Genie Z-45/25 Bi-Energy, Z-45/25J Bi-Energy Service Manual

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Page 1

ServiceManual

Refertoinsidecoverforserialnumberinformation

PartNo.106488

RevA2

March2005

Page 2

Introduction

Important

Read, understand and obey the safety rules and operating instructions in the

Bi-Energy and Manual

Genie Z-45/25J Bi-Energy Operator's

before attempting any maintenance or

repair procedure.

This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.

Genie Z-45/25

July 2004

Technical Publications

Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.

Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

http://www.genieindustries.com e-mail: techsup@genieind.com

106488 Rev A July 2004 Second Edition, First Printing

"Genie" and "Z" are registered trademarks of Genie Industries in the USA and many other countries.

Printed on recycled paper

Printed in U.S.A.

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 3

July 2004

Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual and the

Genie Z-45/25J Bi-Energy Operator’s Manual

result in death or serious injury.

Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.

Genie Z-45/25 Bi-Energy and

will

Do Not Perform Maintenance Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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Page 4

SAFETY RULES

July 2004

Personal Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

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

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or

unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for use.

Keep work surfaces clean and free of debris that could get into machine components and cause damage.

With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Used to indicate operation or maintenance information.

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

Be sure any forklift, overhead crane or other lifting or supporting device is fully

capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one

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

nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 5

August 2004

Introduction

Table of Contents

Important Information ...................................................................................................

Section 1 Safety Rules

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

Section 2 Rev Specifications

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

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

A Hydraulic Specifications ........................................................................................ 2 - 3

A Manifold Component Specifications ....................................................................... 2 - 4

A Machine Torque Specifications .............................................................................. 2 - 4

A Kubota Z482-E Engine Specifications .................................................................... 2 - 5

A Generator ............................................................................................................... 2 - 6

A Generator Torque Specifications ............................................................................ 2 - 6

A Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 7

Section 3 Rev Scheduled Maintenance Procedures

iii

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

Pre-delivery Preparation ......................................................................................... 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

A Checklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................. 3 - 7

A-2 Check for Fuel Leaks ................................................................................... 3 - 7

A-3 Check for Hydraulic Leaks ........................................................................... 3 - 8

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

A-4 Check the Generator Belts and Pulleys ........................................................ 3 - 8

A-5 Perform Function Tests.............................................................................. 3 - 10

A-6 Perform 30 Day Service ............................................................................. 3 - 10

A-7 Perform Engine Maintenance ..................................................................... 3 - 10

A-8 Perform Engine Maintenance ..................................................................... 3 - 11

A-9 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 11

A-10 Perform Engine Maintenance ..................................................................... 3 - 12

A-11 Perform Engine Maintenance ..................................................................... 3 - 12

A-12 Perform Engine Maintenance ..................................................................... 3 - 13

A Checklist B Procedures

August 2004

B-1 Check the Radiator..................................................................................... 3 - 14

B-2 Check the Exhaust System ....................................................................... 3 - 14

B-3 Check the Batteries.................................................................................... 3 - 15

B-4 Inspect the Electrical Wiring ....................................................................... 3 - 16

B-5 Check the Lug Nut Torque (including the tires and wheels)......................... 3 - 16

B-6 Confirm the Proper Brake Configuration ...................................................... 3 - 17

B-7 Check the Oil Level in the Drive Hubs ........................................................ 3 - 17

B-8 Check and Adjust the Engine RPM ............................................................ 3 - 18

B-9 Test the Ground Control Override ............................................................... 3 - 19

B-10 Test the Platform Self-leveling ................................................................... 3 - 20

B-11 Test the Engine Idle Select ........................................................................ 3 - 20

B-12 Test the Drive Brakes ................................................................................ 3 - 21

B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 22

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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March 2005

Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 22

B-15 Test the Alarm Package (if equipped) ........................................................ 3 - 23

B-16 Test the Turntable Rotation Stop ................................................................ 3 - 24

B-17 Check the Electrical Contactors ................................................................. 3 - 24

B-18 Replace the Hydraulic Tank Return Filter ................................................... 3 - 25

B-19 Perform Hydraulic Oil Analysis................................................................... 3 - 25

B-20 Perform Engine Maintenance ..................................................................... 3 - 26

A Checklist C Procedures

C-1 Perform Engine Maintenance ..................................................................... 3 - 27

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 27

TABLE OF CONTENTS

C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 28

C-4 Perform Engine Maintenance ..................................................................... 3 - 30

A Checklist D Procedures

D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 31

D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 31

D-3 Check the Free-wheel Configuration ........................................................... 3 - 33

D-4 Replace the Drive Hub Oil .......................................................................... 3 - 34

D-5 Calibrate the Platform Overload System (if equipped) ................................ 3 - 34

D-6 Perform Engine Maintenance ..................................................................... 3 - 36

D-7 Perform Engine Maintenance ..................................................................... 3 - 36

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 37

E-2 Perform Engine Maintenance ..................................................................... 3 - 38

E-3 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 39

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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Page 8

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

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

A Platform Controls

1-1 Controllers .................................................................................................... 4 - 2

A Platform Components

2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4

2-2 Platform Rotator ........................................................................................... 4 - 6

A Jib Boom Components, Z-45/25J Models

3-1 Jib Boom ...................................................................................................... 4 - 7

3-2 Jib Boom Lift Cylinder .................................................................................. 4 - 8

A Primary Boom Components

August 2004

4-1 Cable Track .................................................................................................. 4 - 9

4-2 Primary Boom ............................................................................................ 4 - 13

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 16

4-4 Primary Boom Extension Cylinder .............................................................. 4 - 17

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 18

A Secondary Boom Components

5-1 Secondary Boom ........................................................................................ 4 - 21

5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 25

A Kubota Z482-E Engine

6-1 Timing Adjustment ..................................................................................... 4 - 27

6-2 RPM Adjustment ........................................................................................ 4 - 27

6-3 Engine Drive Pulley .................................................................................... 4 - 27

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Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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August 2004

Section 4 Rev Repair Procedures, continued

A Generator

7-1 Generator Pulley ........................................................................................ 4 - 29

7-2 Generator Belts .......................................................................................... 4 - 30

7-3 Generator Voltage Regulator ...................................................................... 4 - 30

A Hydraulic Pumps

8-1 Auxiliary Pump ........................................................................................... 4 - 33

8-2 Function Pump ........................................................................................... 4 - 33

B Manifolds

9-1 Function Manifold Components (before serial number 17841) ..................... 4 - 34

9-2 Function Manifold Components (from serial number 17841 to 20379) ......... 4 - 38

TABLE OF CONTENTS

9-3 Function Manifold Components (from serial number 20380 to 22565) ......... 4 - 40

9-4 Function Manifold Components (after serial number 22565) ........................ 4 - 42

9-5 Valve Adjustments - Function Manifold ...................................................... 4 - 44

9-6 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 46

9-7 Turntable Rotation Manifold Components ................................................... 4 - 47

A Turntable Rotation Components

10-1 Rotation Hydraulic Motor (before serial number 18367) ............................... 4 - 48

10-2 Turntable Rotation Assembly (after serial number 18366) ........................... 4 - 50

A Motor Controller

11-1 Motor Controller .......................................................................................... 4 - 52

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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TABLE OF CONTENTS

Section 5 Rev Fault Codes

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

A Fault Code Chart .................................................................................................... 5 - 3

Section 6 Rev Schematics

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

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

Power Cable Diagrams

A Power Cable Diagram (before serial number 16839) ............................................... 6 - 5

A Power Cable Diagram (from serial number 16840 to 21179) ................................... 6 - 6

A Power Cable Diagram (from serial number 21180 to 22050) ................................... 6 - 7

August 2004

A Power Cable Diagram (after serial number 22050) .................................................. 6 - 8

Engine Panel Diagrams

A Engine Panel Diagram (before serial number 13361) .............................................. 6 - 9

A Engine Panel Diagram (from serial number 13361 to 14078) ................................ 6 - 10

A Engine Panel Diagram (from serial number 14079 to 14650) ................................ 6 - 11

A Engine Panel Diagram (from serial number 14651 to 16839) ................................ 6 - 12

A Engine Panel Diagram (from serial number 16840 to 17974) ................................ 6 - 13

A Engine Panel Diagram (from serial number 17975 to 21180) ................................ 6 - 14

A Engine Panel Diagram (from serial number 21181 to 22050) ................................ 6 - 15

A Engine Panel Diagram (after serial number 22050) ............................................... 6 - 16

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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August 2004

Section 6 Rev Schematics, continued

Electrical Schematics, Z-45/25

A Electrical Schematic, Z-45/25 (before serial number 13361) ................................. 6 - 17

A Electrical Schematic, Z-45/25 (from serial number 13361 to 14078) ..................... 6 - 19

A Electrical Schematic, Z-45/25 (from serial number 14079 to 14650) ..................... 6 - 21

A Electrical Schematic, Z-45/25 (from serial number 14651 to 16839) ..................... 6 - 23

A Electrical Schematic, Z-45/25 (from serial number 16840 to 17974) ..................... 6 - 25

A Electrical Schematic, Z-45/25 (from serial number 17975 to 21180) ..................... 6 - 27

A Electrical Schematic, Z-45/25 (from serial number 21181 to 22050) ..................... 6 - 29

A Electrical Schematic, Z-45/25, ANSI and CSA Models

(after serial number 22050) .................................................................................. 6 - 31

A Electrical Schematic, Z-45/25, CE Models

(after serial number 22050) .................................................................................. 6 - 33

TABLE OF CONTENTS

Electrical Schematics, Z-45/25J

A Electrical Schematic, Z-45/25J (before serial number 13361) ............................... 6 - 35

A Electrical Schematic, Z-45/25J (from serial number 13361 to 14078) ................... 6 - 37

A Electrical Schematic, Z-45/25J (from serial number 14079 to 14650) ................... 6 - 39

A Electrical Schematic, Z-45/25J (from serial number 14651 to 16839) ................... 6 - 41

A Electrical Schematic, Z-45/25J (from serial number 16840 to 17974) ................... 6 - 43

A Electrical Schematic, Z-45/25J (from serial number 17975 to 21180) ................... 6 - 45

A Electrical Schematic, Z-45/25J (from serial number 21181 to 22050) ................... 6 - 47

A Electrical Schematic, Z-45/25J, ANSI and CSA Models

(after serial number 22050) .................................................................................. 6 - 49

A Electrical Schematic, Z-45/25J, CE Models

(after serial number 22050) .................................................................................. 6 - 51

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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TABLE OF CONTENTS

Section 6 Rev Schematics, continued

Ground Control Box Wiring Diagrams, Z-45/25

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(before serial number 13361) ................................................................................ 6 - 53

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(before serial number 13361) ................................................................................ 6 - 54

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 13361 to 14078) .................................................................... 6 - 55

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 13361 to 14078) .................................................................... 6 - 56

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 14079 to 14650) .................................................................... 6 - 57

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 14079 to 14650) .................................................................... 6 - 58

August 2004

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 14651 to 16839) .................................................................... 6 - 59

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 14651 to 16839) .................................................................... 6 - 60

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 16840 to 17974) .................................................................... 6 - 61

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 16840 to 17974) .................................................................... 6 - 62

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) .................................................................... 6 - 63

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) .................................................................... 6 - 64

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) .................................................................... 6 - 65

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Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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August 2004

Section 6 Rev Schematics, continued

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) .................................................................... 6 - 66

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

ANSI and CSA Models (after serial number 22050) .............................................. 6 - 67

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

ANSI and CSA Models (after serial number 22050) .............................................. 6 - 68

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

CE Models (after serial number 22050) ................................................................ 6 - 69

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

CE Models (after serial number 22050) ................................................................ 6 - 70

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J

(before serial number 13361) ................................................................................ 6 - 71

TABLE OF CONTENTS

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

(before serial number 13361) ................................................................................ 6 - 72

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J

(from serial number 13361 to 14078) .................................................................... 6 - 73

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

(from serial number 13361 to 14078) .................................................................... 6 - 74

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J

(from serial number 14079 to 14650) .................................................................... 6 - 75

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

(from serial number 14079 to 14650) .................................................................... 6 - 76

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J

(from serial number 14651 to 16839) .................................................................... 6 - 77

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

(from serial number 14651 to 16839) .................................................................... 6 - 78

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25J

(from serial number 16840 to 17974) .................................................................... 6 - 79

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25J

(from serial number 16840 to 17974) .................................................................... 6 - 80

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

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TABLE OF CONTENTS

Section 6 Rev Schematics, continued

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) .................................................................... 6 - 81

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) .................................................................... 6 - 82

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) .................................................................... 6 - 83

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) .................................................................... 6 - 84

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

ANSI and CSA Models (after serial number 22050) .............................................. 6 - 85

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

ANSI and CSA Models (after serial number 22050) .............................................. 6 - 86

August 2004

A Ground Control Box Terminal Srip Wiring Diagram, Z-45/25

CE Models (after serial number 22050) ................................................................ 6 - 87

A Ground Control Box Switch Panel Wiring Diagram, Z-45/25

CE Models (after serial number 22050) ................................................................ 6 - 88

Platform Control Box Wiring Diagrams

A Platform Control Box Wiring Diagram, Z-45/25

(before serial number 13361) ................................................................................ 6 - 89

A Platform Control Box Wiring Diagram, Z-45/25

(with platform load sense and LVI/BCI option)

(before serial number 13361) ................................................................................ 6 - 90

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 13361 to 14078) .................................................................... 6 - 91

A Platform Control Box Wiring Diagram, Z-45/25

(with platform load sense and LVI/BCI option)

(from serial number 13361 to 14078) .................................................................... 6 - 92

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 14079 to 14650) .................................................................... 6 - 93

A Platform Control Box Wiring Diagram, Z-45/25

(with platform load sense and LVI/BCI option)

(from serial number 14079 to 14650) .................................................................... 6 - 94

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Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 15

August 2004

Section 6 Rev Schematics, continued

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 14651 to 16839) .................................................................... 6 - 95

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 14651 to 16839) .................................................................... 6 - 96

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 16840 to 17974) .................................................................... 6 - 97

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 16840 to 17974) .................................................................... 6 - 98

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) .................................................................... 6 - 99

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 17975 to 21180) ...................................................................6 - 100

TABLE OF CONTENTS

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) ...................................................................6 - 101

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 21181 to 22050) ...................................................................6 - 102

A Platform Control Box Wiring Diagram, Z-45/25

(after serial number 22050) ................................................................................. 6 - 103

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(after serial number 22050) ................................................................................. 6 - 104

A Platform Control Box Wiring Diagram, Z-45/25J

(before serial number 13361) ............................................................................... 6 - 105

A Platform Control Box Wiring Diagram, Z-45/25J

(with platform load sense and LVI/BCI option)

(before serial number 13361) ............................................................................... 6 - 106

A Platform Control Box Wiring Diagram, Z-45/25J

(from serial number 13361 to 14078) ...................................................................6 - 107

A Platform Control Box Wiring Diagram, Z-45/25J

(with platform load sense and LVI/BCI option)

(from serial number 13361 to 14078) ...................................................................6 - 108

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy

Page 16

TABLE OF CONTENTS

Section 6 Rev Schematics, continued

A Platform Control Box Wiring Diagram, Z-45/25J

(from serial number 14079 to 14650) ...................................................................6 - 109

A Platform Control Box Wiring Diagram, Z-45/25J

(with platform load sense and LVI/BCI option)

(from serial number 14079 to 14650) ...................................................................6 - 110

A Platform Control Box Wiring Diagram, Z-45/25J

(from serial number 14651 to 16839) ...................................................................6 - 111

A Platform Control Box Wiring Diagram, Z-45/25J (with LVI/BCI option)

(from serial number 14651 to 16839) ...................................................................6 - 112

A Platform Control Box Wiring Diagram, Z-45/25J

(from serial number 16840 to 17974) ...................................................................6 - 113

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 16840 to 17974) ...................................................................6 - 114

August 2004

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 17975 to 21180) ...................................................................6 - 115

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 17975 to 21180) ...................................................................6 - 116

A Platform Control Box Wiring Diagram, Z-45/25

(from serial number 21181 to 22050) ...................................................................6 - 117

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(from serial number 21181 to 22050) ...................................................................6 - 118

A Platform Control Box Wiring Diagram, Z-45/25

(after serial number 22050) ................................................................................. 6 - 119

A Platform Control Box Wiring Diagram, Z-45/25 (with LVI/BCI option)

(after serial number 22050) ................................................................................. 6 - 120

Hydraulic Schematics

B Hydraulic Schematic (before serial number 16962) ..............................................6 - 121

B Hydraulic Schematic (from serial number 16962 to 20379) ..................................6 - 122

B Hydraulic Schematic (from serial number 20380 to 22565) ..................................6 - 123

B Hydraulic Schematic (after serial number 22565) ................................................ 6 - 124

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Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 17

Section 2 • SpecificationsJuly 2004

REV A

Machine Specifications

Tires and wheels

Wheel diameter 14.5 inches

Wheel width 7 inches

Wheel lugs (before serial number 16128) Front 8 @ Rear 9 @

Wheel lugs (after serial number 16127) Front 9 @ Rear 9 @

Lug nut torque 125 ft-lbs

Tire size 9-14.5 LT

Tire ply rating Tread 8

Tire contact area 43.5 sq in

Overall tire diameter 28 in

/8 -18

169.5 Nm

Sidewall 6

280 sq cm

71 cm

Specifications

Fluid capacities

Fuel tank 9 gallons

34.1 liters

Hydraulic tank 8 gallons

30.3 liters

Hydraulic system 11 gallons (including tank) 41.6 liters

Drive hubs (refer to tag on drive hub to determine type) EW1 type 17 fl oz

0.51 liter

W1 type 23 fl oz

0.68 liter

Drive hub oil type: SAE 90 multipurpose hypoid gear oil

API service classification GL5

Batteries

Type 6V DC

Quantity 8

Capacity 350 AH

Reserve capacity @ 25A rate 750 minutes

Tire pressure 100 psi

6.89 bar

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

For operational specifications, refer to the

Performance Specifications

Operator's Manual.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 1

Page 18

Section 2 • Specifications July 2004

REV ASPECIFICATIONS

Drive speeds, maximum

Drive speed, stowed 3 mph All models 4.8 km/h

40 ft/9 sec

12.2 m/9 sec

Drive speed, boom 0.6 mph raised or extended, 1 km/h all models 40 ft/45 sec

12.2 m/45 sec

Braking distance, maximum

High range on paved surface 5 to 7 ft

1.5 to 2 m

Gradeability (boom stowed) 30%

Boom function speeds, maximum from platform controls

Jib boom up, Z-45/25J 30 to 40 seconds

Jib boom down, Z-45/25J 18 to 23 seconds

Primary boom up, Z-45/25 30 to 40 seconds

Primary boom up, Z-45/25J 25 to 35 seconds

Primary boom down, Z-45/25 24 to 34 seconds

Primary boom down, Z-45/25J 20 to 30 seconds

Secondary boom up 35 to 45 seconds

Secondary boom down 26 to 36 seconds

Primary boom extend, Z-45/25 25 to 30 seconds

Primary boom extend, Z-45/25J 16 to 24 seconds

Primary boom retract, Z-45/25 21 to 30 seconds

Primary boom retract, Z-45/25J 13 to 23 seconds

Turntable rotate, 359° 45 to 75 seconds primary boom retracted

Platform rotate, 180°, Z-45/25 6 to 10 seconds

Platform rotate, 160°, Z-45/25J 6 to 10 seconds

Platform level up 50 to 55 seconds

Platform level down 35 to 45 seconds

2 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 19

Section 2 • SpecificationsJuly 2004

REV A

Hydraulic Specifications

Before serial number 20926

Hydraulic oil type Shell Donax TG (Dexron III)

After serial number 20925

Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W-20 Viscosity index rating 200

Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and have a minimum viscosity index rating of 150. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

SPECIFICATIONS

Function pump

Type: Fixed displacement gear pump

Displacement 0.183 cu in

3 cc

Flow rate 2.1 gpm

7.9 L/min

Hydraulic tank 10 micron with return filter 25 psi / 1.7 bar bypass

Function manifold

Function relief valve pressure 3200 psi

220.6 bar

Primary boom down 2300 psi relief valve pressure 158.6 bar (before serial number 11819)

Secondary boom down 1800 psi relief valve pressure 124 bar (before serial number 22566)

Secondary boom down 2100 psi relief valve pressure 145 bar (after serial number 22565)

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Genie specifications require additional equipment and special

Platform level flow regulator 0.1 gpm (before serial number 20380) 0.38 L/min

Platform level flow regulator 0.6 gpm (after serial number 20379) 2.27 L/min

Jib boom/platform rotate flow regulator 0.6 gpm (before serial number 22566) 2.27 L/min

installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use.

Jib boom/platform rotate flow regulator 0.4 gpm (after serial number 22565) 1.5 L/min

Auxiliary pump

Type: fixed displacement gear pump

Displacement 0.5 gpm

1.9 L/min

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 3

Page 20

Section 2 • Specifications July 2004

SPECIFICATIONS

Manifold Component Specifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm

SAE No. 6 14 ft-lbs / 19 Nm

SAE No. 8 38 ft-lbs / 51 Nm

SAE No. 10 41 ft-lbs / 55 Nm

SAE No. 12 56 ft-lbs / 76 Nm

Valve Coil Resistance Specification

Description Specification

Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω (schematic items E, H, J, K, L, M, CC, DD, EE, FF, HH, II, BB, BC, BD, BE, BF, BG, CB, CD, CE, CF and CH)

REV A

Machine Torque Specifications

Platform rotator

1 -8 center bolt (grade 2) 200 ft-lbs

271 Nm

1 -8 center bolt (grade 8) 480 ft-lbs

651 Nm

/8 -16 bolts 47 ft-lbs

63.7 Nm

Turntable rotate bearing

Rotate bearing mounting bolts, dry 220 ft-lbs

298 Nm

Rotate bearing mounting bolts, lubricated 165 ft-lbs

224 Nm

Drive hubs

Drive hub mounting bolts, dry 220 ft-lbs

298 Nm

Drive hub mounting bolts, lubricated 165 ft-lbs

224 Nm

Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω (schematic items N, P, AA, BB, BA, BJ, CA, CK and CR)

Solenoid valve, 2 position 3 way, 20V DC 17 to 21 Ω (schematic item CR)

Solenoid valve, 2 position 3 way, 20V DC 25 to 28 Ω (schematic item DC)

Solenoid valve, 2 position 2 way, 20V DC 22 to 26 Ω (schematic items DA and DB)

Proportional solenoid valve, 24V DC 17 to 21 Ω (schematic items G, JJ, BH and CI)

Solenoid valve, N.C. poppet, 20V DC 25 to 28 Ω (schematic items F, LL and BI)

Solenoid valve, N.O. poppet, 20V DC 25 to 28 Ω (schematic items B, VV and BT)

Hydraulic tank fasteners 4.5 ft-lbs

6.1 Nm

2 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 21

Section 2 • SpecificationsJuly 2004

REV A

Kubota Z482-E Engine

Displacement 29.23 cu in

0.48 liters

Number of cylinders 2

Bore and stroke 2.64 x 2.68 inches

67 x 68 mm

Horsepower

Gross intermitent 12.5 @ 3600 rpm

Firing order 1 - 2

Compression ratio 23:1

Compression pressure 412 to 469 psi

28.4 to 32.3 bar

Low idle 2000 rpm

High idle 3000 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in

0.145 to 0.185 mm

Engine coolant

Capacity 2.9 quarts

2.8 liters

Lubrication system

Oil pressure 36 to 64 psi

2.48 to 4.41 bar

SPECIFICATIONS

Injection system

Injection pump make Bosch MD

Injection timing 21° BTDC

Injection pump pressure 1991 psi

137 bar

Fuel requirement diesel number 2-D

Starter motor

Brush length, new 0.5188 in

13 mm

Brush length, minimum 0.3346 in

8.5 mm

Battery

Type 12V DC, Group 70

Quantity 1

Cold cranking ampere 450A

Reserve capacity @ 25A rate 125 minutes

Alternator

Output 12V DC, 150 watts

Fan belt deflection

/4 to 3/8 inch

7 to 9 mm

Oil capacity 2.6 quarts (including filter) 2.5 liters

Oil viscosity 10W-30 requirements

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

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 5

Page 22

Section 2 • Specifications July 2004

SPECIFICATIONS

Generator

Generator output

with engine @ 3000 rpm 54V DC, 100A

Generator pulley to engine pulley offset, maximum 1.6 mm

Belt deflection, maximum

/16 inch

/4 inch

6.5 mm

Generator Torque Specifications

Generator pulley retaining nut torque 80-90 ft-lbs

108-122 Nm

Engine pulley retaining bolts 108 in-lbs

12.2 Nm

#10 screw 25 in-lbs

2.8 Nm

#10 nut 25 in-lbs

2.8 Nm

REV A

#4 nut 8-10 in-lbs

0.9-1.1 Nm

Voltage regulator 25 in-lbs mounting fasteners 2.8 Nm

2 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 23

Section 2 • SpecificationsJuly 2004

REV A SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok® fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.

The O-rings used in the Parker

Seal Lok® fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and

retained properly.

4 Position the tube and nut squarely on the face

seal end of the fitting and tighten the nut finger tight.

5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.

6 Operate all machine functions and inspect the

hoses and fittings and related components to confirm that there are no leaks.

SAE O-ring Boss Port

(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 2 - 7

Seal-Lok® Fittings

(hose end)

SAE Dash size Torque

-4 18 ft-lbs / 24.4 Nm

-6 27 ft-lbs / 36.6 Nm

-8 40 ft-lbs / 54.2 Nm

-10 63 ft-lbs / 85.4 Nm

-12 90 ft-lbs / 122 Nm

-16 120 ft-lbs / 162.7 Nm

-20 140 ft-lbs / 190 Nm

-24 165 ft-lbs / 223.7 Nm

Page 24

Section 2 • Specifications July 2004

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2 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 25

July 2004 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for each scheduled maintenance inspection.

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

Observe and Obey:

Maintenance inspections shall be completed by

a person trained and qualified on the maintenance of this machine.

Scheduled maintenance inspections shall be

completed daily, quarterly, six months, annually and every 2 years as specified on the

Maintenance Inspection Report.

Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform each

procedure with the machine in the following configuration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

Symbols Legend

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Used to indicate operation or maintenance information.

Indicates that a specific result is expected after

performing a series of steps.

· Key switch in the off position with the key removed

· Wheels chocked

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 1

Page 26

SCHEDULED MAINTENANCE PROCEDURES

July 2004Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

Indicates that tools will be required to perform this procedure.

Indicates that new parts will be required to perform this procedure.

Indicates that a cold motor, pump or engine will be required to perform this procedure.

Maintenance Schedule

There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two year. The

Scheduled Maintenance Procedures Section

and the

Maintenance Inspection Report

have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Indicates that a warm motor, pump or engine will be required to perform this procedure.

Indicates that dealer service will be required to perform this procedure.

Maintenance Inspection Report

The maintenance inspection report contains checklists for each type of scheduled inspection.

Make copies of the

Maintenance Inspection Report

to use for each inspection. Store completed forms for three years.

3 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 27

Pre-Delivery Preparation

July 2004 Section 3 • Scheduled Maintenance Procedures

Fundamentals

It is the responsibility of the dealer to perform the Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests.

Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.

Legend

Y = yes, completed N = no, unable to complete R = repaired

Comments

Genie Industries USA

18340 NE 76th Street PO Box 97030 Redmond, WA 98073-9730 (425) 881-1800

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 3

The Maltings, Wharf Road

Grantham, Lincolnshire

NG31- 6BH England

Genie UK

(44) 1476-584333

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Page 28

July 2004Section 3 • Scheduled Maintenance Procedures

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3 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 29

July 2004 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this page to use for each inspection.

· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hour Inspection: A

Quarterly or 250 hour Inspection: A+B

Six Month or 500 hour Inspection: A+B+C

Annual or 1000 hours Inspection: A+B+C+ D

2 Year or 2000 hour Inspection: A+B+C +D+E

Checklist A - Rev A YNR

A-1 Pre-operation

inspection

A-2 Check for fuel leaks

A-3 Hydraulic leaks

A-4 Generator belts and

pulleys

A-5 Function tests

Perform after 40 hours:

A-6 30 Day Service

Perform every 50 hours:

A-7 Perform engine

maintenance

Perform every 75 hours:

A-8 Perform engine

maintenance

Perform every 100 hours:

A-9 Grease rotation

bearing

A-10 Perform engine

maintenance

Perform every 150 hours:

A-11 Perform engine

maintenance

Perform every 200 hours:

A-12 Perform engine

maintenance

Checklist B - Rev A YNR

B-1 Radiator

B-2 Exhaust system

B-3 Batteries

B-4 Electrical wiring

B-5 Lug nut torque

B-6 Brake configuration

B-7 Drive hub oil level

B-8 Engine RPM

B-9 Ground control

override

B-10 Platform leveling

B-11 Engine idle select

B-12 Drive brakes

B-13 Drive speed - stowed

B-14 Drive speed - raised

B-15 Alarm package

(if equipped)

B-16 Turntable rotation stop

B-17 Electrical contactors

B-18 Hydraulic return filter

B-19 Hydraulic oil analysis

Perform every 400 hours:

B-20 Perform engine

maintenance

· Place a check in the appropriate box after each inspection procedure is completed.

· If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box.

Legend

Y = yes, acceptable N = no, remove from service

R = repaired

Comments

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 5

Page 30

MAINTENANCE INSPECTION REPORT

July 2004Section 3 • Scheduled Maintenance Procedures

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this page to use for each inspection.

· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hour Inspection: A

Quarterly or 250 hour Inspection: A+B

Six Month or 500 hour Inspection: A+B+C

Annual or 1000 hours Inspection: A+B+C+ D

2 Year or 2000 hour Inspection: A+B+C +D+E

· Place a check in the appropriate box after each inspection procedure is completed.

· If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box.

Legend

Y = yes, acceptable N = no, remove from service

R = repaired

Comments

Checklist C - Rev A YNR

C-1 Perform engine

maintenance

C-2 Grease platform

overload (if equipped)

C-3 Test platform

overload (if equipped)

Perform every 800 hours:

C-4 Perform engine

maintenance

Checklist D - Rev A YNR

D-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Free-wheel

configuration

D-4 Drive hub oil

D-5 Calibrate platform

overload system (if equipped)

Perform every 1000 hours:

D-6 Perform engine

maintenance

Perform every 1500 hours:

D-7 Perform engine

maintenance

Checklist E - Rev A YNR

E-1 Hydraulic oil

E-2 Perform engine

maintenance

E-3 Wheel bearings

3 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 31

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

Checklist A Procedures

A-1 Perform Pre-operation Inspection

Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required.

Complete information to perform this procedure is available in the

Genie Z-45/25J Bi-Energy Operator's Manual

your machine.

Genie Z-45/25 Bi-Energy and

A-2 Check for Fuel Leaks

Failure to detect and repair fuel leaks will result in an unsafe condition. An explosion or fuel fire may cause death or serious injury.

Explosion and fire hazard. Engine fuels are combustible. Inspect the machine in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach.

1 Perform a visual inspection around the areas

listed below.

· Fuel tank, shutoff valve (if equipped), hoses and fittings, fuel filter, fuel injection pump and fuel injectors

Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 7

Page 32

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-3 Check for Hydraulic Leaks

Detecting hydraulic fluid leaks is essential to operational safety and good machine performance. Undiscovered leaks can develop into hazardous situations, impair machine functions and damage machine components.

1 Inspect for hydraulic oil puddles, dripping or

residue on or around the following areas:

· Hydraulic tank—filter, fittings, hoses and turntable surface

· Engine compartment—hydraulic power unit, auxiliary power unit, pumps, suction filter, fittings, hoses, and turntable surface

· All hydraulic cylinders

· All hydraulic manifolds

· Z-45/25: Primary and secondary booms

· Z-45/25J: Primary, secondary and jib booms

· The underside of the turntable

· The underside of the drive chassis

· Ground area under the machine

REV A

A-4 Check the Generator Belts and Pulleys

Maintaining the generator belts and the pulleys is essential to good engine performance and service life. The generator will not operate properly with loose or defective belts and continued use may cause component damage.

Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation.

Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns.

Charging the batteries with the engine does not fully charge the batteries. Periodically, use the AC battery charger to fully charge the batteries.

1 Be sure that all fasteners and cables on the

generator are tight.

2 Be sure that the pulley mounting fasteners are

tight and that the pulleys show no signs of damage or unusual wear.

3 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 33

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

3 Check to be sure the engine pulley and the

generator pulley are aligned within specification using a straightedge. Refer to Section 2,

Specifications

a engine pulley b straightedge c maximum pulley offset d generator pulley

CHECKLIST A PROCEDURES

4 Inspect the generator belts for:

· Cracking

· Glazing

· Separation

· Breaks

5 Replace both belts if any damage is found.

6 Check the generator belts for proper tension.

Refer to Section 2,

Specifications

If the belt deflection is not within specification, see repair procedure 7-2,

How to Adjust the Generator

Belts.

If alignment does not meet specification, refer to Repair Procedure 6-3,

Engine Drive Pulley

How to Install the

to adjust the

pulley alignment.

a engine pulley b generator belts c generator pulley

7 Check the torque of the pulley retaining nut on

the generator. Refer to Section 2, S

pecifications

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 9

Page 34

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-5 Perform Function Tests

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.

Complete information to perform this procedure is available in the

Genie Z-45/25J Bi-Energy Operator's Manual

your machine.

Genie Z-45/25 Bi-Energy and

A-6 Perform 30 Day Service

REV A

A-7 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 50 hours.

Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.

1 Perform the following maintenance procedures:

· A-10 Perform Engine Maintenance

· B-5 Check the Lug Nut Torque

(including tires and wheels)

· B-18 Replace the Hydraulic Tank Return

Filter

· D-2 Check the Turnable Rotation Bearing

Bolts

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

3 - 10 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 35

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

A-8 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 75 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

CHECKLIST A PROCEDURES

A-9 Grease the Turntable Rotation Bearing and Rotate Gear

Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage.

1 Locate the grease fitting on the front turntable

cover.

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

2 Pump grease into the turntable rotation bearing.

Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased.

3 Apply grease to each tooth of the drive gear,

located under the turntable.

Grease type Multipurpose grease

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 11

Page 36

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-10 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 100 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

REV A

A-11 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 150 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

3 - 12 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 37

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

A-12 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 200 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

CHECKLIST A PROCEDURES

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 13

Page 38

July 2004Section 3 • Scheduled Maintenance Procedures

Checklist B Procedures

B-1 Check the Radiator

Maintaining the radiator in good condition is essential for good engine performance. Operating a machine with a damaged or leaking radiator may result in engine damage. Also, restricting air flow through the radiator (i.e., dirt or debris) will affect the performance of the cooling system. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems.

Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation.

Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine pivot plate out away from the machine to access the radiator.

3 Inspect the radiator for leaks and physical

damage.

B-2 Check the Exhaust System

Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine pivot plate out away from the machine to access the exhaust system.

3 Be sure that all nuts and bolts are tight.

4 Inspect all welds for cracks.

5 Inspect for exhaust leaks; i.e., carbon buildup

around seams and joints.

REV A

Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation.

Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns.

4 Clean the radiator fins of debris and foreign

materials.

5 Swing the engine back to its original position

and close the engine pivot plate latch.

6 Install the engine pivot plate latch retainer.

3 - 14 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 39

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST B PROCEDURES

B-3 Check the Batteries

Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions.

Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

Charging the batteries with the engine does not fully charge the batteries. Periodically, use the AC battery charger to fully charge the batteries.

3 Be sure that the cable connections are tight.

4 Remove the battery vent caps and check the

specific gravity of each battery cell with a hydrometer.

Result: If any battery cell displays a specific

gravity of less than 1.026, the battery must be replaced.

5 Check the battery acid level of the battery. If

needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill.

6 Install the battery vent caps.

7 Be sure the battery packs are wired correctly.

The engine battery is a maintenance free battery and does not require the replenishing of electrolyte.

Perform this procedure after fully charging the batteries.

For a more accurate determination of battery condition, fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are

free of corrosion.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 15

Page 40

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-4 Inspect the Electrical Wiring

Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage.

Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Inspect the following areas for burnt, chafed,

corroded and loose wires:

· Generator and power units

· Engine wiring harness

· Inside of the ground control box

· Turntable manifold wiring

2 Raise the secondary boom until the mid-pivot is

approximately 10 feet / 3 m off the ground.

3 Remove the center turntable cover.

4 Inspect the turntable center area for burnt,

chafed and pinched cables.

5 Install the center turntable cover.

6 Lower the boom to the stowed position and turn

the machine off.

7 Inspect the following areas for burnt, chafed,

corroded, pinched and loose wires:

· Cable track on the primary, jib and secondary booms

· Jib boom to platform cable harness

· Inside of the platform control box

REV A

B-5 Check the Lug Nut Torque (including the tires and wheels)

Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.

Tip over hazard. An over-inflated tire can explode which will compromise machine stability and and cause the machine to tip over.

Bodily injury hazard. An overinflated tire can explode and may cause death or serious injury.

Tip-over hazard. Do not use temporary flat tire repair products.

The tires on some machines are foam-filled and do not need air added to them.

1 Check the tire surface and sidewalls for cuts,

cracks, punctures and unusual wear.

2 Check each wheel for damage, bends and

cracked welds.

3 Check each lug nut for proper torque. Refer to

Section 2,

4 Check the pressure in each air-filled tire.

Refer to Section 2,

Specifications.

3 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 41

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST B PROCEDURES

B-6 Confirm the Proper Brake Configuration

Proper brake configuration is essential to safe operation and good machine performance. Hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational.

1 Check each drive hub disconnect cap to be

sure it is in the engaged position.

brake disengaged position

brake engaged position

B-7 Check the Oil Level in the Drive Hubs

Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage.

1 Drive the machine to rotate the hub until one of

the plugs is located on top and the other one is at 90 degrees.

models with pipe plugs

a models with o-ring plugs

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 17

Page 42

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

2 Remove the plug located at 90 degrees and

check the oil level.

Result: The oil level should be even with the

bottom of the side plug hole.

3 If necessary, remove the top plug and add oil

until the oil level is even with the bottom of the side plug hole.

4 Models with pipe plugs: Apply pipe thread

sealant to the plugs and install the plugs.

Models with O-ring plugs: Install the plugs

into the drive hub.

5 Repeat steps 1 through 4 for the other drive

hub.

REV A

B-8 Check and Adjust the Engine RPM

Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine pivot plate out away from the machine.

3 Connect an rpm gauge to the engine, and then

start the engine from the ground controls.

Result: Low idle should be 2000 rpm.

Skip to step 5 if the low idle rpm is correct.

3 - 18 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 43

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST B PROCEDURES

4 Loosen the lock nut, then turn the low idle

adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the lock nut and recheck the rpm.

a low idle adjustment screw

(not shown) b high idle adjustment nut c rpm solenoid d fuel shut off solenoid

5 Move the engine idle control switch to high idle

(rabbit symbol) from the ground controls.

Result: High idle should be 3000 rpm.

Skip to step 7 if the high idle rpm is correct.

6 Loosen the lock nut on the solenoid, then turn

the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the lock nut and recheck the rpm.

Be sure the solenoid fully retracts when activating high idle.

7 Swing the engine back to its original position

and close the engine pivot plate latch.

8 Install the engine pivot plate latch retainer.

B-9

Test the Ground Control Override

A properly functioning ground control override is

essential to safe machine operation. The ground control override function is intended to allow

ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the ON or

OFF position. This function is particularly useful if

the operator at the platform controls cannot return the boom to the stowed position.

1 Push in the platform red Emergency Stop

button to the off position.

2 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on position.

3 Operate each boom function through a

partial cycle at the ground controls.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 19

Result: All boom functions should operate.

Page 44

July 2004Section 3 • Scheduled Maintenance Procedures

REV ACHECKLIST B PROCEDURES

B-10 Test the Platform Self-leveling

Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom. A platform self-leveling failure creates an unsafe working condition.

1 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on position.

2 Lower the boom to the stowed position.

3 Hold the function enable toggle switch to either

side and adjust the platform to a level position using the platform level toggle switch.

4 Raise and lower the primary boom through

a full cycle.

Result: The platform should remain level at

all times to within ±5 degrees.

B-11 Test the Engine Idle Select

A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are three settings.

Low idle (turtle symbol): Low idle and slow battery charging.

High idle (rabbit symbol): High idle and quickest battery charging.

Foot switch activated high idle (rabbit and foot switch symbols): Activates high idle only when the foot switch is pressed down.

1 Start the engine from the ground controls. Move

the engine idle select toggle switch to high idle (rabbit symbol).

Result: The engine should change to high idle.

3 Release the engine idle select toggle switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 At the platform controls, move the engine idle

select toggle switch to high idle (rabbit symbol).

Result: The engine should change to high idle.

3 - 20 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 45

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

6 Move the engine idle select toggle switch to low

idle (turtle symbol).

Result: The engine should change to low idle.

7 Move the engine idle select toggle switch to foot

switch activated high idle (rabbit and foot switch symbol).

Result: The engine should not change to

high idle.

8 Press down the foot switch.

Result: The engine should change to high idle.

CHECKLIST B PROCEDURES

B-12 Test the Drive Brakes

Proper brake action is essential to safe machine operation. The machine uses drive motor regenerative braking to stop the machine. Hydraulically-released individual wheel brakes hold the machine once it has stopped. The drive motor regenerative braking should operate smoothly, free of hesitation and jerking. Hydraulically-released individual wheel brakes can appear to operate normally when not fully operational.

Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to B-6,

Brake Configuration

Confirm the Proper

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

1 Mark a test line on the ground for reference.

2 Lower the boom into the stowed position.

3 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use when crossing the test line.

4 Bring the machine to maximum drive speed

before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line.

5 Measure the distance between the test line and

your machine reference point. Refer to Section 2,

Specifications

The brakes must be able to hold the machine on any slope it is able to climb.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 21

Page 46

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-13 Test the Drive Speed Stowed Position

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range.

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

1 Create start and finish lines by marking two

lines on the ground 40 feet / 12.2 m apart.

2 Lower the boom into the stowed position.

3 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use when crossing the start and finish lines.

REV A

B-14 Test the Drive Speed - Raised or Extended Position

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

1 Create start and finish lines by marking two

lines on the ground 40 feet / 12.2 m apart.

2 Raise the platform more than 5 feet / 1.5 m.

3 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use when crossing the start and finish lines.

4 Bring the machine to maximum drive speed

before reaching the start line. Begin timing when your reference point on the machine crosses the start line.

5 Continue at full speed and note the time when

the machine reference point passes over the finish line. Refer to Section 2,

Specifications

4 Bring the machine to maximum drive speed

before reaching the start line. Begin timing when your reference point on the machine crosses the start line.

5 Continue at full speed and note the time when

the machine reference point passes over the

finish line. Refer to Section 2,

Specifications

3 - 22 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 47

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

B-15 Test the Alarm Package (if equipped)

The alarm package includes:

· Travel alarm

· Descent alarm

· Beacon

Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the ground controls side turntable cover.

The alarms and beacon will operate with the engine running or not running.

1 Turn the key switch to ground controls and pull

out the red Emergency Stop button to the on position at both the ground and platform controls.

CHECKLIST B PROCEDURES

3 Turn the key switch to platform control.

Result: The beacon should be flashing.

5 Press down the foot switch. Move the primary

boom toggle switch to the down position, hold for a moment and then release it. Move the secondary boom toggle switch to the down position, hold for a moment and then release it.

Z-45/25J: Move the jib boom toggle switch to

the down position, hold for a moment and then release it.

Result: The descent alarm should sound when

each toggle switch is held down.

6 Press down the foot switch. Move the drive

control handle off center, hold for a moment and then release it. Move the drive control handle off center in the opposite direction, hold for a moment and then release it.

Result: The travel alarm should sound when the

drive control handle is moved off center in either direction.

Result: The beacon should be flashing.

2 Move the primary boom toggle switch to the

down position, hold for a moment and then release it. Move the secondary boom toggle switch to the down position, hold for a moment and then release it.

Z-45/25J: Move the jib boom toggle switch to

the down position, hold for a moment and then release it.

Result: The descent alarm should sound when

each toggle switch is held down.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 23

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July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-16 Test the Turntable Rotation Stop

The turntable is capable of rotating the boom 355 degrees and is stopped midpoint between the steer wheels by the rotation stop. Detecting a rotation stop malfunction is essential to safe operation and good machine performance. If the turntable rotates past the rotation stop, component damage may result.

1 Turn the key switch to platform control and pull

out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Rotate the turntable to the left as far as it

will go.

Result: Movement should stop when the

primary boom reaches mid-point between the steer tires.

3 Rotate the turntable to the right full circle as far

as it will go.

Result: Movement should stop when the

primary boom reaches mid-point between the steer tires.

REV A

B-17 Check the Electrical Contactors

Maintaining the electrical contactors in good condition is essential to safe machine operation. Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage.

1 Remove the non-steer drive chassis cover and

locate the electrical contactors mounted on the component mounting panel.

2 Visually inspect the contact points of each

contactor for the following items:

· Excessive burns

· Excessive arcs

· Excessive pitting

Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Replace the contactors if any damage is found.

3 - 24 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 49

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST B PROCEDURES

B-18 Replace the Hydraulic Tank Return Filter

Replacement of the hydraulic tank return filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

1 Locate the hydraulic return filter next to the

hydraulic tank.

2 Place a suitable container under the hydraulic

filter.

3 Remove the filter with an oil filter wrench.

4 Apply a thin layer of oil to the new oil filter

gasket.

5 Install the new filter and tighten it securely by

hand. Clean up any oil that may have spilled during the installation procedure.

6 Turn the key switch to ground controls and pull

out the red Emergency Stop button out to the on position at both the ground and platform controls.

7 Activate any boom function and inspect the filter

and related components to be sure that there are no leaks.

8 Use a permanent ink marker to write the date

and number of hours from the hour meter on the oil filter.

B-19 Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often.

Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If

the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1,

Test or Replace the Hydraulic Oil.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 25

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July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-20 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 400 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

REV A

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

3 - 26 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 51

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

Checklist C Procedures

C-1 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 500 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

C-2 Grease the Platform Overload Mechanism (if equipped)

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist.

Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage.

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

1 Locate the grease fittings on each pivot pin of

the platform overload assembly.

2 Thoroughly pump grease into each grease

fitting using a mulit-purpose grease.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 27

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July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

C-3 Test the Platform Overload System (if equipped)

Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first.

Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over.

Perform this procedure with the machine on a firm, level surface.

1 Turn the key switch to platform control.

2 Level the platform from the platform controls.

3 Determine the maximum platform capacity.

Refer to the machine serial plate.

REV A

4 Using a suitable lifting device, place an

appropriate test weight equal to that of the maximum platform capacity in one of the locations shown.

Result: The platform overload indicator light

should be off at both the ground and platform controls.

5 Carefully move the test weight to each

remaining location.

Result: The platform overload indicator light

should be off at both the ground and platform controls.

6 Add an additional 66 lbs / 30 kg of weight to

overload the platform.

Result: The alarm should be sounding.

The platform overload indicator light should be flashing at both the ground and platform controls.

3 - 28 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. See D-5,

Overload System

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

Calibrate the Platform

Page 53

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

7 Carefully move the test weights to each

remaining location in the platform.

Result: The alarm should be sounding.

The platform overload indicator light should be flashing at both the ground and platform controls.

Overload System

Calibrate the Platform

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

8 Test all machine functions from the platform

controls.

Result: All platform control functions should not

operate.

9 Turn the key switch to ground control.

CHECKLIST C PROCEDURES

11 Lift the test weights off the platform floor using a

suitable lifting device.

Result: The platform overload indicator light and

alarm should turn off at both the ground and platform controls.

There may be an approximate 2 second delay before the overload indicator light and alarm turn off.

12 Test all machine functions from the ground

controls.

Result: All ground control functions should

operate normally.

13 Turn the key switch to platform control.

14 Test all machine functions from the platform

controls.

Result: All platform control functions should

operate.

If the platform overload system is not operating properly, see D-5,

Calibrate the Platform Overload System.

10 Test all machine functions from the ground

controls.

Result: All ground control functions should not

operate.

Machine functions should still operate with auxiliary power at the ground controls.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 29

Page 54

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

C-4 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 800 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

REV A

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

3 - 30 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 55

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

Checklist D Procedures

D-1 Check the Primary Boom Wear Pads

Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions.

1 Raise the end of the primary boom to a

comfortable working height (chest high), then extend the boom 1 foot / 30 cm.

2 Measure each wear pad. Replace the wear pad

if it is less than 9/16 inch / 14.3 mm. If the wear pad is not less than 9/16 inch / 14.3 mm, shim as necessary to obtain zero clearance with minimal drag.

3 Extend and retract the primary boom through

the entire range of motion to check for tight spots that may cause binding or scraping of the boom.

D-2 Check the Turntable Rotation Bearing Bolts

Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage.

1 Raise the primary boom and place a safety

chock on the lift cylinder rod. Carefully lower the boom onto the lift cylinder safety chock.

Crushing hazard. Keep hands away from cylinder and all moving parts when lowering the boom.

A lift cylinder safety chock is available through Genie (part number 33484).

2 Remove the engine pivot plate latch retainer.

3 Open the engine pivot plate latch and swing the

engine out and away from the machine to access the turntable bearing bolts.

Always maintain squareness between the outer and inner boom tubes.

Wear pad specifications

All wear pads

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 31

/16 inch

14.3 mm

Page 56

July 2004Section 3 • Scheduled Maintenance Procedures

REV ACHECKLIST D PROCEDURES

4 Be sure that each turntable mounting bolt is

torqued in sequence to 220 ft-lbs / 298 Nm.

Bolt torque sequence (before serial number 23332)

5 Lower the boom to the stowed position.

6 Remove drive chassis covers from both the

steer end and the non-steer end of the machine.

7 Check to ensure that each bearing mounting

bolt under the drive chassis is torqued in sequence to 220 ft-lbs / 298 Nm.

Bolt torque sequence (before serial number 23332)

Bolt torque sequence (after serial number 23331)

3 - 32 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST D PROCEDURES

D-3 Check the Free-wheel Configuration

Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge could result in death or serious injury and property damage.

Collision hazard. Select a work site that is firm and level.

Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h.

1 Chock the steer wheels to prevent the machine

from rolling.

2 Center a lifting jack of ample capacity

(20,000 lbs / 10,000 kg) under the drive chassis between the non-steer tires.

3 Lift the wheels off the ground and then place

jack stands under the drive chassis for support.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate with

minimum effort.

6 Re-engage the drive hubs by turning over

the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the jack stands.

Collision hazard. Failure to engage the drive hubs could result in death or serious injury and property damage.

4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each non-steer wheel hub.

brake disengaged position

brake engaged position

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 33

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July 2004Section 3 • Scheduled Maintenance Procedures

REV ACHECKLIST D PROCEDURES

D-4 Replace the Drive Hub Oil

Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage.

1 Select the drive hub to be serviced. Then drive

the machine until one of the two plugs is at the lowest point.

2 Remove both plugs and drain the oil.

3 Drive the machine to rotate the hub until one of

the plugs is located on top and the other one is at 90 degrees.

4 Fill the hub with oil from the top hole until the oil

level is even with the bottom of the side hole.

5 Models with pipe plugs: Apply pipe thread

sealant to the plugs and install the plugs.

Models with O-ring plugs: Install the plugs

into the drive hub.

6 Repeat steps 1 through 5 for the other drive

hub.

D-5 Calibrate the Platform Overload System (if equipped)

Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.

models with pipe plugs

a models with o-ring plugs

Yearly calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.

1 Level the platform.

2 Determine the maximum platform capacity.

Refer to the machine serial plate.

3 Using a suitable lifting device, place an

appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor.

Perform this procedure with the machine on a firm, level surface.

3 - 34 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 59

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

Determine the limit switch trigger point:

4 Gently move the platform up and down by hand,

so it bounces approximately 1 to 2 inches /

2.5 to 5 cm. Allow the platform to settle.

Result: The overload indicator light and the

alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off.

The platform will need to be moved up and down and allowed to settle in between adjustments.

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

Result: The overload indicator light and

alarm is off. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on.

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

The platform will need to be moved up and down and allowed to settle in between adjustments.

CHECKLIST D PROCEDURES

Confirm the setting:

5 Turn the key switch to platform control.

6 Lift the test weight off the platform floor using a

suitable lifting device.

7 Place the test weight back onto the center of

the platform floor using a suitable lifting device.

Result: The alarm should be off. The platform

overload indicator light should be off at both the ground and platform controls.

There may be an approximate 2 second delay before the overload indicator light and alarm turn off.

8 Add an additional 10 lb / 4.5 kg test weight to

the original test weight to overload the platform.

Result: The alarm should be sounding.

The platform overload indicator light should be flashing at both the ground and platform controls.

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

9 Test all machine functions from the platform

controls.

Result: All platform control functions should not

operate.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 35

10 Turn the key switch to ground control.

11 Test all machine functions from the ground

controls.

Result: All ground control functions should not

operate.

If the platform overload system is not operating properly, repeat steps 1 through 4.

Page 60

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

D-6 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

Kubota Z482-E Operator's Manual

Genie part number 52958

REV A

D-7 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 1500 hours.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

3 - 36 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

Page 61

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A

Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil

Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If

the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test.

Perform this procedure with the boom in the stowed position.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Place a suitable container under the hydraulic

tank. See capacity specifications.

Hydraulic Hose and

2 Remove the drain plug from the hydraulic tank.

3 Completely drain the tank into a suitable

container.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

4 Tag, disconnect and plug the hydraulic hose

from the hydraulic tank filter at the tank.

Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

5 Remove the hydraulic tank mounting fasteners.

6 Pull the hydraulic tank out slightly to access the

two suction hoses.

7 Tag, disconnect and plug the two suction hoses

on the back of the hydraulic tank.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 37

Page 62

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST E PROCEDURES

8 Remove the hydraulic tank from the machine.

Component damage hazard. The hydraulic tank is plastic and may become damaged if it is allowed to fall.

9 Remove the suction strainer from the tank and

clean it using a mild solvent.

10 Rinse out the inside of the tank using a mild

solvent.

11 Install the suction strainer and drain plug using

a thread sealer on the threads.

12 Place the hydraulic tank onto the machine.

13 Install the hydraulic hoses.

14 Install the hydraulic tank mounting fasteners

and torque to specification. Refer to Section 2,

Specifications

15 Fill the tank with hydraulic oil until the fluid is

within the FULL and ADD marks on the hydraulic tank. Do not overfill.

Component damage hazard. The hydraulic tank may become damaged if the tank mounting fasteners are over tightened.

REV A

E-2 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first.

Required maintenance procedures and additional engine information are available in the

Kubota Z482-E Operator's Manual

(Kubota part number 16676-89163).

Kubota Z482-E Operator's Manual

Genie part number 52958

To access the engine:

16 Clean up any oil that may have spilled. Properly

discard of oil.

17 Operate all machine functions through a full

cycle and check for leaks.

3 - 38 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine.

Page 63

July 2004 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST E PROCEDURES

E-3 Grease the Steer Axle Wheel Bearings

Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often.

1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels, then center a lifting

jack under the steer axle.

3 Raise the machine 6 inches / 15 cm and place

blocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire and

wheel assembly.

5 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and down.

Result: There should be no side to side or up

and down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove the

cotter pin from the castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm to

seat the bearings.

8 Loosen the castle nut and re-tighten to

8 ft-lbs / 11 Nm.

9 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and down.

Result: If there is side to side or up and down

movement, continue to step 11 and replace the wheel bearings with new ones.

When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced.

Result: If there is no side to side or up and

down movement, continue with step 11 and grease the wheel bearings.

10 Remove the dust cap from the hub. Remove the

cotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer and

outer bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently pry

the bearing seal out of the hub. Remove the rear bearing.

14 Pack both bearings with clean, fresh grease.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 3 - 39

Page 64

July 2004Section 3 • Scheduled Maintenance Procedures

CHECKLIST E PROCEDURES

15 Place the large inner bearing into the rear of the

hub.

16 Install a new bearing grease seal into the hub

by pressing it evenly into the hub until it is flush.

Always replace the bearing grease seal when removing the hub.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the castle nut to 35 ft-lbs / 47 Nm to

seat the bearings.

21 Loosen the castle nut and re-tighten to

8 ft-lbs / 11 Nm.

REV A

22 Install a new cotter pin. Bend the cotter pin

to lock it in.

23 Install the dust cap, then the tire and wheel

assembly. Torque the wheel lug nuts to specification. Refer to Section 2,

Specifications.

3 - 40 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 65

July 2004 Section 4 • Repair Procedures

Repair Procedures

About This Section

Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Observe and Obey:

Repair procedures shall be completed by a

person trained and qualified on the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Before Repairs Start:

Read, understand and obey the safety rules

and operating instructions in the

Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Operator’s Manual

Be sure that all necessary tools and parts are

available and ready for use.

Read each procedure completely and adhere

to the instructions. Attempting shortcuts may produce hazardous conditions.

Unless otherwise specified, perform each

repair procedure with the machine in the following configuration:

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· Wheels chocked

on your machine.

Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order.

Symbols Legend

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Used to indicate operation or maintenance information.

Indicates that a specific result is expected after

performing a series of steps.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 1

Page 66

July 2004Section 4 • Repair Procedures

Platform Controls

1-1 Controllers

Platform Controls

The drive joystick is connected to the drive motor controller located under the non-steer end drive chassis cover. The drive motor controller can also recognize machine drive malfunctions and display controller fault codes by flashing an LED at the ground controls. See the Troubleshooting section of this manual for a list of fault codes and additional information. There are no adjustments needed on the drive joystick controller. For further information or assistance, consult the Genie Industries Service Department.

REV A

Boom Function Speed Controller Adjustments

Do not adjust the controllers unless the static battery supply voltage is above 24V DC at the platform red Emergency Stop button.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Turn the key switch to platform control and pull

out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Open the platform control box lid and locate the

boom function speed controller.

a boom function speed controller b drive joystick

a threshold adjustable trimpot b max-out adjustable trimpot c white/red wire to TP6 d boom function speed controller

4 - 2 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 67

July 2004 Section 4 • Repair Procedures

REV A

Before serial number 21180:

3 Remove the wht/red wire from TP6. Temporarily

insert a short piece of stripped wire into TP6.

4 Connect the red (+) lead from an amp meter to

the wht/red wire. Connect the black (-) lead to the piece of wire at TP6.

After serial number 21179:

3 Disconnect the blk/red wire of the boom

function speed controller from the wht/red wire.

4 Connect the red (+) lead from an amp meter to

the blk/red wire. Connect the black (-) lead to the wht/red wire.

All models:

5 Turn the boom function speed controller to the

CREEP position.

6 Set the threshold: With the boom in the stowed

position, press down the foot switch and move the primary boom toggle switch in the down position until the amperage reading appears. Adjust the amperage to 0.17 to 0.18A. Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage.

PLATFORM CONTROLS

7 Turn the boom function speed controller to

the 9 position.

8 Set the max-out: Press down the foot switch,

then move the primary boom toggle switch in the down position. Adjust the amperage to 0.54 to 0.55A. Turn the max-out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage.

9 Before serial number 21180: Remove the

temporary wire from TP6 and install the wht/red wire into TP6.

Boom function speed controller specifications

Threshold 0.17 to 0.18A

Max-out 0.54 to 0.55A

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 3

Page 68

July 2004Section 4 • Repair Procedures

Platform Components

2-1 Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Platform Leveling Slave Cylinder

Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two,

Hose and Fitting Torque Specifications.

1 Z-45/25J: Extend the primary boom until the

slave cylinder barrel-end pivot pin is accessible.

2 Raise the primary boom slightly and place

blocks under the platform for support.

Hydraulic

REV A

3 Lower the primary boom until the platform is

resting on the blocks just enough to support the platform.

Do not rest the entire weight of the boom on the blocks.

4 Z-45/25J: Tag and disconnect the hydraulic

hoses from the slave cylinder at the union located near the jib/rotate manifold and connect them together using a connector. Connect the hoses from the cylinder together using a connector.

Z-45/25: Tag and disconnect the hydraulic

hoses from the slave cylinder and connect the hoses together using a connector. Cap the fittings on the cylinder. Then pull the slave cylinder hoses out through the primary extension boom.

4 - 4 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

5 Remove the pin retaining fastener from the

slave cylinder rod-end pivot pin. Do not remove the pin.

Page 69

July 2004 Section 4 • Repair Procedures

REV A PLATFORM COMPONENTS

6 Z-45/25J: Remove the external snap rings from

the barrel-end pivot pin. Do not remove the pin.

Z-45/25: Remove the pin retaining fastener

from the slave cylinder barrel-end pivot pin. Do not remove the pin.

7 Support the slave cylinder with a lifting device.

8 Z-45/25J: Support the jib boom bell crank with a

suitable lifting device.

9 Use a soft metal drift to drive the rod-end pivot

pin out.

Crushing hazard. The jib boom bell crank could fall when the slave cylinder rod-end pivot pin is removed if not properly supported.

Component damage hazard. The slave cylinder rod may become damaged if it is allowed to fall if not properly supported by the lifting device.

10 Use a soft metal drift to remove the rod-end

pivot pin.

How to Bleed the Slave Cylinder

1 Raise the primary boom to a horizontal position.

2 Move the platform level switch up and down

through two platform leveling cycles to remove any air that might be in the system.

11 Use a soft metal drift to remove the barrel-end

pivot pin.

12 Carefully pull the cylinder out of the primary

boom.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 5

Page 70

July 2004Section 4 • Repair Procedures

PLATFORM COMPONENTS

2-2 Platform Rotator

How to Bleed the Platform Rotator

1 Move the function enable toggle switch to either

side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right.

2 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a container to collect any drainage. Secure the container to the boom.

3 Open the top bleed valve on the rotator, but do

not remove it.

REV A

4 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve.

Crushing hazard. Keep clear of the platform during rotation.

5 Connect the clear hose to the bottom bleed

valve and open the valve. Do not remove the bleed valve.

6 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve.

Crushing hazard. Keep clear of the platform during rotation.

d c b

a top bleed valve b bottom bleed valve c container d clear hose

7 Remove the hose from the bleed valve and

clean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions and

inspect the bleed valves for leaks.

4 - 6 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 71

July 2004 Section 4 • Repair Procedures

REV A

Jib Boom Components, Z-45/25J

3-1 Jib Boom

How to Remove the Jib Boom

Perform this procedure with the boom in the stowed position.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Remove the platform.

2 Remove the platform mounting weldment

and the platform rotator.

3 Remove the hose and cable cover from the side

of the jib boom.

4 Attach a lifting strap from an overhead crane to

the jib boom.

5 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

Hydraulic Hose and

6 Support the barrel end of the cylinder with a

suitable lifting device.

7 Remove the pin retaining fastener from the jib

boom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pin and let

the cylinder hang down.

9 Remove the pin retaining fastener from the jib

boom pivot pin. Use a soft metal drift to remove the pin, then remove the jib boom from the primary boom bellcrank.

Crushing hazard. The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

10 Remove the pin retaining fastener from the jib

boom lift cylinder rod-end pivot pin. Do not remove the pin.

11 Slide both of the jib boom leveling arms off of

the jib boom cylinder rod-end pivot pin.

12 Attach a lifting strap from an overhead crane to

the lug on the rod end of the jib boom lift cylinder.

13 Use a soft metal drift to remove the jib boom lift

cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the primary boom bellcrank.

Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 7

Page 72

July 2004Section 4 • Repair Procedures

REV AJIB BOOM COMPONENTS, Z-45/25J

3-2 Jib Boom Lift Cylinder

How to Remove the Jib Boom Lift Cylinder

Perform this procedure with the boom in the stowed position.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Raise the jib boom slightly and place blocks

under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform.

Do not rest the entire weight of the boom on the blocks.

2 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

Hydraulic Hose and

3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not remove the pin.

4 Use a soft metal drift to tap the jib boom lift

cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a lifting

device.

6 Remove the pin retaining fastener from the jib

boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.

7 Attach a lifting strap from an overhead crane to

the lug on the rod end of the jib boom lift cylinder.

8 Use a soft metal drift to remove the jib boom lift

cylinder rod-end pin. Remove the cylinder from the machine.

Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

4 - 8 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 73

July 2004 Section 4 • Repair Procedures

REV A

Primary Boom Components

4-1 Cable Track

The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom.

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

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Locate the cables from the primary boom cable

track to the platform control box. Number each cable and its entry location at the platform control box.

2 Disconnect the cables from the platform control

box.

3 Pull all of the electrical cables out of the plastic

cable track. Do not pull out the hydraulic hoses.

4 Raise the primary boom to a horizontal position.

Hydraulic Hose

5 Tag, disconnect and plug the platform rotator

hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions.

6 Tag, disconnect and plug the hydraulic hoses

from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold.

7 Tag, disconnect and plug the hydraulic hoses

from the platform leveling master cylinder. Cap the fittings on the cylinder.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 9

Page 74

July 2004Section 4 • Repair Procedures

REV APRIMARY BOOM COMPONENTS

8 Tag and disconnect the hydraulic hoses from

the platform leveling slave cylinder and connect them together using a connector. Cap the fittings on the cylinder.

9 Pull the four hydraulic hoses toward the

platform to clear the rod end of the primary boom lift cylinder.

10 Place blocks in between the upper and lower

cable tracks and secure the upper and lower tracks together.

Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

11 Remove all hose and cable clamps from the

underside of the primary boom.

12 Attach a strap from an overhead crane to the

cable track.

13 Remove the mounting fasteners from the upper

cable track at the platform end of the extension boom.

14 Remove the cable track mounting fasteners that

attach the lower cable track to the primary boom.

15 Remove the cable track from the machine and

place it on a structure capable of supporting it.

Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Locate the cables from the primary boom cable

track to the platform control box. Number each cable and its entry location at the platform control box.

2 Disconnect the cables from the platform control

box.

3 Pull all of the electrical cables out of the plastic

cable track. Do not pull out the hydraulic hoses.

Hydraulic Hose and

4 - 10 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 75

July 2004 Section 4 • Repair Procedures

REV A

4 Tag, disconnect and plug the hydraulic hoses

from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold.

5 Tag and disconnect the hydraulic hoses from

the platform leveling slave cylinder at the union and connect them together using a connector. Connect the hoses from the cylinder together using a connector.

6 Tag, disconnect and plug the hydraulic hoses

from the jib boom/platform rotate manifold. Cap the fittings on the manifold.

PRIMARY BOOM COMPONENTS

7 Tag, disconnect and plug the platform rotator

hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions.

8 Tag, disconnect and plug the hydraulic hoses

from the platform leveling master cylinder. Cap the fittings on the cylinder.

9 Raise the boom to a horizontal position.

10 Remove the hose and cable cover from the side

of the jib boom.

11 Remove the hose clamp on the primary boom

bellcrank.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 11

12 Place blocks between the upper and lower

cable tracks and secure the upper and lower tracks together.

Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

Page 76

July 2004Section 4 • Repair Procedures

PRIMARY BOOM COMPONENTS

13 Attach a lifting strap from an overhead 5 ton /

5,000 kg capacity crane to the platform end of the primary boom for support. Do not lift it.

14 Remove all hose and cable clamps from the

underside of the primary boom.

15 Support the rod end of the primary boom lift

cylinder with a lifting device.

16 Remove the pin retaining fasteners from the

primary boom lift cylinder rod-end pivot pin. Do not remove the pin.

17 Raise the primary boom slightly with the

overhead crane to relieve the pressure on the primary boom lift cylinder rod-end pivot pin.

18 Use a soft metal drift to remove the primary

boom lift cylinder rod-end pivot pin.

Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device.

REV A

23 Remove the mounting fasteners from the upper

cable track at the platform end of the extension boom.

24 Remove the cable track mounting fasteners that

attach the lower cable track to the primary boom.

25 Remove the cable track from the machine and

place it on a structure capable of supporting it.

Crushing hazard. The cable track could become unbalanced and fall if it is not properly attached to the overhead crane.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

19 Lower the rod end of the primary boom lift

cylinder approximately 12 inches / 30 cm.

20 Pull all of the hoses and cables out and away

from the mounting ears for the rod end of the primary boom lift cylinder.

21 Raise the rod end of the primary boom lift

cylinder back into position and install the rodend pivot pin. Install the pin retaining fastener.

22 Attach a strap from an overhead crane to the

cable track.

4 - 12 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 77

July 2004 Section 4 • Repair Procedures

REV A PRIMARY BOOM COMPONENTS

How to Repair the Primary Boom Cable Track

Component damage hazard. The primary boom cable track can be damaged if it is twisted.

A 7 link repair section of cable track is available through the Genie Industries Service Parts Department.

a link separation point b lower clip

1 Use a slotted screwdriver to pry down on the

lower clip.

2 To remove a single link, open the lower clip

and then use a screw driver to pry the link to the side.

3 Repeat steps 1 and 2 for each link.

4-2 Primary Boom

How to Remove the Primary Boom

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Perform this procedure with the boom in the stowed position.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Remove the platform.

2 Remove the platform rotator and platform

mounting weldment.

Hydraulic Hose

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 13

3 Z-45/25: Remove the platform leveling slave

cylinder. See 2-1,

Leveling Slave Cylinder.

Z-45/25J: Remove the jib boom.

See 3-1,

How to Remove the Jib Boom.

How to Remove the Platform

Page 78

July 2004Section 4 • Repair Procedures

REV APRIMARY BOOM COMPONENTS

4 Remove the cable track. See 4-1,

How to

Remove the Cable Track.

5 Raise the primary boom to a horizontal position.

6 Remove the hose and cable cover from the

upper pivot.

7 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. Then lower the cylinder and let it hang down.

Component damage hazard. When lowering the master cylinder down, be sure not to damage the master cylinder hoses or fittings.

8 Locate the primary boom drive speed limit

switch inside of the upper pivot.

9 Remove the primary boom drive speed limit

switch mounting fasteners. Do not disconnect the wiring.

10 Locate the primary boom extension drive speed

limit switch inside of the extension boom.

11 Remove the primary boom extension drive

speed limit switch mounting fasteners. Do not disconnect the wiring.

14 Remove the hose clamp at the pivot end of the

boom.

15 Attach a 5 ton / 5,000 kg overhead crane to the

center point of the primary boom.

16 Attach a similar lifting device to the primary

boom lift cylinder.

17 Place support blocks under the primary boom

lift cylinder.

18 Remove the pin retaining fastener from the

primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

Crushing hazard. The boom lift cylinder and primary boom will fall if not properly supported.

19 Lower the rod end of the primary boom lift

cylinder onto support blocks. Protect the cylinder rod from damage.

20 Remove the pin retaining fastener from the

primary boom pivot pin.

21 Remove the primary boom pivot pin with a soft

metal drift, then carefully remove the primary boom from the machine and place it on a structure capable of supporting it.

12 Pull the limit switch and the wiring out of the

extension tube and move it out of the way.

13 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

Crushing hazard. The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

4 - 14 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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July 2004 Section 4 • Repair Procedures

REV A PRIMARY BOOM COMPONENTS

How to Disassemble the Primary Boom

Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4,

the Primary Boom Extension Cylinder

1 Remove the primary boom. See

Remove the Primary Boom

2 Place blocks under the barrel end of the primary

boom extension cylinder for support.

3 Remove the pin retaining fastener from the

extension cylinder barrel-end pivot pin at the pivot end of the primary boom. Use a soft metal drift to remove the pin.

4 Remove and label the location of the wear pads

from the platform end of the primary boom.

How to Remove

How to

6 Remove the external snap rings from the

extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin.

7 Support and slide the extension cylinder out of

the base end of the extension tube. Place the extension cylinder on blocks for support.

Crushing hazard. The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported.

During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

Pay careful attention to the location and amount of shims used with each wear pad.

5 Support and slide the extension tube and

extension cylinder assembly out of the boom tube.

Crushing hazard. The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported.

During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 15

Page 80

July 2004Section 4 • Repair Procedures

PRIMARY BOOM COMPONENTS

4-3 Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

How to Remove the Primary Boom Lift Cylinder

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Raise the primary boom until the primary boom

is horizontal.

Hydraulic Hose

REV A

4 Support the rod end and the barrel end of the

primary boom lift cylinder with a second overhead crane or similar lifting device.

5 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

6 Remove the pin retaining fastener from the

primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

The primary boom will fall if not properly supported when the primary boom rod-end pivot pin is removed.

7 Place a support block across both turntable

covers under the primary boom lift cylinder.

8 Lower the lift cylinder onto the block. Protect the

cylinder rod from damage.

Crushing hazard. The primary boom lift cylinder could fall if not properly supported.

2 Raise the secondary boom until the primary

boom lift cylinder barrel-end pivot pin is above the turntable covers.

3 Attach a 5 ton / 5000 kg overhead crane to the

primary boom for support. Do not lift the boom.

4 - 16 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

9 Remove the primary boom lift cylinder barrel-

end pivot pin retaining fasteners. Do not remove the pin.

10 Use a slide hammer to remove the barrel-end

pivot pin. Carefully remove the primary boom lift cylinder from the machine.

Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device.

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July 2004 Section 4 • Repair Procedures

REV A

4-4 Primary Boom Extension Cylinder

The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Primary Boom Extension Cylinder

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Raise the primary boom to a horizontal position.

2 Extend the primary boom until the primary

boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube.

Hydraulic Hose

PRIMARY BOOM COMPONENTS

3 Remove the hose and cable guard from the

upper pivot.

4 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

5 At the platform end, remove the external snap

rings from the extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

6 Remove the barrel-end pivot pin retaining

fasteners.

7 Place a rod through the barrel-end pivot pin and

twist to remove the pin.

8 Support and slide the extension cylinder out of

the upper pivot.

Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported.

Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom.

Component damage hazard. Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 17

Note the length of the cylinder after removal. The cylinder must be at the same length for installation.

Page 82

July 2004Section 4 • Repair Procedures

PRIMARY BOOM COMPONENTS

4-5 Platform Leveling Master Cylinder

The master cylinder acts as a pump for the slave cylinder. It’s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. The master cylinder is located at the base of the primary boom.

How to Remove the Platform Leveling Master Cylinder

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

Hydraulic Hose

REV A

3 Attach overhead crane or similar lifting device to

the master cylinder.

4 Remove the pin retaining fasteners from the

master cylinder barrel-end pivot pin. Do not remove the pin.

5 Place a rod through the barrel-end pivot pin and

twist to remove the pin.

6 Remove the pin retaining fastener from the rod-

end pivot pin.

7 Place a rod through the rod-end pivot pin and

twist to remove the pin.

8 Remove the master cylinder from the machine.

Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane.

1 Raise the secondary boom until both the rod-

end and barrel-end pivot pins on the master cylinder are accessible.

2 Tag, disconnect and plug the master cylinder

hydraulic hoses. Cap the fittings on the cylinder.

4 - 18 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 83

July 2004 Section 4 • Repair Procedures

REV A PRIMARY BOOM COMPONENTS

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Page 84

July 2004Section 4 • Repair Procedures

Secondary Boom Components

a b c

REV A

Secondary Boom components a upper secondary boom

(number 1 arm)

b upper tension link

(number 2 arm)

c lower tension link

(number 3 arm) d mid-pivot e compression link f secondary boom lift cylinder (2) g lower secondary boom

(number 4 arm) h turntable pivot i boom rest j upper pivot

4 - 20 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

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July 2004 Section 4 • Repair Procedures

REV A

5-1 Secondary Boom

How to Disassemble the Secondary Boom

Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required.

Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Remove the platform.

Hydraulic Hose

SECONDARY BOOM COMPONENTS

4 Remove the master cylinder. See 4-5,

Remove the Master Cylinder

5 Attach a lifting strap from an overhead crane to

to the lug on the rod end of the primary boom lift cylinder. Then raise the primary boom lift cylinder with the crane, to a vertical position.

6 Tag, disconnect and plug the hydraulic hoses at

the primary boom lift cylinder. Cap the fittings on the cylinder.

7 Remove the pin retaining fastener from the

primary boom lift cylinder barrel-end pivot pin.

8 Use a slide hammer to remove the pin. Remove

the primary boom lift cylinder from the machine.

Crushing hazard. The primary boom lift cylinder could become unbalanced and fall if not properly supported by the overhead crane.

9 Tag, disconnect and plug the hydraulic hoses

on both of the secondary boom lift cylinders. Cap the fittings on the cylinders.

How to

2 Z-45/25J: Remove the jib boom.

See 3-1,

3 Remove the primary boom. See 3-2,

Remove the Primary Boom

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 21

How to Remove the Jib Boom.

How to

Page 86

July 2004Section 4 • Repair Procedures

REV ASECONDARY BOOM COMPONENTS

10 Remove the pin retaining fasteners from both

sides of the secondary boom lift cylinder rodend pivot pin and barrel-end pivot pin. Do not remove the pins.

11 Attach a strap from an overhead crane to the

lug on the rod end of one of the secondary boom lift cylinders for support. Do not apply any lifting pressure.

12 Use a soft metal drift to drive the barrel-end

pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down.

13 Use a soft metal drift to drive the rod-end pivot

pin half way out.

14 Remove the secondary boom lift cylinder from

the machine.

15 Repeat steps 11 through 14 for the other

secondary boom lift cylinder.

Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder.

16 Attach a lifting strap from an overhead crane to

the upper pivot for support. Do not lift it.

17 Attach a lifting strap from a second overhead

crane to the number 1 arm at the mid-point between the upper pivot and mid-pivot.

18 Remove the pin retaining fasteners from the

number 1 arm pivot pins at the mid-pivot and the upper pivot. Do not remove the pins.

19 Use a soft metal drift to drive both pins out.

20 Remove the number 1 arm from the machine.

Crushing hazard. The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

Crushing hazard. The upper pivot could fall when the number 1 arm is removed from the machine if not properly supported by the overhead crane.

21 Using the overhead crane attached to upper

pivot, raise the secondary boom assembly approximately 30 inches / 76 cm.

22 Insert a 4 x 4 x 11 inch / 10 x 10 x 30 cm block

between the number 2 arm and the boom rest. Then lower the secondary boom assembly onto the block.

Crushing hazard. The secondary boom assembly could fall if not properly supported by the 4 x 4 x 11 inch / 10 x 10 x 30 cm block.

4 - 22 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 87

July 2004 Section 4 • Repair Procedures

REV A SECONDARY BOOM COMPONENTS

23 Pull all of the cables and hoses out through the

upper pivot.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

24 Remove the hose and cable covers from the top

of the number 2 arm.

25 Pull all of the hoses and cables out of the upper

pivot and out through the mid-pivot. Lay the hoses and cables on the ground.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

26 Remove the pin retaining fastener from the

number 2 arm pivot pin at the upper pivot. Use a soft metal drift to remove the pin.

27 Remove the upper pivot from the machine.

Crushing hazard. The upper pivot could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

28 Attach the lifting strap from an overhead crane

to the number 2 arm at the upper pivot end.

29 Raise the number 2 arm slightly and remove the

4 x 4 x 11 inch / 10 x 10 x 30 cm block.

31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 20 cm block

between the number 3 arm and the number 4 arm at the mid-pivot end.

32 Attach a lifting strap from the overhead crane to

the mid-pivot for support. Do not lift it.

33 Remove the pin retaining fasteners from the

number 2, 3 and 4 arm pivot pins at the mid-pivot. Do not remove the pins.

34 Use a soft metal drift to drive each pin out. Then

remove the mid-pivot from the secondary boom assembly.

Crushing hazard. The mid-pivot could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane.

35 Attach the lifting strap from an overhead crane

to the center point of the number 2 arm for support. Do not lift it.

36 Remove the pin retaining fasteners from both

compression link pivot pins. Do not remove the pins.

37 Use a soft metal drift to remove the lower

compression link pivot pin at the number 3 arm.

38 Support the compression link with an

appropriate lifting device.

30 Lower the number 2 arm onto the boom rest

pad.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 23

Page 88

July 2004Section 4 • Repair Procedures

REV ASECONDARY BOOM COMPONENTS

39 Use a soft metal drift to remove the upper

compression link pivot pin from the number 2 arm. Remove the compression link from the machine.

Crushing hazard. The number 2 arm could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane.

Crushing hazard. The compression link may fall if not properly supported when removed from the secondary boom assembly.

40 Remove the number 2 arm from the machine.

Crushing hazard. The number 2 arm could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overhead crane.

41 Remove the upper and lower hose and cable

covers from the number 3 arm.

42 Pull all of the cables and hoses from the

number 3 arm and lay them over the turntable counterweight.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

43 Open the ground controls side turntable cover.

44 Remove the fuel tank.

Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach.

45 Remove the retaining fastener from the ground

control box and function manifold pivot plate.

46 Lower the ground control box and function

manifold pivot plate to access the number 3 arm pivot pin.

47 Attach the lifting strap from the overhead crane

to the centerpoint of the number 3 arm for support. Do not lift it.

48 Remove the mounting fasteners from the cover

located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable pivot.

49 Remove the pin retaining fasteners from the

number 3 arm at the turntable pivot. Do not remove the pin.

50 Use a slide hammer to remove the number 3

arm pivot pin from the turntable pivot through the access hole behind the ground control box.

51 Remove the number 3 arm from the machine.

Crushing hazard. The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

4 - 24 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 89

July 2004 Section 4 • Repair Procedures

REV A

52 Remove the secondary boom drive speed limit

switch mounting fasteners from the number 4 arm at the mid-pivot end. Do not disconnect the wiring.

53 Remove the pin retaining fasteners from the

number 4 arm at the turntable pivot. Do not remove the pin.

54 Attach a lifting strap from the overhead crane to

the center point of the number 4 arm. Do not lift it.

55 Use a slide hammer to remove the number 4

arm from the turntable pivot through the ground controls side bulkhead.

56 Remove the number 4 arm from the machine.

Crushing hazard. The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

SECONDARY BOOM COMPONENTS

5-2 Secondary Boom Lift Cylinders

There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly. These cylinders operate in parallel and require hydraulic pressure to extend and retract. Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

How to Remove a Secondary Boom Lift Cylinder

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

and Fitting Torque Specifications.

1 Lower the secondary boom to the stowed

position.

2 Raise the primary boom so that it is above the

secondary boom lift cylinder rod-end pivot pin.

Hydraulic Hose

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 25

Page 90

July 2004Section 4 • Repair Procedures

SECONDARY BOOM COMPONENTS

3 Tag, disconnect and plug the hydraulic hoses

on the secondary boom lift cylinder.

4 Remove the pin retaining fasteners from the

secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do not remove the pins.

5 Attach a strap from an overhead crane to the

lug on the rod end of the secondary boom lift cylinder for support. Do not apply any lifting pressure.

6 Use a soft metal drift to drive the barrel-end

pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down.

REV A

7 Use a soft metal drift to drive the rod-end pivot

pin half way out.

8 Remove the secondary boom lift cylinder from

the machine.

Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder.

4 - 26 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 91

July 2004 Section 4 • Repair Procedures

REV A

Kubota Z482-E Engine

6-1 Timing Adjustment

Complete information to perform this procedure is available in the (Kubota part number 97897-01165).

Kubota Z482-E Workshop Manual

Genie part number 52956

Kubota Z482-E Workshop Manual

6-2 RPM Adjustment

See the scheduled maintenance procedure B-8,

Check and Adjust the Engine RPM.

4 Pull the generator away from the machine and

remove the belts from the generator pulley.

5 Remove the 3 bolts that attach the engine drive

pulley to the shaft bushing.

6 Install the same 3 bolts that were removed in

step 5 into the threaded holes of the engine drive pulley.

7 Carefully tighten each bolt evenly until the

engine drive pulley slides off the shaft.

Component damage hazard. The engine drive pulley and/or shaft can be damaged if the bolts are not tightened evenly.

8 Loosen the set screw on the pulley bushing,

then slide the pulley bushing off of the engine shaft.

6-3 Engine Drive Pulley

How to Remove the Engine Drive Pulley

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine to access the engine drive pulley.

3 Loosen the tension adjustment bolt on the

generator.

e e

a gap b shaft c set screw d engine drive pulley e engine drive pulley bolt f shaft bushing g woodruff key

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 27

Page 92

July 2004Section 4 • Repair Procedures

KUBOTA Z482-E ENGINE

How to Install the Engine Drive Pulley

The generator pulley must already be installed before performing this procedure. See 7-1,

the Generator Pulley

1 Align the woodruff key on the engine shaft with

the slot in the pulley bushing and slide the pulley bushing onto the engine shaft. Do not tighten the set screw.

2 Align the flywheel side of the pulley bushing on

the engine shaft with the outer face of the generator pulley using a straightedge.

How to Install

REV A

3 Tighten the set screw on the pulley bushing

hand tight.

4 Slide the engine pulley onto the pulley bushing.

5 Install the pulley mounting bolts and tighten

them to specification. Refer to Section 2,

Specifications

Component damage hazard. Do not overtighten the pulley mounting bolts. There must be a gap visible between the engine drive pulley and the pulley bushing.

Specifications

a pulley shaft b pulley bushing c engine flywheel d straightedge e generator pulley f generator

e e

a gap b shaft c set screw d engine drive pulley e pulley mounting bolt f pulley bushing

g woodruff key

6 Check the alignment between the engine drive

pulley and the generator pulley using a straightedge. Refer to Section 2,

If the pulley alignment is not within specification, remove the engine pulley and repeat steps 2 through 6. See 6-4,

How to

Remove the Engine Drive Pulley.

4 - 28 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 93

July 2004 Section 4 • Repair Procedures

REV A

7-1 Generator Pulley

How to Remove the Generator Pulley

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine to access the generator pulley.

3 Loosen the tension adjustment bolt on the

generator.

4 Pull the generator away from the machine and

remove the belts from the generator pulley.

5 Disconnect the battery cables from the engine

battery.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Generator

How to Install the Generator Pulley

The pulley on the generator must be installed before installing the engine drive pulley.

1 Align the woodruff key on the generator shaft

with the slot in the pulley and slide the pulley all the way onto the generator shaft.

2 Install the flat washer and pulley retaining nut

onto the generator shaft, then torque the nut to specification. Refer to Section 2,

3 Adjust the tension of the generator belts.

See 7-2,

How to Adjust the Generator Belts.

Specifications

6 Remove the engine battery hold down, then

remove the battery from the machine.

7 Remove the generator pulley retaining nut from

the generator shaft.

8 Slide the pulley off of the generator shaft.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 29

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July 2004Section 4 • Repair Procedures

GENERATOR

7-2 Generator Belts

How to Adjust the Generator Belts

1 Disconnect the battery packs.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

2 Remove the engine pivot plate latch retainer.

3 Open the engine pivot plate latch and swing the

engine out away from the machine to access the generator belts.

4 Loosen the tension adjustment bolt on the

generator.

5 Push the generator towards the machine and

tighten the adjustment bolt.

6 Check the generator belts for proper tension.

Refer to Section 2, deflection is not within specification, perform steps 4 and 5 and re-check the belt tension.

Specifications

. If the belt

REV A

7-3 Generator Voltage Regulator

How to Adjust the Generator Voltage Regulator

The voltage regulator regulates the output voltage of the generator. A properly adjusted voltage regulator is essential to good generator performance and service life. A defective or improperly adjusted voltage regulator could result in component damage.

Be sure the batteries are fully

charged before performing this procedure.

1 Remove the engine pivot plate latch retainer.

2 Open the engine pivot plate latch and swing the

engine out away from the machine to access the generator.

3 Connect the positive lead of a voltmeter to the

POS terminal on the generator and the negative

lead of the voltmeter to the NEG terminal on the generator.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

a engine pulley b generator belts c generator pulley

4 - 30 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 95

July 2004 Section 4 • Repair Procedures

REV A

4 Start the engine from the ground controls and

move the rpm select toggle switch to the maintained high idle position. Check the voltage on the generator.

Result: The voltage should be 54V DC.

5 If the voltage reading is not 54V DC, insert a

small flat blade screwdriver into the potentiometer located inside of the generator. Use the access hole on the back of the generator labeled VOLT ADJ.

Component damage hazard. Be sure that the screwdriver is properly inserted into the potentiometer or the generator and/or voltage regulator may become damaged.

6 Carefully adjust the potentiometer to obtain a

54V DC voltage reading. Turn the potentiometer clockwise to increase the voltage or counterclockwise to decrease the voltage. Do not rotate the potentiometer past the internal stops.

Component damage hazard. The voltage regulator inside the generator will become damaged if the potentiometer is rotated past the internal stops.

GENERATOR

How to Replace the Voltage Regulator

1 Disconnect the battery packs from the machine.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

2 Remove the engine pivot plate latch retainer.

3 Open the engine pivot plate latch and swing the

engine out away from the machine to access the generator.

4 Tag and disconnect the positive and negative

battery cables from the generator.

5 Loosen the tension adjustment bolt on the

generator.

6 Pull the generator away from the machine and

remove the belts from the generator pulley.

7 Remove the generator mounting fasteners then

remove the generator from the machine.

8 Remove the 3 nuts from the battery cable

terminal posts.

9 Remove the 3 screws that hold the plastic cover

onto the generator. Carefully remove the cover.

The maximum range of motion of

the potentiometer on the voltage regulator is 280° and the maximum allowed torque is 5 oz-in / 0.035 Nm.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 31

Page 96

July 2004Section 4 • Repair Procedures

GENERATOR

10 Locate the 3 white wires that lead from the

voltage regulator to the negative rectifier assembly.

a white wires (#10 nuts) b negative rectifier assembly c black wire (#10 screw) d black wire (#4 nut) e voltage regulator

mounting fastener (#8 screw) f voltage regulator g red wire (#10 screw) h positive rectifier assembly

11 Remove the nuts on those 3 wires from the

negative rectifier assembly, then remove the wires.

Do not remove the spacers from the underneath the wires on the negative rectifier assembly.

12 Locate the red wire that leads from the voltage

regulator to the positive rectifier assembly.

13 Remove the screw that attaches the red wire to

the positive recitfier assembly.

14 Remove the #4 nut that attaches the black wire

to the voltage regulator.

15 Remove the voltage regulator mounting screws.

16 Remove the voltage regulator while carefully

guiding the red and black wires from underneath the bottom support of the positive and negative rectifier assembly.

17 Install the new voltage regulator by following the

previous steps in reverse order.

18 Apply Loctite® removable thread sealant onto

the voltage regulator mounting fasteners and torque to specification. Refer to Section 2,

Specifications

19 Torque all fasteners to specification. Refer to

Section 2,

Specifications

20 Install the plastic cover onto the generator then

install the generator onto the machine.

21 Adjust the generator belts. See 7-2,

Adjust the Generator Belts.

22 Adjust the voltage regulator. See 7-3,

Adjust the Voltage Regulator.

Component damage hazard. The voltage regulator and/or generator may become damaged if the voltage regulator is not properly adjusted after replacement.

When the voltage regulator is

replaced, the voltage regulator must be adjusted. See 7-3,

Adjust the Voltage Regulator.

REV A

How to

4 - 32 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 97

July 2004 Section 4 • Repair Procedures

REV A

8-1 Auxiliary Pump

How to Remove the Auxiliary Pump

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Place a suitable container under the hydraulic

tank. See capacity specifications.

2 Remove the drain plug from the hydraulic tank.

3 Completely drain the tank into a suitable

container.

Hydraulic Hose and

Hydraulic Pumps

8-2 Function Pump

How to Remove the Function Pump

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2,

Fitting Torque Specifications.

1 Place a suitable container under the hydraulic

tank. See capacity specifications.

2 Remove the drain plug from the hydraulic tank.

3 Completely drain the tank into a suitable

container.

Hydraulic Hose and

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

4 Remove the engine pivot plate latch retainer.

5 Open the engine pivot plate latch and swing the

engine pivot plate out away from the machine.

6 Tag, disconnect and plug the hydraulic hoses

from the pump.

7 Remove the pump mounting bolts. Carefully

remove the pump.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

4 Remove the engine pivot plate latch retainer.

5 Open the engine pivot plate latch and swing the

engine pivot plate out away from the machine.

6 Tag, disconnect and plug the hydraulic hoses

from the pump.

7 Remove the pump mounting bolts. Carefully

remove the pump.

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 33

Page 98

August 2004Section 4 • Repair Procedures

Manifolds

REV B

9-1 Function Manifold Components (before serial number 17841)

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index Schematic

No. Description Item Function Torque

1 Differential sensing valve .................. A ........... All functions....................................... 20-25 ft-lbs / 27-34 Nm

2 Solenoid valve, N.O. poppet .............. B ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

3 Orifice, 0.050 inch / 1.27 mm............. C ........... Brake circuit

4 Orifice, 0.060 inch / 1.5 mm............... D ........... Steer circuit

5 Solenoid valve, 3 position 4 way ....... E ........... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm

6 Solenoid valve, N.C. poppet .............. F ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

7 Proportional solenoid valve ............... G........... All functions ....................................... 25-30 ft-lbs / 34-41 Nm

8 Solenoid valve, 3 position 4 way ....... H ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm

9 Counterbalance valve ........................ I ............ Platform level up ............................... 35-40 ft-lbs / 47-54 Nm

10 Solenoid valve, 3 position 4 way ....... J ............ Jib boom up/down and

Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm

11 Solenoid valve, 3 position 4 way ....... K ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm

12 Solenoid valve, 3 position 4 way ....... L ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm

13 Solenoid valve, 3 position 4 way ....... M .......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm

14 Solenoid valve, 2 position 3 way ....... N ........... Primary boom extend ........................ 20-25 ft-lbs / 27-34 Nm

15 Orifice, 0.037 inch / 0.94 mm ............. O ........... Secondary boom up

16 Solenoid valve, 2 position 3 way ....... P ........... Primary boom retract ........................ 20-25 ft-lbs / 27-34 Nm

17 Relief valve, 2300 psi / 158.7 bar

(before serial number 11819) ............ Q ........... Primary boom down ...........................25-30 ft-lbs / 34-41 Nm

18 Relief valve, 1800 psi / 124.1 bar ...... R ........... Secondary boom down ......................25-30 ft-lbs / 34-41 Nm

19 Flow regulator valve,

0.6 gpm / 2.27 L/min .......................... S ........... Turntable rotate left/right

(prevents overflowing

the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm

This list continues. Please turn the page

4 - 34 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Page 99

August 2004 Section 4 • Repair Procedures

REV B MANIFOLDS

943 1421 6 7 8 10 11 125 13

22 21 20 19 18 17

Part No. 106488 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy 4 - 35

Page 100

August 2004Section 4 • Repair Procedures

MANIFOLDS

REV B

Function Manifold Components (before serial number 17841), continued

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index Schematic

No. Description Item Function Torque

20 Flow regulator valve,

0.6 gpm / 2.27 L/min .......................... T ........... Jib boom up/down,

platform rotate left/right and platform level up/down (prevents overflowing

the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm

21 Counterbalance valve ........................U ........... Platform level down ........................... 35-40 ft-lbs / 47-54 Nm

22 Relief valve, 3200 psi / 220.6 bar ...... V ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm

23 Diagnostic nipple ............................... W .......... Testing

24 Check valve ....................................... X ........... Pressure switch circuit ........................ 10-12 ft-lbs / 14-6 Nm

25 Pressure switch ................................. Y ........... Brake circuit

4 - 36 Genie Z-45/25 Bi-Energy and Genie Z-45/25J Bi-Energy Part No. 106488

Genie Z-45/25 Bi-Energy, Z-45/25J Bi-Energy Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual