the hydraulicsuction line shutoffvalve for the lift/steerpump is in the openposition.

Be sure all groundingwires for the hydraulicmanifold valves arefree of corrosion andhave full continuity toground.

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5 - 22 Genie Z-45/22 Part No. 29487


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GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingplatform controls.

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PlatformControlsInoperative,GroundControlsOperateNormallyBe sure all cables arein good condition withno kinks or abrasions.

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SecondaryBoom UpFunctionInoperativePerform this test only ifthe boom is in the fullylowered position.

Be sure all otherfunctions operatenormally.

If secondary boom upfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If secondary boom upfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

Note: Oscillating axleequipped models, fromthe stowed position theauxiliary power can notraise the boom abovethe drive limit switch.Auxiliary power canraise the boom if it isalready raised abovethe drive limit switch.

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SecondaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally includingsecondary up function.

If secondary boomdown function operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If secondary boomdown function operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Chart 18

Primary BoomUp FunctionInoperativeBe sure all otherfunctions operatenormally.

If primary boom upfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If primary boom upfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

Note: Oscillating axleequipped models, fromthe stowed position theauxiliary power can notraise the boom abovethe drive limit switch.Auxiliary power canraise the boom if it isalready raised abovethe drive limit switch.

5 - 30 Genie Z-45/22 Part No. 29487


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Primary BoomDown FunctionInoperativeBe sure all otherfunctions operatenormally includingprimary up function.

If primary boom downfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If primary boom downfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

5 - 32 Genie Z-45/22 Part No. 29487


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Part No. 29487 Genie Z-45/22 5 - 33


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Chart 20

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Primary BoomExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

If primary boom extendfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller.See Repair section.

If primary boom extendfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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5 - 34 Genie Z-45/22 Part No. 29487


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Part No. 29487 Genie Z-45/22 5 - 35


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Chart 21

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Primary BoomRetractFunctionInoperativeBe sure all otherfunctions operatenormally includingprimary extendfunction.

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 butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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5 - 36 Genie Z-45/22 Part No. 29487


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Chart 22

TurntableRotateFunctionInoperativeBe sure all otherfunctions operatenormally.

If turntable rotatefunction operatesnormally from theground controls but notfrom 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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Part No. 29487 Genie Z-45/22 5 - 37


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5 - 38 Genie Z-45/22 Part No. 29487


Chart 23

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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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Part No. 29487 Genie Z-45/22 5 - 39


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Chart 24

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally includingturntable rotate leftfunction.

If turntable rotate rightfunction operatesnormally from theground controls but notfrom 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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5 - 40 Genie Z-45/22 Part No. 29487


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Chart 25

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure both automaticand manual platformleveling do notoperate.

If automatic levelingoperates but manualleveling does not,troubleshoot PlatformLeveling Up FunctionInoperative.

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Part No. 29487 Genie Z-45/22 5 - 41


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Chart 26

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Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level upfunction operatesnormally from theground controls but notfrom 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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5 - 42 Genie Z-45/22 Part No. 29487


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Chart 27

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level downfunction operatesnormally from theground controls but notfrom 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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Part No. 29487 Genie Z-45/22 5 - 43


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Chart 28

Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform rotate leftfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controltoggle switch. SeeRepair section.

If platform 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. 29487


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Platform RotateRight FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform rotate rightfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controltoggle switch. SeeRepair section.

If platform rotate rightfunction operatesnormally from theplatform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch. SeeRepair section.

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Chart 29

Part No. 29487 Genie Z-45/22 5 - 45


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OscillateLock-outFunctionInoperative

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5 - 46 Genie Z-45/22 Part No. 29487


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Steer LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

Machines not equippedwith oscillating axle,disregard the steerunloader valvetroubleshooting.

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Part No. 29487 Genie Z-45/22 5 - 47


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Steer RightFunctionInoperativeBe sure all otherfunctions operatenormally.

Machines not equippedwith oscillating axle,disregard the steerunloader valvetroubleshooting.

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5 - 48 Genie Z-45/22 Part No. 29487


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All DriveFunctionsInoperative,All OtherFunctionsOperateNormallyBe sure the hydraulicsuction line valve is inthe open position.

Be sure machine is notin the free wheelconfiguration.

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Part No. 29487 Genie Z-45/22 5 - 49


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5 - 50 Genie Z-45/22 Part No. 29487


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Drive ForwardOr ReverseFunctionInoperativeBe sure all otherfunctions operatenormally includingdrive in oppositedirection ofmalfunction.

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Part No. 29487 Genie Z-45/22 5 - 51


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High RangeDrive FunctionInoperativeBe sure all otherfunctions operatenormally includingdrive low range (fourwheel symbol).

Be sure all drivemanifold solenoid valvegrounding wires arefree of corrosion andhave full continuity toground.

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Part No. 29487 Genie Z-45/22 5 - 53


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Low RangeDrive FunctionInoperativeBe sure all otherfunctions operatenormally includingdrive high range (twowheel symbol).

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5 - 54 Genie Z-45/22 Part No. 29487


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Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

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Chart 37

Part No. 29487 Genie Z-45/22 6 - 1


Schematics

About This SectionThere are two groups of schematics in thissection. An illustration legend precedes eachgroup of drawings.

Electrical Schematics


Hydraulic Schematics

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.

General Repair Process

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.

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in the GenieZ-45/22 Operating Instruction Manual.

Be sure that all necessary tools and testequipment are available and ready for use. Malfunction

discoveredIdentify

symptomsTroubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

6 - 2 Genie Z-45/22 Part No. 29487


+

-

ORG

/BLK-1

15AMP.

TB20

P1

KS1

GRND

PLAT

PR4

ALARMTILT

NOLS1

NCLS2

HORN P4

T

WHT

#51

TR2

OPS1

N.C.

L4 OP

WTS1

N.O.

TP29

VAC

REDBLK

FS1

CR4

TS3

STARTENGINE

TS6

RIGHT

LEFT

BLK

GRN/BLK

TB17

PWMA

+

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-

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A

PWM

BP1

10

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PWM

BP2

BLK #21 TB21

NONC

LS4

TR1

PR5

1

2

3 6

1

23

6

Battery

Wire colorwith cablenumber

Circuit breaker

Connectionno terminal

Spark plug

Terminal

Emergency Stopbuttonnormally closed

Key switch

Relay panelcontactor

Solenoid orrelay coil

Horn

Tilt sensor

Limit switchnormally closedheld open

Limit switchnormally openheld closed

Horn buttonnormally open

T-circuitsconnect

Time delay relay

Oil pressureswitchnormally closed

Light

Water temperatureswitchnormally closed

Quick disconnectterminal

Diode

Vacuum switch

Foot switch

Relay contactnormally open

Toggle switch SPDI

Circuits crossingno connection

Toggle switch DPDT

Groundsupressioncircuit

Starter motorrelay

Glow plug

Limit switch

T-circuits connectat terminal

Single axisproportionalcontroller

Resistor

Dual axisproportionalcontroller

T

Time delay relay

Electrical Symbol Legend

stonek

6-3

stonek

6-5

stonek

6-6

stonek

6-7

stonek

6-8

stonek

6-10

stonek

6-11

stonek

6-12

Part No. 29487 Genie Z-45/22 6 - 3


Hydraulic Symbol Legend

E

Pressure gauge

Filter

Fixed displacementpump

Bi-directional,variabledisplacement pump

Bi-directional motor

2-speed,bi-directional motor

Pump prime mover(engine or motor)

Cylinder

Accumulator

Orifice with size

0.035

Variable orificeor shut-off valve

Check valve

Relief valve

Priorityflow divider

Solenoid operateddump valve

Differentialsensing valve

Solenoid operatedproportional valve

Flow regulator valve

Solenoid operated 2 pos.,3 way, directional valve

Solenoid operated 2 pos.,4 way, directional valve

Solenoid operated 3 pos.,4 way, directional valve (DO1)

2 pos., 3 way, shuttle valve

3 pos., 4 way, directional valve

Sequencing valve

Counterbalance valve

Part No. 29487 Genie Z-45/22 7 - 1

Service Manual - First Edition Section 7 - Repair Procedures

Repair Procedures

About This SectionMost 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 Process

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.

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 printed in the GenieZ-45/22 Operating Instruction Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure thoroughly. Attemptingshortcuts may produce hazardous conditions.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

7 - 2 Genie Z-45/22 Part No. 29487

Service Manual - First EditionSection 7 - Repair Procedures

1-1Joystick Controllers

Maintaining each joystick controller at the propersettings is essential to safe machine operation.Every joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a horsepower limiterb quick disconnect terminal stripc drive proportional controllerd primary boom proportional controllere turntable rotate proportional controllerf extend/retract proportional controllerg secondary boom proportional

controller

Primary Boom Up/DownController Adjustments1 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 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 theprimary 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 tothe “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.

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.

g d c

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a b c d e f g h i j

Platform Controls

Part No. 29487 Genie Z-45/22 7 - 3


2.50V DC

5.02V DC25-29 seconds


PLATFORM CONTROLS

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.

7 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.

Engine should be at normaloperating temperature.

8 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.

9 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.

Specifications - Primary Boom Up/Down Function

Threshold

Primary boom up -Max-out time

Primary boom down -Dual range time

Primary Boom Extend/RetractController Adjustments1 Check the battery condition with a volt meter.



3 Open the platform control box lid and locate theprimary extend/retract controller.


4 Set the ramp rate: Turn the trimpot adjustmentscrew clockwise 15 turns or until you hear aclick, then turn the screw counterclockwise 5turns.


a b c d e f g h i j

7 - 4 Genie Z-45/22 Part No. 29487


2.50V DC



PLATFORM CONTROLS


7 Set the max-out: Press down the foot switch,then move the control handle all the way to theextend position. Adjust the voltage to7.00V DC. Turn the max-out trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

8 Set the dual (lo) range: Press down the footswitch then move the control handle all the wayto the retract position. Adjust the voltage to7.00V 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 until it is level. Fully retract theprimary boom.

10 Start a timer and record how long it takes forthe primary boom to reach full extension.Adjust the max-out trimpot to achieve a 29 to33 second cycle time.

11 Start a timer and record how long it takes forthe primary boom to fully retract. Adjust thedual range trimpot to achieve a 22 to 26second cycle time.

Specifications - Primary Boom Extend/RetractFunction

Threshold

Primary boom extend -Max-out time

Primary boom retract -Dual Range time

Secondary Boom Up/DownController Adjustments1 Check the battery condition with a volt meter.


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


Part No. 29487 Genie Z-45/22 7 - 5


2.94V DC



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.



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.

Specifications - Secondary Boom Up/DownFunction

Threshold

Secondary boom up -Max-out time

Secondary boom down -Dual Range time

Turntable Rotation ControllerAdjustments1 Check the battery condition with a volt meter.



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 - 6 Genie Z-45/22 Part No. 29487


3.35V DC


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 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.


6 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.

7 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.

Specifications - Turntable Rotation function

Threshold

Turntable rotation -Max-out time

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

a horsepower limiter board

1 Remove the fasteners from the platform controlbox lid.

2 Open the control box lid and locate thehorsepower limiter board.

a

Part No. 29487 Genie Z-45/22 7 - 7


8.0V DC

9.0V DC

PLATFORM CONTROLS

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 stowedpositionb "B" potentiometer-maximum voltage

output to the drive controller in theboom elevated position

c "C" potentiometer-reaction rate orhow fast the voltage output reacts tothe change in engine rpm


3 Connect the black lead(-) from a DC volt meterto the number 2 terminal, and the red lead(+) tothe number 10 terminal.



6 Press down the foot switch and adjust the "A"potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

Specifications - "A" Pot Setting

Voltage setting - 2WD model

Voltage setting - 4WD model

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 (6.1m) and recordthe elapsed time. Do this again in the oppositedirection.

a

7 - 8 Genie Z-45/22 Part No. 29487


Desired result

no continuity (infinite Ω)

no continuity

continuity (zero Ω)

Desired result



no continuity

2.85 seconds (±0.25 seconds)

2.75 seconds (±0.25 seconds)

1 foot per second /30.5cm per second

PLATFORM CONTROLS

15 Adjust the "B" potentiometer to obtain thecorrect elevated drive speed of 1 foot persecond (30.5cm per second).

16 Close the platform control box lid and re-installthe fasteners.

Specifications

Stowed position, high range, distance: 20 ft / 6m

2WD

4WD

Boom raised, high range, distance: 20 ft / 6m

2WD and 4WD

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.

Part No. 29487 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. 29487


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.


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. 29487 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.


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. 29487


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.

9 Rotate the platform to the right and continue

PLATFORM COMPONENTS

holding 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. 29487 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 2 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(25.4cm).

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. 29487


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 (78cm) 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 (12.5cm).

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. 29487 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 of


7 - 16 Genie Z-45/22 Part No. 29487


the primary boom weldment.

Crushing hazard. The extensiontube will fall when it is removedfrom the primary boom if it is notproperly supported.

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.

11 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




b

a

c

Part No. 29487 Genie Z-45/22 7 - 17



Crushing hazard. When thebarrel-end pivot pin is removed,the primary lift cylinder will swingdown if it is not properlysupported.

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 (2.5m) 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 (2.5cm). This will relieve pressure on thebarrel-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

a

b

7 - 18 Genie Z-45/22 Part No. 29487



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





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 (1.5m) off the ground.

3 Extend the extension tube to the primary boomtube 17 inches (43cm). Then secure to preventany 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.

7 Disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.

a

b

c

d

Part No. 29487 Genie Z-45/22 7 - 19




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 (1m).

considered, 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.



b

a

c


3 Extend the primary boom 6 inches (15cm), thenraise the primary boom until it is level.

4 Disconnect and plug the extension cylinderhydraulic hoses. Cap the ports on theextension cylinder.


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 PlatformLeveling Master Cylinder


Before cylinder removal is

7 - 20 Genie Z-45/22 Part No. 29487



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.


ab

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.

a

b

Part No. 29487 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. 29487


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 (78cm) 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.

b

a

c

ab


a

c

b

d

Part No. 29487 Genie Z-45/22 7 - 23


The upper mid-pivot rest shouldbe approximately 1 inch (2.5cm)above the rest block.

The upper mid-pivot rest shouldbe approximately 4 inches(10cm) above the rest block.

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

Rough terrain tires

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 hydrauliccables.

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. 29487


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.


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. 29487 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. 29487




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. 29487 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. 29487


6-1Timing AdjustmentComplete information to perform this procedure isavailable in the Kubota V1702-B Diesel EngineWorkshop Manual (Kubota code number: 97897-00691). Genie part number 29587.

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline against the flywheel.

2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/4 inch(0.635mm) gap between the coupler and pumpend plate.

3 Apply removable Loctite® removable threadsealant to the coupler set screw. Torque theset screw to 36 ft-lbs (49 Nm).

Component damage hazard. Donot force the drive pump duringre-installation or the flex plateteeth may become damaged.

6-5Water Temperature and OilPressure Switches

The water temperature switch is a normally openswitch that closes at approximately 225° F(107° 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 atplatform controls should turn on when the switchcloses.

Component damage hazard. Donot crank the engine with theover-temperature light on.

The oil pressure switch is a normally closed switchthat opens at approximately 7.1 psi (0.5 bar). If theoil pressure drops below the switch point, theswitch closes and shuts off the engine. A low oilpressure indicator light at the ground and platformcontrols should turn on when the switch closes.

Component damage hazard. Donot start or continue to run theengine with the low oil pressurelight on.

6-3RPM AdjustmentSee the scheduled maintenance procedure B-13,Check and Adjust the Engine RPM.

6-4Flex 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.

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

displacement controller (EDC), located on thedrive 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, thenremove the flex plate from the engine.

Kubota V1702-B Engine

6-2Glow Plugs

How to Check the Glow PlugsSee the scheduled maintenance procedure B-11,Check The Glow Plugs - Diesel Models.

Part No. 29487 Genie Z-45/22 7 - 29


8-18 foot-pounds11-24 Newton meters

13/16 inch

225° F (107° C) ±2%


1-1/16 inch

7.1 psi (0.5 bar)

KUBOTA V1702-B ENGINE

a water temperature switchb oil pressure switch

How to Remove the WaterTemperature and Oil PressureSwitches


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

a pivot plate bolts

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.

Specifications

Water temperature switch

Torque

Hex size

Temperature switch point

Oil pressure switch

Torque

Hex size

Oil pressure switch point

b

a

a

a

a

7 - 30 Genie Z-45/22 Part No. 29487


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 70degree 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 70 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

70°

a

Ford LSG 423 Engine

Part No. 29487 Genie Z-45/22 7 - 31


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

Automatic Choke WithoutPoppet ValveThis choke functions in both gasoline and propanemode.

Adjusting the choke to a rich mixture for coldclimates will hamper engine performance whenstarting a cold engine on propane fuel. To avoidthis problem, start the engine in gasoline mode.After the engine reaches normal operatingtemperature, select propane mode.

A flow path past the choke butterfly is required ifthe engine is to be cold started in the propanemode. A ¼ inch (6mm) flow path is recommended.Adjust the choke only when the engine and chokeare cold.

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.

7-2Choke Adjustments

This engine is equipped with one of three differentchoke configurations. Early models were equippedwith manual chokes. They were replaced withelectrically heated automatic chokes. Thesechokes were improved with the addition of apoppet valve to enhance cold starting ability onpropane fuel.

The machine is equipped with an automatic chokeif there is not a choke switch on the control panel.

Choke adjustments are affectedby climate. Richer adjustment willbe necessary in colder climates,leaner adjustment in warmerclimates.

Manual ChokeThe manual choke is solenoid operated and is onlyoperational in the gasoline mode. This choke willnot operate in propane mode.

Component damage hazard.During adjustments, do not allowthe choke butterfly to stop thesolenoid from fully retracting. Theplunger must be able to bottom-out inside the solenoid housing.

rich lean

7 - 32 Genie Z-45/22 Part No. 29487


FORD LSG 423 ENGINE

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.

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline against the flywheel.

2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/4 inch(0.635mm) gap between the coupler and pumpend plate.

3 Apply removable Loctite® thread sealant to thecoupler set screw. Torque the set screw to36 ft-lbs (49 Nm).

Component damage hazard. Donot force the drive pump duringre-installation or the flex plateteeth may become damaged.

7-3Timing Adjustment


7-4Carburetor Adjustment


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.

7-5RPM Adjustment

See the scheduled maintenance procedure B-13,Check and Adjust the Engine RPM.

Part No. 29487 Genie Z-45/22 7 - 33



13/16 inch

230° F (112° C)


1-1/16 inch

3-5 psi (0.21-0.34 bar)

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 and platform controls should turn on whenthe switch closes.

Component damage hazard. Donot start or continue to run theengine with the low oil pressurelight on.

How to Remove the WaterTemperature and Oil PressureSwitches


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.

Specifications

Water temperature switch

Torque

Hex size

Temperature switch point

Oil pressure switch

Torque

Hex size

Oil pressure switch point

a oil pressure switchb water temperature switch

b

a

7 - 34 Genie Z-45/22 Part No. 29487


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

Part No. 29487 Genie Z-45/22 7 - 35


no continuity(infinite Ω)

no continuity

no continuity

no continuity


continuity

160 to 170Ω


no continuity

no continuity

no continuity


continuity

8-1Control Relays

Relays used for single function switching aresingle pole double throw (SPDT) switches. Twofunction switching requires a double pole doublethrow (DPDT) relay.

How to Test a Double Pole DoubleThrow RelayThis procedure covers fundamental relay testingand does not specifically apply to all varieties ofrelays.

1 Turn the keyswitch to the off position andremove the key.

2 Label and then disconnect all the wiring fromthe relay to be tested.

3 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.Terminals 13 and 14 represent the coil andshould not be tested in any other combination.

a terminal no. 5b terminal no. 1c relayd terminal no. 13e terminal no. 9f terminal no. 12g terminal no. 14h terminal no. 4i terminal no. 8

Ground Controls

g

f

h

i

b

a

c

d

e

Test Desired result

terminal 13 to 14

terminal 8 to 5,4,1,12 & 9

terminal 5 to 8,4,1,12 & 9

terminal 4 to 8,5,1 & 9


terminal 4 to 12

terminal 1 to 9

4 Connect 12V DC to terminal 14 and a groundwire to terminal 13, then test the followingterminal combinations.

Test Desired result



terminal 4 to 1,5,9,8 & 12

terminal 1 to 5,9,4,8 & 12

terminal 8 to 12

terminal 5 to 9

7 - 36 Genie Z-45/22 Part No. 29487




190 to 200Ω



GROUND CONTROLS

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.

8-2Toggle Switches

See 1-4, Toggle Switches.

How to Test a Single Pole DoubleThrow RelayThis procedure covers fundamental relay testingand does not specifically apply to all varieties ofrelays.

1 Turn the keyswitch to the off position andremove the key.


3 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 13 to 14represent the coil and should not be tested inany other combination.

Test Desired result

terminal 13 to 14

terminal 5 to 1 & 9

terminal 1 to 9


Test Desired result

terminal 1 to 5 & 9

terminal 5 to 9

Part No. 29487 Genie Z-45/22 7 - 37


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.

GROUND CONTROLS

7 - 38 Genie Z-45/22 Part No. 29487




85 to 95Ω



9-1Control Relays

How to Test a Single Pole DoubleThrow Relay



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.

d

e

c

a

b

Test Desired result

terminal 85 to 86

terminal 87 to 87a & 30

terminal 87a to 30


Test Desired result

terminal 87a to 87 & 30

terminal 87 to 30

a terminal no. 87Ab terminal no. 85c terminal no. 30d terminal no. 86e terminal no. 87

Relay Panel

Part No. 29487 Genie Z-45/22 7 - 39



13 to 17Ω



9-2Power 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

2 large posts

Any small post toany large post

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

RELAY PANEL

a b ab

a high amp power contact terminals(large posts)

b solenoid activate coil terminals(small posts)

7 - 40 Genie Z-45/22 Part No. 29487


6 Remove the pressure gauge and reconnect thehydraulic hose.

7 Gasoline/LPG models: Reconnect the coilwire to the distributor cap.

Diesel models: Reconnect the wiring to thefuel on solenoid.

How to Remove the Lift/SteerPump1 Close the two hydraulic tank valves located at

the main pump.

2 Disconnect the hydraulic hoses from the pumpand cap them.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Component damage hazard. Besure to open the two hydraulictank valves after re-installing thepump.

10-1Lift/Steer Pump

How to Test the Lift/Steer Pump1 Gasoline/LPG models: Remove the coil wire

from the distributor cap.

Diesel models: Disconnect the 3 wires fromthe fuel on solenoid at the fuel injector pump.


2 Disconnect the high pressure hydraulic hosefrom the pump and cap it.

Burn hazard. Contact with hot oilmay cause severe burns.

3 Connect a 0 to 5000 psi (0 to 350 bar) pressuregauge to the high pressure port on the pump.

4 Turn the key switch to ground control and pullthe Emergency Stop button to the on position.

5 Observe the pressure gauge while cranking theengine. Immediately stop cranking if thepressure reaches or exceeds 3000 psi(206 bar).

Hydraulic pressure in excess of3000 psi (206 bar) will causesevere component damage.

Result: If the pressure gauge reads 3000 psi(206 bar), immediately stop cranking theengine. The pump is good.

Result: If pressure fails to reach 3000 psi(206 bar), the pump is bad and will need to bereplaced.

Hydraulic Pumps

open closed

Part No. 29487 Genie Z-45/22 7 - 41


HYDRAULIC PUMPS

10-2Drive 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

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 electrical connection at theelectronic displacement controller (EDC)located on the main pump.


open closed

3 Disconnect the hydraulic hoses from the pumpand cap them.


4 Support the pump and remove the two pumpmounting bolts. Carefully remove the pump.

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.

7 - 42 Genie Z-45/22 Part No. 29487


11-1Function Manifold Components

Index SchematicNo. Description Item Function Torque1 Counterbalance valve ........................ Z ........... Platform leveling cylinder - extend ...10-12 ft-lbs / 15-18Nm

2 3 position 4 way D01 valve ............... D ........... Platform level ....................................30-35 in-lbs / 3-4 Nm

3 Counterbalance valve ........................ Y ........... Turntable rotate - right ......................10-12 ft-lbs / 15-18Nm

4 3 position 4 way valve ....................... F ........... Turntable rotate ................................30-35 in-lbs / 3-4 Nm

5 3 position 4 way valve ....................... C ........... Secondary up/down ..........................30-35 in-lbs / 3-4 Nm

6 3 position 4 way valve ....................... B ........... Primary up/down ...............................30-35 in-lbs / 3-4 Nm

7 Counterbalance valve ........................ AY ......... Turntable rotate - left ........................10-12 ft-lbs / 15-18Nm

8 Check valve ....................................... P ........... Secondary flow regulator ..................11-13 ft-lbs / 15-18 Nm

9 Check valve ....................................... AB ......... Primary flow regulator .......................11-13 ft-lbs / 15-18 Nm

10 Check valve ....................................... AA ......... Extend/Retract flow regulator ...........11-13 ft-lbs / 15-18 Nm

11 3 position 4 way valve ....................... A ........... Extend/Retract ..................................30-35 in-lbs / 3-4 Nm

12 Flow regulator valve .......................... L ........... Extend/Retract ..................................10-12 ft-lbs / 14-16 Nm

13 Flow regulator valve .......................... M .......... Primary ..............................................10-12 ft-lbs / 14-16 Nm

14 Relief valve, 1200 psi (83 bar) .......... T ........... Primary down ....................................25-30 ft-lbs / 34-41 Nm

15 Flow regulator valve .......................... N ........... Secondary .........................................10-12 ft-lbs / 14-16 Nm

16 Relief valve, 1200 psi (83 bar) .......... U ........... Secondary down ...............................25-30 ft-lbs / 34-41 Nm

17 Flow regulator valve .......................... O ........... Swing ................................................10-12 ft-lbs / 14-16 Nm

18 Proportional solenoid valve ............... G ........... Extend/Retract ..................................10-12 ft-lbs / 14-16 Nm

19 Proportional solenoid valve ............... H ........... Primary ..............................................10-12 ft-lbs / 14-16 Nm

20 Proportional solenoid valve ............... I ............ Secondary .........................................10-12 ft-lbs / 14-16 Nm

21 Proportional solenoid valve ............... K ........... Swing ................................................10-12 ft-lbs / 14-16 Nm

22 Differential sensing valve .................. S ........... All functions .......................................10-12 ft-lbs / 14-16 Nm

23 Orifice 0.030 in / 0.76mm .................. AG ........ Platform rotate

24 Normally closed poppet valve ........... R ........... Platform level ....................................25-30 ft-lbs / 34-41 Nm

25 Normally closed poppet valve ........... Q ........... Platform rotate ..................................25-30 ft-lbs / 34-41 Nm

26 Relief valve, 2200 psi (152 bar) ........ AF ......... All functions .......................................35-40 ft-lbs / 47-54 Nm

27 Priority flow regulator valve ............... AE ......... Steering .............................................10-12 ft-lbs / 14-16 Nm

28 Check valve ....................................... AC ........ Platform rotate flow regulator ...........11-13 ft-lbs / 15-18 Nm

29 Orifice 0.015 in / 0.38mm .................. V ........... Differential sensing

30 Check valve ....................................... AD ........ Platform level flow regulator .............11-13 ft-lbs / 15-18 Nm

31 Check valve ....................................... J ............ Swing flow regulator .........................11-13 ft-lbs / 15-18 Nm

32 Counterbalance valve ........................ AZ ......... Platform leveling cylinder - retract ....10-12 ft-lbs / 15-18 Nm

33 3 position 4 way valve ....................... E ........... Platform rotate ..................................30-35 in-lbs / 3-4 Nm

Function Manifold

Part No. 29487 Genie Z-45/22 7 - 43


FUNCTION MANIFOLD

1 2 3 4 5 6

8

9

10

11

12

13

14

18

19

20

21

15

16

17

2425

27

26

33

31

30

29

28

23 22

7

32

7 - 44 Genie Z-45/22 Part No. 29487


4.2 ft-lbs / 6 Nm

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

75 ft-lbs / 102 Nm

FUNCTION MANIFOLD

Plug Torque Specifications

Description Torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

2200 psi / 152 bar

1200 psi / 83 bar

6 Restart the engine. Hold the retract switch andrecheck the valve pressure.

Specifications

Main relief valve pressure

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 14 for primary boom,item 16 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

11-2Valve 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 26).

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.

Part No. 29487 Genie Z-45/22 7 - 45


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 see11-1 Function Manifold Components in thissection.

1 Push the button on the end of the valve in¼ inch (6mm).

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

5Ω

4.5Ω

7Ω

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

3 pos 4 way directional valve

Normally closedpoppet valve

7 - 46 Genie Z-45/22 Part No. 29487


12-1Hydraulic Reservoir

The primary functions of the hydraulic reservoirare to cool, clean and deaerate the hydraulic fluidduring operation. This reservoir has a 25 gallon(94.5 liters) capacity and an oil level gauge withtemperature indicator. It utilizes internal suctionstrainers for the pump supply suction lines andhas an external return line filter.

How to Remove the HydraulicReservoir

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.


3 Completely drain the oil from the reservoir byremoving the drain plug located in the bottomfront of reservoir.

Burn hazard. Contact with hot oilmay cause severe burns.

4 Disconnect the hydraulic hoses from thereservoir.

5 Remove the reservoir anchor hook from theback of the reservoir.

open closed

6 Remove the mounting fasteners from thebottom of the reservoir.

7 Use an appropriate lifting device to remove thereservoir 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. 29487 Genie Z-45/22 7 - 47


FUEL AND HYDRAULIC TANKS

12-2Fuel 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 elevate assembly 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 - 48 Genie Z-45/22 Part No. 29487


13-1Rotation 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.

13-2Rotation 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 (78cm) supportblock installed during primaryboom removal.


Turntable Rotation Components

b

a

c

Part No. 29487 Genie Z-45/22 7 - 49


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 (30cm) 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 elevate assembly. Remove the blockfrom the turntable counterweight and lower theelevate assembly to the fully stowed position.


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 - 50 Genie Z-45/22 Part No. 29487



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 (8165kg) by spreading the forksto an inside width of 3 feet (0.9m).

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. 29487 Genie Z-45/22 7 - 51



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

14

18

11

8

16

17

7

151

43

9

10

95 foot pounds129 Newton meters


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

Second rotation

7 - 52 Genie Z-45/22 Part No. 29487





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

Second rotation

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. 29487 Genie Z-45/22 7 - 53


14-1Yoke 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 - 54 Genie Z-45/22 Part No. 29487


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).

14-2Steering 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. 29487 Genie Z-45/22 7 - 55


14-3Tie 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 (38cm) 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.


1/4 inch (0.635mm) toe-in to1/4 inch (0.635mm) toe-out

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 (5mm)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

7 - 56 Genie Z-45/22 Part No. 29487


15-1Yoke 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 (15cm) 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. 29487 Genie Z-45/22 7 - 57


125 foot-pounds169 Newton meters


15-3Tie Rod

How to Remove the Tie RodWeldmentThis procedure is the same as the 2WDprocedure. See repair procedure 14-3, How toRemove the Tie Rod Weldment.

How to Perform the Tie RodToe-in AdjustmentThis procedure is the same as the 2WDprocedure. See repair procedure 14-3, 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

15-2Steering Cylinders

How to Remove the SteeringCylinderThis procedure is the same as the 2WDprocedure. See repair procedure 14-2, How toRemove the Steering Cylinder.

7 - 58 Genie Z-45/22 Part No. 29487


16-1Oscillating 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 switches

from the oscillating axle lock-out cylinder.

3 Block the non-steering wheels, then center ajack under the oscillating axle and lift themachine 6 inches (15cm).

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. 29487 Genie Z-45/22 7 - 59


17-1Steer 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 - 60 Genie Z-45/22 Part No. 29487


50 in-lbs / 6 Nm

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

75 ft-lbs / 102 Nm

STEER AND OSCILLATE MANIFOLD


Description Torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

17-2Valve 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

1900 psi /131 bar

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

Part No. 29487 Genie Z-45/22 7 - 61


125 foot-pounds169 Newton meters

18-2Torque 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

18-1Drive 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

7 - 62 Genie Z-45/22 Part No. 29487


50 in-lbs / 6 Nm

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

75 ft-lbs / 102 Nm

19-12WD 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


Description Torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

Part No. 29487 Genie Z-45/22 7 - 63


1

2WD DRIVE MANIFOLD

2 3 5 6 94 1087

11

14

13

12

16

15

7 - 64 Genie Z-45/22 Part No. 29487


320 psi / 22 bar

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

Part No. 29487 Genie Z-45/22 7 - 65


2WD DRIVE MANIFOLD

This page intentionally left blank.

7 - 66 Genie Z-45/22 Part No. 29487


20-14WD 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 (0.635mm) .... 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. 29487 Genie Z-45/22 7 - 67


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 - 68 Genie Z-45/22 Part No. 29487


50 in-lbs / 6 Nm

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

75 ft-lbs / 102 Nm

4WD DRIVE MANIFOLD

320 psi / 22 bar


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


Description Torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

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